DDEC

DDEC
DDEC
DDEC
III DDEC IV
Detroit Diesel
Electronic Controls
 DDEC AGENDA

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

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

25ST0072-2
Rev. 04/4/00 4
 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 5
 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 7
 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
25ST0072-2
Rev. 04/4/00 9
 DDEC Necessities

Ignition

Electronic
EUI
Control
Module
(ECM)
Synch Reference

Timing Reference

EEPROM

- +
Battery

25ST0072-2
Rev. 04/4/00 10
 Schematic Diagram DDEC III/ IV

Electronic
Control
Module
(ECM)

EEPROM

25ST0072-2
Rev. 04/4/00 11
 Electronic Control Module

25ST0072-2
Rev. 04/4/00 12
 Electronic Control Module

OEM responsibility DDC

responsibility
Mandatory circuits Power
and Ground Engine sensors,
harness, &
connectors
J1922,J1939, Ignition
Injector harness &
Throttle position sensor connectors
Optional circuits Manual Injectors
fan on switch, Jake Brake,
439 Ignition wire

25ST0072-2
Rev. 04/4/00 13
 Schematic Diagram DDEC III / IV

Electronic
Control
Module
(ECM)

EEPROM

- +
Battery

25ST0072-2
Rev. 04/4/00 14
 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 15
 Power Supply DDEC III/ IV

25ST0072-2
Rev. 04/4/00 16
 Power Supply DDEC III / IV

25ST0072-2
Rev. 04/4/00 17
 Schematic Diagram DDEC III / IV
EUI
Electronic
Control
Module
(ECM)

EEPROM

- +
Battery

25ST0072-2
Rev. 04/4/00 18
 Electronic Unit Injectors

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

Series 4000 Spray Nozzle Series 53 EUI

Series 2000 EUP
25ST0072-2
Rev. 04/4/00 19
 Voltage in Series 50/60
Rocker Arm Injector
Solenoid Animation
Cam

Poppet
Valve
Plunger

Fuel out

Fuel in

Needle Valve
 Series 4000
Solenoid Rocker Arm
Nozzle
filter CAM Animation

Fuel High
Return Pressure
Fuel

Needle Nozzle
Valve
 Series 2000
EUP
Rocker Arm
Solenoid Fuel In
Animation
CAM

EUP

Cam

Spay
Nozzle
 Electronic Unit Pump

25ST0072-2
Rev. 04/4/00 23
 Top Of Stroke

Fuel
In

Fuel
Out

Injector
Tip

25ST0072-2
Rev. 04/4/00 24
 Start Of Injection

Fuel
In

Fuel
Out

Injector
Tip

25ST0072-2
Rev. 04/4/00 25
 End Of Injection

Fuel
In

Fuel
Out

Injector
Tip

25ST0072-2
Rev. 04/4/00 26
 Injection Sequence

Fuel Fuel Fuel

In In In
Fuel Fuel Fuel
Out Out Out

Injector Injector Injector

Tip Tip Tip

25ST0072-2
Rev. 04/4/00 27
 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 28
 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

25ST0072-2
Rev. 04/4/00 29
 Injector Response Times

25ST0072-2
Rev. 04/4/00 30
 Cylinder Cut-Out

25ST0072-2
Rev. 04/4/00 31
 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 32
 Sensor Operations

Operates on 5 Volts for All D.C. Sensors

0 .25 4.75 5

Low Voltage Normal High Voltage

Operating
Range

25ST0072-2
Rev. 04/4/00 34
 Sensor Wiring

• Common Return
Circuit. #452
• Thermistor

• Piezoresistive
Pressure sensor
• Voltage is Proportional
to Pressure

25ST0072-2
Rev. 04/4/00 35
 2-wire Sensors

5V Supply

Signal

Return

ECM Sensor
Open = HI VOLTAGE
Short = LO VOLTAGE

25ST0072-2
Rev. 04/4/00 36
 3-wire Sensors
ECM Sensor
5V Supply

Signal

Return

Open Supply = LO VOLTAGE

Open Signal = LO VOLTAGE
Open Return = HI VOLTAGE
Supply short to Signal = HI VOLTAGE
Supply short to Return = LO VOLTAGE
Signal short to Return = LO VOLTAGE

