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Volume

MAXIMA TECHNOLOGIES & SYSTEMS, INC.

DDBI™ Direct Data-Bus Instruments

Technical Manual
© December 2004 by Maxima Technologies & Systems, Inc. All Rights Reserved.

The contents of this manual are intended for the sole benefit of Maxima's customer and must not be disclosed to
persons outside the intended user's company without Maxima’s permission. This material is regarded as intellectual
property and the user is, therefore, advised that he/she must treat its contents as being confidential between Maxima
and the User Company.
 MAXIMA TECHNOL OGIES & SYSTEMS, INC.

DDBI™ Technical Manual

Maxima Technologies & Systems, Inc.

1811 Rohrerstown Road
Lancaster, PA 17601
Phone 717-581-1000 • Fax 717-581-5800
Table of Contents
 Scope & Use of This Manual 1
Scope 1
Using This Manual 1
 Understanding Data-Bus Operation 2
Data-Bus Basics 2
Data-Bus Hardware 2
Data-Bus Types 3
Data-Bus Communication Protocol Basics 3
 DDBI™ Instruments 4
The DDBI™ Concept 4
DDBI™ 2” Instruments 5
DDBI™ 3” Instruments 6
 DDBI™ Specifications 7
General Specifications 7
DDBI™ 2” Instrument Specifications 7
DDBI™ 3” Instrument Specifications 8
DDBI™ 2” Instrument Dimensions 9
DDBI™ 3” Instrument Dimensions 10
DDBI™ Instrument Protocol Information 11
 DDBI™ Instrument Selection 12
Getting Started 12
Fuel Level 12
Front & Rear Air Brake Pressure 14
Ammeter 14
Voltmeter 14
Data-Bus Instruments 14
 DDBI™ Installation Instructions 15
Getting Started 15
DDBI™ 2” Instrument Mounting 15
DDBI™ 3” Instruments 16
DDBI™ 2” Data-Bus Instrument Wiring 17
DDBI™ 2” Analog Instrument Wiring 17
DDBI™ 3” Without Fault & Analog Inputs Wiring 18
DDBI™ 3” With Fault & Analog Inputs Wiring 19
Data-Bus Termination 20
Data-Bus Installation Examples 21
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Chapter
D D B I ™ T E C H N I C A L M A N U A L

Scope & Use of This

Manual
…provide the reader with enough background information to understand the
overall operation of a data-bus, as well as install and troubleshoot Direct Data-
Bus Instruments - DDBI™…

Scope
The intent of this manual is to provide the reader with enough background
information to understand the overall operation of a data-bus, as well as install and
troubleshoot Direct Data-Bus Instruments -DDBI™.

This manual primarily covers the SAE J1939 data-bus standard, but the basic data-bus
information does pertain to the SAE J1708 standard as well. Additional information
not covered in this manual is available from SAE. Refer to the specific SAE documents
for any additional information.

The user is expected to have a basic knowledge of vehicle electrical wiring, circuits and
schematics. Basic knowledge of engine operating parameters normally displayed on an
instrument cluster, such as engine RPM, vehicle speed, engine & transmission
temperature, transmission and engine oil pressure, etc., is also expected.

Using This Manual

To help the reader better understand the variety of instruments in the DDBI™ line,
the inside margin of each page contains icons and technical information related to
specific styles of instruments and options. It is necessary to be familiar with these icons
to fully understand the diagrams and sample system layouts.

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Chapter
D D B I ™ T E C H N I C A L M A N U A L

Understanding Data-Bus
Operation
… data-bus is like an information super-highway in the vehicle…

Data-Bus Basics
The data-bus is like an information super-highway in the vehicle. A data-bus allows
various controllers, such as the engine controller, transmission controller, chassis
controller, etc., to communicate with each other and any other components connected
to the data-bus.

Most new diesel engines are computer controlled, meaning there is a computer (ECM)
that reads sensors on the engine to determine operating conditions, then adjusts
parameters, such as fuel injection, for optimum power, economy and minimal
emissions. The data-bus enables the ECM to send/receive vast amounts of
information to/from the transmission computer or any other computer connected to
the data-bus, greatly simplifying the vehicle’s electrical system.

