ddec iii iv v class

September 9, 2017 | Author: argento313 | Category: Turbocharger, Fuel Economy In Automobiles, Fuel Injection, Electrical Engineering, Machines
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Description

III

IV V

DDEC

DDEC

DDEC

DDEC

DDEC Detroit Diesel Electronic Controls WITH EXHAUST GAS RECIRCULATION

DDEC AGENDA • • • • • • • • • • • 25ST0072-2 Rev. 04/4/00

Pre-Test Objectives Review Manuals Features & Components System Hardware Repair Tools Basic Electricity System Operation Trouble Shooting DDEC Reprogramming Post-Test, Evaluations 2

What is DDEC? An advanced electronic fuel injection control system that can be integrated into many applications

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

• Injectors 25ST0072-2 Rev. 04/4/00

3

DDEC History • DDEC I Introduced in 1985 on 92 Series • Series 60 Introduced in 1987 As the First Engine Ever Designed Exclusively for Electronic Controls • DDEC II Introduced in 1987 • DDEC III Introduced April, 1993 • DDEC III Full Production January, 1994 • DDEC IV Initial Release, August, 1997 • DDEC IV Full Production, January, 1998 • DDEC IV Series 60 EGR, October, 2002 • DDEC V Series 60 EGR, December, 2003

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 • Four New ECM’s Standard Truck Universal S4000 Natural Gas

• • • • • 25ST0072-2 Rev. 04/4/00

ECM Description 6 Cylinder 8 Cylinder 8 Cylinder 8 Cylinder

12 12/24 12/24 12/24

Volt Volt Volt Volt

23519307 23519308 23519309 23519310

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 6

DDEC Necessities Ignition

EUI

Electronic Control Module (ECM)

Synch Reference Timing Reference

EEPROM

-

25ST0072-2 Rev. 04/4/00

+ Battery

7

Electronic Control Module

25ST0072-2 Rev. 04/4/00

8

Electronic Control Module OEM responsibility Mandatory circuits Power and Ground

DDC responsibility Engine sensors, harness, & connectors

J1922,J1939, Ignition Throttle position sensor Optional circuits Manual fan on switch, Jake Brake, 439 Ignition wire 25ST0072-2 Rev. 04/4/00

Injector harness & connectors Injectors

9

Schematic Diagram DDEC III / IV Electronic Control Module (ECM)

EEPROM

-

25ST0072-2 Rev. 04/4/00

+ Battery

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 Electronic Control Module (ECM)

EUI

EEPROM

-

25ST0072-2 Rev. 04/4/00

+ Battery

13

Electronic Unit Injectors

Series 50/60 EUI

25ST0072-2 Rev. 04/4/00

14

Series 50/60 Injector Animation

Voltage in Rocker Arm Solenoid

Poppet Valve

Cam

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

Fuel In

Fuel In

Fuel Out

Fuel Out

Injector Tip

25ST0072-2 Rev. 04/4/00

Fuel In Fuel Out

Injector Tip

Injector Tip

19

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

Part Number Calibration Code 25ST0072-2 Rev. 04/4/00

20

Injector Cycle Terminology zIRT Injector Response Time - Length of Time (ms) required to close the Control Valve zPW Pulse Width - Degrees of Crankshaft Rotation when Fuel is Injected zBOI Beginning Of Injection – When Fuel Injection Starts in Crankshaft Degrees (Not Available in DDEC IIIIV Systems) 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 Closed

Open

Current Control Valve Lift

Injection Rate IRT BOE

PW EOE EOI

BOI

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

24

Typical EUI Fuel Injection Systems

Injection Pressure

Injection Events Occur as Shown 2200 bar Peak Pressure

Injection Begins

345 bar

Injection Ends

Crank Angle Degrees Pulse Width 25ST0072-2 Rev. 04/4/00

25

Sensor types •Two wire sensors are called Thermistors ¾Common return wire is #452 ¾Range -40* to +150* C •As the temperature increases the resistance decreases. •Three wire sensors are called Piezoresistive. ¾These are pressure sensors. ¾Voltage is proportional to pressure. •Also, two other sensors with twisted wires and a two pin connector are the TRS and SRS called Variable Reluctance

25ST0072-2 Rev. 04/4/00

26

5 Volt Sensor Operation

0

.25

Low Voltage

25ST0072-2 Rev. 04/4/00

VOLTS

Normal Operating Range

4.75

5

High Voltage

27

2-wire Sensors

5V Supply Signal

Return Sensor

ECM Open Short

25ST0072-2 Rev. 04/4/00

= =

HIGH VOLTAGE LOW VOLTAGE

28

3-wire Sensors ECM

Sensor 5V Supply Signal Return

Open Supply Open Signal Open Return Supply short to Signal Supply short to Return Signal short to Return

25ST0072-2 Rev. 04/4/00

= LOW VOLTAGE = LOW VOLTAGE = HIGH VOLTAGE = HIGH VOLTAGE = LOW VOLTAGE = LOW VOLTAGE

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 452 432 416

Cavity A Cavity B Cavity C

Open Low voltage code

Definitions • Open Circuit – An “open” describes a complete break in the path of current at some point in the circuit. The result of an “open” is that one or more loads in the circuit do not work. 25ST0072-2 Rev. 04/4/00

31

Electrical System 452 432 416

Short

Cavity A Cavity B Cavity C

High Voltage Code

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 452 432 416 Ground

Cavity A Cavity B Cavity C

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

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

25ST0072-2 Rev. 04/4/00

34

Schematic Diagram DDEC III / IV Synch Reference Timing Reference

Electronic Control Module (ECM)

