DDEC

DDEC
DDEC
DDEC
DDEC
III DDEC IV
Detroit Diesel
Electronic Controls
 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

JVr - Swedmotor
Rev. 10/27/99 3
 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

JVr - Swedmotor
Rev. 10/27/99 4
 Electronic Engine Advantages

• Engine Protection
• Engine Diagnostics
• Reduced Maintenance
• Improved Engine Governing
• Fuel Economy Optimization
• Enhanced Cold Starting
• Smoke Control
• Reduced Emission Levels
JVr - Swedmotor
Rev. 10/27/99 5
 DDEC IV Features
• Four New ECM’s
ECM Description
Standard Truck 6 Cylinder 12 Volt
Universal 8 Cylinder 12/24 Volt
S4000 8 Cylinder 12/24 Volt
Natural Gas 8 Cylinder 12/24 Volt

• Increased Memory - 57% Over DDEC III

• Faster Processing Time - 50% Over DDEC III
• J1939 Communication Link - Standard
• Battery Backed Real Time Clock & Calendar
• DDEC Data (Enhanced ECM Data Pages) -
Standard
JVr - Swedmotor
Rev. 10/27/99 6
 DDEC Necessities

Ignition

Electronic
EUI
Control
Module
(ECM)
Synch Reference

Timing Reference

EEPROM

- +
Battery

JVr - Swedmotor
Rev. 10/27/99 7
 Schematic Diagram DDEC III/ IV

Electronic
Control
Module
(ECM)

EEPROM

JVr - Swedmotor
Rev. 10/27/99 8
 Electronic Control Module

JVr - Swedmotor
Rev. 10/27/99 9
 Electronic Control Module

OEM responsibility DDC

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

JVr - Swedmotor
Rev. 10/27/99 10
 Schematic Diagram DDEC III / IV

Electronic
Control
Module
(ECM)

EEPROM

- +
Battery

JVr - Swedmotor
Rev. 10/27/99 11
 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
• The ECM Case Must be Electrically Isolated from any
Chassis Ground

JVr - Swedmotor
Rev. 10/27/99 12
 Power Supply DDEC III / IV

JVr - Swedmotor
Rev. 10/27/99 13
 Schematic Diagram DDEC III / IV
EUI
Electronic
Control
Module
(ECM)

EEPROM

- +
Battery

JVr - Swedmotor
Rev. 10/27/99 14
 Electronic Unit Injectors

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

Series 4000 Spray Nozzle Series 2000

JVr - Swedmotor
Rev. 10/27/99 EUP 15
 Voltage in Series 50/60
Rocker Arm Injector
Solenoid Animation
Cam

Poppet
Valve
Plunger

Fuel out

Fuel in

Needle Valve
 Top Of Stroke

Fuel
In

Fuel
Out

Injector
Tip

JVr - Swedmotor
Rev. 10/27/99 20
 Start Of Injection

Fuel
In

Fuel
Out

Injector
Tip

JVr - Swedmotor
Rev. 10/27/99 21
 End Of Injection

Fuel
In

Fuel
Out

Injector
Tip

JVr - Swedmotor
Rev. 10/27/99 22
 Injection Sequence

Fuel Fuel Fuel

In In In
Fuel Fuel Fuel
Out Out Out

Injector Injector Injector

Tip Tip Tip

JVr - Swedmotor
Rev. 10/27/99 23
 Injector Calibration Codes

• DDEC II No Calibration Codes

• DDEC III IV Calibration Codes From 00-99

Part Number

Calibration Code
JVr - Swedmotor
Rev. 10/27/99 24
 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

JVr - Swedmotor
Rev. 10/27/99 25
 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
JVr - Swedmotor
Rev. 10/27/99 26
 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

JVr - Swedmotor
Rev. 10/27/99 27
 Sensor Operations

Operates on 5 Volts for All D.C. Sensors

0 .25 4.75 5

Low Voltage Normal High Voltage

Operating
Range

JVr - Swedmotor
Rev. 10/27/99 28
 Sensor Wiring
• Common Return
Circuit. #452
• Thermistor
• Range -40°F to +244°F

• Piezoresistive
Pressure sensor
• Voltage is Proportional
to Pressure

JVr - Swedmotor
Rev. 10/27/99 29
 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

JVr - Swedmotor
Rev. 10/27/99 30
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference Electronic
Control
Module
(ECM)