The data-bus contains most operating information about the vehicle, such as engine
and vehicle speed, coolant and oil temperatures, oil and fuel pressures, as well as error
codes from the various controllers.

Data-Bus Hardware
The physical aspects of the data-
bus are generally quite simple. It’s
nothing more than a pair of wires
twisted together commonly
referred to as a twisted pair,
running from one controller to
another.

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Data-Bus Types
There are generally two data-bus standards, SAE J1939 and J1708/1587. Most newer
systems use the J1939 standard.

Data-Bus Communication Protocol Basics

The SAE J1939 data-bus devices transmit data to the bus and/or receive data from the
bus. Data is broken down into a structured format, designated specifically by the SAE
standard, containing a source address (SA), a parameter group number (pgn), and
parameter data.

The source address is the number at the beginning of the data packet that identifies
from where the data was transmitted. For example, SA 0 identifies that the data packet
being transmitted is from the primary engine controller.

The parameter group number is the identification label for the group of data that
follows the pgn. This defines what type of information will follow in the parameter
data, i.e. engine pressure values.

The parameter data is a group of 8 data bytes that contain the specific values of the
particular pgn’s parameters, i.e. engine oil pressure.

When a device listening to the data-bus, hears the appropriate SA and pgn, it then reads
the desired data to complete the data transmission.

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D D B I ™ T E C H N I C A L M A N U A L

DDBI™ Instruments
… state-of-the-art instrument platform designed to connect directly to the data-bus
…

The DDBI™ Concept

DDBI™ instruments are a state-of-the-art instrument platform designed to connect
directly to the data-bus. Each individual gauge is smart enough to communicate directly
with the data-bus, identify the appropriate information and display the information for
the operator. There is no need for any costly adapter boxes or specific gateway
instruments.

DDBI™ instruments are available as 2-1/16” gauges and 3-3/8” meters. There are
several versions available for specific applications and functions.

The 2” gauges are available for direct data-bus connection, as well as non-data-bus
instruments to connect directly to senders when the information is not available on the
data-bus.

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D D B I ™ T E C H N I C A L
The ICONS below identify the
various instruments throughout
the remainder of this manual
M A N U A L
DDBI™ 2” Instruments
The 2” instruments have an LED warning light integrated in the dial. The trip point for
the warning LED can be either pre-programmed in the gauge or triggered from
information on the bus from the particular controller.
They are also available with three different signal input styles. If the information is not
available on the data-bus, the gauge will not work and a different gauge is needed to
connect directly to a sender.
DIRECT SAE J1939 DATA-BUS INTERFACE
The first input style is SAE J1939, meaning the indicated information is pulled directly
from the data-bus.
ANALOG–RESISTIVE DIRECT TO SENDER
The second style has an ANALOG – RESISTIVE input. The indicated information
comes directly from a resistive sender with an electrical match of 240Ω – 33Ω. Examples
include air pressure sender and fuel level sender.
NOTE: The analog - resistive input DDBI™ instruments are NOT compatible
with the simulated 240Ω – 33Ω output IntelliSensor® fuel level sender.
ANALOG–VOLTAGE DIRECT FROM SENDER
The third style has an ANALOG – VOLTAGE input. The indicated information comes
directly from a sender with a 0.5 – 4.5 voltage output. Examples include voltage-out
current transducers and voltage-output IntelliSensors®.
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D D B I ™ T E C H N I C A L
The ICONS below identify the
various instruments throughout
the remainder of this manual
M A N U A L
DDBI™ 3” Instruments
The 3” units are available as Tachometers and Speedometers. These instruments can
be divided into 3 groups; Instruments only with no display, instruments with a display,
and instruments with a display, analog (resistive) inputs, and fault display capability.
DIRECT SAE J1939 DATA-BUS INTERFACE NO DISPLAY
Direct connection to SAE J1939 data-bus. No display or warning LEDs.
DIRECT SAE J1939 DATA-BUS INTERFACE WITH DISPLAY
Direct connection to SAE J1939 data-bus. Includes a 2-line display to indicate hours and
trip hours (tachometer) or indicate odometer and trip odometer (speedometer).
DIRECT SAE J1939 DATA-BUS INTERFACE WITH DISPLAY
Direct connection to SAE J1939 data-bus. Includes a 2-line display to indicate hours and
trip hours (tachometer) or indicate odometer and trip odometer (speedometer). The
display can indicate additional parameters including the engine temperature group, engine
pressure/level group, engine configuration, and diagnostic trouble (fault) codes.
These instruments also have the capability to connect to resistive senders to read fuel
level, front and rear air brake pressure. These values are then transmitted to the data-bus
for use with other devices.
NOTE: The analog - resistive inputs are NOT compatible with the simulated
240Ω – 33Ω output IntelliSensor® fuel level sender.
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D D B I ™ T E C H N I C A L M A N U A L

