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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
25ST0072-2
Rev. 04/4/00 4
What is DDEC?
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
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
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
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
25ST0072-2
Rev. 04/4/00 27
Injector Calibration Codes
Part Number
Calibration Code
25ST0072-2
Rev. 04/4/00 28
Injector Cycle Terminology
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
0 .25 4.75 5
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
25ST0072-2
Rev. 04/4/00 37
SRS/TRS Sensors
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
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
EEPROM
- +
Battery
25ST0072-2
Rev. 04/4/00 53
Turbo Boost Sensor
Series 53
DDEC III Series 50/60/2-Cycle
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
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
- +
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
25ST0072-2
Rev. 04/4/00 61
On Engine Components
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 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
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
• Example
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
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
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
Coolant Level
Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 79
Multiple Horsepower Ratings
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
Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 81
Cruise Control
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
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
Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 85
Crankcase Pressure
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
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
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
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
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
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
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
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
Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 117
DDEC III/IV
Engine Brakes
Range Example
• Cruise Engine Brake Yes/No Yes
Engine Brake MPH 1-10 3
Engine Brake Increment 0-4 2
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
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
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”
#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
Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 129
Optimized Idle
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.
25ST0072-2
Rev. 04/4/00 132
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.
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.
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
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
Digital Inputs
25ST0072-2
Rev. 04/4/00 143
Digital Outputs
Digital Output Functions
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
25ST0072-2
Rev. 04/4/00 148
Fuel Economy Incentive
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
25ST0072-2
Rev. 04/4/00 154
DDC Installed Components
25ST0072-2
Rev. 04/4/00 155
On Engine Components
25ST0072-2
Rev. 04/4/00 156
On Engine Components
25ST0072-2
Rev. 04/4/00 157
Optional OEM Installed Components
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
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
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
0 .25 4.75 5
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
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
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
Volt-Ohm Meter
25ST0072-2
Rev. 04/4/00 209
Troubleshooting Tools
25ST0072-2
Rev. 04/4/00 210
Troubleshooting Tools
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