EUI

EEPROM

-

25ST0072-2 Rev. 04/4/00

+ Battery

35

Series 50/60 SRS/TRS Sensors

SRS/TRS Timing Wheel DDEC II DDEC II Bull Gear

25ST0072-2 Rev. 04/4/00

36

Series 50/60 SRS/TRS Sensors

SRS/TRS

Bull Gear DDEC III/ IV

25ST0072-2 Rev. 04/4/00

Timing Wheel DDEC III/ IV

37

Series 60 Sensor Locations

Schematic Diagram DDEC IV Synch Reference Timing Reference Electronic Foot Pedal Assembly

EUI

Electronic Control Module (ECM)

EEPROM

+

Battery

25ST0072-2 Rev. 04/4/00

39

Schematic Diagram DDEC IV Synch Reference Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure

EUI

Electronic Control Module (ECM)

EEPROM

+

Battery

25ST0072-2 Rev. 04/4/00

40

Turbo Boost Sensor

Series 50/60 DDEC IV Series 50/60 DDEC IV V W/EGR Series 50/60 DDEC III 25ST0072-2 Rev. 04/4/00

41

Schematic Diagram DDEC III / IV Synch Reference Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure

Electronic Control Module (ECM)

EUI

Fuel / Oil / Coolant/ Air Temperature

EEPROM

-

25ST0072-2 Rev. 04/4/00

+ Battery

42

Temperature Sensors

Coolant Temperature Sensor Series 50/60

Air Temperature Sensor Series 50/60

Fuel/Oil/Coolant Temperature Sensor Series 50/60 25ST0072-2 Rev. 04/4/00

43

Schematic Diagram DDEC III / IV Synch Reference Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure

Electronic Control Module (ECM)

EUI

Fuel / Oil / Coolant Temperature Oil / Fuel Pressure

EEPROM

-

25ST0072-2 Rev. 04/4/00

+ Battery

44

Pressure Sensors

Series 50/60 Oil Pressure

25ST0072-2 Rev. 04/4/00

45

Schematic Diagram DDEC III / IV Synch Reference Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure

Electronic Control Module (ECM)

EUI

Fuel / Oil / Coolant Temperature Oil / Fuel Pressure

EEPROM Oil level/Fuel Restriction

-

25ST0072-2 Rev. 04/4/00

+ Battery

46

Schematic Diagram DDEC III / IV non EGR Synch Reference

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Fuel / Oil / Coolant Temperature Oil / Fuel Pressure

MASS

EEPROM

EUI

Optimized Idle Fan Controls Engine Brake

ISD / Vehicle Power Down Communication DDR Interface/ DDDL/ Reprogramming PWM Ports Check Engine

Stop Engine

Oil level/Fuel Restriction Crankcase Pressure Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor

Coolant Level VSG Control Progressive Shift Pressure Governor Diagnostic Request 25ST0072-2 Rev. 04/4/00

Engine Rating / Cruise Power / Switch Power

-

+ Battery

Stop Engine Override 47

DDR Communication- On Highway

DDEC II or III 12-Pin

25ST0072-2 Rev. 04/4/00

DDEC III/ IV 6-Pin

48

DDR Communication- On Highway

DDEC IV 9 Pin

25ST0072-2 Rev. 04/4/00

49

Diagnostic Socket Pin- Outs for On-Highway Cable 6 Pin Deutsche C 12V

25ST0072-2 Rev. 04/4/00

9 Pin Deutsche B 12V

E

Ground

A

Ground

A

J1587 +

F

J 1587 +

B

J1587 –

G

J 1587 –

C

J 1939 +

D

J 1939 – 50

DDR Interface with MPSI Printer

25ST0072-2 Rev. 04/4/00

51

Diagnostics

Flash Codes

25ST0072-2 Rev. 04/4/00

53

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

h

Volt-Ohm Meter

25ST0072-2 Rev. 04/4/00

h The use of the lead ends of the volt ohm meter to probe the terminal ends will damage the DDEC connectors and will cause intermittent codes. hDVOM w/jumper wire kit J39197 hVEHICLE INTERFACE MODULE hBREAK OUT BOX hDDEC SENSOR TESTER

54

Troubleshooting Tools

Breakout Box (30 Pin) J35634 DDEC II III IV

25ST0072-2 Rev. 04/4/00

DDEC III/IV Interface J41005 DDEC V with J-41005-5 CABLE

55

Diagnostic Tools • DDEC II- III- IV- V Electronic 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

HARDWARE KIT # J-42384-GCD SOFTWARE KIT # J-DDDL-6.2 CD

57

DDDL Information • New PC based DDEC service tool – Release 6.2 » Windows 95 / 98 / 2000 » VGA color monitor » Pentium, 300MHz, 128MB RAM » Supports all DDEC Systems including EGR & MBE On-Highway » Support Data Extractions & Trip Reporting Features

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

• • • • • • • • • • •

25ST0072-2 Rev. 04/4/00

Volts Amps Ohms Shorts Open Grounds Resistance DVOM Soldering Shrink Tube Wiring Schematics

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 • Utilizes New Tyco/AMP Connectors for Improved Harness Design and Reliability • Uses Framatome (FCI) Connectors for Sensors – Connectors were introduced for EGR engines in Oct 2002

• Has Full Support for J1587 and J1939 Data Links (J1922 is not supported) • Maintains Same Footprint as DDEC III / IV • Application and Installation Manual Now Available on the DDC Extranet

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 25ST0072-2 Rev. 04/4/00

Series 50 EGR Sensors

DDEC IV System 73

Right Side View Oil Temp Sensor

25ST0072-2 Rev. 04/4/00

74

Auxiliary Emission Control Device

AECD Function • Shuts Off EGR Flow to Protect Engine from Damage when Conditions Produce High Levels of Condensation. • AECD’s are EPA Approved • High Altitude above 6500 ft. • High Humidity / Low Ambient Temperature • Low Engine Temperature

25ST0072-2 Rev. 04/4/00

76

Schematic Diagram DDEC III / IV Additional EGR Sensors and Circuits AECD

Turbo Speed

Electronic Control Module (ECM)