DDBI™ Specifications
…available with various specifications to suit most applications …

General Specifications
DDBI™ instruments are available with various specifications to suit most
applications.

DDBI™ 2” Instrument Specifications

 Supported Data-bus Protocols (Instrument Specific):
 SAE J1939
 SAE J1708/J1587
 Analog Instruments (Instrument Specific):
 240Ω – 33Ω (Resistive Input)
 0.5 – 4.5 V (Voltage Input)
 Operating Temp: -40C to +85C
 Operating Voltage (Instrument Specific):
 12V (10-16V)
 24V(18-32V)
 Illumination: Amber LED (PWM Dimmer Recommended)
 Sealing: Fully Sealed to 6psi
 Vibration: 9.8G RMS, 3hr, 3 planes, 20-2000 Hz
 Crystal: Polycarbonate, Anti-Fog, Anti-Scratch Coated (Domed & Flat)
 Mating Connector:
 Deutsche #DT06-6S
 6-Wire Pigtail Harness Part #115022
 Panel Hole Size: 2.098” ±0.02” 53.3mm. ±0.5mm

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D D B I ™ T E C H N I C A L M A N U A L

DDBI™ 3” Instrument Specifications

 Supported Data-bus Protocols (Instrument Specific):
 SAE J1939 & SAE J1708/J1587
 3 Tachometer & Speedometer Versions Available
 Tachometer/Speedometer Only (No Display)
 Tachometer/Speedometer With Display
 Tachometer/Speedometer With Display, Fault Reading Capability, and
Analog Inputs
NOTE: There are four different interpretations of J1939 fault code standards.
All DDBI™ instruments conform to the most recent fourth version.
 Analog Inputs (Instruments With Fault Capability Only):
 3 Inputs (Fuel Level, Front & Rear Air Brake Pressure)
 240Ω – 33Ω (Resistive input, 150 psi sender required for air pressure)
 All analog inputs converted & transmitted to the data-bus
 Operating Temp: -40°C – +85°C
 Operating Voltage (Instrument Specific):
 12V (10-16V)
 24V(18-32V)
 Illumination: Amber LED - PWM Dimmer Recommended
 Sealing: Fully Sealed to 6psi
 Vibration: 9.8G RMS, 3hr, 3 planes, 20-2000 Hz
 Crystal: Polycarbonate, Anti-Fog, Anti-Scratch Coated (Domed & Flat)
 Mating Connector:
 Deutsche #DT06-6S
 6-Wire Pigtail Harness Part #115022
 Panel Hole Size: 3.4” ±0.02” 86.4mm. ±0.5mm

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D D B I ™ T E C H N I C A L M A N U A L

DDBI™ 2” Instrument Dimensions

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D D B I ™ T E C H N I C A L M A N U A L

DDBI™ 3” Instrument Dimensions

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D D B I ™ T E C H N I C A L M A N U A L