25ST0072-2
Rev. 04/4/00 37
 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 38
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference Electronic
Control
Module
(ECM)

EEPROM

- +
Battery

25ST0072-2
Rev. 04/4/00 39
 Series 50/60
SRS/TRS Sensors

SRS/TRS

Timing Wheel
Bull Gear
DDEC III/ IV
DDEC III/ IV

25ST0072-2
Rev. 04/4/00 41
Series 60
Sensor
Locations
 Series 2000
SRS/TRS Sensors

SRS/TRS TIMING
WHEEL

TIMING
WHEEL
Cam Gear/SRS

25ST0072-2
Rev. 04/4/00 43
Series 2000
Sensor
Locations
 Series 4000
SRS/TRS Sensors

SRS/TRS

Timing Wheels

Cam Gear/SRS

25ST0072-2
Rev. 04/4/00 45
Series 4000
Sensor
Locations
 Two Cycle
SRS/TRS with Timing Wheel

SRS/TRS SRS/TRS
Sensor Sensor

Timing Wheel Timing Wheel

& Cam Pulley & Cam Pulley

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

25ST0072-2
Rev. 04/4/00 47
 Two Cycle
SRS/TRS with Timing Wheel

SRS/TRS SRS/TRS
Sensors Sensors

Timing Timing
Wheels Wheels

Series 149
Series 92, 12V, 16V
25ST0072-2
Rev. 04/4/00 48
 Series 53
SRS/TRS with Timing Wheel

Timing
Wheel SRS/TRS
Sensors

SRS PIN

25ST0072-2
Rev. 04/4/00 49
 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 50
 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
25ST0072-2
failure
Rev. 04/4/00 51
 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 53
 Turbo Boost Sensor

Series 53
DDEC III Series 50/60/2-Cycle

Series 2000 / 4000 Series 50/60 DDEC IV

25ST0072-2
Rev. 04/4/00 54
 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 55
 Temperature Sensors

Coolant Temperature Sensor Air Temperature Sensor

Series 50/60 Series 50/60

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

Series 50/60/2-Cycle - Air Temp 53 Series 2000/4000

25ST0072-2
Rev. 04/4/00 56
 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

- +
Battery

25ST0072-2
Rev. 04/4/00 58
 Pressure Sensors
Coolant
Oil / Fuel
Pressure
Pressure

Series 50/60/2-Cycle

Series 2000/4000
Different Harness Connectors

Series 4000
High Pressure Fuel
Series 2000/4000

25ST0072-2
Rev. 04/4/00 59
 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 60
 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

25ST0072-2
Rev. 04/4/00 61
 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 62
 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

Coolant Level

- +
Battery

25ST0072-2
Rev. 04/4/00 63
 Coolant Level Sensor

DDEC II/ III Coolant Level Sensor

DDEC III or IV
Coolant Level Sensor

25ST0072-2
Rev. 04/4/00 64
 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

Coolant Level

VSG Control

- +
Battery

25ST0072-2
Rev. 04/4/00 65
 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 66
 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

Coolant Level

VSG Control

Progressive Shift - +
Battery

25ST0072-2
Rev. 04/4/00 67
 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
25ST0072-2
Rev. 04/4/00 68
 Progressive Shift

25ST0072-2
Rev. 04/4/00 69
 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

Coolant Level

VSG Control

Progressive Shift - +
Pressure Governor Battery

25ST0072-2
Rev. 04/4/00 70
 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 71
 Electronic Fire Commander

Control Buttons
Engine Data

System Status

Message Window

25ST0072-2
Rev. 04/4/00 74
 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

Coolant Level

VSG Control

Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 75
 Diagnostic Request
or Stop Engine Override

25ST0072-2
Rev. 04/4/00 76
 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.

25ST0072-2
Rev. 04/4/00 78
 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

Coolant Level

VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 79
 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 80
 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

Cruise Control Vehicle Speed Limiting

Coolant Level 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 81
 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.

