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
 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 6
 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
 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 8
 DDEC IV Features
Four New ECMs
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 Engine sensors,

and Ground harness, &
connectors

J1922,J1939, Ignition Injector harness &

connectors
Throttle position sensor Injectors
Optional circuits Manual
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
25ST0072-2 EUP 19
Rev. 04/4/00
 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
Solenoid Fuel In
Rocker Arm
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
 Injector Response Time
Limits & Default Values
2.8
Response Time - ms

2.4 IRT Min - Default

2 Default =
IRT Max - Std.
IRTMIN
1.6
Value
1.2 DDEC III
IV
0.8

0.4 Supplied by DDC Engineering

8 12 16 20 24 28 32
Vbat-Volts

25ST0072-2
Rev. 04/4/00 33
 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
DDEC II

DDEC II Bull Gear

25ST0072-2
Rev. 04/4/00 40
 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
 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 52
 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
 Temperature Sensors

Coolant Temperature Sensor Air Temperature Sensor

Series 50/60 Series 50/55/60

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

Series 50/55/60/2-Cycle Series 2000/4000

25ST0072-2
Rev. 04/4/00 57
 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
 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 72
 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 73
 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
 Diagnostic Request
or Stop Engine Override

25ST0072-2
Rev. 04/4/00 77
 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
(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 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
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. 04/4/00 111
 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
Rev. 04/4/00 118
 DDEC III/IV
Engine Brakes

DDEC III/IV controls engine brake operation

If configured for cruise control engine brake
the ECM will automatically turn on the brake if
the set speed is exceeded.
Two digital inputs and two positive outputs are
used to control the brake.
25ST0072-2
Rev. 04/4/00 119
 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
 Fan Control
Four fan configurations can be used
Single fan
Dual fans
Two speed fan
Variable speed fan (PWM)
Fan controlled by digital output(s)
Fan override & air conditioning active
digital inputs can force the fan on

25ST0072-2
Rev. 04/4/00 125
 Fan Control
Four fan configurations can be used
Single fan
Dual fans
Two speed fan
Variable speed fan (PWM)
Fan controlled by digital output(s)
Fan override & air conditioning active
digital inputs can force the fan on

25ST0072-2
Rev. 04/4/00 126
 Fan Control
Four fan configurations can be used
Single fan
Dual fans
Two speed fan
Variable speed fan (PWM)
Fan controlled by digital output(s)
Fan override & air conditioning active
digital inputs can force the fan on

25ST0072-2
Rev. 04/4/00 127
 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
Rev. 04/4/00 130
 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
Rev. 04/4/00 131
 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.

25ST0072-2
Rev. 04/4/00 132
 Optimized Idle Shutdown Sequence
With Battery Voltage above 12.2V, Oil Temp between
15C/60F and 40C/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
Rev. 04/4/00 133
 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
Optimized Idle
 CRUISE
ENABLE
BATTERY VOLTAGE
BATTERY VOLTAGE
ENGINE TEMP

ENGINE
SHUT DOWN

ECM
 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 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 (Contd)
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
 Digital Outputs
Coolant Level Low Light VSG Active Indication
Cruise Control Active Light (PGS (Release 2.00 or Later only)
Active Light) Low Oil Pressure Light
Deceleration Light High Oil Temperature Light
Engine Brake Active High Coolant Temp. Light
Fan Control #1 (Release 3.00 or Later Only)
Fan Control #2 Ether Injection
Low Coolant Pressure Light
Low DDEC Voltage
High Crankcase Pressure Light
Pressure Governor System
Pressure Mode Light (Release 4.00 or Later Only)
Optimized Idle Active light
Starter Lockout
Gas Solenoid Shutdown
Transmission Retarder
Air Compressor Load Switch
Vehicle Power Shutdown
25ST0072-2
Rev. 04/4/00 147
 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
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 176
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 177
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 178
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 179
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 180
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 181
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 182
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 183
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 184
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 185
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 186
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 187
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 188
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 189
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 190
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 191
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 192
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 193
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 194
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 195
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 196
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 197
 Series 71/92 SRS/TRS Adjustment

25ST0072-2
Rev. 04/4/00 198
 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
 DDEC IV
TROUBLESHOOTING
 DDEC IV Troubleshooting Tips

Troubleshooting tips that are not found in

the A&I Manual or the TS Manual

Most ECM diagnosed as failed and replaced on DDEC III units

were No Trouble Found
77% are OK for reuse
Tips Useful for Both DDEC III and DDEC IV

25ST0072-2
Rev. 04/4/00 213
 Coolant Level Sensor Low Voltage
Code 13
False code logged due to high conductivity of used
coolant
Drain and flush cooling system
Code disabled in current S60 program, Reprogram
to resolve

25ST0072-2
Rev. 04/4/00 214
 TRS/SRS Circuit Problems

Code 41/42
Oil wicking through the sensor
Injector harness shorted to cylinder head
S60 - insufficient clearance on TRS - shim .020
Misfire in DDEC IV = ECM/ECM problem

25ST0072-2
Rev. 04/4/00 215
 TRS/SRS Circuit Problems

Code 41/42 (contd)