DDBI™ Instrument Protocol Information

DDBI 3" W/DSP & ANALOG INPUTS
SA PGN PARAMETER
0 65271 Voltage( Bat Switched, Alternator, Electrical Potential )
0 61444 Engine speed (Tachometer Only)
0 65253 Engine hours (Tachometer Only)
0 65262 Coolant Temperature
0 65262 Fuel Temperature
0 65262 Engine Oil Temperature1
0 65262 Engine Intercooler Temperature
0 65263 Engine Oil Level
0 65263 Engine Oil Pressure
0 65263 Coolant Pressure
0 65263 Coolant Level
0 65265 Wheel based Vehicle Speed (Speedometer Only)
0 65217 Vehicle Distance( Hi Res, Low Res) (Speedometer Only)
23 65274 Front Brake
23 65274 Rear Brake
23 65276 Fuel Level

DDBI 3" W/DISPLAY

SA PGN PARAMETER
0 61444 Engine speed (Tachometer Only)
0 65253 Engine hours (Tachometer Only)
0 65265 Wheel based Vehicle Speed (Speedometer Only)
0 65217 Vehicle Distance( Hi Res, Low Res) (Speedometer Only)

DDBI 3" NO DISPLAY

SA PGN PARAMETER
0 61444 Engine speed (Tachometer Only)
0 65265 Wheel based Vehicle Speed (Speedometer Only)

DDBI 2"
SA PGN PARAMETER
3 65272 Transmission Oil Temperature
0 65271 Voltage( Bat Switched, Alternator )
0 65262 Coolant Temperature
0 61444 Engine speed
0 65270 Boost Pressure
0 65263 Engine Oil Pressure
0 65262 Engine Oil Temperature1
23 65276 Fuel Level
23 65274 Front Brake
23 65274 Rear Brake

Source Address (decimal) 0 = Engine Controller, 3 = Transmission, 23 = Cluster

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Chapter
D D B I ™ T E C H N I C A L M A N U A L

DDBI™ Instrument
Selection
… is quite simple compared to traditional data-bus and sender specific
instruments …

Getting Started
Selecting DDBI™ instruments is quite simple when compared to traditional data-bus
and sender specific instruments. There are no gateway instruments to worry about, no
sender mounting problems and no tachometer or speedometer calibration difficulties.
Since the signals are read, conditioned, and converted to a standardized format before
they are transmitted to the data-bus, there is no additional calibration required.

Before purchasing any instruments, verify that the appropriate data is available on the
data-bus. If the data for any parameter, except fuel level, voltage, current, front and rear
air brake pressure is not currently available on the data-bus, consult with the engine or
chassis controller supplier to determine if those parameters may be added.

Fuel Level
If fuel level is not available on the data bus, there are a couple of options from
which to select.
 If the fuel level sender is a resistive (float arm 0-90 or 240-33 ohm) sender, the
sender can be connected directly to an analog-resistive input instrument. In
this installation, the instrument has no connection to the data-bus.
 If the fuel level sender is a resistive (float arm 240-33 ohm) sender, the sender
can be connected directly to the analog-resistive fuel level input of a DDBI™
3” instrument with display & analog inputs. The signal is then converted and
broadcast to the data-bus. In this case, the data-bus fuel level gauge may be
used now that the information is available on the data-bus.
 If the sender is connected to the analog-resistive input of a DDBI™ 3”
instrument with display & analog inputs, the parameter is available to view on
the display of the 3” DDBI™ instrument.

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D D B I ™ T E C H N I C A L M A N U A L

 If an IntelliSensor® with voltage output is used as the fuel level sender, the
sender can be connected directly to an analog-voltage input instrument. In this
installation, the instrument has no connection to the data-bus.

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D D B I ™ T E C H N I C A L M A N U A L

Front & Rear Air Brake Pressure

If front & rear air pressure is not available on the data bus, there are a couple of
options from which to select.
 If the front & rear air pressure senders are resistive (240-33 ohm) type senders,
the senders can be connected directly to analog-resistive input instruments. In
this installation, the instruments have no connection to the data-bus.
 If the front & rear air pressure senders are resistive (240-33 ohm) type senders
the senders can be connected directly to analog-resistive inputs of a DDBI™
3” instrument with display & analog inputs. The signals are then converted and
broadcast to the data-bus. In this case, the data-bus air pressure gauges may be
used now that the information is available on the data-bus.
 If the senders are connected to the analog-resistive inputs of a DDBI™ 3”
instrument with display & analog inputs, those parameters are available to view
on the display of the 3” DDBI™ instrument.

