Detroit Diesel DDEC IV engine control module Application and installation manual
Below you will find brief information for engine control module DDEC IV. This manual provides guidance on using DDEC IV, with detailed information on features, settings, and communication protocols. It covers the installation process, including hardware and wiring requirements, inputs and outputs, and available features. In addition, it offers tools for obtaining engine data and diagnostic information, and for reprogramming key parameters, along with application specific recommendations and information on codes and kit availability.
PDF
Document
Advertisement
Advertisement
ATTENTION This document is a guideline for qualified personnel. It is intended to be used by vehicle manufacturers and contains Detroit Diesel Corporation's recommendations for the ancillary systems supporting the Detroit Diesel engines covered by this document. The vehicle manufacturer is responsible for developing, designing, manufacturing and installing these systems, including component qualification. The vehicle manufacturer is also responsible for furnishing vehicle users complete service and safety information for these systems. Detroit Diesel Corporation makes no representations or warranties regarding the information contained in this document and disclaims all liability or other responsibility for the design, manufacture or installation of these ancillary systems, or the preparation or distribution to vehicle users of appropriate information regarding these systems. The information contained in this document may not be complete and is subject to change without notice. Allison® is a registered trademark of General Motors Corporation. Bendix® is a registered trademark of Allied-Signal Corporation. Eaton® is a registered trademark of Eaton Corporation. Engine Synchro Shift® is a registered trademark of Meritor Corporation. Kent-Moore® is a registered trademark of SPX Corporation. Series 4000™ is a trademark of Detroit Diesel Corporation. Data Hub®, DDEC®, Electronic Fire Commander®, Ether Start®, Optimized Idle®, ProDriver®, ProManager®, Series 60®, and Series 2000® are registered trademarks of Detroit Diesel Corportion. All other trademarks and resigstered trademarks are the property of their respective owners. DDEC IV APPLICATION AND INSTALLATION MANUAL DDEC IV APPLICATION AND INSTALLATION MANUAL ABSTRACT Detroit Diesel Corporation has produced electronically controlled engines for nearly two decades. DDEC IV, the fourth generation electronic engine controller, offers improved engine control and a more extensive range of engine and vehicle options. The detail provided will facilitate the following: The selection of features and settings, based on individual applications The fabrication and installation of a vehicle interface harness, based on individual applications The communication of messages & data between sensors and various electronic control modules within the installation The use of industry standard tools to obtain engine data and diagnostic information, as well as to reprogram key parameters The manual is arranged as follows: The initial portion covers the installation, beginning with an overview and safety precuations, followed by hardware and wiring requirements, inputs and outputs, and available features. The second portion covers communication protocol. The third portion covers the tools capable of obtaining engine data and diagnostic information from the Electronic Control Module, as well as reprogramming of its key parameters. The fourth portion covers application specific recommendations. The final portion summarizes detailed information on codes and kit availability. This manual does not cover the installation of the engine itself into various applications. For this, the reader should refer to the specific engine application and installation manual. This manual is intended for those with an electrical background. A simple installation may require a basic understanding of electrical circuits while a more comprehensive electrical/electronics background is required to access all the capability of DDEC IV. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION i ABSTRACT ii All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL TABLE OF CONTENTS 1 INTRODUCTION ................................................................................................................. 1-1 2 SAFETY PRECAUTIONS ................................................................................................... STANDS .......................................................................................................................... GLASSES ....................................................................................................................... WELDING ....................................................................................................................... WORK PLACE ................................................................................................................ CLOTHING ...................................................................................................................... ELECTRIC TOOLS ......................................................................................................... AIR .................................................................................................................................. FLUIDS AND PRESSURE .............................................................................................. BATTERIES ..................................................................................................................... FIRE ................................................................................................................................ DIAGNOSTIC DATA READER ........................................................................................ DETROIT DIESEL DIAGNOSTIC LINK .......................................................................... PAINT .............................................................................................................................. FLUOROELASTOMER (VITON) ..................................................................................... PRESSURE SENSOR GOVERNOR INSTALLATION ..................................................... OPTIMIZED IDLE ............................................................................................................ 2-1 2-1 2-1 2-2 2-2 2-3 2-3 2-4 2-4 2-5 2-5 2-6 2-6 2-6 2-7 2-7 2-8 HARDWARE AND WIRING ................................................................................................ 3.1 SUPPLIED HARDWARE ................................................................................................. 3.1.1 OEM-SUPPLIED HARDWARE ................................................................................... 3.1.2 DDC-SUPPLIED HARDWARE ................................................................................... 3.2 ELECTRONIC CONTROL MODULE .............................................................................. 3.2.1 MULTI-ECMS .............................................................................................................. 3.2.2 ECM PART NUMBERS ............................................................................................... 3.2.3 ENVIRONMENTAL CONDITIONS .............................................................................. TEMPERATURE ................................................................................................... ATMOSPHERIC PRESSURE ............................................................................... WATER INTRUSION ............................................................................................. 3.3 ENGINE SENSOR HARNESS ........................................................................................ 3.3.1 ENGINE SENSOR HARNESS FOR MULTI-ECM ENGINES ..................................... 3.4 VEHICLE INTERFACE HARNESS ................................................................................. 3.4.1 VIH DESIGN ............................................................................................................... 3.4.2 VIH INSTALLATION .................................................................................................... 3.4.3 VEHICLE INTERFACE HARNESS FOR MULTI-ECM ENGINES ............................... ENGINE INTERFACE HARNESS ......................................................................... 3.4.4 HARNESS DESIGN GUIDELINES ............................................................................. PULSE WIDTH MODULATED PORT (PWM #1, 2, 4) .......................................... DIGITAL OUTPUT PORTS ................................................................................... DIGITAL INPUT PORTS ....................................................................................... SWITCH GROUND ............................................................................................... IGNITION .............................................................................................................. 3-1 3-3 3-3 3-3 3-5 3-6 3-6 3-7 3-7 3-7 3-7 3-9 3-13 3-17 3-19 3-19 3-20 3-20 3-23 3-23 3-23 3-24 3-25 3-25 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 3 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION iii TABLE OF CONTENTS 3.5 COMMUNICATION HARNESS ....................................................................................... 3.5.1 DESIGN GUIDELINES ............................................................................................... 3.6 INJECTOR HARNESS AND INJECTION SYSTEMS ..................................................... 3.6.1 ELECTRONIC UNIT INJECTORS .............................................................................. 3.6.2 COMMON RAIL ELECTRONICS ............................................................................... 3.6.3 ELECTRONIC UNIT PUMP ........................................................................................ 3.7 POWER HARNESS ........................................................................................................ 3.7.1 DUAL-FUSE INSTALLATION ...................................................................................... 3.7.2 SINGLE-FUSE INSTALLATION .................................................................................. 3.7.3 POWER HARNESS DESIGN ..................................................................................... WIRE RESISTANCES .......................................................................................... FUSE HOLDER AND CONNECTOR .................................................................... 3.7.4 POWER HARNESS INSTALLATION .......................................................................... 3.7.5 ENGINE POWER HARNESS - MULTI-ECMS ............................................................ 3.7.6 VEHICLE POWER HARNESS ................................................................................... 3.8 POWER SUPPLY ............................................................................................................ 3.8.1 AVERAGE BATTERY DRAIN CURRENT ................................................................... 3.8.2 REQUIREMENTS FOR 12 OR 24 VOLT SYSTEM .................................................... 3.8.3 BATTERY ISOLATOR ................................................................................................ 3.8.4 MAIN POWER SHUTDOWN ...................................................................................... 3.8.5 WELDING CAUTION ................................................................................................. 3.9 FUSES ............................................................................................................................ 3.10 CONNECTORS ............................................................................................................... 3.10.1 METRI-PACK 150 SERIES CONNECTORS .............................................................. 3.10.2 WEATHER PACK, METRI-PACK 280, AND METRI-PACK 630 SERIES CONNECTORS .......................................................................................................... 3.10.3 DEUTSCH CONNECTORS ........................................................................................ 3.10.4 ECM VEHICLE HARNESS CONNECTORS -SINGLE ECM ...................................... VIH-TO-ECM CONNECTOR ................................................................................ POWER HARNESS-TO-ECM CONNECTOR ....................................................... COMMUNICATION HARNESS-TO-ECM CONNECTOR ..................................... 3.10.5 ECM VEHICLE HARNESS CONNECTORS - MULTI-ECM ........................................ ENGINE INTERFACE HARNESS QUICK DISCONNECT CONNECTOR ........... ENGINE POWER HARNESS CONNECTOR ....................................................... 3.10.6 ECM ENGINE HARNESS CONNECTORS ................................................................ ESH-TO-ECM CONNECTOR ............................................................................... 3.10.7 DATA LINK CONNECTORS ........................................................................................ SAE J1939/J1587 DATA LINK NINE-PIN CONNECTOR (RECOMMENDED) ..... SAE J1708/J1587 DATA LINK SIX-PIN CONNECTOR ........................................ 3.11 WIRES AND WIRING ..................................................................................................... 3.11.1 GENERAL REQUIREMENTS ..................................................................................... 3.11.2 GENERAL WIRE ....................................................................................................... 3.11.3 WIRING FOR VIH-TO-ECM CONNECTOR ................................................................ 3.11.4 RETURN POWER (GROUND) CIRCUITS ................................................................. 3.11.5 DATA LINK CIRCUITS ................................................................................................ 3.11.6 POWER HARNESS WIRE RESISTANCE .................................................................. 3.11.7 TERMINAL INSTALLATION AND REMOVAL ............................................................. iv 3-27 3-28 3-29 3-30 3-30 3-31 3-33 3-33 3-35 3-38 3-38 3-38 3-39 3-40 3-40 3-43 3-44 3-46 3-46 3-48 3-49 3-51 3-53 3-54 3-54 3-54 3-55 3-56 3-58 3-59 3-60 3-60 3-61 3-63 3-64 3-66 3-66 3-67 3-69 3-69 3-69 3-70 3-70 3-70 3-70 3-71 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL CRIMP AND REMOVAL TOOLS .......................................................................... PUSH-TO-SEAT TERMINAL INSTALLATION GUIDELINES ................................ PUSH-TO-SEAT TERMINAL REMOVAL .............................................................. PULL-TO-SEAT TERMINAL INSTALLATION GUIDELINES ................................. PULL-TO-SEAT TERMINAL REMOVAL ............................................................... DEUTSCH TERMINAL INSTALLATION GUIDELINES ......................................... DEUTSCH TERMINAL REMOVAL ....................................................................... QUICK DISCONNECT CANON CONNECTOR INSTALLATION GUIDELINES ... TERMINAL REMOVAL ......................................................................................... 3.11.8 SPLICING GUIDELINES ............................................................................................ CLIPPED AND SOLDERED SPLICING METHOD ............................................... SPLICING AND REPAIRING STRAIGHT LEADS-ALTERNATE METHOD 1 ....... SPLICING AND REPAIRING STRAIGHT LEADS - ALTERNATE METHOD 2 ..... SHRINK WRAP .................................................................................................... STAGGERING WIRE SPLICES ............................................................................ 3.12 CONDUIT AND LOOM .................................................................................................... 3.13 TAPE AND TAPING ......................................................................................................... 3.14 SENSORS ....................................................................................................................... 3.14.1 FACTORY-INSTALLED SENSORS ............................................................................ 3.14.2 AIR TEMPERATURE AND CHARGE AIR TEMPERATURE SENSOR ...................... 3.14.3 COMMON RAIL FUEL PRESSURE SENSOR ........................................................... 3.14.4 COOLANT AND INTERCOOLER COOLANT PRESSURE SENSOR ...................... 3.14.5 COOLANT AND INTERCOOLER COOLANT TEMPERATURE SENSOR ............... 3.14.6 CRANKCASE PRESSURE SENSOR ........................................................................ 3.14.7 FUEL PRESSURE SENSOR ...................................................................................... 3.14.8 FUEL RESTRICTION SENSOR ................................................................................. 3.14.9 FUEL TEMPERATURE SENSOR .............................................................................. 3.14.10 OIL LEVEL SENSOR .................................................................................................. 3.14.11 OIL PRESSURE SENSOR ......................................................................................... 3.14.12 OIL TEMPERATURE SENSOR .................................................................................. 3.14.13 TIMING AND SYNCHRONOUS REFERENCE SENSORS ...................................... 3.14.14 TURBO BOOST SENSOR ........................................................................................ 3.14.15 OEM-INSTALLED SENSORS .................................................................................... 3.14.16 AIR COMPRESSOR PRESSURE SENSOR .............................................................. 3.14.17 AIR FILTER RESTRICTION SENSOR ....................................................................... 3.14.18 AIR INTAKE TEMPERATURE SENSOR .................................................................... 3.14.19 COOLANT LEVEL SENSOR ...................................................................................... 3.14.20 ADD COOLANT LEVEL SENSOR ............................................................................. 3.14.21 OPTICAL COOLANT LEVEL SENSOR ...................................................................... 3.14.22 EXHAUST TEMPERATURE SENSOR ....................................................................... EXHAUST TEMPERATURE SENSOR INSTALLATION ....................................... 3.14.23 FIRE TRUCK PUMP PRESSURE SENSOR .............................................................. 3.14.24 THROTTLE POSITION SENSOR ............................................................................... 3.14.25 VEHICLE SPEED SENSOR ....................................................................................... MAGNETIC PICKUP ............................................................................................ OPEN COLLECTOR ............................................................................................. SAE J1939 DATA LINK ......................................................................................... All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-71 3-72 3-75 3-76 3-79 3-79 3-82 3-83 3-89 3-90 3-91 3-93 3-96 3-98 3-99 3-101 3-103 3-105 3-106 3-111 3-112 3-112 3-113 3-114 3-115 3-116 3-117 3-118 3-118 3-119 3-120 3-123 3-125 3-126 3-128 3-129 3-130 3-133 3-136 3-138 3-138 3-140 3-141 3-142 3-142 3-144 3-145 v TABLE OF CONTENTS VSS ANTI-TAMPER .............................................................................................. 3.14.26 AFTERMARKET INSTALLED SENSORS .................................................................. 3.14.27 AMBIENT AIR TEMPERATURE SENSOR ................................................................. AMBIENT AIR TEMPERATURE SENSOR INSTALLATION ................................. 3.14.28 EXHAUST BACK PRESSURE SENSOR ................................................................... 3.15 THROTTLE DEVICES ..................................................................................................... 3.15.1 ELECTRONIC FOOT PEDAL ASSEMBLY ................................................................. 3.15.2 CRUISE CONTROL SWITCHES ................................................................................ 3.15.3 HAND THROTTLE ...................................................................................................... 3.15.4 FAST IDLE SWITCH (ALTERNATE MINIMUM VSG) ................................................. 3.15.5 VOLTAGE DIVIDERS .................................................................................................. 3.15.6 FREQUENCY INPUT ................................................................................................. 3.16 LIGHTS ........................................................................................................................... 3.16.1 CHECK ENGINE LIGHT ............................................................................................. CHECK ENGINE LIGHT REQUIREMENTS AND GUIDELINES ......................... CHECK ENGINE LIGHT WIRING ....................................................................... 3.16.2 STOP ENGINE LIGHT ................................................................................................ STOP ENGINE LIGHT REQUIREMENTS AND GUIDELINES ............................ STOP ENGINE LIGHT WIRING ........................................................................... 3.16.3 MULTIPLE ECM ENGINES ........................................................................................ 3.16.4 MULTIPLE CEL/SEL WIRING .................................................................................... 3.17 DDEC REQUIREMENTS FOR GASEOUS HAZARDOUS ENVIRONMENTS ............... 3.17.1 HAZARDOUS GASEOUS ENVIRONMENT OVERVIEW ........................................... HAZARDOUS ENVIRONMENT CLASSIFICATION - NORTH AMERICA ............ HAZARDOUS ENVIRONMENT CLASSIFICATION - EUROPE ........................... GAS CLASSIFICATION ........................................................................................ INGRESS PROTECTION ..................................................................................... TEMPERATURE CLASSIFICATION ..................................................................... 3.18 HARDWARE AND INSTALLATION REQUIREMENTS FOR HAZARDOUS ENVIRONMENT .............................................................................................................. 3.18.1 POWER SUPPLY ........................................................................................................ CLASS I DIVISION 2 ............................................................................................ GROUP II ZONE 2 (CATEGORY 3) ...................................................................... 3.18.2 FUSES AND FUSE ASSEMBLIES ............................................................................. CLASS I DIVISION 2 ............................................................................................ GROUP II ZONE 2 (CATEGORY 3) ...................................................................... 3.18.3 DDEC WIRING ........................................................................................................... CLASS I DIVISION 2 ............................................................................................ GROUP II ZONE 2 (CATEGORY 3) ...................................................................... 3.18.4 JUNCTION BOX ......................................................................................................... 3.18.5 EXHAUST TEMPERATURE SENSOR ....................................................................... 3.18.6 SERIES 50/SERIES 60 ENGINE-MOUNTED ECM (STANDARD OPTION) .............. SERIES 50/SERIES 60 ENGINE SIDE OF ECM ................................................. SERIES 50/SERIES 60 OEM SIDE OF ECM ....................................................... INSTALLATION INFORMATION FOR ENGINE-MOUNTED ECM STANDARD OPTION ................................................................................................................ OEM HARNESS ASSEMBLY INSTRUCTIONS ................................................... vi 3-145 3-146 3-146 3-147 3-149 3-155 3-155 3-156 3-156 3-156 3-156 3-157 3-159 3-159 3-160 3-161 3-162 3-162 3-163 3-164 3-164 3-165 3-166 3-166 3-166 3-166 3-166 3-167 3-169 3-169 3-170 3-170 3-170 3-170 3-170 3-171 3-171 3-172 3-172 3-172 3-173 3-175 3-176 3-177 3-179 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.18.7 3.18.8 4 REMOTE-MOUNTED ECM OPTION ......................................................................... SERIES 2000 ENGINE-MOUNTED ECM (STANDARD OPTION) ............................. SERIES 2000 ENGINE SIDE OF ECM ................................................................ SERIES 2000 EQUIPMENT OR OEM SIDE OF ECM ......................................... INSTALLATION INFORMATION FOR ENGINE-MOUNTED ECM STANDARD OPTION ................................................................................................................ OEM HARNESS ASSEMBLY INSTRUCTIONS ................................................... 3-179 3-179 3-181 3-182 DIGITAL INPUTS AND OUTPUTS ..................................................................................... 4.1 DIGITAL INPUTS ............................................................................................................ 4.1.1 CRUISE CONTROL .................................................................................................... CRUISE ENABLE ................................................................................................ SET / COAST ON (DECREASE) .......................................................................... RESUME / ACCEL ON (INCREASE) ................................................................... CLUTCH RELEASED (MANUAL TRANSMISSIONS) .......................................... SERVICE BRAKE RELEASED (AUTOMATIC AND MANUAL TRANSMISSIONS) .............................................................................................. PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... INTERACTION WITH OTHER FEATURES .......................................................... 4.1.2 ENGINE BRAKE ......................................................................................................... ENGINE BRAKE DISABLE ................................................................................... ENGINE BRAKE LOW .......................................................................................... ENGINE BRAKE MEDIUM ................................................................................... KONSTANTDROSSEL SWITCH .......................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... 4.1.3 ENGINE PROTECTION .............................................................................................. AUXILIARY SHUTDOWN #1 AND #2 .................................................................. DIAGNOSTIC REQUEST SWITCH ...................................................................... DIAGNOSTIC REQUEST SWITCH/STOP ENGINE OVERRIDE SWITCH ......... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIAGNOSTICS ..................................................................................................... 4.1.4 ENGINE RATINGS ..................................................................................................... LIMITING TORQUE CURVE ................................................................................. RATING SWITCH #1 AND #2 ............................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIAGNOSTICS ..................................................................................................... 4.1.5 FAN CONTROL .......................................................................................................... AIR CONDITIONER STATUS OPERATION ......................................................... FAN CONTROL OVERRIDE OPERATION ........................................................... TRANSMISSION RETARDER ACTIVE OPERATION .......................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... 4.1.6 PRESSURE SENSOR GOVERNOR .......................................................................... PRESSURE ENABLE SWITCH ............................................................................ PRESSURE/RPM MODE SWITCH ..................................................................... DECREASE (SET/COAST ON) ........................................................................... INCREASE (RESUME/ACCELERATION ON) ..................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... 4-1 4-3 4-6 4-6 4-6 4-6 4-7 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-183 3-184 4-7 4-7 4-7 4-8 4-8 4-8 4-8 4-8 4-9 4-10 4-10 4-10 4-10 4-11 4-11 4-12 4-12 4-12 4-12 4-12 4-13 4-13 4-13 4-13 4-13 4-14 4-14 4-14 4-14 4-14 4-14 vii TABLE OF CONTENTS 4.1.7 4.1.8 4.1.9 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 viii INTERACTION WITH OTHER FEATURES .......................................................... THROTTLE CONTROL .............................................................................................. ALTERNATE MINIMUM VSG SPEED/FAST IDLE OPERATION .......................... DUAL THROTTLE (LSG) OPERATION ................................................................ EXTERNAL ENGINE SYNCHRONIZATION/FREQUENCY INPUT ACTIVE ....... IDLE VALIDATION SWITCH OPERATION ........................................................... THROTTLE INHIBIT ............................................................................................. VSG STATION CHANGE AND VSG STATION CHANGE COMPLEMENT ......... VSG INHIBIT (RELEASE 28.0 OR LATER) .......................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... ENGINE SYNCHRO SHIFT TRANSMISSION ........................................................... IN NEUTRAL ........................................................................................................ IN GEAR ............................................................................................................... ESS TRANSMISSION PROGRAMMING FLEXIBILITY ....................................... DIAGNOSTICS ..................................................................................................... ADDITIONAL FUNCTIONS ........................................................................................ AUXILIARY COOLANT LEVEL SWITCH ............................................................. PARKING BRAKE INTERLOCK OPERATION ..................................................... AIR COMPRESSOR LOAD SWITCH OPERATION ............................................. THROTTLE KICKDOWN OPERATION ................................................................. RPM FREEZE OPERATION ................................................................................. PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIGITAL OUTPUTS ........................................................................................................ AIR COMPRESSOR LOAD SOLENOID .................................................................... INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... COLD ENGINE OPERATION (SERIES 4000 ONLY) ................................................. INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... COOLANT LEVEL LOW LIGHT ................................................................................. INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... INTERACTION WITH OTHER FEATURES .......................................................... CRUISE CONTROL ACTIVE LIGHT (PRESSURE SENSOR GOVERNOR ACTIVE LIGHT) ........................................................................................................................ INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... INTERACTION WITH OTHER FEATURES .......................................................... DECELERATION LIGHT ............................................................................................ INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... ENGINE BRAKE ACTIVE ........................................................................................... INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... ENGINE OVERSPEED ............................................................................................... INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS & FLEXIBILITY .......................................... 4-15 4-15 4-15 4-15 4-15 4-16 4-16 4-16 4-16 4-16 4-17 4-17 4-17 4-17 4-17 4-18 4-18 4-18 4-19 4-19 4-19 4-19 4-20 4-22 4-22 4-22 4-22 4-22 4-22 4-23 4-23 4-23 4-23 4-23 4-23 4-23 4-23 4-24 4-24 4-24 4-24 4-24 4-24 4-25 4-25 4-25 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 4.2.8 4.2.9 4.2.10 4.2.11 4.2.12 4.2.13 4.2.14 4.2.15 4.2.16 4.2.17 4.2.18 4.2.19 4.2.20 ENGINE SYNCHRO SHIFT LOW RANGE SOLENOID ............................................. INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... ENGINE SYNCHRO SHIFT HIGH RANGE SOLENOID ............................................ INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIAGNOSTICS ..................................................................................................... ETHER INJECTION .................................................................................................... INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIAGNOSTICS ..................................................................................................... EXTERNAL ENGINE BRAKE ENABLE ...................................................................... INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... EXTERNAL ENGINE SYNCHRONIZATION/FREQUENCY INPUT ACTIVE ............. INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... FAN CONTROL #1 & #2 ............................................................................................. INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... HIGH COOLANT TEMPERATURE LIGHT ................................................................ INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIAGNOSTICS ..................................................................................................... HIGH CRANKCASE PRESSURE LIGHT ................................................................... INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIAGNOSTICS ..................................................................................................... HIGH OIL TEMPERATURE LIGHT ............................................................................ INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIAGNOSTICS ..................................................................................................... LOW COOLANT PRESSURE LIGHT ......................................................................... INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIAGNOSTICS ..................................................................................................... LOW DDEC VOLTAGE WARNING LIGHT .................................................................. INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIAGNOSTICS ..................................................................................................... LOW OIL PRESSURE LIGHT .................................................................................... INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIAGNOSTICS ..................................................................................................... OPTIMIZED IDLE ACTIVE LIGHT .............................................................................. INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-25 4-25 4-25 4-26 4-26 4-26 4-26 4-26 4-26 4-26 4-26 4-27 4-27 4-27 4-27 4-27 4-27 4-28 4-28 4-28 4-29 4-29 4-29 4-29 4-29 4-29 4-29 4-29 4-30 4-30 4-30 4-30 4-30 4-30 4-30 4-30 4-31 4-31 4-31 4-31 4-31 4-31 4-31 4-31 4-32 4-32 4-32 ix TABLE OF CONTENTS DIAGNOSTICS ..................................................................................................... PRESSURE SENSOR GOVERNOR PRESSURE MODE LIGHT .............................. INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... SERVICE NOW LAMP ................................................................................................ INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... STARTER LOCKOUT ................................................................................................. INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... TOP2 SHIFT SOLENOID ............................................................................................ INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIAGNOSTICS ..................................................................................................... TOP2 SHIFT LOCKOUT SOLENOID ......................................................................... INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIAGNOSTICS ..................................................................................................... TRANSMISSION RETARDER .................................................................................... INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... VEHICLE POWER SHUTDOWN ................................................................................ INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... DIAGNOSTICS ..................................................................................................... INTERACTION WITH OTHER FEATURES .......................................................... VSG ACTIVE INDICATION ......................................................................................... INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... INTERACTION WITH OTHER FEATURES .......................................................... 4-32 4-32 4-32 4-32 4-33 4-33 4-33 4-35 4-35 4-35 4-35 4-35 4-35 4-35 4-36 4-36 4-36 4-36 4-36 4-36 4-36 4-37 4-37 4-37 4-38 4-38 4-38 4-38 4-38 4-38 DDEC FEATURES .............................................................................................................. 5.1 AIR COMPRESSOR CONTROL ..................................................................................... 5.1.1 OPERATION ............................................................................................................... INCREASE (RESUME/ACCELERATION ON) ...................................................... DECREASE (SET/COAST ON) ............................................................................ AIR COMPRESSOR LOAD SWITCH ................................................................... AIR COMPRESSOR SOLENOID ......................................................................... AIR COMPRESSOR SHUTDOWN ....................................................................... MULTIPLE PRESSURE RATINGS ....................................................................... 5.1.2 INSTALLATION ........................................................................................................... 5.1.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... 5.1.4 INTERACTION WITH OTHER FEATURES ................................................................ 5.2 ANTI-LOCK BRAKE SYSTEMS ...................................................................................... 5.2.1 OPERATION ............................................................................................................... 5.3 CRUISE CONTROL ........................................................................................................ 5.3.1 OPERATION ............................................................................................................... 5-1 5-3 5-3 5-3 5-4 5-4 5-4 5-4 5-4 5-5 5-6 5-7 5-9 5-9 5-13 5-13 4.2.21 4.2.22 4.2.23 4.2.24 4.2.25 4.2.26 4.2.27 4.2.28 5 x All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.3.2 5.3.3 5.3.4 5.3.5 5.4 5.4.1 5.4.2 5.4.3 5.5 5.5.1 5.5.2 5.6 5.6.1 5.6.2 5.6.3 5.6.4 5.6.5 5.7 5.7.1 5.7.2 5.7.3 5.7.4 5.8 5.8.1 5.8.2 5.9 5.9.1 ENGINE SPEED CRUISE CONTROL .................................................................. VEHICLE SPEED CRUISE CONTROL ................................................................ SMART CRUISE ................................................................................................... CRUISE ENABLE ................................................................................................. SET / COAST ON ................................................................................................. RESUME / ACCEL ON ......................................................................................... CLUTCH RELEASED (MANUAL TRANSMISSIONS) .......................................... SERVICE BRAKE RELEASED (AUTOMATIC AND MANUAL TRANSMISSIONS) .............................................................................................. INSTALLATION ........................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... DIAGNOSTICS ........................................................................................................... INTERACTION WITH OTHER FEATURES ................................................................ CRUISE CONTROL FOR DRILLING/PUMPING APPLICATIONS WITH OPTIONAL DUAL STATION CONTROL ............................................................................................ OPERATION ............................................................................................................... PROGRAMMING REQUIREMENTS & FLEXIBILITY ................................................. DUAL STATION CONTROLS ...................................................................................... DIAGNOSTICS ............................................................................................................... OPERATION ............................................................................................................... DIAGNOSTIC REQUEST SWITCH ...................................................................... DIAGNOSTIC REQUEST SWITCH/STOP ENGINE OVERRIDE ......................... DEFINITIONS AND ABBREVIATIONS ....................................................................... EDM AND AIM ................................................................................................................ OPERATION ............................................................................................................... INSTALLATION ........................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... INTERACTION WITH OTHER FEATURES ................................................................ DIAGNOSTICS ........................................................................................................... ELECTRONIC FIRE COMMANDER ............................................................................... OPERATION ............................................................................................................... INSTALLATION ........................................................................................................... ORDERING EFC ........................................................................................................ PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... ELECTRONIC SPEED SWITCH ..................................................................................... OPERATION ............................................................................................................... ELECTRICAL LATCH ........................................................................................... MANUAL RESET .................................................................................................. AUTOMATIC RESET ............................................................................................ ADJUSTABLE (AUTOMATIC) RESET .................................................................. INSTALLATION ........................................................................................................... ENGINE BRAKE CONTROLS ........................................................................................ OPERATION ............................................................................................................... CRUISE CONTROL WITH ENGINE BRAKE ....................................................... ENGINE BRAKE DISABLE ................................................................................... ENGINE BRAKE ACTIVE ..................................................................................... ENGINE FAN BRAKING ....................................................................................... All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-13 5-13 5-13 5-14 5-14 5-14 5-15 5-15 5-15 5-17 5-18 5-19 5-21 5-21 5-22 5-22 5-23 5-23 5-25 5-26 5-26 5-27 5-27 5-28 5-28 5-29 5-29 5-31 5-32 5-32 5-32 5-34 5-35 5-35 5-35 5-35 5-35 5-35 5-35 5-39 5-39 5-39 5-39 5-40 5-40 xi TABLE OF CONTENTS CLUTCH RELEASED INPUT ............................................................................... SERVICE BRAKE CONTROL OF ENGINE BRAKES .......................................... MIN MPH FOR ENGINE BRAKES ....................................................................... 5.9.2 INSTALLATION ........................................................................................................... 5.9.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... 5.9.4 INTERACTION WITH OTHER FEATURES ................................................................ 5.10 ENGINE PROTECTION .................................................................................................. 5.10.1 OPERATION ............................................................................................................... WARNING ONLY .................................................................................................. RAMPDOWN ........................................................................................................ SHUTDOWN ......................................................................................................... 5.10.2 ENGINE OVERTEMPERATURE PROTECTION ........................................................ 5.10.3 ENGINE PROTECTION SWITCHES .......................................................................... DIAGNOSTIC REQUEST SWITCH ...................................................................... 5.10.4 STOP ENGINE OVERRIDE OPTIONS ....................................................................... 5.10.5 INSTALLATION ........................................................................................................... 5.10.6 PROGRAMMING FLEXIBILITY .................................................................................. 5.10.7 INTERACTION WITH OTHER FEATURES ................................................................ 5.11 ENGINE RATINGS .......................................................................................................... 5.11.1 OPERATION ............................................................................................................... ENGINE RATING SWITCHES .............................................................................. CRUISE POWER .................................................................................................. LIMITING TORQUE CURVE OPTION (DIGITAL TORQUE LIMITING) ................ 5.11.2 INSTALLATION ........................................................................................................... 5.11.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... RATING SWITCHES ............................................................................................. CRUISE POWER .................................................................................................. LIMITING TORQUE OPTION ............................................................................... 5.12 ETHER START ................................................................................................................ 5.12.1 OPERATION ............................................................................................................... 5.12.2 INSTALLATION ........................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... 5.13 EXTERNAL ENGINE SYNCHRONIZATION ................................................................... 5.13.1 OPERATION ............................................................................................................... 5.13.2 INSTALLATION ........................................................................................................... 5.13.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... 5.14 FAN CONTROL ............................................................................................................... 5.14.1 OPERATION ............................................................................................................... 5.14.2 INSTALLATION ........................................................................................................... 5.14.3 SINGLE FAN ............................................................................................................... INSTALLATION ..................................................................................................... 5.14.4 DUAL FANS ................................................................................................................ INSTALLATION - DUAL FANS .............................................................................. 5.14.5 TWO-SPEED FAN ...................................................................................................... INSTALLATION - TWO-SPEED FANS .................................................................. 5.14.6 VARIABLE SPEED SINGLE-FAN ............................................................................... INSTALLATION - VARIABLE SPEED SINGLE-FAN ............................................. xii 5-40 5-40 5-40 5-40 5-43 5-44 5-45 5-45 5-46 5-46 5-47 5-47 5-53 5-53 5-54 5-55 5-56 5-56 5-57 5-57 5-57 5-58 5-58 5-59 5-60 5-60 5-60 5-60 5-61 5-61 5-63 5-64 5-65 5-65 5-65 5-67 5-69 5-69 5-70 5-71 5-72 5-75 5-76 5-77 5-79 5-80 5-81 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.14.7 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... 5.15 FUEL ECONOMY INCENTIVE ....................................................................................... 5.15.1 OPERATION ............................................................................................................... 5.15.2 PROGRAMMING FLEXIBILITY .................................................................................. 5.15.3 INTERACTION WITH OTHER FEATURES. ............................................................... 5.16 GLOW PLUG CONTROLLER ......................................................................................... 5.16.1 OPERATION ............................................................................................................... 5.16.2 INSTALLATION ........................................................................................................... 5.16.3 OEM CONNECTIONS ................................................................................................ SWITCHED +12 VDC IGNITION (CIRCUIT 50) ................................................... GROUND (CIRCUIT 151) ..................................................................................... STARTER INHIBIT CIRCUIT (CIRCUIT 968) ....................................................... GLOW PLUG PANEL LIGHT ................................................................................ FIRE SUPPRESSION SYSTEM INTERFACE/CATALYTIC CONVERTER HIGH TEMPERATURE (CIRCUIT 906 & 416) ............................................................... 5.16.4 DIAGNOSTICS .......................................................................................................... 5.16.5 FUEL SYSTEM REQUIREMENTS ............................................................................. 5.17 HALF ENGINE IDLE ....................................................................................................... 5.17.1 OPERATION ............................................................................................................... 5.17.2 INSTALLATION ........................................................................................................... 5.17.3 PROGRAMMING FLEXIBILITY .................................................................................. 5.17.4 DIAGNOSTICS ........................................................................................................... 5.18 IDLE SHUTDOWN TIMER AND VEHICLE POWER SHUTDOWN ................................ 5.18.1 OPERATION ............................................................................................................... IDLE SHUTDOWN OVERRIDE - OPTIONAL ....................................................... VEHICLE POWER SHUTDOWN - OPTIONAL .................................................... ENABLED ON VARIABLE SPEED GOVERNOR (VSG) - OPTIONAL ................. AMBIENT AIR TEMPERATURE OVERRIDE DISABLE - OPTIONAL .................. INACTIVE SHUTDOWN ....................................................................................... 5.18.2 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... 5.18.3 INTERACTION WITH OTHER FEATURES ................................................................ 5.19 IRIS ................................................................................................................................. 5.19.1 OPERATION ............................................................................................................... 5.19.2 INSTALLATION ........................................................................................................... MOBILE UNIT INSTALLATION ............................................................................. BASE UNIT INSTALLATION ................................................................................. BASE UNIT INSTALLATION WITH REMOTE DATA INTERFACE (RDI) .............. IRIS MOBILE SERVICE KIT INSTALLATION ....................................................... 5.20 LOW GEAR TORQUE LIMITING .................................................................................... 5.20.1 OPERATION ............................................................................................................... 5.20.2 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... 5.21 MAINTENANCE ALERT SYSTEM .................................................................................. 5.21.1 OPERATION ............................................................................................................... ECM POWER DOWN BEHAVIOR ........................................................................ CEL/SEL FLASHING ............................................................................................ PRODRIVER ........................................................................................................ MAINTENANCE ALERT SYSTEM DISPLAY MODULE ....................................... All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-82 5-83 5-83 5-84 5-84 5-85 5-85 5-85 5-86 5-86 5-86 5-86 5-86 5-87 5-87 5-87 5-89 5-89 5-89 5-89 5-89 5-91 5-91 5-92 5-93 5-93 5-93 5-94 5-94 5-95 5-97 5-97 5-99 5-100 5-101 5-102 5-103 5-105 5-105 5-105 5-107 5-107 5-108 5-108 5-109 5-110 xiii TABLE OF CONTENTS DIAGNOSTIC DATA READER .............................................................................. DETROIT DIESEL DIAGNOSTIC LINK ................................................................ 5.21.2 INSTALLATION ........................................................................................................... AIR FILTER RESTRICTION SENSOR ................................................................. ADD COOLANT LEVEL SENSOR ....................................................................... FUEL RESTRICTION SENSOR ........................................................................... OIL LEVEL SENSOR ............................................................................................ MAINTENANCE ALERT SYSTEM DISPLAY MODULE INSTALLATION ............. MAINTENANCE ALERT SYSTEM DISPLAY HARNESS ..................................... 5.21.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... 5.21.4 DIAGNOSTICS ........................................................................................................... 5.21.5 INTERACTION WITH OTHER FEATURES ................................................................ 5.22 MANAGEMENT INFORMATION PRODUCTS ................................................................ 5.22.1 OPERATION ............................................................................................................... 5.22.2 DDEC III DATA PAGES ............................................................................................... 5.22.3 DDEC IV DATA ............................................................................................................ 5.22.4 DDEC REPORTS ....................................................................................................... 5.22.5 DETROIT DIESEL DATA SUMMARIES ...................................................................... 5.22.6 PRODRIVER REPORTS ........................................................................................... 5.22.7 PROMANAGER 2.10 .................................................................................................. 5.22.8 DATA LOGGER ........................................................................................................... DATA LOGGER INSTALLATION ........................................................................... 5.22.9 PRODRIVER .............................................................................................................. PRODRIVER INSTALLATION ............................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... 5.22.10 PRODRIVER DC ........................................................................................................ PRODRIVER DC INSTALLATION ........................................................................ 5.22.11 MANAGEMENT INFORMATION PRODUCTS KITS .................................................. 5.23 MARINE CONTROLS ..................................................................................................... 5.23.1 OPERATION ............................................................................................................... CONTROL STATION ............................................................................................ ENGINE ROOM .................................................................................................... 5.24 OPTIMIZED IDLE ............................................................................................................ 5.24.1 OPERATION ............................................................................................................... ENGINE MODE .................................................................................................... THERMOSTAT MODE .......................................................................................... OPTIMIZED IDLE START UP SEQUENCE .......................................................... 5.24.2 INSTALLATION ........................................................................................................... 5.24.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... 5.24.4 DIAGNOSTICS ........................................................................................................... 5.24.5 INTERACTION WITH OTHER FEATURES ................................................................ 5.25 OPTIMUM LOAD SIGNAL .............................................................................................. 5.25.1 OPERATION ............................................................................................................... 5.25.2 INSTALLATION ........................................................................................................... 5.25.3 PROGRAMMING REQUIREMENT AND FLEXIBILITY .............................................. 5.26 OVERALL GOVERNOR GAIN ........................................................................................ 5.26.1 PROGRAMMING REQUIREMENTS & FLEXIBILITY ................................................. xiv 5-112 5-113 5-116 5-118 5-120 5-122 5-123 5-124 5-128 5-128 5-129 5-129 5-131 5-131 5-132 5-133 5-133 5-141 5-142 5-144 5-146 5-147 5-151 5-151 5-160 5-161 5-163 5-170 5-175 5-175 5-176 5-177 5-179 5-179 5-180 5-180 5-180 5-181 5-182 5-183 5-183 5-185 5-185 5-185 5-185 5-187 5-187 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.27 PASSMART ..................................................................................................................... 5.27.1 OPERATION ............................................................................................................... 5.27.2 INSTALLATION ........................................................................................................... 5.27.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... 5.27.4 INTERACTION WITH OTHER FEATURES ................................................................ 5.28 PASSWORDS ................................................................................................................. 5.28.1 RATING PASSWORD ................................................................................................. 5.28.2 INJECTOR PASSWORD ............................................................................................ 5.28.3 CUSTOMER PASSWORD .......................................................................................... PARAMETER GROUP LOCKOUT ....................................................................... 5.28.4 PROGRAMMING REQUIREMENTS & FLEXIBILITY ................................................. 5.29 PRESSURE SENSOR GOVERNOR .............................................................................. 5.29.1 PSG OPERATION ..................................................................................................... RPM MODE ......................................................................................................... PRESSURE MODE ............................................................................................. 5.29.2 SWITCHES - DECREASE AND INCREASE .............................................................. INCREASE (RESUME/ACCELERATION ON) ...................................................... DECREASE (SET/COAST ON) ............................................................................ 5.29.3 INSTALLATION ........................................................................................................... 5.29.4 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... 5.29.5 INTERACTION WITH OTHER FEATURES ................................................................ 5.30 PROGRESSIVE SHIFT ................................................................................................... 5.30.1 OPERATION ............................................................................................................... 5.30.2 LOW RANGE #1 ......................................................................................................... 5.30.3 LOW RANGE #2 ......................................................................................................... 5.30.4 HIGH RANGE ............................................................................................................. 5.30.5 INSTALLATION INFORMATION ................................................................................. 5.30.6 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... 5.30.7 INTERACTION WITH OTHER FEATURES ................................................................ 5.31 PULSE TO VOLTAGE MODULE ..................................................................................... 5.31.1 OPERATION ............................................................................................................... SYSTEM SWITCHED POWER INPUT REQUIREMENTS ................................... STEADY STATE OPERATING VOLTAGE RANGES ............................................. PULSE WIDTH MODULATED SIGNAL INPUT REQUIREMENTS ...................... GROUND REQUIREMENTS ................................................................................ PVM ANALOG VOLTAGE OUTPUT ..................................................................... 5.31.2 INSTALLATION REQUIREMENTS ............................................................................. CONNECTOR TO PVM ........................................................................................ 5.32 TACHOMETER DRIVE .................................................................................................... 5.33 THROTTLE CONTROL/GOVERNORS ........................................................................... 5.33.1 LIMITING SPEED GOVERNOR - ON-HIGHWAY ...................................................... LSG PRIMARY WITH VSG AS A SECONDARY CONTROL ............................... LSG CONTROL OPTIONS ................................................................................... LSG ELECTRONIC FOOT PEDAL ASSEMBLY ................................................... LSG ELECTRONIC FOOT PEDAL ASSEMBLY INSTALLATION ......................... LSG ELECTRONIC FOOT PEDAL ASSEMBLY DIAGNOSTICS ......................... LSG DUAL ELECTRONIC FOOT PEDAL ASSEMBLY THROTTLE CONTROLS All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-189 5-189 5-190 5-191 5-191 5-193 5-193 5-193 5-193 5-193 5-195 5-197 5-197 5-197 5-197 5-198 5-198 5-198 5-199 5-200 5-201 5-203 5-203 5-204 5-204 5-205 5-207 5-208 5-208 5-209 5-209 5-209 5-209 5-210 5-210 5-210 5-211 5-212 5-213 5-215 5-215 5-215 5-217 5-217 5-217 5-218 5-219 xv TABLE OF CONTENTS LSG DUAL THROTTLE CONTROL INSTALLATION ............................................ LSG DUAL THROTTLE CONTROL PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................................................................................ LSG DUAL THROTTLE CONTROL DIAGNOSTICS ............................................ 5.33.2 VARIABLE SPEED GOVERNOR - NONROAD .......................................................... VSG PROGRAMMING REQUIREMENTS AND FLEXIBILITY ............................. CRUISE SWITCH VSG ........................................................................................ CRUISE SWITCH VSG INSTALLATION REQUIREMENTS ................................. CRUISE SWITCH VSG PROGRAMMING REQUIREMENTS AND FLEXIBILITY VSG HAND THROTTLE ....................................................................................... VSG HAND THROTTLE INSTALLATION ............................................................. VSG HAND THROTTLE CALIBRATION ............................................................... VSG ELECTRONIC FOOT PEDAL ASSEMBLY ................................................... ALTERNATE MINIMUM VSG (FAST IDLE) .......................................................... ALTERNATE MINIMUM VSG INSTALLATION ...................................................... ALTERNATE MINIMUM VSG PROGRAMMING FLEXIBILITY ............................. VSG VOLTAGE DIVIDERS ................................................................................... VSG VOLTAGE DIVIDERS INSTALLATION ......................................................... VSG RESISTOR SELECTION FOR VOLTAGE DIVIDERS .................................. VSG DUAL THROTTLE CONTROLS ................................................................... VSG DUAL THROTTLE CONTROLS INSTALLATION ......................................... DUAL THROTTLE CONTROLS PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................................................................................ VSG DUAL THROTTLE CONTROLS DIAGNOSTICS ......................................... VSG FREQUENCY INPUT ................................................................................... VSG FREQUENCY INPUT INSTALLATION ......................................................... VSG FREQUENCY INPUT PROGRAMMING FLEXIBILITY ................................ 5.34 TRANSMISSION INTERFACE ........................................................................................ 5.34.1 PWM1 OPERATION .................................................................................................. MODULATED SIGNAL ......................................................................................... DISCRETE ON/OFF SIGNAL ............................................................................... 