EEPROM

- +
Battery

JVr - Swedmotor
Rev. 10/27/99 31
 Series 50/60
SRS/TRS Sensors

Bull Gear

Timing Wheel
DDEC II
DDEC II
SRS/TRS

Bull Gear

Timing Wheel
DDEC III DDEC III
JVr - Swedmotor
Rev. 10/27/99 32
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control
Module
(ECM)

EEPROM

- +
Battery

JVr - Swedmotor
Rev. 10/27/99 33
 Throttle Position Sensor
• 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 failure

JVr - Swedmotor
Rev. 10/27/99 34
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control
Module
Turbo Boost Pressure
(ECM)

EEPROM

- +
Battery

JVr - Swedmotor
Rev. 10/27/99 35
 Turbo Boost Sensor

DDEC III Series 50/55/60/2-Cycle

Series 50/60 DDEC IV

JVr - Swedmotor
Rev. 10/27/99 36
 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

JVr - Swedmotor
Rev. 10/27/99 37
 Temperature Sensors

Coolant Temperature Sensor Air Temperature Sensor

Series 50/60 Series 50/55/60
Fuel/Oil/Coolant Temperature Sensor
Series 50/55/60/2-Cycle

JVr - Swedmotor
Rev. 10/27/99 38
 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

JVr - Swedmotor
Rev. 10/27/99 39
 Pressure Sensors

Series 50/55/60/2-Cycle

JVr - Swedmotor
Rev. 10/27/99 40
 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

JVr - Swedmotor
Rev. 10/27/99 41
 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

JVr - Swedmotor
Rev. 10/27/99 42
 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

JVr - Swedmotor
Rev. 10/27/99 43
 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

JVr - Swedmotor
Rev. 10/27/99 44
 Coolant Level Sensor

DDEC II Coolant Level Sensor

DDEC III or IV
Coolant Level Sensor

JVr - Swedmotor
Rev. 10/27/99 45
 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

JVr - Swedmotor
Rev. 10/27/99 46
 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.

JVr - Swedmotor
Rev. 10/27/99 47
 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

JVr - Swedmotor
Rev. 10/27/99 48
 Progressive Shift

JVr - Swedmotor
Rev. 10/27/99 49
 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

JVr - Swedmotor
Rev. 10/27/99 50
 Pressure Governor

•Fire Commander and Mastermind

use the same digital inputs and
outputs as cruise control

High Pressure
Sensor

Fire Commander

Mastermind

JVr - Swedmotor
Rev. 10/27/99 51
 Electronic Fire Commander

Control Buttons
Engine Data

System Status

Message Window

JVr - Swedmotor
Rev. 10/27/99 52
 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
JVr - Swedmotor
Rev. 10/27/99 53
 Diagnostic Request
or Stop Engine Override

JVr - Swedmotor
Rev. 10/27/99 54
 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.

JVr - Swedmotor
Rev. 10/27/99 55
 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 - + Cruise Control

Pressure Governor Battery Vehicle Speed Limiting
Vehicle Speed Sensor
Diagnostic Stop Engine
Request Override
JVr - Swedmotor
Rev. 10/27/99 56
 Cruise Control

• Determined by vehicle speed (VSS) or engine speed

(RPM)
• 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
• Cruise switch on VSG is also available.
• Use cruise switches to set high idle and lower high
idle in a step down sequence.

JVr - Swedmotor
Rev. 10/27/99 57
 Cruise Control

JVr - Swedmotor
Rev. 10/27/99 58
 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
Crankcase Pressure
VSG Control

Progressive Shift - + Cruise Control

Pressure Governor Battery Vehicle Speed Limiting
Vehicle Speed Sensor
Diagnostic Stop Engine
Request Override
JVr - Swedmotor
Rev. 10/27/99 59
 Crankcase Pressure

Series 60 CCM

JVr - Swedmotor
Rev. 10/27/99 60
 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 Stop Check
Engine Engine

Coolant Level
Crankcase Pressure
VSG Control

Progressive Shift - + Cruise Control

Pressure Governor Battery Vehicle Speed Limiting
Vehicle Speed Sensor
Diagnostic Stop Engine
Request Override
JVr - Swedmotor
Rev. 10/27/99 61
 Stop Engine / Check Engine Lights

JVr - Swedmotor
Rev. 10/27/99 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
PWM Ports
EEPROM
Oil level/Fuel Restriction Stop Check
Engine Engine