RH / TCITS OEM Engine Brake 10 Pin Connector

EGR Temperature

EGR Delta

EEPROM Barometric Pressure TCOTS

12-24 Volt VPODS EGR 25ST0072-2 Rev. 04/4/00

VNT 77

Schematic Diagram DDEC III / IV with EGR AECD

Synch Reference

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Fuel / Oil / Coolant / EGR Temperature

RH / TCITS OEM

Fan Controls Engine Brake ISD / Vehicle 10 Pin Power Down Connector Communication DDR Interface/ DDDL/ Reprogramming PWM Ports

Oil / Fuel Pressure

MASS

EUI

Optimized Idle

Check Engine

EEPROM

Stop Engine

Oil level/Fuel Restriction Crankcase Pressure

Barometric Pressure

Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor

Coolant Level TCOTS

VSG Control Progressive Shift Pressure Governor Diagnostic Request

25ST0072-2 Rev. 04/4/00

Engine Rating / Cruise Power / Switch Power

-

+ Battery

Stop Engine Override

12-24 Volt VPODS EGR

VNT 78

Schematic Diagram DDEC III / IV with EGR Synch Reference Timing Reference

Electronic Control Module (ECM)

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 Timing Reference Electronic Foot Pedal Assembly

Electronic Control Module (ECM)

EEPROM

25ST0072-2 Rev. 04/4/00

82

Schematic Diagram DDEC III / IV w/EGR Synch Reference Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure

Electronic Control Module (ECM)

EEPROM

25ST0072-2 Rev. 04/4/00

83

Schematic Diagram DDEC III / IV with EGR Synch Reference Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed

Electronic Control Module (ECM)

EEPROM

25ST0072-2 Rev. 04/4/00

84

TSS • Turbo Speed Sensor • • • •

25ST0072-2 Rev. 04/4/00

Measures Shaft Speed in 500 RPM Increments Protects Turbo and Charge Air Cooler Magnetic Pick Up Signals From Turbo Shaft Displays Shaft Speed in k-rpm

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 Pedal Assembly

Turbo Boost Pressure Turbo Speed

Electronic Control Module (ECM)

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 Pedal Assembly

Turbo Boost Pressure Turbo Speed

Electronic Control Module (ECM)

Fuel / Oil / Coolant / EGR Temperature

EGR Delta

EEPROM

25ST0072-2 Rev. 04/4/00

90

EGR Delta Pressure Sensor • Provides DDEC With Measurements Resulting In EGR Flow Rate • Pressure Differential (Delta P) Between Venturi Inlet and Throat, Along with EGR Temperature, Are Converted to Mass Flow Rate in DDEC • Actual Rate is Displayed as in.H2O and Counts • A Temperature sensor allows DDEC to correct for density variations that result from temperature changes. • This feedback is used only in the EGR mode

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 Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Electronic Control Module (ECM)

Fuel / Oil / Coolant / EGR Temperature Oil / Fuel Pressure

EEPROM Barometric Pressure

25ST0072-2 Rev. 04/4/00

94

Barometric Pressure Sensor • Used to Calculate Fuel Tables at Various Altitudes and AECD Controls

25ST0072-2 Rev. 04/4/00

95

BARO • Barometric Pressure Sensor • Smoke Control • Fuel Table Calculation • High Altitude Turbo Protection

25ST0072-2 Rev. 04/4/00

96

Schematic Diagram DDEC III / IV with EGR Synch Reference Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Electronic Control Module (ECM)

Fuel / Oil / Coolant / EGR Temperature 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 • • •

25ST0072-2 Rev. 04/4/00

Protects Charge Air Cooler Located in Turbo Compressor Outlet Housing Used for AECD Controls

99

Schematic Diagram DDEC III / IV with EGR Synch Reference

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Fuel / Oil / Coolant / EGR Temperature Oil / Fuel Pressure

MASS

EEPROM

Oil level/Fuel Restriction Barometric Pressure Coolant Level TCOTS

VSG Control Progressive Shift Pressure Governor Diagnostic Request

25ST0072-2 Rev. 04/4/00

-

+ Battery

Stop Engine Override

12 or 24 Volt VPODS EGR

VNT 100

Variable Pressure Operating Device • VPOD • • • • • •

25ST0072-2 Rev. 04/4/00

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

101

VPOD

• PWM

4 VNT Control/Left

VPOD • PWM

2 EGR Control/Right VPOD

• Rear 25ST0072-2 Rev. 04/4/00

Mount VPOD Option 102

Series 60 EGR Components Variable Nozzle Turbocharger • Uses Exhaust Energy To Provide Intake Boost And Exhaust Pressure To Drive EGR – Pneumatically Actuated Vane Set – Turbo Speed Sensor (TSS) – Turbocharger Compressor Outlet Temperature Sensor (TCOTS)

25ST0072-2 Rev. 04/4/00

103

Series 60 EGR Variable Nozzle Turbocharger • Provides the means to drive EGR by a set of moveable vanes which increase the exhaust manifold pressure • Can be varied to change EGR rate in EGR mode or boost level when in the boost mode • Controlled via PWM signal from ECM to a Variable Pressure Operating Device (VPOD)

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 Vane set

Exhaust Turbine

Unison Ring 25ST0072-2 Rev. 04/4/00

106

EGR Valve & Actuator Oct 2002 thru 2003: Pneumatic Actuator & Control Valve

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

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Fuel / Oil / Coolant / EGR Temperature Oil / Fuel Pressure

MASS

EEPROM

Oil level/Fuel Restriction Crankcase Pressure

Barometric Pressure

Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor

Coolant Level TCOTS

VSG Control Progressive Shift Pressure Governor Diagnostic Request

25ST0072-2 Rev. 04/4/00

Engine Rating / Cruise Power / Switch Power

-

+ Battery

Stop Engine Override

12-24 Volt VPODS EGR

VNT 110

Crankcase Pressure

Series 60 CCM

25ST0072-2 Rev. 04/4/00

111

Schematic Diagram DDEC III / IV with EGR Synch Reference

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Fuel / Oil / Coolant / EGR Temperature