5.34.2 PWM1 INSTALLATION ............................................................................................... ALLISON INTERFACE MODULES ....................................................................... GE PROPULSION SYSTEM CONTROLLER ....................................................... ZF ECOMAT AND VOITH TRANSMISSIONS ...................................................... ALLISON HYDRAULIC TRANSMISSION ............................................................. PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... 5.34.3 COMMUNICATION LINKS OPERATION ................................................................... 5.34.4 COMMUNICATION LINKS INSTALLATION ................................................................ ALLISON WORLD TRANSMISSION .................................................................... EATON CEEMAT TRANSMISSION ..................................................................... SAE J1939 TRANSMISSIONS ............................................................................. PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... 5.34.5 DIGITAL INPUT AND DIGITAL OUTPUT TRANSMISSIONS ..................................... 5.34.6 EATON TOP2 OPERATION ........................................................................................ INSTALLATION ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... xvi 5-219 5-220 5-220 5-220 5-221 5-222 5-222 5-223 5-223 5-223 5-224 5-224 5-225 5-225 5-225 5-225 5-226 5-226 5-228 5-229 5-230 5-231 5-231 5-231 5-232 5-233 5-233 5-233 5-235 5-235 5-236 5-238 5-239 5-240 5-241 5-241 5-241 5-242 5-244 5-244 5-244 5-245 5-245 5-245 5-246 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL DIAGNOSTICS ..................................................................................................... MERITOR ENGINE SYNCHRO SHIFT OPERATION ................................................ INSTALLATION ..................................................................................................... DIAGNOSTICS ..................................................................................................... PROGRAMMING REQUIREMENTS AND FLEXIBILITY ..................................... 5.35 TRANSMISSION RETARDER ........................................................................................ 5.35.1 OPERATION ............................................................................................................... 5.35.2 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... 5.35.3 INTERACTION WITH OTHER FEATURES ................................................................ 5.36 VEHICLE SPEED LIMITING ........................................................................................... 5.36.1 OPERATION ............................................................................................................... 5.36.2 INSTALLATION ........................................................................................................... 5.36.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY ........................................... 5.36.4 INTERACTION WITH OTHER FEATURES ................................................................ 5.37 VEHICLE SPEED SENSOR ANTI-TAMPERING ............................................................ 5.37.1 PROGRAMMING FLEXIBILITY .................................................................................. 5-247 5-247 5-249 5-250 5-251 5-253 5-253 5-253 5-253 5-255 5-255 5-255 5-255 5-255 5-257 5-257 COMMUNICATION PROTOCOLS ...................................................................................... 6.1 OVERVIEW ..................................................................................................................... 6.2 SAE J1587 ...................................................................................................................... 6.2.1 MESSAGE FORMAT .................................................................................................. 6.2.2 1708/1587 MESSAGE PRIORITY .............................................................................. SAE J1587 PARAMETERS AVAILABLE WITH DDEC IV ..................................... 6.2.3 SAE J1587 PIDS REQUIRING DDEC ACTION ......................................................... DATA REQUEST ................................................................................................... COMPONENT SPECIFIC REQUEST .................................................................. RETARDER STATUS REQUEST .......................................................................... TRANSMITTER DATA REQUEST / CLEAR COUNT ........................................... J1587 OUTPUTS - SINGLE BYTE PARAMETERS .............................................. DOUBLE BYTE PARAMETERS ........................................................................... VARIABLE LENGTH PARAMETERS ................................................................... 6.3 SAE J1922 ...................................................................................................................... 6.3.1 MESSAGE FORMAT .................................................................................................. 6.3.2 SAE J1922 PARAMETERS AVAILABLE WITH DDEC III/IV ....................................... 6.3.3 SAE J1922 MIDS ........................................................................................................ ENGINE TO POWERTRAIN ................................................................................. ENGINE INITIALIZATION RESPONSE ................................................................ TRANSMISSION TO POWERTRAIN MESSAGE ................................................. TRANSMISSION INITIALIZATION REQUEST ..................................................... ABS/TRACTION CONTROL TO POWERTRAIN .................................................. ABS/TRACTION CONTROL INITIALIZATION REQUEST ................................... RETARDER TO POWERTRAIN ........................................................................... RETARDER INITIALIZATION RESPONSE .......................................................... 6.4 SAE J1939 ...................................................................................................................... 6.4.1 MESSAGE FORMAT .................................................................................................. 6.4.2 SAE J1939/71 APPLICATION LAYER ........................................................................ ELECTRONIC ENGINE CONTROLLER #1 -- EEC1 ............................................ 6-1 6-3 6-5 6-5 6-6 6-6 6-8 6-8 6-8 6-8 6-9 6-10 6-20 6-26 6-35 6-35 6-35 6-35 6-36 6-37 6-38 6-39 6-40 6-41 6-42 6-42 6-43 6-43 6-44 6-44 5.34.7 6 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION xvii TABLE OF CONTENTS 6.4.3 xviii ELECTRONIC ENGINE CONTROLLER #2 -- EEC2 ............................................ IDLE OPERATION ................................................................................................ TURBOCHARGER ............................................................................................... ELECTRONIC ENGINE CONTROLLER #3 -- EEC3 ............................................ VEHICLE DISTANCE ............................................................................................ IDLE SHUTDOWN ................................................................................................ ENGINE HOURS, REVOLUTIONS ...................................................................... TIME/DATE ........................................................................................................... VEHICLE HOURS ................................................................................................ FUEL CONSUMPTION ......................................................................................... CRUISE CONTROL / VEHICLE SPEED SETUP ................................................. ENGINE TEMPERATURE .................................................................................... ENGINE FLUID LEVEL/PRESSURE .................................................................... POWER TAKEOFF INFORMATION ..................................................................... CRUISE CONTROL / VEHICLE SPEED .............................................................. FUEL ECONOMY ................................................................................................. AMBIENT CONDITIONS ...................................................................................... INLET / EXHAUST CONDITIONS ........................................................................ EXHAUST PORT TEMPERATURE #1 ................................................................. EXHAUST PORT TEMPERATURE #2 ................................................................. EXHAUST PORT TEMPERATURE #3 ................................................................. EXHAUST PORT TEMPERATURE #4 ................................................................. VEHICLE ELECTRICAL POWER ......................................................................... ALTERNATE FUEL #1 .......................................................................................... AUXILIARY WATER PUMP PRESSURE .............................................................. ENGINE FLUID LEVEL/PRESSURE #2 ............................................................... HIGH RESOLUTION VEHICLE DISTANCE ......................................................... ELECTRONIC ENGINE CONTROLLER #4 : EEC4 ............................................. FAN DRIVE ........................................................................................................... ELECTRONIC RETARDER CONTROLLER #1 - ERC1 ....................................... SOFTWARE IDENTIFICATION ............................................................................ COMPONENT IDENTIFICATION ......................................................................... RETARDER CONFIGURATION ............................................................................ ENGINE CONFIGURATION ................................................................................. ADAPTIVE CRUISE CONTROL ........................................................................... TORQUE SPEED CONTROL - TSC1 .................................................................. ELECTRONIC TRANSMISSION CONTROLLER #1 -- ETC1 .............................. SAE J1939/21 DATA LINK LAYER .............................................................................. ACKNOWLEDGE / NEGATIVE ACKNOWLEDGE ................................................ REQUESTS .......................................................................................................... TRANSPORT PROTOCOL BROADCAST ANNOUNCE (TP.CM_BAM) .............. TRANSPORT PROTOCOL DATA (TP.DT) ............................................................ TRANSPORT PROTOCOL REQUEST TO SEND (TP.CM_RTS) ......................... TRANSPORT PROTOCOL CONNECTION ABORT (TP.CONNABORT) ............. TRANSPORT PROTOCOL END OF MESSAGE (TP.ENDOFMSGACK) ............. TRANSPORT PROTOCOL CLEAR TO SEND (TP.CM_CTS) .............................. TP.DT .................................................................................................................... 6-45 6-45 6-46 6-46 6-47 6-47 6-48 6-49 6-49 6-50 6-50 6-51 6-52 6-53 6-54 6-56 6-56 6-57 6-58 6-59 6-60 6-61 6-61 6-62 6-62 6-62 6-63 6-63 6-64 6-65 6-66 6-67 6-68 6-68 6-70 6-71 6-72 6-73 6-73 6-74 6-74 6-75 6-75 6-76 6-76 6-77 6-77 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 6.4.4 7 SAE J1939/73 DIAGNOSTIC LAYER ......................................................................... STOP START BROADCAST ................................................................................. 6-78 6-78 TOOLS ................................................................................................................................ 7.1 DIAGNOSTIC REQUEST SWITCH ................................................................................ 7.2 VEHICLE ELECTRONIC PROGRAMMING SYSTEM .................................................... 7.2.1 SOFTWARE ................................................................................................................ 7.2.2 HARDWARE ............................................................................................................... 7.2.3 OPTIONAL PARTS KITS ............................................................................................ 7.3 DIAGNOSTIC DATA READER ........................................................................................ 7.3.1 REQUIREMENTS ....................................................................................................... 7.3.2 ENGINE DATA LIST .................................................................................................... 7.3.3 DIAGNOSTIC CODES ................................................................................................ ACTIVE CODES ................................................................................................... INACTIVE CODES ............................................................................................... CLEARING CODES WITH A DDR ....................................................................... 7.3.4 VIEW CALIBRATION .................................................................................................. ENGINE CONFIGURATION ................................................................................. 7.3.5 FUEL INJECTOR ........................................................................................................ 7.3.6 ENGINE/TRIP DATA ................................................................................................... 7.3.7 CALIBRATION CHANGES ......................................................................................... REPROGRAM CALIBRATION .............................................................................. 7.3.8 SWITCH/LIGHT STATUS ............................................................................................ 7.3.9 ACTIVATE OUTPUTS ................................................................................................. 7.3.10 MIDS RECEIVED ....................................................................................................... 7.3.11 RESET COMPONENTS ............................................................................................. 7.3.12 TRANSMISSIONS ...................................................................................................... 7.3.13 RESET AFR TABLE .................................................................................................... 7.3.14 MAINTENANCE STATUS ........................................................................................... 7.4 DETROIT DIESEL DIAGNOSTIC LINK .......................................................................... 7.4.1 CALIBRATION ............................................................................................................ 7.4.2 DIAGNOSTICS AND MAINTENANCE ....................................................................... 7.5 DDEC REPROGRAMMING SYSTEM ............................................................................ 7.5.1 REQUIREMENTS ....................................................................................................... 7.5.2 DRS PROGRAMMING SOFTWARE .......................................................................... 7.5.3 ECM PROGRAMMING MENU ................................................................................... PROGRAM ECM .................................................................................................. PROGRAM FLEET ECM ...................................................................................... PROGRAM ECM WITH MAINFRAME DATA ........................................................ DISPLAY AVAILABLE ECM S/W VERSIONS ....................................................... DISPLAY CUSTOMER CALIBRATION ................................................................. UPDATE CALIBRATION AT DDC ......................................................................... DISPLAY STATION LOG FILE .............................................................................. UPDATE CUSTOMER CALIBRATION .................................................................. UPDATE LOGON PARAMETERS ........................................................................ UPGRADE ECM SOFTWARE .............................................................................. UPDATE INJECTOR CALIBRATION .................................................................... 7-1 7-3 7-5 7-5 7-5 7-6 7-7 7-7 7-11 7-12 7-12 7-13 7-14 7-15 7-16 7-17 7-18 7-19 7-20 7-21 7-22 7-23 7-23 7-24 7-24 7-25 7-27 7-27 7-27 7-29 7-29 7-29 7-29 7-29 7-30 7-30 7-30 7-30 7-30 7-30 7-30 7-31 7-31 7-31 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION xix TABLE OF CONTENTS DISPLAY DOWNLOADED UNITS ........................................................................ UPDATE ECM ACCUMULATORS ........................................................................ PRINT ECM PARAMETERS ................................................................................. DDC MAINFRAME INTERFACE MENU ............................................................... DDECCOMM .............................................................................................................. DOWNLOAD ENGINE SERIAL CALIBRATION(S) ............................................... DOWNLOAD FLEET CALIBRATION(S) ............................................................... UPLOAD HISTORY .............................................................................................. DISPLAY AVAILABLE ECM S/W VERSIONS ....................................................... DISPLAY STATION LOG FILE .............................................................................. DISPLAY DOWNLOADED UNITS ........................................................................ UPDATE LOGON PARAMETERS ........................................................................ DDEC ENGINE PROTECTION SIMULATION KIT .......................................................... COOLANT LEVEL LOW SIMULATOR ........................................................................ HIGH OIL/COOLANT TEMPERATURE SIMULATOR ................................................ LOW OIL PRESSURE SIMULATOR ........................................................................... HIGH CRANKCASE PRESSURE SIMULATOR (SERIES 4000 ONLY) ..................... DDEC MANUALS ............................................................................................................ 7-31 7-31 7-32 7-32 7-32 7-32 7-32 7-32 7-32 7-32 7-33 7-33 7-35 7-35 7-35 7-36 7-36 7-37 APPLICATIONS .................................................................................................................. 8.1 APPLICATION CODE SYSTEM ...................................................................................... 8.2 TYPICAL ON-HIGHWAY APPLICATION ......................................................................... 8.3 TYPICAL INDUSTRIAL APPLICATION - UNDERGROUND HAUL TRUCK ................... 8.4 TYPICAL INDUSTRIAL APPLICATION - AIR COMPRESSOR ...................................... 8.5 TYPICAL INDUSTRIAL APPLICATION - ON-HIGHWAY CRANE .................................. 8.6 TYPICAL GENSET APPLICATIONS ............................................................................... 8.6.1 1,500 RPM GENSET ................................................................................................. 8.6.2 1,800 RPM GENSET ................................................................................................. 8.7 TYPICAL FIRE TRUCK APPLICATION .......................................................................... 8.8 DDEC REQUIREMENTS FOR GASEOUS HAZARDOUS ENVIRONMENTS ............... 8.8.1 HAZARDOUS GASEOUS ENVIRONMENT OVERVIEW ........................................... HAZARDOUS ENVIRONMENT CLASSIFICATION - NORTH AMERICA ............ HAZARDOUS ENVIRONMENT CLASSIFICATION - EUROPE ........................... GAS CLASSIFICATION ........................................................................................ INGRESS PROTECTION ..................................................................................... TEMPERATURE CLASSIFICATION ..................................................................... 8.8.2 DDEC IV SYSTEM CERTIFICATION ......................................................................... CLASS I DIVISION 2 CERTIFICATION ................................................................ GROUP II ZONE 2 (CATEGORY 3) CERTIFICATION .......................................... 8.8.3 PRODUCT MARKINGS .............................................................................................. CLASS I DIVISION 2 ............................................................................................ GROUP II ZONE 2 (CATEGORY 3) ...................................................................... 8.8.4 APPLICABLE STANDARDS ....................................................................................... CLASS I DIVISION 2 ............................................................................................ GROUP II ZONE 2 (CATEGORY 3) ...................................................................... 8.8.5 TEMPERATURES ....................................................................................................... 8-1 8-3 8-11 8-13 8-15 8-17 8-19 8-19 8-21 8-23 8-25 8-26 8-26 8-26 8-26 8-26 8-27 8-28 8-28 8-30 8-41 8-41 8-42 8-46 8-46 8-46 8-46 7.5.4 7.6 7.6.1 7.6.2 7.6.3 7.6.4 7.7 8 xx All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8.9 TYPICAL INDUSTRIAL APPLICATION - HAZARDOUS ENVIRONMENT PETROLEUM .................................................................................................................. 8.9.1 HAZARDOUS ENVIRONMENT PETROLEUM UNIQUE 6N4C GROUP ................... APPENDIX A: 8-47 8-47 CODES .................................................................................................................. A-1 A.1 PIDS .................................................................................................................................... A-9 A.2 SIDS .................................................................................................................................... A-13 APPENDIX B: HARNESS WIRING DIAGRAMS .......................................................................... B-1 APPENDIX C: SYMBOLS ............................................................................................................. C-1 APPENDIX D: ACRONYMS .......................................................................................................... D-1 APPENDIX E: VENDORS ............................................................................................................. E-1 GLOSSARY ..................................................................................................................................... G-1 INDEX ............................................................................................................................................ INDEX-1 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION xxi TABLE OF CONTENTS xxii All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 1 INTRODUCTION The Detroit Diesel Electronic Control System (DDEC®) is an advanced electronic fuel injection and control system that can be integrated into many applications. DDEC provides the customer value throughout the life of the unit and at time of resale. DDEC IV provides three industry standard serial data links: SAE Standards J1587, J1922, and J1939. SAE Standard J1587 provides two way communications for the diagnostic equipment and vehicle displays. SAE Standards J1922 and J1939 provide control data to other vehicle systems such as transmissions and traction control devices. FEATURES DDEC IV offers significant operating advantages over traditional mechanically governed engines. The following features can be tailored to achieve specific customer preferences: Cruise Control operation Vehicle speed limit control Variable speed governing Fast Idle operation Idle Shutdown control Crank and throttle inhibiting Device controlling power take-off (PTO) is both in-cab and remotely operable Application specific safety features, such as door interlock Application specific control features A customer security/reprogramming password Fan control All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 1-1 INTRODUCTION ADVANTAGES DDEC IV offers significant operating advantages over traditional mechanically governed engines offering end users: State-of-the-art fuel management and economy, including compensation for changing environmental conditions and user preferences EPA and CARB smoke and emissions compliance (nonroad and on-highway applications) Total system integration including the availability of SAE Standards J1587, J1922, and J1939 data links Application specific features to meet customer needs Multi-level password protected security and reprogramming flexibility Proven reliability and durability that customers demand Easily accessible components, reducing maintenance time and simplifying troubleshooting Integrated engine protection features with lights for visual awareness Easily retrievable historical fault codes for diagnostic capability Operating statistics are tracked, fuel consumed, miles traveled (hours used), for accurate unit and fleet management TYPICAL INSTALLATION A typical installation includes: A fused ignition wire to the ECM A Power Harness that supplies 12 or 24 volts to the ECM. (Series 4000 requires 24V) An Engine Sensor Harness from the engine-mounted sensors to the ECM and to the injector solenoids An OEM supplied Vehicle Interface Harness (VIH) from the remaining sensors, switches, throttle device, and other components attached to the SAE 1587 Data Link back to the ECM A Communication Harness that connects the ECM's J1922 and J1939 ports to other vehicle systems such as traction control devices and transmissions Display devices (lights, tachometer, etc.) 1-2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The schematic for a typical on-highway installation is shown in the following illustration (see see Figure 1-1). Figure 1-1 The DDEC IV System, On-highway Application - Series 60 Engine All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 1-3 INTRODUCTION The schematic for a typical construction and industrial installation is shown in the following illustration (see Figure 1-2). Figure 1-2 1-4 The DDEC IV System, Construction and Industrial Application Series 2000 Engine All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL APPLICATION FLEXIBILITY DDEC IV can be tailored to operate and/or interact with various systems, drivelines, and driven devices including: Manual, automatic, and electronically controlled transmissions Electronically controlled transmission retarders and other engine retarders Various types of single or dual throttle devices like foot- and hand-actuated, in-cab and remote controlled devices PTOs A Pressure Sensor Governor Air compressors Anti-lock brakes and automatic traction control Electronic speedometers, tachometers, and instruments and displays, such as the Electronic Display Module, ProDriver® and Electronic Fire Commander™ DIAGNOSTICS AND TOOLS Diagnostic and other fleet management tools offer additional flexibility and convenience. Pressing a panel-mounted Data Request Button retrieves active and inactive (historic) codes. A hand-held Diagnostic Data Reader (DDR) obtains the same codes, performs self-checks, collects snapshot data, and reprograms certain features. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 1-5 INTRODUCTION The Detroit Diesel Diagnostic Link™ (DDDL) is a sophisticated software package supporting the set up, maintenance and repair of engines using DDEC. Used as a diagnostic tool DDDL can be used to change the engine rating, view an audit trail of ECM and injector calibration change, monitor fault codes as they occur, snap shot recording, and set the ECM output functions to particular values to support troubleshooting. ELECTRONIC DISPLAYS DDEC IV SAE J1587 Data Link is used to transmit and display sensor and engine data to other vehicle modules including electronic dashboard displays. A panel-mounted ProDriver or ProDriver DC display shows operational data such as instantaneous fuel economy and idle time. Electronic Display Module (EDM) is an electronic display system which displays engine and equipment parameters. Electronic Fire Commander (EFC) is a complete pressure governor control unit which displays engine speed, battery voltage, engine oil pressure, and either engine oil temperature or engine coolant temperature (programmable). 1-6 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Optimized Idle® automatically stops and restarts the engine to keep the engine oil temperature between factory set limits, keep the battery charged, and keep the vehicle interior at the desired temperature (using the optional thermostat). Engine idle time is reduced, there is an overall reduction in exhaust emissions and noise, and improved starter and engine life. The system also reduces dead batteries due to electrical loads, such as refrigerators or satellite systems. The Maintenance Alert System (MAS) monitors engine fluid levels and filter restrictions and notifies the driver and/or technician when maintenance is required. THE BASICS The ECM can be considered the most important component of the DDEC system, as it controls the engine operation and acts as an interface with the other subsystems and devices, via the SAE J1587, J1922, or J1939 data links. In these roles, the ECM adjusts engine speed and torque by transmitting output signals to the electronic unit injectors or electronic unit pumps via the Injector Harness and interacts with the other subsystems by: Monitoring system status Transmitting engine status Receiving sensor input All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 1-7 INTRODUCTION Receiving system requests The ECM adjusts engine speed and torque after: Receiving input signals, diagnostic information, and requests from sensors and other subsystems and devices Conditioning input signals Performing calculations Determining output signals necessary to achieve operating goals The ECM also monitors and reacts to various situations as detailed below: Certain ambient conditions can result in fuel rate and timing adjustments to control smoke during starting Certain barometric conditions can result in fuel rate and timing adjustments to compensate for altitude Certain oil temperatures require changes to compensate for differences in oil viscosity, reducing fuel injection variation Engine speed and cranking time is monitored to determine if crank inhibiting is necessary Vehicle speed is monitored and compared to user settings and instantaneous preferences specified by input switches to meet cruise control requirements Requirements for driven devices like PTOs, air compressors, and pumps are monitored and compared to user settings, monitored conditions, and instantaneous preferences specified by input switches to achieve in-cab or remotely controlled PTO operation requirements The ECM also: Performs self-checks and retains fault codes within its memory Monitors operating conditions and either signals the user with a light or cuts back fuel in an attempt to control overtemperature and abnormal pressure conditions for engine protection Monitors operations to signal the user of an impending service interval Broadcasts operational and diagnostic information over the data link 1-8 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 2 SAFETY PRECAUTIONS The following safety measures are essential when installing DDEC IV in a vehicle equipped with a Detroit Diesel engine. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system. 2.1 STANDS Use safety stands in conjunction with hydraulic jacks or hoists. Do not rely on either the jack or the hoist to carry the load. 2.2 GLASSES Select appropriate safety glasses for the job. Safety glasses must be worn when using tools such as hammers, chisels, pullers and punches. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 2-1 SAFETY PRECAUTIONS 2.3 WELDING Consider the consequences of welding. NOTICE: When welding, the following must be done to avoid damage to the electronic controls or the engine: Both the positive (+) and negative (-) battery leads must be disconnected before welding. Ground cable must be in close proximity to welding location - engine must never be used as a grounding point. Welding on the engine or engine mounted components is NEVER recommended. Wear welding goggles and gloves when welding or using an acetylene torch. To avoid injury from fire, check for fuel or oil leaks before welding or carrying an open flame near the engine. Insure that a metal shield separates the acetylene and oxygen which must be chained to a cart. 2.4 WORK PLACE Organize your work area and keep it clean. To avoid injury from slipping and falling, immediately clean up any spilled liquids. Eliminate the possibility of a fall by: Wiping up oil spills Keeping tools and parts off the floor A fall could result in a serious injury. 2-2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL After installation of the engine is complete: To avoid injury from rotating belts and fans, do not remove and discard safety guards. Reinstall all safety devices, guards or shields Check to be sure that all tools and equipment used to install the engine are removed from the engine 2.5 CLOTHING Wear work clothing that fits and is in good repair. Work shoes must be sturdy and rough-soled. Bare feet, sandals or sneakers are not acceptable foot wear when installing an engine. To avoid injury when working near or on an operating engine, remove loose items of clothing, jewelry, tie back or contain long hair that could be caught in any moving part causing injury. 2.6 ELECTRIC TOOLS Improper use of electrical equipment can cause severe injury. To avoid injury from electrical shock, follow OEM furnished operating instructions prior to usage. Check power tools before using. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 2-3 SAFETY PRECAUTIONS 2.7 AIR Use proper shielding to protect everyone in the work area. To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure. 2.8 FLUIDS AND PRESSURE Be extremely careful when dealing with fluids under pressure. To avoid injury from the expulsion of hot coolant, never remove the cooling system pressure cap while the engine is at operating temperature. Remove the cap slowly to relieve pressure. Wear adequate protective clothing (face shield or safety goggles, rubber gloves, apron, and boots). Fluids under pressure can have enough force to penetrate the skin. To avoid injury from penetrating fluids, do not put your hands in front of fluid under pressure. Fluids under pressure can penetrate skin and clothing. These fluids can infect a minor cut or opening in the skin. See a doctor at once, if injured by escaping fluid. Serious infection or reaction can result without immediate medical treatment. 2-4 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 2.9 BATTERIES Electrical storage batteries give off highly flammable hydrogen gas when charging and continue to do so for some time after receiving a steady charge. To avoid injury from battery explosion or contact with battery acid, work in a well-ventilated area, wear protective clothing, and avoid sparks or flames near the battery. Always establish correct polarity before connecting cables to the battery or battery circuit. If you come in contact with battery acid: Flush your skin with water. Apply baking soda or lime to help neutralize the acid. Flush your eyes with water. Get medical attention immediately. Always disconnect the battery cable before working on the Detroit Diesel Electronic Controls system. 2.10 FIRE Keep a charged fire extinguisher within reach. Be sure you have the correct type of extinguisher for the situation. The correct fire extinguisher types for specific working environments are listed in Table 2-1. Fire Extinguisher Work Environment Type A Wood, Paper, Textile and Rubbish Table 2-1 Type B Flammable Liquids Type C Electrical Equipment The Correct Type of Fire Extinguisher All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 2-5 SAFETY PRECAUTIONS 2.11 DIAGNOSTIC DATA READER For mobile applications, the Diagnostic Data Reader (DDR) must be used by personnel other than the vehicle operator. To avoid injury from loss of vehicle/vessel control, the operator of a DDEC equipped engine must not attempt to use or read the Diagnostic Data Reader when the vehicle/vessel is moving. The vehicle operator must maintain control of the vehicle while an assistant performs the diagnostic evaluations. 2.12 DETROIT DIESEL DIAGNOSTIC LINK For mobile applications, Detroit Diesel Diagnostic Link (DDDL) must be used by personnel other than the vehicle operator. To avoid injury from loss of vehicle/vessel control, the operator of a DDEC equipped engine must not use or read any diagnostic tool while the vehicle/vessel is moving. The vehicle operator must maintain control of the vehicle while an assistant performs the diagnostic evaluations. 2.13 PAINT NOTICE: Do not apply paint to the ECM or EFC. The application of paint may affect the performance of the ECM and EFC. Mask off the ECM and EFC, prior to applying any paint. 2-6 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 2.14 FLUOROELASTOMER (VITON) Fluoroelastomer (Viton) parts such as O-rings and seals are perfectly safe to handle under normal design conditions. To avoid injury from chemical burns, wear a face shield and neoprene or PVC gloves when handling fluoroelastomer O-rings or seals that have been degraded by excessive heat. Discard gloves after handling degraded fluoroelastomer parts. A potential hazard may occur if these components are raised to a temperature above 600 F (316 C) (in a fire for example). Fluoroelastomer will decompose (indicated by charring or the appearance of a black, sticky mass) and produce hydrofluoric acid. This acid is extremely corrosive and, if touched by bare skin, may cause severe burns (the symptoms could be delayed for several hours). 2.15 PRESSURE SENSOR GOVERNOR INSTALLATION The Vehicle Interface Harness requires unique additional circuits to accommodate the Pressure Sensor Governor (PSG). The OEM must supply a series of interlock switches to insure the vehicle is in the specified state in order to activate the PSG. To avoid injury from the vehicle moving while in either Pressure or RPM Mode, the required interlock switches must be engaged. Interlock switches may include but are not limited to the following: Parking brake Transmission state - in neutral (PTO pump) or engaged (midship pump) Pump mechanically engaged All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 2-7 SAFETY PRECAUTIONS 2.16 OPTIMIZED IDLE Optimized Idle enhances the DDEC Idle Shutdown feature. Optimized Idle will automatically stop and restart the engine when required in order to keep the engine temperature above 60 F, the battery charged, and/or the vehicle interior at the desired temperature. To avoid injury from an accidental startup of an engine equipped with the Optimized Idle® system, remove the starter relay from the relay holder. 2-8 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3 HARDWARE AND WIRING Section Page 3.1 SUPPLIED HARDWARE ......................................................................... 3-3 3.2 ELECTRONIC CONTROL MODULE ...................................................... 3-5 3.3 ENGINE SENSOR HARNESS ................................................................ 3-9 3.4 VEHICLE INTERFACE HARNESS ......................................................... 3-17 3.5 COMMUNICATION HARNESS ............................................................... 3-27 3.6 INJECTOR HARNESS AND INJECTION SYSTEMS ............................. 3-29 3.7 POWER HARNESS ................................................................................ 3-33 3.8 POWER SUPPLY .................................................................................... 3-43 3.9 FUSES .................................................................................................... 3-51 3.10 CONNECTORS ....................................................................................... 3-53 3.11 WIRES AND WIRING ............................................................................. 3-69 3.12 CONDUIT AND LOOM ............................................................................ 3-101 3.13 TAPE AND TAPING ................................................................................. 3-103 3.14 SENSORS ............................................................................................... 3-105 3.15 THROTTLE DEVICES ............................................................................. 3-155 3.16 LIGHTS ................................................................................................... 3-159 3.17 DDEC REQUIREMENTS FOR GASEOUS HAZARDOUS ENVIRONMENTS ................................................................................... 3-165 3.18 HARDWARE AND INSTALLATION REQUIREMENTS FOR HAZARDOUS ENVIRONMENT .............................................................. 3-169 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-1 HARDWARE AND WIRING THIS PAGE INTENTIONALLY LEFT BLANK 3-2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.1 SUPPLIED HARDWARE Hardware supplied by the Original Equipment Manufacturer (OEM) and DDC is required to install DDEC IV. The following sections list the minimum hardware required. 3.1.1 OEM-SUPPLIED HARDWARE The minimum OEM-supplied hardware required is listed in Table 3-1. Hardware Ignition Switch (refer to section 3.4.4) Vehicle Interface Harness (VIH) (refer to section 3.4) Communication Harness (refer to section 3.5) Power Harness (refer to section 3.7) Vehicle Power Harness (refer to section 3.7.6) Diagnostic Connector (refer to section 3.10.7) Throttle Input Device (refer to section 3.15) Coolant Level Sensor (CLS) (refer to section 3.14.19) Check Engine Light (CEL) (refer to section 3.16.1) Stop Engine Light (SEL) (refer to section 3.16.2) Table 3-1 3.1.2 Description Switched 12 or 24 volt ignition source Connects the vehicle functions to the ECM. Connects the ECM's SAE J1922 and SAE J1939 data links to other vehicle systems. Single-ECM Applications only - Connects battery power (12/24 volts) and ground to the ECM and includes fuse(s) or circuit breaker(s). Multi-ECM Applications only - Connects battery (12/24 V) and ground to ECMs and includes fuses and/or critical breakers. Cab-mounted diagnostic connector An electronic foot pedal assembly (EFPA), hand throttle, or alternative throttle device A radiator top tank or remote surge tank mounted sensor A panel mounted yellow indicator light. A panel mounted red indicator light. OEM-supplied Hardware DDC-SUPPLIED HARDWARE The minimum DDC-supplied hardware required is listed in Table 3-2. Hardware Engine Sensor Harness (refer to section 3.3) Engine Interface Harness (refer to section 3.4.3) Injector Harness (refer to section 3.6) Engine Power Harness (refer to section 3.7.5) Table 3-2 Description Factory installed harness that facilitates the receipt of inputs and outputs signals, controlling the fuel injection process and engine speed. Multi-ECM Applications - Factory installed, interface between ECM and VIH. Factory installed harness that is connect to the injection unit and the ECM(s). Multi-ECM Applications - Factory installed, interface between ECM and OEM Vehicle Power Harness. Minimum DDC Supplied Hardware All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-3 HARDWARE AND WIRING THIS PAGE INTENTIONALLY LEFT BLANK 3-4 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.2 ELECTRONIC CONTROL MODULE The engine-mounted ECM includes control logic to provide overall engine management. The ECM continuously performs self diagnostic checks and monitors other system components. System diagnostic checks are made at ignition-on and continue throughout all engine operating modes. See Figure 3-1. Figure 3-1 The Electronic Control Module The ECM contains an Electronically Erasable Programmable Read Only Memory (EEPROM). The EEPROM controls the basic engine functions, such as rated speed and power, timing of fuel injection, engine governing, torque shaping, cold start logic, transient fuel delivery, diagnostics, and engine protection. The control logic determines duration and timing of fueling, which results in precise fuel delivery and improved fuel economy. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-5 HARDWARE AND WIRING 3.2.1 MULTI-ECMS Engines with more than eight cylinders operate with multiple ECMs. One ECM is called the master, while the others are referred to as receivers. The master ECM is the primary controller of the engine. It receives input from the various sensors, determines proper timing and communicates this information to the injectors that the master ECM controls. The master ECM sends this information to the receiver ECM. The receiver ECM instructs its injectors to operate in the same manner. Capability exists to enable independent operation of each portion of the engine in the unlikely event that the communications fail between the master and receiver ECMs. 3.2.2 ECM PART NUMBERS Part numbers for DDEC III and IV ECMs are listed in Table 3-3. Part Number Description Voltage No. of Cylinders 23518645* DDEC III - Standard On-highway ECM 12/24 V 6 23518743 DDEC III - Universal ECM 12/24 V 8 23518744 DDEC III - Series 4000 ECM only 24 V 8 23519307 DDEC IV - Standard On-highway ECM 12 V 6 23519308 DDEC IV - Universal ECM 12/24 V 8 23519309 DDEC IV - Series 4000 ECM only 24 V 8 * Does not have SAE J1939, all other ECMs are SAE J1939 compatible Table 3-3 ECM Part Numbers for DDEC III and DDEC IV NOTE: All DDEC IV ECMs are compatible with SAE J1939. The part numbers for the ECM connectors are listed in Table 3-4. Description Injector Harness Connectors (5-pin) (2 connectors) Part Number 12162825 12162830 Engine Sensor Harness Connector (30-pin) 12034400 Power Harness Connector (5-pin) 12124634 Communication Harness Connector (6-pin) 12066317 Vehicle Interface Harness Connector (30-pin) 12044398 Table 3-4 ECM Connectors For more information on the ECM connectors, refer to section 3.10. 3-6 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.2.3 ENVIRONMENTAL CONDITIONS The following environmental conditions must be considered. Temperature The ambient operating temperature is – 40 F (-40 C) minimum and 221 F (105 C) maximum. Atmospheric Pressure The engine mounted ECM can withstand atmospheric pressures ranging from 62.0 to 120.0 kPa absolute that result from altitude and weather changes in the operating and non-operating conditions. Water Intrusion The ECM can be exposed to steam cleaning and pressure washing. Care should be taken not to pressure spray the connectors. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-7 HARDWARE AND WIRING THIS PAGE INTENTIONALLY LEFT BLANK 3-8 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.3 ENGINE SENSOR HARNESS The Engine Sensor Harness (ESH) is installed at the factory and is delivered connected to all engine sensors and the ECM. See Figure 3-2 for an illustration of a typical on-highway ESH. Refer to Appendix B for a harness schematic. Figure 3-2 A Typical On-highway Engine Sensor Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-9 HARDWARE AND WIRING See Figure 3-3 for an illustration of a Series 60 construction and industrial ESH. Figure 3-3 3-10 A Typical Series 60 Construction and Industrial Engine Sensor Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL See Figure 3-4 for an illustration of a Series 2000 construction and industrial ESH. Refer to Appendix B for a harness schematic. Figure 3-4 A Typical Series 2000 Single-ECM Construction and Industrial Engine Sensor Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-11 HARDWARE AND WIRING See Figure 3-5 for an illustration of a Series 2000 generator set ESH. Refer to Appendix B for a harness schematic. Figure 3-5 3-12 Series 2000 Single ECM Genset Engine Sensor Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.3.1 ENGINE SENSOR HARNESS FOR MULTI-ECM ENGINES Multi-ECM engines operate with more than one Electronic Control Module. The controlling ECM is referred to as the master ECM, while one receiver is referred to as the first receiver and the other, if required, is the second receiver. The Engine Sensor Harness is installed at the factory and is delivered connected to all sensors and all ECMs. This harness contains the following: SAE J1939 communication link between the ECMs A Turbo Boost Sensor for each ECM The Timing Reference Sensor (TRS) and Synchronous Reference Sensor (SRS) are shared by the ECMs See Figure 3-6 for an illustration of the Series 4000 multi-ECM Sensor Harness and see Figure 3-7 for an illustration of the Series 2000 multi-ECM Sensor Harness. Refer to Appendix B for a harness schematic. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-13 HARDWARE AND WIRING Figure 3-6 3-14 A Typical Series 4000 Multi-ECM Engine Sensor Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 3-7 A Typical Series 2000 Multi-ECM Engine Sensor Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-15 HARDWARE AND WIRING THIS PAGE INTENTIONALLY LEFT BLANK 3-16 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.4 VEHICLE INTERFACE HARNESS The OEM supplied Vehicle Interface Harness (VIH) connects the ECM to other vehicle systems as shown in the VIH illustrations. See Figure 3-8 and Figure 3-9. Refer to Appendix B for a harness schematic. Figure 3-8 Typical On-highway Vehicle Interface Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-17 HARDWARE AND WIRING Figure 3-9 3-18 Typical Construction and Industrial Vehicle Interface Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.4.1 VIH DESIGN The following criteria are to be used when designing the VIH. Criteria: VIH Design The VIH 30-pin connector is designed to accept 18 gage (0.75 - 0.80 mm2) standard wall thickness cable only. The acceptable cable insulations are Teflon (EFTE), cross-link polyethylene (XLPE) or any equivalent self-extinguishing insulation such as GXL having a minimum rating of -40 C to 125 C. An equivalent insulation must meet the acceptable cable diameters from 2.00 - 2.42 mm. The conductor must be annealed copper, not aluminum, and must comply with the industry standard SAE J1128 document. Detroit Diesel Corporation recommends color coding and hot stamping wire numbers in contrasting colors at intervals of four inches or less. NOTE: Avoid renumbering DDC circuits since all troubleshooting guides reference the circuit numbers shown in the schematic. DDC suggests including a prefix or suffix with the DDC circuit numbers when conflicts exist. NOTE: The Vehicle Speed Sensor (VSS) circuits 556 and 557 and the Data Link circuits 900 and 901 (SAE J1587) must be twisted pairs. The twists are a minimum of 12 turns per foot (305 mm) and are required to minimize electromagnetic field coupling. NOTE: The maximum length for the SAE J1708/J1587 Data Link is 40 m (130 ft). The maximum length for the SAE J1939 Data Link is 40 m (130 ft). 3.4.2 VIH INSTALLATION The following concepts have proven to be effective in installing the VIH. Provide maximum physical separation of the VIH from other vehicle electrical systems. Other electrical system cables should ideally be at least three feet away from the VIH and should not be parallel to the VIH. This will eliminate coupling electromagnetic energy from other systems into the VIH. Do not route the harness near any vehicle moving parts, exhaust or any high heat source. Use a protective sheath to prevent wires from being cut or frayed when weaving harness through the frame. The 30-pin VIH-to-ECM connector assembly (12034398) center screw must be torqued to 7-13 in.·lbs (0.79 - 1.47 Nm). Adhere to industry standards for relief length and maximum wire bend radius at the connectors. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-19 HARDWARE AND WIRING 3.4.3 VEHICLE INTERFACE HARNESS FOR MULTI-ECM ENGINES Multi-ECM engines operate with more than one engine mounted ECM. The controlling ECM is referred to as the master ECM, while one receiver is referred to as the first receiver and, if required, the other is the second receiver. The VIH is similar to the VIH used for single-ECM engines with the following exceptions: The Series 149 engine has a single SEL and a single CEL for each ECM. The Stop Engine Override Switch operates all ECMs with the engine running and acts as a diagnostic code flashing switch on the CEL and SEL for the master ECM only when the engine is not running. The Stop Engine Override/Diagnostic Request Switch is used to flash codes on the CEL and SEL from the master ECM when the engine is not running or the engine is at idle. All receiver ECMs have a separate Diagnostic Request Switch that cannot enable the Stop Engine Override function. Engine Interface Harness The Engine Interface Harness used in multi-ECM applications is usually installed at the factory and delivered connected to all ECMs. The factory installed Engine Interface Harness (see Figure 3-10), normally terminates with a quick disconnect connector. Figure 3-10 3-20 A Typical Multi-ECM Engine Interface Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The OEM Vehicle Interface Harness connects to the quick disconnect connector (see Figure 3-11 and Figure 3-12). Refer to Appendix B for a harness schematic. Figure 3-11 Typical Multi-ECM Construction and Industrial Vehicle Interface Harness Schematic - Series 4000 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-21 HARDWARE AND WIRING Figure 3-12 3-22 Typical Multi ECM Construction and Industrial Vehicle Interface Harness Schematic - Series 2000 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.4.4 HARNESS DESIGN GUIDELINES The electrical characteristics of some of the system elements including the ECM are described in the following sections. This information is useful for harness design. NOTE: All output loads (PWM and digital outputs), ignition, and ECM power must be powered by the same battery voltage. Pulse Width Modulated Port (PWM #1, 2, 4) The output of this port is capable of providing 50 to 1000 Hz modulation between 0% and 100% duty cycle with a resolution of less than or equal to 0.1% duty cycle and an accuracy of less than or equal to 20 µsec. Output Characteristics: Eout is less than or equal to 0.8 volts with respect to ECM ground. Output On: Isink is less than or equal to 5 mA. Output Off: Ileakage (Isink) is less than or equal to 1.0 mA while 0 ≤ Eout ≤Vbattery. Load Drive Capabilities: Capable of driving a resistance greater than or equal to 32 ohms for a 12 volt ignition. Resistance: Capable of driving a resistance greater than or equal to 64 ohms for a 24 volt ignition. Inductance: Capable of connecting to an inductance less than or equal to 60 mH at 100 Hz. Isink: Capable of sinking an average current of 3 A or less and peak current of 6 A or less. Digital Output Ports The digital output ports are: 419, 509, 988, 555, 499, 563, 564, and 565. Wire numbers 419 and 509 are reserved for the CEL and SEL, respectively. Refer to section 4.2, "Digital Outputs" for additional information. Output Characteristics: Eout is less than or equal to 0.8 volts with respect to ECM ground (#150). Output On: Isinkis less than or equal to 1.5 A. Output Off: Ileakage (Isink) is less than or equal to 1.0 mA while 0 ≤Eout ≤Vbattery. Load Drive Capabilities: Capable of driving a resistance greater than or equal to 11 for a 12 volt ignition. Resistance: Capable of driving a resistance greater than or equal to 21 for a 24 volt ignition. Capable of connecting to an inductance less than or equal to 85 mH. If load is >85 mH Inductance: then external clamping is required. Isink: Capable of sinking less than or equal to 1.5 A. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-23 HARDWARE AND WIRING The digital output ports are capable of driving a #168 bulb (three candlepower lamp) in a 12 volt system or a # 313 bulb (three candlepower lamp) in a 24 volt system. See Figure 3-13. Figure 3-13 DDEC III and DDEC IV Internal Digital Output Circuits Digital Input Ports The digital input ports are: 451, 542, 528, 523, 541, 544, 543, 524, 531, 583, 545 and 979. Refer to section 4.2, "Digital Inputs" for additional information. Input Requirements: 32 volts > Ein > 4 volts at less than 0.2 mA leakage current. High State: The ECM has an internal 1k pull-up to 5 volts. Low State: Ein< 1.0 volts. Isource: Capable of sourcing up to 5 mA. NOTE: Use switches that will not oxidize with the passage of time and environmental factors due to the low source current. 3-24 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL A DDEC IV digital input circuit may be seen in the next illustration (see Figure 3-14). Figure 3-14 DDEC IV Digital Input Circuit Switch Ground Switch ground (circuit 953) must only be used to provide ground for DDEC components (i.e. digital inputs) and must be sourced directly from the negative battery or bus bar terminal; refer to section 3.7, "Power Harness." NOTE: This circuit can not be used to provide ground for non-DDEC OEM-supplied electronics. Ignition The ignition source may be either 12 or 24 volts depending on the ECM configuration. The DDEC ignition must be an independent input sourced directly from the battery post via a 5 amp weatherproof blade type fuse, circuit breaker, or equivalent. Fuse holders for blade type fuses may be purchased from the DDC Parts Distribution Center. Part numbers are listed in Table 3-5. Table 3-5 Part Part Number Fuse Holder 12033769 Cover 12033731 Terminals 12066614 Fuse Holder Part Numbers Ignition voltage must be continuously provided in the crank and run modes. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-25 HARDWARE AND WIRING THIS PAGE INTENTIONALLY LEFT BLANK 3-26 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.5 COMMUNICATION HARNESS The OEM-supplied Communication Harness connects the ECM ports for SAE J1922 and SAE J1939 to other vehicle systems such as traction control devices, transmissions, braking systems, and retarders as shown in the communication harness schematic; see Figure 3-15. Figure 3-15 Communication Harness Both SAE J1922 and SAE J1939 provide for the interchange of interactive control data between vehicle systems and eliminate the need for redundant sensors. SAE J1922 runs at 9.6K baud while SAE J1939 runs at 250K baud. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-27 HARDWARE AND WIRING 3.5.1 DESIGN GUIDELINES The design guidelines for the Communication Harness are as follows: SAE J1922: SAE J1939: The SAE J1922 wire pairs (800 & 801) must be twisted a minimum of 12 turns per foot (305 mm). Twisting this wire pair will minimize the electromagnetic coupling effects. The SAE J1939 wiring must follow the SAE J1939 wiring guidelines including termination resistors. The SAE J1939 wires (925, 926, and 927) must be twisted at nine turns per foot (305 mm). Refer to SAE J1939-11 for further details. The following list of SAE documents covering the SAE J1939: J1939 - Top Layer (Overview) J1939-11 Physical Layer J1939-21 Data Link J1939-71 Application Layer J1939-01 Recommended Practice for Control and Communications Network for On-highway Equipment The SAE document that covers the SAE J1922 Data Link is "Powertrain Control Interface for Electronic Controls Used in Medium and Heavy Duty Diesel On-Highway Vehicle Applications." To obtain a copy of the SAE documents for SAE J1922 and SAE J1939, contact the Society of Automotive Engineers (SAE). SAE International 400 Commonwealth Drive Warrendale, PA 15096 Attention: Publications Phone: (412) 776-4970 For a list of messages supported by DDEC, refer to Chapter 5, "Communication Protocols." 3-28 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.6 INJECTOR HARNESS AND INJECTION SYSTEMS The injector harnesses (see Figure 3-16) are installed at the factory and are delivered completely connected to the injection units and the ECMs. Figure 3-16 Typical On-highway Injector Harness Injector harness schematics for various engine series and applications may be found in the Appendix (refer to Appendix B). All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-29 HARDWARE AND WIRING 3.6.1 ELECTRONIC UNIT INJECTORS The Electronic Unit Injector (EUI) (see Figure 3-17) operates on the same basic principle as the Mechanical Unit Injector (MUI) which has been incorporated in Detroit Diesel engines for over fifty years. Figure 3-17 The Electronic Unit Injector The EUI uses a solenoid operated valve to control injection timing and metering. The source for high pressure fuel delivery is the cam/rocker arm system. Fuel injection begins when the solenoid valve is closed. Opening the solenoid valve ends injection. The duration of valve closure determines the quantity of fuel injected. 3.6.2 COMMON RAIL ELECTRONICS The Series 4000 common rail fuel injection system relies on a single high pressure fuel pump that provides a continuous supply of fuel, at injection pressure, to all of the injectors. The ECM(s) receives data (such as engine temperatures and engine speed), analyzes this data, and modulates the fuel system accordingly to ensure efficient engine operation. The signals that the ECM(s) sends to the high pressure pump determines the timing and amount of fuel delivered to each cylinder. 3-30 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.6.3 ELECTRONIC UNIT PUMP The Series 2000 Electronic Unit Pump (EUP) provides fuel to the fuel injector nozzle. The nozzle directs pressurized fuel directly into the combustion chamber. The EUP uses a solenoid operated valve to control injection timing and metering. The source for high pressure fuel delivery is the cam/rocker arm system. Fuel injection begins when the solenoid valve is closed. Opening the solenoid valve ends injection. The duration of valve closure determines the quantity of fuel injected. See Figure 3-18. Figure 3-18 Electronic Unit Pump Assembly All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-31 HARDWARE AND WIRING THIS PAGE INTENTIONALLY LEFT BLANK 3-32 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.7 POWER HARNESS The OEM-supplied Power Harness supplies either 12 or 24 volts depending on the ECM. The system must be sourced directly from the battery or bus bar. 3.7.1 DUAL-FUSE INSTALLATION DDC's primary recommendation is a dual-fuse installation. This will provide redundancy on a critical circuit and prevent splicing of wire into fuse holders or power connectors. Dual-fuse installations have two lines wired in parallel. This configuration also allows for a greater distance from ECM to battery. See Figure 3-19. Figure 3-19 Power Harness - Single-ECM, Dual-Fuses All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-33 HARDWARE AND WIRING The resistance requirement is unchanged. The correct fuse size is listed in Table 3-6. NOTICE: Connection to reverse polarity will damage the system if not properly fused. Table 3-6 Number of Cylinders Dual-Fuse or Circuit Breaker Size 6 2@ 15 A 8 2@ 20 A 12 4@ 15 A 16 4@ 20 A 20 4@ 15 A 2@ 20 A Fuse Size For Dual-Fuse Installations To determine minimum cable gage based upon harness length from the battery source to the ECM, use the information listed in Table 3-7. Length from ECM to Battery or Bus Bar U.S. (ft) Minimum Wire Size International (m) U.S. (Ga.) International (mm2) Total Resistance of Maximum Length U.S. (m ) International (m ) 0 to 28 0 to 6 12 2.5 24.8 22.8 28 to 44 6 to 10 10 4 24.57 23.55 44 to 70 10 to 14 8 6 24.58 21.98 70 to 110 14 to 26 6 10 24.7 23.66 110 to 178 26 to 40 4 16 25.0 23.2 Table 3-7 Power Harness Length Criteria for Dual Fuse Installations NOTE: For international wire sizes the harness length must be recalculated to meet the resistance requirement. 3-34 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL If larger than 12 AWG wire is required, it should be spliced to 12 AWG wire as close as possible to the connector (see Figure 3-20). Figure 3-20 Spliced Power Connector Wire These length and sizes are based on the use of stranded annealed copper not aluminum wire. Splices must be soldered and sealed with a waterproof insulator. Alpha FIT-300, Raychem TAT-125 or any equivalent heat shrink - dual wall epoxy encapsulating adhesive polyolefin is required. 3.7.2 SINGLE-FUSE INSTALLATION Single-fuse installations have one line from the battery to the ECM. The correct fuse size is listed in Table 3-8. Table 3-8 Number of Cylinders Single-Fuse or Circuit Breaker Size 6 1@ 30 A 8 1@ 40 A 12 2@ 30 A 16 2@ 40 A 20 2@ 30 A 1@ 40 A Fuse Size for Single Fuse Installations NOTE: A single-fuse installation does not provide redundancy on a critical circuit and does not prevent splicing of wire into fuse holders or power connectors. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-35 HARDWARE AND WIRING Single fuse installations are simpler and less expensive than two fuse installations. See Figure 3-21. Figure 3-21 Power Harness - Single-ECM, Single-Fuse The minimum cable gage based upon harness length from the battery source to the ECM is listed in Table 3-9. Length from ECM to Battery or Bus Bar Total Resistance of Maximum Length U.S. (ft) International (m) U.S. (Ga.) International (mm2) U.S. (m ) International (m ) 0 to 14 0 to 3 12 2.5 24.8 22.8 14 to 22 3 to 5 10 4 24.57 23.55 22 to 35 5 to 7 8 6 24.58 21.98 35 to 55 7 to 13 6 10 24.7 23.66 55 to 89 13 to 20 4 16 25.0 23.2 Table 3-9 3-36 Minimum Wire Size Power Harness Length Criteria for Single Fuse Installations All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL If larger than 12 AWG wire is required, it should be spliced to 12 AWG wire as close as possible to the connector (see Figure 3-22). Figure 3-22 Spliced Power Connector Wire These length and sizes are based on the use of stranded annealed copper not aluminum wire. Splices must be soldered and sealed with a waterproof insulator. Alpha FIT-300, Raychem TAT-125 or any equivalent heat shrink - dual wall epoxy encapsulating adhesive polyolefin is required. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-37 HARDWARE AND WIRING 3.7.3 POWER HARNESS DESIGN The following criteria are to be used when designing the Power Harness. Criteria: Power Harness Design The power connector is designed to accept 12 Ga. standard wall cable only. The acceptable cable insulations are Teflon (EFTE), cross-link polyethylene (XLPE) or any equivalent self-extinguishing insulation such as GXL having a minimum rating of -40 C to 125 C. An equivalent insulation must meet the acceptable cable diameters 3.49 - 3.65 mm. The conductor must be annealed copper not aluminum and must comply with the industry standard SAE J1128 document. Splices must be soldered and sealed with a waterproof insulator. Alpha FIT-300, Raychem TAT-125 or any equivalent heat shrink - dual wall epoxy encapsulating adhesive polyolefin is required. Detroit Diesel Corporation recommends color coding and hot stamping wire numbers in contrasting colors at intervals of four inches or less. Wire Resistances Twelve gage wires are required at the power harness connector. The total resistance of any power harness wire from the ECM to the battery (or bus bar) can not exceed 50 m . The characteristics for Teflon coated and GXL type wire gages are listed in Table 3-10. SAE Wire Gage Metric Gage # Area mm2 Resistance m /m Resistance m /ft @ 20 C Resistance m /ft @ 120 C Diameter mm 16 1 1.129 15.300 4.66 6.50 0.72 14 2 1.859 9.290 2.83 3.94 1.18 12 3 2.929 5.900 1.80 2.50 1.86 10 5 4.663 3.720 1.13 1.58 2.97 8 8 7.277 2.400 0.73 1.02 4.63 Table 3-10 Wire Characteristics Fuse Holder and Connector The use of weatherproof blade type fuses, circuit breakers, or equivalent protection is required. Blade fuse holders may be purchased from DDC parts distribution network. The part numbers are listed in Table 3-11. 3-38 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Part Part Number Fuse Holder 12033769 Cover 12033731 Terminal 12033997 Table 3-11 Fuse Holder Part Numbers Power harness connectors and terminals may be purchased from the DDC parts distribution network. The part numbers are listed in Table 3-12. Part Part Number Connector Assembly 12124634 Terminal 12077413 Cable Seal 12015193 Secondary Lock 12052816 Table 3-12 3.7.4 Power Harness Connector Assembly POWER HARNESS INSTALLATION The following criteria should be used when installing power harnesses. See Figure 3-28for main power supply shutdown. Criteria: Power Harness Installation Power must be sourced directly from the battery or bus bar. An electrically solid connection to the battery or bus bar is required so the battery can filter electrical noise from the power lines. Power for other vehicle systems must not be sourced from the power harness assembly. Do not use chassis ground. The DDEC ground wire must be electrically separate from chassis ground. Power and ground bus bars may be used. The bus bar must be connected to the battery posts with 0 AWG or larger wire depending upon the total vehicle current requirement. The connecting wires must be as short as possible to minimize circuit resistance. Do not connect the ground wire to the chassis ground. Provide maximum physical separation of the power harness from other vehicle electrical systems. Other electrical system cables should ideally be at least three feet away from the power harness and should not be parallel to the power harness. This will eliminate coupling electromagnetic energy from other systems into the power harness. Do not route harness near any vehicle moving parts. Do not route harness assembly near exhaust system or any high heat source. Use a protective sheath and clips to prevent wires from being cut or frayed when weaving a harness through the frame. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-39 HARDWARE AND WIRING 3.7.5 ENGINE POWER HARNESS - MULTI-ECMS The Engine Power Harness (see Figure 3-23) for multi-ECM applications is usually installed at the factory and delivered connected to all ECMs. The Engine Power Harness terminates with a quick disconnect connector where the OEM Vehicle Power Harness connection is made. Refer to Appendix B for Engine Power Harness schematics. Figure 3-23 3.7.6 The Multi-ECM Engine Power Harness VEHICLE POWER HARNESS OEMs are required to provide a Vehicle Power Harness to interface the vehicle power and engine. Similar Power Harness guidelines for single ECM engines apply to multi-ECM engines. See Figure 3-24and Figure 3-25 that detail the Vehicle Power Harness for multi-ECM engines. 3-40 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 3-24 Series 149 Vehicle Power Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-41 HARDWARE AND WIRING Figure 3-25 3-42 Series 4000 Vehicle Power Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.8 POWER SUPPLY Normal operating voltage for DDEC, listed in Table 3-13, is ECM dependent. NOTICE: Operating the ECM over the voltage limits listed in Table 3-13will cause damage to the ECM. Part Number Description Normal Operating Voltage Voltage Limits 23518645 DDEC III - Standard On-highway ECM 11-32 Volts DC 32 Volts 23518743 DDEC III - Universal ECM 11-32 Volts DC 32 Volts 23518744 DDEC III - Series 4000 ECM 11-32 Volts DC 32 Volts 23519307 DDEC IV - Standard On-highway ECM 11-14 Volts DC 14 Volts 23519308 DDEC IV - Universal ECM 11-32 Volts DC 32 Volts 23519309 DDEC IV - Series 4000 ECM 11-32 Volts DC 32 Volts Table 3-13 Operating Voltage Operating the ECM between 8 and 11 volts may result in degraded engine operation. (Transient operation in this range during engine starting is considered normal for 12 volt systems.) NOTICE: Reversing polarity will cause damage to the ECM if the power harness is not properly fused. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-43 HARDWARE AND WIRING 3.8.1 AVERAGE BATTERY DRAIN CURRENT The average battery drain current for various engines may be found in the following tables. The current draw for single, dual and triple ECM configurations is listed in Table 3-14. Engine Condition Current for 12V System (Average DC) Current for 24V System (Average DC) Single ECM Ignition Off 20 mA 25 mA Single ECM Ignition On & Engine Stopped 500 mA 400 mA Dual ECM Ignition Off 40 mA 50 mA Dual ECM Ignition On & Engine Stopped 1.0 A 800 mA Triple ECM Ignition Off 60 mA 75 mA Triple ECM Ignition On & Engine Stopped 1.5 A 1.2 A NOTE: Add up to 1.5 A to the current draw total for every digital output. NOTE: Power supply and harness must be able to transition from 0 A to 30 A in .6 milliseconds with no more than 0.75 volt loss at the ECM. Table 3-14 Average Battery Drain Current for Single, Dual, and Triple ECM Configurations The current draw for two cycle engines is listed in Table 3-15. Condition Current for 12V System (Average DC) Current for 24V System (Average DC) 6 Cylinder Idle 1.5 A 1.0 A 6 Cylinder Rated RPM, Full Load 6.0 A 3.8 A 8 Cylinder Idle 2.0 A 1.5 A 8 Cylinder Rated RPM, Full Load 8.0 A 4.5 A Engine 12 Cylinder Idle 3.2 A 2.0 A 12 Cylinder Rated RPM, Full Load 12.0 A 7.5 A 16 Cylinder Idle 4.0 A 2.5 A 16 Cylinder Rated RPM, Full Load 16.0 A 9.0 A 20 Cylinder Idle 5.0 A 3.0 A 20 Cylinder Rated RPM, Full Load 20.0 A 12.0 A NOTE: Add up to 1.5 A to the current draw total for every digital output. NOTE: Power supply and harness must be able to transition from 0 A to 30 A in .6 milliseconds with no more than 0.75 volt loss at the ECM. Table 3-15 3-44 Average Battery Drain Current for Two Cycle Engines - Series 71, Series 92, and Series 149 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The current draw for the Series 50 engine is listed in Table 3-16. Condition Current for 12V System (Average DC) Current for 24V System (Average DC) 4 Cylinder Idle 1.0 A 0.8 A 4 Cylinder Rated RPM, Full Load 3.0 A 2.0 A Engine NOTE: Add up to 1.5 A to the current draw total for every digital output. NOTE: Power supply and harness must be able to transition from 0 A to 30 A in .6 milliseconds with no more than 0.75 volt loss at the ECM. Table 3-16 Average Battery Drain Current for the Series 50 The current draw for the Series 60 is listed in Table 3-17. Engine Condition Current for 12V System (Average DC) Current for 24V System (Average DC) 6 Cylinder Idle 1.0 A 0.8 A 6 Cylinder Rated RPM, Full Load 4.5 A 3.0 A NOTE: Add up to 1.5 A to the current draw total for every digital output. NOTE: Power supply and harness must be able to transition from 0 A to 30 A in .6 milliseconds with no more than 0.75 volt loss at the ECM. Table 3-17 Average Battery Drain Current for the Series 60 The current draw for the Series 2000 is listed in Table 3-18. Engine Condition Current for 12V System (Average DC) Current for 24V System (Average DC) 8 Cylinder Idle 1.4 A 1.1 A 8 Cylinder Rated RPM, Full Load 6.0 A 4.0 A 12 Cylinder Idle 2.0 A 1.6 A 12 Cylinder Rated RPM, Full Load 9.0 A 6.0 A 16 Cylinder Idle 2.7 A 2.2 A 16 Cylinder Rated RPM, Full Load 12.0 A 8.0 A NOTE: Add up to 1.5 A to the current draw total for every digital output. NOTE: Power supply and harness must be able to transition from 0 A to 30 A in .6 milliseconds with no more than 0.75 volt loss at the ECM. NOTE: Series 2000 engines with sequential turbo control require 24 volt supplies. Table 3-18 Average Battery Drain Current for the Series 2000 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-45 HARDWARE AND WIRING The current draw for the Series 4000 is listed in Table 3-19. Condition Current for 12V System (Average DC)* Current for 24V System (Average DC) 8 Cylinder Idle N/A 1.5 A 8 Cylinder Rated RPM, Full Load N/A 4.5 A 12 Cylinder Idle N/A 2.0 A 12 Cylinder Rated RPM, Full Load N/A 7.5 A 16 Cylinder Idle N/A 2.5 A 16 Cylinder Rated RPM, Full Load N/A 9.0 A Engine * Series 4000 engines require 24 volt supplies. NOTE: Add up to 1.5 A to the current draw total for every digital output. NOTE: Power supply and harness must be able to transition from 0 A to 30 A in .6 milliseconds with no more than 0.75 volt loss at the ECM. Table 3-19 3.8.2 Average Battery Drain Current for the Series 4000 REQUIREMENTS FOR 12 OR 24 VOLT SYSTEM The alternator size must be suitable for the amount of current drawn as listed in Table 3-14, Table 3-15, Table 3-16, Table 3-17, Table 3-18, and Table 3-19. The ECM will not activate injectors at speeds below 120 RPM. 3.8.3 BATTERY ISOLATOR Some applications require a battery that is dedicated to the engine and completely isolated from the rest of the vehicle. Commercially available battery isolators can be used. When interfacing inputs, outputs, analog throttle, and PWM outputs to other OEM control systems that utilize isolated battery systems with uncommon battery grounds, one of the following must be done: 3-46 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The DDEC circuit must be isolated using an isolation amplifier (see Figure 3-26). Figure 3-26 DDEC Circuit Isolated Using an Isolation Amplifier The battery grounds of the various battery systems MUST be connected together using a high ampacity cable (see Figure 3-27). Figure 3-27 Battery System Grounds Connected Using a High Ampacity Cable All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-47 HARDWARE AND WIRING 3.8.4 MAIN POWER SHUTDOWN The main power supply shutdown schematic shows the DDC approved method for main power switch implementation. See Figure 3-28. NOTE: Disconnecting positive power is not sufficient to isolate the ECM for welding purposes. Figure 3-28 3-48 Main Power Supply Shutdown 12 or 24 Volt Systems All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.8.5 WELDING CAUTION Prior to any weldingon the vehicle or equipment, the following precautions must be taken to avoid damage to the electronic controls and/or the engine (see Figure 3-29 and Figure 3-30). Figure 3-29 Welding Precaution All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-49 HARDWARE AND WIRING Figure 3-30 3-50 Welding Precaution - Multi-ECMs All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.9 FUSES A Battery (+) fuse and an ignition circuit fuse must be provided by the vehicle wiring harness. Blade-type automotive fuses are normally utilized; however, manual or automatic reset circuit breakers which meet the following requirements are also acceptable. The fuse voltage rating must be compatible with the ECU's maximum operating voltage. To avoid injury from fire, additional loads should not be placed on existing circuits. Additional loads may blow the fuse (or trip the circuit breaker) and/or cause the circuit to overheat and burn. To avoid injury from fire, do not replace an existing fuse with a larger amperage fuse. The increased current may overheat the wiring, causing the insulation and/or surrounding materials to burn. The ignition fuse current rating must be sized for the loads utilized in each application; however, a rating of between 5 and 10 amps is usually sufficient. The Battery (+) fuse current rating must satisfy two criteria: Must not open during normal operation Must open before the ECU is damaged during a reverse battery condition All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-51 HARDWARE AND WIRING Acceptable blow times versus current and temperature derating characteristics are listed in Table 3-20and Table 3-21. % of Rated Fuse Current Minimum Blow Time Maximum Blow Time 100% 100 hours - 135% 1 minute 30 minutes 200% 6 seconds 40 seconds Table 3-20 Table 3-21 3-52 Fuse Current and Blow Time Temperature % of Rated Fuse Current -40 C 110% max +25 C 100% +120 C 80% min Fuse Temperature and Current All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.10 CONNECTORS The connectors listed in this section are required to properly wire a Detroit Diesel engine equipped with DDEC. The OEM is responsible for procuring most of these connectors. The terminals, locks, cavity plugs, etc. needed to properly install connectors are contained in the component section. For example, the terminals and locks needed to properly install the Ambient Air Temperature Sensor connector are contained in the Air Temperature Sensor section. The DDEC connectors are listed in Table 3-22. Connector Part Number Comments Pressure Sensor Harness 12162182 Metri-Pack 150 Series, pull-to-seat Communication Harness Connector Assembly 12066317 Metri-Pack 150 Series, pull-to-seat Temperature Sensor Harness 12162193 Metri-Pack 150 Series, pull-to-seat Fire Truck Pressure Sensor (PSG) 12065287 Metri-Pack 150 Series, pull-to-seat ESH-to-ECM 12034400 Metri-Pack 150 Series, pull-to-seat VIH-to-ECM 12034398 Metri-Pack 150 Series, pull-to-seat SRS Harness 12162193 Metri-Pack 150 Series, pull-to-seat TRS Harness 12162197 Metri-Pack 150 Series, pull-to-seat MAS Pigtail Connector Mate 12047937 Metri-Pack 150 Series, pull-to-seat Air Filter Restriction Sensor 12110293 Metri-Pack 150 Series, pull-to-seat Coolant Level Sensor 15300027 Metri-Pack 280 Series, push-to-seat Power Harness/Engine Power Harness 12124634 Metri-Pack 280 Series, push-to-seat Ignition Connector Power Harness Side 12034074 Weather Pack, push-to-seat Ignition Connector VIH Side 12015378 Weather Pack, push-to-seat Engine Brake Connector Series 60 12010973 Weather Pack, push-to-seat Allison Interface Module 12015791 Weather Pack, push-to-seat Allison Interface Module Maximum Feature 12015799 Weather Pack, push-to-seat Diagnostic 23513052 Deutsch, push-to-seat Engineminder 23512222 Deutsch, push-to-seat Mastermind - Power and Communication Link 23512221 Deutsch, push-to-seat Mastermind - Inputs and Outputs 23512223 Deutsch, push-to-seat Glow Plug Lamps - Methanol Engines Deutsch P/N: HD16-5-16S Deutsch, push-to-seat Vehicle Power Harness 23513815 Deutsch, push-to-seat Vehicle Interface Harness (multi-ECM) 23515462 Cannon, push-to-seat Engine Interface Harness Cannon P/N: CA3106E2821PBF80A176 Cannon, push-to-seat Table 3-22 DDEC Connectors All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-53 HARDWARE AND WIRING 3.10.1 METRI-PACK 150 SERIES CONNECTORS Metri-Pack 150 series connectors are pull-to-seat connectors. Each wire must be pushed through the connector prior to crimping the terminal. Cable seals are inserted into the shell of the connector and hold many wires. NOTE: DDC does not require the use of dielectric grease. 3.10.2 WEATHER PACK, METRI-PACK 280, AND METRI-PACK 630 SERIES CONNECTORS Weather Pack, Metri-Pack 280, and Metri-Pack 630 series connectors are push-to-seat. The terminal is crimped onto each wire before it is inserted into the connector. A cable seal is crimped onto each wire at the same time the terminal is crimped onto the wire. Weather Pack connectors use a secondary lock on both male and female connector bodies and the lock snaps into place over the cable seals after installation. Some Metri-Pack connectors have secondary locks as well. NOTE: The power harness uses a minimum of 12 AWG wire. Use the appropriate crimp and removal tools listed in Table 3-34. Refer to section 3.7.3, "Power Harness Design." 3.10.3 DEUTSCH CONNECTORS Deutsch connectors have cable seals molded into the connector. These connectors are push-to-seat connectors with cylindrical terminals. The diagnostic connector terminals are gold plated for clarity. Refer to section 3.10.7. 3-54 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.10.4 ECM VEHICLE HARNESS CONNECTORS -SINGLE ECM The ECM vehicle harness connections are on the right side of the ECM (see Figure 3-31). Figure 3-31 ECM Right Side, Vehicle Harness Connections All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-55 HARDWARE AND WIRING VIH-to-ECM Connector The digital input and output ports of the VIH 30-pin connector (see Figure 3-32) can be configured for a variety of software options. The location of the connector pin for each software option can be specified at the time of engine order or with VEPS or the DDEC Reprogramming System. For more information on software options for these ports refer to section 4.1 and section 4.2. Figure 3-32 VIH-to-ECM Connector NOTICE: The wire comb for the 30-pin VIH connector must be used in all Series 50, Series 149, and industrial applications. The wire comb is a strain relief for the back of the VIH connector to prevent water from entering the connector from the back. To use the wire comb, the original bolt in the VIH connector must be removed and discarded. The wire comb should be attached to the back of the VIH connector. The new bolt must be inserted through the assembly and used to tighten the VIH connector into the ECM. These parts listed in Table 3-23are available from the Detroit Diesel Parts Distribution Center. Table 3-23 Description Part Number Wire Comb 12110546 Bolt 12129426 Wire Comb Part Numbers The ECM connector assembly (12034398) center screw must be torqued to 7-13·lb in. (0.79 1.47 N·m). 3-56 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The wiring for the 30-pin VIH-to-ECM connector is listed in Table 3-24. Cavity Wire No. Label H-3 115 COOLANT LEVEL D-2 417 LIMITING SPEED GOVERNOR B-1 419 CHECK ENGINE LIGHT B-3 439 IGNITION E-1 451 DIGITAL INPUT #1 F-3 499 DIGITAL OUTPUT #1 K-1 505 TACHOMETER DRIVE B-2 509 STOP ENGINE LIGHT D-1 510 VARIABLE SPEED GOVERNOR H-1 523 DIGITAL INPUT #9 H-2 524 DIGITAL INPUT #10 G-1 528 DIGITAL INPUT #7 J-2 531 DIGITAL INPUT #5 J-1 541 DIGITAL INPUT #8 F-1 542 DIGITAL INPUT #2 G-2 543 DIGITAL INPUT #6 F-2 544 DIGITAL INPUT #4 G-3 545 DIGITAL INPUT #3 A-2 555 DIGITAL OUTPUT #2 E-2 556 VEHICLE SPEED (+) E-3 557 VEHICLE SPEED (-) K-2 583 DIGITAL INPUT #11 D-3 749 FIRE TRUCK PUMP PRESSURE OR ESS TRANSMISSION OR EXHAUST TEMPERATURE C-2 900 DATA LINK (+) C-1 901 DATA LINK (-) J-3 908 PWM #1 OUTPUT A-3 916 SENSOR SUPPLY (5VDC) C-3 952 SENSOR RETURN K-3 979 DIGITAL INPUT #12 A-1 988 DIGITAL OUTPUT #8 Table 3-24 VIH-to-ECM Connector Typical VIH-to-ECM Connector Pin Definitions All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-57 HARDWARE AND WIRING The 30-pin VIH-to-ECM connector, listed in Table 3-25, is a Metri-Pack 150 series pull-to-seat connector. Table 3-25 Part Part Number Connector 12034398 Terminal 12103881 Seal In Connector Plug 12034413 30-pin VIH-to-ECM Connector Part Numbers Power Harness-to-ECM Connector See Figure 3-33 for the wiring for the ECM-to-Power Harness connector. Refer to section 3.7for more information on the Power Harness. Figure 3-33 3-58 Five-Pin Power Harness Connector All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Communication Harness-to-ECM Connector See Figure 3-34 for the wiring for the ECM-to-Communication Harness connector. Refer to section 3.5for more information on the Communication Harness. Figure 3-34 Communication Harness Connector All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-59 HARDWARE AND WIRING 3.10.5 ECM VEHICLE HARNESS CONNECTORS - MULTI-ECM The multi-ECM Engine Interface Harness is usually installed at the factory and delivered connected to all ECMs. The Power Harness is installed at the factory and delivered connected to all ECMs. Both harnesses end with a quick disconnect connector. Engine Interface Harness Quick Disconnect Connector The multi-ECM Engine Interface Harness normally terminates with a quick disconnect connector where the OEM Vehicle Interface Harness begins. The recommended wiring for the Engine Interface Harness quick disconnect connector for the Series 4000 and Series 149 Vehicle Interface Harness is listed in Table 3-26. Cavity Wire No. Label Cavity Wire No. Label c 115M Coolant Level m 564M Digital Output X-3 N 417 Limiting Speed Governor s 565M Digital Output Y-3 P 419 Check Engine Light X 573 Auxiliary Timed Input A 439 Ignition B 583 Digital Input K-2 J 440 Power Harness-jumper d 749M Analog Input g 451M Digital Input E-1 H 900 Data Link (+) a 451R Digital Input E-1--R1 P 901 Data Link (-) S 451R2 Digital Input E-1--R2 Series 149 K 908M PWM #1 Output r 499M Digital Output F-3 U 916M Sensor Supply (5VDC) E 505M Tachometer Drive-master W 952M Sensor Return n 509 Stop Engine Light G 953 Battery Ground V 510 Variable Speed Governor C 979 Digital Input K-3 b 523M Digital Input H-1 R 988M Digital Output A-1 T 524 Digital Input H-2 j 528 Diagnostic Request / SEO-M F 531M Digital Input J-2 L 541M Digital Input J-1 e 542M Digital Input F-1 543M Digital Input G-2 Series 4000 S k 544 Digital Input F-2 h 545M Digital Input G-3 Z 555M Digital Output A-2 M 556 Vehicle Speed (+) D 557 Vehicle Speed (-) f 563M Digital Output W-3 Table 3-26 3-60 Recommended Interface Harness Connector Pin Definitions - Series 4000 and Series 149 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The Engine Interface Harness quick disconnect connector is a single-point, sealed, weatherproof, bayonet-type connector. The connectors must be protected with a suitable cover, when disconnected. Refer to section 3.11.7 for assembly instructions for the plug and socket end of the 37-pin connector. Engine Power Harness Connector The Engine Power Harness terminates with a quick disconnect connector where the OEM Vehicle Power Harness connection is made. The connector is a 16 pin Deutsch connector. The recommended wiring for the Engine Power Harness quick disconnect connector for the Series 4000 Vehicle Power Harness is listed in Table 3-27. Cavity Wire No. Label A 150M Battery Negative B 150M Battery Negative C 150R Battery Negative D 150R Battery Negative E Plug -- F Plug -- G 240M Battery Positive H 241M Battery Positive J 240R Battery Positive K 241R Battery Positive L Plug -- M Plug -- N 440 Battery Positive P 151 (ALL ECM) Battery Negative R 953 Battery Negative S 953 Battery Negative Table 3-27 Series 4000 - Recommended Vehicle Power Harness Connector Pin Definitions All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-61 HARDWARE AND WIRING The wiring for the Engine Power Harness quick disconnect connector for the Series 149 Vehicle Power Harness is listed in Table 3-28. Cavity Wire No. Label A 150M Battery Negative B 150M Battery Negative C 150R1 Battery Negative D 150R1 Battery Negative E 150R2 Battery Negative F 150R2 Battery Negative G 240M Battery Positive H 241M Battery Positive J 240R1 Battery Positive K 241R1 Battery Positive L 240R2 Battery Positive M 241R2 Battery Positive N 440* Battery Positive P 150 Battery Negative R 953 Battery Negative S 953 Battery Negative * Used only when switched power is not provided through 440 from VIH. Table 3-28 3-62 Series 149 - Recommended Vehicle Power Harness Connector Pin Definitions All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.10.6 ECM ENGINE HARNESS CONNECTORS The ECM engine harness connections are on the left side of the ECM and come factory installed (see Figure 3-35). Figure 3-35 ECM Left Side, Engine Harness Connections All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-63 HARDWARE AND WIRING ESH-to-ECM Connector The digital output ports of the ESH 30-pin connector (see Figure 3-36) can be configured for a variety of software options. The three digital output ports (563, 564, 565) are located on a pigtail off the Engine Sensor Harness. The software options can be ordered at the time of engine order or with VEPS or the DDEC Reprogramming System. The location of the connector pin for each option can be specified at the time of engine order. For more information on software options for these ports refer to section 4.2. Figure 3-36 ESH-to-ECM Connector The 30-pin ESH-to-ECM connector, listed in Table 3-29, is a Metri-Pack 150 series pull-to-seat connector. Table 3-29 3-64 Part Part Number Connector 12034400 Terminal 12103881 Seal In Connector Plug 12034413 30-pin ESH-to-ECM Connector Part Numbers All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The wiring for the 30-pin ESH-to-ECM connector is listed in Table 3-30. Cavity Wire No Label T-1 109 TRS (-) T-2 110 TRS (+) S-2 111 SRS (+) S-1 112 SRS (-) R-2 120 OIL TEMPERATURE N-2 132 AIR TEMPERATURE P-3 133 COOLANT TEMP W-1 416 SENSOR SUPPLY (5VDC) P-1 432 TURBO BOOST Y-2 452 SENSOR RETURN (ENGINE) R-3 472 FUEL TEMP P-2 530 OIL PRESSURE S-3 561 ENGINE BRAKE MED T-3 562 ENGINE BRAKE LO W-3 563 DIGITAL OUTPUT W-3 X-3 564 DIGITAL OUTPUT X-3 Y-3 565 DIGITAL OUTPUT Y-3 X-1 573 TIMED INPUT L-1 904 AIR FILTER RESTRICTION* M-1 905 FUEL RESTRICTION* N-1 906 ADD COOLANT LEVEL* R-1 907 AMBIENT AIR TEMPERATURE* Y-1 909 OI ALARM* W-2 910 OI STARTER* X-2 911 ESH-to-ECM Connector FAN CONTROL — VARIABLE SPEED* L-3 925 J1939 (+) M-3 926 J1939 (-) N-3 927 J1939 SHIELD M-2 958 OI THERMOSTAT* L-2 976 OIL LEVEL* * Used in some applications Table 3-30 Typical On-highway ESH-to-ECM Connector Pin Definitions All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-65 HARDWARE AND WIRING 3.10.7 DATA LINK CONNECTORS The connectors used to connect the data links are a 6-pin Deutsch connector for the J1708/J1587 Data Link or a 9-pin Deutsch connector for the J1939/1708 Data Link. DDC recommends that the OEM-supplied Data Link Connector be conveniently positioned in a well protected location facilitating subsequent DDDL/DDR usage (i.e., reprogramming, diagnostics, etc.). SAE J1939/J1587 Data Link Nine-pin Connector (Recommended) The SAE J1939/J1587 nine-pin data link connector is the recommended diagnostic connector. The following components are required to incorporate an SAE J1939/J1587 Data Link in a VIH so a DDR or other diagnostic devices can be attached without a unique jumper are listed in Table 3-31. Component DDC Part Number Deutsch Part Number Nine-pin Deutsch connector 23529496 HD10-9-1939P Connector Cover 23529497 HDC 16–9 Two (2) Cavity Plugs 23507136 11407 Seven (7) Terminals 23507132 0460-202-16141 Table 3-31 Required Components to Incorporate an SAE J1939/J1587 Data Link in the VIH The following illustration shows the wiring for the nine-pin connector (see Figure 3-37). Figure 3-37 Wiring for Nine-pin Data Link Connector The SAE J1939 Data Link must be twisted nine turns per foot. The maximum length for the SAE J1939 Data Link is 130 ft (40m). 3-66 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL SAE J1708/J1587 Data Link Six-pin Connector The components are required to incorporate a SAE J1708/J1587 Data Link in a VIH so a DDR or other diagnostic devices can be attached without a unique jumper are listed in Table 3-32. Components DDC Part Numbers Deutsch Part Numbers Six-pin Deutsch Connector 23513052 HD-10-6-12P Two (2) Cavity plugs 23507136 11407 Connector Cover 23507154 HDC-16-6 Four (4) Terminals 23513053 0460-220-1231 Table 3-32 Required Components to Incorporate an SAE J1708/J1587 Data Link in the VIH The following illustration shows the wiring for the 6-pin connector (see Figure 3-38). Figure 3-38 Wiring for Six-pin Data Link Connector The SAE J1708/J1587 Data Link must be twisted a minimum of 12 turns per foot. The maximum length for the SAE J1708/J1587 Data Link is 130 ft (40m). All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-67 HARDWARE AND WIRING THIS PAGE INTENTIONALLY LEFT BLANK 3-68 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.11 WIRES AND WIRING Detroit Diesel Corporation recommends color coding and hot stamping wire numbers in contrasting colors at intervals of four inches or less. 3.11.1 GENERAL REQUIREMENTS NOTE: Avoid renumbering DDC circuits since all troubleshooting guides reference the circuit numbers shown in the schematic. DDC suggests including a prefix or suffix with the DDC circuit numbers when conflicts exist. 3.11.2 GENERAL WIRE All wires used in conjunction with the DDEC must meet the following criteria: NOTICE: DDC does not recommend using any type of terminal lubricant or grease compounds. These products may cause dirt or other harmful substances to be retained in the connector. DDC has not tested these products and cannot stand behind their use. NOTICE: Insulation must be free of nicks. Criteria: Wires Tape, conduit, loom or a combination thereof must be used to protect the wires. Refer to sections 3.12 and 3.13. All wires must be annealed copper wire (not aluminum). All wires must comply with SAE J1128. All wires should be insulated with cross-link polyethylene (XLPE) such as GXL, or any self-extinguishing insulation having a minimum rating of -40 C (-40 F) to 125 C (257 F). All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-69 HARDWARE AND WIRING 3.11.3 WIRING FOR VIH-TO-ECM CONNECTOR NOTICE: Wires greater than 2.97 mm (.117 in.) must not be used in the VIH-to-ECM connector, as irreparable damage to the seal may result. NOTICE: Failure to use the proper cable diameter may result in the inability to obtain proper terminal installation. The VIH 30-pin connector is designed to accept 18 gage (0.75 - 0.80 mm2) standard wall thickness cable, only. 3.11.4 RETURN POWER (GROUND) CIRCUITS Switch ground (circuit 953) must only be used to provide ground for DDEC components and must be sourced directly from the negative battery or bus bar terminal NOTE: This circuit can not be used to provide ground for non- DDEC IV OEM-supplied electronics. 3.11.5 DATA LINK CIRCUITS Twisting of the following wire pairs a minimum of 12 turns per foot (305 mm), is required to minimize electromagnetic field coupling effects. Data link circuits 900 and 901 (SAE J1587) Data link circuits 800 and 801 (SAE J1922) Data link circuits 925 and 926 (SAE J1939) Circuits 900 (Data Link +) and 901 (Data Link -) are used as the J1587 communication link. These circuits also exist in the DDEC six-pin or nine-pin diagnostic connector for use with the DDR. Circuits 800 (Data Link +) and 801 (Data Link-) as shown on the communications harness schematic are used as the SAE J1922 communication link. Circuits 925 [CAN_H/J1939 (+)], 926 [CAN_L J1939 (-)] and 927 (CAN_SHLD/J1939 Shield) as shown on the communications harness schematic are used as the SAE J1939 communication link. See Figure 3-15. 3.11.6 POWER HARNESS WIRE RESISTANCE Twelve gage wires are required at the power harness connector. The total resistance of any power harness wire from the ECM to the battery (or bus bar) can not exceed 50 m . The characteristics for Teflon coated and GXL type wire gages are listed in Table 3-33. 3-70 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL SAE Wire Gage Metric Gage # Area mm2 Resistance m /m Resistance m /ft @ 20 C Resistance m /ft @ 120 C Diameter mm 16 1 1.129 15.300 4.66 6.50 0.72 14 2 1.859 9.290 2.83 3.94 1.18 12 3 2.929 5.900 1.80 2.50 1.86 10 5 4.663 3.720 1.13 1.58 2.97 8 8 7.277 2.400 0.73 1.02 4.63 Table 3-33 3.11.7 Power Harness Wire Characteristics TERMINAL INSTALLATION AND REMOVAL The method of terminal installation and removal varies, depending on the terminal/connector design. Crimp techniques and harness dressing must also be performed in accordance with recommended procedures to assure waterproof connections. NOTICE: Terminals should not be soldered to the cable. Crimp and Removal Tools Crimp tools and connector removing tools can be purchased from Kent-Moore. The part and associated part numbers are listed in Table 3-34 below: Tool Connector Metri-Pack 150 Weather Pack Metri-Pack 280 Deutsch Table 3-34 Kent-Moore P/N Removing J 35689-A Crimp J 35123 Removing J 36400-5 Removing (18 AWG) J 33095 Crimp (18 AWG) J 38125-12A Removing (12 AWG - Used for power harness) J 33095 Crimp (12 AWG - Used for power harness) J 39848 Removing (12 AWG) J 37451 Removing (16-18 AWG) J 34513-1 Crimp J 34182 Crimp and Removal Tools Kent-Moore 29784 Little Mack Roseville, Michigan 48066-2298 Phone: (800) 328-6657 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-71 HARDWARE AND WIRING Push-to-Seat Terminal Installation Guidelines The following guidelines apply to all push-to-seat terminals. NOTICE: If a separate seal is required, be sure to install the seal onto the wire before stripping the insulation. NOTICE: No more than one strand in a 16 strand wire may be cut or missing. 1. Position a seal on each terminal lead so 5.0 0.5 mm (.20 .02 in.) conductor and 1.0 0.1 mm (.05 .005 in.) cable protrudes past the seal after being stripped (see Figure 3-39). Figure 3-39 Seal Positioning 2. Remove the insulation from the end of the cable with J 35615 (or equivalent), exposing 5.0 0.5 mm (0.2 .02 in.) conductor (wire), a sufficient amount of wire to be crimped by the terminal core wings (see Figure 3-40). 3-72 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 3-40 Terminal Installation (Shown with a Seal) 3. Insert the terminal into the locating hole of the crimping tool using the proper hole according to the gage and function of the cable to be used. See Figure 3-41. Figure 3-41 Terminal Position (Shown With a Seal) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-73 HARDWARE AND WIRING 4. Insert the cable in the terminal so the stripped portion is positioned in the cable core wings and the insulated portion of the cable is in the insulation wings (see Figure 3-41). Position the seal on the cable so the insulation wings grip the seal (see Figure 3-40). 5. Compress the handles of the crimping tool to crimp the core and insulation wings until the ratchet automatically releases. 6. To install the remaining terminals, repeat steps 3 and 4. NOTE: Release the crimping tool with the lock lever located between the handles, in case of jamming. 7. Gently tug on the terminal to make sure it is secure. The criteria listed in Table 3-35 must be met. Table 3-35 Wire Gage Must Withstand Applied Load 14 AWG 45 lb (200 N) 16 AWG 27 lb (120 N) 18 AWG 20 lb (90 N) Applied Load Criteria for the Terminal NOTICE: Any terminal that is cracked or ruptured is unacceptable as malfunctions may occur. 8. Replace incorrectly installed and damaged terminals by cutting off the terminal just after the insulation wings. 3-74 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 9. Insert terminals into connector and push to seat (see Figure 3-42). Insert the secondary lock(s) to position and secure the assembly. Figure 3-42 Typical Push-to-Seat Terminal Installation Push-to-Seat Terminal Removal One locking tang secures the push-to-seat terminals to the connector body. Use the following instructions for removing terminals from the connector body. 1. Grasp the cable to be removed and push the terminal to the forward position. 2. Insert the removal tool straight into the front of the connector cavity until it rests on the cavity shoulder. See Figure 3-43. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-75 HARDWARE AND WIRING Figure 3-43 Removal Tool Procedure 3. Grasp the cable and push it forward through the connector cavity into the tool while holding the tool securely in place. The tool will depress the locking tangs of the terminal. 4. Pull the cable rearward (back through the connector). 5. Remove the tool from the connector cavity. 6. Cut the wire immediately behind the terminal crimp. 7. Follow the installation instructions for crimping on a replacement terminal. Pull-to-Seat Terminal Installation Guidelines The following guidelines apply to all pull-to-seat terminals. Use the following instructions for pull-to-seat terminal installation without a seal: 1. Insert the wire through the appropriate connector hole/cavity (see Figure 3-44). 3-76 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 3-44 Wire Inserted Through the Connector 2. Remove the insulation from the end of the cable, exposing a sufficient amount of core leads to be crimped by the terminal core wings (see Figure 3-44). 3. Insert the terminal into the locating hole of the crimping tool using the proper hole according to the gage of the cable to be used (see Figure 3-45). Figure 3-45 Typical Terminal Position All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-77 HARDWARE AND WIRING 4. Insert the cable into the terminal so the stripped portion is positioned in the cable core wings and the insulated portion of the cable is in the insulation wings (see Figure 3-46). Figure 3-46 Typical Terminal Installation 5. Compress the handles of the crimping tool to crimp the core wing until the ratchet automatically releases. 6. Repeat steps 3, 4, and 5. NOTE: Release the crimping tool with the lock lever located between the handles, in case of jamming. 7. Gently tug on the terminal to make sure it is secure. The criteria listed in Table 3-36 must be met. Table 3-36 3-78 Wire Gage Must Withstand Applied Load 14 AWG 45 lb (200 N) 16 AWG 27 lb (120 N) 18 AWG 20 lb (90 N) Applied Load Criteria for the Terminal All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL NOTICE: Any terminal that is cracked or ruptured is unacceptable as malfunctions may occur. 8. Replace incorrectly installed and damaged terminals by cutting off the terminal just after the insulation wings. Pull-to-seat Terminal Removal A tang on the terminal locks into a tab molded into the plastic connector to retain the cable assembly. Remove terminals using the following instructions: 1. Insert the removal tool into the cavity of the connector, placing the tip of the tool between the locking tang of the terminal and the wall of the cavity. 2. Depress the tang of the terminal to release it from the connector. 3. Push the cable forward through the terminal until the complete crimp is exposed. 4. Cut the cable immediately behind the damaged terminal to repair it. 5. Follow the installation instructions for crimping the terminal and inserting it into the connector. Deutsch Terminal Installation Guidelines Deutsch connectors have cable seals molded into the connector. These connectors are push-to-seat connectors with cylindrical terminals. The diagnostic connector terminals are gold plated for clarity. NOTICE: Improper selection and use of crimp tools have varying adverse effects on crimp geometry and effectiveness. Proper installation of terminals require specialized tools. Do not attempt to use alternative tools. The crimp tool to use in Deutsch terminal installation is J 34182 (Kent-Moore part number). All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-79 HARDWARE AND WIRING NOTICE: Terminal crimps must be made with the Deutsch crimp tool P/N: HDT-48-00 to assure gas tight connections. NOTICE: If a separate seal is required, be sure to install the seal onto the wire before stripping the insulation. Use the following instructions for installing Deutsch terminals: 1. Strip approximately .25 inch (6 mm) of insulation from the cable. 2. Remove the lock clip, raise the wire gage selector, and rotate the knob to the number matching the gage wire that is being used. 3. Lower the selector and insert the lock clip. 4. Position the contact so that the crimp barrel is 1/32 of an inch above the four indenters. See Figure 3-47. Crimp the cable. Figure 3-47 Setting Wire Gage Selector and Positioning the Contact 5. Grasp the contact approximately one inch behind the contact crimp barrel. Hold the connector with the rear grommet facing you. See Figure 3-48. 3-80 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 3-48 Pushing Contact Into Grommet 6. Push the contact into the grommet until a positive stop is felt. See Figure 3-48. A slight tug will confirm that it is properly locked into place. See Figure 3-49. Figure 3-49 Locking Terminal Into Connector All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-81 HARDWARE AND WIRING Deutsch Terminal Removal The appropriate size removal tool should be used when removing cables from connectors. The proper removal tools are listed in Table 3-37. Tool Kent-Moore Part Number Removing (12 AWG) J 37451 Removing (16-18 AWG) J 34513-1 Table 3-37 Removal Tools for Deutsch Terminals Remove Deutsch terminals as follows: 1. With the rear insert toward you, snap the appropriate size remover tool over the cable of contact to be removed. See Figure 3-50. Figure 3-50 Removal Tool Position 2. Slide the tool along the cable into the insert cavity until it engages and resistance is felt. Do not twist or insert tool at an angle. See Figure 3-51. 3-82 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 3-51 Removal Tool Insertion 3. Pull contact cable assembly out of the connector. Keep reverse tension on the cable and forward tension on the tool. Quick Disconnect Canon Connector Installation Guidelines The terminals must be crimped and installed on the VIH wires for both the plug and socket end of the 37-pin connector. Crimp the terminals on to the wires as follows: 1. Strip the wires to the appropriate length, .245 in. (6.2 mm). 2. Open the crimp tool (ITT Canon P/N: 192990-2050) by squeezing the handles. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-83 HARDWARE AND WIRING 3. Push the latch on the turret to pop up the locator. Attach the turret (ITT P/N: 995-0002-052) to the crimp tool using the two captive hex bolts in the turret (see Figure 3-52). 4. Select the proper locator position, as listed in Table 3-38, by rotating the locator until the proper color is aligned with the index mark. Push the locator down until it snaps into position. Table 3-38 Pin Locator Color Socket Locator Color Green Red Proper Locator Position 5. Adjust the dial for proper wire gauge with the lock pin. Remove the lock pin and lift the center of the dial. Turn to the desired wire gauge and replace the lock pin on the dial (see Figure 3-52). Figure 3-52 Hand Crimp Tool for 37-pin Connector Terminals 6. Cycle the tool before inserting the terminal to be sure the tool is in the open position. 7. Drop the terminal, mating end first, into the crimp cavity. Squeeze the tool handle just enough to grip the terminal without actually crimping it (see Figure 3-53, A). 3-84 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8. Insert the stripped wire into the terminal with a slight twisting motion. All wire strands must be inside the contact (see Figure 3-53, B). Figure 3-53 Inserting the Terminal and the Stripped Wire. 9. Squeeze the handle. The handle will not release until the terminal is completely crimped. NOTICE: Any terminal that is cracked or ruptured is unacceptable as malfunctions may occur. 10. Remove the crimped terminal. Visually inspect the crimp for the following: [a] The conductor must be visible through the wire inspection hole on the terminal. [b] The insulation should butt up against the end of the terminal. The parts of the plug end can be seen in the following illustration (see Figure 3-54). All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-85 HARDWARE AND WIRING 1. 37-pin Insulator 6. Grommet 2. O-ring 7. Ferrule 3. Barrel 8. Optional Telescope Bushing (Small) 4. Bayonet Coupling Nut 9. Telescope Bushing (Large) 5. Terminals (Male, Pull-to-Seat) Figure 3-54 10. Cable Clamp Exploded View of 37-Pin Plug Kit Insert terminals into the plug end (P/N: 23516830) as follows: 1. Slide the rear accessories over the wire bundle in the proper sequence for reassembly (see Figure 3-55): 3-86 [a] Cable clamp [b] Large Telescope bushing [c] Small telescope bushing, if needed to reduce side-to-side clearance between bundle and the large telescope bushing. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL [d] Ferrule [e] Bayonet coupling nut 2. Place the terminal in a pliers style insertion tool (ITT Canon P/N: CIT-F80-16). The tool should butt against the shoulder of the terminal (see Figure 3-55, A). Install guide pin ( guide pins, ITT Canon P/N: 226-1017-000, must be used with socket terminals). 3. Lubricate the grommet with isopropyl alcohol. Do not use any other lubricant. 4. Insert the terminal through the appropriate cavity in the grommet (starting at the center of the grommet pattern, see Figure 3-55, B). Figure 3-55 Inserting Terminals 5. Lubricate the contact cavities of the connector insulator with isopropyl alcohol (do not use any other type of lubricant). 6. Starting at the center of the connector insulator pattern, push guide pin and terminal straight down with a firm even pressure until the terminal snaps into position (see Figure 3-55, C). Allow clearance on the mating face of the connector for the guide pins to come through the connector during insertion. 7. Fill any unused connector insulator cavities with uncrimped terminals. 8. Check the mating face of the connector to insure that all the same size terminals are on the same plane and fully inserted (see Figure 3-55, D). Any terminal not fully inserted must be removed and reinserted. Do not reinsert the insertion tool to correct the problem. 9. Insert a plug into the grommet behind the uncrimped terminals to maintain the sealing integrity of the connector. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-87 HARDWARE AND WIRING 10. Slide the connector accessories back down the cable over the rear of the connector and tighten using appropriate tools. The parts of the socket end can be seen in the following illustration (see Figure 3-54). 1. Cable Clamp 5. Grommet 2. Telescope Bushing (Large) 6. Terminals (Female, Pull-to-Seat) 3. Optional Telescope Bushing (Small) 7. Shell 4. Ferrule 8. 37-pin Insulator Figure 3-56 Exploded View of the 37-pin Receptacle (Socket End) Insert terminals into the socket end (P/N: 23515462) as follows: 1. Slide the rear accessories over the wire bundle in the proper sequence for reassembly: 3-88 [a] Cable clamp [b] Telescope bushing [c] Ferrule All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 2. Place the terminal in a pliers style insertion tool. The tool should butt against the shoulder of the terminal. 3. Lubricate the grommet with isopropyl alcohol. Do not use any other lubricant. 4. Insert the terminal through the appropriate cavity in the grommet (starting at the center of the grommet pattern). 5. Starting at the center of the connector insulator pattern, push guide pin and terminal straight down with a firm even pressure until the terminal snaps into position. 6. Fill any unused cavities with uncrimped terminals. 7. Insert a plug into the grommet behind the uncrimped terminals to maintain the sealing integrity of the connector. 8. Slide the connector accessories back down the cable over the rear of the connector and tighten. Terminal Removal Remove the terminals as follows: 1. Remove the endbell accessories and slide them back over the wires. 2. Use extraction tool, ITT Canon P/N: CET-F80-16 (see Figure 3-57). Figure 3-57 Extraction Tool All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-89 HARDWARE AND WIRING 3. On the mating face of the connector, insert the tool over the pin terminal or into the socket terminal until the tool stops (see Figure 3-58). Figure 3-58 Connector Cross-section With Pin and Socket Terminals 4. Apply a slow continuous pressure to push the contact out the rear of the connector. When the shoulder of the tool hits ("thunks") against the insulator, the contact is extracted. 5. Carefully remove the extraction tool from the connector to avoid damage to the insulator. 3.11.8 SPLICING GUIDELINES The following are guidelines which may be used for splices. The selection of crimpers and splice connectors is optional. Select a high quality crimper equivalent to the Kent-Moore tool, J 38706, and commercially available splice clips. The recommended technique for splicing and repairing circuits (other than power and ignition circuits) is a clipped and soldered splice. Alternatively, any method that produces a high quality, tight (mechanically and electronically sound) splice with durable insulation is considered to be acceptable. 3-90 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Clipped and Soldered Splicing Method The tools required are listed in Table 3-39. Tool Part Number Heat Gun -- Sn 60 solder with rosin core flux -- Wire Stripper Kent-Moore J 35615 or equivalent Splice Clips (commercially available) Wire size dependent Heat Shrink Tubing Raychem HTAT or equivalent Table 3-39 Recommended Splicing Tools Criteria: Splicing Straight Leads No more than one strand in a 16 strand wire may be cut or missing. Use Sn 60 solder with rosin core flux. The exposed wire must be clean before the splice is soldered. Soldering splice connectors is optional. To solder splice connectors: 1. Position the leads, so one overlaps the other. See Figure 3-59. Figure 3-59 Positioning the Leads 2. Secure the leads with a commercially available clip and hand tool. See Figure 3-60. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-91 HARDWARE AND WIRING Figure 3-60 Securing the Leads With a Clip 3. Use a suitable electronic soldering iron to heat the wires. Apply the solder to the heated wire and clip (not to the soldering iron) allowing sufficient solder flow into the splice joint. 4. Pull on wire to assure crimping and soldering integrity. The criteria listed in Table 3-40 must be met. Table 3-40 Wire Gage Must Withstand Applied Load 14 AWG 45 lb (200 N) 16 AWG 27 lb (120 N) 18 AWG 20 lb (90 N) Applied Load Criteria for Terminals 5. Loop the lead back over the spliced joint and tape. See Figure 3-61. 3-92 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 3-61 Recommended Strain Relief of Spliced Joint Splicing and Repairing Straight Leads-Alternate Method 1 The tools required are listed in Table 3-41. Tool Part Number Heat Gun -- Wire Stripper Kent-Moore J 35615 or equivalent Splice Clips (commercially available) Wire size dependent Heat Shrink Tubing Raychem HTAT or equivalent Terminal Crimper for Metri-Pack 280 (12 AWG) Kent-Moore J 38125-6 Terminal Crimper for Metri-Pack 280 (18 AWG) Kent-Moore J 39848 Terminal Crimper for Weather Pack Kent-Moore J 35606 Terminal Crimper for Deutsch Kent-Moore J 34182 Terminal Crimper for Metri-Pack 150 Kent-Moore J 35123 Table 3-41 Recommended Splicing Tools All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-93 HARDWARE AND WIRING Criteria: Splicing Straight Leads No more than one strand in a 16 strand wire may be cut or missing. The recommended method to splice straight leads follows: 1. Locate broken wire. 2. Remove insulation as required; be sure exposed wire is clean and not corroded. 3. Insert one wire into the splice clip until it butts against the clip. Stop and crimp (see Figure 3-62, A). 4. Insert the other wire into the splice clip until it butts against the clip stop (see Figure 3-62, B). NOTICE: Any terminal that is cracked or ruptured is unacceptable as malfunctions may occur. 5. Visually inspect the splice clip for cracks, rupture, or other crimping damage. Remove and replace damaged clips before proceeding. 6. Pull on wire to ensure the splice integrity. The criteria listed in Table 3-42 must be met. Table 3-42 Wire Gage Must Withstand Applied Load 14 AWG 45 lb (200 N) 16 AWG 27 lb (120 N) 18 AWG 20 lb (90 N) Applied Load Criteria for Terminals 7. Shrink the splice clip insulative casing with a heat gun to seal the splice (see Figure 3-62, C). NOTICE: Splices may not be closer than 12 in. (.3 m) apart to avoid degradation in circuit performance. Replace wire to avoid having splices closer than 12 in. (.3 m) apart. 8. Loop the lead back over the spliced joint and tape. See Figure 3-61. 3-94 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 3-62 Splicing Straight Leads - Alternate Method 1 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-95 HARDWARE AND WIRING Splicing and Repairing Straight Leads - Alternate Method 2 This method is not allowed or recommended for power or ignition circuits. The tools required are listed in Table 3-43. Tool Part Number Heat Gun -- Wire Stripper Kent-Moore J 35615 or equivalent Splice Clips (commercially available) Wire size dependent Heat Shrink Tubing Raychem HTAT or equivalent Terminal Crimper for Metri-Pack 280 (12 AWG) Kent-Moore J 38125-6 Terminal Crimper for Metri-Pack 280 (18 AWG) Kent-Moore J 39848 Terminal Crimper for Weather Pack Kent-Moore J 35606 Terminal Crimper for Deutsch Kent-Moore J 34182 Terminal Crimper for Metri-Pack 150 Kent-Moore J 35123 Table 3-43 Recommended Splicing Tools Criteria: Splicing Straight Leads No more than one strand in a 16 strand wire may be cut or missing. An acceptable option for splicing straight leads is: 1. Locate broken wire. 2. Remove insulation as required; be sure exposed wire is clean and not corroded. 3. Slide a sleeve of glue lined, shrink tubing (Raychem HTAT or equivalent) long enough to cover the splice clip on the wire and overlap the wire insulation, about .25 in. (6 mm) on both sides (see Figure 3-63, A). 4. Insert one wire into splice clip until it butts against the splice clip. Stop and crimp (see Figure 3-63, B). 5. Insert the remaining wires into the splice clip one at a time until each butts against the splice clip; stop and crimp (see Figure 3-63, B). NOTICE: Any terminal that is cracked or ruptured is unacceptable as malfunctions may occur. 6. Visually inspect the terminal for cracks, rupture, or other crimping damage. Remove and replace damaged terminal before proceeding. 7. Slide the shrink tubing over the crimped splice clip (see Figure 3-63, C). 8. Shrink tubing with a heat gun to seal the splice (see Figure 3-63, D). 3-96 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL NOTICE: A minimum of two layers of heat shrink tubing must be applied to splices that have more than one lead in or out. 9. Loop the lead back over the spliced joint and tape. See Figure 3-61. Figure 3-63 Splicing Straight Leads - Alternate Method 2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-97 HARDWARE AND WIRING Shrink Wrap Shrink wrap is required when splicing non insulated connections. Raychem HTAT or any equivalent heat shrink dual wall epoxy encapsulating adhesive polyolefin is required. Shrink wrap must extend at least .25 in. (6 mm) over wire insulation past splice in both directions. Alpha Wire Corporation Raychem Corporation, Corporate Division 711 Lidgerwood Ave 300 Constitution Drive, Bldg. B P.O. Box 711 Menlo Park, CA 94025 Elizabeth, New Jersey 07207-0711 650-361-2755 1-800-52ALPHA To heat shrink wrap a splice: NOTICE: The heat shrink wrap must overlap the wire insulation about .25 in. (6 mm) on both sides of the splice. 1. Select the correct diameter to allow a tight wrap when heated. 2. Heat the shrink wrap with a heat gun; do not concentrate the heat in one location, but apply the heat over the entire length of shrink wrap until the joint is complete. 3. Repeat step 2 to apply a second layer of protection (if required by splicing guidelines). 3-98 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Staggering Wire Splices Position spliced wires properly as follows: NOTICE: You must stagger positions to prevent a large bulge in the harness and to prevent the wires from chafing against each other. 1. Stagger the position of each splice (see Figure 3-64) so there is at least a 2.5 in. (65 mm) separation between splices. Figure 3-64 The Correct and Incorrect Method of Staggering Multiple Splices NOTICE: A minimum of two layers of heat shrink tubing extending .25 in. (6 mm) past the splice must be used to complete the splice. 2. Heat shrink a minimum of two layers of heat shrink tubing. 3. Tape the spliced wires to each other. Refer to section 3.12. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-99 HARDWARE AND WIRING THIS PAGE INTENTIONALLY LEFT BLANK 3-100 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.12 CONDUIT AND LOOM Conduit must be used to protect the harness cable and cable splices. NOTICE: The conduit must not cover any connectors, switches, relays, fuses, or sensors. The following guidelines should be used when designing a harness: NOTICE: Wires should be sized and cut to near equal length prior to installing conduit. The distance between the back of the connector or other listed devices to the end of the conduit should not exceed: 1.0 in. (25 mm) for a single connector/device 3 in. (75 mm) for multiple connectors/devices All cable breakouts and conduit ends must be secured in place with conduit outlet rings or tape. Criteria: Conduit and Loom Due to the wide variety of operating conditions and environments, it is the responsibility of the OEM to select a conduit that will survive the conditions of the specific applications. Flame retardant convoluted polypropylene conduit or equivalent may be used for most installations. Heat retardant nylon conduit or oil, water, acid, fire, and abrasion resistant non-metallic loom conforming to SAE J562A* is also acceptable. The diameter of conduit should be selected based on the number of wires being protected. * If non-metallic loom is used, secure the ends with tightly wrapped nylon straps to prevent unraveling. Conduit should cover the wires without binding and without being excessively large. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-101 HARDWARE AND WIRING THIS PAGE INTENTIONALLY LEFT BLANK 3-102 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.13 TAPE AND TAPING Tape must be used when conduit is utilized. Be sure to follow the tape manufacturers' guidelines. The harness manufacturer may use tape under the harness covering (conduit or loom) to facilitate harness building. Tape must be tightly wrapped at all conduit interconnections with a minimum of two layers (refer to section 3.12). Be sure to firmly secure the start and finish ends of tape. Criteria: Tape NOTICE: Black vinyl electrical tape should not be used in applications where the temperature exceeds 176 F (80 C). In applications where the temperature doesn't exceed 176 F (80 C), black vinyl electrical tape that is flame retardant and weather resistant may be used. In applications where temperature exceeds 176 F (80 C), vinyl electrical tape should not be used. For these applications, adhesive cloth backed, flame retardant polyethylene or fiber glass tape (Delphi #PM-2203, Polikan #165 or equivalent) is recommended. Criteria: Taping The tape must extend a minimum of 1 in. (25 mm) past the conduit. The tape must be crossed over butted conduit ends. The tape must be extended a minimum of 1 in. (25 mm) in each direction at all branches. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-103 HARDWARE AND WIRING THIS PAGE INTENTIONALLY LEFT BLANK 3-104 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.14 SENSORS The DDEC IV system is designed to operate with several types of sensors as listed in Table 3-44. Description Sensor Type Variable Reluctance Thermistor Variable Capacitance Variable Resistance (Potentiometer) Switch Magnetic Pickup Table 3-44 Used to monitor the crankshaft position and the engine speed. Used to monitor temperatures. Used to monitor barometric air, manifold, oil gallery and optional pump pressures. Used to sense throttle position. The output should between .5 and 4.5 V. Used to signal coolant level, inlet air restriction, and oil level. Used to sense vehicle speed, accumulate trip distance, and to use several vehicle features. Sensor Types The sensors integrated into the Engine Sensor Harness are factory-installed (refer to section 3.14.1). The sensors integrated into the Vehicle Interface Harness are installed by the OEM (refer to section 3.14.15). All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-105 HARDWARE AND WIRING 3.14.1 FACTORY-INSTALLED SENSORS The sensors integrated into the factory-installed Engine Sensor Harness are listed in Table 3-45. Function Sensor Air Temperature Sensor (ATS) and Charge Air Temperature Sensor* Common Rail Fuel Pressure Sensor (CFPS)* Coolant Pressure Sensor (CPS)* and Intercooler Coolant Pressure Sensor (ICPS)* Coolant Temperature Sensor (CTS) and Intercooler Coolant Temperature Sensor (ICTS)* Senses air temperature for functions such as fan control and engine fueling. Senses fuel pressure to warn of impending power loss and engine fueling. Crankcase Pressure Sensor (CCPS) * Senses crankcase pressure for functions such as engine protection. Fuel Restriction Sensor (FRS)† Fuel Pressure Sensor (FPS)* Fuel Temperature Sensor (FTS) Oil Level Sensor (OLS)† Oil Pressure Sensor (OPS) Oil Temperature Sensor (OTS) Synchronous Reference Sensor (SRS) Timing Reference Sensor (TRS) Turbo Boost Sensor (TBS) Senses coolant pressure for functions such as engine protection. Senses coolant temperature for functions such as engine protection, fan control and engine fueling. Senses fuel filter restriction to warn of the condition of the fuel filter for maintenance purposes. Senses fuel pressure to warn of impending power loss and engine fueling. Senses fuel temperature for functions such as engine fueling. Senses oil level for functions such as engine protection. Senses gallery oil pressure for functions such as engine protection. Senses oil temperature for functions such as reducing variation in fuel injection and fan control. Indicates a specific cylinder in the firing order. Senses crankshaft position and engine speed for functions such as fuel control strategy. Senses turbo boost for functions such as smoke control and engine protection. * Available in some applications † Available with the Maintenance Alert System Table 3-45 3-106 Function of Factory-installed Sensors All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 1. Oil Temperature Sensor 6. Turbo Boost Sensor 2. Oil Pressure Sensor 7. Fuel Pressure Sensor 3. Timing Reference Sensor 8. Coolant Temperature Sensor 4. Fuel Temperature Sensor 9. Coolant Pressure Sensor 5. Charge Air Temperature Sensor Figure 3-65 10. Synchronous Reference Sensor Typical Location for Factory-installed Sensors - Series 2000 C&I All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-107 HARDWARE AND WIRING Figure 3-66 3-108 Engine Sensor Harness and Sensor Location - Series 60 Engine All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 1. Timing Reference Sensor 6. Oil Temperature Sensor 2. Fuel Pressure Sensor 7. Oil Pressure Sensor 3. Coolant Temperature Sensor 8. Turbo Boost Sensor 4. Synchronous Reference Sensor 9. Air Temperature Sensor 5. Electronic Control Module Figure 3-67 Engine Sensor Harness and Sensor Location - Series 50 Engine, On-highway All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-109 HARDWARE AND WIRING 1. Timing Reference Sensor 9. Intercooler Coolant Pressure Sensor (Behind Thermostat Housing) 2. Air Temperature Sensor (Receiver) 10. Engine Coolant Pressure Sensor 3. Turbo Boost Sensor (Receiver) 11. Engine Coolant Temperature Sensor 4. Oil Temperature Sensor 12. Oil Pressure Sensor 5. Crankcase Pressure Sensor 13. Fuel Supply Pressure Sensor 6. Intercooler Coolant Temperature Sensor 14. Fuel Temperature Sensor 7. Turbo Boost Sensor (Master) 15. Common Rail Fuel Pressure Sensor 8. Air Temperature Sensor (Master) 16. Synchronous Reference Sensor Figure 3-68 3-110 Typical Location for Factory-installed Sensors - Series 4000 C&I All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.14.2 AIR TEMPERATURE AND CHARGE AIR TEMPERATURE SENSOR The ATS (see Figure 3-69) is a thermistor type sensor that has a variable resistance, when exposed to different temperatures. The ATS provides necessary input for various functions such as varying hot idle speed, fan control, and injection timing which results in improved cold starts and reduced white smoke. Figure 3-69 Air Temperature Sensor See Figure 3-70 for the Charge Air Temperature Sensor used in the Series 2000. Figure 3-70 Charge Air Temperature Sensor - Series 2000 C & I Applications All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-111 HARDWARE AND WIRING 3.14.3 COMMON RAIL FUEL PRESSURE SENSOR The FPS is a variable capacitance sensor that produces a linear analog signal, indicating fuel pressure to warn the operator of impending power loss. See Figure 3-71. Figure 3-71 3.14.4 Common Rail Fuel Pressure Sensor - Series 4000 COOLANT AND INTERCOOLER COOLANT PRESSURE SENSOR The CPS is a variable capacitance sensor that produces a linear analog signal, indicating coolant pressure; the same sensor is used as the ICPS. See Figure 3-72. Figure 3-72 3-112 Coolant Pressure Sensor - Series 2000 and Series 4000 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.14.5 COOLANT AND INTERCOOLER COOLANT TEMPERATURE SENSOR The CTS is a thermistor type sensor that has a variable resistance, when exposed to different temperatures. The CTS senses coolant temperature. See Figure 3-73. Figure 3-73 Coolant Temperature Sensor - Series 50 and Series 60 See Figure 3-74 for the CTS used in the Series 2000 C & I applications and Intercooler Coolant Temperature Sensor (ICTS) used in Series 4000, C& I applications. Figure 3-74 Series 2000 CTS , Series 4000 ICTS All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-113 HARDWARE AND WIRING 3.14.6 CRANKCASE PRESSURE SENSOR A Crankcase Pressure Sensor is available on Series 149 (see Figure 3-75) and Series 4000 (see Figure 3-76) engines. The sensor activates engine protection if the crankcase pressure is too high. An activated sensor for the Series 149 must be reset by removing the safety cover and pushing in the reset button. Figure 3-75 Crankcase Pressure Sensor - Series 149 See Figure 3-76 for the Crankcase Pressure Sensor for the Series 4000. Figure 3-76 3-114 Crankcase Pressure Sensor - Series 4000 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.14.7 FUEL PRESSURE SENSOR The FPS is a variable capacitance sensor that produces a linear analog signal, indicating fuel pressure to warn the operator of impending power loss. The FPS for the Series 2000 engine has a green dot (see Figure 3-77). Figure 3-77 Fuel Pressure Sensor - Series 2000 The FPS for the Series 4000 engine has a white dot (see Figure 3-78). Figure 3-78 Fuel Pressure Sensor - Series 4000 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-115 HARDWARE AND WIRING 3.14.8 FUEL RESTRICTION SENSOR The FRS (see Figure 3-79) monitors the condition of the fuel filter. FRS is factory installed at DDC for applications which have the Maintenance Alert System (MAS). Figure 3-79 3-116 Fuel Restriction Sensor All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.14.9 FUEL TEMPERATURE SENSOR The FTS (see Figure 3-80) is a thermistor type sensor that has a variable resistance, when exposed to different temperatures. The FTS measures fuel temperatures necessary for fuel consumption calculations and fuel input compensation. Figure 3-80 Fuel Temperature Sensor See Figure 3-81 for the FTS used in the Series 2000, Construction and Industrial applications. Figure 3-81 Fuel Temperature Sensor - Series 2000 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-117 HARDWARE AND WIRING 3.14.10 OIL LEVEL SENSOR The OLS (see Figure 3-82) is factory-installed at DDC and is incorporated into the DDC Engine Sensor Harness for applications which have the Maintenance Alert System (MAS). Figure 3-82 3.14.11 Oil Level Sensor OIL PRESSURE SENSOR The OPS is a variable capacitance sensor that produces a linear analog signal, indicating engine oil pressure (see Figure 3-83). Figure 3-83 3-118 Oil Pressure Sensor - Series 2000 and Series 4000 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.14.12 OIL TEMPERATURE SENSOR The OTS is a thermistor type sensor that has a variable resistance, when exposed to different temperatures. See Figure 3-84. Figure 3-84 Oil Temperature Sensor See Figure 3-85 for the OTS used in the Series 2000 and Series 4000, Construction and Industrial applications. Figure 3-85 Oil Temperature Sensor - Series 2000 and Series 4000 The ECM uses the OTS signal to determine the quantity and timing of fuel required to optimize starting over a range of temperatures. The OTS provides a signal to vary idle speed and injection timing resulting in improved cold starts and reduced white smoke. It also activates the engine protection, if the oil temperature exceeds the specified limits. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-119 HARDWARE AND WIRING 3.14.13 TIMING AND SYNCHRONOUS REFERENCE SENSORS The Timing Reference Sensor (TRS) is a variable reluctance type sensor that indicates crank position of every cylinder. The TRS tells the ECM where the rotation of the engine is or when to fuel each cylinder. The Synchronous Reference Sensor (SRS) indicates a specific cylinder in the firing order. The SRS and TRS are mounted in the flywheel housing for the Series 2000 engine. The same SRS and TRS as those used for the Series 60 engine are used for the Series 2000 engine when the standard option flywheel housing is used. See Figure 3-86 for the Series 50, Series 60, and Series 2000 engine TRS and SRS. Figure 3-86 The SRS and TRS - Series 50, Series 60, and Series 2000 Engines See Figure 3-87 for the Series 4000 engine TRS and SRS. Figure 3-87 3-120 The SRS and TRS - Series 4000 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL See Figure 3-88 for the Series 92 6/8V, 8V-92, and Series 71 12V engine TRS and SRS. Figure 3-88 The SRS and TRS - Series 92 6/8V and Series 71 12V Engines See Figure 3-89 for the Series 71 4/6V engine TRS and SRS. Figure 3-89 The SRS and TRS - Series 71 4/6V Engines All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-121 HARDWARE AND WIRING See Figure 3-90 for the Series 149, Series 92 12/16V engine TRS and SRS. Figure 3-90 The SRS and TRS - Series 149, Series 92 12/16V Engines See Figure 3-91 for the Series 53 6V engine TRS and SRS. Figure 3-91 3-122 The SRS and TRS - Series 53 6V Engine All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.14.14 TURBO BOOST SENSOR The TBS provides data to the ECM for use in engine fueling (smoke control). See Figure 3-92 for the sensor used in on-highway applications. Figure 3-92 The Turbo Boost Sensor - On-highway Applications See Figure 3-93 for the sensor used in construction and industrial applications. Figure 3-93 The Turbo Boost Sensor - Construction and Industrial Applications All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-123 HARDWARE AND WIRING See Figure 3-94 for the Turbo Boost Sensor used in the Series 2000 and Series 4000 engines. Figure 3-94 3-124 Turbo Boost Sensor - Series 2000 and Series 4000 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.14.15 OEM-INSTALLED SENSORS All sensors must be of the proper type and continuously monitor vehicular and environmental conditions, so the ECM can react to changing situations. The OEM is responsible for installing the sensors listed in Table 3-46. These sensors are application dependent. Sensor Part Number Add Coolant Level Sensor (ACLS)† 23522855 23520380 23520381 Air Compressor Pressure Sensor (ACPS)* Air Filter Restriction Sensor (AFRS)† 23518254 23526140 Air Intake Temperature Sensor* -- Coolant Level Sensor (CLS) 23522855 23520380 23520381 Exhaust Temperature Sensor (ETS)* Fire Truck Pump Pressure Sensor * 23521882 23520795 Optical Coolant Level Sensor* 23519175 Throttle Position Sensor (TPS) -- Vehicle Speed Sensor (VSS) -- Function Senses coolant level for engine maintenance. Refer to section 3.14.20. Senses air outlet pressure to maintain a set pump pressure. Refer to section 3.14.16. Senses the condition of the air inlet filter for engine maintenance. Refer to section 3.14.17. Senses the air intake temperature and derates the engine if the temperature exceeds DDC factory set limits. Used on Series 149 engines only. Refer to section 3.14.18. Senses coolant level for engine protection. Refer to section 3.14.19. Senses exhaust temperature for engine protection. Refer to section 3.14.22. Senses water pump pressure to maintain a constant fire truck pump pressure. Refer to section 3.14.23. Senses coolant level for engine protection in applications where electrical isolation from the chassis is required. Refer to section 3.14.21. Senses operator's input to the ECM for throttle input. Refer to section 3.14.24. Senses vehicle speed for Cruise Control and PTO Control. Total distance accumulation required for ProDriver and a speedometer. Refer to section 3.14.25. * Available in some applications † Available with the Maintenance Alert System Table 3-46 Function and Guidelines for OEM-installed Sensors All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-125 HARDWARE AND WIRING 3.14.16 AIR COMPRESSOR PRESSURE SENSOR The ACPS (see Figure 3-95) is a variable capacitance sensor that produces a linear analog (voltage) signal proportional to air outlet pressure. The ECM monitors the air outlet pressure while varying the engine speed and controlling the compressor inlet or outlet valve to maintain the set pump pressure. The ACPS range is 0 to 300 psi. Figure 3-95 3-126 Air Compressor Pressure Sensor All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL See Figure 3-96 for ACPS installation. Figure 3-96 Air Compressor Pressure Sensor Installation All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-127 HARDWARE AND WIRING 3.14.17 AIR FILTER RESTRICTION SENSOR The AFRS is available only with the Maintenance Alert System (Release 27.0 or later software). The AFRS (see Figure 3-97) has two trip points, one at 18 in. of water and the second at 25 in. of water. Figure 3-97 Air Filter Restriction Sensor The AFRS is mounted downstream of the air filter and upstream of the turbocharger. The AFRS must be in a straight section of pipe or where the OEM mechanical unit is normally mounted. This sensor must be enabled with VEPS or the DDEC Reprogramming System (DRS). A pigtail on the DDC installed Engine Sensor Harness will be used to wire the sensor (see Figure 3-98). 