Coolant Level
Crankcase Pressure
VSG Control

Progressive Shift - + Cruise Control

Pressure Governor Battery Vehicle Speed Limiting
Vehicle Speed Sensor
Diagnostic Stop Engine
Request Override
JVr - Swedmotor
Rev. 10/27/99 63
 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

JVr - Swedmotor
Rev. 10/27/99 64
 PWM
Circuit Wire
No. Color
• PWM #1 Output - VIH (Transmission) 908 White
• PWM #2 Output - ESH 909 Lt. Green
• PWM #3 Output - ESH 910 Orange
• PWM #4 Output - ESH (Fan Control) 911 Pink

JVr - Swedmotor
Rev. 10/27/99 65
 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
DDR Interface
Oil / Fuel Pressure
PWM Ports
EEPROM
Oil level/Fuel Restriction Stop Check
Engine Engine

Coolant Level

VSG Control Crankcase Pressure

Progressive Shift - + Cruise Control

Pressure Governor Battery Vehicle Speed Limiting
Vehicle Speed Sensor
Diagnostic Stop Engine
Request Override
JVr - Swedmotor
Rev. 10/27/99 66
 DDR Interface with MPSI Printer

JVr - Swedmotor
Rev. 10/27/99 67
SAE Standards
 SAE Standards

•MIDs
•PIDs
•FMIs
•SIDs

JVr - Swedmotor
Rev. 10/27/99 69
 DDR Communication- On Highway

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

JVr - Swedmotor
Rev. 10/27/99 70
 DDR Communication- On Highway

DDEC IV
9 Pin

JVr - Swedmotor
Rev. 10/27/99 71
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control
Module
Turbo Boost Pressure
(ECM)
Fuel / Oil / Coolant Engine Rating / Cruise Power / Switch Power
Temperature
DDR Interface
Oil / Fuel Pressure
PWM Ports
EEPROM
Oil level/Fuel Restriction Stop Check
Engine Engine

Coolant Level

VSG Control Crankcase Pressure

Progressive Shift - + Cruise Control

Pressure Governor Battery Vehicle Speed Limiting
Vehicle Speed Sensor
Diagnostic Stop Engine
Request Override
JVr - Swedmotor
Rev. 10/27/99 72
 Multiple Horsepower Ratings

• Three Independent Ratings

• One Dependent Cruise Power Rating

• Switch Power Options (C&I)

– Max. Power for Full Loads
– Min. Power for a non loaded engine

JVr - Swedmotor
Rev. 10/27/99 73
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control
Module
Turbo Boost Pressure
(ECM) Communication
Fuel / Oil / Coolant Engine Rating / Cruise Power / Switch Power
Temperature
DDR Interface
Oil / Fuel Pressure
PWM Ports
EEPROM
Oil level/Fuel Restriction Stop Check
Engine Engine
Coolant Level

VSG Control Crankcase Pressure

Progressive Shift - + Cruise Control

Pressure Governor Battery Vehicle Speed Limiting
Vehicle Speed Sensor
Diagnostic Stop Engine
Request Override
JVr - Swedmotor
Rev. 10/27/99 74
 Communication

• J1587
– 9600 Baud Rate, used to transmit sensor and engine data
(electronic dash display, vehicle management systems
and electronic transmissions).
• J1922
– 9600 Baud Rate, controls Transmissions, braking
systems and retarders
• J1939
– 250k Baud Rate, controls Transmissions, braking
systems and retarders

JVr - Swedmotor
Rev. 10/27/99 75
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control
Module ISD / Vehicle
Turbo Boost Pressure Power Down
(ECM) Communication
Fuel / Oil / Coolant Engine Rating / Cruise Power / Switch Power
Temperature
DDR Interface
Oil / Fuel Pressure
PWM Ports
EEPROM
Oil level/Fuel Restriction Stop Check
Engine Engine

Coolant Level

VSG Control Crankcase Pressure

Progressive Shift - + Cruise Control

Pressure Governor Battery Vehicle Speed Limiting
Vehicle Speed Sensor
Diagnostic Stop Engine
Request Override
JVr - Swedmotor
Rev. 10/27/99 76
 ISD/Vehicle Power Shutdown

• Idle Shut Down: Turns engine off after programmed idle

time has elapsed (optional “override” disables idle
timer)
• Vehicle power shutdown relay (optional/OEM) turns off
electrical power to the vehicle as well as stopping the
engine