RH / TCITS OEM

10 Pin Connector

Communication DDR Interface/ DDDL/ Reprogramming PWM Ports

Oil / Fuel Pressure

MASS

Check Engine

EEPROM

Stop Engine

Oil level/Fuel Restriction Crankcase Pressure

Barometric Pressure

Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor

Coolant Level TCOTS

VSG Control Progressive Shift Pressure Governor Diagnostic Request

25ST0072-2 Rev. 04/4/00

Engine Rating / Cruise Power / Switch Power

-

+ Battery

Stop Engine Override

12-24 Volt VPODS EGR

VNT 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

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Fuel / Oil / Coolant / EGR Temperature

RH / TCITS OEM Engine Brake ISD / Vehicle 10 Pin Power Down Connector Communication DDR Interface/ DDDL/ Reprogramming PWM Ports

Oil / Fuel Pressure

MASS

Check Engine

EEPROM

Stop Engine

Oil level/Fuel Restriction Crankcase Pressure

Barometric Pressure

Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor

Coolant Level TCOTS

VSG Control Progressive Shift Pressure Governor Diagnostic Request

25ST0072-2 Rev. 04/4/00

Engine Rating / Cruise Power / Switch Power

-

+ Battery

Stop Engine Override

12-24 Volt VPODS EGR

VNT 114

DDEC III/IV Engine Brakes (NON EGR)

• 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. 25ST0072-2 Rev. 04/4/00

115

Schematic Diagram DDEC III / IV with EGR Synch Reference

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Fuel / Oil / Coolant / EGR Temperature

RH / TCITS OEM

Fan Controls Engine Brake ISD / Vehicle 10 Pin Power Down Connector Communication DDR Interface/ DDDL/ Reprogramming PWM Ports

Oil / Fuel Pressure

MASS

EUI

Optimized Idle

Check Engine

EEPROM

Stop Engine

Oil level/Fuel Restriction Crankcase Pressure

Barometric Pressure

Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor

Coolant Level TCOTS

VSG Control Progressive Shift Pressure Governor Diagnostic Request

25ST0072-2 Rev. 04/4/00

Engine Rating / Cruise Power / Switch Power

-

+ Battery

Stop Engine Override

12-24 Volt VPODS EGR

VNT 116

Schematic Diagram DDEC III / IV with EGR AECD

Synch Reference

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Fuel / Oil / Coolant / EGR Temperature

RH / TCITS OEM

Fan Controls Engine Brake ISD / Vehicle 10 Pin Power Down Connector Communication DDR Interface/ DDDL/ Reprogramming PWM Ports

Oil / Fuel Pressure

MASS

EUI

Optimized Idle

Check Engine

EEPROM

Stop Engine

Oil Level/Fuel Restriction Crankcase Pressure

Barometric Pressure

Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor

Coolant Level TCOTS

VSG Control Progressive Shift Pressure Governor Diagnostic Request

25ST0072-2 Rev. 04/4/00

Engine Rating / Cruise Power / Switch Power

-

+ Battery

Stop Engine Override

12-24 Volt VPODS EGR

VNT 117

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 • CANNOT Be Used with DDEC IV EGR Programming 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 – – – –

25ST0072-2 Rev. 04/4/00

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

119

Maintenance Alert System

Oil Level Sensor

Fuel Restriction Sensor 25ST0072-2 Rev. 04/4/00

Air Filter Restriction Sensor

2nd Coolant Level Sensor

Monitor Display Unit

120

On Engine Components • Oil Level Sensor – Mounts in Front Sump Nonmetal Oil Pan – Utilizes Optical Technology to "See" Oil Level – Engine Must Be Off (Zero RPM ) for "X" Minutes (Based on Oil Temp.) to Drain Oil Back to the Pan – Switches at Four Quart Low Level – OEM Impact » Order Maintenance Alert System on the Engine

25ST0072-2 Rev. 04/4/00

121

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

25ST0072-2 Rev. 04/4/00

122

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

25ST0072-2 Rev. 04/4/00

123

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

25ST0072-2 Rev. 04/4/00

124

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"

25ST0072-2 Rev. 04/4/00

125

OEM Installed Components •

25ST0072-2 Rev. 04/4/00

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

126

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

25ST0072-2 Rev. 04/4/00

127

Summary • Monitors and Displays Service Requirements – – – – – –

Oil Level Fuel System Restriction Air Filter Restriction 2nd Coolant Level Monitor Display Unit - in Cab DDR and DDDL

Engine Vehicle

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

25ST0072-2 Rev. 04/4/00

128

Schematic Diagram DDEC III / IV with EGR Synch Reference Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Electronic Control Module (ECM)

Fuel / Oil / Coolant / EGR Temperature 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 II/ III 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 Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Electronic Control Module (ECM)

Fuel / Oil / Coolant / EGR Temperature Oil / Fuel Pressure

MASS

EEPROM

Oil level/Fuel Restriction Barometric Pressure Coolant Level TCOTS

25ST0072-2 Rev. 04/4/00

VSG Control

131

Progressive Shift

25ST0072-2 Rev. 04/4/00

132

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.

25ST0072-2 Rev. 04/4/00

133

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

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

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Fuel / Oil / Coolant / EGR Temperature Oil / Fuel Pressure

MASS

EEPROM

Oil level/Fuel Restriction Barometric Pressure Coolant Level TCOTS

VSG Control Progressive Shift Pressure Governor Diagnostic Request

25ST0072-2 Rev. 04/4/00

-

+ Battery

Stop Engine Override 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 • 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

25ST0072-2 Rev. 04/4/00

140

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..