Ammeter
 The DDBI™ instrument line includes an analog-voltage input ammeter
designed for use with the current transducer produced by InPower, Galena,
Ohio, USA. Model # DCS25-300-1, ±300AMP, 0.5V – 4.5V output.

Voltmeter
The DDBI™ instrument line includes data-bus and analog-voltage input
instruments.
 If the voltage information is NOT available on the data-bus, use the analog
version to indicate this parameter.
 If the voltage information is available on the data-bus, a DDBI™ 2”
instrument can be used to indicate this parameter.
 If the voltage information is available on the data-bus and a DDBI™ 3”
instrument with display & analog inputs is installed, the parameter is available
to view on the display of the 3” DDBI™ instrument.

Data-Bus Instruments
 The remaining parameters are generally available on the data-bus, simply
connect the DDBI™ instruments to the data-bus.

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6
Chapter

DDBI™ Installation
Instructions
… is quite simple compared to traditional data-bus and sender specific
instruments …

Getting Started
Selecting DDBI™ instruments is quite simple when compared to traditional data-bus
and sender specific instruments. There are no gateway instruments to worry about, no
sender mounting problems and no tachometer or speedometer calibration difficulties.
Since the signals are read, conditioned, and converted to a standardized format before
they are transmitted to the data-bus, there is no additional calibration required.

DDBI™ 2” Instrument Mounting

1. Recommended panel hole size is 2.098” ±0.02” or 53.3mm. ±0.5mm.
2. Insert the instrument in the panel and place the U-Bracket over the mounting
studs.
3. Install one washer & one nut on each stud over the U-Bracket.
4. Tighten the nuts (4 to 6 in.-Lb.) to secure the instrument.

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D D B I ™ T E C H N I C A L M A N U A L

DDBI™ 3” Instruments
1. Recommended panel hole size is 3.4” ±0.02” or 68.4mm ±0.5mm.
2. Insert the instrument in the panel and place the U-Bracket over the mounting
studs.
3. Install one washer & one nut on each stud over the U-Bracket.
4. Tighten the nuts (4 to 6 in.-Lb.) to secure the instrument.