2 - 100 Minutes
JVr - Swedmotor
Rev. 10/27/99 77
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control Engine Brake
Module ISD / Vehicle
Turbo Boost Pressure Power Down
(ECM) Communication
Fuel / Oil / Coolant Engine Rating / Cruise Power / Switch Power
Temperature
DDR Interface
Oil / Fuel Pressure
PWM Ports
EEPROM
Oil level/Fuel Restriction Stop Check
Engine Engine

Coolant Level

VSG Control Crankcase Pressure

Progressive Shift - + Cruise Control

Pressure Governor Battery Vehicle Speed Limiting
Vehicle Speed Sensor
Diagnostic Stop Engine
Request Override
JVr - Swedmotor
Rev. 10/27/99 78
 DDEC III/IV
Engine Brakes

• DDEC III/IV controls engine brake operation

• If configured for “cruise control engine brake”
the ECM will automatically stage on the brake if
the set speed is exceeded.
• Two digital inputs and two ‘positive’ outputs are
used to control the brake.
JVr - Swedmotor
Rev. 10/27/99 79
 Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic Fan Controls
Pedal Assembly
Control Engine Brake
Module ISD / Vehicle
Turbo Boost Pressure Power Down
(ECM) Communication
Fuel / Oil / Coolant Engine Rating / Cruise Power / Switch Power
Temperature
DDR Interface
Oil / Fuel Pressure
PWM Ports
EEPROM
Oil level/Fuel Restriction Stop Check
Engine Engine

Coolant Level

VSG Control Crankcase Pressure

Progressive Shift - + Cruise Control

Pressure Governor Battery Vehicle Speed Limiting
Vehicle Speed Sensor
Diagnostic Stop Engine
Request Override
JVr - Swedmotor
Rev. 10/27/99 81
 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

JVr - Swedmotor
Rev. 10/27/99 82
 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 Engine Rating / Cruise Power / Switch Power
Temperature
DDR Interface
Oil / Fuel Pressure PWM Ports
EEPROM
Oil level/Fuel Restriction Stop Check
Engine Engine

Coolant Level

VSG Control Crankcase Pressure

Progressive Shift - + Cruise Control

Pressure Governor Battery Vehicle Speed Limiting
Vehicle Speed Sensor
Diagnostic Stop Engine
Request Override
JVr - Swedmotor
Rev. 10/27/99 84
 Optimized Idle

• Automatic Starting and Stopping of the Engine

• Maintains Engine Temperature and / or Battery
Voltage
• Optional Sleeper Thermostat
• Saves Fuel by Running the Engine Only When
Needed
• Warm Engines Start Much Easier With Less Exhaust
Emissions

JVr - Swedmotor
Rev. 10/27/99 85
 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 Engine Rating / Cruise Power / Switch Power
Temperature
DDR Interface
Oil / Fuel Pressure PWM Ports
EEPROM
Oil level/Fuel Restriction Stop Check
Engine Engine

Coolant Level

VSG Control Crankcase Pressure

Progressive Shift - + Cruise Control

Pressure Governor Battery Vehicle Speed Limiting
Vehicle Speed Sensor
Diagnostic Stop Engine
Request Override
JVr - Swedmotor
Rev. 10/27/99 88
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”

JVr - Swedmotor
Rev. 10/27/99 90
 DIGITAL INPUTS

No Function
ECM No Function
No Function
Cruise Enable
Fan Override

#953
EEPROM
#150
_
+
Battery

JVr - Swedmotor
Rev. 10/27/99 91

• 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
JVr - Swedmotor
Rev. 10/27/99
Digital Inputs (Cont’d)
• Pressure Governor System
(PGS) (Uses Five Inputs)
– Pressure Governor System
Enable
– Pressure/RPM Mode Switch
– Set/Coast On (Decrease)
– Resume/Acceleration On
(Increase)
• Additional Functions
– Auxiliary Coolant Level
Sensor
– Parking Brake Interlock
93
Digital Outputs
 Digital Output Functions