25ST0072-2 Rev. 04/4/00

141

Vehicle Speed Sensor • Revs per Mile (Tires) High Gear Ratio (Transmission) Rear End Ratio (Ring & Pinion) Sensor Type (Magnetic or Switched) # of teeth on Pulse Wheel (Trans. or Wheel End) • 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

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

External Fault

25ST0072-2 Rev. 04/4/00

Internal Fault

144

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. • ENGINE PROTECTION NOT AVAILABLE ON ALL APPLICATIONS 25ST0072-2 Rev. 04/4/00

145

Pulse Width Modulated Outputs • Signals sent by the ECM to other microprocessor controlled systems

Signal High Signal Low

20% 1 Hz

• • •

25ST0072-2 Rev. 04/4/00

50% 1 Hz

80% 1 Hz

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

146

NON EGR PWM CIRCUTS

• • • •

Circuit No. PWM #1 Output - VIH (Transmission) 908 PWM #2 Output - ESH (Throttle/GAS) 909 PWM #3 Output - ESH (Gas Valve/GAS) 910 PWM #4 Output - ESH (Fan Control) 911

Wire Color White Lt. Green Orange Pink

• ESH = Engine Sensor Harness • VIH = Vehicle Interface Harness

25ST0072-2 Rev. 04/4/00

147

EGR PWM CIRCUTS

• • • •

Circuit No. PWM #1 Output - VIH (Transmission) 908 PWM #2 Output - ESH (EGR Control) 909 PWM #3 Output - ESH (OI STARTER) 910 PWM #4 Output - ESH (VNT Control) 911

Wire Color White Lt. Green Orange Pink

• ESH = Engine Sensor Harness • VIH = Vehicle Interface Harness

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 •



25ST0072-2 Rev. 04/4/00

Idle Shut Down (ISD): Turns engine off after programmed idle time has elapsed (optional “override” disables idle timer if the engine speed is increased by 100 during last 90 seconds of ISD sequence. The check engine light (CEL) will flash during this 90 seconds. Vehicle Power Shutdown relay (optional/OEM) turns off electrical power to the vehicle as well as stopping the engine

2 - 100 Minutes 155

Fan Control • Four fan configurations can be used – Single fan – Dual fans – Two speed fan – Variable speed fan (PWM) # 4 Hydraulically Operated (Coach) • 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 25ST0072-2 Rev. 04/4/00

156

Fan Control • Conditions which activate the fan; – High Oil, Coolant, or Air Inlet Temp – Circuit fault codes (HI VOLT, LO VOLT) on any of these three sensors – A/C Compressor On – Fan Override input – Dynamic Braking (Fan is Activated During Engine Overspeed to Help Slow The Vehicle)

25ST0072-2 Rev. 04/4/00

157

DDEC Fan Controls Normal Temperatures Allow High Temperatures Turn FanFan On Off

Air Supply

Temp sensor Inputs Optional Fan # 2

Output Output “off” “on” “off”

ECM

Ign. +

“on” “on” Fan “off”

Fan Override (Input Off) #953 (-) Aux. Fan Control (Input On) Off) Air Conditioning Conditioning -- On off Air (Fan on for at least 3 minutes)

7SA741 I&T Manual

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 • Engine Mode – Thermostat Mode – Customer Mode 25ST0072-2 Rev. 04/4/00

159

Requirements for Optimized Idle h Cruise Enable Switch h Idle Shutdown Enabled h Vehicle Power Down Relay h Op Idle light on dash h Park Brake Switch h Transmission Neutral Switch (Some transmissions require high range in Neutral)

25ST0072-2 Rev. 04/4/00

hHood Switch hUnder-hood Alarm hStart Relay hOverlay Relay hVSS Enabled hOptional Sleeper Thermostat

160

Optimized Idle Shutdown Sequence h 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. h Optimized Idle is activated by turning on the Cruise Enable Switch which supplies ground on the Cruise Enable input. h Optimized Idle Light flashes until the engine shuts down then remains on.

25ST0072-2 Rev. 04/4/00

161

Optimized Idle Shutdown Sequence h 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. h Vehicle Power Down Relay opens powering down the vehicle Ignition Circuit. h With Ignition key on, the ECM is still awake and it continuously monitors Battery Voltage, Oil Temperature and Sleeper Temperature.

25ST0072-2 Rev. 04/4/00

162

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 25ST0072-2 Rev. 04/4/00

163

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 proprietary data link in multi ECM engines

25ST0072-2 Rev. 04/4/00

164

Infrared Information System

Infrared Information System • The IRIS System Consists of Simple Infrared Transceivers • One Transceiver is Mounted on the Vehicle & Another Transceiver is Mounted at the Location where the Vehicle Owner Wants to Extract Information • Once the Vehicle is in Position, an Indicator Light Lets the Driver Know the Infrared Connection has Been Made • Information Can Then Begin to Flow 25ST0072-2 Rev. 04/4/00

166

Schematic Diagram DDEC III / IV Synch Reference

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Fuel / Oil / Coolant Temperature

EUI

Communication DDR Interface/ DDDL/ Reprogramming PWM Ports

Oil / Fuel Pressure

EEPROM

Check Engine

Stop Engine

Oil level/Fuel Restriction Crankcase Pressure Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor

Coolant Level VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift Pressure Governor Diagnostic Request 25ST0072-2 Rev. 04/4/00

-

+ Battery

Stop Engine Override 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

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Fuel / Oil / Coolant Temperature

EUI

Idle Shut Down/Vehicle Power Down Communication DDR Interface/ DDDL/ Reprogramming PWM Ports

Oil / Fuel Pressure

EEPROM

Check Engine

Stop Engine

Oil level/Fuel Restriction Crankcase Pressure Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor

Coolant Level VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift Pressure Governor Diagnostic Request 25ST0072-2 Rev. 04/4/00