25ST0072-2
Rev. 04/4/00 82
 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
25ST0072-2
Rev. 04/4/00 83
 Cruise Control

25ST0072-2
Rev. 04/4/00 84
 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
Crankcase Pressure

Cruise Control Vehicle Speed Limiting

Coolant Level 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 85
 Crankcase Pressure

Series 149 CCM Series 4000 CCPS Series 60 CCM

25ST0072-2
Rev. 04/4/00 86
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control
Module
Turbo Boost Pressure
(ECM) Stop
Fuel / Oil / Coolant Engine
Temperature

Oil / Fuel Pressure

Check
EEPROM Engine

Oil level/Fuel Restriction

Crankcase Pressure

Cruise Control Vehicle Speed Limiting

Coolant Level 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 87
 Stop Engine / Check Engine Lights

25ST0072-2
Rev. 04/4/00 88
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control
Module
Turbo Boost Pressure
PWM Ports
(ECM)
Fuel / Oil / Coolant Stop
Temperature Engine

Oil / Fuel Pressure

Check
EEPROM Engine

Oil level/Fuel Restriction

Crankcase Pressure

Cruise Control Vehicle Speed Limiting

Coolant Level 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 89
 Pulse Width Modulated Outputs
• Signals sent by the ECM to other microprocessor controlled
systems

20% 50% 80%

Signal High
Signal Low
1 Hz 1 Hz 1 Hz

• 50 Hz duty cycle modulated

• Four ports available-- circuits 908, 909, 910, 911
• Factory programmed only

25ST0072-2
Rev. 04/4/00 90
 PWM

Circuit Wire
No. Color
• PWM #1 Output - VIH (Transmission) 908 White
• PWM #2 Output - ESH (Throttle/GAS) 909 Lt. Green
• PWM #3 Output - ESH (Gas Valve/GAS) 910 Orange
• PWM #4 Output - ESH (Fan Control) 911 Pink

• ESH = Engine Sensor Harness

• VIH = Vehicle Sensor Harness

25ST0072-2
Rev. 04/4/00 91
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control
Module DDR Interface/ DDDL/ Reprogramming
Turbo Boost Pressure
(ECM) PWM Ports

Fuel / Oil / Coolant Stop

Temperature Engine

Oil / Fuel Pressure

Check
EEPROM Engine

Oil level/Fuel Restriction

Crankcase Pressure

Cruise Control Vehicle Speed Limiting

Coolant Level 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 92
 DDR Interface with MPSI Printer

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

•MIDs
•PIDs
•FMIs
•SIDs

25ST0072-2
Rev. 04/4/00 95
 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)
Oil Pressure 4 - Circuit Low (LO VOLT)

25ST0072-2
Rev. 04/4/00 96
 Detroit Diesel
Diagnostic Link

25ST0072-2
Rev. 04/4/00 97
 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

25ST0072-2
Rev. 04/4/00 98
 Detroit Diesel
Diagnostic Link

25ST0072-2
Rev. 04/4/00 99
 Detroit Diesel
Diagnostic Link

25ST0072-2
Rev. 04/4/00 100
 Detroit Diesel
Diagnostic Link

25ST0072-2
Rev. 04/4/00 101
 DDR Communication- On Highway

DDEC II or III
DDEC III/ IV
12-Pin
6-Pin

25ST0072-2
Rev. 04/4/00 102
 DDR Communication- On Highway

DDEC IV
9 Pin

25ST0072-2
Rev. 04/4/00 103
DDEC II / III / IV
Reprogramming
 Reprogramming Station

25ST0072-2
Rev. 04/4/00 105
 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

25ST0072-2
Rev. 04/4/00 106
 Reprogramming Station
Windows Based for Download

25ST0072-2
Rev. 04/4/00 107
 Reprogramming Station
Windows Based for Download

25ST0072-2
Rev. 04/4/00 108
 Reprogramming Station
Windows Based for Download

25ST0072-2
Rev. 04/4/00 109
 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