• ECM commands (internal switches) action of some

external devise- 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

JVr - Swedmotor
Rev. 10/27/99 95
 OUTPUTS
SEL

ECM
To Jake brake

Ignition
#439

JVr - Swedmotor
Rev. 10/27/99 96

• Coolant Level Low Light
• Cruise Control Active Light (PGS
Active Light)
• Deceleration Light
• Engine Brake Active
• Fan Control #1
• Fan Control #2
• Low DDEC Voltage
• Pressure Governor System
Pressure Mode Light
• Starter Lockout
• Transmission Retarder
• Vehicle Power Shutdown
JVr - Swedmotor
Rev. 10/27/99
Digital Outputs
• VSG Active Indication
• (Release 2.00 or Later only)
– Low Oil Pressure Light
– High Oil Temperature Light
– High Coolant Temp. Light
• (Release 3.00 or Later Only)
– Ether Injection
– Low Coolant Pressure Light
– High Crankcase Pressure Light
• (Release 4.00 or Later Only)
– Optimized Idle Active light
• Gas Solenoid Shutdown
• Air Compressor Load Switch
97
Wire Crimping Exercise
 Wire Crimping Tools

JVr - Swedmotor
Rev. 10/27/99 112
 Wire Crimping Tools

JVr - Swedmotor
Rev. 10/27/99 113
 Wire Crimping Tools

JVr - Swedmotor
Rev. 10/27/99 114
 Wire Crimping Tools

JVr - Swedmotor
Rev. 10/27/99 115
 Wire Crimping

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Rev. 10/27/99 116
Wire Splicing
 Wire Splicing Tools

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Rev. 10/27/99 118
 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

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 Sensor Wiring
• Common Return
Circuit. #452
• Thermistor
• Range -40°F to +255° F

• Piezoresistive
Pressure sensor
• Voltage is Proportional
to Pressure

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Rev. 10/27/99 121
 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

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Rev. 10/27/99 122
 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.
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Rev. 10/27/99 123
 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).

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Rev. 10/27/99 124
 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.

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Troubleshooting Tools
 Troubleshooting Tools

Sensor Tester Breakout Box (30 Pin)

DDEC II Interface DDEC III Interface

JVr - Swedmotor
Rev. 10/27/99 127
 Troubleshooting Tools

Volt-Ohm Meter

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Rev. 10/27/99 128
 Troubleshooting Tools
DDDL Software

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Rev. 10/27/99 129
 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

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 Troubleshooting Tools
DDDL Software

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 Troubleshooting Tools
DDDL Software

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Rev. 10/27/99 132
 Troubleshooting Tools
DDDL Software

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Rev. 10/27/99 133
 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

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Rev. 10/27/99 135
 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

JVr - Swedmotor
Rev. 10/27/99 136
 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 = ECU problem

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Rev. 10/27/99 137
 TRS/SRS Circuit Problems

• Code 41/42 (cont’d)

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

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Rev. 10/27/99 138
 Coolant Temperature High

• Code 44
• code logged for 4-10 seconds
• corrosion on terminals result in rapid signal
changes
• clean terminals at CLS and 30 pin connector
• D4- ECU fault
• D4- Optimized Idle thermostat

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Rev. 10/27/99 139
 Non-volatile Memory Fault

• Code 53
• Active code - replace 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

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Rev. 10/27/99 140
 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 fault

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Rev. 10/27/99 141
 J1939 Data Link Fault

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

JVr - Swedmotor
Rev. 10/27/99 142
 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, ABS use
900 and 901 for data
• Check polarity of wiring to components wired to
900/901 for open or short circuit

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 J1587 Data Link Fault

• Code 56 (cont’d)
• 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

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Rev. 10/27/99 144
 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

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Rev. 10/27/99 145
 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

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Rev. 10/27/99 146
 Throttle Concerns

• Intermittent Jake Brakes

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

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Rev. 10/27/99 147
 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

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Rev. 10/27/99 148
 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

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 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 ECU if all else fails

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 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

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 Engine Won’t 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

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Rev. 10/27/99 152
 Fan Operational Concern

• Fan always on or inoperative

• Review and correct ECM input/outputs
• Verify fan control wiring

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Rev. 10/27/99 153
 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

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Rev. 10/27/99 154
 Misfire, Response Time Codes

• Incorrectly crimped wire terminals

• Replace terminals

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Rev. 10/27/99 155
DDEC II / III / IV
Reprogramming
 Reprogramming Station

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Rev. 10/27/99 157
 Reprogramming Station
Windows Based for Download

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Rev. 10/27/99 158
 Reprogramming Station
Windows Based for Download

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Rev. 10/27/99 159
 Reprogramming Station
Windows Based for Download

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Rev. 10/27/99 160