-

+ Battery

Stop Engine Override 169

Schematic Diagram DDEC III / IV Synch Reference

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Fuel / Oil / Coolant Temperature

EUI Engine Brake Idle Shut Down/Vehicle Power Down Communication DDR Interface/ DDDL/ Reprogramming PWM Ports

Oil / Fuel Pressure

EEPROM

Check Engine

Stop Engine

Oil level/Fuel Restriction Crankcase Pressure Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor

Coolant Level VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift Pressure Governor Diagnostic Request 25ST0072-2 Rev. 04/4/00

-

+ Battery

Stop Engine Override 170

Schematic Diagram DDEC III / IV Synch Reference

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Fuel / Oil / Coolant Temperature Oil / Fuel Pressure

EEPROM

EUI

Optimized Idle Fan Controls Engine Brake

ISD / Vehicle Power Down Communication DDR Interface/ DDDL/ Reprogramming PWM Ports Check Engine

Stop Engine

Oil level/Fuel Restriction Crankcase Pressure Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor

Coolant Level VSG Control Progressive Shift Pressure Governor Diagnostic Request 25ST0072-2 Rev. 04/4/00

Engine Rating / Cruise Power / Switch Power

-

+ Battery

Stop Engine Override 171

Digital Inputs

Digital Input Functions

• External Switch Requests Function from the ECM • 37 Options to Choose from • 12 pins Available on the 30 Pin Vehicle Harness Connector for Input Functions • Functions are Assignable to any of these Pins through the use of a “Reprogramming Station”

25ST0072-2 Rev. 04/4/00

173

DDEC III – IV Digital Inputs

ECM

No Function No Function No Function

EEPROM

#953

Cruise Enable Fan Override #150

_

+ Battery

25ST0072-2 Rev. 04/4/00

174

DDEC III – IV Digital Inputs • •



25ST0072-2 Rev. 04/4/00

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

175

DDEC III – IV Digital Inputs (Cont’d) • Throttle Control

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

– Alternate Minimum – Pressure Governor System VSG/Fast Idle (Release Enable 2.00 or Later Only) – Pressure/RPM Mode Switch – Dual Throttle (LSG) – Set/Coast On (Decrease) – Idle Validation Switch – Resume/Acceleration On – Throttle Inhibit (Increase) – VSG Station Change • Additional Functions – VSG Station – Auxiliary Coolant Level Complement Sensor – Parking Brake Interlock

25ST0072-2 Rev. 04/4/00

176

Digital Outputs

DDEC III – IV Digital Output Functions • ECM Commands ( Internal Switches ) Action of some External Device- Fan Control • 32 Output Options • 6 Pins Available, 3 on the 30 pin Vehicle Connector, 3 on the 30 Pin Engine Harness Connector ( Auxiliary Outputs ) • Configurable with the Distributor or Dealer Reprogramming Station

25ST0072-2 Rev. 04/4/00

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

Coolant Level Low Light Cruise Control Active Light Deceleration Light Engine Brake Active Fan Control #1 Fan Control #2 Low DDEC Voltage Pressure Mode Light Starter Lockout Transmission Retarder Vehicle Power Shutdown

• • • • • • •

VSG Active Indication Low Oil Pressure Light High Oil Temperature Light High Coolant Temp. Light Ether Injection Low Coolant Pressure Light High Crankcase Pressure Light • Optimized Idle Active Light • Gas Solenoid Shutdown • Fuel Regulator Solenoid

180

DDEC –III – IV Digital Outputs (Cont’d) • • • • •

25ST0072-2 Rev. 04/4/00

Air Compressor Solenoid Exhaust Brake Enabled Fuel Supply Solenoid Low Range Solenoid High Range Solenoid

• • • • •

Turbo Recirculation Valve Cold Engine Signal Rpm Synchronize Light Shift Lockout Shift Solenoid

181

Fuel Economy Incentive • Encourages better driving habits by rewarding good fuel economy with extra road speed • If driver exceeds the target fuel economy extra road speed will automatically be added to his maximum vehicle speed

25ST0072-2 Rev. 04/4/00

182

Fuel Economy Incentive Parameter Min MPG Max MPH Scaler MPH/MPG Calc Type

Range 5-10 mpg 0-10 mph 0.1-20 mph/mpg Filtered/Trip

Example 7.0 4 10.0 Trip

If Scaler is set at: 20.0 = 1 extra mph for every .05 mpg above target mpg 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 25ST0072-2 Rev. 04/4/00

183

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.

25ST0072-2 Rev. 04/4/00

184

Series 60 EGR Electrical Schematic ECM

25ST0072-2 Rev. 04/4/00

W1

416

R2

907

2

Y2

452

1

1.5KΩ

ECM EGR Temp Sensor

W1

416

M2

958

Y2

452

1 1.5KΩ

2

DPS

3

185

DDEC V

History of DDEC V • 1999 - Kick off for use with EGR in Oct 2002 – Designed for Common Rail Injection

• 2001 - Removed Common Rail and Went back to Unit Injectors • 2002-2003 – Field Test – SOP Dec. 1 2003

25ST0072-2 Rev. 04/4/00

187

DDEC V Features • DDEC V Electronic Control Module (ECU) – 4 Times More Memory – Two 68 Pin Connectors Instead of Current Six Connectors

• Benefits – Ability to Add Options to EGR Engines » Maintenance Alert System

– New Connectors With Improved Seals to Prevent Water Intrusion – Improved Vehicle Integration With Other Control Systems

25ST0072-2 Rev. 04/4/00

188

DDEC V Improvements Over DDEC IV • More Terminal Pins (136 vs. 81) • More Flexible Inputs – Frequency Inputs: 6 vs. 4 » OEM has 2 Frequency Inputs