3-128 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 3-98 3.14.18 Air Filter Restriction Sensor Wiring Diagram AIR INTAKE TEMPERATURE SENSOR The OEM is responsible for installing the Air Intake Temperature Sensor on Series 149 engines. The sensor should be located in the left bank compressor inlet. This sensor is used to monitor the air temperature and derate the engine if the temperature exceeds DDC factory set limits. The sensor is connected to the pigtail labeled Air Temperature Sensorsupplied with the engine. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-129 HARDWARE AND WIRING 3.14.19 COOLANT LEVEL SENSOR The CLS is required for DDEC IV installations. Its purpose is to provide an input to the engine protection system and warn the operator if a low coolant level has been reached. Other non-DDC supplied coolant level sensors may be used but may require the use of a signal interface. The main component of the CLS consists of a conductivity probe, which connects to the ECM (see Figure 3-99). NOTICE: The probe has an operational temperature range of -58 to 257 F (-50 to 125 C). Exposure to temperatures beyond this range may result in unacceptable component life, or degraded sensor accuracy. Figure 3-99 Coolant Level Sensor Specifications The connector listed in Table 3-47is a Metri-Pack 280 series push-to-seat connector. Coolant Level Sensor Connector Table 3-47 3-130 Connector P/N: 15300027 Terminal P/N: 12077411 Seal P/N: 12015323 Secondary Lock P/N: 15300014 Metri-Pack 280 Connectors and Part Numbers All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The OEM must connect the CLS probe as shown in the next illustration (see Figure 3-100). Polarity of the ground and signal must be correct for proper operation. Figure 3-100 Coolant Level Sensor Installation The probe should be located in either the radiator top tank or a remote mounted surge tank. It should be mounted horizontally in the center of the tank to minimize tilt operation sensitivity and must be in a position to signal low coolant before aeration occurs. Typically, this is a height representing 98% of the drawdown quantity. The probe should be located so that it is not splashed by deaeration line, stand pipe or coolant return line flows. The insulated portion of the probe should be inserted into the coolant .5 in. or more past the inside wall of the tank. See Figure 3-101. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-131 HARDWARE AND WIRING Figure 3-101 Coolant Level Sensor Location - Top of Radiator Tank Determine proper location for low coolant level sensor while running the drawdown test. It must actuate a warning before the satisfactory drawdown level is reached. The CLS components are OEM-supplied hardware and can be purchased as kits or individual components, depending on OEM requirements. The following kits listed in Table 3-48and Table 3-49 provide all the necessary hardware for proper installation of the CLS. Kits are available through the DDC parts distribution network. Component Part Number CLS Probe 23520380 Metri-Pack Connector Kit 15300027 Metri-Pack Terminals 12077411 Secondary Lock 15300014 Cable Seal 12015323 Terminal 12103881 Table 3-48 3-132 CLS Installation Kit 1/4 in. NPTF P/N: 23515397 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Component Part Number CLS Probe 23520381 Metri-Pack Connector Kit 15300027 Metri-Pack Terminals 12077411 Secondary Lock 15300014 Cable Seal 12015323 Terminal 12103881 Table 3-49 3.14.20 CLS Installation Kit 3/8 in. NPTF P/N: 23515398 ADD COOLANT LEVEL SENSOR The ACLS is used to warn the driver that the coolant level is below the recommended level. If the tank is equipped with an "ADD" level, the sensor should be installed there. This sensor will be activated approximately mid-way between the cold full level and the level where the standard (engine protection) CLS is located (see Figure 3-102). Figure 3-102 Add Coolant Level Sensor Location - Radiator Surge Tank All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-133 HARDWARE AND WIRING The ACLS probe is connected to a separate module. The module provides an output to drive an indicator light on the dash or can be used with the Maintenance Alert System. See Figure 3-103for the installation of a Coolant Level Low Light. Figure 3-103 3-134 Add Coolant Level Sensor with Dash-mounted Light Installation All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL When the ACLS is used with MAS, an additional module (P/N: 23524054) is required to condition the sensor signal. The module output will be connected to a pigtail on the DDC supplied Engine Sensor Harness. See Figure 3-104 for wiring schematic. This sensor must be enabled with VEPS (Release 24 software or later) or the DDEC Reprogramming System. Figure 3-104 Add Coolant Level Sensor Installation All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-135 HARDWARE AND WIRING 3.14.21 OPTICAL COOLANT LEVEL SENSOR The optical CLS (see Figure 3-105) can be used in place of the standard coolant level sensor in applications where electrical isolation from the chassis is required. Figure 3-105 Optical Coolant Level Sensor Specifications The optical CLS does not have a connection to the chassis but uses the angle of refraction of light emitted from the probe to determine if the sensor is in or out of the coolant. See Figure 3-106for a schematic of the optical CLS harness. 3-136 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 3-106 Optical Coolant Level Sensor Harness NOTE: This sensor is to be used with DDEC III or IV only. The sensor part numbers are listed in Table 3-50. Description Part Number Optical CLS - DDEC III or IV 23519175 Connector 12110293 Terminals 12048074 Cable Seals 12048086 Secondary Lock 12052845 Table 3-50 Optical Coolant Level Sensor and Parts All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-137 HARDWARE AND WIRING 3.14.22 EXHAUST TEMPERATURE SENSOR Excessive exhaust temperature may indicate a concern with the fuel system or a mechanical fault. An Exhaust Temperature Sensor (see Figure 3-107) will provide early warning and prevent damage for certain applications. This sensor is configured by the Application Code System (ACS). Figure 3-107 Exhaust Temperature Sensor Exhaust Temperature Sensor Installation Kits containing the Exhaust Temperature Sensor Harness and sensor are available from Canton Parts Distribution Center. The kits are listed in Table 3-51. Kit Part Numbers 23524968 23525702 23525703 Description Component Part Numbers Harness - 232 in.* 23524831 Exhaust Temperature Sensor 23521882 Harness - 170 in. length* 23525686 Exhaust Temperature Sensor 23521882 Harness - 100 in. length* 23525685 Exhaust Temperature Sensor 23521882 * Total length includes 72 in. lead on P/N: 23521882 Table 3-51 Exhaust Temperature Sensor and Harness Kits To install the Exhaust Temperature Sensor (see Figure 3-108): 1. Unplug the connector from the TBS. 2. Plug the Exhaust Temperature Sensor Harness connector (P/N: 12162182) into the TBS. 3-138 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3. Plug the TBS connector (from the ESH) you unplugged in step 1 into the 3-pin connector on the Exhaust Temperature Sensor Harness. 4. Route the harness along the ESH toward the ECM-VIH 30-pin connector. Remove the VIH 30-pin connector from the ECM. 5. Insert the single lead (circuit 749) into cavity D3 of the VIH 30-pin connector. Crimp the terminal on the lead and pull to seat. Figure 3-108 Exhaust Temperature Sensor Installation 6. Reinstall the VIH 30-pin connector. 7. Route the body of the harness to the location of the Exhaust Temperature Sensor and plug the connector (P/N: 12103784) into the sensor. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-139 HARDWARE AND WIRING 3.14.23 FIRE TRUCK PUMP PRESSURE SENSOR The Fire Truck Pump Pressure Sensor is used with the DDEC IV pressure sensor governor. It provides a fire truck pump pressure signal to the ECM, which modulates engine fueling to maintain a constant fire truck pump pressure. See Figure 3-109. The Pressure Sensor is capable of reading up to 400 psia and is located in the water pump discharge manifold. Figure 3-109 The Fire Truck Pump Pressure Sensor The Fire Truck Pump Pressure Sensor connector, listed in Table 3-52, is a Metri-Pack 150 series pull-to-seat connector. Fire Truck Pressure Sensor (PSG) Table 3-52 Connector P/N: 12065287 Terminal P/N: 12089289 Cable Seal P/N: 12065285 Fire Truck Pump Pressure Sensor Connector See Figure 3-110 for the installation of the Fire Truck Pump Pressure Sensor. 3-140 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 3-110 3.14.24 Fire Truck Pump Pressure Sensor Installation THROTTLE POSITION SENSOR The EFPA contains the Throttle Position Sensor (TPS) which converts the operator's hand throttle and/or foot pedal input into a signal for the ECM. Refer to section 3.15.1 for additional information on the Electronic Foot Pedal Assembly. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-141 HARDWARE AND WIRING 3.14.25 VEHICLE SPEED SENSOR The DDEC IV ECM can calculate vehicle speed providing that the ECM is properly programmed and interfaced with a vehicle speed signal that meets DDC requirements. The VSS (see Figure 3-111) provides a vehicle speed signal for use in Cruise Control and Vehicle Speed Limiting. The VSS signal type can be changed with the DDR, VEPS, or DRS. NOTE: DDC does not approve of the use of signal generator sensors. Figure 3-111 Vehicle Speed Sensor To obtain accurate vehicle mileage, the parameters listed in Table 3-53 must be programmed with the DDR, DDDL, VEPS, DRS or at order entry. Parameter Description Choice / Display VSS ENABLED Enables or disables the vehicle speed sensor input. YES, NO VSS TYPE Type of vehicle speed sensor used TAIL, WHEEL VSS TEETH Number of teeth on the vehicle speed sensor wheel. 0 to 250 VSS SIGNAL Type of vehicle speed sensor signal. SWITCHED, MAGNETIC TIRE REVS/MI or REV/KM Vehicle tire revolutions per mile. 100 to 999 AXLE RATIO Indicates the rear axle ratio of the vehicle. 2.00 to 19.99 TOP GEAR RATIO Indicates the vehicle transmission final drive ratio. 0.5 to 2.55 Table 3-53 Vehicle Speed Sensor Parameters Magnetic Pickup The magnetic pickup requirements are listed in Table 3-54. Magnetic Pickup size is determined by installation requirements. Both circuits 556 and 557 must be used. 3-142 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Parameters Range Input amplitude Range 800 mV-100V peak to peak Input Frequency Range 1 - 3000 Hz Table 3-54 Magnetic Pickup Vehicle Speed Sensor Requirements See Figure 3-112 for the installation of magnetic pickup VSS. Figure 3-112 Magnetic Pickup Vehicle Speed Sensor Installation Magnetic Vehicle Speed Sensors can be obtained from the following sources: Wabash Technologies Airpax Instruments Electro Corporation 1375 Swan Street Phillips Technologies 1845 57th Street Huntington, Indiana 46750-0829 150 Knotter Drive Sarasota, Florida 34243 Tel: 219-356-8300 Chesire, Connecticut 06410 Tel: 941-355-8411 Fax: 219-356-3846 Tel: 800-643-0643 Fax: 941-355-3120 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-143 HARDWARE AND WIRING Open Collector The open collector input is defined as a single wire input that alternates between a high voltage of at least 4 V DC and a low voltage of 1.0 V DC or less. Typically, the input is connected to a transistor collector output whether open or through a pull up resistor. A pull up resistor is preferred as this eliminates the need to configure the signal type as open collector. See Figure 3-113 for open collector VSS installation. Figure 3-113 Open Collector Vehicle Speed Sensor Installation Allison Transmission Electronic Controls have an open collector output. DDEC IV circuit #556 is connected to Allison circuit #205 (Allison Transmission Electronic Controls) or Allison circuit #157 (World Transmission). This device is an electrically operated switch that grounds or opens the input signal. The VSS frequency (pulses/mile) may range between 7,000 and 145,000 pulses/mile. The open collector requirements are listed in Table 3-55. Only circuit 556 is used. 557 cavity must be empty. 3-144 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Parameters Range High State 4.0 <Ein <Battery (+) with Ileakage <0.2mA Peak to Peak Voltage Maximum -2.0 <Ein <1.0 V while Isource <5.0mA Input Frequency Range 1 - 3000 Hz Table 3-55 Open Collector Vehicle Speed Sensor Requirements SAE J1939 Data Link A VSS wired to the ECM is not required if the transmission output shaft speed message is being transmitted over the SAE J1939 Data Link. The transmission type, listed in Table 3-56, must be set to 16 (Auto/J1939). The transmission type is set by VEPS or the DRS. Parameter Description Choice Transmission Type Select the transmission type. 16 Table 3-56 Transmission Type To obtain accurate vehicle mileage, the parameters listed in Table 3-57 must be programmed with the DDR, DDDL, VEPS, DRS, or at order entry. The VSS type will automatically be set to SAE J1939 when the appropriate transmission type is selected (trans type = 16). Parameter Description Choice / Display VSS ENABLED Enables or disables the vehicle speed sensor input. YES, NO VSS TYPE Type of vehicle speed sensor used J1939 TIRE REVS/MI or REV/KM Vehicle tire revolutions per mile. 100 to 999 AXLE RATIO Indicates the rear axle ratio of the vehicle. 2.00 to 19.99 TOP GEAR RATIO Indicates the vehicle transmission final drive ratio. 0.5 to 2.55 Table 3-57 Vehicle Mileage Parameters Two faults (SID 216 FMI 14 and PID 84 FMI 12) will be logged simultaneously if DDEC is calibrated to receive output shaft speed over a SAE J1939 Data Link and the data is not being received or the data is bad. This indicates that there is a problem with the sensor on the transmission or the transmission controller. The fault is available with Release 27.0 or later software). If these faults are received in addition to a SAE J1939 Data Link failure (SID 231, FMI 12), then the problem is with the SAE J1939 Data Link itself. VSS Anti-Tamper If the sensor appears to be working improperly but the vehicle speed is not zero, VSS Anti-Tamper logs a VSS fault and limits engine speed. VSS Anti-Tamper must be programmed by the DRS, DDDL, or the DDR. Refer to section 5.37for additional information. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-145 HARDWARE AND WIRING 3.14.26 AFTERMARKET INSTALLED SENSORS Two sensors are installed aftermarket, the Ambient Air Temperature Sensor (Ambient ATS) and the Exhaust Back Pressure Sensor. 3.14.27 AMBIENT AIR TEMPERATURE SENSOR The Ambient ATS is a thermistor type sensor with a variable resistance that produces an analog signal between 0 and 5 V, representing the temperature of the ambient air. The Ambient ATS (see Figure 3-114and see Figure 3-115) is used with the Idle Shutdown Timer, specifically for the Ambient Air Temperature Override Disable feature. Figure 3-114 Ambient Air Temperature Sensor This option allows the override to be disabled based on ambient air temperature. Although DDEC can calculate ambient air temperature, an Ambient ATS should be installed. If the upper and lower temperature limits are set and the ambient temperature is within the specified limits, the override will be disabled and the engine will be shutdown after the specified time limit is met. To disable this feature, the upper and lower limits must be set to 167 F. The installation of an Ambient ATS is recommended if the Ambient Air Temperature Override Disable feature is enabled. Install the Ambient ATS where ambient air temperature can be read. A protected location on the frame rails where it will not be splattered with dirt and grime and is removed from any heat source such as exhaust is preferred. Refer to section 5.18 for more information on the Idle Shutdown Timer. 3-146 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 3-115 Ambient Air Temperature Sensor With Integrated Mounting Brackets Ambient Air Temperature Sensor Installation An Ambient ATS Kit (P/N: 23524171) is available through the Canton Parts Distribution Center. The Kit contains all the necessary hardware to install an Ambient ATS. To install the Ambient ATS and harness (see Figure 3-116): 1. Select the desired Ambient ATS (listed in Table 3-58) for the application: All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-147 HARDWARE AND WIRING Mounting Ambient ATS Mounts in a 3/8 in. NPTF hole Ambient ATS P/N: 23515250 (see Figure 3-114) Ambient ATS P/N: 23518328 With Integrated Mounting Brackets (see Figure 3-115) Table 3-58 Requires that a bracket be fabricated with a drilled and tapped hole. Mounting: Integrated mounting pad/ not threaded Available Ambient Air Temperature Sensors 2. Unplug the connector from the Oil Pressure Sensor (OPS) located on the intake manifold. 3. Plug the connector (P/N: 12162182) on the Ambient ATS harness into the OPS. 4. Plug the OPS connector that you unplugged in step 2 into the 3-pin connector (OPS connector mate) on the Ambient ATS harness. Figure 3-116 Ambient ATS Harness 5. Route the harness along the Engine Sensor Harness towards the ECM 30-pin connector. 3-148 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 6. Remove the Engine Sensor Harness 30-pin connector from the ECM. 7. Insert the single lead (circuit 907) into cavity R-1. Crimp a terminal (P/N: 12103881) on the lead using tool J 35123. 8. Seat the terminal into the connector and reinstall the 30-pin connector. 9. Route the body of the harness to the desired location for the Ambient ATS. Remove any excess harness material and discard. NOTE: Do not splice wire 452 on the Engine Sensor Harness. 10. Install the black lead (circuit 452) into cavity "A" of Ambient ATS connector (P/N: 12162193) and the green lead (circuit 907) into cavity "B." Crimp the terminals (P/N: 12103881) on each lead using tool J 35123. Insert the terminals into the connector. 11. Secure the sensor to the desired location with connector pointing down and plug in the Ambient ATS connector. 12. Secure the harness to adjacent components with wire ties. The following kit, parts listed in Table 3-59, is available from Detroit Diesel's Parts Distribution Center. Part No. Qty. Description 23524102 1 Harness, Air Temp. Sensor 23518328 1 Sensor, Air Temp. (W/ Mtg. Brkt.) 23515250 1 Sensor, Air Temp. (3/8 in. NPTF) 12162193 1 Connector, Air Temp. Sensor 12103881 5 Terminal, Female 18SP397 1 18SP397 Installation Instructions Table 3-59 3.14.28 Ambient Air Temperature Kit P/N: 23524171 EXHAUST BACK PRESSURE SENSOR The Exhaust Back Pressure Sensor comes in the Exhaust Back Pressure Sensor Kit. This kit is intended for installation on Detroit Diesel DDEC IV Series 50 Diesel and Series 60 Diesel Coach Engines. The Kit components, used in conjunction with aftertreatment systems, provides diagnostic capability and engine protection in the event of excessive exhaust backpressure. This kit is required for Emitless® particulate filter installations. It may be used as an option with catalytic converter installations. NOTE: Contact an authorized Detroit Diesel distributor to inquire if the kit is released for your engine model. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-149 HARDWARE AND WIRING The Exhaust Back Pressure Sensor is bracket mounted and ported to the exhaust pipe upstream of the particulate filter or catalytic converter. The exhaust temperature sensor is installed directly into the outlet side of the Emitless particulate filter or catalytic converter. NOTE: An exhaust temperature sensor is required for all particulate filter and catalytic converter installations. The wiring harness in these exhaust back pressure kits include both Exhaust Back Pressure and Exhaust Temperature Sensor connectors. See Figure 3-117. 3-150 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 3-117 Exhaust Temperature and Pressure Sensor Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-151 HARDWARE AND WIRING Three service kits with different length sensor harnesses are available. The parts to the three kits are listed in Table 3-60, Table 3-61, and Table 3-62. NOTE: Kits are assembled without an Exhaust Temperature Sensor to accommodate customers retrofitting engines have sensor P/N: 23521882 (with 182 cm/72 in. cable) previously installed. If an exhaust temperature sensor was not previously installed, obtain one from an authorized Detroit Diesel distributor. Part Number Quantity Description 23528951 1 Exhaust Temperature/Pressure Harness, 589 cm/232 in. in Length 23528948 1 Exhaust Back Pressure Sensor 23529151 1 Stainless Steel Braided hose, 91 cm/36 in. in Length 23529152 1 Sensor Mounting Bracket 23529150 1 Bulkhead Compression Fitting with Female 3/8 in. NPTF Pipe Thread 23528903 1 Compression Fitting with Weld End 11505299 2 Bolt, M10 X 1.5 X 30 (Flange Head) 11506101 2 Nut, M10 X 1.5 (Flange Head) 18SP548 1 Installation Instructions Kits do not include an Exhaust Temperature Sensor Table 3-60 Exhaust Back Pressure Sensor Kit with 589 cm/232 in. Harness, P/N: 23529470 Part Number Quantity Description 23528952 1 Exhaust Temperature/Pressure Harness 432 cm/170 in. Length 23528948 1 Exhaust Back Pressure Sensor 23529151 1 Stainless Steel Braided hose, 91 cm/36 in. Length 23529152 1 Sensor Mounting Bracket 23529150 1 Bulkhead Compression Fitting with Female 3/8 in. NPTF Pipe Thread 23528903 1 Compression Fitting with Weld End 11505299 2 Bolt, M10 X 1.5 X 30 (Flange Head) 11506101 2 Nut, M10 X 1.5 (Flange Head) 18SP548 1 Installation Instructions Kits do not include an Exhaust Temperature Sensor Table 3-61 3-152 Exhaust Back Pressure Sensor Kit with 432 cm/170 in. Length Harness, P/N: 23529471 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Part Number Quantity Description 23528953 1 Exhaust temperature/Pressure Harness, 254 cm/100 in. Length 23528948 1 Exhaust Back Pressure Sensor 23529151 1 Stainless Steel Braided hose, 91 cm/36 in. Length 23529152 1 Sensor Mounting Bracket 23529150 1 Bulkhead Compression Fitting with Female 3/8 in. NPTF Pipe Thread 23528903 1 Compression Fitting with Weld End 11505299 2 Bolt, M10 X 1.5 X 30 (Flange Head) 11506101 2 Nut, M10 X 1.5 (Flange Head) 18SP 1 Installation Instructions Kits do not include an Exhaust Temperature Sensor Table 3-62 Exhaust Back Pressure Sensor Kit with 254 cm/100 in. Length Harness P/N: 23529472 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-153 HARDWARE AND WIRING THIS PAGE INTENTIONALLY LEFT BLANK 3-154 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.15 THROTTLE DEVICES There are several types of throttle controls which may be used for engine control. Hand throttle Electronic Foot Pedal Assembly (EFPA) Cruise Control switches Fast Idle Switch (beginning with Release 2.0 software) Voltage dividers Frequency input The throttle input device is OEM-supplied. There are two types of engine governors that are used with throttle controls. The engine governors are: The Limiting Speed Governor (LSG) for torque control The Variable Speed Governor (VSG) for speed control 3.15.1 ELECTRONIC FOOT PEDAL ASSEMBLY The EFPA contains the Throttle Position Sensor (TPS) which converts the operator's hand throttle and/or foot pedal input into a signal for the ECM. The EFPA and the TPS are shown in Figure 3-118. Figure 3-118 Typical EFPA Throttle Device (Shown with 6-pin Connector) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-155 HARDWARE AND WIRING The EFPA sends the ECM an input signal which controls engine power on the LSG, proportional to the foot pedal position. This assembly is also referred to as the Throttle Position Sensor (TPS) assembly. The system fault detection diagnostics will return the engine to idle speed in the event of a sensor or associated wiring malfunction. The fault detection diagnostics work with or without an idle validation switch on the EFPA. An idle validation switch provides redundancy to assure that the engine will be at idle in the event of an in-range malfunction. The connectors for the TPS are Weather Pack push-to-seat connectors and are listed in Table 3-63. Throttle Position Sensor, Harness Side Throttle Position Sensor, Sensor Side Connector P/N: 12015793 Connector P/N: 12010717 Terminal P/N: 12089188 Terminal P/N: 12034051 Seal P/N: 12015323 Seal P/N: 12015323 Table 3-63 Connectors for the Throttle Position Sensor The EFPA can be used with both LSG and VSG. 3.15.2 CRUISE CONTROL SWITCHES The Cruise Control switches can be used to control the VSG set speed. This feature is referred to as Cruise Switch VSG. For more information on Cruise Switch VSG, refer to section 5.3.3 and section 5.33.2. 3.15.3 HAND THROTTLE A hand throttle (potentiometer) may be used to control engine speed on the VSG between the minimum and maximum VSG speed. The total resistance must be between 1k and 10 k . When active, the hand throttle will control the engine speed on the VSG between the VSG minimum speed and the VSG maximum speed. For more information on the hand throttle, refer to section 5.33.2. 3.15.4 FAST IDLE SWITCH (ALTERNATE MINIMUM VSG) The Alternate Minimum VSG option allows a customer to select an alternate idle speed when its digital input is switched to battery ground. For more information on Alternate Minimum VSG/Fast Idle, refer to section 5.33.2. 3.15.5 VOLTAGE DIVIDERS Voltage dividers can be used with the VSG input to provide a means to select a predetermined engine speed. Voltage dividers can be used to provide a fast idle operation or other engine operations where a fixed engine speed is desired. For more information on voltage dividers, refer to section 5.33.2. 3-156 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.15.6 FREQUENCY INPUT A frequency input can be used to control the VSG. This frequency is connected to the vehicle speed input or ATI port. Frequency speed control offers better resolution than analog throttles. For more information on frequency input, refer to section 5.33.2. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-157 HARDWARE AND WIRING THIS PAGE INTENTIONALLY LEFT BLANK 3-158 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.16 LIGHTS The instrument panel warning lights, the Check Engine Light (CEL) and the Stop Engine Light (SEL), are supplied by the OEM. The functionality of each light along with the wiring requirements are covered separately in the following sections. 3.16.1 CHECK ENGINE LIGHT The CEL is controlled by the DDEC ECM. The CEL remains ON: For approximately five (5) seconds at the start of every ignition cycle (a bulb check) When an electronic system fault occurs (This indicates the problem should be diagnosed as soon as possible.) The CEL flashes: When the Diagnostic Request Switch is used to activate the CEL to flash inactive codes During last 90 seconds before Idle Shutdown if programmed for override When Idle Shutdown occurs or the Optimized Idle system shutdown occurs CEL activity with the Maintenance Alert System (MAS) is set with the DDR (Release 24), VEPS, DRS, or DDDL. The four options for using the CEL with MAS are: 1. CEL and SEL will not illuminate or flash for MAS Warnings - sensor faults will still be logged (recommended for vehicles equipped with display modules). 2. CEL will illuminate continuously while the warning is active, i.e. low fluid levels (oil or coolant), filter restrictions. 3. Flashes CEL and SEL for 15 seconds when the ignition is first turned ON and warnings have been present. 4. Both 2 and 3. The CEL is active with the PasSmart feature. When the Passing Speed Duration time expires, the CEL will begin to flash one minute prior to ramping the Vehicle Limit Speed (VLS) down to the normal limit. The rampdown event always takes five seconds regardless of the Passing Speed Increment programmed into the ECM. The rampdown alert can be distinguished from an engine fault warning in that the CEL flashes for the former and remains on constantly for the latter. PasSmart still operates when there is an active engine fault. In this situation, the CEL goes from constant illumination to flashing one minute before rampdown from the VSL. At the end of the passing event when PasSmart is deactivated, the CEL returns to constant illumination if the engine fault is still active. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-159 HARDWARE AND WIRING The CEL is also active the DDEC Reports Periodic Maintenance Intervals. If a maintenance interval is within a specified percentage of expiration (default is 20%), the CEL flashes six times when the ignition is turned on. The ignition must have been off for less than 30 seconds prior to being turned on. If the off time has been greater than 30 seconds, no indication of maintenance interval status is given. Check Engine Light Requirements and Guidelines The following requirements and guidelines apply to the CEL: The CEL must be supplied by the OEM. A 12 or 24 volt light of less than 1.5 A (DC) is required depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. A low-side digital output sinks 60 A when OFF. The CEL must be integrated into the instrument panel or placed in clear view of the equipment operator. The lens color must be amber. The words CHECK ENGINE must appear on or near the CEL lamp. 3-160 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Check Engine Light Wiring The CEL is connected to wire 419 in the VIH. See Figure 3-119 for the recommended CEL wiring. Figure 3-119 Check Engine Light Wiring All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-161 HARDWARE AND WIRING 3.16.2 STOP ENGINE LIGHT The SEL is controlled by the DDEC ECM. The SEL remains ON: For approximately five (5) seconds at the start of every ignition cycle (a bulb check) When a potentially engine damaging fault is detected The SEL flashes: After Engine Protection Shutdown occurs When the Diagnostic Request Switch is used to activate the SEL to flash active codes SEL activity with the MAS is set with the DDR (Release 24 or later), VEPS, DRS, or DDDL. The two options for using the SEL with MAS are: 1. CEL and SEL will not illuminate or flash for MAS Warnings - sensor faults will still be logged (recommended for vehicles equipped with display modules). 2. Flashing CEL and SEL for 15 seconds when the ignition is first turned ON and warnings have been present. Stop Engine Light Requirements and Guidelines The following requirements and guidelines apply to the SEL: The SEL must be incorporated into the VIH by the OEM. A 12 or 24 volt light of less than 1.5 A (DC) is required depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. A low-side digital output sinks 60 A when OFF. The SEL must be integrated into the instrument panel or placed in clear view of the equipment operator. The lens color must be red. The words STOP ENGINE must appear on or near the SEL lamp. 3-162 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Stop Engine Light Wiring See Figure 3-120 for the recommended SEL wiring. Figure 3-120 Stop Engine Light Wiring All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-163 HARDWARE AND WIRING 3.16.3 MULTIPLE ECM ENGINES Each ECM uses a common SEL and CEL except for the Series 149 engine. The Series 149 Engine has a single SEL and CEL for each ECM. 3.16.4 MULTIPLE CEL/SEL WIRING Some applications require two sets of CEL and SEL at different control stations. See Figure 3-121. Figure 3-121 3-164 Multiple CEL/SEL Configuration - Single ECM Engine All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.17 DDEC REQUIREMENTS FOR GASEOUS HAZARDOUS ENVIRONMENTS A hazardous environment DDEC package has been developed that meets North American, European, and Asian hazardous environment certification requirements. The DDEC system has been certified for operation in Class 1 Division 2 or Group II Zone 2 (Category 3) hazardous gaseous environments for all gas groups. The means used to obtain compliance vary somewhat between engine series due to engine hardware differences. Engine series currently available for Class I Division 2 and Group II Zone 2 hazardous environments include Series 60, Series 50 and Series 2000. The information provided is necessary to install a DDEC IV engine certified and/or listed for Class 1 Division 2 or Group II Zone 2 (Category 3) category hazardous environments. The information is intended to supplement current DDEC requirements as listed in this manual. NOTE: This section is to take precedence over other sections in this manual in the event of conflicting information. Explosion Hazard — Substitution of components may impair suitability for Class 1 Division 2. UL1604 Explosion Hazard — Do not connect or disconnect equipment unless power has been switched off or the area is known to be non-hazardous. Explosion Hazard — Substitution of components may impair suitability for Group II Zone 2 (Category 3). EN 50021, EN 50014, and EN 50028 This section is written for those familiar with hazardous environment applications. It is the responsibility of the installer to procure the standards that are discussed in this section in order to ensure their compliance with the appropriate standard. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-165 HARDWARE AND WIRING 3.17.1 HAZARDOUS GASEOUS ENVIRONMENT OVERVIEW The following information should be used to provide a broad overview of Hazardous Environments only, it is not intended to be a definitive reference guide. Hazardous Environment Classification - North America Class I: Hazardous location due to the presence of flammable substances such as gases or vapors. Division 1: Danger can be present during normal functioning, during repair or maintenance, or where a fault may cause the simultaneous failure of electrical equipment. Division 2: Combustible material is present but confined to a closed container or system, or an area adjacent to a Division 1 location. Hazardous Environment Classification - Europe Group II: Hazardous location due to the presence of flammable substances such as gases or vapors. Zone 1 (Category 2): An area in which an explosive air/gas mixture is LIKELY to occur in normal operation. Zone 2 (Category 3): An area in which an explosive air/gas mixture is UNLIKELY to occur; but, if it does, only for short periods of time. Gas Classification Gas classifications are made on the basis of the gas or vapors ease of ignition. North America: Groups A - D A Is Most Stringent (readily ignitable) D Is Least Stringent ( more difficult to ignite) Europe: Groups C - A C Is Most Stringent (readily ignitable) A Is Least Stringent ( more difficult to ignite) The DDC-supplied hardware IP code is listed in Table 3-67, “Hazardous Environment Classification for DDC Supplied Hardware.”. Ingress Protection Ingress protection specifies the degree of protection: From contact with live or moving parts Against the intrusion of solid foreign bodies or liquid into a component 3-166 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The codes for the level of protection are listed in Table 3-64. Degree of Protection Solid Bodies Degree of Protection 0 No Protection 0 No Protection 1 Objects > 50 mm 1 Vertically Dripping Water 2 Objects > 12mm 2 Angled Dripping Water 3 Objects > 2.5 mm 3 Sprayed Water 4 Objects > 1.0 mm 4 Splashed Water 5 Dust Protected 5 Water Jets 6 Dust Tight 6 Heavy Seas -- -- 7 Effects of Immersion -- -- 8 Indefinite Immersion Table 3-64 Liquid Ingress Protection Codes Example: Protection degree is specified by a code such as IP64. The first numeral (6) defines the degree of protection against contact with live or moving parts and against the intrusion of solid foreign bodies. The second numeral (4) defines the degree of protection against the intrusion of liquid. Therefore, IP64 is a dust tight device that is resistant to splashed water. The DDC-supplied hardware IP code is listed in Table 3-67, “Hazardous Environment Classification for DDC Supplied Hardware.”. Temperature Classification The maximum surface temperature must be lower than the minimum ignition temperature of the gas present. Temperature classifications are listed in Table 3-65. Maximum Surface Temperature (oC) Temperature Class 450oC T1 o T2 o 200 C T3 135oC T4 300 C o 100 C T5 o T6 85 C Table 3-65 Temperature Classification The DDC-supplied hardware IP code is listed in Table 3-67, “Hazardous Environment Classification for DDC Supplied Hardware.”. Detroit Diesel provides two options, which have been certified by both Nemko and Underwriters Laboratories for use in Group II Zone 2 (Category 3) and Class 1 Division 2 for all types of combustible gases. Refer to Chapter 8 for certification information. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-167 HARDWARE AND WIRING THIS PAGE INTENTIONALLY LEFT BLANK 3-168 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.18 HARDWARE AND INSTALLATION REQUIREMENTS FOR HAZARDOUS ENVIRONMENT The following sections list the additional hardware and installation requirements for Group II Zone 2 (Category 3), or Class I Division 2 hazardous environment. The supplier of the specific hardware components, OEM or DDC, is listed in Table 3-66. Hardware Supplier Power Supply (refer to section 3.18.1 for specific installation requirements) Fuses (refer to section 3.18.2 for specific installation requirements) Wiring (refer to section 3.18.3 for specific installation requirements) Junction Box (Optional) (refer to section 3.18.4 for specific installation requirements) Exhaust Temperature Sensor (Optional) (refer to section 3.18.5 for specific installation requirements) Engine-mounted ECM (Standard Option) (refer to section 3.18.6 for specific installation requirements) Table 3-66 OEM OEM OEM OEM OEM DDC Hardware Supplied by OEM and DDC The hazardous environment ingress protection (IP), gas group and temperature classifications for DDC-supplied hardware listed in Table 3-67 apply to Class I Division 2 and Group II Zone 2 (Category 3). Hardware Rating IP Gas Group Temperature Engine-mounted ECM (with molded connectors) IP65 All T4 Series 50/60 Rocker Cover IP54 All T4 Series 2000 EUP with Pigtail IP54 All T4 Table 3-67 3.18.1 Hazardous Environment Classification for DDC-supplied Hardware POWER SUPPLY Detroit Diesel's standard power supply requirements (refer to section 3.8, "Power Supply") are valid. Table 3-13 indicates a normal operating voltage of 11 – 32 volts DC for all DDEC IV ECMs except for ECM (P/N: 23519307) . ECM (P/N: 23519307) which is limited to a normal operating voltage of 11 – 14 Volts DC and is not typically used. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-169 HARDWARE AND WIRING Class I Division 2 UL requires that electronic systems complying with UL 1604 “Electrical Equipment for Use in Class I and II, Division 2, and Class III Hazardous (Classified) Locations” also comply with UL 508, “Industrial Control equipment.” Devices that are listed or recognized by UL must be used within their electrical ratings. The DDEC system power supply must be a limited voltage circuit (refer to UL 508, Section 32.5, Seventeenth Edition). The power supply must be a limited voltage circuit (Refer to UL 508 Section 32.5, Seventeenth Edition). Compliance with the DDEC power supply and fuse requirements for hazardous environments will meet the requirements for a limited voltage circuit. The power supply must be located in a safe (non-hazardous) location. The connections between the power supply and the ECM must comply with National Electric Code (NEC) (ANSI/NFPA 70-1993) section 501-4b or appropriate safety standard. Group II Zone 2 (Category 3) It is the customers responsibility to provide a power supply and connection to the DDEC ECM according to the relevant requirements in EN 50021. 3.18.2 FUSES AND FUSE ASSEMBLIES DDEC power may be fused using dual 15 amp fuses or a single 30 amp fuse per ECM (refer to section 3.7, "Power Harness" and section 3.9, "Fuses"). Class I Division 2 Class I, Division 2 hazardous locations overcurrent protection devices shall be provided in accordance with the requirements for limited voltage overcurrent protection, which are found in UL 508 Section 33. UL requires that the overcurrent protective devices comply with the National Electric Code (NEC) (ANSI/NFPA 70-1993). Some acceptable overcurrent devices include: Circuit breakers Class CC, J, T, G, HK, L, RK1, RK5 cartridge fuses NOTE: The overcurrent protection must be located in a safe (non-hazardous) environment. Group II Zone 2 (Category 3) It is the customers responsibility to comply with the relevant requirements of EN 50021. 3-170 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.18.3 DDEC WIRING The following requirements are in ADDITION to those already listed in other sections of this manual. The OEM-installed components listed in Table 3-68have been classified as non-incendive and do not require hazardous environment wiring. NOTE: Devices which are not listed must be certified prior to use with the DDEC system in Class I Division 2 and Group II Zone 2 (Category 3) hazardous environment. Item Switches Throttle Controls NTC Thermistors (Simple Apparatus) Level Sensors Pressure Sensors Description Part Number Air Filter Restriction Sensor 23526140 Alarmstat Single Switch No. 220 23518803 Morse Hand Throttle Clockwise Increase 310714-001 (Morse P/N) Morse Hand Throttle Counter Clockwise Increase 310714-004 (Morse P/N) Exhaust Temperature Sensor 23521882 Ambient Air Temperature Sensor 23518328 Optical Coolant Level Sensor 23517763 *Optical Coolant Level Sensor 1/4 in. 23519175 Oil Level Sensor 23522788 Coolant Level Sensor 1/4-18 PTF 23520380 Coolant Level Sensor 3/8-18 PTF 23520381 Coolant Level Sensor 9/16-18 UNF 23522855 DDEC IV Add Coolant Level Sensor Module 23524054 Sensor Asm - Governing Pressure 23505962 Pressure Sensor 23520795 Air Compressor Pressure 23518254 * - 310 mA for 100 sec max Table 3-68 Non-incendive Components Class I Division 2 The harnesses must use UL approved wire for Class I, Division 2 hazardous locations for all gas groups. DDEC wiring to the non-incendive components listed in Table 3-68 must comply with non-hazardous locations wiring requirements as detailed in the National Electric Code (NEC). These non-incendive components must be connected directly to the ECM with a maximum wire length of 200 ft (61 m) of cable/wire. The cable/wire provided with these non-incendive circuits does not need to be a UL Recognized Component (R/C) (AVLV2) and does not need to comply with NEC 501-4b. The sensors receive all electrical power from the ECM. Devices which are not listed in Table 3-68 must comply with hazardous locations wiring requirements as detailed in NEC (ANSI/NFPA 70-1993) section 501-4b or appropriate safety standard. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-171 HARDWARE AND WIRING The electrical circuits for the DDEC IV ECM must be installed in accordance with Class I, Division 2 wiring methods. NOTE: Class 1 Division 2 hazardous environment locations where the ECM ambient temperature is not kept below 60 C may void compliance with UL standards. It is the customer/installer's responsibility to ensure compliance. Group II Zone 2 (Category 3) The standard used for Group II Zone 2 (Category 3) wiring is "CENELEC EN 50021; 1999 Electrical apparatus for potentially explosive atmospheres – TYPE N." All OEM supplied wiring to the DDEC ECM must fulfill the relevant requirements of EN 50021. The following DDEC information is pertinent to EN 50021: The DDEC ECM is a low power apparatus according to Clause 13. Devices complying with Clause 13 are not required to comply with Clause 8 or Clause 9. All DDEC ECM connections to engine sensors and certain OEM installed components (i.e. the Coolant Level Sensor and hand throttle) are energy limited according to Clause 21. 3.18.4 JUNCTION BOX The OEM is responsible for complying with the appropriate standard for termination of the OEM-side wiring. A typical installation may include an EExe box with appropriate cable entries. 3.18.5 EXHAUST TEMPERATURE SENSOR Exhaust Temperature Sensor configuration is currently available only as part of the unique 06N04C0784 group for hazardous environments. Refer to section 8.9.1, "Hazardous Environment Petroleum Unique 6N4C Group," for more information. The Exhaust Temperature Sensor helps prevent damage by providing early warning of excessive exhaust temperature. An Exhaust Temperature Sensor placed in the exhaust gas cooler of a hazardous environment DDEC engine will provide torque reduction if the exhaust gas temperature approaches 200 C. Torque reduction may reduce exhaust temperature low enough for the operator to continue running the engine. If the temperature does not drop below 200 C, DDEC will shut down the engine. Refer to section 3.14.22, "Exhaust Temperature Sensor," for installation information. 3-172 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 3.18.6 SERIES 50/SERIES 60 ENGINE-MOUNTED ECM (STANDARD OPTION) This option contains an engine-mounted ECM that has anodized aluminum ECM connector shields mounted on each end of the ECM (See Figure 3-122). The ECM with the certified hazardous environment connectors installed complies with IP65. NOTE: Class 1 Division 2 hazardous environment locations where the ECM ambient temperature is not kept below 60 C may void compliance with UL standards. It is the customer/installer's responsibility to ensure compliance. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-173 HARDWARE AND WIRING Figure 3-122 Series 50/Series 60 Engine-mounted ECM The purpose of the ECM connector shields is to provide a method of attaching the flexible conduit required by UL for both the Injector Harness and Power Harness. The shields are also used to prevent access to the connectors without the use of a tool. 3-174 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Series 50/Series 60 Engine Side of ECM The engine side of the ECM includes the connector shield, Engine Sensor Harness, Injector Harness and associated wiring that is factory installed (see Figure 3-123). Figure 3-123 Series 50/Series 60 Engine Side Connectors, Cables, and Shield All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-175 HARDWARE AND WIRING Series 50/Series 60 OEM Side of ECM The side containing the ECM shield and associated wiring that is not typically factory installed is referred to as the OEM side. This includes the ECM connector shield, Vehicle Interface Harness, Communication Harness (contains only the ignition wire), and Power Harness (see Figure 3-124). This assembly Figure 3-124 is included Series in 50/Series group 12H00-6001. 60 OEM Side The OEM Connectors, side harness Cables, assembly andisShield intended to be connected to an EExe junction box. 3-176 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Installation Information for Engine-mounted ECM Standard Option The OEM side of the ECM assembly includes the ECM connector shield, Vehicle Interface Harness, Communication Harness (contains only the ignition wire), and Power Harness which are all included in the OEM Side Harness Assembly, groups 12H00-6001 and 12H06002. Group 12H00–6001 is listed in Table 3-69. Group 12H00–6002 is listed in Table 3-70. The ECM shield is made of anodized aluminum. NOTE: This harness assembly must be used to comply with certification and is included in the base engine model. OEM Side Harness Assembly (20 ft) Group 12H00–6001 Part Number Description Qty 2 11504603 Bolts (self-tapping) 1 23528802 1 HCM 0404 (Kopex P/N) Harness Assembly includes the next two parts: I/2 in. U.S. thread size (20 mm) EExe/EExd Conduit Fitting - Brass* 1 WHMB04 (Kopex P/N) I/2 in. U.S. thread size (20 mm) lock nut* 1 N/A Epoxy Putty Kit (Epoxy Constitutens, Gloves, Installation Instruction) * For customer EExe junction box Table 3-69 OEM Side Harness Assembly (20 ft) OEM Side Harness Assembly (40 ft) Group 12H00–6002 Qty Part Number 2 11504603 Bolts (self-tapping) 1 23529816 Harness Assembly includes the next two parts: 1 HCM 0606 (Kopex P/N) I/2 in. U.S. thread size (20 mm) EExe/EExd Conduit Fitting Brass* 1 WHMB06 (Kopex P/N) I/2 in. U.S. thread size (20 mm) lock nut* Table 3-70 Description OEM Side Harness Assembly (40 ft) Vehicle Interface Harness Specifications: This harness contains conductors for all 30 cavities Material: The VIH has a neoprene jacket with a nominal temperature range of -55 C to +110 C Dimensions: 0.71 in. (18 mm) OD (nominal) 20 ft (6 m) long (optional 40 ft) Max current rating – This is a function of the installation NOTE: The ignition wire is NOT to be used on the 30-pin ECM connector for Class I Division 2 applications. The ignition wire is provided via the Communications Harness (pin C) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-177 HARDWARE AND WIRING through a UL listed conduit. Using the ignition wire on the 30–pin ECM connector is a violation of the hazardous environment requirements. Power/Communication Harness Specifications: Harness Length: 20 ft (optional 40 ft) UL 3173 Wire Wires 240/241 - 12 gauge Wires 150 - 12 gauge Wire 439 - 18 gauge Conduit fitting straight: Kopex HCM0404 20 mm brass EExe/EExd Locknut: WHMB04, Brass locknut 20 mm - Torque Specification: British Standards BS6121 specify turning compression nut and locknut to hand-tight plus 1/2 to 3/4 turns for clamping. Conduit Specifications: P/N: FUG0430 (Kopex P/N) — 20 ft UL/CSA Approval Ingress Protection IP66 & IP67 when used with KF-F or KF-C connectors Temperature Rating: - 25 C to + 105 C Construction: Helically wound galvanized steel core with copper packing and a PVC covering Connector Pull off classification: Heavy Conduit Crush classification: Heavy Flame propagation: Flame dies in less than 60 seconds after ignition source is removed (3 applications) 3-178 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL OEM Harness Assembly Instructions Use the following general assembly instructions when installing the OEM harness assembly: 1. Carefully push at least an additional 6 in. (152 mm) to 1 ft (0.30 m) of black neoprene cable into the shield. Do not dislodge the rubber grommet. 2. Insert the 30-pin VIH connector into the mating connector on the ECM. NOTE: You will need to tilt the ECM shield to access the connector (this is the reason for the additional cable in step 1). 3. Using a 9/32 in. socket, tighten the 30-pin VIH-to-ECM connector assembly (P/N: 12034398) center screw to 7-13 in.·lbs (0.79 - 1.47 Nm). 4. Pull the additional black cable out of the shield. 5. Plug in both 5-pin and 6-pin connectors. 6. Seat the shield on the ECM, aligning the bolt holes. 7. Install the two self-tapping bolts (P/N: 11504603) and tighten. 8. Check to ensure the grommet has not been dislodged. 3.18.7 REMOTE-MOUNTED ECM OPTION For remote-mounted ECM information, contact Detroit Diesel Application Engineering. An application that might need a remote mount ECM is a Series 50 Engine with a left side dipstick. 3.18.8 SERIES 2000 ENGINE-MOUNTED ECM (STANDARD OPTION) This option contains engine-mounted ECM installed under a protective steel cover (see Figure 3-125). The ECMs with the certified hazardous environment connectors installed comply with IP65. NOTE: Class 1 Division 2 hazardous environment locations where the ECM ambient temperature is not kept below 60 C may void compliance with UL standards. It is the customer/installer's responsibility to ensure compliance. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-179 HARDWARE AND WIRING Figure 3-125 3-180 Series 2000 Engine-mounted ECMs All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Series 2000 Engine Side of ECM The engine side of the ECM includes the Engine Sensor Harness, Injector Harness and associated wiring under the protective steel cover (see Figure 3-123). Figure 3-126 Series 2000 Engine Side Connectors and Cables All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-181 HARDWARE AND WIRING Series 2000 Equipment or OEM Side of ECM The side containing the ECM and associated wiring that is not typically factory installed is referred to as the Equipment or OEM side. This includes the access cover, Vehicle Interface Harness, Communication Harness (contains only the ignition wire), and Power Harness (see Figure 3-127). Figure 3-127 Series 2000 Equipment Side Connectors and Cables This assembly is included in group 12H00-0554. The OEM side harness assembly is intended to be connected to an EExe junction box. 3-182 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Installation Information for Engine-mounted ECM Standard Option The Equipment or OEM side of the ECM assembly that includes the ECM access cover, Vehicle Interface Harness, Communication Harness (contains only the ignition wire), and Power Harness are included in group 12H00-0554 as listed in Table 3-71. NOTE: This harness assembly must be used to comply with certification and is included in the base engine model. Qty OEM Side Harness Assembly (20 ft) Group 12H00–0054 Part Number Description 9 11509511 1 23529424 1 HCM 0606 (Kopex P/N) 1 WHMB06 (Kopex P/N) Bolts Harness Assembly which includes the following two parts: 1 in. (32 mm) thread size EExe/EExd Conduit Fitting - Brass* 1 in. (32 mm) thread size lock nut* * For customer EExe junction box Table 3-71 OEM Side Harness Assembly Vehicle Interface Harness Specifications: Material: The VIH has a neoprene jacket with a nominal temperature range of -55 C to +110 C Dimensions: 0.71 in. (18 mm) OD (nominal) 20 ft (6 m) long Max current rating – This is a function of the installation NOTE: The ignition wire is NOT to be used on the 30-pin ECM connector for Class I Division 2 applications. The ignition wire is provided via the Communications Harness (pin C) through a UL listed conduit. Using the ignition wire on the 30–pin ECM connector is a violation of the hazardous environment requirements. Power/Communication Harness Specifications: Harness Length: 20 ft UL 3173 Wire Wires 240/241 - 12 gauge Wires 150 - 12 gauge Wire 439 - 18 gauge Conduit fitting straight: Kopex HCM0606 32 mm brass EExe/EExd Locknut: WHMB06, Brass locknut 1 in. (32 mm) - Torque Specification: British Standards BS6121 specify turning compression nut and locknut to hand-tight plus 1/2 to 3/4 turns for clamping. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 3-183 HARDWARE AND WIRING Conduit Specifications: PN: FUG0430 UL/CSA Approval Ingress Protection IP66 & IP67 when used with KF-F or KF-C connectors Temperature Rating: - 25 C to + 105 C Construction: Helically wound galvanized steel core with copper packing and a PVC covering Connector Pull off classification: Heavy Conduit Crush classification: Heavy Flame propagation: Flame dies in less than 60 seconds after ignition source is removed (3 applications) OEM Harness Assembly Instructions Use the following general assembly instructions when installing the OEM harness assembly: 1. Carefully push at least an additional 6 in. (152 mm) to 1 ft (0.30 m) of black neoprene cable into the access cover. Do not dislodge the rubber grommet. 2. Insert the 30-pin VIH connectors into the mating connectors on the ECMs. NOTE: You will need to tilt the ECM access cover to access the connector (this is the reason for the additional cable in step 1). 3. Using a 9/32 in. socket, tighten the 30-pin VIH-to-ECM connector assemblies (P/N: 12034398) center screws to 7-13 in.·lbs (0.79 - 1.47 Nm). 4. Pull the additional black cable out of the access cover. 5. Plug in both 5-pin and 6-pin connectors. 6. Seat the access cover on the engine cover, aligning the bolt holes. 7. Install the mounting bolts and tighten. 8. Check to ensure the grommet has not been dislodged. 3-184 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 4 DIGITAL INPUTS AND OUTPUTS Section Page 4.1 DIGITAL INPUTS .................................................................................... 4-3 4.2 DIGITAL OUTPUTS ................................................................................ 4-20 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-1 DIGITAL INPUTS AND OUTPUTS THIS PAGE INTENTIONALLY LEFT BLANK 4-2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 4.1 DIGITAL INPUTS DDEC IV has twelve digital input ports located on the Vehicle Interface Harness. The Application Code System (ACS) sets the default function number for each of the twelve ports. These digital inputs can be configured for various functions. These functions can be ordered at the time of engine order, configured by VEPS or the DDEC Reprogramming System (DRS). Some digital input features are further customized by programming the ECM with a DDR, DDDL, VEPS, or DRS. DDEC does not detect broken or shorted wires on digital inputs. The digital input functions are listed in Table 4-1. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-3 DIGITAL INPUTS AND OUTPUTS Feature Cruise Control (Uses up to five inputs) Refer to section 4.1.1, page 4-6. Engine Brake Refer to section 4.1.2, page 4-8. Engine Protection Refer to section 4.1.3, page 4-10. Engine Ratings Refer to section 4.1.4, page 4-12. Fan Control Refer to section 4.1.5, page 4-13. Pressure Sensor Governor (PSG) (Uses four inputs) Refer to section 4.1.6, page 4-14. Throttle Control Refer to section 4.1.7, page 4-15. Engine Synchro Shift Transmission Refer to section 4.1.8, page 4-17. Additional Functions Refer to section 4.1.9, page 4-18. Table 4-1 4-4 Digital Input Function Number Cruise Enable 23 Clutch Released 18 Service Brake Released 17 Set/Coast On (decrease) 20 Resume/Acceleration On (Increase) 22 Engine Brake Disable 26 Engine Brake Low 1 Engine Brake Medium 2 Konstantdrossel Switch 40 Auxiliary Shutdown #1 3 Auxiliary Shutdown #2 4 Diagnostic Request Switch 15 SEO/Diagnostic Request Switch 25 Limiting Torque Curve 14 Rating Switch #1 12 Rating Switch #2 13 Transmission Retarder Status (Release 2.00 or later only) 27 Air Conditioner Status 29 Fan Control Override 32 Pressure Sensor Governor Enable 24 Pressure/RPM Mode Switch 8 Set/Coast On (Decrease) 20 Resume/Acceleration On 22 Alternate Minimum VSG/Fast Idle (Release 2.00 or later only) 16 Dual Throttle (LSG) 28 Idle Validation Switch 6 Throttle Inhibit 9 VSG Station Change 33 VSG Station Change Complement 34 External Engine Synchronization/ Frequency Input Active 10 VSG Inhibit (Release 28.0 or later) 42 In Neutral 38 In Gear 39 Auxiliary Coolant Level Switch 31 Parking Brake Interlock 5 Air Compressor Load Switch 35 Throttle Kickdown 7 RPM Freeze 11 Digital Inputs Listed by Feature All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Digital input functions are activated when the digital input wire is switched to battery ground (circuit 953), see Figure 4-1. The digital input can be controlled by either a switch or an OEM interlock depending on the function. Figure 4-1 Two Methods to Activate a Digital Input NOTE: Digital input circuits are designed to source no more than 5 mA (DC). For more information on the digital input configuration refer to section 3.10.4, "ECM Vehicle Harness Connectors - Single ECM," and section 3.10.5, "ECM Vehicle Harness Connectors - Multi-ECM." This section covers the location of the digital inputs on the Vehicle Interface Harness. Refer to chapter 8 for typical application dependent configurations. The following sections contain a description of the available options. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-5 DIGITAL INPUTS AND OUTPUTS 4.1.1 CRUISE CONTROL Up to five digital inputs are required (four for automatic transmission) for Cruise Control operation. Refer to section 5.3, "Cruise Control," for additional information. The Cruise Control inputs are described in the following sections. Cruise Enable Cruise Control is enabled, but not active when the Cruise Control Enable digital input is switched to battery ground. Set / Coast On (Decrease) Set: Cruise Speed is set by momentarily contacting the switch to the ON position (switching the digital input to battery ground). Cruise Control will become active and maintain the engine or vehicle speed present at the time. Coast: When Cruise Control is active, the Set/Coast input can be used to reduce power and speed by toggling the switch. Momentarily toggling and releasing the Set/Coast switch will decrease the set point by 1 MPH increments for Vehicle Speed Cruise Control and 25 RPM increments for Engine Speed Cruise Control. Holding the Set/Coast will decrease the set point by 1 MPH per second (Vehicle Speed CC) or 25 RPM per seconds (Engine Speed CC). When released the Cruise Control set point will be at the new speed. Resume / Accel On (Increase) Resume: If Cruise Control has been disabled with the service brake or the clutch switch, momentary contact to the ON position (switching the input to battery ground) restores the previously set cruise speed. Accel: When Cruise Control is active, the Resume/Accel input can be used to increase power and speed by toggling the switch. Momentarily toggling and releasing the Resume/Accel switch will increase the set point by 1 MPH increments for Vehicle Speed Cruise Control and 25 RPM increments for Engine Speed Cruise Control. Holding the Resume/Accel will increase the set point by 1 MPH per second (Vehicle Speed CC) or 25 RPM per seconds (Engine Speed CC). When released the Cruise Control set point will be at the new speed. 4-6 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Clutch Released (Manual Transmissions) This input indicates that the clutch is released and is used for suspending Cruise Control and Auto Resume. When the clutch is released, the input is at battery ground. Cruise Control is suspended if the clutch is depressed once. If the clutch is depressed twice within three seconds, Cruise Control is automatically resumed. NOTE: When engine brake is configured and auto resume is enabled, the first time the clutch is depressed to suspend Cruise Control, the engine brakes will be delayed for three seconds. The digital input logic for the Clutch Switch disables Cruise Control in the unlikely event of a broken clutch switch wire. Service Brake Released (Automatic and Manual Transmissions) This input indicates that the brake is released when switched to battery ground. If the brake is activated, then the input is not grounded and Cruise Control is suspended. Cruise Control is resumed by using the Resume/Accel Switch. Programming Requirements and Flexibility The digital inputs listed in Table 4-2can be configured at the time of engine order, configured by VEPS or DRS. Auto resume (Clutch Released) can be disabled/enabled with a DDR, DDDL, or VEPS. Table 4-2 Description Function Number Cruise Enable 23 Service Brake Released 17 Clutch Released 18 Set/Coast On 20 Resume/Accel On 22 Cruise Control Digital Inputs Interaction with Other Features The Set/Coast On and Resume/Accel On inputs are also used by the Pressure Sensor Governor and the Air Compressor Governor. The Set/Coast On and Resume/Accel On switches follow similar logic as the Pressure Sensor Governor switches (Increase and Decrease). Refer to section 4.1.6for more information on the Pressure Sensor Governor digital inputs and section for more information on the Pressure Sensor Governor. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-7 DIGITAL INPUTS AND OUTPUTS 4.1.2 ENGINE BRAKE The digital inputs associated with the engine brake option are described in the following sections. Refer to section 5.9, "Engine Brake Controls" for additional information. Engine Brake Disable Engine Brake Disable is a digital input which is switched to battery ground whenever a vehicle system such as a traction control device does not want engine braking to occur. The ECM, which controls the engine brake directly, will not allow engine braking when the input is switched to battery ground. Allison Transmission requires that this input be used in all applications using engine brakes. This is to prevent engine brake operation when the transmission is in converter mode. Engine Brake Low The Engine Brake Low digital input selects Low Engine Brake when the input is switched to battery ground. The No Engine Brake option occurs when the Engine Brake Low and Engine Brake Medium digital inputs are not switched to battery ground. This can be overridden by SAE J1939 communications, even if both switches are off (Release 2.00 or later only). To select High Engine Brake both the Engine Brake Low and the Engine Brake Medium digital inputs are switched to battery ground. Engine Brake Medium The Engine Brake Medium digital input selects Medium Engine Brake for Series 60 engines. The No Engine Brake option occurs when the Engine Brake Low and Engine Brake Medium digital inputs are not switched to battery ground. This can be overridden by SAE J1939 communications, even if both switches are off (Release 2.00 or later only). To select High Engine Brake both the Engine Brake Low and the Engine Brake Medium digital inputs are switched to battery ground. Konstantdrossel Switch The Konstantdrossel (KD) digital input selects low engine brake when the input is switched to battery ground. The No Engine Brake option occurs when this digital input is not switched to battery ground. This can be overridden by SAE J1939 communications, even if the switch is off. 4-8 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Programming Requirements and Flexibility These digital inputs may be ordered at the time of engine order, configured by VEPS or DRS. The digital inputs associated with Engine Brake and their function numbers are listed in Table 4-3. Table 4-3 Description Function Number Engine Brake Disable 26 Engine Brake Low 1 Engine Brake Medium 2 Konstantdrossel 40 Engine Brake Digital Inputs All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-9 DIGITAL INPUTS AND OUTPUTS 4.1.3 ENGINE PROTECTION The digital inputs related to engine protection are described in the following sections. Auxiliary Shutdown #1 and #2 The auxiliary shutdown digital inputs (auxiliary shutdown #1 and #2) are used by other vehicle systems when it is desirable to use the ECM's engine protection function. For example, the engine protection function may be used to protect a transmission or pump against failure. When a vehicle system needs the engine to shutdown, a digital input port configured as auxiliary shutdown is switched to battery ground. The ECM can take three types of actions when an auxiliary shutdown digital input port is switched to battery ground: warning, rampdown or shutdown. Refer to section 5.10, "Engine Protection," for more information on engine protection. Diagnostic Request Switch The Diagnostic Request Switch is used to activate the CEL and SEL to flash codes. The SEL will flash the active codes and the CEL will flash the inactive codes. The inactive codes are flashed in numerical order and the active codes are flashed in the order they occur, most recent to least recent. The Diagnostic Request Switch can also be used as the Stop Engine Override (SEO) Switch. The Diagnostic Request Switch is used to flash codes in the following circumstances: The engine is not running and ignition is ON The engine is idling In both circumstances pressing and holding the Diagnostic Request Switch will flash out the engine codes. The codes are flashed out of the ECM connected to the switch. For multi-ECM installations, the Diagnostic Request Switch and SEO are combined on the master ECM. All receiver ECMs have a separate Diagnostic Request Switch. Diagnostic Request Switch/Stop Engine Override Switch A single digital input can be used as a Diagnostic Request Switch and a SEO Switch. The Diagnostic Request Switch is used to activate the CEL and SEL to flash codes. The SEL will flash the active codes and the CEL will flash the inactive codes. The inactive codes are flashed in numerical order and the active codes are flashed in the order they occur, most recent to least recent. The Diagnostic Request Switch is also used as the SEO Switch. The Diagnostic Request Switch is used to flash codes in the following circumstances: The engine is not running and ignition is ON The engine is idling and not in an "engine protection" condition 4-10 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL In both circumstances activating and releasing the Diagnostic Request Switch will flash out the engine codes; activating the Diagnostic Request Switch a second time will stop the ECM from flashing the engine codes. Otherwise, the switch will act as a SEO Switch. The SEO Switch overrides an Engine Protection Shutdown sequence if Shutdown is enabled. Refer to section 5.10, "Engine Protection," for more information on the SEO Switch. The codes are flashed out of the ECM connected to the switch. For multi-ECM installations, the Diagnostic Request and SEO Switch are combined on the master ECM. All receiver ECMs have a separate Diagnostic Request Switch. Programming Requirements and Flexibility The type of engine protection, warning, rampdown or shutdown can be selected with the DDR, DDDL, VEPS, or DRS. The digital inputs listed in Table 4-4 can be configured at the time of engine order, by VEPS or DRS. Description Function Number Diagnostic Request Switch 15 Stop Engine Override/Diagnostic Request Switch 25 Auxiliary Shutdown Protection #1 3 Auxiliary Shutdown Protection #2 4 Table 4-4 Engine Protection Digital Inputs Diagnostics When either Auxiliary Shutdown #1 or #2 is activated, the codes listed in will be logged. Fault Description SID FMI Flash Code Auxiliary Shutdown #1 25 11 26 Auxiliary Shutdown #2 61 11 26 Table 4-5 Auxiliary Shutdown Flash Codes All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-11 DIGITAL INPUTS AND OUTPUTS 4.1.4 ENGINE RATINGS The digital inputs related to engine ratings are described in the following sections. Limiting Torque Curve A digital input activates the limiting torque curve. The limiting torque curve limits the torque with respect to speed whenever this digital input is switched to battery ground. This torque curve is part of the engine rating. Refer to section 5.11, "Engine Ratings," for additional information. Rating Switch #1 and #2 Engine rating switch(es) are digital inputs used to switch between multiple engine ratings stored in the ECM. The first rating is the default rating and does not need to be selected with the digital input switches. Rating Switch #1 selects the second engine rating when the input is switched to battery ground. Rating Switch #2 selects the third engine rating when the input is switched to battery ground. The inputs and their function number are listed in Table 4-6. Description Function Number Rating Switch #1 12 Rating Switch #2 13 Limiting Torque Curve 14 Table 4-6 Rating Switches To select fourth engine rating, typically the cruise-power rating, both Rating Switch #1 and Rating Switch #2 digital inputs are switched to battery ground. The higher rating will activate only if Cruise control is enabled. Refer to section 5.11, "Engine Ratings," for more information. Programming Requirements and Flexibility Limiting torque curve tables are generated by Application Engineering and can either be selected at the time of engine order or selected after engine order by DDC Technical Service. The rating switches function must be enabled with the DDR, DDDL or VEPS. The ECM can hold up to four different engine ratings that can be selected with a DDR or with the use of digital inputs, depending upon application. Engine ratings are determined at the time of engine order. The DDR will display the engine rating choices that can be selected. The digital inputs Rating Switch #1, #2, and Limiting Torque Curve may be configured at the time of engine order, by VEPS, or DRS. Diagnostics The horsepower rating can be monitored on the DDR via the Engine Configuration menu. After a switch change, the DDR must be disconnected and then reconnected to see the hp change. 