Oil / Fuel Pressure Stop

Check
Engine Engine
EEPROM
Oil level/Fuel Restriction
Crankcase Pressure

Cruise Control Vehicle Speed Limiting

Coolant Level Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 112
 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. 04/4/00 113
 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

Oil / Fuel Pressure Stop

Check
Engine Engine
EEPROM
Oil level/Fuel Restriction
Crankcase Pressure

Cruise Control Vehicle Speed Limiting

Coolant Level Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 114
 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. 04/4/00 115
 Vehicle Power Shutdown
Idle
Ignition
Shutdown
On
Ignition switch

To Vehicle

ECM

25ST0072-2
Rev. 04/4/00 116
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control Engine Brake

Module Idle Shut Down/Vehicle Power Down

Turbo Boost Pressure Communication
(ECM) DDR Interface/ DDDL/ Reprogramming
Fuel / Oil / Coolant
Temperature PWM Ports

Oil / Fuel Pressure Stop

Check
Engine Engine
EEPROM
Oil level/Fuel Restriction
Crankcase Pressure

Cruise Control Vehicle Speed Limiting

Coolant Level Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 117
 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.
25ST0072-2
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 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
25ST0072-2
Rev. 04/4/00 120
 DDEC Engine Brakes

#953 (Battery Negative)

T3 Low Brake Off

On LO
HIGH
MED

S3 Med. Med.
Low

ECM
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic Fan Controls
Pedal Assembly
Control Engine Brake

Module Idle Shut Down/Vehicle Power Down

Turbo Boost Pressure Communication
(ECM) DDR Interface/ DDDL/ Reprogramming
Fuel / Oil / Coolant
Temperature PWM Ports

Oil / Fuel Pressure Stop

Check
Engine Engine
EEPROM
Oil level/Fuel Restriction
Crankcase Pressure

Cruise Control Vehicle Speed Limiting

Coolant Level Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 122
 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
25ST0072-2
Rev. 04/4/00 123
 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)

25ST0072-2
Rev. 04/4/00 124
 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”

Fan Override (Input Off)

#953 (-)
Aux. Fan Control (Input On)
Off)
Air Conditioning
Air Conditioning -- On
off
(Fan on for at least 3 minutes)
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic Optimized Idle
Fan Controls
Pedal Assembly
Control 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 Stop
Check
Engine Engine
EEPROM
Oil level/Fuel Restriction
Crankcase Pressure

Cruise Control Vehicle Speed Limiting

Coolant Level Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 129
 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

25ST0072-2
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 Requirements for Optimized Idle
 Cruise Enable Switch Hood Switch
 Idle Shutdown Enabled Under-hood Alarm
 Vehicle Power Down Start Relay
Relay Overlay Relay
 Op Idle light on dash VSS Enabled
 Park Brake Switch Optional Sleeper Thermostat
 Transmission Neutral
Switch (Some
transmissions require
high range in Neutral)

25ST0072-2
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 Optimized Idle Shutdown Sequence
 Park Brake set with hood closed and transmission in Neutral
supplies ground to the Park Brake input and the Overlay
Relay. Idle Timer starts and the Overlay Relay closes
supplying power to the Start Relay.

 Optimized Idle is activated by turning on the Cruise Enable

Switch which supplies ground on the Cruise Enable input.

 Optimized Idle Light flashes until the engine shuts down

then remains on.

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 Optimized Idle Shutdown Sequence
 With Battery Voltage above 12.2V, Oil Temp between
15ºC/60ºF and 40ºC/104F, and Sleeper Temp within limits, the
Idle Timer shuts the engine down.

 Vehicle Power Down Relay opens powering down the vehicle

Ignition Circuit.

 With Ignition key on, the ECM is still awake and it

continuously monitors Battery Voltage, Oil Temperature and
Sleeper Temperature.

25ST0072-2
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 Optimized Idle Start Sequence
• With the hood closed, Transmission in Neutral, Park
Brake set, and the Optimized Idle dash light ON,the
ECM supplies ground on PWM #2, wire 909 which
activates the under-hood alarm.

• ECM then supplies ground on PWM #3, wire 910

which closes the Start Relay.