• Digital Outputs: 19 (8 Hi),B+ (11 Lo)B- vs. 10 (2 Hi, 8 Lo) » OEM has 10 Low Side Digital Inputs – 2 are used for CEL/SEL

• PWM Outputs: 6 vs. 4 (Low Side) » OEM has 2 PWM Outputs

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 • Utilizes New Tyco/AMP Connectors for Improved Harness Design and Reliability • Uses Framatome (FCI) Connectors for Sensors – Connectors were introduced for EGR engines in Oct 2002

• Has Full Support for J1587 and J1939 Data Links (J1922 is not supported) • Maintains Same Footprint as DDEC II / III / IV • Application and Installation Manual Now Available on the DDC Extranet

25ST0072-2 Rev. 04/4/00

194

DDEC V ECU Connectors Terminal Side of Connector Pins 1 to 60 are for 18 gauge wire Pins 61 to 68 are for 14 gauge wire Both the wire end and the terminal end are different sizes On the Engine Harness Connector, EHC, pins 61- 68 are used for the EUI’s

25ST0072-2 Rev. 04/4/00

On the Vehicle Harness Connector, VHC, pins 61- 68 are used for the Battery connection 195

DDEC V Software • First Release for December 2003 – R 1.0 Includes all DDEC IV Software Features » Return of Maintenance Alert System

– J1939 ECU Programming – J1708 Diagnostics

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

• First Official Complete Edition – Publication Number: 7SA821 – Available on the DDC Extranet

25ST0072-2 Rev. 04/4/00

198

DDEC V Codes

25ST0072-2 Rev. 04/4/00

Sensor

Function

Barometric Pressure Sensor (Baro Sensor)

Senses barometric pressure.

Camshaft Position Sensor (CMP Sensor)

Senses crankshaft position and engine speed for functions such as fuel control strategy.

Crankshaft Position Sensor (CKP Sensor)

Indicates a specific cylinder in the firing order.

Engine Coolant Temperature Sensor (ECT Sensor)

Senses coolant temperature for functions such as engine protection, fan control and engine fueling.

Engine Oil Level (EOL Sensor)

Detects oil level at four quarts low. Used in the Maintenance Alert System.

199

DDEC V Codes (cont.) Sensor

Function

Engine Oil Pressure Sensor (EOP Sensor)

Senses gallery oil pressure for functions such as engine protection.

Engine Oil Temperature Sensor (EOT Sensor)

Senses oil temperature for functions such as reducing variation in fuel injection and fan control.

Fuel Restriction Sensor

Detects fuel restriction for replacement of fuel filter. Used in the Maintenance Alert System.

Intake Air Temperature Senses air temperature for functions such as fan Sensor (IAT Sensor) control and engine fueling. Intake Manifold Pressure Sensor (IMP Sensor) 25ST0072-2 Rev. 04/4/00

Senses turbo boost for functions such as smoke control and engine protection.

200

DDEC V Codes (cont.)

25ST0072-2 Rev. 04/4/00

Sensor

Function

Supply Fuel Temperature Sensor (SFT Sensor)

Senses fuel temperature for functions such as engine fueling.

Turbo Compressor Temperature Out Sensor

Senses turbo out air temperature.

Turbo Speed Sensor (TSS)

Senses turbo speed for over-speed conditions.

201

Schematic Diagram DDEC V Synch Reference

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Fuel / Oil / Coolant / EGR Temperature

(ECU)

V

Oil / Fuel Pressure

EUI

Optimized Idle

TCITS OEM

Fan Controls Engine Brake ISD / Vehicle Power Down Communication DDR Interface/ DDDL/ Reprogramming PWM Ports Stop Engine

Check Engine

MASS Oil level/Fuel Restriction

Crankcase Pressure

Barometric Pressure

Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor

Coolant Level TCOTS

VSG Control Progressive Shift Pressure Governor Diagnostic Request

25ST0072-2 Rev. 04/4/00

Engine Rating / Cruise Power / Switch Power

-

+ Battery

Stop Engine Override

12-24 Volt VPOD

Hydraulic EGR Valve

VNT 202

Schematic Diagram DDEC V Synch Reference

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Fuel / Oil / Coolant / EGR Temperature

(ECU)

V

Oil / Fuel Pressure

MASS Oil level/Fuel Restriction Barometric Pressure Coolant Level TCOTS

VSG Control Progressive Shift Pressure Governor Diagnostic Request

25ST0072-2 Rev. 04/4/00

-

+ Battery

Stop Engine Override

12-24 Volt VPOD

Hydraulic EGR Valve

VNT 203

DDEC V Hydraulic EGR Valve • Current Controlled from DDEC • Actual Current Displayed in DDDL Using Mill volts • Increasing Current Allows More Oil Flow to Hydraulically Open 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 • New EGR Valve Design • Electronically Controlled Hydraulic Valve Actuation – Utilizes Engine Oil to “Power” the Valve With Supply Line from the Oil Cooler Adapter – Direct DDEC Input – Reduced Linkage “Parts”

• Replaces Pneumatic Actuator, Air Lines and EGR VPOD

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

• Distributor Reprogramming System – V3.61 Released to key distributors on Aug 24 » Supports engineering test calibrations » Supports most customer features, not fully functional

• Production release of DRS on Dec 15

25ST0072-2 Rev. 04/4/00

209

Distributor Reprogramming DDEC V • DDEC V Electronic Tools DDEC V Hardware Components for Programming Station (DRS)

Distributor Reprogramming Kit

DDEC V Programming Software Supporting Test Vehicles Production Version Scheduled for Release 12/1/03 New High Speed Kit Features J-1939 Connection

25ST0072-2 Rev. 04/4/00

210

Schematic Diagram DDEC V Synch Reference

Electronic Control Module (ECM)

Timing Reference Electronic Foot Pedal Assembly

Turbo Boost Pressure Turbo Speed EGR Delta

Fuel / Oil / Coolant / EGR Temperature

(ECU)

V

Oil / Fuel Pressure

EUI

Optimized Idle

TCITS OEM

Fan Controls Engine Brake ISD / Vehicle Power Down Communication DDR Interface/ DDDL/ Reprogramming PWM Ports Stop Engine

Check Engine

MASS Oil level/Fuel Restriction

Crankcase Pressure

Barometric Pressure

Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor

Coolant Level TCOTS

VSG Control Progressive Shift Pressure Governor Diagnostic Request

25ST0072-2 Rev. 04/4/00

Engine Rating / Cruise Power / Switch Power

-

+ Battery

Stop Engine Override

12-24 Volt VPOD

Hydraulic EGR Valve

VNT 211

Bosch N-3 Fuel Injector

25ST0072-2 Rev. 04/4/00

212

Bosch N3 • Removal Force Applied to this Surface Only !