4-12 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 4.1.5 FAN CONTROL The digital inputs related to fan control are described in the following sections. Refer to section 5.14 for further information on fan control. Air Conditioner Status Operation This digital input indicates that the air conditioner is inactive. When a digital input is configured for air conditioner status and the input is open then the fan is turned ON (A/C switch is open). If A/C input is configured and not used that input must remain grounded for proper fan operation. The digital input logic enables the fan in the event of a broken A/C status wire. The default on-time for the fan is 180 seconds. Vehicle speed over 20 MPH disables the air conditioner control of the fan. Fan Control Override Operation This digital input is used to activate the fan when the input is switched to battery ground. Transmission Retarder Active Operation This digital input indicates that the transmission retarder is active. When the digital input is grounded, the fan is turned off. When the digital input is open, the fan will be turned on. The fan will be ON for a minimum of 30 seconds. Refer to the transmission manufacturers documentation to determine where to connect the input. Programming Requirements and Flexibility The digital inputs listed in Table 4-7 can be configured at the time of engine order, by VEPS, or DRS. Description Function Number Air Conditioner Status 29 Fan Control Override 32 Transmission Retarder Status (Release 2.00 or later only) 27 Table 4-7 Fan Control Digital Inputs The fan on-time can be set with VEPS or DRS as listed in Table 4-8. Parameter Description Choice AC Fan Timer The minimum duration of time the fan will remain ON after the AC status digital input has indicated that the A/C unit has turned OFF. The timer starts when the input is grounded after being open. 0-255 seconds Table 4-8 Fan On-time Parameter All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-13 DIGITAL INPUTS AND OUTPUTS 4.1.6 PRESSURE SENSOR GOVERNOR The digital inputs related to PSG are described in the following sections. Refer to section 5.29, "Pressure Sensor Governor," for additional information. Pressure Enable Switch The PSG enable switch is a digital input switch used to enable the PSG when the digital input is switched to battery ground. If the PSG enable switch is moved to the OFF position (not at battery ground), the PSG will be interrupted. Pressure/RPM Mode Switch This digital input switch is used in the PSG to switch between RPM and pressure mode. When the digital input is switched to battery ground, pressure mode is selected. Decrease (Set/Coast On) The pressure or engine speed is set by momentarily contacting the switch to the decrease position (grounding the digital input). The pressure/RPM setting will decrease by 4 psi (approximately 27.6 kPa) or 25 RPM increments when the decrease switch is momentarily contacted. Holding the switch in the decrease position (grounding the digital input) will decrease the pressure or engine speed. The pressure or engine speed will decrease by 4 psi (approximately 27.6 kPa) or 25 RPM increments at a rate of two increments per second. Releasing the switch sets the pressure/RPM to the lower setting. Increase (Resume/Acceleration On) Momentarily contacting the increase switch at the initiation of PSG operation will set the pressure/RPM setting. The pressure/RPM setting will increase by 4 psi (approximately 27.6 kPa) or 25 RPM increments by momentarily contacting the Increase switch. Holding the switch in the Increase position (grounding the digital input), will increase the pressure or engine speed. The pressure or engine speed will increase by 4 psi (approximately 27.6 kPa) or 25 RPM increments at a rate of two increments per second. Releasing the switch sets the PSG to the higher setting. Programming Requirements and Flexibility The digital inputs listed in Table 4-9can be configured at the time of engine order, by VEPS or DRS. 4-14 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Description Function Number Pressure Sensor Governor Enable 24 Pressure/RPM Mode Switch 8 Set/Coast On (Decrease) 20 Resume/Acceleration On (Increase) 22 Table 4-9 Pressure Sensor Governor Digital Inputs Interaction with Other Features The Increase and Decrease input functions (Set/Coast On and Resume/Accel On) are also used for Cruise Control operation and the Air Compressor Governor. The Increase and Decrease switches follow similar logic as the Cruise Control switches (Set/Coast On and Resume/Accel On). Cruise Control cannot be used with the Pressure Sensor Governor. 4.1.7 THROTTLE CONTROL This section discusses throttle control digital inputs. Alternate Minimum VSG Speed/Fast Idle Operation The Alternate Minimum VSG option (ALT MIN VSG) allows the use of a customer-selected high idle speed instead of the hot idle engine speed. The higher idle speed is called the alternate minimum VSG speed. A higher idle speed is useful in applications such as air compressors and generators. The Alternate Minimum VSG speed is active when a digital input is switched to battery ground. The fast idle input is used instead of resistors on the VSG input to obtain a fast idle engine speed. When the digital input is switched to ground and the engine is running on the idle governor, the engine speed will be changed to the calibrated fast idle speed. Dual Throttle (LSG) Operation Some applications require Limiting Speed Governor controls at two stations. This special configuration is implemented with two EFPAs and a digital input. The digital input is switched to either ground potential or system voltage to indicate which EFPA is active. This configuration allows an EFPA to be at two locations with only one EFPA active at any one time. Refer to section 5.33, "Throttle Controls," for more information and a schematic. External Engine Synchronization/Frequency Input Active External Engine Synchronization provides a method of synchronizing the engine RPM of two or more engines using a frequency signal generated by an external vehicle controller or the tach drive output of another engine. This digital input is one of the required conditions. This also functions as an activation of open collector. Refer to section 5.33.2, "Variable Speed Governor - Nonroad." All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-15 DIGITAL INPUTS AND OUTPUTS Idle Validation Switch Operation An idle validation switch provides redundancy to assure that the engine will be at idle in the event of a throttle malfunction. The idle validation switch is connected to a digital input on the ECM. When the idle validation switch on the EFPA is switched to battery ground, the engine speed will be at idle unless the vehicle is operating in Cruise Control or Cruise Switch VSG. There are fault detection diagnostics with the Idle Validation Switch and its wiring when compared to the Throttle Position Sensor (TPS) input. Throttle Inhibit This option disables the LSG whenever the throttle inhibit digital input is grounded. The operator can depress the throttle pedal, but the engine speed will remain unchanged as long as the digital input is grounded. Throttle inhibit is usually offered as a standard in coach calibrations to inhibit throttle input when the rear door is open, a wheelchair lift is operated, etc. VSG Station Change and VSG Station Change Complement The dual throttle Variable Speed Governor (VSG) feature provides the capability of having VSG throttles at two locations, with only one throttle active at any time. The dual throttle feature requires two digital inputs. DDEC monitors the switch inputs and maintains the current engine RPM when a station switch occurs until the newly selected station is qualified by reducing the station position to idle and then increasing it to the current engine speed position. After qualification, the engine speed is controlled by the new station. If qualification does not occur within 30 seconds, the engine speed will be ramped down from its current value to VSG minimum speed. If the new station becomes qualified, the rampdown process will be stopped and the new station will have control. Refer to section 5.33, "Throttle Control/Governors." VSG Inhibit (Release 28.0 or later) This option disables the analog VSG (wire #510) and ALT MIN VSG whenever the VSG digital input is grounded. Grounding the VSG Inhibit digital input will reduce engine speed to idle. When the ground is removed from the input, the throttle must be reset to zero before engine speed can be increased from idle. Frequency input and J1939 commands are not affected. The engine speed will remain unchanged as long as the digital input is grounded regardless of VSG request. Programming Requirements and Flexibility The digital inputs listed in Table 4-10can be configured at the time of engine order, by VEPS or DRS. VSG Inhibit can be set at the time of engine order, by WinVeps (Release 3.00 or later) or DRS. 4-16 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Description Function Number Alternate Minimum VSG/Fast Idle (Release 2.00 or later only) 16 Dual Throttle (LSG) 28 External Engine Synchronization/Frequency Input Active 10 Idle Validation Switch 6 Throttle Inhibit 9 VSG Station Change 33 VSG Station Change Complement 34 VSG Inhibit (Release 28.00 or later) 42 Table 4-10 4.1.8 Throttle Control Digital Inputs ENGINE SYNCHRO SHIFT TRANSMISSION Two digital inputs are required when an Engine Synchro Shift (ESS) Transmission is installed. Refer to section 5.34, "Transmission Interface," for additional information. In Neutral This digital input is switched to battery ground when the ESS transmission is in neutral. In Gear This digital input is switched to battery ground when the ESS transmission is in gear. ESS Transmission Programming Flexibility The digital inputs listed in Table 4-11can be configured at the time of engine order, by VEPS or DRS. Description Function Number In Neutral 38 In Gear 39 Table 4-11 Engine Synchro Shift Inputs Diagnostics Code 73 (SID 226 FMI 11) will be logged if both switches are grounded at the same time. This should be impossible since the two digital switches occupy the same component. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-17 DIGITAL INPUTS AND OUTPUTS 4.1.9 ADDITIONAL FUNCTIONS The following digital inputs are used for special applications. Auxiliary Coolant Level Switch A digital coolant level switch can be connected to the ECM through a digital input. The digital switch is placed in the coolant tank (see Figure 4-2) to indicate low coolant and is located above the analog coolant level sensor. Figure 4-2 Coolant Level Switch Location When the digital switch is in coolant, the digital input to DDEC is at battery ground. When the coolant level is below the digital switch (digital input open) for a period of time (to ignore the effects of slosh) a digital output is switched to battery ground. The digital output can be used to drive a coolant level low light to avoid a Stop Engine Light event. The light provides a warning that the coolant level is getting low before it gets below the analog Coolant Level Sensor. This will not activate the Maintenance Alert System Add Coolant Level Sensor and will not log a code. If the coolant is below the analog sensor, the engine may be programmed for CEL to come on. Refer to section 4.2, "Digital Outputs," for more information. DDC recommends that the auxiliary coolant level module be used to drive a dash light directly. Refer to section 3.14.20, "Coolant Level Sensor," for additional information. Parking Brake Interlock Operation Several DDEC functions need an indication that the vehicle is stopped before the function can be engaged. By using the parking brake to switch a digital input to battery ground when in use, the ECM can determine that the vehicle is stopped and engage the function. 4-18 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Air Compressor Load Switch Operation The air compressor load switch digital input is used to activate the air compressor control in the ECM. This digital input controls when the ECM will run the engine up to speed to maintain the setpoint pressure. Refer to section 5.1, "Air Compressor Control," for additional information. Throttle Kickdown Operation In determining the throttle position, DDEC IV first determines a throttle position offset to ensure that when the throttle is fully released, the throttle position value is zero, and that it is forced to zero in error conditions as a precaution. However, if the throttle position sensor is configured, the throttle kickdown switch is on, and the throttle position is greater than 94.90%, then the throttle position is automatically considered to be 100%. RPM Freeze Operation The RPM Freeze feature allows the operator to request that the VSG governor maintain the current engine RPM. Locking onto a fixed engine RPM is desirable in applications where the input is subjected to electrical noise which in turn causes the engine RPM to fluctuate. The operator can request that the VSG governor maintain the current engine speed by switching this digital input to battery ground. Programming Requirements and Flexibility The digital inputs listed in Table 4-12can be configured at the time of engine order, by VEPS or DRS. Description Function Number Auxiliary Coolant Level Sensor 31 Parking Brake Interlock 5 Air Compressor Load Switch 35 Table 4-12 Throttle Kickdown 7 RPM Freeze 11 Additional Functions Digital Inputs All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-19 DIGITAL INPUTS AND OUTPUTS 4.2 DIGITAL OUTPUTS DDEC IV has three digital output ports (988,555,499) located on the Vehicle Interface Harness and three digital output ports (563, 564, 565) located on a pigtail off the Engine Sensor Harness. The digital output functions are listed in Table 4-13. Digital Output Function Function Number Section Air Compressor Load Solenoid 21 Refer to section 4.2.1, page 4-22 Cold Engine Operation * (Release 22.00 or later, Series 4000 only) 37 Refer to section 4.2.2, page 4-22 Coolant Level Low Light 10 Refer to section 4.2.3, page 4-23 Cruise Control Active Light (PSG Active Light) 11 Refer to section 4.2.4, page 4-23 Deceleration Light 15 Refer to section 4.2.5. page 4-24 Engine Brake Active 16 Refer to section 4.2.6, page 4-24 Engine Overspeed (Release 29.0 or later) 39 Refer to section 4.2.7, page 4-25 ESS Low Range (Release 5.06 or later) 28 Refer to section 4.2.8, page 4-25 ESS High Range (Release 5.06 or later) 29 Refer to section 4.2.9, page 4-26 Ether Injection (Release 3.00 or later only) 24 Refer to section 4.2.10, page 4-26 External Engine Brake Enable 8 Refer to section 4.2.11, page 4-27 External Engine Synchronization/Frequency Input Active* 4 Refer to section 4.2.12, page 4-27 13 & 14 Refer to section 4.2.13 page 4-28 20 Refer to section 4.2.14, page 4-29 22 Refer to section 4.2.15, page 4-29 19 Refer to section 4.2.16, page 4-30 23 Refer to section 4.2.17, page 4-30 3 Refer to section 4.2.18, page 4-31 18 Refer to section 4.2.19, page 4-31 26 Refer to section 4.2.20, page 4-32 Pressure Sensor Governor Pressure Mode Light 5 Refer to section 4.2.21, page 4-32 Service Now Lamp (Release 31.0 or later) 44 Refer to section 4.2.22, page 4-33 Starter Lockout 7 Refer to section 4.2.23, page 4-34 Top2 Shift Solenoid (Release 4.01 or later) 30 Refer to section 4.2.24, page 4-35 Top2 Lockout Solenoid (Release 4.01 or later) 31 Refer to section 4.2.25, page 4-36 Transmission Retarder 9 Refer to section 4.2.26, page 4-36 Vehicle Power Shutdown 6 Refer to section 4.2.27, page 4-37 VSG Active Indication 17 Refer to section 4.2.28, page 4-38 Fan Control #1 & Fan Control #2 High Coolant Temperature Light (Release 2.00 or later only) High Crankcase Pressure Light (Release 3.00 or later only) High Oil Temperature Light (Release 2.00 or later only) Low Coolant Pressure Light (Release 3.00 or later only) Low DDEC Voltage Warning Light Low Oil Pressure Light (Release 2.00 or later only) Optimized Idle Active Light (Release 4.00 or later only) * Not supported by the Vehicle Electronic Programming System (VEPS) Table 4-13 4-20 Digital Outputs All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The Application Code System (ACS) sets the default function number for each of the six digital output ports. These digital outputs can be configured for various functions. These functions can be configured at the time of engine order, by VEPS or DRS. A digital output function is activated by the ECM when the digital output wire is switched to battery ground, except fan controls #1 and #2. See Figure 4-3. NOTE: Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Figure 4-3 Two Methods to Use a Digital Output All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-21 DIGITAL INPUTS AND OUTPUTS 4.2.1 AIR COMPRESSOR LOAD SOLENOID The air compressor load solenoid digital output is switched to ground to open the air compressor outlet valve to begin loading the air compressor. The output is used to regulate the system pressure. When the output is open, the valve must be off. This digital output is available with DDEC III Release 4.00 or DDEC IV (any release). Refer to section 5.1, "Air Compressor Control," for additional information. Installation Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 21) may be ordered at the time of engine order or configured by VEPS or DRS. 4.2.2 COLD ENGINE OPERATION (SERIES 4000 ONLY) This digital output is switched to ground when either coolant, oil, intercooler, or air temperature falls below specified values. This feature can be used to activate coolant heating systems, extra parasitic loads, or shutters. This digital output is available with Release 22.00 or later. Temperature set points are set by ACS. Installation Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six digital output ports. This digital output (function number 37) may be ordered at the time of engine order or configured by VEPS or DRS. ACS configures the coolant, oil, intercooler, and air temperature limits. 4-22 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 4.2.3 COOLANT LEVEL LOW LIGHT This digital output is switched to battery ground when the coolant falls below the Coolant Level Sensor (CLS) or a digital input configured for an Auxiliary Coolant Switch is open for 30 seconds. This output is typically used to drive a light to warn the operator. The CEL and the SEL will illuminate with this output when the coolant level falls below the CLS. Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 10) may be ordered at the time of engine order or configured by VEPS or DRS. Polarity can be set at order entry or by DDC Technical Service or DRS. Interaction with other Features This digital output could be used with a digital input configured as a Auxiliary Coolant Level Switch. Refer to section 4.1, "Digital Inputs," for additional information. The Auxiliary CLS acts as a digital switch. When the coolant level is below the Auxiliary CLS or analog CLS, the Coolant Level Low Light will illuminate. 4.2.4 CRUISE CONTROL ACTIVE LIGHT (PRESSURE SENSOR GOVERNOR ACTIVE LIGHT) A digital output is switched to battery ground when Cruise Control, Cruise-switch VSG or the Pressure Sensor Governor is active. This digital output could be used to drive a light indicating the active state of the above. Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility The ACS sets the default function number and polarity for each of the six ports. This digital output (function number 11) may be ordered at the time of engine order or configured by VEPS or DRS. Interaction with other Features For VSG operation, use the VSG Active indicator instead of the Cruise Control Active Light. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-23 DIGITAL INPUTS AND OUTPUTS 4.2.5 DECELERATION LIGHT The Deceleration Light option is a light in the back of a vehicle to warn that the vehicle is slowing down. This digital output could be used to drive a Deceleration Light or, more typically, a relay which drives the deceleration lights. This digital output is switched to battery ground whenever the percent throttle is zero and Cruise Control is inactive. Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 15) may be ordered at the time of engine order or configured by VEPS or DRS. 4.2.6 ENGINE BRAKE ACTIVE The Engine Brake Active digital output is switched to battery ground whenever the engine brake is active. This digital output could be used to drive an engine brake active light or give an engine brake active indication to another vehicle system. Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility The ACS sets the default function number and polarity for each of the six ports. This digital output (function number 16) may be ordered at the time of engine order or configured by VEPS or DRS. Polarity can be set at order entry or by DDC Technical Service. 4-24 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 4.2.7 ENGINE OVERSPEED The Engine Overspeed digital output is switched to ground when a calibrated engine overspeed enable speed is exceeded. The output remains closed until the engine speed reaches or drops below another calibrated engine overspeed disable speed. An option is available to log a fault code when the engine speed meets or exceeds the minimum of the overspeed enable speed and rpm overspeed calibrations. The fault that will be logged is PID 190 FMI 14, Flash Code 85 – Engine Overspeed Signal. Installation A low-side digital output circuit is capable of sinking less than or equal to 1.5A and have less than 85 mH of inductance. Programming Requirements & Flexibility ACS Sets the default function number and polarity for each of the six ports. This digital output (function number 39) may be ordered at the time of engine order or configured by DRS. The enable and disable overspeed values can be set at the time of engine order or by the Application Code System (ACS). The fault code option can be turned on at the time of engine order, ACS or DRS. 4.2.8 ENGINE SYNCHRO SHIFT LOW RANGE SOLENOID The ESS Low Range digital output is used to control the low range solenoid on the Meritor® Engine Synchro Shift (ESS) transmission. The correct transmission type must be selected when this digital output is programmed. This digital output is available with Release 5.06 or later only. Installation Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 28) may be ordered at the time of engine order or configured by VEPS or DRS. Polarity can be set at order entry or by DDC Technical Service. Engine Synchro Shift™ and, ESS™ are trademarks of the Meritor Corporation. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-25 DIGITAL INPUTS AND OUTPUTS 4.2.9 ENGINE SYNCHRO SHIFT HIGH RANGE SOLENOID The ESS High Range digital output is used to control the high range solenoid on the Meritor Engine Synchro Shift™ (ESS™) transmission. The correct transmission type must be selected when this digital output is programmed. This digital output is available with Release 5.06 or later only. Installation Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 29) may be ordered at the time of engine order or configured by VEPS or DRS. Diagnostics A code is logged for an open or shorted circuit. 4.2.10 ETHER INJECTION The Ether Injection digital output is switched to battery ground when ether should be injected into the engine for cold start purposes. Installation The digital output must be wired to the Ether Start Relay Module. Refer to section 5.12, "Ether Start," for additional information. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 24) may be ordered at the time of engine order or configured by VEPS or DRS. Diagnostics If the Ether Start digital output remains grounded for longer than a factory set time, the relay module will cause the inline fuse to blow. This prevents excess ether from being injected into the cylinders. If the output is shorted to battery (+), a code will be logged and the CEL will be illuminated. 4-26 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 4.2.11 EXTERNAL ENGINE BRAKE ENABLE This output will be switched to battery ground when the retarder is enabled, Cruise Control is inactive, and the engine retarder level is not 0. Installation Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 8) may be ordered at the time of engine order or configured by VEPS or DRS. 4.2.12 EXTERNAL ENGINE SYNCHRONIZATION/FREQUENCY INPUT ACTIVE When the engine is in external engine synchronization mode this digital output is switched to ground. The output is cycled on and off at 2 Hz if all conditions for external engine synchronization are satisfied except the Sync RPM is less than the minimum Sync RPM. Refer to section 5.33.2 , "Variable Speed Governor - Nonroad." Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 4) may be ordered at the time of engine order or configured by VEPS or DRS. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-27 DIGITAL INPUTS AND OUTPUTS 4.2.13 FAN CONTROL #1 & #2 Two digital outputs provide fan control for three different fan configurations: one single-speed fan, two separate single-speed fans, or one two-speed fan. For additional information, refer to section 5.14, "Fan Control." The first configuration, one single-speed fan, uses Fan Control #1 output to turn a single fan on/off. Fan Control #1 is opened to activate the fan and switched to battery ground to turn the fan off. The second configuration, two separate single-speed fans, uses Fan Control #1 and Fan Control #2 to operate two separate fans independently. The fans are activated by opening Fan Control #1 or #2. The fans are turned off by switching the outputs to battery ground. Fan Control #1 is typically activated by high coolant or oil temperature. Fan Control #2 is typically activated by high intake air temperature. The third configuration, one two-speed fan, uses both fan outputs to drive a two-speed fan. When Fan Control #1 output is opened, the low speed mode is activated. The fan operates in the high speed mode if Fan Control #2 is opened. The fan outputs are always in opposite states with ECM software release prior to R5.05. For R5.05 and after, both fan outputs must be opened for the fan to operate in high speed mode. Installation Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function numbers 13 and 14) may be ordered at the time of engine order or configured by VEPS or DRS. 4-28 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 4.2.14 HIGH COOLANT TEMPERATURE LIGHT This digital output is also switched to ground with the CEL and the SEL when the coolant temperature is above the stop engine code value and EOP is not enabled. This output will be grounded along with the CEL and the SEL when the ignition is cycled ON for the bulb check. This use for a digital output is for release 2.00 or later only. Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 20) may be ordered at the time of engine order or configured by VEPS or DRS. Diagnostics A code is logged for high coolant temperature. 4.2.15 HIGH CRANKCASE PRESSURE LIGHT This digital output is switched to ground with the CEL and the SEL when the crankcase pressure is above the stop engine code value. The output is grounded along with the CEL and the SEL when the ignition is cycled ON for the bulb check. This digital output is available with Release 3.00 or later only. Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 22) may be ordered at the time of engine order or configured by VEPS or DRS. The stop engine pressure threshold is set by the application (6N4C) code. Diagnostics A code is logged for high crankcase pressure. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-29 DIGITAL INPUTS AND OUTPUTS 4.2.16 HIGH OIL TEMPERATURE LIGHT This digital output is switched to battery ground with the CEL if Engine Overtemperature Protection (EOP) is enabled when the oil temperature is above the check engine code value. This digital output is also switched to ground with the CEL and the SEL when the oil temperature is above the stop engine code value and EOP is not enabled.. This output will be grounded along with the CEL and the SEL when the ignition is cycled ON for the bulb check. The output will be switched to ground. This use for a digital output is for Release 2.00 or later only. Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 19) may be ordered at the time of engine order or configured by VEPS or DRS. Diagnostics A code is logged for high oil temperature. 4.2.17 LOW COOLANT PRESSURE LIGHT This digital output is switched to battery ground with the CEL and the SEL when the coolant pressure is below the stop engine code value. The output is grounded along with the CEL and the SEL when the ignition is cycled ON for the bulb check. This use for a digital output is for Release 3.00 or later only. Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 23) may be ordered at the time of engine order or configured by VEPS or DRS. The stop engine pressure threshold is set by the application (6N4C) code. Diagnostics A code is logged for low coolant pressure. 4-30 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 4.2.18 LOW DDEC VOLTAGE WARNING LIGHT This digital output is switched to battery ground when the ECM battery voltage is below a factory set value. This digital output could be used to drive a low DDEC voltage light. Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 3) may be ordered at the time of engine order or configured by VEPS or DRS. Diagnostics A code is generated when the ECM battery voltage falls below a factory set value. 4.2.19 LOW OIL PRESSURE LIGHT This digital output is switched to battery ground with the CEL and SEL when the oil pressure is below the Stop Engine Code value. The output will be grounded along with the CEL and SEL when the ignition is cycled ON for the bulb check. The output will be switched to ground. This use for a digital output is for Release 2.00 or later only. Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 18) may be ordered at the time of engine order or configured by VEPS or DRS. Diagnostics A code is logged for low oil pressure. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-31 DIGITAL INPUTS AND OUTPUTS 4.2.20 OPTIMIZED IDLE ACTIVE LIGHT The Optimized Idle active light digital output will flash at a rate of once every half second while the idle timer is counting down, after the system has initialized. The output will be grounded after the idle timer has timed out and Optimized Idle has become active. The output will be grounded along with the CEL and the SEL when the ignition is cycled ON for the bulb check. This digital output is available with Release 4.00 or later only. For more information on Optimized Idle, refer to section 5.24. Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 26) may be ordered at the time of engine order or configured by VEPS or DRS. Diagnostics A code is logged for an open or shorted circuit. 4.2.21 PRESSURE SENSOR GOVERNOR PRESSURE MODE LIGHT This digital output is switched to battery ground when the PSG pressure mode is activated. This digital output can be used to drive the pressure mode light. For more information, refer to section 5.29, "Pressure Sensor Governor." Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 5) may be ordered at the time of engine order or configured by VEPS or DRS. 4-32 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 4.2.22 SERVICE NOW LAMP The Service Now Lamp (SNL) digital output (function number 44) is switched to battery ground for certain engine critical faults as defined by the product engineers and the 6N4C settings of the Application Code System (ACS). This can be wired as a substitute for the Check Engine Lamp circuit, as a secondary indicator (which activates for fewer fault conditions) in addition to the standard CEL (which activates for all faults), or the normal CEL circuit can be configured to act as a SNL without the need to add a wire nor configure a digital output function. This feature does not affect the engine protection reaction to a fault condition, such as those that provide a WARN/RAMP/STOP setting, because it does not disable any faults. It merely alters the behavior of the dash lamp. The SNL output will also be activated any time a Stop Engine fault is active. Installation If the output is to be used for a light, a 12 or 24 volt light of less than 1.5 A (DC) is needed depending on the ignition source. Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility When the "CEL Faults Excluded" parameter is ENABLED by ACS, the CEL circuit's operation is changed. The CEL will illuminate for an active fault ONLY if the bit corresponding to that FMI (Failure Mode Indicator) within the "fault group" is enabled in the base calibration. These groups are configured by the product engineers in such a way as to conceal alerts that do not require immediate operator action and are more productively serviced during scheduled periodic maintenance, yet maintaining comprehensive engine protection by alerting the operator for fault conditions that can cause immediate harm to the engine or vehicle. For FMIs that are excluded, faults are still logged, but the dash lamp is not activated. If the SNL digital output function is additionally configured, both lamps will illuminate for the same faults. Only the CEL circuit provides the "code flashing" features such as for Maintenance Alert System, however. In this ACS configuration, the CEL (and SNL if configured) will also activate if any inactive or active fault is present for more than programmable number of engine hours, typically equal to less than twice the maximum allowed oil change interval, and a new "SNL FAULT EXPIRED" fault (SID-151 FMI-11) will be logged. When the "CEL Faults Excluded" parameter is DISABLED by ACS, the CEL will function normally while the SNL will not be turned on for those faults whose corresponding FMI within the Fault Group is disabled in the calibration. In this ACS configuration, the SNL (but not the CEL) will also activate if any inactive or active fault within that Fault Group, regardless of whether it activates the dash lamp or not, is present for more than the programmed number of engine hours. The base calibration configurable Fault Groups are listed in Table 4-14. Also shown is an example of Fault Groups, which would typically have certain fault conditions excluded from activating the dash lamp and require the maintenance personnel to inspect and erase inactive codes each periodic maintenance interval. Those in boldtypically have at least one FMI excluded from activating the dash lamp. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-33 DIGITAL INPUTS AND OUTPUTS PID/SID Expiration Applies (Typical Series 4000 Configuration) Air filter Differential Pressure PID107 — Ambient Air Temperature PID 171 — Backup Battery SID 214 — PID 48, PID 108 — Battery Voltage PID 168 — Boost Pressure PID 102 — Calibration Memory SID 253 — Coolant Level PID 111 — PID 20, PID 109 — Coolant Temperature PID 110 — Crankcase Pressure PID 101, PID 153 Yes Engine Speed PID 190 — Exhaust Back Pressure PID 81 Yes Exhaust Temperature PID 173 Yes Fire Pump Pressure PID 73 — Fuel Filter Differential Pressure PID 95 — PID 94, PID 18 Yes Fuel Temperature PID 174 Yes Injection Pressure PID 164 — Fault Group Barometric Pressure Coolant Pressure Fuel Pressure Injector Response Time SID 1–16, 47–50, 72–75 Intercooler Coolant Temperature PID 52 — J1708 Data Link Fault PID 250 — Manifold Air Pressure PID 106 Yes Manifold Air Temperature PID 172 Yes Oil Filter Differential Pressure PID 99 Yes PID 100, PID 19 — Oil Temperature PID 175 Yes Percent Throttle PID 91 — Proprietary Data Link SID 248 — PTO Set Speed PID 187 — PWM #1 SID 57 — PWM #2 SID 58 Yes PWM #3 SID 59 — SRS/TRS SID 21 — — — Oil Pressure All Other Faults Table 4-14 4-34 Base Calibration Configurable Fault Groups All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 4.2.23 STARTER LOCKOUT This digital output is used to disable/enable the starter. This signal is used to inhibit starter reengagement while the engine is running. A battery ground signal means that the starter cannot be reengaged when the engine speed is above a programmable speed (typically 500 RPM). An open circuit means that the starter could be reengaged when the engine is below a programmable speed (typically 60 RPM). The RPM values can be set to any value. These values can be changed by Detroit Diesel Technical Service or on the mainframe. This digital output can also be used to indicate that the engine is running. Installation Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 7) may be ordered at the time of engine order or configured by VEPS or DRS. The RPM values can be set to any value. The values can be selected at time of engine order or selected after engine order by DDC Technical Service. 4.2.24 TOP2 SHIFT SOLENOID The shift solenoid is used to command an automatic shift between the top two gears in a Eaton® Top2™ transmission. When the output is grounded, the shift solenoid commands a shift to the top gear position. When the output is not grounded, the shift solenoid commands a shift to the gear one lower than the top position. The correct transmission type must be selected when this digital output is programmed. This digital output is available with Release 4.01 or later only. For additional information on Top2, refer to section 5.34, "Transmission Interface." Installation Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 30) may be ordered at the time of engine order or configured by VEPS or DRS. Diagnostics A code is logged for an open or shorted circuit. Eaton® and Top2™ trademarks of the Eaton Corporation. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-35 DIGITAL INPUTS AND OUTPUTS 4.2.25 TOP2 SHIFT LOCKOUT SOLENOID The shift lockout solenoid is used to disable the driver splitter position switch in an Eaton Top2 transmission. When this output is grounded, the splitter position control is taken away from the driver and controlled by the ECM. The correct transmission type must be selected. This digital output is available with Release 4.01 or later only. For additional information on Top2, refer to section 5.34, "Transmission Interface." Installation Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 31) may be ordered at the time of engine order or configured by VEPS or DRS. Diagnostics A code is logged for an open or shorted circuit. 4.2.26 TRANSMISSION RETARDER This digital output is switched to battery ground whenever the throttle is in at 0% position and cruise control is inactive. This signal in conjunction with a relay, may be used to control a transmission retarder. This output will also be enabled if a SAE J1922 or J1939 data link message is received requesting transmission retarder. Installation Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 9) may be ordered at the time of engine order or configured by VEPS or DRS. 4-36 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 4.2.27 VEHICLE POWER SHUTDOWN This digital output actuates a relay that shuts down the rest of the electrical power to the vehicle. See Figure 4-4. This illustration provides a method to turn OFF the ignition when vehicle electrical power is shutdown. Refer to section 5.18, "Idle Timer and Vehicle Power Shutdown." Figure 4-4 Vehicle Power Shutdown Installation Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 6) may be ordered at the time of engine order or configured by VEPS or DRS. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 4-37 DIGITAL INPUTS AND OUTPUTS Diagnostics A code is logged for an open or shorted circuit. Interaction with Other Features Vehicle Power Shutdown is used with Idle Timer Shutdown, and required for Optimized Idle, or Engine Protection Shutdown. 4.2.28 VSG ACTIVE INDICATION The VSG Active indication is used for electric drive vehicles. This digital output is used to keep the vehicle from creeping by disconnecting the wheel motor contacts while the vehicle is stopped and the engine is operating. When the ECM detects that the VSG counts are greater than 140, the output is switched to battery ground. If the VSG counts drop below 100, the output is opened. Installation Digital output circuits are designed to sink no more than 1.5 A (DC) current and have less than 85 mH of inductance. Programming Requirements and Flexibility ACS sets the default function number and polarity for each of the six ports. This digital output (function number 17) may be ordered at the time of engine order or configured by VEPS or DRS. Interaction with Other Features For Cruise Control state, use the Cruise Control Active Light instead of this output. 4-38 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5 DDEC FEATURES Section Page 5.1 AIR COMPRESSOR CONTROL ............................................................. 5-3 5.2 ANTI-LOCK BRAKE SYSTEMS .............................................................. 5-9 5.3 CRUISE CONTROL ................................................................................ 5-13 5.4 CRUISE CONTROL FOR DRILLING/PUMPING APPLICATIONS WITH OPTIONAL DUAL STATION CONTROL ................................................. 5-21 5.5 DIAGNOSTICS ........................................................................................ 5-23 5.6 EDM AND AIM ........................................................................................ 5-27 5.7 ELECTRONIC FIRE COMMANDER ....................................................... 5-31 5.8 ELECTRONIC SPEED SWITCH ............................................................. 5-35 5.9 ENGINE BRAKE CONTROLS ................................................................ 5-39 5.10 ENGINE PROTECTION .......................................................................... 5-45 5.11 ENGINE RATINGS .................................................................................. 5-57 5.12 ETHER START ........................................................................................ 5-61 5.13 EXTERNAL ENGINE SYNCHRONIZATION ........................................... 5-65 5.14 FAN CONTROL ....................................................................................... 5-69 5.15 FUEL ECONOMY INCENTIVE ............................................................... 5-83 5.16 GLOW PLUG CONTROLLER ................................................................. 5-85 5.17 HALF ENGINE IDLE ............................................................................... 5-89 5.18 IDLE SHUTDOWN TIMER AND VEHICLE POWER SHUTDOWN ........ 5-91 5.19 IRIS ......................................................................................................... 5-97 5.20 LOW GEAR TORQUE LIMITING ............................................................ 5-105 5.21 MAINTENANCE ALERT SYSTEM .......................................................... 5-107 5.22 MANAGEMENT INFORMATION PRODUCTS ........................................ 5-131 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-1 DDEC FEATURES 5.23 MARINE CONTROLS ............................................................................. 5-175 5.24 OPTIMIZED IDLE .................................................................................... 5-179 5.25 OPTIMUM LOAD SIGNAL ...................................................................... 5-185 5.26 OVERALL GOVERNOR GAIN ................................................................ 5-187 5.27 PASSMART ............................................................................................. 5-189 5.28 PASSWORDS ......................................................................................... 5-193 5.29 PRESSURE SENSOR GOVERNOR ...................................................... 5-197 5.30 PROGRESSIVE SHIFT ........................................................................... 5-203 5.31 PULSE TO VOLTAGE MODULE ............................................................. 5-209 5.32 TACHOMETER DRIVE ............................................................................ 5-213 5.33 THROTTLE CONTROL/GOVERNORS ................................................... 5-215 5.34 TRANSMISSION INTERFACE ................................................................ 5-233 5.35 TRANSMISSION RETARDER ................................................................ 5-253 5.36 VEHICLE SPEED LIMITING ................................................................... 5-255 5.37 VEHICLE SPEED SENSOR ANTI-TAMPERING .................................... 5-257 5-2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.1 AIR COMPRESSOR CONTROL Air Compressor Controlis an optional DDEC feature that allows DDEC to regulate engine speed and load/unload a valve in order to maintain a requested compressor outlet air pressure for air compressor applications. The DDEC Air Compressor Control Feature is available with the following software releases: DDEC III - Release 4.0 (only) DDEC IV - all software versions (Release 20.0 or later) 5.1.1 OPERATION The ECM monitors the air outlet pressure while varying the engine speed and operating load/unload a valve. The valve will be opened or closed. The desired operating pressure may be varied by the operator, within limits preset by the OEM. The ECM will activate the Air Compressor Governor Controls when the digital input “Air Compressor Load Switch” is grounded. Engine speed is governed based on the actual air compressor outlet pressure versus the desired output pressure. The Air Compressor Pressure Sensor provides a pressure signal to the ECM. The engine response to various pressure conditions is listed in Table 5-1. Result Pressure Set Point Current outlet pressure is below the pressure set point Pressure in the system continues to increase and a threshold pressure is exceeded Current outlet pressure is above the pressure set point Engine speed increases as required up to PTO maximum speed* The air compressor solenoid digital output is enabled† (opened) Engine speed decreases as required down to the minimum PTO speed. * The engine will continue to run at PTO maximumuntil the outlet pressure matches the sensor pressure. † DDEC will open and close the loading valve as a function of pressure with hysteresis. When the pressure reaches a programmable limit above the pressure set point the DDEC digital output will be grounded. This output may be used to either open an air compressor vent or close the air inlet. Once the air pressure has dropped to a lower programmable limit, the digital output will be open circuited which will either close the vent Table 5-1 Engine Operation with Air Compressor Controls Each horsepower rating has an associated pressure range. Horsepower ratings are defined at time of order entry. The minimum and maximum pressure setting for each of the horsepower curves is set with the DDDL/DDR, Vehicle Electronic Programming System (VEPS), or DRS. The initial pressure set point is saved between ignition cycles. Increase (Resume/Acceleration On) Momentarily toggling and releasing the Increase Switch (grounding the "Resume/Acceleration On" digital input) increases set point pressure by 4% of the pressure range. Holding the switch in the increase position (grounding the digital input), will increase the set point pressure at a rate of two increments per second. Releasing the switch sets the compressor controls to the higher setting. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-3 DDEC FEATURES Decrease (Set/Coast On) Momentarily toggling and releasing the decrease switch decreases set point pressure by 4% of the pressure range. See Figure 5-1. Holding the switch in the decrease position (grounding the digital input), will decrease the set point pressure at a rate of two increments per second. Releasing the switch sets the compressor controls to the lower setting. Air Compressor Load Switch Closing (grounding) the air compressor load switch digital input activates the air compressor control system. See Figure 5-1. Opening the air compressor load switch digital input deactivates the air compressor control system. Air Compressor Solenoid When the pressure reaches a programmable limit above the pressure set point the DDEC digital output will be grounded. This output may be used to either open an air compressor vent or close the air inlet. Once the air pressure has dropped to a lower programmable limit, the digital output will be open circuited which will either close the vent or open the air inlet. Air Compressor Shutdown DDEC will respond to a proprietary immediate engine shut down message sent over the SAE J1587/J1708 data link by the Electronic Display Module (EDM). This feature requires both an EDM and an Auxiliary Information Module (AIM); refer to section 5.6 for addition information on EDM and AIM. Multiple Pressure Ratings The pressure ranges are linked to the engine ratings. A pressure range can be associated with each rating. The maximum number of engine ratings and pressure ranges is three. Choosing the rating, with the DDR/DDDL or rating switches will automatically select the associated pressure range. The proper 6N4D group with multiple 6N4M groups must be specified. For additional information, contact your DDC Applications Engineer. 5-4 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.1.2 INSTALLATION See Figure 5-1 for the Air Compressor Control Harness. Figure 5-1 Air Compressor Control Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-5 DDEC FEATURES 5.1.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY Air Compressor Controls must be specified at the time of engine order or added to the ECM calibration by Detroit Diesel Technical Service. An Application Code (6N4C) Group must be selected that is configured for Air Compressor Control at order entry or by contacting Detroit Diesel Technical Service. The digital outputs and inputs listed in Table 5-2 are required for Air Compressor Controls and must be configured by order entry, VEPS, or the DRS. Description Type Function Number Set/Coast On (Decrease) Digital Input 20 Resume/Acceleration On (Increase) Digital Input 22 Air Compressor Load Switch Digital Input 35 Air Compressor Solenoid Digital Output 21 Table 5-2 Air Compressor Control Required Digital Inputs and Outputs At order entry, the Application Code System (ACS) sets the default values for the parameters listed in Table 5-3. These parameters may be modified using either VEPS or DRS. Parameter Description Choice/Display Air Compressor Integral Gain Integral Gain 0-128 RPM/(PSI x SEC) Air Compressor Proportional Gain Proportional Gain 0-128 RPM/PSI Percent Pressure Increment 0-50% (of fuel scale pressure range) Air Compressor Pressure Increment Table 5-3 Air Compressor Control Parameters Multiple pressure ratings can be selected with the use of rating switches. The proper 6N4D groups with multiple 6N4M groups must be specified at engine order or by Detroit Diesel Technical Service. The digital inputs listed in Table 5-4 are required. Description Type Function Number Rating Switch #1 Digital Input 12 Rating Switch #2 Digital Input 13 Table 5-4 Multiple Pressure Ratings Required Digital Inputs The VSG maximum and minimum RPM can be set with VEPS, DRS, DDR or DDDL as listed in Table 5-5. 5-6 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Parameter Description Choice/Display VSG Minimum RPM Sets the VSG minimum speed. Idle to VSG, Maximum RPM VSG Maximum RPM Sets the VSG maximum speed. VSG Minimum RPM to (Rated Speed + LSG Droop) Variable Speed Governor Maximum and Minimum RPM Table 5-5 The minimum and maximum pressure is set with the DDDL/DDR, DRS or VEPS as listed in Table 5-6. There is a minimum and maximum pressure setting for each of the horsepower curves. Parameter LOAD PSI UNLOAD PSI MAX RAT#1 PSI MIN RAT#1 PSI MAX RAT #2 PSI MIN RAT#2 PSI MAX RAT#3 PSI MIN RAT #3 PSI Table 5-6 5.1.4 Description Indicates the delta value above the current air pressure set point that will initiate the air compressor governor to reload the system. Indicates the delta value above the current air pressure set point that will initiate the air compressor governor to unload the system. Indicates the maximum allowable air pressure set point for engine rating #1 Indicates the minimum allowable air pressure set point for engine rating #1. Indicates the maximum allowable air pressure set point for engine rating #2. Indicates the minimum allowable air pressure set point for engine rating #2. Indicates the maximum allowable air pressure set point for engine rating #3. Indicates the minimum allowable air pressure set point for engine rating #3. Range 0 to UNLOAD PSI LOAD PSI to 31 PSI MIN RAT#1 to 999 PSI 0 to MAX RAT#1 MIN RAT#2 to 999 PSI 0 to MAX RAT#2 MIN RAT#3 to 999 PSI 0 to MAX RAT#3 Air Compressor Parameters INTERACTION WITH OTHER FEATURES Air Compressor Control may not be used with Cruise Control or the Pressure Sensor Governor. A proprietary immediate engine shut down message for immediate air compressor shutdown is sent over the SAE J1587/J1708 data link by the EDM. This feature requires both an EDM and an AIM; refer to section 5.6 for addition information on EDM and AIM. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-7 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-8 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.2 ANTI-LOCK BRAKE SYSTEMS Anti-lock Brake Systems (ABS) are electronic systems that monitor and control wheel speed during braking. The systems are compatible with standard air brake systems. The system monitors wheel speed at all times, and controls braking during emergency situations. Vehicle stability and control are improved by reducing wheel lock during braking. 5.2.1 OPERATION The ECM transmits engine data via SAE J1587, SAE J1922, or SAE J1939. Anti-lock brake systems monitor data on one or more of these communication links. In the event that an excessive wheel spin is detected, the ECM receives a message from the ABS requesting a 0% output torque limit. The message is transmitted on SAE J1922 or SAE J1939. SAE J1922 and SAE J1939 both implement the same message set. The difference being hardware and performance. SAE J1922 transmits and receives data at 9.6 K baud while SAE J1939 transmits/receives data at 250 K baud. SAE J1939 has a much higher bit rate so messages reach their destination very quickly nearly eliminating the latency found with SAE J1922. SAE J1922 is enabled on all DDEC IV ECMs. SAE J1939 is enabled on all DDEC IV ECMs (Release 24.0 or later). ECMs prior to Release 24.0 must be configured if SAE J1939 is required. See Figure 5-2 and Figure 5-3 for interface with Meritor/WABCO and Bosch respectively. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-9 DDEC FEATURES Figure 5-2 5-10 Meritor/WABCO ABS/ATC Interface All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 5-3 Bosch ABS/ATC Interface All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-11 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-12 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.3 CRUISE CONTROL Cruise Control is available with any DDEC engine. Cruise Control will operate in either Engine or Vehicle Speed Mode and maintain a targeted speed (MPH or RPM) by increasing or decreasing fueling. The targeted speed can be selected and adjusted with dash-mounted switches. Up to five digital inputs are required (four for automatic transmission) for Cruise Control operation and a digital output is optional (refer to section 4.1.1 for additional information on digital inputs). A Vehicle Speed Sensor (VSS) is required for Vehicle Speed Cruise Control. 5.3.1 OPERATION There are two types of Cruise Control: Engine Speed Cruise Control and Vehicle Speed Cruise Control. Engine Speed Cruise Control Power is varied under Engine Speed Cruise Control to maintain constant engine speed. Vehicle speed will vary depending on powertrain components. Engine Speed Cruise Control does not need a VSS. Engine Speed Cruise Control cannot be used with automatic transmissions. Vehicle Speed Cruise Control Vehicle Speed Cruise is enabled when "Enable Cruise" and a Vehicle Speed Sensor (VSS) are installed. Engine speed and power are varied under Vehicle Speed Cruise Control to maintain the set vehicle speed. The maximum Cruise Control speed cannot exceed the programmed maximum Vehicle Speed Limit (when programmed). The vehicle speed must be above 20 MPH and the engine speed above 1,100 RPM (1,000 RPM for on-highway 1999 model year or later engines) to set Cruise Control. This type of Cruise Control is required when either of the following conditions exists: Vehicle Speed Limiting -- Vehicle Speed Cruise Control is mandatory if the vehicle speed limit is programmed and Cruise Control is desired. This will prevent the ECM from fueling the engine at speeds greater than the vehicle speed limit. Automatic Transmissions -- Vehicle Speed Cruise Control must be selected if the vehicle is equipped with an automatic transmission. This will ensure proper transmission upshifts while in Cruise Control. Refer to the transmission manufacturer's manual for more information and see the Vehicle Interface Harness schematic. Cruise control can be overridden at any time with the foot pedal if the vehicle is not operating at the programmed Vehicle speed Limit. Smart Cruise The Eaton® Smart Cruise™ system will send a "heart beat" message on the SAE J1939 Data Link. Manual Cruise Control and Smart Cruise will be disabled if the message is not received over the data link or the message indicates that there is a failure in Smart Cruise. To regain manual control, the driver must toggle the Cruise Master Switch twice within 10 seconds. Eaton® and Smart Cruise™ trademarks of the Eaton Corporation. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-13 DDEC FEATURES This feature is available with Release 27.0 or later. Smart Cruise must be configured by VEPS (Release 27.0 or later), WinVeps (Release 2.0 or later) or the DRS. For additional information on Smart Cruise, contact Eaton Corporation. Cruise Enable Cruise Control is enabled, but not active when the Cruise Control Enable digital input is switched to battery ground. Set / Coast On Set: Cruise Speed is set by momentarily contacting the switch to the ON position (switching the digital input to battery ground). Cruise Control will become active and maintain the engine or vehicle speed present at the time. Coast: When Cruise Control is active, the Set/Coast input can be used to reduce power and speed by toggling the switch. Momentarily toggling and releasing the Set/Coast switch will decrease the set point by 1 MPH increments for Vehicle Speed Cruise Control and 25 RPM increments for Engine Speed Cruise Control. Holding the Set/Coast will decrease the set point by 1 MPH per second (Vehicle Speed CC) or 25 RPM per seconds (Engine Speed CC). When released the Cruise Control set point will be at the new speed. Resume / Accel On Resume: If Cruise Control has been disabled with the service brake or the clutch switch, momentary contact to the ON position (switching the input to battery ground) restores the previously set cruise speed. Accel: When Cruise Control is active, the Resume/Accel input can be used to increase power and speed by toggling the switch. Momentarily toggling and releasing the Resume/Accel switch will increase the set point by 1 MPH increments for Vehicle Speed Cruise Control and 25 RPM increments for Engine Speed Cruise Control. Holding the Resume/Accel will increase the set point by 1 MPH per second (Vehicle Speed CC) or 25 RPM per seconds (Engine Speed CC). When released the Cruise Control set point will be at the new speed. 5-14 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Clutch Released (Manual Transmissions) This input indicates that the clutch is released and is used for suspending Cruise Control and Auto Resume. When the clutch is released, the input is at battery ground. Cruise Control is suspended if the clutch is depressed once. If the clutch is depressed twice within three seconds, Cruise Control is automatically resumed. NOTE: When engine brake is configured and auto resume is enabled, the first time the clutch is depressed to suspend Cruise Control, the engine brakes will be delayed for three seconds. The digital input logic for the Clutch Switch disables Cruise Control in the unlikely event of a broken clutch switch wire. Service Brake Released (Automatic and Manual Transmissions) This input indicates that the brake is released when switched to battery ground. If the brake is activated, then the input is not grounded and Cruise Control is suspended. Cruise Control is resumed by using the Resume/Accel Switch. The input logic for the Brake Switch disables Cruise Control in the unlikely event of a broken brake switch wire. 5.3.2 INSTALLATION The following is a list of switches that are required for Cruise Control operation. Cruise Enable Switch Brake Switch Clutch Switch -- optional for automatic transmissions Set/Coast Switch Resume/Accel Switch Cruise Active Light -- optional All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-15 DDEC FEATURES See Figure 5-4 for a diagram of the Cruise Control circuit. Figure 5-4 5-16 Cruise Control Circuit All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.3.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY To configure an engine for Cruise Control, the digital inputs, output and VSS settings listed in Table 5-7 must be selected either with the Vehicle Electronic Programming System (VEPS), the DDEC Reprogramming System (DRS) or on engine order entry. The required and optional digital inputs and outputs are listed in Table 5-7. Description Type Function Number Service Brake Released Digital Input 17 Set/Coast Digital Input 20 Resume/Accel Digital Input 22 Cruise Control Enable Digital Input 23 Digital Input 18 Digital Output 11 Clutch Released (required for manual transmissions) Cruise Control Active Light (optional for Cruise Control) Table 5-7 Cruise Control Related Digital Input and Output Signals A Vehicle Speed Sensor must be configured for Vehicle Speed Cruise Control. Refer to section 3.14.25, "Vehicle Speed Sensor," for additional information. If Eaton Smart Cruise is installed on the vehicle, the feature as listed in Table 5-8 must be enabled by VEPS or DRS. Parameter Description Choice Adaptive Cruise Control (Smart Cruise) Enables or disables the Smart Cruise Control feature. YES, NO Table 5-8 Smart Cruise Parameter The Cruise Control parameters listed in Table 5-9 can be set by order entry, DDR, DDDL, the DRS, or VEPS. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-17 DDEC FEATURES Parameter CRUISE CONTROL Description Range Enables or disables the vehicle speed Cruise Control feature. MIN CRUISE SPEED Sets the maximum cruise speed in MPH or KPH. MAX CRUISE MPH or KPH Sets the maximum cruise speed in MPH or KPH. AUTO RESUME CRUISE SWITCH VSG INITIAL VSG SET SPEED RPM INCREMENT CRUISE/ENGINE BRAKE FEATURE CRUISE/ENGINE BRAKE ACTIVATION SPEED ENG BRAKE INCREMENT MPH or KPH MAX OVERSPEED LIMIT MAX SPEED NO FUEL Table 5-9 5.3.4 Enables or disables the automatic Cruise Control set speed resume feature. Enables or disables the cruise switch VSG set speed feature. YES, NO 20 MPH to MAX CRUZ SPD MIN CRUZ to Vehicle Speed Limit or 127 mph if VSL = NO YES, NO YES, NO VSG MIN RPM to VSG MAX RPM Sets the cruise switch VSG initial set speed. Sets the cruise switched VSG RPM increment. Enables or disables the feature that allows the engine brake to be used while on Cruise Control if the vehicle exceeds the cruise set speed. Sets the additional speed before the engine brake is applied to slow down the vehicle. The engine brake is activated at low level unless the operator has turned off the engine brakes with the dash board switches. Sets the additional incremental speed that must be reached before the engine brake will activate the medium and/or high level of retardation. Sets the vehicle speed above which a diagnostic code will be logged if the driver fuels the engine and exceeds this limit. Entering a 0 will disable this option. Sets the vehicle speed above which a diagnostic code will be logged if the vehicle reaches this speed without fueling the engine. Entering a 0 will disable this option. 1 to 255 RPM YES, NO 0 to 10 MPH 1 to 5 MPH 0 to 127 MPH 0 to 127 MPH Cruise Control Parameters DIAGNOSTICS Two faults (SID 216 FMI 14 and PID 86 FMI 14) will be logged simultaneously if Smart Cruise is enabled and the data is not being received, the received data is bad or the Smart Cruise unit has been removed. If these faults are received in addition to an SAE J1939 Data Link failure (SID 231 FMI 12), then the problem is with the SAE J1939 Data Link itself. 5-18 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.3.5 INTERACTION WITH OTHER FEATURES The Cruise Control logic is also used with the DDEC Pressure Sensor Governor in fire trucks. Both systems cannot be configured on the same engine. Refer to section 5.29 for more information on the Pressure Sensor Governor. DDEC can be configured to allow the engine brakes to activate during Cruise Control operation. NOTE: Cruise Control maximum speed cannot exceed the vehicle speed limit. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-19 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-20 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.4 CRUISE CONTROL FOR DRILLING/PUMPING APPLICATIONS WITH OPTIONAL DUAL STATION CONTROL Cruise control for drilling/pumping applications is an optional DDEC feature that allows the setting of a targeted engine speed and a easy return to the targeted speed from idle. For example, petroleum mud pumps are used to supply fluid to a drilling bit when a well is being drilled. The operator will carefully adjust engine speed until he/she achieves the desired pumping rate. The optimum speed will vary from job to job. The operator will continue until a new section of drilling pipe must be added. At that point, the engine must be brought back to idle and the transmission or clutch disengaged while new pipe is threaded in place. The operator can then bring the engine back up to operating speed and continue the drilling and pumping operation. 5.4.1 OPERATION This feature allows the operator to set an engine speed during the drilling and pumping process, drop to idle speed, and then return to the original speed. Returning to the original set speed is desirable since it has been carefully dialed in by the operator and is ideal for the particular job. The Engine Speed Cruise Control feature would work to provide the desired engine set speed for the pumping operation, but it is not configured to resume speed from engine idle. This process operates as follows: 1. Start the engine, idle, and warm up. 2. Engage the ALT_MIN_VSG Switch - engine goes to ALT_MIN_VSG speed (e.g. 650 rpm). 3. Engage the Cruise Enable Switch. 4. Adjust the hand throttle to the desired speed, e.g. 1700 rpm. 5. Engage set/coast - sets speed to the desired speed, 1700 rpm. 6. Adjust the hand throttle back to idle position. 7. When the need to add pipe arises, engage the brake switch. The engine drops to 650 rpm. 8. When ready to continue, engage Resume/Accel and the speed returns to 1700 rpm. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-21 DDEC FEATURES 5.4.2 PROGRAMMING REQUIREMENTS & FLEXIBILITY The hardware and software configuration include the proper 6N4C group for VSG engine governing such as 06N04C0720 and customer selectable parameters. The customer selectable parameters settings are listed in Table 5-10. Parameter Description Cruise Control Enable Enables the engine speed cruise control feature. YES Sets the Alternate Minimum VSG speed 650 RPM (set above the idle speed) Alternate Minimum VSG Table 5-10 Setting Customer Selectable Parameters The digital inputs listed in Table 5-11 must be programmed. Description Type Function Number Cruise Enable Digital Input 23 Set/Coast Digital Input 20 Resume/Accel Digital Input 22 Service Brake Digital Input 17 Alt Min VSG Digital Input 16 Table 5-11 5.4.3 Digital Inputs DUAL STATION CONTROLS This feature will also work with dual control stations. The operator has the capability of starting the engine at Station 1 mounted near the engine, follow the operation procedure above, and while at the desired operating speed, switch to throttle Station 2 and adjust engine speed remotely, if desired. The operator could then switch back to Station 1 when pipe was to be added. For dual station controls, the digital inputs listed in Table 5-10 are required in addition to the digital inputs listed in Table 5-12. Description Type Function Number VSG Station Change Digital Input 33 VSG Station Change Complement Digital Input 34 Table 5-12 Additional Dual Station Control Digital Inputs For additional installation information on VSG Dual Station Controls, refer to section, 4.31 "Throttle Controls/Governors". 5-22 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.5 DIAGNOSTICS Diagnostics is a standard feature of the DDEC system. The purpose of this feature is to provide information for problem identification and problem solving in the form of a code. The ECM continuously performs self diagnostic checks and monitors the other system components. Information for problem identification and problem solving is enhanced by the detection of faults, retention of fault codes and separation of active from inactive codes. 5.5.1 OPERATION The engine-mounted ECM includes control logic to provide overall engine management. System diagnostic checks are made at ignition on and continue throughout all engine operating modes. Sensors provide information to the ECM regarding various engine and vehicle performance characteristics. The information is used to regulate engine and vehicle performance, provide diagnostic information, and activate the engine protection system. Instrument panel warning lights (see Figure 5-5), the Check Engine Light (CEL) and the Stop Engine Light (SEL), warn the engine operator. The CEL is an amber light and the SEL is a red light. Figure 5-5 Typical Diagnostic Request/SEO Switch and Warning Lights All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-23 DDEC FEATURES The CEL is illuminated and a code is stored if an electronic system fault occurs. This indicates the problem should be diagnosed as soon as possible. The ECM illuminates the CEL and SEL and stores a malfunction code if a potentially engine damaging fault is detected. These codes can be accessed in one of four ways: Using the Diagnostic Data Reader (DDR) Flashing the CEL and SEL with the Diagnostic Request Switch (may be combined with Stop Engine Override switch, see Figure 5-5) Using the Detroit Diesel Diagnostic Link™ (DDDL) PC software package By ProDriver®, Electronic Fire Commander™, Electronic Display Module (EDM), or other display There are two types of diagnostic codes: An active code - a fault present at the time when checking for codes An inactive code - a fault which has previously occurred; inactive codes are logged into the ECM and time stamped with the following information: First occurrence of each diagnostic code in engine hours Last occurrence of each diagnostic code in engine hours Total time in seconds that the diagnostic code was active 5-24 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Diagnostic Request Switch The Diagnostic Request Switch is used to activate the CEL/SEL to flash codes. Active codes are flashed on the SEL and inactive codes are flashed on the CEL (see Figure 5-6). Inactive codes are flashed in numerical order, active codes are flashed in the order received, most recent to least recent. The Diagnostic Request Switch can also be used as the Stop Engine Override (SEO) Switch. The codes are flashed out of the ECM connected to the switch. Figure 5-6 Flash Codes NOTE: For multi-ECM installations, the Diagnostic Request Switch and SEO are combined on the master ECM. All receiver ECMs have a separate Diagnostic Request Switch. The Diagnostic Request Switch is used to flash codes in the following circumstances: The engine is not running and ignition is ON The engine is idling In both circumstances, activating and holding the Diagnostic Request Switch will flash out the diagnostic codes. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-25 DDEC FEATURES Diagnostic Request Switch/Stop Engine Override If no separate Diagnostic Request Switch is configured, the SEO Switch serves as both a Diagnostic Request Switch and an SEO Switch. The Diagnostic Request/Stop Engine Override Switch is used to flash codes in the following circumstances: The engine is not running and ignition is on The engine is idling In both circumstances, activating and releasing the switch will flash out the diagnostic codes; activating and releasing the switch a second time will stop the ECM from flashing the diagnostic codes. Codes will also cease flashing if the engine is no longer at idle. The codes are flashed out of the ECM connected to the switch. NOTE: For multi-ECM installations, the Diagnostic Request Switch and SEO Switch are combined on the master ECM. All receiver ECMs have a separate Diagnostic Request Switch. 5.5.2 DEFINITIONS AND ABBREVIATIONS Parameter Identification Character (PID): A PID is a single byte character used in SAE J1587 messages to identify the data byte(s) that follow. PIDs in the range 0-127 identify single byte data, 128-191 identify double byte data, and 192-253 identify data of varying length. Subsystem Identification Character (SID): A SID is a single byte character used to identify field-repairable or replaceable subsystems for which failures can be detected or isolated. SIDs are used in conjunction with SAE standard diagnostic codes defined in SAE J1587 within PID 194. Failure Mode Identifier (FMI): The FMI describes the type of failure detected in the subsystem and identified by the PID or SID. The FMI and either the PID or SID combine to form a given diagnostic code defined in SAE J1587 within PID 194. Flashing Codes: Provides a two digit number (see Figure 5-6). This code may cover several specific faults. It is provided to advise the operator of the general severity of the fault so the operator can decide if engine operation can continue without damaging the engine. Refer to Appendix A for a list of codes, the code number when flashed, the SAE J1587 number and a description of each code. 5-26 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.6 EDM AND AIM The Construction and Industrial Electronic Display Module (EDM) and Auxiliary Information Module (AIM) are the two components which comprise the Detroit Diesel Construction and Industrial Electronic Display system for engine and equipment parameters. 5.6.1 OPERATION The EDM (see Figure 5-7) may be used alone to display engine parameters or in conjunction with the AIM to display additional equipment parameters. AIM cannot be used without the EDM. Figure 5-7 Electronic Display Module The EDM will display the following parameters at all times if the sensor is installed on the equipment: Engine RPM Engine Coolant or Oil Temperature (Oil Temperature only when coolant temperature is unavailable from the ECM) Engine Oil Pressure ECM Battery Voltage or Auxiliary Current (Requires AIM) - (Battery Voltage display) Vehicle Speed or Auxiliary Pump Pressure or Engine Load Equipment Temperature or Pressure (Requires AIM) Equipment Temperature or Pressures (Requires AIM) or Engine Turbo Boost Pressure Fuel Level (Requires AIM) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-27 DDEC FEATURES Check and Stop Indicators The AIM (see Figure 5-8) is used in conjunction with the EDM to display additional equipment parameters. Figure 5-8 5.6.2 Auxiliary Interface Module INSTALLATION For information on installing the Construction and Industrial EDM and AIM refer to the Construction & Industrial EDM and AIM Installation and Troubleshooting manual (7SA801). 5.6.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY Refer to Construction & Industrial EDM and AIM Installation and Troubleshooting manual (7SA801). 5-28 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.6.4 INTERACTION WITH OTHER FEATURES DDEC installations equipped with both the EDM and AIM may initiate engine shutdowns based on equipment parameters. The shutdown option include the standard 30 second shutdown as well as an option for an immediate engine shutdown. 5.6.5 DIAGNOSTICS Refer to the Construction & Industrial EDM and AIM Installation and Troubleshooting manual (7SA801). All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-29 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-30 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.7 ELECTRONIC FIRE COMMANDER The Detroit Diesel Electronic Fire Commander™ (EFC) is designed to support DDEC III and DDEC IV engines in the fire fighting and emergency services market. It combines the DDEC Pressure Sensor Governor (PSG), a system monitor, and a pump panel display for vital engine operating parameters into one compact, durable package (see Figure 5-9). EFC replaces the PSG switches, as well as many pump panel gauges as it provides complete control and monitoring of both DDEC III and DDEC IV systems on the fire truck. Figure 5-9 Electronic Fire Commander Pump Panel Display RPM, Oil Pressure, Oil or Coolant Temperature, and ECM Voltage are displayed continuously in the Engine Data section of the EFC. Messages and any known diagnostic code accompanying a Check Engine or Stop Engine condition will be displayed on the Information Center message display. The external alarm output will also be activated. The EFC displays the PSG status in the Information Center whenever the OEM interlocks are met. The real time of day will also be displayed. The EFC logs the time that the pump is engaged and that time can be displayed using the Information Center. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-31 DDEC FEATURES 5.7.1 OPERATION The Electronic Fire Commander has two modes of operation: RPM Mode (engine speed) Pressure Mode (water pump pressure, psi) RPM Mode controls engine speed to a desired RPM and Pressure Mode controls engine speed to maintain a desired discharge manifold pressure. The operating modes are selectable and may be changed by pressing the MODE button providing the appropriate interlocks have been met. The engine will continue to run at the same speed when the mode switch is toggled between the RPM and Pressure modes. The maximum preset pressure for EFC is 200 psi. 5.7.2 INSTALLATION The Electronic Fire Commander Harness schematic shows the minimum requirements for the PSG to operate (see Figure 5-10). Additional functions and interlocks may be used. Refer to the Electronic Fire Commander Installation and Troubleshooting manual (6SE476). EFC may be powered from a 12/24 V supply. 5.7.3 ORDERING EFC The hardware listed in Table 5-13 is needed for Pressure Governor installation with EFC. The 6N4C group must be specified at engine order entry or through Detroit Diesel Technical Service. Component Part Number Electronic Fire Commander 23519655 Pressure Sensor 23520795 Electronic Fire Commander Harness (see Figure 5-10) OEM Supplied OEM Interlocks OEM Supplied Table 5-13 Electronic Fire Commander and Pressure Sensor Hardware available from the DDC Parts Distribution Center for installation of Electronic Fire Commander (EFC) is listed in Table 5-13 as a complete kit. The 6N4C group must be specified at engine order entry or through Detroit Diesel Technical Service. Component Part Number Electronic Fire Commander Kit (contains Electronic Fire Commander and the pressure sensor) 23520139 Table 5-14 5-32 Electronic Fire Commander Kit All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 5-10 Electronic Fire Commander Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-33 DDEC FEATURES 5.7.4 PROGRAMMING REQUIREMENTS AND FLEXIBILITY The digital inputs listed in Table 5-15 are required for use with EFC and can be configured at order entry, by VEPS, or DRS. Refer to section 4.1, "Digital Inputs," for additional information. Description Function Number Circuit Number* VIH-to-ECM Connector Assignment* Pressure/RPM Mode 8 523 H1 PSG Enable 24 543 G2 Resume/Accel On (increase) 22 545 G3 Set/Coast On (decrease) 20 541 J1 * DDC circuit numbers and port assignments shown are default settings but can differ from application to application. Table 5-15 Required Digital Inputs for EFC The digital outputs required for use with EFC are listed in Table 5-16 and can be configured at order entry, by VEPS, or DRS. Refer to section 4.2, "Digital Outputs," for additional information. Description Function Number Circuit Number* PSG Active 5 499 Cruise Active 11 565 Connector Assignment* VIH-to-ECM Connector - Cavity F3 Pigtail off the Engine Sensor Harness - Cavity Y3 * DDC circuit numbers and port assignments shown are default settings but can differ from application to application. Table 5-16 Required Digital Outputs for EFC The correct 6N4C group must be specified at engine order entry or through Detroit Diesel Technical Service. More information is available in the manual Electronic Fire Commander Installation and Troubleshooting (6SE476). 5-34 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.8 ELECTRONIC SPEED SWITCH The Electronic Speed Switch (ESSE-2) is a two channel electronic speed switch typically used in generator set applications. Two channels can be used for crank (starter motor) disconnect and overspeed protection, or for underspeed and overspeed warnings. 5.8.1 OPERATION The switches on the cover of ESSE-2 are used for two conditions: no power and power applied with no signal present. When the engine reaches proper speed during cranking, Switch 1 will close causing the cranking motor to be disconnected. Switch 2 closes during an overspeed condition causing the engine to cease operation. by removing power from the fuel solenoid. The setpoint for switch closing is determined by the two setpoint potentiometers. There are four reset options available for resetting the speed switch: electrical latch, manual reset, automatic reset and adjustable reset. Electrical Latch After the setpoint has been reached, the switch will close and remain closed even if the input signal frequency has been lowered to 0 Hz. The only way to reset the unit is to remove power This switch is typically used for overspeed protection. Manual Reset The ESSE-2 is supplied with a reset button. The unit will be reset by pressing the reset button. Automatic Reset The switch automatically resets if the frequency of the input signal is lowered to 85 ± 5% of the setpoint. This switch is typically used for crank disconnect. Adjustable (Automatic) Reset The switch will automatically reset at the frequency determined by the setting of the supplied reset potentiometer. The reset can be selected anywhere between 25% and 95% by adjusting the potentiometer. 5.8.2 INSTALLATION Four mounting holes are provided on the ESSE-2 case. Mount the unit in a location where vibration effects are minimized. Two conductor shielded cable should be used to connect the signal source, Mini-Gen, mag pickup, to ESSE-2. Single conductor shielded cable is recommended for alternator or ignition signal sources. The shield should be connected to ground only at one end. The shield is connected to Terminal 2 for the Mini-Gen or mag pickup connection and to Terminal 5 for the alternator connection. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-35 DDEC FEATURES Fuses or circuit breakers should be connected in series with the load to protect ESSE-2. The fuse should be a 10 Amp slow blow. The circuit breaker should be rated at 10 Amps. If load currents in excess of 10 Amps are expected, interface relays should be used. See Figure 5-11. Figure 5-11 5-36 Electronic Speed Switch Installation All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The pin definition for the connector, current, and wire gage are listed in Table 5-17. Current Terminals Wire Gauge Under 5 Amps 1-2, 7-12 16 AWG 5 - 10 Amps 1-2, 7-12 14 AWG -- 3-6 18 - 20 AWG Table 5-17 Wire Gauge for ESSE-2 The electrical input voltage options for ESSE-2 are listed in Table 5-18. Input Voltage Option Max. Operating Current Max. Standby Current 8 - 40 VDC 40 - 80 VDC At 40 V: 250 MA At 80 V: 115 MA At 24 V: 220 MA At 64 V: 100 MA At 12 V: 200 MA At 40 V: 50 MA At 40 V: 70 MA At 80 V: 75 MA At 40 V: 45 MA At 64 V: 60 MA At 40 V: 30 MA At 40 V: 50 MA 0.1 to 10 Amps - 28 VDC Resistive Load 0.1 to 4 Amps - 75 VDC Resistive Load 0.1 to 8 Amps - 28 VDC Inductive Load 0.1 to 3 Amps - 75 VDC Inductive Load Power Supply Transient Protection 900 VDC for 100 microseconds Exponential Decay 140 VDC for 1 milliseconds Exponential Decay 110 VDC for 0.45 seconds Exponential Decay 900 VDC for 100 microseconds Exponential Decay 140 VDC for 1 milliseconds Exponential Decay 110 VDC for 0.45 seconds Exponential Decay Reverse Polarity Protection 1000 VDC 1000 VDC Relay Contact Ratings Table 5-18 ESSE-2 Electrical Input Voltage Options All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-37 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-38 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.9 ENGINE BRAKE CONTROLS The Engine Brake option converts a power-producing diesel engine into a power-absorbing air compressor. This is accomplished by opening the cylinder exhaust valves near the top of the normal compression stroke and releasing the compressed cylinder charge to exhaust. The release of the compressed air to atmospheric pressure prevents the return of energy to the engine piston on the expansion stroke, the effect being a net energy loss. Fueling is cut off when this occurs. 5.9.1 OPERATION A dash mounted On/Off Switch is used to enable the Engine Brake option. DDEC IV will directly control the engine brake solenoids using an intensity switch to select two, four or six cylinders to produce low, medium, or high braking power on a Series 60. For Series 71/92, the intensity switch is used to select left bank or left and right bank cylinders to produce low or high braking power for 6V and 8V engines. Inline 6-71 engines use an intensity switch to select the front three or all cylinders to produce low or high braking power. The engine brakes are engaged every time the foot pedal is brought back to the idle position and Cruise Control is not active. The following are six options for Engine Brake: Cruise Control with Engine Brake Engine Brake Disable Engine Brake Active Engine Fan Braking Clutch Released Input Service Brake Control of Engine Brakes Min. MPH for Engine Brakes Cruise Control with Engine Brake The Engine Brake option can also provide Engine Brake capability when the vehicle is in Cruise Control. For example, if the vehicle is going down hill in Cruise Control while the engine brake is selected, the ECM will control the amount of Engine Brake with respect to the Cruise Control set speed. The level of Engine Brake (low, medium, high) selected with the dash switches will be the maximum amount of engine braking the ECM allows. Cruise Control with Engine Brake can be set with DDDL/DDR, VEPS, and DRS. Engine Brake Disable The Engine Brake Disable option uses a digital input which is switched to ground whenever a vehicle system, such as a traction control device, does not allow engine braking to occur. This option is required for most automatic transmissions. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-39 DDEC FEATURES Engine Brake Active The Engine Brake Active option uses a digital output that can be used to drive an Engine Brake Active Light. This output is switched to battery ground whenever the engine brake is active. Engine Fan Braking The Engine Fan Braking option turns on the cooling fan when the engine brake level is high and DDEC fan control is enabled. This creates about 20 to 40 hp additional engine braking power depending on the size of the cooling fan. This option is selected at the time of engine order or set by DDDL/DDR, VEPS or DRS. For additional information, refer to section 5.14, "Fan Controls." Clutch Released Input The Clutch Released digital input will prevent the engine brakes from being turned on when the clutch is pressed. This input is required for use with manual transmissions. Refer to section 4.1, "Digital Inputs," for additional information. Service Brake Control of Engine Brakes This option will allow the dash-mounted engine brake switch to be set to the ON position but not engage the engine brakes until the service brake pedal is pressed. A digital input must be programmed for service brake. Refer to section 4.1, Digital Inputs for additional information. VEPS, DDR/DDDL or DRS can set this function. This feature is available with Release 5.0 or later. Min MPH for Engine Brakes This option will disable the engine brakes until a minimum vehicle speed is reached. This parameter can be configured by VEPS, DRS, or DDR/DDDL. A Vehicle Speed Sensor is required. Refer to section 3.14.25, "Vehicle Speed Sensor," for additional information. 5.9.2 INSTALLATION See Figure 5-12 for a schematic of the internal engine brake for the DDEC III/IV ECM and see Figure 5-13 for a schematic of the internal engine brake for the DDEC III/IV ECM World Transmission interface. 5-40 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 5-12 Internal Engine Brake for DDEC III/IV ECM All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-41 DDEC FEATURES Figure 5-13 5-42 Internal Engine Brake for DDEC III/IV ECM World Trans Interface All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.9.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY Engine Brake must be specified at the time of engine order or by contacting Detroit Diesel Technical Service. This enables the two digital outputs required. The digital inputs listed in Table 5-19 must be configured by order entry, VEPS, DRS: Description Function Number Engine Brake Low 1 Engine Brake Medium 2 Engine Brake Disable (required for most automatic transmissions) Clutch Switch (required for manual transmissions) Table 5-19 26 18 Required Digital Inputs for Engine Brake Controls The parameters listed in Table 5-20 can be set by order entry, VEPS, DDDL/DDR or DRS for the Cruise Control Engine Brake option. Parameter CRUISE CONTROL ENGINE BRAKE CRUISE ENGINE BRAKE ACTIVATION SPEED ENGINE BRAKE INCREMENT Table 5-20 Description Enables or disables the feature that allows the engine brake to be used while on cruise control if the vehicle exceeds the cruise set speed. Sets the delta speed that the engine brake should be applied to slow the vehicle while in cruise control. Sets the additional incremental speed that must be reached before the engine brake will activate the medium and/or high level of retardation. Choice / Display YES, NO 1 to 10 MPH 1 to 5 MPH Cruise Control Engine Brake Parameters The optional digital output listed in Table 5-21 can be configured by order entry, VEPS or DRS. It can be used to drive an Engine Brake Active Light. Description Type Function Number Engine Brake Active Digital Output 16 Table 5-21 Optional Digital Output for Engine Brakes All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-43 DDEC FEATURES The Engine Fan Braking option as listed in Table 5-22 can be configured at the time of engine order, VEPS, DDR, DDDL or DRS. Parameter Description Choice/Display DYNAMIC BRAKING Provides additional engine braking by activating the DDEC controlled fan whenever the engine brakes are active in high. This function requires both DDEC engine brake controls and DDEC fan controls. YES, NO Table 5-22 Optional Fan Braking for Engine Brakes The parameter listed in Table 5-23 can be set by order entry, VEPS, DDDL/DDR or DRS for the Service Brake Control of the Engine Brakes option. Parameter Description Choice / Display SERVICE BRAKE ENABLE When this function is enabled, an input from the service brake is required in order to activate the engine brake. YES, NO Table 5-23 Service Brake Control of Engine Brakes Parameter The parameter listed in Table 5-24 can be configured by order entry, VEPS, DDR, and DDDL for the Minimum Vehicle Speed for engine braking to occur. Parameter Description Choice/Display ENGINE BRAKE MIN MPH The minimum vehicle speed required before engine braking will occur. 0-40 MPH Table 5-24 5.9.4 Minimum MPH for Engine Brakes Option INTERACTION WITH OTHER FEATURES DDEC will respond to requests from other vehicle systems via SAE J1939 data link or SAE J1922 data link to disable the engine brakes. 5-44 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.10 ENGINE PROTECTION The DDEC engine protection system monitors all engine sensors and electronic components, and recognizes system malfunctions. If a critical fault is detected, the Check Engine Light (CEL) and Stop Engine Light (SEL) illuminate. The malfunction codes are logged into the ECM's memory. The standard parameters which are monitored for engine protection are: Low coolant level High coolant temperature Low oil pressure High oil temperature The additional parameters for Series 4000 and Series 2000 which are monitored for engine protection are: Low coolant pressure High crankcase pressure High intercooler temperature Low intercooler coolant pressure Auxiliary digital input(s) 5.10.1 OPERATION Engine protection is a vital part of ECM programming and software. The ECM monitors coolant level, various pressures and temperatures, and compares these parameters against the allowable limits to determine when a critical fault is reached. The CEL is illuminated and a code logged if there is an electronic system fault. This indicates the problem should be diagnosed as soon as possible. The ECM illuminates the CEL and SEL and stores a malfunction code if a potentially engine damaging fault is detected. Once a critical fault is reached, the CEL and SEL are illuminated and a 30 second timer starts a countdown to the desired level of protection. Temperature and pressure limits are established in the engine's calibration and may differ slightly from one engine model to another. Engine protection consists of different protection levels: Warning Only Rampdown Shutdown All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-45 DDEC FEATURES Warning Only The CEL and SEL will illuminate if a fault is detected. There is no power and/or speed reduction when "Warning Only" is selected. The resulting engine protection is at the discretion of the engine operator. NOTE: The operator has the responsibility to take action to avoid engine damage. Some applications require two sets of warning lights for different control stations. The wiring for two sets of lights is in Chapter 3, refer to section 3.16.4. NOTE: A diagnostic switch is not required but applications using one, must have a separate diagnostic switch for each ECM on the engine. The Diagnostic Request switch is used to activate the CEL and SEL to flash codes. Rampdown The CELand SEL will illuminate if a fault is detected. The ECM reduces torque and/or speed over a 30 second period after the SEL illuminates. The initial torque/speed, which is used for reduction, is the operating torque or speed prior to the SEL fault condition. See Figure 5-14. Figure 5-14 Rampdown A Stop Engine Override (SEO)/Diagnostic Request switch is required when this engine protection option is selected. The SEO options are available to prevent engine shutdown at the operator's discretion. 5-46 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Shutdown This option operates in the same manner as rampdown, except the engine shuts down 30 seconds after the SEL is illuminated (see Figure 5-15). (The initial torque and/or speed which is used for reduction, is the torque and/or speed which occurred immediately prior to the fault condition.) The Stop Engine Override options are available to prevent engine shutdown at the operator's discretion. Figure 5-15 Engine Shutdown A SEO/Diagnostic Request Switch is required when this engine protection option is selected. Refer to section 5.10.3. The SEO options are available to prevent engine shutdown at the operator's discretion. 5.10.2 ENGINE OVERTEMPERATURE PROTECTION Engine Overtemperature Protection (EOP) is additional logic programmed into the ECM and used in conjunction with standard temperature protection. When EOP is part of the engine calibration, engine torque and/or speed is reduced as a function of temperature. The CEL illuminates and a fault code is logged when the EOP calibrated temperature is reached. If the temperature does not decrease as torque/speed is reduced, the SEL will illuminate when a still higher temperature is reached. The subsequent action taken by the ECM depends on customer selection of one of the following: Warning only (see Figure 5-16) 30 second rampdown (see Figure 5-17) Shutdown (see Figure 5-18) Torque reduction is based on the average torque/speed in use prior to the fault condition. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-47 DDEC FEATURES Figure 5-16 Engine Overtemperature Protection and Warning Only EOP can be disabled when Warning Only is selected for engine protection (Release 22.00 or later only). This feature is based on the engine series as listed in Table 5-25. Enabled/Disabled Series 50, Series 60 Will not be disabled with Warning Only Series 71, Series 92, Series 149 Will not be disabled with Warning Only Series 2000 Will not be disabled with Warning Only Series 4000 Will be disabled with Warning Only Table 5-25 5-48 Engine Series Warning Only Disabled All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 5-17 Engine Overtemperature Protection and Rampdown All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-49 DDEC FEATURES Figure 5-18 Engine Overtemperature Protection and Shutdown Some 1999 Model Year Series 60 engines and later (DDEC Release 26.0 or later) have additional logic to start the overtemperature torque reduction logic earlier without alerting the driver. Engine torque and/or speed is reduced as a function of temperature. A code will be logged and torque reduction will begin when the first EOP calibrated temperature is reached. The CEL will illuminate and a fault code is logged when the second higher temperature limit is reached. If the temperature does not reduce as torque/speed is reduced, the SEL will illuminate when a still higher temperature is reached. 5-50 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The subsequent action taken by the ECM is the 30 second rampdown (see Figure 5-19) or shutdown (see Figure 5-20) depending on the customer selection. Torque reduction is based on the average torque/speed in use prior to the fault condition. Figure 5-19 Series 60 1999 Model Year Engine Overtemperature Protection and Rampdown All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-51 DDEC FEATURES Figure 5-20 5-52 Series 60 1999 Model Year Engine Overtemperature Protection and Shutdown All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.10.3 ENGINE PROTECTION SWITCHES The SEO/Diagnostic Request switch can be combined. A separate Diagnostic Request switch is an option. NOTE: EOP is active even if engine protection is configured for Warning only for the Series 60, Series 50, and Series 2000 engines. Diagnostic Request Switch The Diagnostic Request switch is used to activate the CEL and SEL to flash codes (see Figure 5-21). The SEL will flash the active codes and the CEL will flash the inactive codes. Refer to section 4.1.3. Figure 5-21 Typical SEO Switch, Diagnostic Request Switch and Warning Lights The Diagnostic Request switch is used to flash codes when: The engine is not running and ignition is on The engine is idling and not in an "engine protection" condition Activating and releasing the switch will flash out the diagnostic codes for either condition. Activating and releasing the switch a second time will stop the ECM from flashing the diagnostic codes. Codes will also cease flashing if the engine is no longer at idle. The codes are flashed out of the ECM connected to the switch. For multi-ECM installations, the Diagnostic Request Switch and SEO switchare combined on the master ECM. All receiver ECMs use a separate Diagnostic Request Switch. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-53 DDEC FEATURES 5.10.4 STOP ENGINE OVERRIDE OPTIONS Two types of stop engine overrides are available, Momentary Override and Continuous Override. Continuous Override has two options. These types are dependent upon specific engine applications. The ECM will record the number of times the override is activated after a fault occurs. Momentary Override - An SEO switch is used to override the shutdown sequence. This override resets the 30 second shutdown timer, restoring power to the level when the SEL was illuminated. The switch must be recycled after five seconds to obtain a subsequent override. See Figure 5-22. NOTE: The operator has the responsibility to take action to avoid engine damage. Figure 5-22 5-54 Engine Overtemperature Protection and Shutdown Protection with Stop Engine Override All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Continuous Override, Option 2- This option is used when the vehicle needs full power during a shutdown sequence. Full torque capability is maintained as long as the override switch is pressed. This is intended for Coach applications only. Continuous Override, Option 2- This option is used for a one time continuous override of the shutdown sequence. This is primarily used in construction and industrial applications. The engine protection system is disabled until the ignition key is cycled. See Figure 5-23. Figure 5-23 5.10.5 Engine Overtemperature Protection and Shutdown Protection with Continuous Override, Option 1 INSTALLATION Some application require two sets of warning lights (CEL and SEL) at different control stations (refer to section 3.16.4). All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-55 DDEC FEATURES 5.10.6 PROGRAMMING FLEXIBILITY All ECMs are programmed with pressure, temperature, and level protection limits. The level of protection can be any of the three engine protection features (Warning, Rampdown, or Shutdown) for each parameter monitored by the ECM. These can be set at time of order entry or with any of the available service tools, VEPS, DRS, DDR, or DDDL. The DDEC engine protection system monitors all engine sensors and electronic components, and recognizes system malfunctions. The choices listed in Table 5-26 are available for reprogramming Engine Protection. Parameter Definition Range RECEIVER 1 OIL TEMPERATURE Determines the type of engine protection with high oil temperature on the Receiver ECM #1 Determines the type of engine protection with low oil pressure. N/A will be displayed if the sensor is not present. Determines the type of engine protection with high crankcase pressure. N/A will be displayed if the sensor is not present. Determines the type of engine protection with low coolant pressure. N/A will be displayed if the sensor is not present. Determines the type of engine protection with low coolant pressure on the Receiver ECM #1 Determines the type of engine protection with low oil level. N/A will be displayed if the sensor is not present. Determines the type of engine protection with low coolant level. N/A will be displayed if the sensor is not present. Determines the type of engine protection with an active auxiliary switch #1 input. N/A will be displayed if auxiliary switch #1 has not been configured as a switch input. Determines the type of engine protection with an active auxiliary switch #1 INPUT on the Receiver ECM #1 Determines the type of engine protection with an active auxiliary switch #2 input. N/A will be displayed if auxiliary switch #2 has not been configured as a switch input. N/A; WARN, RAMP,SHTDWN OIL PRESSURE CRANKCASE PRESSURE COOLANT PRESSURE RECEIVER 1 COOLANT PRESSURE OIL LEVEL COOLANT LEVEL AUXILIARY SHUTDOWN #1 RECEIVER 1 AUXILIARY SHUTDOWN #1 AUXILIARY SHUTDOWN #2 Table 5-26 5.10.7 N/A; WARN, RAMP,SHTDWN N/A; WARN, RAMP,SHTDWN N/A; WARN, RAMP,SHTDWN N/A; WARN, RAMP,SHTDWN N/A; WARN, RAMP,SHTDWN N/A; WARN, RAMP,SHTDWN N/A; WARN, RAMP,SHTDWN N/A; WARN, RAMP,SHTDWN N/A; WARN, RAMP,SHTDWN Engine Protection INTERACTION WITH OTHER FEATURES Cruise Control operation, Optimized Idle, and PSG are disabled when the SEL is illuminated. For Applications with LSG and VSG, the governor will revert to the primary governor when Engine Protection is enabled. 5-56 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.11 ENGINE RATINGS Engine ratings are designated by horsepower rating and engine speed. For on-highway applications, three independent engine ratings and an additional dependent rating (cruise power) are provided. For construction and industrial applications, up to three independent ratings are provided. Although multiple ratings are stored in the ECM, only one rating is in operation at any time. 5.11.1 OPERATION The engine rating may be selected with the DDR, DDDL or OEM supplied rating switches. Detroit Diesel's method of designating engine ratings is listed in Table 5-27. Example #1 Example #2 430 bhp @ 2100 RPM Rating #0 470 bhp @ 2100 RPM Rating #0 400 bhp @ 2100 RPM Rating #1 470 bhp @ 1800 RPM Rating #1 370 bhp @ 2100 RPM Rating #2 430 bhp @ 1800 RPM Rating #2 370/430 bhp @ 2100 RPM Rating #3 430/370 bhp @ 1800 RPM Rating #3 Table 5-27 Examples of Engine Ratings Detroit Diesel can provide additional security to prevent the ECM rating selection from being modified with the DDR or DDDL. The additional security is not available with the use of rating switches. The Maximum Rating Security or the Rating Password (if configured) will protect DDEC III/IV engine ratings. Engine Rating Switches Engine rating switches may be used to select any of the individual ratings (maximum of three) and the dependent rating. Engine rating switches are only offered on select horsepower group ratings. The rating switches must be used in conjunction with up to two digital inputs, Rating Switch #1 and Rating Switch #2. Rating Switch #1 selects between Engine Rating #0 and Engine Rating #1 when used without Rating Switch #2 as listed in Table 5-28. Rating Switch #1 Position Engine Rating #0 OFF Engine Rating #1 ON Table 5-28 Rating Selections with One Rating Switch All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-57 DDEC FEATURES Rating Switch #2, in conjunction with Rating Switch #1, is used to select any of the four engine ratings (three independent and one dependent) as listed in Table 5-29. Rating Switch #1 Switch #2 Engine Rating #0 OFF OFF Engine Rating #1 ON OFF Engine Rating #2 OFF ON Engine Rating #3 ON ON Table 5-29 Rating Selections with Two Rating Switches Cruise Power Cruise Power is an optional engine rating which operates on a higher horsepower curve during Cruise Control operation. The ECM provides the higher horsepower when Cruise Control is ON and not being overridden with the foot pedal. The additional power provides an incentive for the driver to operate in Cruise Control. Limiting Torque Curve Option (Digital Torque Limiting) The Limiting Torque Curve option provides the ability to operate the engine on a reduced torque curve when the appropriate digital input is enabled. Limiting torque curve tables are generated by Applications Engineering and can either be selected at the time of engine order or selected after engine order by DDC Technical Service. The Limiting Torque Curve option use is shown in the following examples: Articulated Coach - The Limiting Torque Curve option is used to limit torque in an extreme articulated condition, which could occur during reverse operation. Transmission - The Limiting Torque Curve option provides a customized reduced torque curve during conditions which would otherwise exceed the maximum allowable torque limit set by the transmission manufacturer. Locomotive - The Limiting Torque Curve option provides a reduced torque to reduce wheel slip at low vehicle speed. The following must be considered when using the Limiting Torque Curve option: The DDEC system cannot detect or display a malfunction of the digital input wiring. Limiting vehicle speed is best accomplished by utilizing DDEC's Vehicle Speed Limiting feature. Refer to section 5.36. The % Load display on the DDR / DDDL is a function of the main rating torque curve. 5-58 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.11.2 INSTALLATION The rating switches must be used in conjunction with up to two digital inputs, Rating Switch #1 and Rating Switch #2. Refer to section 4.1, "Digital Inputs," for additional information. See Figure 5-24 for an installation using one rating switch. Figure 5-24 Simple Engine Rating Switch See Figure 5-25 for an installation using two rating switches. Figure 5-25 Rotary Switch for Multiple Engine Ratings All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-59 DDEC FEATURES 5.11.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY The Maximum Rating Security to protect DDEC III/IV engine rating must be enabled at the time of engine order. Maximum Rating Security locks out all other ratings and will only operate on the rating selected at order entry. The DDR or DDDL cannot change a rating selection if the rating is maximum security protected. The Rating Password is a four digit alphanumeric password that may be set at the time of engine order, by the DDR, DDDL, or VEPS. This offers additional protection above and beyond the standard DDR, DDDL password protection. Rating Switches The Rating Switches option and the digital inputs listed in Table 5-30 must be configured by order entry, VEPS, or DRS. Description Type Function # Rating Switch #1 Digital Input 12 Rating Switch #2 Digital Input 13 Table 5-30 Rating Switches Digital Input Requirements Cruise Power Cruise Power may be selected at the time of engine order, by VEPS, DDR, DDDL or using the engine rating switches. Limiting Torque Option Limiting Torque Curves must be selected at the time of engine order or selected after engine order by Technical Service. The digital input listed in Table 5-31 must be configured by order entry, VEPS, or DRS. Description Type Function Number Limiting Torque Curve Digital Input 14 Table 5-31 5-60 Limiting Torque Curve Option Digital Input Requirements All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.12 ETHER START The DDEC Ether Start™ System is a fully-automatic engine starting fluid system used to assist a Series 50, Series 60 or Series 2000 diesel engine in cold starting conditions. The amount of ether is properly controlled to optimize the starting process and prevent engine damage. DDEC will control ether injection using standard sensors to control the ether injection hardware. 5.12.1 OPERATION Ether Start will occur in two modes, preload (before cranking) and block load (during and after cranking). The mode and duration of injection is determined by DDEC based on engine speed and coolant, air and oil temperatures. Since excessive preloading could be harmful to engine components, DDEC will not allow multiple preloads. The engine speed must exceed 1500 RPM to reset the preload. The system is composed of the DDEC ECM, Ether Injection Relay Module, ether canister, Dieselmatic valve, injection nozzle, metering orifice, nylon tubing, harness and miscellaneous hardware (see Figure 5-26). Figure 5-26 DDEC Ether Start System All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-61 DDEC FEATURES It will be necessary to configure a DDEC digital output to control the relay module. Battery power and ground must also be supplied to the module. To avoid injury from flames, explosion, and toxicants when using ether, the following precautions must be taken: Do not smoke when servicing ether system. Work in well-ventilated area. Do not work near open flames, pilot flames (gas or oil heaters), or sparks. Do not weld or carry an open flame near the ether system if you smell ether or otherwise suspect a leak. Always wear goggles when testing. If fluid enters the eyes or if fumes irritate the eyes, wash eyes with large quantities of clean water for 15 minutes. A physician, preferably an eye specialist, should be contacted. Contents of cylinder are under pressure. Store cylinders in a cool dry area. Do not incinerate, puncture or attempt to remove cores from cylinders. The relay module performs a number of important functions. The module will not allow ether injection unless it receives a signal from DDEC, it will prevent ether injection in the event of a faulty signal, and it will illuminate a light on the module when the ether canister is 90% consumed. If the digital output remains grounded for longer than a factory set time, the relay module will cause an inline fuse to blow to prevent excessive ether from being injected into the cylinders. If the output is shorted to ground, a code will be logged by DDEC and the CEL will be illuminated. The system does not operate without the fuse in place. The cause of the digital output short must be fixed before replacing the fuse. 5-62 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.12.2 INSTALLATION The injector nozzle is installed in the intake manifold (see Figure 5-27). Figure 5-27 Series 60 Intake Manifold - Injector Nozzle Location A red dot indicates the direction of spray, which should be pointed against the airflow. The cylinder assembly should be mounted vertically in an accessible location away from extreme heat such as the exhaust system and protected from road dirt, ice and snow. If protected, it can be mounted in the engine compartment on the firewall, frame or any other convenient location. The Ether Injection Relay (EIR) should be located near the valve and cylinder assembly. The DDEC Ether Start system requires a harness (see Figure 5-28) to supply battery power, receive a signal from DDEC and control the ether injection valve. A fuse is required on the battery input (15 amp for 12 V systems, 10 amps for 24 V systems). Circuit breakers cannot be used. For complete information on installing Ether Start and other details of the Ether Start system, refer to the DDEC Ether Start Installation Manual (7SA0727). All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-63 DDEC FEATURES Figure 5-28 DDC Ether Start Harness Programming Requirements and Flexibility To configure an engine for Ether Injection, digital output function # 24 must be selected with VEPS, DRS, or on order entry. This feature does not have any reprogrammable parameters. 5-64 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.13 EXTERNAL ENGINE SYNCHRONIZATION External Engine Synchronization (EES) provides a method of synchronizing the engine RPM of two or more engines using a frequency signal generated by an external vehicle controller or the tach drive output of another engine. 5.13.1 OPERATION ESS is configured in an Application Code (6N4C group). To use EES, the ECM must be programmed with the same Application Code (6N4C group). The engine must be running and the digital input “Engine Synchronization” (function # 10) must be configured and enabled. When in EES mode, the external engine synchronization RPM is limited to the PTO maximum RPM. Engines operating in ESS mode must be operating with 100 RPM of each other to exit ESS. If the engine speed differential between the follower and master engines is greater than 100 RPM, the follower engine will not exit ESS. However, it is possible to disable the engine synchronization input (function # 10) and remain in ESS until the engine speed differential is less than 100 RPM. 5.13.2 INSTALLATION See Figure 5-29 for a schematic for wiring engines for EES. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-65 DDEC FEATURES Figure 5-29 5-66 External Engine Synchronization Schematic All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The tach output from the controlling engine's ECM is wired to the VSS input or the ATI port on the follower engine's ECM. Both ECMs can be programmed as followers to provide flexibility. Be sure to only have one engine follow at a time by having one of the digital inputs open. Establish a switchable ground to the digital input “External Engine Sync.” Connect the tach output (wire #555) to the VSS (+) input (wire #556) or the ATI port (wire #973) between the two ECMs. Now you can ground one of the assigned digital input wires through the switch and that engine will become the follower to the other. Avoid the possibility of having both switches closed at the same time otherwise you won't have proper control of the master RPM. 5.13.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY Engine Sync must be specified at the time of engine order with the correct Application Code (6N4C group) that enables this feature. For existing units in the field, contact Detroit Diesel Technical Service. The digital input listed in Table 5-32 must be configured by order entry, VEPS, or the DRS. Description Function Number External Engine Synchronization Enable 10 Table 5-32 The Vehicle Speed Sensor parameters listed in Table 5-33 can be programmed with the DDR, DDDL, VEPS, DRS, or on order entry. Parameter Choice/Display VSS ENABLED YES VSS SIGNAL VSS TEETH SWITCHED Appropriate Pulses/rev Table 5-33 Vehicle Speed Sensor Parameters All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-67 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-68 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.14 FAN CONTROL The purpose of the Fan Control feature is to electronically control engine cooling fan activation and to provide a load for vehicle retardation, when required. DDEC Fan Controls are designed to optimally control the engine cooling fan(s) based on engine cooling requirements. Fan Controls are designed to use other system inputs such as A/C pressure switches, transmission retarder status, and operator requested fan operation. Transmission Retarder Status may be received via the Transmission Retarder Digital Input or on demand by a data link. NOTE: Fan Controls are required for some on-highway truck and on-highway bus applications. 5.14.1 OPERATION The DDEC IV ECM continuously monitors and compares the coolant, oil, and air temperature, engine torque, engine operation mode, and various optional inputs to calibrated levels stored within the ECM. These limits are factory configured based on application. When these temperature levels exceed the preset fan ON temperature value, the ECM will enable the fan control digital output(s) that activate the fan. The fan will remain on, cooling the engine with the increased air flow until the temperature levels reach the preset fan OFF temperature. At this point, the ECM will switch fan control to battery ground, which will deactivate the fan, effectively maintaining the coolant temperature between the two preset levels. DDEC IV provides fan control for four different fan configurations: Single fan (refer to section 5.14.3, page 5-70) Dual fans (refer to section 5.14.4, page 5-75) Two-speed fan (refer to section 5.14.5, page 5-76) Variable speed single fan (PWM) (refer to section 5.14.6, page 5-80) In accordance with the proposed Truck Maintenance Council (TMC) Standard, the minimum fan-on time for on-highway applications is 30 seconds. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-69 DDEC FEATURES 5.14.2 INSTALLATION This section provides a schematic of the specific connection from the ECM to the fan. See Figure 5-30 and Figure 5-31 for the input and outputs used for fan control. Figure 5-30 Fan Control Inputs with Two Digital Outputs Figure 5-31 Fan Control Inputs with PWM Output for Variable Speed Fan Control Compatible fans may be obtained from several vendors. 5-70 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.14.3 SINGLE FAN The single-fan control uses one digital output to drive a single-speed fan. The digital output is called Fan Control #1. Fan Control #1 is deactivated to turn the fan OFF. The fan remains ON for 30 seconds when turned ON. The fan output will not be enabled until five seconds after the engine has started. NOTE: Digital output circuits are designed to sink no more than 1.5 A (DC) current. Fan Control #1 is enabled (opened) when at least one of the following conditions occur: Oil or coolant temperature above DDC factory set levels Air temperature and engine torque above DDC factory set levels Air conditioner is active (OEM supplied A/C switch is opened), the fan remains ON for three minutes (the default) after the switch is grounded if vehicle speed is less than 20 MPH Oil, coolant, or air temperature sensor fails Fan engine brake enabled and engine brake is active at high level for a minimum of five seconds and air temperature is above factory set levels Transmission retarder is active and coolant temperature above DDC factory set level (Release 2.00 or later only) Fan Control Override Switch is enabled Pressure Sensor Governor is active NOTE: If either the A/C or transmission retarder inactive digital input is configured, the input must be grounded to prevent continuous fan operation. The digital inputs and outputs for a single fan are listed in Table 5-34. Fan State Fan Control Output 1 A/C Input Override Input Jake Brake Status Primary Control On Open Grounded Open Not in High Mode Engine Temperature Sensors Off Grounded Grounded Open Not in High Mode Engine Temperature Sensors On Open Open Don't Care Not in High Mode OEM A/C Switch On Open Don't Care Grounded Not in High Mode OEM Override Switch On Open Don't Care Don't Care High Mode On Open Don't Care Don't Care Not in High Mode Table 5-34 Jake Brake in High Mode and Air Temperature Above Limit Transmission Retarder Active and Coolant Temperature Above Limit Single Fan Digital Inputs and Outputs All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-71 DDEC FEATURES Installation See Figure 5-32 for the specific connection from the ECM to the fan. Figure 5-32 Fan Control Inputs and Outputs Electro Magnetic Single-Speed Digital Fans (Linnig) For additional information, contact the fan vendor: Linnig Corp. P.O. Box 2002 Tucker, GA 30084 Phone: (770) 414–9499 5-72 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL See Figure 5-33 for the specific connection from the ECM to the fan. Figure 5-33 Fan Control Inputs and Outputs Index Control Module For additional information, contact the fan vendor: Index Sensors and Controls, Inc. 12335 134th Court NE Redmond, WA 98052 Phone: 1-800-726-1737 Fax: 425-821-4112 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-73 DDEC FEATURES See Figure 5-34 for the specific connection from the ECM to the control module. Figure 5-34 Fan Control Inputs - Normally Closed Air Solenoid Single-Speed Fan (Kysor, Bendix, and Horton) For additional information, contact the fan vendors: Kysor 1100 Wright Street Cadillac, MI 49601 Phone: (616) 779-7528 Bendix Truck Brake Systems 901 Cleveland Street Elyria, OH 44036 Phone: 1-800-AIR-BRAKE 5-74 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Horton, Inc 2565 Walnut Street Roseville, MN. 55113 Phone: 1–800–621–1320 Fax: 1–651–361–3801 www.hortoninc.com 5.14.4 DUAL FANS This configuration uses two digital outputs, Fan Control #1 and Fan Control #2, to drive two separate single-speed fans. Fan Control #1 and Fan Control #2 are opened (switched to battery ground) to turn OFF each fan respectively. The fan remains on for 30 seconds whenever it is turned ON. The fan outputs will not be enabled until five seconds after the engine has started. The two fans are independent of one another and are controlled by different conditions. Both fans will be activated when either the Fan Control Override is enabled or when the conditions are met for Fan Engine Brake. Fan Control #1 is enabled (opened) when at least one of the following conditions occur: Air temperature and engine torque above DDC factory set levels Air temperature sensor fails Air conditioner is active (OEM supplied A/C switch is opened), the fan remains ON for three minutes (the default) after the switch is grounded if vehicle speed is less than 20 MPH Fan engine brake enabled and engine brake level is active at high level and air temperature is above DDC factory set levels Fan control override switch is enabled Pressure governor system is active Fan control #2 is enabled (opened) when one of the following conditions occur: Oil or coolant temperature above DDC factory set levels Oil or coolant temperature sensor fails Fan engine brake enabled and engine brake level is active at high level and air temperature is above DDC factory set levels Fan control override switch is enabled Transmission retarder is active and coolant temperature above DDC factory set level (Release 2.00 or later only) NOTE: If either the A/C or transmission retarder inactive digital input is configured, the input must be grounded to prevent continuous fan operation. The digital inputs and outputs for dual fans are listed in Table 5-35. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-75 DDEC FEATURES Fan State 1-On 2-On 1-On 2-Off 1-Off 2-On 1-Off 2-Off 1-On 2-Off 1-On 2-Off 1-On 2-Off Fan Control Output 1 Fan Control Output 2 A/C Input Override Input Open Open Grounded Open Open Grounded Grounded Open Grounded Open Grounded Open Grounded Grounded Grounded Open Open Grounded Open Don't Care Open Grounded Don't Care Grounded Open Grounded Don't Care Don't Care 1-Off 2-On Table 5-35 Open Grounded Don't Care Don't Care Jake Brake Status Primary Control Not in High Mode Not in High Mode Not in High Mode Not in High Mode Not in High Mode Not in High Mode Engine Temperature Sensors Engine Temperature Sensors Engine Temperature Sensors Engine Temperature Sensors High Mode Jake Brake in High Mode High Mode Transmission Retarder Active and Coolant Temperature Above Limit OEM A/C Switch Override Switch Dual Fans Digital Inputs and Outputs Installation - Dual Fans The compatible fan manufacturers are the same as the manufacturers for the single fan. Follow the wiring diagrams for single fans for the first fan. See Figure 5-35 for the specific connection from the ECM to the second fan. Figure 5-35 5-76 Fan Control Inputs and Outputs - Second Fan All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.14.5 TWO-SPEED FAN This configuration uses two digital outputs, Fan Control #1 and Fan Control #2, to drive a two-speed fan. When Fan Control #1 output is opened, the fan operates in low-speed mode. When Fan Control #1 and Fan Control #2 are both open, the fan operates in high-speed mode. Fan Control #1 is enabled (opened) when at least one of the following conditions occur: Oil or coolant temperature above DDC factory set levels Air temperature and engine torque above DDC factory set levels Fan control #2 is enabled (opened) when one of the following conditions occur: Oil or coolant temperature above DDC factory set levels Air temperature and engine torque above DDC factory set levels Oil, coolant, or air temperature sensor fails Air conditioner is active (OEM supplied A/C switch is opened), the fan remains ON for three minutes (the default) after the switch is grounded when vehicle speed is less than 20 MPH Fan engine brake enabled and engine brake level is active at high level and air temperature is above DDC factory set levels Fan control override switch is enabled Pressure governor system is active Transmission retarder is active and coolant temperature above DDC factory set level (Release 2.00 or later only) Once the fan has been enabled due to the Transmission Retarder, the fan will remain on high speed until the Transmission Retarder is deactivated. The Fan will remain on high speed for a minimum of 30 seconds. NOTE: If either the A/C or transmission retarder digital input is configured and not used, they should be deconfigured. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-77 DDEC FEATURES The digital inputs and outputs for a two-speed fan are listed in Table 5-36. Fan State Fan Control Output 1 Fan Control Output 2 A/C Input Override Input Off Grounded Grounded Grounded Open Low Open Grounded Grounded Open High Open Open Grounded Open High Open Open Open Don't Care High Open Open Don't Care Grounded High Open Open Don't Care High Table 5-36 5-78 Open Open Don't Care Jake Brake Status Primary Control Not in High Mode Not in High Mode Not in High Mode Not in High Mode Not in High Mode Engine Temperature Sensors Engine Temperature Sensors Engine Temperature Sensors Don't Care High Mode Jake Brake in High Mode Don't Care Not in High Mode Transmission Retarder Active and Coolant Temperature Above Limit OEM A/C Switch Override Switch Two-speed Fan Digital Inputs and Outputs All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Installation - Two-speed Fans See Figure 5-36 for the specific connection from the ECM to the fan. Figure 5-36 Fan Control Inputs and Outputs - Electro Magnetic Two-Speed Fans (Linnig) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-79 DDEC FEATURES For additional information, contact the fan vendor: Linnig U.S.A. P.O. Box 670 Mineola, NY 11501-0670 Phone: (516) 742-1900 5.14.6 VARIABLE SPEED SINGLE-FAN DDEC uses a pulse width modulated (PWM) output to drive a variable speed fan. Presently available PWM outputs and specifications are listed in Table 5-37. Engine Series PWM Output Frequency Duty Cycle @ Minimum Fan Speed Duty Cycle @ Maximum Fan Speed Series 4000 PWM #2 10 Hz 80% 5% All Others PWM #4 50 Hz 90% 10% Table 5-37 PWM Outputs and Specifications The fan may be enabled by specific engine temperature sensors and various other inputs. The fan will ramp up to the requested speed in order to reduce noise, shock-loading, and belt slippage. If the fan is turned on for any reason other than high temperature, it will ramp up to the full fan speed (i.e. 5% or 10% duty cycle, application dependent). The ramp rate is set by the Application Code System (ACS). A decrease in fan speed will occur after a short time delay and will step down to the value dictated by the highest sensor request. If the A/C switch is opened, the fan will increase speed at the ramp rate until it is at a maximum. After the A/C switch is grounded the fan will remain on for a short time delay and then turn off. If the oil temperature (Series 4000 only), intercooler temperature or jacket coolant temperature are not received from the receiver ECM, the master ECM requests the maximum fan speed. The PWM output is initiated when at least one of the following conditions occur: Air, oil, coolant, or intercooler temperatures above DDC factory set limits Air conditioner is active (OEM supplied A/C switch is opened), the fan remains on for 3 minutes (the default) after the switch is grounded when vehicle speed is less than 20 mph Jacket coolant temperature above DDC factory set limits Oil, coolant, intercooler, or air temperature sensor fails Fan Control Override Switch is enabled NOTE: If A/C input is configured and not used, that input must be deconfigured. The Series 4000 DDEC system uses a PWM output to control the oil pressure governing solenoid for the Rockford variable speed fan clutch. The PWM signal to the solenoid operates at a frequency of 10 Hz. Several engine temperatures are monitored to determine the required fan speed. 5-80 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The fan is off when the PWM signal is at or above 80%. Maximum fan speed is requested when the PWM2 signal is at 5% or below. The fan speed will ramp up to the required speed at a set rate to prevent belt slippage. If the A/C switch is closed the fan will ramp up to maximum speed. In the event that the fan governing solenoid loses the PWM signal the fan will operate at maximum speed. The digital inputs and outputs for PWM fan control are listed in Table 5-38. Fan State PWM Output A/C Input Override Input Jake Brake Status On Modulated Grounded Open Not in High Mode Off Open Grounded Open Not in High Mode Full On Grounded Open Don't Care Not in High Mode OEM A/C Switch Full On Grounded Don't Care Grounded Not in High Mode OEM Override Switch Full On Grounded Don't Care Don't Care High Mode Full On Grounded Don't Care Don't Care Not in High Mode Table 5-38 Primary Control Engine Temperature Sensors Engine Temperature Sensors Jake Brake in High Mode and Air Temperature Above Limit Transmission Retarder Active and Coolant Temperature Above Limit PWM Fan Control Digital Inputs and Outputs Installation - Variable Speed Single-Fan See Figure 5-37 for the specific connection from the ECM to the fan. Figure 5-37 Series 4000 Fan Control Inputs and Outputs All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-81 DDEC FEATURES For additional information, contact the clutch manufacturer: Rockford Powertrain, Inc. 1200 Windsor Road, Rockford, Il 61132-2908 Phone: (815) 633-7460 5.14.7 PROGRAMMING REQUIREMENTS AND FLEXIBILITY To have fan control for single, dual, or two-speed fans, fan control must be enabled and a fan type defined at engine order entry or by DDC Technical Service. For single, dual, and two-speed speed fans the digital inputs and outputs listed in Table 5-39 may be required based on the fan vendor's requirements. The digital inputs and outputs can be configured by order entry, VEPS or DRS. Function Number Type Description 13 Digital Output Fan Control #1 14 Digital Output Fan Control #2 27 Digital Input Transmission Retarder 32 Digital Input Fan Control Override 29 Digital Input Air Conditioner Status Table 5-39 Fan Control Digital Input and Outputs - Single and Dual Speed Fans For variable speed fans, the PWM output is enabled at the time of engine order or by ACS. The digital inputs and outputs listed in Table 5-40 may be required based on fan vendor's requirements. The digital inputs and outputs can be configured by order entry, VEPS or DRS. Function Number Type Description 27 Digital Input Transmission Retarder 32 Digital Input Fan Control Override 29 Digital Input Air Conditioner Status Table 5-40 Fan Control Digital Input and Outputs - Variable Speed Fans VEPS or the DRS can set the A/C Fan time. The default for the parameter listed in Table 5-41 is three minutes. Parameter AC Fan Timer Table 5-41 5-82 Description Choices The minimum duration of time the fan will remain ON after the AC status digital input has indicated that the AC unit has turned OFF. The timer starts when the input is grounded after being open. 0-255 seconds Fan Timer Parameter All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.15 FUEL ECONOMY INCENTIVE Fuel Economy Incentive is a standard DDEC feature for on-highway Detroit Diesel engines. The purpose of this feature is to allow the fleet manager to set a target fuel economy while providing the driver an incentive to meet the target. 