• After the engine starts, the ECM supplies ground to

the Vehicle Power Down relay which closes to
supply Ignition power to the vehicle
25ST0072-2
Rev. 04/4/00 134
 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. 04/4/00 137
Digital Inputs
 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”

25ST0072-2
Rev. 04/4/00 140
 DIGITAL INPUTS

No Function
ECM No Function
No Function
Cruise Enable
Fan Override

#953
EEPROM
#150
_
+
Battery

25ST0072-2
Rev. 04/4/00 141

• 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
25ST0072-2
Rev. 04/4/00
Digital Inputs
• 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
142

• 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
25ST0072-2
Rev. 04/4/00
Digital Inputs (Cont’d)
• 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
143
Digital Outputs
 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

25ST0072-2
Rev. 04/4/00 145
 OUTPUTS
SEL

ECM
To Jake brake

Ignition
#439

25ST0072-2
Rev. 04/4/00 146

• 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
25ST0072-2
Rev. 04/4/00
Digital Outputs
• 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
147
 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. 04/4/00 148
 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
25ST0072-2
Rev. 04/4/00 149
 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. 04/4/00 150
Maintenance Alert System
 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

25ST0072-2
Rev. 04/4/00 152
 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. 04/4/00 153
 Maintenance Alert System

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

Fuel Restriction Sensor Monitor Display Unit

25ST0072-2
Rev. 04/4/00 154
 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. 04/4/00 155
 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

25ST0072-2
Rev. 04/4/00 156
 On Engine Components

• Fuel Restriction Sensor

– Measures Fuel System
Restriction at Fuel Pump Inlet
– Sensor Measures Actual Inlet
Restriction

25ST0072-2
Rev. 04/4/00 157
 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

25ST0072-2
Rev. 04/4/00 158
 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. 04/4/00 159
 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. 04/4/00 160
 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
25ST0072-2
Rev. 04/4/00 161
 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. 04/4/00 162
 Summary
• Monitors and Displays Service Requirements
– Oil Level
Engine
– Fuel System Restriction
– Air Filter Restriction
– 2nd Coolant Level Vehicle
– 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

25ST0072-2
Rev. 04/4/00 163
Construction & Industrial
 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

25ST0072-2
Rev. 04/4/00 165
Wire Crimping Exercise
 Wire Crimping Tools

25ST0072-2
Rev. 04/4/00 167
 Wire Crimping Tools

25ST0072-2
Rev. 04/4/00 168
 Wire Crimping Tools

25ST0072-2
Rev. 04/4/00 169
 Wire Crimping Tools

25ST0072-2
Rev. 04/4/00 170
 Wire Crimping

25ST0072-2
Rev. 04/4/00 171
Wire Splicing
 Wire Splicing Tools

25ST0072-2
Rev. 04/4/00 173
 Series 71 & 92
SRS / TRS Adjustment
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 175
 Basic Electricity -
Wire Harness Exercise
 Sensor Operations

Operates on 5 Volts for All D.C. Sensors

0 .25 4.75 5

Low Voltage Normal High Voltage

Operating
Range

25ST0072-2
Rev. 04/4/00 200
 Sensor Wiring

• Common Return
Circuit. #452
• Thermistor

• Piezoresistive
Pressure sensor
• Voltage is Proportional
to Pressure

25ST0072-2
Rev. 04/4/00 201
 2-wire Sensors

5V Supply

Signal

Return

ECM Sensor
Open = HI VOLTAGE
Short = LO VOLTAGE

25ST0072-2
Rev. 04/4/00 202
 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

25ST0072-2
Rev. 04/4/00 203
 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. 04/4/00 204
 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. 04/4/00 205
 Electrical System
452 Cavity A
432 Cavity B
416 Cavity C

Short 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. 04/4/00 206
 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. 04/4/00 207
Troubleshooting Tools
 Troubleshooting Tools

 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.

Volt-Ohm Meter

25ST0072-2
Rev. 04/4/00 209
 Troubleshooting Tools

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

J37164-A J35634 J41005

25ST0072-2
Rev. 04/4/00 210
 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

25ST0072-2
Rev. 04/4/00 211