Insert pry bar Copper Gasket 25ST0072-2 Rev. 04/4/00

213

Bosch N3 • Electronic Fuel Injector – Internal Solenoid – Reduced Internal Fuel Volume – Utilize Electrical Connector Instead of Ring Terminals – Designed to Accept SS Injector Sleeve

• Benefits – Improved Reliability Due to Higher Design Factor of Safety ( 1.6 ) » Less Susceptible to Tip and Body Cracks

– Crisper Injection Event (Efficiency)

25ST0072-2 Rev. 04/4/00

214

Bosch N-3 Injector • Improved Response Times .7-.9ms • Continue to Utilize High Injection Pressure for Optimization of Emissions and Efficiency Tradeoffs – 2200 bar Peak Injection Pressure

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 -

E-18

TRS +

E-20

SRS -

E-19

SRS +

1 2

1 2

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

219

DDEC V On-Highway Governors ECU Signal

V-13/14

TPS A

V-11

5 Volt

B

V-60

Return

C D

V-16

IVS, Closed @ Idle Return

V-59 VHC 25ST0072-2 Rev. 04/4/00

E F

. .

13: ALSG 14: VSG 220

DDEC V Turbo Speed Sensor ECU

E-35

TSS -

E-34

TSS +

1 2

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

221

DDEC V Temperature Sensor ECU

E-15 XX

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

XX is CTS: E-5 OTS: E-7 EGR: E-10

Return

1

Signal

2

2 seconds to set a high temp. code

222

DDEC V Three Wire Engine Sensors ECU Return

E-15

Signal

XX

5 Volt

E-12

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

XX is OPS: E-31 BPS: E-37 TBS: E-39

1 2 3

7 seconds to set a low pressure code

223

DDEC V Coolant Level Sensors ECU

V-37/38 V-60

Signal Return

A B

37: ACLS (MAS) 38: CLS, Shutdown 15 seconds to set a low coolant code VHC 25ST0072-2 Rev. 04/4/00

224

DDEC V Three Wire Vehicle Sensor ECU

V-60

Return

A

V-11

5 Volt

B

V-29

Signal

C

PGS

Pressure Governor VHC 25ST0072-2 Rev. 04/4/00

225

Diagnostic Test Mode/Stop Engine Override DDEC V Switch - DTM/SEO ECU

V-24 V-59

Diag. Request Return

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

226

DDEC V Diagnostic Connector ECU

V-43 V-58 V-44 V-56 V-57

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

Ground Power J1939 + J1939 J1939 Shield J1587 + J1587 Plug Plug

A B C D E F G H J

D E F

C B

A J G

H

J 1587 & 1939 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

E-46

Switched Power

1

E-4

PWM Control

2

E-42

Ground

3

V P O D

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

229

DDEC V Cruise Control

ECU V-9 V-47 V-8 V-10 V-3 V-59 V-XX

Input, Cruise On/Off Input, Set/Coast Input, Resume/Accel Input, Clutch Released Input, Service Brake Released Sensor Return Low Output, Cruise Light

V-17

VSS +

V-18

VSS -

Ignition

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

230

DDEC V Warning Lights ECU

V-1

V-2

V-X VHC 25ST0072-2 Rev. 04/4/00

CEL/AWL

Ignition

SEL/RSL

Ignition

Indicator

Ignition

Max current to be grounded per output 2.0 A. Max total current for all 10 low-side D.O.’s is 10.0 A. 231

DDEC V ISD and Vehicle Power Shutdown ECU PB Sw V-50 V-59

Neutral Sw

PB Input Sensor return To Veh. Systems

V-7

Low Output, VPS

Ign. Sw

VHC

25ST0072-2 Rev. 04/4/00

232

DDEC V Jakes ECU V-39 V-51 V-59 E-49 E-48

Analog Input, Brake Low Analog Input, Brake Med Sensor return Digital Output, High Side. Low/High Brake Digital Output, High Side. Med/High Brakes

EHC/VHC 25ST0072-2 Rev. 04/4/00

233

DDEC V Series 60 Injector Wiring ECU E-63 1 E-65 E-61 E-64

Bank 1 Return

2 3

E-68 4 E-66 E-62 E-67 EHC 25ST0072-2 Rev. 04/4/00

Bank 2 Return

5 6 234

DDEC V VIH Schematic

25ST0072-2 Rev. 04/4/00

235

DDEC V Service Tools

Service Tools Test Sensors

DDEC V Test ECM DDEC V Harness Repair Kit 25ST0072-2 Rev. 04/4/00

237

Summary of Major Benefits • Improved Component Reliability – – – –

• • • • •

25ST0072-2 Rev. 04/4/00

EGR Cooler Injector Overhead EGR Valve

Reduced Ring/Liner Wear and Oil Soot Loading Eliminated Compressor Surge at Altitude Enhanced Technology With DDEC V Reduced Engine Weight Potential for Fuel Economy Improvements From 2003 Depending on Current Driveline Gearing 238

We Define Performance

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