Code active only when Jakes applied?
Check resistance of Jake solenoid
Resistance measured @ 70o F
> 10 ohm - replace solenoid
< 10 ohm - try test ECM

25ST0072-2
Rev. 04/4/00 216
 Coolant Temperature High

Code 44
Code logged for 4-10 seconds
Corrosion on terminals result in rapid signal
Changes
Clean terminals at Coolant Level Sensor (CLS) and
30 pin connector
DDEC IV- ECM/ECM fault
DDEC IV- Optimized Idle thermostat

25ST0072-2
Rev. 04/4/00 217
 Non-volatile Memory Fault

Code 53
Active code - replace ECM/ECM
Inactive code - use DDR to clear
Check power down sequence at wire 439
Must have power at 439 for 30 seconds - key off
Is unit cutting in & out when driving?
May indicate intermittent open circuit on 439
If DDEC 4 update to 24.03 or greater

25ST0072-2
Rev. 04/4/00 218
 Vehicle Speed Sensor Fault

Code 54
Road speed < 3 mph & RPM > 1500 & pulsewidth >
15
VSS anti-tamper option will indicate driver
tampering to defeat Road Speed Limit
Not an ECM/ECM fault

25ST0072-2
Rev. 04/4/00 219
 J1939 Data Link Fault

Code 55
Caused by use of ProLink 9000 version 1.2 software
Software activates J1939 data link when Diagnostic
Data Reader (DDR) is used to perform any functions
Replace cartridge with newer software
Distributor resets transmission option with
reprogramming station

25ST0072-2
Rev. 04/4/00 220
 J1587 Data Link Fault

Code 56
Can DDR communicate with ECM?
If yes, fault is not in ECM
Possible cause - wiring fault on 900 and 901
ProDriver, Transmission, Traction Control, Anti-
locking Braking System (ABS) use 900 and 901 for
data
Check polarity of wiring to components wired to
900/901 for open or short circuit

25ST0072-2
Rev. 04/4/00 221
 J1587 Data Link Fault

Code 56 (contd)
Use vehicle interface module to isolate ECM and
check data link function
If no data received, reprogram ECM
ECM cannot be programmed?
Cause external short of < 16 volts to 900/901
Note: ABS in the test mode will cause code to log as
soon as you attempt to move vehicle

25ST0072-2
Rev. 04/4/00 222
 Low Coolant Light Always On

Incorrect ECM program

Open or grounded Output wire
Check coolant level sensor polarity
Check wiring for open or short circuit

25ST0072-2
Rev. 04/4/00 223
 No Throttle Concerns

Throttle position sensor faulty

Open or shorted wiring to TPS
Use vehicle interface module to test ECM
Check TPS counts - out of spec. unplug the engine
sensor harness and recheck counts.
Check oil pressure sensor and turbo boost pressure
sensor

25ST0072-2
Rev. 04/4/00 224
 Throttle Concerns

Intermittent Jake Brakes

Throttle position sensor is not sending 0% throttle
signal to ECM
Refer to OEM for correction

25ST0072-2
Rev. 04/4/00 225
 Throttle Concerns

RPMs go up, Idle shutdown shuts down engine

during override
Improper throttle signal input
Isolate ECM from vehicle inputs
Replace throttle position sensor

25ST0072-2
Rev. 04/4/00 226
 Engine Brake Problems

Verify proper ECM programming

To activate engine brake must have
TPS % = 0
Pulsewidth less than or = 0
Clutch switch grounded
RPM greater than 850

25ST0072-2
Rev. 04/4/00 227
 Engine Cuts Out or Dies

Intermittent open circuit on ignition wire 439

May also see Check Engine Light and Stop Engine
Light come on for a few seconds
No codes logged
Use test ECM if all else fails

25ST0072-2
Rev. 04/4/00 228
 Engine Cuts Out or Dies

No start or engine stall

No codes
Injector wires shorted to ground
Check resistance on all wires to block < 10 ohms -
short to ground
Replace harness

25ST0072-2
Rev. 04/4/00 229
 Engine Wont Start

Check for proper function of CEL & SEL when the

run switch is turned on
DDR reads no data received with ignition on
Check for fuel in the vehicle
DDR reads SRS received NO
Isolate ECM with Vehicle Interface Module
If no smoke at cranking, check injectors and
injector harness
Install a test ECM
Injector Harness shorted to head

25ST0072-2
Rev. 04/4/00 230
 Fan Operational Concern

Fan always on or inoperative

Review and correct ECM input/outputs
Verify fan control wiring

25ST0072-2
Rev. 04/4/00 231
 Injector Response Times
Erratic or Log Code
Remove alternator belt
If OK clean or repair alternator grounds
Use Vehicle Interface Module 5 pin power harness
direct to battery
If OK clean or repair ground wires in power harness
Check injectors and harness
Install test ECM

25ST0072-2
Rev. 04/4/00 232
 Misfire, Response Time Codes

Incorrectly crimped wire terminals

Replace terminals

25ST0072-2
Rev. 04/4/00 233