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 D D B I ™ T E C H N I C A L
Mating Connector
• Deutsche #DT06-6S
• 6-Wire Pigtail Harness
Part #115022
Mating Connector
• Deutsche #DT06-6S
• 6-Wire Pigtail
Harness Part #115022
M A N U A L
DDBI™ 2” Data-Bus Instrument Wiring
1. Connect Pin (1) to the positive side of the battery through the ignition switch.
2. Connect Pin (2) to data-bus negative (-).
3. Connect Pin (3) to data-bus positive (+).
4. Connect Pin (4) to the instrument panel dimmer switch.
5. For dimming, a PWM dimmer switch is recommended.
6. Connect Pin (5) to the data-bus shield (J1939 ONLY).
7. Connect Pin (6) to the vehicle ground.
Per SAE-J1939 specification, the instrument does not contain a bus termination
resistor. Proper data-bus termination is required for correct operation (J1939
ONLY). Install a 120Ω ¼ Watt resistor between bus (+) and bus (-). See data-bus
termination section for additional information.
DDBI™ 2” Analog Instrument Wiring
This section applies to both resistive and voltage input 2” instruments.
1. Connect Pin (1) to the positive side of the battery through the ignition switch.
2. Connect Pin (3) to the appropriate sender or the specific circuit for voltmeter
applications.
3. The sender must be grounded to the same location as the instrument for
accurate operation.
4. Connect Pin (4) to the instrument panel dimmer switch.
5. For dimming, a PWM dimmer switch is recommended.
6. Connect Pin (6) to the vehicle ground.
7. Pins (2) & (5) have no connection.
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Mating Connector
• Deutsche #DT06-6S
• 6-Wire Pigtail
Harness Part #115022
M A N U A L
DDBI™ 3” Without Fault & Analog Inputs Wiring
All connections are made to connector #1.
There are no connections to connector #2.
1. Connect Pin (1) to the positive side of the battery through the ignition switch.
2. Connect Pin (2) to data-bus-.
3. Connect Pin (3) to data-bus+.
4. Connect Pin (4) to the instrument panel dimmer switch.
For dimming, a PWM dimmer switch is recommended.
5. Connect Pin (5) to the data-bus shield (J1939 ONLY).
6. Connect Pin (6) to the vehicle ground.
Per SAE-J1939 specification, the instrument does not contain a bus termination
resistor. Data-bus termination is required for proper operation. Use a 120Ω ¼
Watt resistor between Bus+ and Bus- to terminate the Data-bus. See data-bus
termination section for additional information.
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 D D B I ™ T E C H N I C A L
Mating Connector
• Deutsche #DT06-6S
• 6-Wire Pigtail
Harness Part #115022
M A N U A L
DDBI™ 3” With Fault & Analog Inputs Wiring
Both connectors are used to make the electrical connections.
Connector 1
1. Connect Pin (1) to the positive side of the battery through the ignition switch.
2. Connect Pin (2) to data-bus- (J1939 ONLY).
3. Connect Pin (3) to data-bus+ (J1939 ONLY).
4. Connect Pin (4) to the data-bus shield (J1939 ONLY).
5. Connect Pin (5) through a momentary contact switch to ground. This will be
the user interface button.
6. Connect Pin (6) to the vehicle ground.
Per SAE-J1939 specification, the instrument does not contain a bus termination
resistor. Data-bus termination is required for proper operation. Use a 120Ω ¼
Watt resistor between Bus+ and Bus- to terminate the Data-bus. See data-bus
termination section for additional information.
Connector 2
1. Connect Pin (1) to the instrument panel dimmer switch.
For dimming, a PWM dimmer switch is recommended.
2. Pin (2) & Pin (3) are not used (reserved for J1708/1587 data-bus).
The following connections are optional and only apply to the instruments with
fault capability, and analog inputs.
If two instruments with fault capability and analog input are installed on the same
data-bus, only one instrument can have the inputs active.
3. Connect Pin (4) to a resistive fuel sender (240Ω – 33Ω).
4. Connect Pin (5) to a resistive 150 psi pressure sender (240Ω – 33Ω) to
measure rear air pressure.
5. Connect Pin (6) to a resistive 150 psi pressure sender (240Ω – 33Ω) to
measure front air pressure.
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Data-Bus Termination
The SAE specification for the J1939 data-bus requires data-bus termination. The
J1708/1587 data-bus does not require termination. Termination is required to
attenuate any electrical noise developed by the high-speed data transfer. If the resistors
are not present, loss of data-bus communication may occur.

Termination simply means installing two 120Ω ½-Watt resistors between bus (+) and
bus (-) at each end of the data-bus backbone. If the installation involves connecting to
an existing data-bus, termination should already exist and no additional termination is
required. The SAE specification forbids the use of internal data-bus termination,
because the data-bus must remain intact if any device is removed. If a specific module
terminated the data-bus, and that module was removed, the data-bus could cease
operation.

The data-bus shield must also terminate properly. Using a wire, the shield should be
connected to ground as close as possible to the battery ground. This termination
connection to ground can be anywhere along the data-bus, but it must only be
connected at ONE point. The shield should also connect to the shield pin of all
data-bus devices (NOT GROUND).

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Data-Bus Installation Examples

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D D B I ™ T E C H N I C A L M A N U A L

Data-Bus Installation Examples

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D D B I ™ T E C H N I C A L M A N U A L

Data-Bus Installation Examples

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D D B I ™ T E C H N I C A L M A N U A L

Data-Bus Installation Examples

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