5.15.1 OPERATION Using the Fuel Economy Incentive option, a fleet manager can set a target fuel economy for each engine. If this fuel economy is exceeded, the driver will be given a slightly increased vehicle speed limit. Target fuel economy, road speed limit, maximum MPH increase, conversion factor for MPH/MPG and the option of total average fuel economy or trip fuel economy are all calibrated using the DDR, DDDL, VEPS, DRS or at engine order entry. The feature is enabled by setting the Maximum MPH to a non-zero value. In this example the following limits are set as listed in Table 5-42. Item Set Limit Vehicle Speed Limit 60 MPH Maximum MPH - the maximum allowable increase in vehicle speed 5 MPH Conversion Factor 20 MPH/MPG Target Fuel Economy Table 5-42 7 MPG Fuel Economy Limits If the driver has an average fuel economy of 7.1 MPG then the new vehicle speed limit is 62 MPH. (60 MPH + (7.1-7.0 MPG) x (20 MPH/MPG) = 62 MPH) The maximum vehicle speed obtainable regardless of the fuel economy is 65 MPH. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-83 DDEC FEATURES 5.15.2 PROGRAMMING FLEXIBILITY The parameters listed in Table 5-43 can be set using the DDR, DDDL, VEPS, or DRS. Parameter MINIMUM ECONOMY MAXIMUM MPH or MAXIMUM KPH CONVERT FACTOR MPH/MPG or CONVERT FACTOR KPH/KPL CALC TYPE Table 5-43 5.15.3 Definition Choice Indicates the minimum economy for fuel economy incentive. Indicates customer set maximum vehicle speed increase for vehicle. The miles per hour you want to allow for each full mile per gallon above the minimum MPG. FILT ECON bases the calculations on the fuel information, by periodic sampling of fuel consumption, recorded in the ECM. TRIP ECON bases the calculation on the trip portion of the fuel usage information. 5 to 10 MPG, 50.8 to 23.3 L/100 K 0 to 10 MPH, 0.0 to 16.1 KPH 0.1 to 20 MPH/MPG, 0.4 to 75.8 KPH/KPL TRIP ECON, FILT ECON Fuel Economy Incentive Parameters INTERACTION WITH OTHER FEATURES. Fuel Economy Incentive will increase the Cruise Control and vehicle speed limits. A vehicle can be have with both PasSmart and Fuel Economy Incentive, but the extra speed increments provided by the two features do not add together. For example, if Fuel Economy Incentive is set for 7 MPH of extra speed when the driver hits the maximum fuel economy target and the same vehicle has a 5 MPH PasSmart increase, the resulting speed increase is 7 MPH, not 12 MPH. 5-84 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.16 GLOW PLUG CONTROLLER The Glow Plug Controller is used for warm-up for alcohol fueled engine applications. 5.16.1 OPERATION Alcohol engines are similar to standard diesel engines. A metered amount of fuel is injected into the cylinder after the air is compressed. Ignition is accomplished by the heat of compression. Glow plugs are used to aid in combustion during starting and warm-up. The alcohol engine is equipped with several unique components not found on the diesel engine. These components are designed using alcohol compatible materials. Fuel, glow plug, air induction and catalytic converter systems are unique to alcohol engines. 5.16.2 INSTALLATION The Glow Plug Controller requires a direct battery +12/24 VDC supply into the stud on the side of the glow plug controller (see Figure 5-38). Figure 5-38 Glow Plug Controller Power Supply All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-85 DDEC FEATURES A #6 AWG wire or larger is required. This stud and exposed wire must be covered with a rubber boot to prevent shorting. No other accessories can be sourced from this line. 5.16.3 OEM CONNECTIONS Several OEM connections are required involving the engine sensor harness and the glow plug controller. Switched +12 VDC Ignition (Circuit 50) Circuit 50 is a dedicated +12 VDC ignition wire to activate the glow plug controller. No other accessories should be sourced from this line. Ground (Circuit 151) Circuit 151 from the glow plug controller must be connected directly to the negative battery post. No splices, chassis grounds, or other intermediate connections are permitted. Starter Inhibit Circuit (Circuit 968) The starter inhibit circuit is required. Typically, the starter inhibit circuit (Circuit 968) uses a continuous, transient suppressed relay placed in the starter solenoid system. The starter wire is connected to the normally open contacts. The relay coil is connected to a power source and grounded by circuit 968. No ground exists on circuit 968 when the glow plugs light is illuminated. The relay contacts to the starter are open, preventing the starter from operating. Circuit 968 is grounded when the glow plug circuit 968 is grounded when the glow plug light is not illuminated thus permitting the starter to operate. The glow plug controller enables/disables the Starter Inhibit circuit. An override circuit must be provided to allow starting if the glow plug lamp is illuminated. This circuit should be incorporated into the stop engine override switch. The starter inhibit circuit must be installed to protect the catalytic converter during engine startup. Glow Plug Panel Light The glow plug controller provides ground for the glow plug light on circuit 905. A switched +12/24 VDC source must be provided for the light. This light is OEM supplied and must be integrated into the instrument panel. The lens color must be blue and the words GLOW PLUG must appear to identify the display. The light will be illuminated for 60 seconds each time the ignition is cycled. The lamp will also illuminate to in indicate an electrical problem in the glow plug system. This lamp does not necessarily indicate glow plug operation. 5-86 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Fire Suppression System Interface/Catalytic Converter High Temperature (Circuit 906 & 416) This optional circuit interfaces with DDEC and will provide engine shutdown with a diagnostic code if the fire suppression system is activated. The fire suppression system must also shut off the electric fuel pump. A 27 k resistor must be connected if the fire suppression circuit is not utilized. See Figure 5-39 for an installation schematic. 5.16.4 DIAGNOSTICS The glow plug controller illuminates the glow plug light for startup. The light is also illuminated when one or more of the following faults are detected: Open circuit in either a glow or glow plug output circuit Short circuit in either a glow plug or glow plug output circuit Short or open circuit in the glow plug activation circuit 910 (PWM #3) from the ECM 5.16.5 FUEL SYSTEM REQUIREMENTS An electrically driven fuel pump is required for alcohol engines. A fuel pressure switch must be incorporated into the fuel pump power supply. This switch must interrupt the power to the fuel pump if the fuel pressure drops below 45 psi (approximately 310 kPa). A low fuel pressure light must be incorporated into the circuit and integrated into the instrument panel. The lens color must be red and the words LOW FUEL PRESSURE must appear to identify the display. A fuel pump override must be incorporated with the SEO switch. A high fuel temperature lamp must be incorporated into the instrument panel. The light must illuminate when the fuel temperature on the discharge side of the fuel cooler reaches 150 F (approximately 132 C). The lens color must be orange and the words HIGH FUEL TEMP must appear to identify the display. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-87 DDEC FEATURES Figure 5-39 5-88 Glow Plug Controller Installation Schematic All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.17 HALF ENGINE IDLE Half Engine Idle (HEI) mode allows the engine to run on half the cylinders. Running in HEI significantly reduces white smoke in cold engine operation, after startup or during extreme cold weather operation. The HEI logic continuously reviews several engine conditions to determine if it should be deactivated. 5.17.1 OPERATION HEI can be set to three modes of operation: disabled, enabled or enabled-cold. If disabled, HEI will not function. The conditions necessary for the engine to run in HEI mode set to "enabled" are listed in Table 5-44. If HEI is set to "enabled-cold" mode, the conditions necessary for operation in enabled mode must be met in addition to certain engine temperatures being below limits. Engine HEI Allowed DDR Configuration Allowed Parking Brake Required Vehicle Speed Limit Default Series 50 No -- -- -- -- Series 60 Yes Yes Yes 5 MPH -- Series 71 Yes No No None Enabled - Cold Series 92 Yes No No None Enabled - Cold Series 149 Yes No No None Enabled - Cold Series 2000 Yes No No 5 MPH Enabled - Cold Series 4000 Yes No No None Enabled - Cold Table 5-44 Conditions for HEI HEI can be deactivated and reactivated if certain conditions are met. This is likely only during extended idle if HEI is in the enabled-cold mode. 5.17.2 INSTALLATION HEI was not released for Series 60 engines prior to DDEC Release 5.0. Series 60 engines require a park brake input to run in HEI. 5.17.3 PROGRAMMING FLEXIBILITY DDEC Release 5.0 software or higher requires that HEI be calibrated by DDC and will not support DDR HEI configuration. For Series 60 engines, DDR calibration of HEI requires DDEC Release 7.0. On select engines, DDDL/DDR may configure HEI mode (enabled/disabled). The rest of the parameters are factory set and cannot be changed. VEPS is not capable of setting the HEI mode. 5.17.4 DIAGNOSTICS The DDR or DDDL display will tell the user if the engine is running in HEI. This display is part of the Data List menu. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-89 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-90 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.18 IDLE SHUTDOWN TIMER AND VEHICLE POWER SHUTDOWN The Idle Shutdown Timer will shutdown the engine if it remains idling for a specified period of time. There are four options that can operate with Idle Shutdown Timer. Idle Shutdown Override Vehicle Power Shutdown Variable Speed Governor (VSG) Shutdown Ambient Air Temperature Override Disable 5.18.1 OPERATION There are two types of idle shutdown: The engine has been idling for a specified time period. The engine has been idling for a specified time period and the ambient temperature is within a specified range. Certain conditions must be met for the entire time-out period for shutdown to occur. These conditions include: Engine temperature above 104 F (40 C) Engine operation at idle or VSG minimum The parking brake interlock digital input switched to battery ground OEM supplied interlocks enabled Ignition ON (Circuit 439) Fueling is stopped after the specified idle time; the ignition circuit 439 remains active after the engine shuts down. The ignition switch must be cycled to OFF (wait 10 seconds) and back to ON before the engine will restart, if shutdown occurs. The CEL will blink until the ignition is turned off to indicate shutdown has occurred. If the ignition is not turned off within 20 minutes, the ECM will begin its low power mode. This will cause the CEL to turn off. In low power mode, the ignition cycle will be considered over. All steps which normally occur after the ignition cycle was turned off will take place even though the ignition switch is still on. This prevents excessive battery drain by the ECM. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-91 DDEC FEATURES A Park Brake Switch must be installed (see Figure 5-40). Idle Shutdown Timer operates with a digital input configured as a park brake and switched to battery ground. The time can range from 1 to 100 minutes in one minute intervals. An optional digital output can be programmed for vehicle power shutdown. This is used with idle timer shutdown or the engine protection shutdown features to shut off any electrical loads on the vehicle. Figure 5-40 Park Brake Digital Input Idle Shutdown Override - Optional Idle Shutdown Override allows the operator to override the idle shutdown to keep the engine idling if this feature is enabled. Ninety seconds before the specified idle time is reached, the CEL will begin flashing. The idle timer can be disabled if the percent throttle is increased to greater than 1%. This will allow the idle timer to be overridden if longer engine idling is desired. The timing sequence can be re-initiated by disengaging and reapplying the parking brake, by cycling the ignition OFF (waiting 10 seconds) and back to ON or by once again increasing the percent throttle greater than 1%. 5-92 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Vehicle Power Shutdown - Optional Vehicle Power Shutdown is used with Idle Timer Shutdown or Engine Protection Shutdown. After the idle timer times out or engine protection shuts the engine down, the Vehicle Power Shutdown relay shuts down the rest of the electrical power to the vehicle. A Vehicle Power Shutdown relay can be installed to shutdown all electrical loads when the engine is shutdown (see Figure 5-41). This figure also provides a method to turn OFF the ignition while the idle timer is active. The engine will shutdown after the specified idle time and will reset the relay (ignition circuit). Figure 5-41 Vehicle Power Shutdown Relay All electrical loads that should be turned OFF when the engine shuts down should be wired through this relay. Refer to section 4.2, "Digital Outputs" for additional information. Enabled on Variable Speed Governor (VSG) - Optional This option, when enabled, allows the engine to be shutdown when operating on the VSG when the conditions are met for the Idle Timer Shutdown. Ambient Air Temperature Override Disable - Optional This option allows the override to be disabled based on ambient air temperature. If the upper and lower temperature limits are set and the ambient temperature is within the specified limits, the override will be disabled and the engine will be shutdown after the specified time limit is met. To disable this feature, the upper and lower limits must be set to 167 F. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-93 DDEC FEATURES For example, if the upper limit is set to 80 F and the lower limit is set to 65 F, the override would be disabled if the ambient air temperature was between 65 F and 80 F (see Figure 5-42). Figure 5-42 Ambient Air Temperature Override Disabled Inactive Shutdown The Idle Shutdown Timer can be defeated by holding down the throttle or by not setting the park brake. The inactive timer will shutdown the engine after 20 minutes if the fueling is not sufficient to accelerate the vehicle To improve the accuracy of ambient air temperature sensor readings, an ambient air temperature sensor can be installed. This installation is recommended if the ambient air temperature shutdown feature is enabled. Refer to section 3.14.27, "Ambient Air Temperature Sensor," for additional information. 5.18.2 PROGRAMMING REQUIREMENTS AND FLEXIBILITY To program the Idle Shutdown timer, the digital inputs listed in Table 5-45 must be configured by order entry, VEPS or DRS. Description Function # Type Park Brake/ISD 5 Digital Input Vehicle Power Shutdown - optional 6 Digital Output Table 5-45 Idle Shutdown Timer Digital Input The Idle Shutdown timer options listed in Table 5-46 can be programmed by the DDR, DDDL, VEPS or DRS. 5-94 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Parameter ENABLED TIME (MIN) OVERRIDE ENABLED ON VSG OVERRIDE TEMP DISAB LOWER LIMIT UPPER LIMIT Table 5-46 5.18.3 Description Enables or Disables the Idle Shutdown feature. N/A will be displayed if the parking brake has not been configured as a digital input. The amount of engine idle time that is allowed before the Idle Shutdown feature stops fueling the engine. The override will flash the CEL 90 seconds before shutdown to allow the driver to cancel the shutdown by pressing the throttle. Enables or disables the Idle Timer Shutdown feature when operating on the Variable Speed Governor. Allows choice between lower or upper limit to disable the Idle Shutdown Override feature based on ambient air temperature. The lower limit of the ambient air temperature range that will disable the Idle Shutdown Override feature. The upper limit of the ambient air temperature range that will disable the Idle Shutdown Override feature. Choice / Display YES, NO 1 to 100 minutes YES, NO YES, NO LOWER LIMIT, UPPER LIMIT -40 to "UPPER LIMIT" F "LOWER LIMIT" to 167 F Idle Shutdown Timer Programming Options INTERACTION WITH OTHER FEATURES The Idle Shutdown Timer is required for Optimized Idle. Refer to section 5.24, "Optimized Idle," for additional information. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-95 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-96 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.19 IRIS The Infrared Information System (IRIS) is an optional feature that provides for infrared two-way communication between a vehicle and a PC. Detailed IRIS installation information can be found in the IRIS User and Installation Guide(6SE0036). 5.19.1 OPERATION All data which is currently transmitted via cable, can now be sent using IRIS. This includes downloading of all information in the ECM, ProDriver DC, ProDriver, engine diagnosis, and complete engine reprogramming. IRIS replaces direct hook-up via cables with an infrared beam (see Figure 5-43). Figure 5-43 IRIS Configuration All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-97 DDEC FEATURES Downloading and uploading time takes place with IRIS at the same high speed as a direct cable connection. IRIS eliminates the need for the driver to exit the vehicle, locate a cable and plug into the vehicle. No physical connections are required. IRIS can also be used in a service bay with diagnostic equipment, eliminating the need to bring the computer cart to the vehicle. IRIS works with most devices communicating via the J1708 Data Link. One transceiver, the Mobile Unit, is mounted on the vehicle and the other, the Base Unit, is located where the vehicle owner wants to extract information, such as the entrance to the shop or the fuel island. The base transceiver is continuously polling for a vehicle, while the mobile transceiver is silent until it receives a message from the base transceiver. When the mobile transceiver on the vehicle is in general alignment to the base transceiver, handshaking will take place and establish the infrared link. (see Figure 5-44). Figure 5-44 IRIS - Infrared Two-way Communication The base transceiver will only communicate with one mobile transceiver at a time. The vehicle must be moved out of the infrared connection area for the base transceiver to start polling for another vehicle. The IRIS dash light will flash during the handshaking communication between the two transceivers. Once the infrared link is established the light will be solidly illuminated until the connection is broken. If the remote Data Interface (RDI) is used with IRIS, the RDI lights will indicate when the extraction has been completed. For installations without RDI, the service technician will need to indicate to the driver that the reprogramming or extraction has been completed. 5-98 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.19.2 INSTALLATION As long as the two transceivers are in general alignment, IRIS will function up to a distance of 25 ft outdoors to 50 ft indoors (see Figure 5-45). Figure 5-45 Horizontal and Vertical Alignment is not Critical Use the following guidelines when installing IRIS: The control module should be mounted in a cab environment. The transceiver can be shaded to obtain more distance. Do not shine electronic ballast fluorescent lights into the transceiver. Do not install transceivers where they are exposed to strobe lights. Do not add more than two transceivers with one control module. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-99 DDEC FEATURES Mobile Unit Installation The Mobile Unit installation consists of an transceiver and the Mobile Unit Module (see Figure 5-46). The transceiver should be mounted outside either on the side or the front of the vehicle at least seven feet above the ground for optimal performance. Figure 5-46 IRIS Mobile Unit The Mobile Unit Module can be mounted anywhere inside the vehicle. It can be hidden behind the dash, but should be accessible for the transceiver and vehicle harness connection and for troubleshooting purposes. 5-100 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Base Unit Installation The Base Unit consists of a transceiver and the Base Unit Module. Refer to Figure 5-47. Figure 5-47 Base Unit Installation The Base Unit Module can be near the PC running the programming or extraction software programs. A DDC Translator Box is between the base unit and the PC. The cable length between the base unit and the translator box can be as long as 100 ft. This is the same translator box used when data communication occurs using a direct cable. Refer to the IRIS User and Installation Guide (6SE0036) for more installation information. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-101 DDEC FEATURES Base Unit Installation with Remote Data Interface (RDI) The Base Unit installation with an Remote Data Interface (RDI) consists of an eyeball and the Base Unit Module (see Figure 5-48). Figure 5-48 Base Unit Module with RDI Installation The IRIS bracket should be located near the RDI where extractions will be done. To assemble the eyeball and module on to the bracket. Bolts, screws, and other hardware for mounting the IRIS bracket to a wall, post, or fence is required to complete the installation. These parts are not included in the kit. The Standard IRIS Harness (P/N: 23528635) is used for this installation. Its wires are routed into the RDI case via one of the cable entry bushings; the power connection wires are routed to the RDI power connection on the RDI circuit board and the J1708 date link wires are spliced with the RDI data link wires. Refer to the IRIS User and Installation Guide (6SE0036) for detailed installation information. 5-102 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL IRIS Mobile Service Kit Installation The IRIS Mobile Service Kit (P/N: 23528563) provides a temporary installation of IRIS that can be removed and used on multiple vehicles. The bracket hangs on the window of the vehicle and plugs directly into the diagnostic connector (see Figure 5-49). Figure 5-49 IRIS Mobile System on Vehicle Detailed IRIS installation information can be found in the IRIS User and Installation Guide(6SE0036). All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-103 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-104 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.20 LOW GEAR TORQUE LIMITING Low Gear Torque Limiting is an optional feature that allows a transmission to be used with engines capable of producing more torque than the transmission's peak torque rating. 5.20.1 OPERATION Low Gear Torque Limiting provides a limit on the available torque if the ratio of vehicle speed to engine speed is below a set point. This limits full torque in lower gears and allows a transmission to be used with engines above the transmission's regular torque rating. For example, the customer wants to hold the torque to 1400 ft lbs up to 8th gear. The transmission operates with the ratios listed in Table 5-47. Gear Ratio 5 3.57 6 2.79 7 2.14 << Threshold Table 5-47 8 1.65 9 1.27 10 1.00 Transmission Ratios Under Low Gear Torque Limit, set the "torque limit" (actual maximum torque you want to limit to) to 1400 and "threshold" to 1.89 (value between the gear you want to limit and the previous gear's ratio). To summarize, the customer wants to limit torque up to the 8th gear to 1400. Find the ratio between 7th and 8th (1.89). From 8th gear on up, the full rated torque will be available. 5.20.2 PROGRAMMING REQUIREMENTS AND FLEXIBILITY A VSS or output shaft speed message over SAE J1939 is required (refer to section 3.14.25, "Vehicle Speed Sensor"). VEPS or DRS can enable the parameters listed in Table 5-48. Parameter Description Choice / Display LOW GEAR TORQUE LIMITING Provides a limit on the available torque if the ratio of vehicle speed to engine speed is below a set point. 0 to 65535 ft lbs 65535 ft lbs disables this feature. LOW GEAR THRESHOLD The gear ratio below which torque is limited. 0.047 to 300 Table 5-48 Low Gear Torque Limiting Parameters All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-105 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-106 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.21 MAINTENANCE ALERT SYSTEM The Maintenance Alert System (MAS) is an optional feature that monitors engine fluid levels and filter restrictions and notifies the driver and/or technician when maintenance is required. MAS parameters that can be monitored are: Air Filter Restriction - OEM installed sensor Add Coolant Level - OEM installed sensor Oil Level - factory installed sensor Fuel Restriction - factory installed sensor The Oil Level Sensor and Fuel Restriction Sensor are standard MAS sensors. The CEL and SEL may be used to indicate the codes or an optional MAS display, ProDriver, Diagnostic Data Reader (DDR) or Detroit Diesel Diagnostic Link (DDDL) may be used. MAS is available with DDEC IV software Release 27.0 or later. 5.21.1 OPERATION DDEC continuously monitors the various sensors and logs and displays a code when a fault occurs. MAS faults do not engage any Engine Protection features (rampdown or shutdown). DDEC will notify the operator/technician of maintenance requirements by one or more of the following methods: CEL/SEL indication ProDriver Maintenance Alert System Display Module DDR DDDL For mobile applications, the DDR, DDDL, or MAS display must be used by personnel other than the vehicle operator. To avoid injury from loss of vehicle/vessel control, the operator of a DDEC equipped engine must not use or read any diagnostic tool while the vehicle/vessel is moving. The vehicle operator must maintain control of the vehicle while an assistant performs the diagnostic evaluations. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-107 DDEC FEATURES Oil level can only be determined when the engine is not running (i.e. after the ignition is turned off and after the drain down period or before the engine has been started). There is a minimum of four minutes and a maximum of 15 minutes (based on oil temperature) to determine the oil level after the engine has shutdown. The Air Filter Restriction Sensor (AFRS) has two trip points, one at 18 in.H2O and the second at 25 in.H2O. An air filter is considered to be restricted if the AFRS reads 18 in.H2O and the engine is operating below 1500 RPM or the AFRS reads 25 in.H2O at any engine speed. The air filter restriction logic will look for either of these two restrictions that have occurred at least 24 engine hours apart but no more than 72 hours apart. When this condition is met, the ECM will activate an air filter restriction fault. The air filter restriction fault and fuel restriction fault will remain active for the entire ignition cycle. If the MAS display is used, the fault will be latched in the display until a FILTER RESET is done. ECM Power Down Behavior If the Add Coolant Level Sensor (ACLS) or Oil Level Sensor (OLS) are configured, the ECM will go into a reduced activity mode after ignition off. In this mode, the ECM will not continuously broadcast data, but will still accept and respond to requests for two hours. The ECM will continue to monitor all the sensors, but the injectors will not fire. Just before the reduced activity mode ends, the ECM will broadcast the fluid levels, all faults (active and inactive) and preventative maintenance status. After the ECM has powered down, it will not respond to data link requests. CEL/SEL Flashing There are four options for using the CEL and SEL for MAS, which may be set with the DDR (Release 24.0 or later), DDDL (Release 3.0 or later), VEPS (Release 24.0 or later), or DRS. 1. CEL and SEL will not illuminate or flash for MAS Warnings - sensor faults will still be logged (recommended for vehicles equipped with the optional display modules). 2. CEL will illuminate continuously while the warning is active, i.e. low fluid levels (oil or coolant), filter restrictions. 3. Blinking CEL and SEL for 15 seconds when the ignition is first turned ON and warnings have been present. 4. Both 2 and 3. 5-108 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The DDR, DDDL, or VEPS can set options for filter restriction and fluid levels independently. For example, filter restrictions can be set so the CEL/SEL do not flash, but the sensor code is logged and the fluid levels can be set so that CEL will turn on when the warning is active. The factory set default is listed in Table 5-49. Parameters Default Fluid Levels CEL and SEL flash for 15 seconds when the ignition is first turned on. Filter Restrictions CEL will illuminate while the warning is active. Table 5-49 Factory Set Defaults for CEL and SEL ProDriver ProDriver(Release 2.03 or later) will display any active faults and descriptions as they occur. The active faults listed in Table 5-50 will be displayed (PID and FMI) without description. * DDC Code # (Flashed) SAE J1587 Code # (PID) FMI Description 13 111 6 Add Coolant Level Sensor (ACLS) Circuit Failed Low 16 111 5 Add Coolant Level Sensor (ACLS) Circuit Failed High 89 111 12 Maintenance Alert System Coolant Level Fault* 37 95 3 Fuel Restriction Circuit Failed High 38 95 4 Fuel Restriction Circuit Failed Low 89 95 0 Fuel Restriction High This fault will be logged when the Add Coolant Level Circuit (ACLS) reports the coolant level is OK and the Engine Protection Coolant Level Circuit (CLS) reports that coolant is low. Table 5-50 Active Faults Displayed by ProDriver Without Description All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-109 DDEC FEATURES Maintenance Alert System Display Module The MAS display is cab mounted to easily display the current maintenance conditions. The display (see Figure 5-50) has seven tricolor LEDs and two switches (FILTER RESET and CHECK), each labeled for their function. Figure 5-50 Maintenance Alert System Display (P/N: 23525655) To display the current status of MAS parameters (listed in Table 5-51), press the CHECK button at any time to start the bulb check sequence. 5-110 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Parameter Green Amber Flashing Red Air Filter OK N/A Filter restriction is high. Coolant Level OK N/A Coolant Level is low. (Add coolant) DDEC Codes No sensor fault codes Inactive sensor fault codes present; No Active sensor fault codes Active sensor fault code is present. N/A DDEC Reports Preventive Maintenance configured, no maintenance required N/A Preventive Maintenance configured and needs service. Preventive Maintenance not configured. fuel RESTRICT OK N/A Filter restriction is high. IGN Key ON N/A N/A Oil Level OK Oil is still draining to the oil pan. Table 5-51 ECM asleep, memory data displayed. Low oil level (minimum of 4 quarts) Blank Sensor fault or not configured. Sensor fault or not configured. Sensor fault or not configured. ECM active, current data displayed. Sensor fault or not configured. Maintenance Alert System Display Light Status During the bulb check the display will request the current Preventative Maintenance (PM) data and update its memory with the received information. The LEDs will go through the following bulb check sequence: 1. All of the LEDs turn on and are green for approximately one (1) second. 2. All LEDs turn off very briefly. 3. All LEDs turn on and are red for approximately one (1) second. 4. All LEDs turn off very briefly. 5. The current information from memory will turn the LEDs to their appropriate color. 6. The LEDs will turn off after approximately 10 seconds with no switch activity. The display will latch the fault for filter restrictions until cleared from the display. To reset the faults, press and hold the FILTER RESET button for three (3) seconds while the data is displayed. This will initiate the reset sequence for filters. This reset will only clear the display memory for each of the configured filters. FILTER RESET will change the flashing red filter LEDs to green until new and/or differing data is received and stored. If a filter LED is off and stays off after a reset this indicates that a problem other than Filter Restriction High (FMI 0) exists for that filter. The other LEDs (not used for filters) will still display the current data as they did before the reset sequence was initiated. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-111 DDEC FEATURES The MAS display will also perform minor diagnostics to inform the operator if the connection to the data link has been broken while the ignition is on. When this condition occurs, the display will flash all LEDs red at roughly two times/second while the ignition is on and until the FILTER RESET button is pushed, at which time the display will go blank. If the MAS display is energized via the CHECK button before the link connection has been repaired, the LEDs will again flash red in place of the normal service item status until the 10 second "no activity" timer has expired. After the display sees data bus activity, it will revert back to normal operation with the currently stored data and normal updates to the stored data. Diagnostic Data Reader The DDR (Release 24.0 or later) Maintenance Status menu will display the current status of MAS parameters, as listed in Table 5-52. Parameter OIL LEVEL COOL LEVEL AIR FILTER FUEL FILTER Table 5-52 Description Choices Indicates the engine oil level. NOTE: While the engine is running, or for a maximum of 15 minutes after shutting down, the engine oil level will be UNKNOWN. Indicates the coolant level in the reservoir. Indicates the condition of the air inlet filter. Indicates the condition of the fuel filter. OK, ADD, N/A, UNKNOWN, FAIL FULL, ADD, LOW, N/A, FAIL OK, PLUGGED, ERROR, N/A OK, PLUGGED, ERROR, N/A DDR Maintenance Status Menu List of MAS Parameters The DDR (Release 24.0 or later) main data list will display the MAS parameters, as listed in Table 5-53. 5-112 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Parameter OIL LEVEL COOL LEVEL AIR FILT RS "H2O or kPa FUEL IN RES "HG or kPa Table 5-53 Description Indicates the engine oil level. NOTE: While the engine is running, or for a maximum of 15 minutes after shutting down, the engine oil level will be UNKNOWN. Indicates the coolant level in the reservoir. Indicates the relative amount of restriction measured at the air inlet filter. Choices OK, ADD, N/A, UNKNOWN, FAIL Indicates the restriction measured at the fuel pump inlet. FULL, ADD, LOW, N/A, FAIL 0.0 to 99.9 "H2O 0.0 to 99.9 kPa FAIL, N/A 0.0 to 99.9 "Hg 0.0 to 99.9 kPa FAIL, N/A DDR Main Data List MAS Parameters NOTE: After replacing the filter, PLUGGED will be displayed on the DDR until inactive codes or maintenance codes are cleared. Maintenance codes can be cleared by the DDR under the Maintenance Alert menu. Only the MAS faults listed in Table 5-54 will be cleared under the Maintenance Alert menu. Table 5-54 PID FMI Description 98 1 Oil Level Low 111 1 Coolant Level Low 107 0 Air Filter Restriction High 95 0 Fuel Restriction High Maintenance Codes that Can Be Cleared by the DDR Detroit Diesel Diagnostic Link The DDDL (Release 3.0 or later) Maintenance Alert menu will display the current status of the MAS parameters and preventative maintenance status as listed in Table 5-55. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-113 DDEC FEATURES Parameter OIL LEVEL COOLANT LEVEL AIR FILTER RESTRICTION FUEL FILTER RESTRICTION PREVENTATIVE MAINTENANCE STATUS SERVICE A PREVENTATIVE MAINTENANCE STATUS SERVICE B PREVENTATIVE MAINTENANCE STATUS SERVICE C Table 5-55 5-114 Description Indicates the engine oil level. NOTE: While the engine is running, or for a few minutes after shutting down, the engine oil level will be UNKNOWN. Indicates the coolant level in the reservoir. Indicates the relative amount of restriction measured at the air inlet filter. Indicates the restriction measured at the fuel pump inlet. Choices OK, ADD, N/A, UNKNOWN, FAIL FULL, ADD, LOW, N/A, FAIL OK, PLUGGED, ERROR, N/A OK, PLUGGED, ERROR, N/A Indicates the status of preventative maintenance limits. EXPIRED, NOT EXPIRED, NOT CONFIGURED Indicates the status of preventative maintenance limits. EXPIRED, NOT EXPIRED, NOT CONFIGURED Indicates the status of preventative maintenance limits. EXPIRED, NOT EXPIRED, NOT CONFIGURED DDDL Maintenance Alert Menu List of MAS Parameters All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The DDDL (Release 3.0 or later) Instrumentation menu will display the MAS parameters as listed in Table 5-56 under the "User ∧6" tab. Parameter OIL LEVEL COOLANT LEVEL AIR FILTER DIFFERENTIAL PRESSURE FUEL FILTER DIFFERENTIAL PRESSURE Table 5-56 Description Choices Indicates the engine oil level. NOTE: While the engine is running, or for a few minutes after shutting down, the engine oil level will be UNKNOWN. Indicates the coolant level in the reservoir. Indicates the relative amount of restriction measured at the air inlet filter. Indicates the restriction measured at the fuel pump inlet. OK, ADD, N/A, UNKNOWN, FAIL FULL, ADD, LOW, N/A, FAIL 0.0 to 99.9 "H2O 0.0 to 99.9 kPa FAIL, N/A 0.0 to 99.9 "Hg 0.0 to 99.9 kPa FAIL, N/A DDDL Instrumentation Menu List of MAS Parameters NOTE: After replacing the filter, DDDL will display PLUGGED until the inactive or maintenance codes are cleared. Maintenance Codes can be cleared by DDDL under the Diagnostic Maintenance Alert menu. Only the MAS faults listed in Table 5-57 will be cleared under the Maintenance Alert menu. PID FMI Description 98 1 Oil Level Low 111 1 Coolant Level Low 107 0 Air Filter Restriction High 95 0 Fuel Restriction High Table 5-57 MAS Maintenance Codes DDDL Can Clear Under the Maintenance Alert Menu All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-115 DDEC FEATURES 5.21.2 INSTALLATION The Oil Level Sensor (OLS) and the Fuel Restriction Sensor (FRS) are factory installed. The Air Filter Restriction Sensor (AFRS), the Add Coolant Level Sensor (ACLS), and the MAS Display Module are installed by the OEM using the MAS pigtail on the ESH (see Figure 5-51). Figure 5-51 5-116 Location of MAS Pigtail All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The MAS pigtail (see Figure 5-52) on the DDC installed Engine Sensor Harness will be used to wire the AFRS and ACLS (see Figure 5-54). Figure 5-52 MAS Pigtail Connection to the Air Filter Restriction Sensor All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-117 DDEC FEATURES Air Filter Restriction Sensor The AFRS (see Figure 5-53) is mounted downstream of the air filter and upstream of the turbocharger. Figure 5-53 Air Filter Restriction Sensor The AFRS must be in a straight section of pipe or where the OEM mechanical unit is normally mounted. This sensor must be enabled with VEPS (Release 24.0 software or later) or DRS. NOTE: The AFRS sensor and associated wiring is OEM installed. 5-118 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Two fittings are provided with the sensor (see Figure 5-54). Each OEM can pick the application appropriate fitting. Figure 5-54 Air Filter Restriction Wiring Diagram All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-119 DDEC FEATURES Add Coolant Level Sensor is used to warn the driver that the coolant level is below the recommended level but engine damage is not imminent. If the tank is equipped with an "ADD" level, the sensor should be installed there. This sensor will be activated approximately mid-way between the cold full level and the level where the standard (engine protection) CLS is located (see Figure 5-55). Figure 5-55 Add Coolant Level Sensor Location - Radiator Surge Tank The ACLS must be enabled with VEPS (Release 24.0 or later) or DRS. NOTE: All ACLS components are OEM installed. 5-120 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL ACLS will require an additional module (P/N: 23524054) to condition the sensor signal. The module output will be connected to the MAS pigtail on the DDC supplied Engine Sensor Harness. See Figure 5-56 for wiring schematic. Figure 5-56 Add Coolant Level Sensor Installation All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-121 DDEC FEATURES Fuel Restriction Sensor The FRS is factory installed at DDC and is incorporated into the DDC Engine Sensor Harness (see Figure 5-57). No OEM installation is required. The proper 6N4C and 6N4 groups must be specified. The FRS will log a fault code at 12 in. Hg. Figure 5-57 5-122 Fuel Restriction Sensor Installation All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Oil Level Sensor The OLS is factory installed at DDC and is incorporated into the DDC Engine Sensor Harness (see Figure 5-58). No OEM installation is required. The proper 6N4C and 6N4 groups must be specified. The OLS is mounted in the Series 60 engine oil pan at four quarts low. Figure 5-58 Oil Level Sensor Installation All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-123 DDEC FEATURES Maintenance Alert System Display Module Installation The display must be mounted in an interior location easily accessible from outside the vehicle for mechanics and other service personnel to view. It cannot be mounted in the engine compartment. The display may be installed in other enclosed areas such as a bus battery compartment. If the display is installed anywhere outside of the vehicle cab or passenger compartment, it must be completely sealed inside a protective enclosure to protect it from dirt and moisture.The part number for the MAS display is P/N: 23525655. See Figure 5-59 for the dimensions of the MAS display. Figure 5-59 5-124 Maintenance Alert System Display Dimensions All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL An example of a typical bracket used to mount the MAS display in passenger compartment applications may be seen in the next two illustrations (see Figure 5-60 and Figure 5-61). Figure 5-60 Maintenance Alert Display Bracket All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-125 DDEC FEATURES Figure 5-61 5-126 Maintenance Alert Display and Bracket All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The bracket is the responsibility of the OEM. A label on the front face of the bracket should be used for operating instructions and light definition. See Figure 5-62 for an example. Figure 5-62 Maintenance Alert Display Bracket with Label All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-127 DDEC FEATURES Maintenance Alert System Display Harness The connector for the MAS display is a molded integral connector that mates to Delphi Packard 12065425 with the connections shown in the following schematic. See Figure 5-63 for the wiring schematic. Figure 5-63 5.21.3 Maintenance Alert System Display Harness PROGRAMMING REQUIREMENTS AND FLEXIBILITY The OLS and FRS must be specified with the correct 6N4C and 6N4 groups. The OEM installed sensors must be setup by VEPS or DRS. These sensors are the Air Filter Restriction Sensor, Add Coolant Level Sensor. NOTE: The MAS display must be wired to a 12 V battery and a 12 V ignition source only. 5-128 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The DDR can set options for the CEL and SEL indication of MAS codes as listed in Table 5-58. Parameter Description Choices Action Filters Determines if the CEL/SEL will flash a maintenance alert for filters. NO, FLASH, CONTINUOUS, BOTH Levels Determines if the CEL/SEL will flash a maintenance alert for fluid levels. NO, FLASH, CONTINUOUS, BOTH NO - no illumination or flashing FLASH - flash at ignition on CONTINUOUS - Light will stay on when there is an alert (CEL only) BOTH - light will flash at ignition on, then stay on Table 5-58 5.21.4 DDR Options DIAGNOSTICS The codes that will be logged are listed in Table 5-59. * DDC Code # (Flashed) SAE J1587 Code # (PID) FMI Description 13 111 4 (Engine Protection) Coolant Level (CLS) Circuit Failed Low 13 111 6 Add Coolant Level (ACLS) Circuit Failed Low 16 111 3 (Engine Protection) Coolant Level (CLS) Circuit Failed High 16 111 5 Add Coolant Level (ACLS) Circuit Failed High 37 95 3 Fuel Restriction Circuit Failed High 38 95 4 Fuel Restriction Circuit Failed Low 43 111 1 Coolant Level (CLS or ACLS) Low 65 107 3 Air Filter Restriction Circuit Failed High 65 107 4 Air Filter Restriction Circuit Failed Low 73 107 0 Air Filter Restriction High 81 98 3 Oil Level Circuit Failed High 82 98 4 Oil Level Circuit Failed Low 84 98 1 Oil Level Low 89 111 12 Maintenance Alert System Coolant Level Fault* 89 95 0 Fuel Filter Restriction High This fault will be logged when the Add Coolant Level Circuit (ACLS) reports the coolant level is OK and the Engine Protection Coolant Level Circuit (CLS) reports that coolant is low. Table 5-59 Maintenance Alert System Codes NOTE: Filter restrictions will latch a high restriction fault to active status for the entire ignition cycle. 5.21.5 INTERACTION WITH OTHER FEATURES There are four options for using the CEL and SEL for MAS, which may be set with the DDR (Release 24.0). ProDriver (Release 2.30 or later) will display any active faults as they occur. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-129 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-130 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.22 MANAGEMENT INFORMATION PRODUCTS The Management Information Products, formerly called Data Hub, comprise a modular system that provides monitoring of any DDEC-equipped engine. These products provide substantial storage capacity, flexible data extraction and communication capabilities. Members of the system that collect data include DDEC III Data Pages (refer to section 5.22.2) DDEC IV Data (refer to section 5.22.3) Data Logger (refer to section 5.22.8) ProDriver®(Release 3.0) (refer to section 5.22.9) ProDriver DC™ (refer to section 5.22.10) PC software for data analysis and reporting include: DDEC Reports (refer to section 5.22.4) Detroit Diesel Data Summaries (refer to section 5.22.5) ProDriver Reports (refer to section 5.22.6) ProManager® Rel. 2.1 (refer to section 5.22.7) 5.22.1 OPERATION The Management Information Products are designed to provide instantaneous feedback to the driver via the ProDriver or ProDriver DC display module. These driver-friendly features help provide an understanding of the effect of the driver's actions on the engine and vehicle performance. The DDEC ECM provides engine control and monitoring as well as a stored summary of engine performance. The Data Logger compliments DDEC III Data Pages by extending the memory available to store detailed trip information. Data in these devices can be extracted and analyzed with the PC software products as follows: DDEC Reports extracts data from all hardware devices and analyzes data from DDEC III Data Pages and DDEC IV Data. ProDriver Reports extracts and analyzes ProDriver (Release 3.0) data. ProManager Rel. 2.1 software extracts and analyzes the Data Logger data and DDEC III Data Pages. Data Summaries extracts data from all hardware devices and analyzes data from all but the Data Logger. All these products allow printing of comprehensive reports for managing vehicle operation. Additional diagnostic data available from Management Information includes: Instantaneous and average fuel economy Trip time, miles, fuel, total fuel used economy, and average speed All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-131 DDEC FEATURES Driving time, percentage, miles, fuel, and fuel economy Idle time, fuel and percentage Cruise time, percentage, miles, fuel, and fuel economy Top gear time, percentage, miles, fuel used, and fuel economy One gear down time, percentage, miles, fuel used, and fuel economy VSG time, fuel, and percentage Overspeed time and percentage for two speed thresholds Over-rev time and percentage Maximum speed and RPM Coasting time and percentage Driving average load factor (ProDriver 3.0 and DDEC IV Rel. 21 and higher) Automated oil change interval tracking Hard braking incident records Driver initiated incident records Stop and check engine code logs Optimized Idle™ active time, idle time, and estimated fuel savings SAE J1587 data link time-outs and power interruptions Leg time, distance, fuel used, fuel economy, average speed, and cruise time and percentage Last Stop records 5.22.2 DDEC III DATA PAGES DDEC III Data Pages is an optional feature of the DDEC III ECM. When activated, it utilizes available memory and processing speed to record engine and vehicle operating information. Data is stored in daily records for a maximum of 14 working days. Information on engine performance trends, service intervals and ECM diagnostics are also stored. 5-132 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.22.3 DDEC IV DATA DDEC IV Data is a standard part of the DDEC IV ECM. DDEC IV Data utilizes available memory and processing speed, along with a built-in, battery-backed clock/calendar to document the performance of the driver and vehicle. Data is stored in three monthly records and in a trip file that may be reset at extraction. Data on periodic maintenance intervals, hard brake incidents, last stop records, daily engine usage, and ECM diagnostics is also stored. DDEC IV Data can be extracted onto a PC hard disk through a wide range of options: Direct extraction using a DDEC translator box and cables connected to a PC running DDEC Reports. A Remote Data Interface (RDI) which adds automation to the process. This weatherproof extraction module is usually located at a fuel island and the PC it connects to is remotely located. The PC will be operating the communications part of DDEC Reports called DDEC Communications. Wireless extraction via cellular telephone, satellite radio communications equipment. The PC can be operating DDEC Reports or DDEC Communications. 5.22.4 DDEC REPORTS After the data is extracted from the ECM, DDEC Reports software produces a wide range of diagnostic and management reports. DDEC Reports produces comprehensive trip reports in both on-highway and nonroad markets. The on-highway reports are listed in Table 5-60. Available Reports DDEC III Data Pages Trip Activity X Vehicle Speed/RPM X DDEC IV - R20 DDEC IV - R21 or Later DDEC Reports Version Required X 2.0 or Later X X 2.0 or Later Overspeed / Over Rev X X 2.0 or Later Engine Load/RPM X X 2.0 or Later X X 2.0 or Later Vehicle Configuration X Periodic Maintenance X X 2.1 or Later Hard Brake Incident X 2.1 or Later Last Stop X 2.1 or Later DDEC Diagnostic X 2.1 or Later X 2.1 or Later Monthly Activity Profile X X 2.1 or Later Daily Engine Usage X 2.1 or Later X 2.1 or Later Life to Date Table 5-60 X On-highway Reports Available from DDEC Reports All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-133 DDEC FEATURES The nonroad reports are listed in Table 5-61. DDEC III Data Pages DDEC IV - R20 DDEC IV R21 or Later DDEC Reports Version Required Period Activity X X 3.0 or Later High RPM X X 3.0 or Later Engine Load/RPM X X 3.0 or Later Configuration X X 3.0 or Later Periodic Maintenance X Available Reports X 3.0 or Later DDEC Diagnostic X 3.0 or Later Profile X 3.0 or Later Monthly Activity X 3.0 or Later Daily Engine Usage X 3.0 or Later Life to Date X 3.0 or Later Table 5-61 Nonroad Reports Available from DDEC Reports See Figure 5-64, Figure 5-65, and Figure 5-66 for examples of on-highway DDEC Reports. See Figure 5-67, Figure 5-68, and Figure 5-69 for examples of nonroad DDEC Reports. This Windows® 95 compatible product is included as part of the Detroit Diesel Diagnostic Link (DDDL) service tool. DDDL is designed for the service technician and with the built-in troubleshooting manual it is ideal for extracting data, analyzing and printing information from the ECM. A set of Marine reports is now available in DDEC Reports 3.10. 5-134 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 5-64 DDEC Reports, On-highway - Idle and Drive Time All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-135 DDEC FEATURES Figure 5-65 5-136 DDEC Reports, On-highway - Daily Engine Usage All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 5-66 DDEC Reports, On-highway - Engine Load/RPM All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-137 DDEC FEATURES Figure 5-67 5-138 DDEC Reports, Nonroad - Periodic Maintenance All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 5-68 DDEC Reports, Nonroad - High RPM Detail All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-139 DDEC FEATURES Figure 5-69 5-140 DDEC Reports, Nonroad - Diagnostic Record All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.22.5 DETROIT DIESEL DATA SUMMARIES This new PC program for Windows 95/98 is used to analyze and report trip data from DDEC Data, ProDriver and ProDriver DC. Data Summaries can report trip data one vehicle at a time, summary reports for the whole fleet, and reports of driver trip activity. Trip extractions from individual vehicles are loaded into Data Summaries database. The database divides trip extractions into yearly files. New extractions are added to the current year database making it possible to run reports for any time period within the year. this make it possible for the user to form summary reports of the entire fleet, for a group of vehicles, or an individual vehicle. It is also possible to do the same for all drivers, groups of drivers, or individual drivers. Data Summaries also supports ProDriver DC. Utilities in Data Summaries allow the user to format and setup the different data card types, such as the Driver Card, the Configuration Card, etc. A driver ID can be placed on Driver Cards. The extracted data is read from Driver Cards and placed into the database. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-141 DDEC FEATURES 5.22.6 PRODRIVER REPORTS This Windows® 95 compatible software sends set-up parameters to, extracts data and generates Activity and Incident reports from ProDriver (Release 3.0). ProDriver Reports replaces ProManager 1.02, the DOS version of ProDriver reporting software. ProDrivers containing firmware versions prior to Release 3.0 must be reprogrammed to Release 3.0. ProDriver reports cannot analyze data from these older versions. See Figure 5-70 and Figure 5-71. Figure 5-70 5-142 ProDriver Reports Trip Page All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 5-71 ProDriver Hard Brake Incident Report All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-143 DDEC FEATURES 5.22.7 PROMANAGER 2.10 ProManager 2.10 is a DOS-based fleet management software that extracts data from DDEC III Data Pages and the Data Logger to produce comprehensive trip, summary and exception reports for fleet managers. Several levels of data presentation are available, from management overviews to detailed analysis reports (see Figure 5-72). A custom reporting feature allows users to meet their specific needs. Figure 5-72 5-144 ProManager Screen All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Reports available from ProManager 2.10 are listed in Table 5-62. Available Reports Data Pages Data Logger Logger + ProDriver Operational Overview X X X Management Overview X X X Exceptions X X X Custom X X X Driver Grading X Driver Activity User-defined X X X Event List X X Leg/Stop List X X Event Summary X X X Event Analysis X X X Detailed Incident Record X X State Activity X Trends X X X Performance Trend Analysis X X X X X Detailed Alert ECM Diagnostics X X X Service Interval Summary X X X Distance Left Graph X X X Service Schedule X X X Speed Histogram X X X RPM Histogram X X X Speed vs. RPM X X X Engine Usage Profile X X X Table 5-62 Reports Available from ProManager 2.10 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-145 DDEC FEATURES 5.22.8 DATA LOGGER The Data Logger (see Figure 5-73) is a data storage module designed for DDEC III and other electronically controlled engines that communicate on the SAE J1708 diagnostic data link and follow the SAE J1587 protocol. Data is stored in daily records for a maximum of 100 days. Data on engine performance trends, service intervals, hard brake incidents, events, and ECM diagnostics is also stored. Figure 5-73 The Data Logger The Data Logger can be used by itself or combined with a ProDriver display. When combined with a ProDriver, the Data Logger can record separate data for individual drivers, and accumulate data by state for tax purposes. Information stored in the Data Logger can be extracted to a PC using ProManager Rel. 2.1 software or DDEC Reports. Data Logger data is analyzed with ProManager Release 2.1. 5-146 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Data Logger Installation The Data Logger should be mounted in the cab of the vehicle. The Data Logger module is splash resistant, but not water tight, so the module must be mounted in a location that is not exposed to water. The Data Logger should NOT be mounted with connectors facing up. See Figure 5-74. Figure 5-74 Data Logger Installation All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-147 DDEC FEATURES The Data Logger has two harnesses, the Power Harness and the Modem Harness. The Power Harness provides both power and data link connections to the Data Logger. The Modem Harness is the connection from the Data Logger to all the external devices associated with the Management Information System. See Figure 5-75 for the diagram to use for constructing a Power Harness for the Data Logger. Figure 5-75 Data Logger Power Harness The modem harness is the connection from the Data Logger to all the external devices associated with the Management Information. The harness branches from the Data Logger to the download connector. The download connector is used for a high-speed download of the stored data in the Data Logger. The download can also be done through the diagnostic connector at a much slower rate. The download connector should be easily accessible, most likely near the engine diagnostic connector. The battery positive wire should be sourced from the same place as the Power harness battery positive wire. The remainder of the wires should run direct from the Data Logger to the download connector. 5-148 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The Modem connector can be located anywhere in the cab of the vehicle. The Modem branch of the Modem harness is used for wireless extraction of the data from the Data Logger. A modem can be used with a cellular phone to extract data either by standard phone lines or by satellite. The communication from the Data Logger to the modem is done over a standard RS232 Serial port. NOTE: Battery positive must have a 3-amp fuse between the battery and the Data Logger. The schematic for constructing the modem harness for the Data Logger is shown in the next illustration (see Figure 5-76). This harness is also available through DDC, P/N: 23515651. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-149 DDEC FEATURES Figure 5-76 5-150 Data Logger Modem Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.22.9 PRODRIVER ProDriver is a dashboard-mounted graphic device that displays data stored in its memory. The display is a vacuum fluorescent (VF) display for wide viewing angles and excellent visibility in all ambient light conditions. It provides automated intensity control of the VF display, based on the dashboard instrument panel lights for improved driver convenience. There are two automatically shown display screens which offer real-time feedback based on vehicle activity, the ‘‘Fuel Economy" screen and the ‘‘Idle Percentage" screen (see Figure 5-77). Figure 5-77 ProDriver Screens The ‘‘Fuel Economy" screen displays MPG achieved versus the fleet's target when the truck is in motion and the ‘‘Idle Percentage" screen displays idle time and percentage achieved versus the fleet's target when the truck is stopped. Drivers use the information to improve their performance, especially fuel economy. Fleets use the data to evaluate driver and fleet performance. ProDriver extracts data from all releases of ProDriver firmware. However, it produces reports only from ProDriver Release 3.0. Previous releases of ProDriver firmware were analyzed and reported by Promanager 1.0 PC software. This software operates under DOS and is not year 2000 compliant. Any users of ProManager 1.0 can obtain a free upgrade to ProDriver Reports 1.0. A free upgrade to ProDriver 3.0 firmware is included with ProDriver Reports 1.0. ProDriver Installation The ProDriver module should be dashboard mounted in a location that is easily seen so the driver's eyes do not have to leave the road for a long period of time. ProDriver is available in two styles: flush mount and surface mount. The flush mount is intended to be mounted in the dash with only a bezel above the dash surface. See Figure 5-78. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-151 DDEC FEATURES Figure 5-78 5-152 ProDriver Flush Mount All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The mounting bracket for the flush mount ProDriver is shown in Figure 5-79. Figure 5-79 ProDriver Flush Mount Mounting Bracket All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-153 DDEC FEATURES The flush mount display cutout template is shown in Figure 5-80. Figure 5-80 5-154 ProDriver Flush Mount Display Template All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The surface mounted display is installed on top of the dash, the overhead or the face of the dash. Refer to Figure 5-81. Figure 5-81 ProDriver Surface Mount All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-155 DDEC FEATURES See Figure 5-82 for bracket dimensions and characteristics of the surface mount bracket. Figure 5-82 5-156 ProDriver Surface Mount Bracket All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL See Figure 5-83 for the bolt pattern layout, which defines mounting without the adjustable bracket. Figure 5-83 ProDriver Surface Mount Template ProDriver has one harness for connection to the vehicle. The following paragraphs contain information that will be helpful in designing this harness. Battery positive can be sourced from the same place as the Data Logger (if installed). The panel light on/off wire detects when the instrument panel lights are on. It is recommended that the 12/24 volt signal be taken from the high side of the intensity control potentiometer. This will ensure that the display intensity will change when the running lights are on as well as when the headlights are on. The external alert signal from the ProDriver can be used to drive either an audible or visual alert device. The output will provide a ground when there is an alarm and be open where there is no alarm. The external alert signal will be turned on when there is an engine diagnostic code or when one of the preset limits in the ProDriver is exceeded. The alarm will also be active when a button is pressed if this feature is enabled. The load on the output must not exceed 1 amp. Refer to the ProDriver User Manual (6SE701), for more detail on alarms. DDC offers an audible alarm, P/N: 23515915. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-157 DDEC FEATURES See Figure 5-84 for the diagram to use when constructing a harness for ProDriver. Figure 5-84 ProDriver Vehicle Harness When the Data Logger and ProDriver are both installed in a vehicle, the harness schematic shown next applies (see Figure 5-85). 5-158 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 5-85 Management Information System All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-159 DDEC FEATURES Programming Requirements and Flexibility ProDriver configuration (user settings) can be viewed and changed with ProDriver Reports. Items that can be changed at any time are: Display Intensity, Measurement Units, Language, and Alarm Status. Other setup parameters such as Vehicle Overspeed Limits can be changed, but only if the trip information in the ProDriver memory has first been extracted and cleared. ProDriver configuration can be reviewed at any time with ProDriver Reports without clearing trip information. The PC running ProDriver Reports must be connected to the vehicle diagnostic connector through the DDC Translator Box. The software then allows the user to retrieve and view the current settings in the ProDriver connected to the PC. ProDriver has two access modes: Owner/Operator and Manager/Driver. The Owner/Operator mode does not require a password to change Setup. If the ProDriver access mode is set to Manager/Driver, a password is needed to enable changes to the ProDriver Setup menu. Refer to the ProDriver User Manual (6SE701), for more detail. 5-160 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.22.10 PRODRIVER DC ProDriver DC (P/N: 23525745) is a dashboard-mounted display (see Figure 5-86) that provides real time and summary information on vehicle and engine operation. Real time graphic displays, shown when the engine is running, provide driver feedback on idle and driving performance relative to fleet goals. ProDriver DC also has a Fuel Economy Incentive status screen and a clock/calendar with battery backup. Engine alerts provide a descriptive message when the CEL and SEL are illuminated. Figure 5-86 ProDriver DC The Data Card provides a convenient way to transport data to and from the vehicle. The Data Card can hold up to two megabytes of data. It can also be formatted to perform various functions through the Detroit Diesel Data Summaries software. These functions are listed in Table 5-63. Functions Data Card Driver Card Assigned to a specific driver Capacity: 10 vehicles or 10 trips plus 2 months Extracts stored vehicle data Extraction Card Capacity: 100 extractions Loads new ProDriver DC user settings Configuration Card Multiple vehicles Vehicle ID and odometer not affected Reprogramming Card Table 5-63 Upgrade ProDriver DC features, as new software becomes available Data Card Functions Data Cards are the Smart Media product used in many digital cameras. The cards and card readers are readily available from local retail stores. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-161 DDEC FEATURES ProDriver configuration (user settings) can be viewed and changed with Detroit Diesel Data Summaries. Configuration options that can be changed at any time are: Display Intensity, Measurement Units, Language, and Alarm Status. Other setup parameters such as Vehicle Overspeed Limits can be changed, but only if the trip information in the ProDriver DC memory has first been extracted and cleared. ProDriver DC has two access modes: Owner/Operator and Manager/Driver. The Owner/Operator mode does not require a password to change Setup. If the ProDriver access mode is set to Manager/Driver, a password is needed to enable changes to the ProDriver Setup menu. Programming ProDriver DC with a Configuration Card is perhaps more convenient. When the card is inserted in ProDriver DC, the technician will be prompted through a few simple steps. Using the same Configuration Card on all ProDriver DC units in a fleet assures that each one has the same setup. Trip summary data may be reviewed on the ProDriver DC screen or extracted to a PC for later analysis. Extraction options include: Direct connection to a PC running Detroit Diesel Data Summaries software through a translator box Automated direct connection with the Remote Data Interface Wireless communications such as the Highway Master cellular telephone service Extraction to a Driver Card or Extraction Card 5-162 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL ProDriver DC Installation The ProDriver DC module should be dashboard mounted in a location that is easily seen so the driver's eyes do not have to leave the road for a long period of time. The ProDriver DC module has the same installation dimensions as the ProDriver module. ProDriver DC can be mounted as either a flush mount or a surface mount. See Figure 5-87. Figure 5-87 ProDriver DC Flush Mount All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-163 DDEC FEATURES See Figure 5-88 for the mounting bracket for the flush mount ProDriver DC. Figure 5-88 5-164 ProDriver DC Flush Mount Mounting Bracket All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL See Figure 5-89 for a cutout template of the flush mount display. Figure 5-89 ProDriver DC Flush Mount Display Template All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-165 DDEC FEATURES The surface mounted display for ProDriver DC is installed on top of the dash, the overhead or the face of the dash. See Figure 5-90. Figure 5-90 5-166 ProDriver DC Surface Mount All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL See Figure 5-91 for bracket dimensions and characteristics of the surface mount bracket. Figure 5-91 ProDriver DC Surface Mount Bracket All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-167 DDEC FEATURES ProDriver DC has one harness for connection to the vehicle. The following paragraphs contain information that will be helpful in designing this harness. The panel light on/off wire detects when the instrument panel lights are on. It is recommended that the 12 volt signal be taken from the high side of the intensity control potentiometer. This will ensure that the display intensity will change when the running lights are on as well as when the headlights are on. See Figure 5-92 for the diagram to use when constructing a harness for ProDriver DC. Figure 5-92 ProDriver DC Vehicle Harness NOTE: ProDriver DC is 12V only. The ignition and battery wires must be connected to +12V only. 5-168 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL A jumper harness (P/N: 23524862) is available to install a ProDriver DC in place of a ProDriver (see Figure 5-93). Figure 5-93 ProDriver DC Jumper Harness All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-169 DDEC FEATURES 5.22.11 MANAGEMENT INFORMATION PRODUCTS KITS Several kits are available to install the Management Information Products. The Management Information kits include the Data Logger, ProDriver (flush mount or surface mount), ProDriver DC (flush mount or surface mount), and the appropriate harnesses and hardware to install the system. Management Information may be installed by the OEM or installed as aftermarket options. The standard kits are listed in Table 5-64. Management Information Flush Mount Kit, P/N: 23516620 Part Number Management Information Surface Mount Kit, P/N: 23516619 Part Part Number Part 23514077 Data Logger 23514077 Data Logger 23515650 Cable - Power Connections 23515650 Cable - Power Connections 23515651 Cable - Modem Connections 23515651 Cable - Modem Connections 23515448 ProDriver Flush Mounted 23515649 ProDriver Surface Mounted 23515655 Cable - Vehicle to ProDriver 23515655 Cable - Vehicle to ProDriver 12033769 2-Way 630 Metri-Pack Connector 23515893 Bracket Kit for Surface Mounted ProDriver 12033731 Fuse Holder Cover 12033769 2 Way 630 Metri-Pack Connector 12004003 3 Amp Fuse 12033731 Fuse Holder Cover 12020156 Fuse Terminals 16 Ga. 12004003 Fuse 3 Amp 05101020 Nylon Tie Strap 12020156 Fuse Terminals 16 Ga. 23515915 Audible External Warning Alarm 05101020 Nylon Tie Strap 23515915 Audible External Warning Alarm 23516459 23516460 23516591 23516976 018SP365 23519866 Management Information Reference Card Management Information User Manual Management Information Reference Card Management Information User Manual 23516459 Download Connector Bracket 23516460 Management Information Warranty Booklet Management Information Installation Instruction 23516591 Download Connector Bracket Management Information Warranty Booklet Management Information Installation Instruction 23516976 018SP365 RDI Driver Card - 7SE0424 23519866 Table 5-64 RDI Driver Card - 7SE0424 Management Information Kits The harnesses are listed in Table 5-65. Table 5-65 5-170 Part Number Description 23515655 Vehicle to ProDriver Display Harness 23515651 Data Logger Modem Harness 23515650 Data Logger Power Harness Management Information Harnesses All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL ProDriver can also be installed separately. The available kits are listed in Table 5-66. Surface Mount Kit P/N: 23515866 Flush Mount Kit P/N: 23515867 Part Number Part Part Number 23515649 ProDriver Display - Surface Mount 23515448 ProDriver Display - Flush Mount 23515893 Bracket kit for Surface Mount 23515655 Cable - Vehicle to ProDriver Display 23515655 Cable - Vehicle to ProDriver Display 12033769 Connector 2 way 630 Metri-Pack Fuse 12033769 Connector 2 way 630 Metri-Pack Fuse 12033731 Cover Fuse Holder 12033731 Cover Fuse Holder 12004003 3 AMP Fuse 12004003 3 AMP Fuse 12020156 Fuse Terminals 12020156 Fuse Terminals 05101020 Strap Nylon Tie 05101020 Strap Nylon Tie 23515915 Audible Alarm 23515915 Audible Alarm 23516025 ProDriver Reference Card 23516025 ProDriver Reference Card 23516026 ProDriver Operator's Manual 23516026 ProDriver Operator's Manual 23516976 Management Information Warranty Booklet 23516976 Management Information Warranty Booklet 018SP362 ProDriver Installation 018SP362 ProDriver Installation 23519866 Card RDI Driver 7SE0424 23519866 Card RDI Driver 7SE0424 -- -- Table 5-66 Part ProDriver Kits Other available Management Information and ProDriver kits are listed in Table 5-67 and Table 5-68. Table 5-67 Part Number Description 23515649 Pro Driver Display 23515893 Bracket kit for Surface Mount 23516025 ProDriver Reference Card 23516026 ProDriver Operating Manual 23516028 ProDriver Registration Card ProDriver Surface Mount Kit P/N: 23516789 Surface Mount Kit P/N: 23515698 Part Number Part Flush Mount Kit P/N: 23515697 Part Number Part 23515649 ProDriver Display - Surface Mount 23515448 ProDriver Display - Flush Mount 23514077 Data Logger 23514077 Data Logger Table 5-68 Management Information System Mounting Kits All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-171 DDEC FEATURES ProDriver DC Kits are listed in Table 5-69, Table 5-70, and Table 5-71. Part Number Description Quantity 23525745 ProDriver DC Display Unit 1 23525872 ProDriver DC Flush Mount Bracket 1 23525874 ProDriver DC Wiring Harness 1 12033769 Connector 2–way 630 Metri-Pack Fuse Holder 1 12033731 Cover Fuse Holder 1 12020156 Fuse Terminals — 16 ga. 2 12004003 Fuse — 3 Amp. 1 05101020 Nylon Tie Strap 5 23525762 ProDriver DC Data Card 1 18SP528 ProDriver DC Installation Instructions 1 23529660 ProDriver DC User Manual (6SE703) 1 23529661 ProDriver DC Pocket Card (7SE447) 1 Table 5-69 Part Number Description Quantity 23525745 ProDriver DC Display Unit 1 23525873 ProDriver DC Surface Mount Bracket 1 23525874 ProDriver DC Wiring Harness 1 12033769 Connector 2–way 630 Metri-Pack Fuse Holder 1 12033731 Cover Fuse Holder 1 12020156 Fuse Terminals — 16 ga. 2 12004003 Fuse — 3 Amp 1 05101020 Nylon Tie Strap 5 23525762 ProDriver DC Data Card 1 18SP528 ProDriver DC Installation Instructions 1 23529660 ProDriver DC User Manual (6SE703) 1 23529661 ProDriver DC Pocket Card (7SE447) 1 Table 5-70 Table 5-71 5-172 ProDriver DC Flush Mount Kit P/N: 23525759 ProDriver DC Surface Mount Kit P/N: 23525760 Part Number Description 23525762 Data Card 23529276 ProDriver DC USB Data Card Reader 23529277 ProDriver DC PCMCIA Data Card Reader Other ProDriver DC Parts All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL The OEM ProDriver DC Kits are listed in Table 5-72 and Table 5-73. Table 5-72 Table 5-73 Part Number Description 23525745 ProDriver DC Display Unit 23525872 ProDriver DC Flush Mount Bracket 23524862 ProDriver DC Adapter Harness OEM ProDriver DC Flush Mount Kit P/N: 23525753 Part Number Description 23525745 ProDriver DC Display Unit 23525873 ProDriver DC Surface Mount Bracket 23524862 ProDriver DC Adapter Harness OEM ProDriver DC Surface Mount Kit P/N: 23525754 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-173 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-174 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.23 MARINE CONTROLS The DDEC III Level II Bridge Control system combines the advantages of an advanced technological electronic fuel injection and control system with the ability to control up to six control stations and as many as four engines. Additional engines require additional control systems. For additional information, refer to DDEC III Marine Level II Bridge Control Application and Installation (18SA372). The DDEC III system optimizes control of critical engine functions which affect fuel economy and provides the capability to protect the engine from serious damage resulting from conditions such as high engine temperatures or low oil pressure. The Level II Bridge Control system supports up to six independent control stations located in separate areas in the vessel and allows interrupt-free transfer among them. A panel-mounted Electronic Display Module(s) (EDM) shows operational data including the status of the engines, transmissions and bridge control system. The DDEC III Level I Bridge Control system is designed for use on vessels with only one control station and no more than two engines. The DDEC III bridge controls and displays are available for Series 60, 71, 92, 149, 2000, and 4000 engines. The DDEC III Level II Bridge Control system provides the following features: Seamless transfer of control from the active control station to any one of the additional control stations Control and synchronization of two to four engines Two levels of idle, low idle and user idle High engine speed shifting protection that allows forward motion to be stopped quickly without damaging the transmission Drag down prevention routine designed to prevent engine stall when changing gear direction Trolling gear control (optional) 5.23.1 OPERATION The Engine Room Interface Module (ERIM), the master module in the DDEC III Level II Bridge Control system, can be considered the most important component of the system. The ERIM acts as an interface with the ECM and other subsystems and devices. In this role the ERIM: Coordinates the transfer of control from one station to another Routes ECM outputs to each control station Permits control of the ECM inputs from any one station (one at a time) Arbitrates throttle and gear control transfer from one station to another All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-175 DDEC FEATURES Allows for engine synchronization Provides high (user) and low speed idle In engine synchronization mode, both engines receive a common signal generated in the ERIM. A troll function is also available on this system. The ECM used in DDEC engines is designed for a single control station. Many marine applications require control of multiple engines from more than one control station. DDEC III Level II Bridge Control forms the interface between the engine speed commands from the vessel captain and the engine-mounted ECM. DDEC III Level II Bridge Control also interfaces between the captain's commands for gear direction and the shift mechanism in the transmission. These two control signals are coordinated by the control system to prevent shifts at high engine speeds that may damage internal gearbox components. Control may be locked to any desired station once vessel control is transferred to it. See Figure 5-94 for a system block diagram of a throttle and gear control system for a two-engine marine application. The system will also shift the marine gears. Throttle and shift commands from the captain are transmitted via control heads. The control heads located at each station are either single or dual lever designs. A single lever head combines control of both throttle and gear shifting in the same lever, while a dual lever head has separate throttle and gear shift levers. A means for emergency backup of the bridge control system is provided. This backup scheme maintains control of engine speed and transmission gear direction in the event that the primary control system no longer functions correctly. The DDEC III Level II Bridge Control system supports up to six independent control stations located in separate areas in the vessel and allows interrupt-free transfer among them. The Level II Bridge Control system is situated in two locations, the control station and the engine room. Control Station A control station is defined as any location on the vessel from which the propulsion system is controlled. One station is designated as the master station when there are multiple control stations. A typical control station includes: One Control Station Interface Module (CSIM) One Control Button Panel (CBP) One set of gear and throttle levers (port and starboard) One Electronic Display Module (EDM) for each engine One Emergency Backup Control Panel (EBCP) (master station only) Ignition switch (master station only) 5-176 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Engine Room The following components of the DDEC III Level II Bridge Control system are located in the engine room Engine Room Interface Module (ERIM) (required) Marine Interface Module (MIM) (required) Electronic Gear Interface Module (EGIM), Gear Actuators, Backup Gear Actuators and Troll Actuators Electronic Backup Power Module (EBPM) Local Control Panel (LCP) For additional information, refer to DDEC III Marine Level II Bridge Control Application and Installation (18SA372). All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-177 DDEC FEATURES Figure 5-94 5-178 Two-Engine Marine Application All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.24 OPTIMIZED IDLE Optimized Idle enhances the DDEC Idle Shutdown feature. Optimized Idle will automatically stop and restart the engine when required in order to keep the engine temperature above 60 F, the battery charged, and/or the vehicle interior at the desired temperature (using the optional Optimized Idle thermostat). Other benefits include an overall reduction in exhaust emissions and noise and improved starter and engine life (by starting a warm engine). The DDR, Detroit Diesel Diagnostic Link (DDDL), ProManager® software, and DDEC Reports provide access to the Optimized Idle fuel and idle time savings, and run time information. 5.24.1 OPERATION The following conditions must be met in order to use the Optimized Idle function: The Ignition must be ON with the vehicle idling Hood, cab, and/or engine compartment doors closed Transmission in neutral and splitter in high range (if equipped) Park brake set Idle shutdown timer must be enabled Cruise master switch turned to ON position (if in the ON position, turn to OFF then to ON) Once these conditions are met, remain idling and the Optimized Idle Active light will flash. This indicates that Optimized Idle will begin operation only after the idle shutdown timer is over. Optimized Idle allows the operation of all DDEC features such as PTO, throttle control, and VSG Cruise, while the active light is flashing. The active light will stop flashing and stay on, after the shutdown timer has expired. The operator no longer can use other DDEC features, including the throttle, until the park brake is released, one of the safety conditions are broken, or the cruise switch is turned OFF. The engine operates in engine mode or thermostat mode. Once Optimized Idle becomes active, the engine will either shutdown if Optimized Idle parameters are satisfied or ramp to 1100 RPM. If the engine does not start after the second attempt, or if the vehicle moves while Optimized Idle is active, the Check Engine Light will turn ON to indicate that Optimized Idle has been turned OFF (Active Light will turn OFF) due to the above condition. The ignition must be turned OFF and the engine restarted in order to use Optimized Idle. The alarm will sound briefly prior to any engine start. After Optimized Idle starts the engine, the speed will be 1100 RPM. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-179 DDEC FEATURES Engine Mode Optimized Idle will start and stop the engine to keep the following parameters within limits. Battery Voltage - The engine will start when the battery voltage drops below 12.2 Volts for 12 Volt systems or 24.4 Volts for 24 Volt systems. A DDEC III (Release 9.0 or later) and DDEC IV engines (Release 22.01 or later) will run for a minimum of two hours when started due to low battery voltage. Oil Temperature - The engine will start when the oil temperature drops below 60 F (15.55 C) and will run until the oil temperature reaches 104 F (40 C). Thermostat Mode The optional Optimized Idle thermostat must be turned ON. Engine mode parameters as well as the interior temperature are monitored in this mode. The thermostat informs the ECM when to start/stop the engine to keep the interior warm/cool based on the thermostat setting. It also monitors the outside temperature by way of the skin temperature sensor to determine if the ambient temperature is extreme enough that the engine should run continuously. Any other accessories connected to the Vehicle Power Shutdown relay will turn ON for Thermostat Mode engine starts. The heater and A/C fans will remain OFF for Engine Mode starts. If Optimized Idle starts the engine for the Engine Mode, and Thermostat Mode is then requested, the heater and A/C fan will turn ON approximately 30 seconds after the Thermostat Mode is requested. For additional information, refer to the Optimized Idle Installation and Troubleshooting manual (7SA741). Optimized Idle Start Up Sequence The following occurs during to any Optimized Idle engine start: 1. Optimized Idle Active Light is ON. The ECM determines when the engine needs to start to charge the battery, warm the engine, or heat/cool the vehicle interior. 2. The alarm (mounted in the engine compartment) will sound briefly. 3. The starter will engage and the engine will start. If the engine speed does not reach a predetermined level within a few seconds, Optimized Idle will attempt a second engine start after 45 seconds. The alarm will sound again prior to the second engine start. If the engine still does not start after the second start attempt, the system will disarm for the rest of the ignition cycle. The CEL will flash and the ECM will go into low power mode after 20 minutes. 4. The engine will ramp up to 1100 RPM. If the engine was started in the Thermostat Mode, the heater or A/C fans will turn ON after approximately 30 seconds. 5-180 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.24.2 INSTALLATION New installations must be approved by Detroit Diesel. See Figure 5-95 for the Optimized Idle overall system schematic. Refer to the Optimized Idle Installation and Troubleshooting manual (7SA741) for installation requirements. Figure 5-95 Optimized Idle System Overview All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-181 DDEC FEATURES 5.24.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY Optimized Idle must be turned on by the factory via order entry or by Detroit Diesel Technical Service. Software group 6N5-3 must be specified. The digital inputs and outputs listed in Table 5-74 can be programmed at order entry, VEPS or DRS. Function Number Type Description 5 Digital Input Park Brake / ISD 23 Digital Input Cruise Enable 6 Digital Output Vehicle Power Shutdown 26 Digital Output Optimized Idle Active Light Table 5-74 Optimized Idle Digital Inputs and Digital Outputs The Idle Timer must be enabled by VEPS, DDR, DDDL or DRS. The recommended Idle Timer parameters are listed in Table 5-75. Parameter Description Recommended Setting IDLE SHUTDOWN TIMER ENABLE Enables/Disables the Idle Shutdown Feature YES (Required) TIME (min) OVERRIDE ENABLED ON VSG Table 5-75 The amount of engine idle time that is allowed before the idle shutdown feature stops fueling the engine Disables the Idle Shutdown timer Override feature. Allows the Idle timer to shutdown the engine when operating on PTO 1-100 minutes (customer's choice) NO YES Idle Shutdown Timer Parameters Optimized Idle installations should have the parameters listed in Table 5-76 set to Shutdown. 5-182 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL NOTICE: DDC recommends that Shutdown be enabled for all Engine Protection parameters with Optimized Idle installations. Parameter OIL TEMP COOLANT TMP OIL PRS COOLANT LVL Table 5-76 5.24.4 Description Indication of the type of engine protection based on high engine oil temp. Indication of the type of engine protection based on high engine coolant temp. Indication of the type of engine protection based on low engine oil pressure. Indication of the type of engine protection based on low coolant level. Setting SHTDWN SHTDWN SHTDWN SHTDWN Engine Protection Parameters DIAGNOSTICS Refer to the Optimized Idle Installation and Troubleshooting manual (7SA741) for diagnostic and troubleshooting information. 5.24.5 INTERACTION WITH OTHER FEATURES The Vehicle Power shutdown feature is used by Optimized Idle to turn off all accessory loads when the engine is shutdown. Optimized Idle will turn these loads on for Thermostat Mode starts. Anti-Theft is a new feature that protects the vehicle from being driven by an unauthorized driver. When ProDriver DC is installed and Anti-Theft is enabled (Release 27.0 or later), the vehicle is protected during Optimized Idle operation. No other DDEC features can be used when Optimized Idle is active. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-183 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-184 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.25 OPTIMUM LOAD SIGNAL The optimum load signal provides feedback relative to current engine loading versus the optimum engine loading necessary to maximize engine performance and fuel economy. This feature is available with Software Release 21.0 or later. 5.25.1 OPERATION The feedback is in the form of a Pulse Width Modulated (PWM) output where a duty cycle of 50% indicates operation on the preferred load curve. The PWM output ranges from 5% to 95% where a 5% duty cycle indicates the maximum engine overload and 95% indicates the maximum engine underload. They duty cycle broadcast at various engine load points between the optimum curve and either the minimum or maximum load curves is determined by linear interpolation. The ECM will broadcast a 50% duty cycle if the engine is in start mode, operating on the idle governor, or if the ignition is on and the engine is not running. The PWM output signal may be converted into an analog voltage output through the use of DDC's Pulse to Voltage Module (P/N: 23522828). Refer to section 5.31 for additional information. 5.25.2 INSTALLATION See Figure 5-96 for the installation of optimum load signal interface. Figure 5-96 5.25.3 Optimum Load Signal Interface PROGRAMMING REQUIREMENT AND FLEXIBILITY Configuring the transmission type to 32 sets the Optimum Load Signal. This configures PWM #1 output for the Optimum Load Signal. The transmission type can be set by order entry, VEPS or the DRS. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-185 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-186 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.26 OVERALL GOVERNOR GAIN Overall Governor Gain is used to just to adjust the governor gain between the minimum and the maximum governor gain parameters. The Overall Governor Gain can be modified on generator set applications in the field to work with different inertia alternators. The Overall Governor Gain can be displayed with Detroit Diesel Diagnostic Link (DDDL, release 3.1 or later) or the DDEC Reprogramming System (DRS). 5.26.1 PROGRAMMING REQUIREMENTS & FLEXIBILITY The Overall Governor Gain can only be modified by the DRS as long as the feature has been configured in the 6N4C group. The DRS will display the minimum and maximum values for the Overall Governor Gain. This feature is available with Release 28.0 or later ECM software for generator set applications only. The description and range are listed in Table 5-77. Parameter Description Overall Governor Gain The Overall Governor Gain can be changed between the minimum and maximum governor gain values. Table 5-77 Range The value is set by the Base Calibration and varies by engine series. Overall Governor Gain All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-187 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-188 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.27 PASSMART The PasSmart™ feature is available on selected on-highway DDEC engines equipped with a Vehicle Speed Sensor. This feature is available with DDEC IV ECM software (Release 28.00). 5.27.1 OPERATION The PasSmart feature allows a fleet manager to enable a second Vehicle Limit Speed (VLS) above the normal VLS to assist while passing other vehicles on the highway. This second VLS is programmed for a limited duration during a given time period (interval). The passing speed interval starts when the feature is programmed. An interval of 8, 12, or 24 hours will always reset at midnight. The driver activates PasSmart by double-pumping the EFPA. Starting at the full throttle position, the driver releases the throttle completely, returns the throttle to the full throttle position, releases it again and then returns to full throttle. If the driver completes this action within 5 seconds, PasSmart is activated. After double-pumping the EFPA, the vehicle is given 20 seconds to accelerate to a speed above the normal VLS limit. If the vehicle speed does not exceed the normal VLS speed in 20 seconds, the driver must repeat the double-pump action. Once the normal VLS has been exceeded, a new higher VLS becomes the maximum vehicle speed limit. This limit is the normal VLS plus the Passing Speed Increment. A passing speed duration timer starts when vehicle speed exceeds the normal VLS limit and continues to count until the vehicle speed drops back below the normal VLS speed. At the end of the passing event when the vehicle speed drops back below the normal VLS, PasSmart is automatically deactivated and the driver cannot exceed the normal VLS unless the Accelerator Pedal is double-pumped again. PasSmart operates only with the foot pedal and not with the Cruise Control switches or hand throttle. However, activating PasSmart does not disturb or deactivate Cruise Control if it is on when the passing event begins. Once the driver has passed the other vehicles and PasSmart has deactivated, Cruise Control automatically takes over. To deactivate Cruise Control during the pass, the driver must turn the Cruise Control switch to off. When the Passing Speed Duration time expires, the CEL will begin to flash one minute prior to ramping the VLS limit back down to the normal VLS limit. The rampdown event always takes 5 seconds regardless of the Passing Speed Increment programmed into the ECM. The rampdown alert can be distinguished from an engine fault warning in that the CEL flashes for the PasSmart alert and remains on constantly for an engine fault. If intervals of 8, 12, or 24 hours are selected, the interval will always reset after the chosen interval and at midnight. This allows fleets to synchronize the reset with driver change periods. All other intervals reset from the time they are selected. For example, if you select 4 hours, then a reset will occur every 4 hours from the time of programming but not necessarily at midnight. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-189 DDEC FEATURES PasSmart still operates when there is an active (non-shutdown) system fault. In this situation the CEL goes from constant illumination to flashing one minute before the VLS limit ramps down. At the end of the passing event when PasSmart is deactivated, the CEL will return to constant illumination if the fault is still active. If there is an active stop engine fault, the rampdown/shutdown activity overrides PasSmart. The additional passing speed is not available until the fault is cleared. For example, if the normal fleet speed limit is 65 MPH, the fleet manager can increase the VLS an additional 5 MPH for up to 30 minutes each day with a reset interval of 8 hours. An example of these limits is listed in Table 5-78. Parameter Limit Passing Speed Duration 30 minutes Passing Speed Interval 8 hours Passing Speed Increment 10 MPH Table 5-78 PasSmart Limits Each time the driver exceeds 65 MPH, the 30 minute clock counts down as long as the speed remains above 65 MPH. He or she can continue to enter and exit the PasSmart extra speed zone to pass vehicles until the entire 30 minutes of higher VLS is used up. The driver is warned by the CEL one minute before the time expires. The vehicle speed is then limited to 65 MPH until the 8 hour period expires and an additional 30 minutes of passing time is available. 5.27.2 INSTALLATION An OEM supplied Vehicle Speed Sensor or output shaft speed over the SAE J1939 Data Link is required. Refer to section 3.14.25, "Vehicle Speed Sensor," for additional information. 5-190 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.27.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY The PasSmart parameters are programmable at engine order entry or with DDDL (release 3.1 or later), WinVeps (Release 3.0 or later), Vehicle Electronic Programming System (VEPS), the DDEC Reprogramming System (DRS), or the DDR (Suite 7) as listed in Table 5-79. Parameter Passing Speed Duration Passing Speed Interval Passing Speed Increment * Description The duration of time per interval that is permitted at the higher speed. A value of zero will disable the feature. The period of time when the ECM resets to begin a new period. The additional vehicle speed permitted above the programmed vehicle speed limit. A value of zero will disable the feature. Choice / Display 0 to 255 minutes 1 to 24 hours* 0 to 20 MPH A value of 8, 12, or 24 will always reset the interval at midnight otherwise it resets every reset interval after the reprogramming was done. Table 5-79 5.27.4 PasSmart Parameters INTERACTION WITH OTHER FEATURES PasSmart will increase the Vehicle Speed Limit. A vehicle can be set up with both PasSmart and Fuel Economy Incentive, but the extra speed increments provided by the two features do not add together. For example, if Fuel Economy Incentive is set up to give 7 MPH of extra speed when the driver hits the maximum fuel economy target and the PasSmart increase is 5 MPH the resulting speed increase is 7 MPH, not 12 MPH. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-191 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-192 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.28 PASSWORDS DDEC provides various levels of password protection such as Rating Password, Injector Password, Anti-Theft Password, and Customer Password. Parameter Group Lockout is needed for another level of password protection that affects groups of functions. 5.28.1 RATING PASSWORD DDEC provides up to four preprogrammed horsepower ratings. The entry of a valid Rating Password and Customer Password are required in order to select a different rating. The rating password can be four alphanumeric characters consisting of the uppercase letters A-Z and the numerals 0-9. The default password is 0000. The Rating Password can be changed with VEPS, DRS, or DDDL. The Customer Password and the current Rating Password are required to change it. 5.28.2 INJECTOR PASSWORD A valid Injector Password is required to update/change injector calibrations. The Injector Password can be four alphanumeric characters consisting of the uppercase letters A-Z and the numerals 0-9. The default password is 0000. The Injector Password can be changed with DDDL or DRS. 5.28.3 CUSTOMER PASSWORD The entry of a valid password is required in order to reprogram any parameter(s). Current parameters may be read without entering a password. The password can be four alphanumeric characters consisting of the uppercase letters A-Z and the numerals 0-9. A random Maximum Security Password can be set by VEPS or DRS for the Customer Password. When set, the factory backdoor password is required to make any changes. The factory backdoor password can be obtained from DDC Technical Service. The Customer Password can be changed with VEPS, DRS, or DDDL. The current Customer Password is required to change to another Customer Password. The default password is 0000. Parameter Group Lockout DDEC is capable of providing a second level of password protection for groups of functions. The entry of a valid Parameter Group Lockout Password and Customer Password are requirements before allowing changes to groups that are locked out. The lockout password can be four alphanumeric characters consisting of the uppercase letters A-Z and the numerals 0-9. The default password is 0000. NOTE: The parameters are not locked out until a four number non-zero lockout password has been defined. The groups selected for additional password protection are listed in Table5-80 and Table 5-81 . All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-193 DDEC FEATURES Feature with Lockout Enabled Cruise Control Lockout Password Needed to Reprogram These Parameters Enable Cruise Control Tire Revs/Mile Minimum Cruise Control Speed Axle Ratio Max Cruise Control Speed Top Gear Ratio Enable Engine Brake on Cruise Control VSS Teeth Engine Brake Increment Max Speed with Fuel Enable Auto Resume Max Speed without Fuel Enable Vehicle Speed Limiting Cruise Switch VSG Enable Maximum Vehicle Limit Speed Cruise Switch VSG Initial RPM Enable Vehicle Speed Sensor Cruise Switch VSG Increment Sensor Type Enable Adaptive Cruise Control VSS Signal -- Enable Idle Shutdown Idle Shutdown Timer Enable Idle Shutdown on VSG Enable Idle Shutdown Override Engine Protection Engine Protection on Oil Temperature High Engine Protection on Coolant Temperature High Engine Protection on Oil Pressure Low Engine Protection on Coolant Level Low Air Compressor Progressive Shift ESS and Top2 Maintenance Alert Table 5-80 5-194 Idle Shutdown Duration Idle Shutdown Min Ambient Temperature Idle Shutdown Max Ambient Temperature Engine Protection on Intercooler Temperature High Engine Protection on Crankcase Pressure High Engine Protection on Auxiliary Shutdown #1 Engine Protection on Auxiliary Shutdown #2 Air Compressor Load Delta Air Compressor Max #2 Pressure Air Compressor Unload Delta Air Compressor Max #3 Pressure Air Compressor Min#1 Pressure Air Compressor Pressure Increment Air Compressor Min#2 Pressure Air Compressor Gain Proportional Air Compressor Min#3 Pressure Air Compressor Gain Integral Air Compressor Max#1 Pressure -- Enable Progressive Shift Low Gear #2 RPM Limit Low Gear #1 Off Speed Low Gear #2 Max Limit Low Gear #1 RPM Limit High Gear On Speed Low Gear #1 Max Limit High Gear RPM Limit Low Gear #2 Off Speed -- ESS Late Change ESS Skip Shift ESS Second Chance Top2 Cruise Switch ESS Engine Brake Shift -- MAS CEL/SEL to flash for Levels MAS CEL/SEL to flash for Filters Features and Parameters Selected for Additional Password Protection All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Feature with Lockout Enabled Lockout Password Needed to Reprogram These Parameters VIN A/C Fan Timer Engine/Vehicle Dynamic Brake Enabled Table 5-81 5.28.4 Fuel Economy Incentive MPH to MPG Fuel Economy Incentive Trip Mileage Fuel Economy Incentive MPG Threshold -- LSG Droop VSG Droop VSG Minimum RPM VSG Maximum RPM Alternate Minimum VSG RPM -- Engine Droop VSG Fuel Economy Incentive MPH Delta Features and Parameters Selected for Additional Password Protection (continued) PROGRAMMING REQUIREMENTS & FLEXIBILITY VEPS, DRS, or DDDL can set the group lockouts listed in Table 5-82. Parameter Description Choice ENGINE/VEHICLE OPTIONS Enables/Disables lockout for Engine/Vehicle parameters. YES, NO DROOP Enables/Disables lockout for Droop parameters. YES, NO VSG Enables/Disables lockout for VSG parameters. YES, NO CRUISE CONTROL Enables/Disables lockout for Cruise Control parameters. YES, NO IDLE SHUTDOWN TIMER Enables/Disables lockout for Idle Shutdown parameters. YES, NO ENGINE PROTECTION AIR COMPRESSOR PROGRESSIVE SHIFT Enables/Disables lockout for Engine Protection parameters. Enables/Disables lockout for Air Compressor parameters. Enables/Disables lockout for Progressive Shift parameters. YES, NO YES, NO YES, NO ESS / TOP2 Enables/Disables lockout for ESS/Top2 parameters. YES, NO MAINTENANCE ALERT SYSTEM Enables/Disables lockout for Maintenance Alert System parameters. YES, NO Table 5-82 Group Lockout Parameters The Lockout Password can be changed with the VEPS, DRS, or DDDL. The Customer Password and the current Lockout Password are required to change it. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-195 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-196 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.29 PRESSURE SENSOR GOVERNOR The Pressure Sensor Governor (PSG) is an optional DDEC feature designed primarily for fire truck applications. PSG is a unique governor system which electronically controls engine speeds based on one of two selected modes of operation. An optional panel display is available (refer to section 5.7, "Electronic Fire Commander"). 5.29.1 PSG OPERATION The Pressure Sensor Governor operates in one of two modes: Pressure Mode - monitors water pump discharge pressure while varying engine speed to maintain the set pump pressure RPM Mode - maintains a set engine speed regardless of engine load, similar to Variable Speed Governor (VSG) operation Once PSG has been enabled, the mode is selected with the Pressure/RPM Mode Switch. PSG is enabled by grounding the digital input "PSG Enable" (function #24). The mode is selected by either providing battery ground (Pressure Mode) or an open circuit (RPM Mode) to the digital input "Pressure/RPM Mode" (function #8). The engine will maintain the engine speed or pump pressure that is current when the mode switch is toggled between the RPM and Pressure modes. The PSG Ready Light illuminates when PSG is waiting for an operating point. After the Increase or Decrease button has been pressed the PSG active output will be turned on illuminating the PSG Active Light. See Figure 5-97 for a schematic of the PSG system. RPM Mode RPM Mode allows the governor to maintain the set speed within engine operating capabilities. RPM Mode is selected when the digital input "Pressure/RPM Mode" (Function #8) is an open circuit. If the pump is not engaged, RPM Mode can still be used to vary engine speed. Pressure Mode Pressure Mode allows the governor to monitor and maintain the fire pump discharge pressure. Pressure Mode is selected by providing battery ground via the digital input Pressure/RPM Mode (Function #8). In Pressure Mode, the maximum allowable increase above the RPM at which the pressure setpoint was established is 400 RPM. This protects the fire fighter from a pressure surge which may result from a momentary loss of pressure if the maximum allowable increase in engine speed is not limited. Also, the maximum allowable increase in engine speed protects the pump from cavitation. The Pressure Mode is maintained until one of the following situations occurs: All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-197 DDEC FEATURES Situation 1 - The Pressure/RPM Mode switch is moved to the RPM Mode. The system reverts to RPM Mode and the same engine speed is maintained. Situation 2 - The Pressure Sensor signal exceeds diagnostic limits. The system reverts to RPM Mode. The same engine speed will be maintained. The Check Engine Light (CEL) illuminates, and either Code 86 or 87 will be logged into the ECM memory. Situation 3 - If the water pump discharge pressure falls below 40 psi and the engine RPM rises a minimum of 400 rpm above the current set point for more than five (5) seconds, the system also considers cavitation to have occurred and the following happens: 1. The engine will return to idle. 2. The current engine speed and discharge pressure set points will be cleared. 3. The CEL will illuminate. 5.29.2 SWITCHES - DECREASE AND INCREASE The Increase and Decrease switches follow similar logic as the Cruise Control switches (Set/Coast On and Resume/Accel On). The Increase and Decrease switches use digital inputs. Increase (Resume/Acceleration On) Momentarily toggling and releasing the increase switch (grounding the Resume/Acceleration On digital input) at the initiation of PSG operation will set the Pressure or RPM operating point. The Pressure or RPM setting will increase by 4 psi (approximately 27.6 kPa) or 25 RPM per increment by momentarily contacting the increase switch as listed in Table 5-83. Mode Switch Amount RPM Mode Increase/Decrease +/- 25 rpm Pressure Mode Increase/Decrease +/- 4 psi Table 5-83 Increase and Decrease for RPM and Pressure Mode Holding the switch in the increase position (grounding the Resume/Acceleration On digital input), will increase the pressure or engine speed. The pressure or engine speed will increase by 4 psi (approximately 27.6 kPa) or 25 RPM per increment at a rate of two increments per second. Releasing the switch sets PSG to the higher setting. Decrease (Set/Coast On) The pressure or engine speed is decreased by momentarily contacting the switch to the decrease position (grounding the Set/Coast On digital input). The Pressure/RPM setting will decrease by 4 psi (approximately 27.6 kPa) or 25 RPM per increment when the Decrease Switch is momentarily contacted as listed in Table 5-83. Holding the switch in the decrease position (grounding the Set/Coast On digital input) will decrease the pressure or engine speed. The pressure or engine speed will decrease by 4 psi (approximately 27.6 kPa) or 25 RPM per increment at a rate of two increments per second. Releasing the switch sets the Pressure/RPM to the lower setting. 5-198 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.29.3 INSTALLATION See Figure 5-97 Figure 5-97 Pressure Sensor Governor System - Vehicle Interface Harness Connector All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-199 DDEC FEATURES 5.29.4 PROGRAMMING REQUIREMENTS AND FLEXIBILITY There are four digital inputs and two digital outputs required for PSG. The four digital inputs required for use with PSG are listed in Table 5-15. Order Entry Function Number Circuit Number* VIH-to-ECM Connector Assignment* DDR Description 8 523 H1 Pressure/RPM Mode 24 543 G2 PSG Enable 22 545 G3 Resume/Accel On (increase) 20 541 J1 Set/Coast On (decrease) * DDC circuit numbers and port assignments shown are default settings but can differ from application to application. Table 5-84 Required Digital Inputs for PSG The digital outputs required for use with PSG are listed in Table 5-16. Order Entry Function Number Circuit Number* 5 499 11 565 Connector Assignment* VIH-to-ECM Connector - Cavity F3 Pigtail off the Engine Sensor Harness - Cavity Y3 DDR Description PSG Active Cruise Active * DDC circuit numbers and port assignments shown are default settings but can differ from application to application. Table 5-85 Required Digital Outputs for PSG The Pressure Sensor Governor is programmed with unique operational parameter defaults intended to cover a wide variety and range of pump applications. The PSG parameter defaults are listed in Table 5-86. Parameter Default Range Integral Gain 10.00 rpm/(psi-s) 0.000 - 39.845 Proportional Gain 0.75 rpm/s 0.00 - 512.00 Engine Speed Increment 25.00 rpm 0 - 250 Pump Pressure Increment 4.00 psi (27.6 kPa) 0 - 99 Cavitation Time Out 5.00 s 0 - 99 Table 5-86 PSG Parameters and Defaults Customizing the parameter defaults can be accomplished at the time of engine order, by VEPS or DRS. Changes to the parameter defaults can not be made with DDDL/DDR. 5-200 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.29.5 INTERACTION WITH OTHER FEATURES The EFPA (LSG) remains active while PSG is operating unless the digital input Throttle Inhibit (function #9) is configured and enabled by switching to battery ground. PSG has priority in installations where both VSG and PSG are used. The VSG input is completely independent of PSG. When the PSG Enable digital input is grounded, the VSG system is disabled. PSG uses logic similar to Cruise Control and requires many of the same digital inputs and outputs. Therefore, neither Cruise Control or the digital input Cruise Enable (function #23) may be specified in conjunction with PSG (refer to section 4.1.1 for more information on Cruise Control digital inputs). Refer to section 4.1.6 for more information on PSG digital inputs. Refer to section 5.7 for information on PSG interaction with Electronic Fire Commander. Cruise Switch VSG can not be used if PSG is configured. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-201 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-202 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.30 PROGRESSIVE SHIFT The Progressive Shift option offers a high range maximum vehicle speed limit to encourage the use of high (top) gear during cruise operation. Progressive Shift encourages the driver to upshift from a lower to a higher gear prior to reaching the engine's governed speed. The resulting lower engine speed in high range should result in improved fuel economy. Progressive shifting techniques should be practiced by every driver, but can be forced if fleet management considers it necessary. The benefits from progressive shifting are best realized during stop-and-go driving cycles. The rate of acceleration will be limited below the programmed MPH to encourage up shifting. As the driver accelerates beyond a specified MPH, the rate of engine acceleration is limited in higher RPM, to encourage (force) the operator to select the top gear. Progressive Shift should be used with 2100 RPM rated engines in fleet applications where the reduced driveability will not impede trip times or productivity. Progressive Shift is not compatible with most automatic transmission. NOTICE: Progressive Shift may be selected only when Spec Manager is run. Progressive Shift selection without Spec Manager could result in mismatched equipment, poor fuel economy, and poor performance. Your local Detroit Diesel Distributor will run the program. 5.30.1 OPERATION The Progressive Shift option has two sets of low ranges and one set of high range parameters, which should be selected at the time of engine order, but also are programmable with the DDR, DDDL, or VEPS. Refer to section 5.30.6. The example shift pattern chart (see Figure 5-98) reflects default values when the Progressive Shift option is chosen and the low and high gear parameters are not modified. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-203 DDEC FEATURES Figure 5-98 Progressive Shift Chart - Represents Default An alternate use for the Progressive Shift option would be to encourage a driver (or force him/her) into top gear. Normally this condition exists when the gearing selected at the time of order allows a vehicle speed limit to be reached in a gear lower than top gear. See Figure 5-99. 5.30.2 LOW RANGE #1 The low range #1 area of operation is bound by a maximum vehicle speed, a maximum engine speed and a maximum turnoff speed. In the first illustration (see Figure 5-98) the default values are 12 MPH (approximately 19.3 kmh), 1400 RPM and 1800 RPM, respectively. During vehicle acceleration, when the vehicle speed is below selected maximum vehicle speed value attained, the maximum rate the engine can be accelerated is reduced to 33 RPM/s. During light load operation, the driver will feel this and be encouraged to up-shift to regain his rate of acceleration. If the engine continues to be operated above the low range #1 maximum speed, it may eventually reach the low range #1 turnoff speed. When the low range #1 turnoff speed is obtained, no additional increase in engine speed will be allowed. At this point, the transmission must be up-shifted if the vehicle is to continue accelerating. 5.30.3 LOW RANGE #2 The low range #2 area of operation is bounded by a maximum speed (MPH), a maximum engine speed and a maximum engine turnoff speed. In the first illustration (see Figure 5-98) the default values shown are 27 MPH (approximately 43.5 km/h), 1600 RPM and 1800 RPM, respectively. (The lower vehicle speed boundary is the low range #1 maximum speed value.) Different values can be selected at the time of the engine order or programmed with the DDR. The engine acceleration rate for low range #2 is 25 RPM/sec. 5-204 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.30.4 HIGH RANGE Two high range parameters should be selected; a high range maximum vehicle speed (MPH) and a high range maximum engine speed (RPM). The default values shown in the first illustration (see Figure 5-98) are 50 MPH (approximately 80.5 km/h) and 1650 RPM, respectively. Once the high range maximum engine speed is attained, the engine will not be allowed to operate above the high range maximum engine speed. This is meant to encourage up-shifting to high gear in order to increase vehicle speed (see Figure 5-99 and Figure 5-99). Spec Manager should be used if the HIGH GEAR MPH is set such that it reduces the vehicle speed and the engine MPH; this limit will not work as desired. NOTE: The HIGH GEAR maximum engine speed could change the maximum vehicle speed limit if the high gear maximum engine speed (RPM) limits the vehicle speed limit. With Progressive Shift enabled, the high gear RPM limit overrides the rated speed of the engine rating. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-205 DDEC FEATURES Figure 5-99 5-206 Progressive Shift Corrects Problem with High and Low Gears Modified All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.30.5 INSTALLATION INFORMATION A Vehicle Speed Sensor (VSS) must be installed. It must be enabled, and all proper calculations entered into the ECM with DRS, DDDL, VEPS, or the DDR as listed in Table 5-87. Refer to section 3.14.25, "Vehicle Speed Sensor," for additional information. Table 5-87 Parameter Choice VSS ENABLED Yes VSS TYPE Tail/Wheel VSS TEETH 8 - 160 VSS SIGNAL Magnetic/Switched TIRES REVS/MI Actual revolutions per mile AXLE RATIO Rear Axle ratio TOP GEAR RATIO Gear ratio in top gear. VSS Parameters The Spec Manager program should be utilized to determine maximum vehicle speed for low range #1 and #2. If the maximum engine speed and maximum vehicle speed coincide, the Progressive Shift logic may not correctly compensate faster or slower on either side of the maximum vehicle speed. Spec Manager can alert the programmer to this dilemma and advise accordingly on maximum vehicle speed set points. Example: If the maximum vehicle speed #1 was 12 MPH (approximately 19.5 kmh), the Progressive Shift logic may not determine if the maximum engine speed is 1400 or 1600 RPM. Spec Manager would advise moving the maximum vehicle speed #1 plus or minus 2 MPH (approximately 3.2 kmh) to eliminate any possible confusion. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-207 DDEC FEATURES 5.30.6 PROGRAMMING REQUIREMENTS AND FLEXIBILITY Enabling all areas required for Progressive Shift can be performed with the DDR, DDDL, VEPS, or at DRS. The Progressive Shift option has two sets of low gear and one set of high gear parameters as listed in Table 5-88. Parameter Description Indicates the enabled/disabled status of the progressive shift feature. ENABLED LG#1 OFF SPD Indicates the low gear #1 turn off speed. LG#1 RPM LMT Indicates the low gear #1 RPM limit. LG#1 MAX LMT Indicates the low gear #1 maximum RPM limit. LG#2 OFF SPD Indicates the low gear #2 turn off speed. LG#2 RPM LMT Indicates the low gear #2 RPM limit. LG#2 MAX LMT Indicates the low gear #2 maximum RPM limit. HG ON SPD HG RPM LMT Table 5-88 5.30.7 Indicates the high gear turn on speed. Indicates the high gear RPM limit. RANGE YES, NO, N/A 0 to Low LG#2 OFF SPD 1000 to LG,#1 MAX LMT LG#1 RPM LMT to Rated Speed LG#1 OFF SPD to HG ON SPD 1000 to LG#2 MAX LMT LG#2 RPM LMT to Rated Speed LG#2 OFF SPD to 127 MPH 1650 to Rated Engine Speed, N/A Progressive Shift Programming INTERACTION WITH OTHER FEATURES When Progressive Shift is enabled the ECM will treat "HG RPM LMT" as the rated speed of the engine. Vehicle maximum speed or maximum Cruise Control settings can not be set higher then engine speed will allow based on the VSS data entered. 5-208 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.31 PULSE TO VOLTAGE MODULE The Pulse to Voltage Module (PVM) (see Figure 5-100) may be used for any application in which it is necessary to convert a PWM signal (50 Hz +/- 1 Hz) into a 0 to 10 volt analog voltage output. Figure 5-100 5.31.1 Pulse to Voltage Module OPERATION The PVM is currently used to convert the PWM signal produced by the DDEC III or IV ECM into a 0 - 10 volt analog voltage which is input into the GE Propulsion System Controller (PSC). System Switched Power Input Requirements The electrical input power shall be nominally a 15 volt fused switched DC supply directly from Battery or equivalent. For 12 volt systems, PVM power can be sourced from the DDEC ignition wire #439. Do not to exceed the current rating on the fuse in the ignition circuit. Steady State Operating Voltage Ranges The PVM is capable of normal operation in a voltage range from 11 to 20 volts DC. The system shall perform to the requirements stated herein when supplied with primary input power voltages measured across the Battery (+) and (-) terminals as follows (Ignition on state): Note: Operation will be degraded if the system voltage drops below 11 volts. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-209 DDEC FEATURES Pulse Width Modulated Signal Input Requirements The input signal that is to be converted to an analog voltage via the PVM must meet the requirements listed in Table 5-89. Input Parameter Input Requirement Frequency Range 50 Hz +/- 1 Hz Low State: (On) @ -1<Eout<2.0 V I Sink < 500 mA High State: (Off) Voltage determined by PVM I Leakage < 1.0 mA Table 5-89 PVM Input Signal Requirements Ground Requirements The PVM ground connection may be sourced from DDEC accessory ground wire #953 or a separate wire that goes to the battery negative post or equivalent ground bus bar. PVM Analog Voltage Output The PVM analog output voltage is proportional to the input duty cycle as listed in Table 5-90. Input Duty Cycle % Output Analog Voltage <5 10.0 5 0.5 10 1.0 25 2.5 50 5.0 75 7.5 90 9.0 95 9.5 >95 10.0 Table 5-90 PVM Output Voltage Requirements The PVM conforms to the table listed above with an accuracy of +/- 1% (+/- 0.1 volts) in the 10 to 90% PWM duty cycle range and +/- 2% (+/- 0.2 volts) in the 5 to 10% and 90 to 95% PWM duty cycle range. 5-210 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.31.2 INSTALLATION REQUIREMENTS The PVM must be hard mounted in a cab environment, see Figure 5-101 for installation information. Figure 5-101 Pulse to Voltage Module Installation All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-211 DDEC FEATURES Connector to PVM The pin definition for the 18 pin Amp connector (P/N: 344106-1) is listed in Table 5-91. Terminal Number Signal 1 - 6 Plugged 7 GND Table 5-91 8 +15 VOLTS 9 PWM INPUT SIGNAL 10 Plugged 11 0 TO 10 VOLT OUTPUT 12 - 18 Plugged Connector To PVM The PVM operating temperature range is -40 C to 85 C. Connector part numbers are listed in Table 5-92. Amp Part Number DDC Part Number Description 171662–1 23530076 Amp Terminal 344106–1 23530075 Amp Connector 172748–2 23530077 Plug 344103–01 23530078 Lock Table 5-92 Connector Part Numbers A kit containing all parts as listed in Table 5-93 is available. Part Number Quanity Description 23522828 1 PVM 23530075 1 18–pin Connector 23530076 4 Terminal 23530077 14 Plug 23530078 1 Lock Table 5-93 5-212 PVM Connector Kit, P/N: 23530079 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.32 TACHOMETER DRIVE DDEC uses the TRS signals to compute engine speed (refer to section 3.14.13). The engine speed is transmitted over the 1708/1587 Data Link. Engine speed can be displayed by connecting a tachometer from VIH connector pin K-1. Circuit 505 provides the standardized output signals for the tachometer drive per ATA recommended practice RP123. See Figure 5-102. Figure 5-102 Tachometer Drive Installation Signal output characteristics are listed in Table 5-94. Signal Table 5-94 Signal Characteristics PULSE RATE 12 Pulse/Rev (all engines) DUTY CYCLE 50% ± 30% SIGNAL LOW 0V<V<.5V when sinking less than 50mA out SIGNAL HIGH 4.0<V<V Batt + sourcing less than 5mA out Tachometer Drive Signal Output Characteristics All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-213 DDEC FEATURES See Figure 5-103 for the tachometer output signal. Figure 5-103 5-214 Tachometer Output Signal All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.33 THROTTLE CONTROL/GOVERNORS There are two types of engine governors that are used with throttle controls. The engine governors are: The Limiting Speed Governor (LSG) for torque control, typical governor for on-highway (refer to section 5.33.1) The Variable Speed Governor (VSG) for speed control, typical governor for nonroad (refer to section 5.33.2) 5.33.1 LIMITING SPEED GOVERNOR - ON-HIGHWAY In on-highway applications and some nonroad applications, LSG is the primary throttle source. The throttle input in a LSG sets percent load. The amount of fuel input to the engine is determined by the throttle position. As the load on the engine varies the resulting engine speed will vary between idle speed and rated speed. The Hot Idle and Governor Droop are selected at the time of engine order. Both of these variables can be adjusted with DDDL/DDR. Hot idle is the engine idle RPM when the oil temperature is greater than 140 F and governor droop/overrun is the overrun beyond rated speed. The droop/overrun can be adjusted in the range from 0 to 300 RPM, depending on engine rating. VSG droop cannot exceed LSG droop. The idle can be adjusted in a range from 25 RPM below to 100 RPM above hot idle depending on engine rating. If a wire is installed in circuit 510 (VSG Control) and is not terminated, the wire must be grounded to circuit 953 or sensor return circuit 952. Alternatively, if no wire exists, the cavity can be plugged, but there is a risk of water intrusion. LSG Primary with VSG as a Secondary Control VSG is available as a secondary control (LSG is primary) for specialized on-highway applications. For these applications, the LSG is programmed to override the VSG under certain conditions. VSG is disabled during initial start-up, until the VSG throttle is moved to the idle range (less than 140 counts) and the LSG throttle is near idle (less than 4% throttle). VSG may be disabled when a predetermined (set by ACS) LSG percent throttle is exceeded as listed in Table 5-95. Table 5-95 Application % Throttle On-highway Trucks 4% Transit Bus 100% Fire Truck 100% Motor Coach 100% Crane 4% Predetermined LSG % Throttle All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-215 DDEC FEATURES VSG operation is disabled when the engine protection option has been selected and the SEL is illuminated because one of the engine parameters being monitored is out of limits. See Figure 5-104 for an example of VSG or LSG only operation using switch selection. Figure 5-104 VSG or LSG Only Operation Using Switch Selection VSG low side diagnostics must be disabled or a code will be logged. The proper 6N4C group must be specified at the time of engine order or by Detroit Diesel Technical Service. For additional information, contact your DDC Applications Engineer. For another example of VSG or LSG only operation using two inputs see Figure 5-105. 5-216 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 5-105 VSG or LSG Only Operation Using VSG Inhibit Low-side diagnostics do not have to be disabled for this implementation. Grounding the VSG Inhibit digital input will reduce the engine speed to idle. When the ground is removed from the input, the throttle must be reset to zero before engine speed can be increased from idle. LSG Control Options The LSG control options are the following: Electronic Foot Pedal Assembly (EFPA) Dual Electronic Foot Pedal Assembly LSG Electronic Foot Pedal Assembly The EFPA sends an input signal which the LSG uses to calculate engine power proportional to the foot pedal position. This assembly is also referred to as the Throttle Position Sensor (TPS) assembly. LSG Electronic Foot Pedal Assembly Installation DDEC IV is compatible with an EFPA, which has an output voltage that meets SAE J1843 and has less than 5% of voltage supply closed throttle variability. The EFPA is an OEM supplied part. Vendor sources that may be contacted for additional design and installation details are: All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-217 DDEC FEATURES Williams Controls Bendix Heavy Vehicle Systems 14100 S.W. 72nd Avenue 901 Cleveland Portland, Oregon 97223 Elyria, Ohio 44036 (503) 684-8600 1-800-AIR-BRAKE King Controls 5100 West 36th Street St. Louis Park, Minnesota 55416 (612) 922-6889 The EFPA must be wired so at low engine speed a small resistance is seen between circuits 417 (signal) and 952 (reference ground). At high engine speed a larger resistance must be seen between circuits 417 and 952 (see Figure 5-106). A Volt/Ohm meter must be used to measure resistance to ensure correct installation. Figure 5-106 Electronic Foot Pedal Assembly Installation The Idle Validation Switch is provided as an option and uses a digital input. Refer to section 4.1, "Digital Inputs," for additional information. LSG Electronic Foot Pedal Assembly Diagnostics An idle validation switch provides redundancy to assure that the engine will be at idle in the event of an EFPA in-range malfunction. The idle validation switch is connected to a digital input on the ECM. When the idle validation switch on the EFPA is switched to battery ground, the engine speed will be at idle. 5-218 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL LSG Dual Electronic Foot Pedal Assembly Throttle Controls Some applications require LSG controls at two stations. LSG Dual Throttle Control Installation The dual EFPA schematic (see Figure 5-107) shows an EFPA at two locations with only one EFPA active at a time. The dual EFPA option requires one digital input. The digital input is switched to either battery ground or system voltage to indicate which EFPA is active. Figure 5-107 LSG Dual Electronic Foot Pedal Assembly Throttle All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-219 DDEC FEATURES LSG Dual Throttle Control Programming Requirements and Flexibility The digital input listed in Table 5-96 is required for LSG dual throttle control. This digital inputs may be ordered at the time of engine order, configured by VEPS or DRS. Table 5-96 Digital Input Function Number Dual EFPA 28 LSG Dual Throttle Control Digital Input Refer to section 4.1, "Digital Inputs" for additional information. LSG Dual Throttle Control Diagnostics System diagnostics will detect active sensor or associated wiring malfunction and return the engine to idle speed. System diagnostics will work with or without an Idle Validation Switch on the EFPA. An Idle Validation Switch provides redundancy to assure that the engine will be at idle in the event of an in-range malfunction. An Idle Validation Switch provides redundancy and swiftly returns the engine to idle. 5.33.2 VARIABLE SPEED GOVERNOR - NONROAD The throttle input to a VSG controls engine speed between idle and rated speed. The engine speed is set by the throttle position. The VSG senses load and fuels the engine to maintain a set speed (within the capability of the engine). Upon start-up the engine will go to the speed selected by the VSG throttle position. The Variable Speed Governor (VSG) throttle control options are: Cruise Switch VSG Hand Throttle EFPA Alternate Minimum VSG (Release 2.0 or later) Voltage Dividers Dual Throttle Controls Frequency Input In on-highway applications and some nonroad applications, the LSG is the primary throttle source. In these applications, the following conditions must be met to operate on the VSG: On-highway truck applications disable VSG operation when the EFPA is pressed. In truck applications the EFPA must be released. Note that coach and motor home, and fire truck applications do not disable VSG operation when the EFPA is depressed as listed in Table 5-95. Once disabled, the VSG voltage must be reduced to < 0.68 volts before it can be reactivated. 5-220 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL When fault code 12 (VSG voltage high) occurs, the VSG is disabled and the engine returns to idle. To regain VSG throttle control, the VSG throttle must be returned to the idle position (less than 140 counts). VSG will not operate when the vehicle speed exceeds a predetermined, application specific vehicle limit. Contact DDC Application Engineering for application specific details. VSG Programming Requirements and Flexibility The VSG parameters which can be selected at the time of engine order or programmed with a DDR, DDDL, VEPS or DRS are listed in Table 5-97. Parameter Description VSG MIN SPD The VSG minimum speed can be set between the hot idle speed and the rated engine speed (or VSG MAX SPD when selected). This causes the engine speed to jump from the hot idle speed to VSG idle speed when the VSG throttle position is first moved (above 140 counts, 205 counts - Series 4000). VSG MAX SPD The VSG maximum speed can be set between the hot idle (or VSG MIN SPD when selected) and the engine rated speed. VSG ALT MIN SPD The alternate minimum VSG (VSG ALT MIN SPD) option allows the customer to switch to a VSG idle speed greater than the VSG minimum speed (VSG MIN SPD). VSG ALT MIN SPD is active when its digital input is switched to battery ground. When VSG ALT MIN SPD is active and the throttle position is less than or equal to 140 counts (205 counts - Series 4000), the engine speed will jump from the VSG MIN SPD directly to the VSG ALT MIN SPD. After the throttle is moved above 140 counts (205 counts - Series 4000), the throttle will control the engine speed between VSG ALT MIN SPD and VSG MAX SPD (VSG maximum speed). VSG DROOP The VSG droop can be programmed between 0 and LSG droop but not greater than 300 RPM (125 RPM - Series 4000), depending on engine rating. Table 5-97 VSG Options NOTE: Error code 22 (LSG Low) is disabled for most nonroad applications. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-221 DDEC FEATURES Cruise Switch VSG The Cruise Control switches can be used to control the VSG set speed. This feature is referred to as Cruise Switch VSG. NOTE: This option is not recommended for fire truck pumping applications or crane applications and is not available for Pressure Sensor Governor systems. The cruise switches are used to activate and control the Cruise Switch VSG option. The Cruise On/Off switch must be turned ON and the park brake must be engaged to enable this feature. If Cruise Switch VSG is inactive and the Cruise Switch VSG conditions are met, pressing and releasing the Resume/Accel Switch will activate Cruise Switch VSG at the VSG initial speed. The VSG initial speed can be programmed with the DDR/DDDL, VEPS, DRS and cannot be greater than the VSG maximum speed. Pressing and releasing the Set/Coast Switch will activate Cruise Switch VSG at the current engine operating speed. Once the VSG set speed is established, pressing and releasing the Resume/Accel Switch will increment the set speed by the amount defined by the VSG increment speed up to the VSG maximum speed. Pressing and holding the Resume/Accel Switch will initiate a speed increase, up to the VSG maximum speed. Releasing the Resume/Accel Switch will set the engine speed at the current operating speed. Pressing and releasing the Set/Coast Switch will decrement the set speed by the amount defined by the VSG increment speed, down to the hot idle speed. Pressing and holding the Set/Coast Switch will initiate a speed decrease, down to the hot idle speed. Releasing the Set/Coast Switch will set the engine speed at the current operating speed. NOTE: VSG Min Speed is not recognized by Cruise Switch VSG. Cruise Switch VSG Installation Requirements The following must be installed for Cruise Switch VSG to operate: Vehicle Speed Sensor (VSS) Cruise Control Switches - digital inputs Park Brake Switch - digital input Refer to section 4.1.1, Cruise Control and section 4.1, Digital Inputs. 5-222 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Cruise Switch VSG Programming Requirements and Flexibility The digital inputs listed in Table 5-98 are required for Cruise Switch VSG. These digital inputs may be configured at the time of engine order, configured by VEPS or DRS. Digital Input Function Number Cruise Enabled Switch 23 Service Brake Switch 17 Clutch Switch (optional) 18 Set/Coast Switch 20 Resume/Accel Switch 22 Park Brake Switch 5 Table 5-98 Cruise Switch VSG Digital Inputs Refer to section 4.1, "Digital Inputs," for additional information. The DDR, DDDL, VEPS or DRS must enable a Vehicle Speed Sensor (VSS). Refer to section 3.14.25 for additional information on VSS. The parameters listed in Table 5-99 can be set with at engine order entry DDDL/DDR, VEPS or DRS. Parameter Description Choice / Display VSG MAXIMUM RPM Sets the maximum VSG RPM. VSG MIN RPM to (Rated Engine RPM + LSG Droop) CRUIZE SWITCH VSG CRUIZE SWITCH VSG INITIAL SET SPEED VSG RPM INCREMENT Table 5-99 Enables or disables the cruise switch VSG set speed feature. Sets the cruise switch VSG initial set speed. Sets the cruise switched VSG RPM increment. YES, NO VSG MIN RPM to VSG MAX RPM 1 to 255 RPM Cruise Switch VSG Programming VSG Hand Throttle A hand throttle (potentiometer) may be used to control engine speed on the VSG between the minimum VSG speed and maximum VSG speed. The total resistance must be between 1kW and 10 kW. VSG Hand Throttle Installation The hand throttle must be wired so at low engine speed a small resistance is seen between circuits 510 (signal) and 952 (reference ground). The low engine speed position is typically fully counter-clockwise. At high engine speed a larger resistance must be seen between circuits 510 (signal) and 952 (reference ground). See Figure 5-108. NOTE: A Volt/Ohm meter must be used to measure resistance to ensure correct installation. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-223 DDEC FEATURES Figure 5-108 Hand Throttle Installation VSG Hand Throttle Calibration The hand throttle is calibrated with a DDR/DDDL as follows: 1. Display the VSG counts. The VSG counts will range from 0 to 1023. 2. In the low speed position, set the hand throttle between 100 and 130 counts. 3. In the high speed position, set the hand throttle between 920 and 950 counts. The hand throttle is an OEM supplied part. Vendor sources that may be contacted for additional design and installation details are: Morse Controls 21 Clinton Street Hudson, Ohio 44236 (330) 653-7701 (330) 653-7799 - fax VSG Electronic Foot Pedal Assembly The EFPA can be used as an alternative to a hand throttle. The EFPA provides an input signal to the ECM to control engine speed on the VSG, proportional to the foot pedal position. The idle validation switch is not applicable to the EFPA when used as an input to the VSG. The Alternate Minimum VSG/Fast Idle digital input may also be used with the EFPA to provide an alternate engine operating speed range. 5-224 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Alternate Minimum VSG (Fast Idle) The Alternate Minimum VSG option allows a customer to switch to an alternate VSG operating range when its digital input is switched to battery ground and VSG is the active governor. Example: VSG Minimum Speed - 500 RPM VSG Alternate Minimum Speed - 1000 RPM VSG Maximum Speed - 1500 RPM When the Alternate Minimum VSG/Fast Idle digital input is inactive, the engine speed will be controlled between 500 and 1500 RPM. When the Alternate Minimum VSG option is initiated, the engine speed will increase and be controlled between 1000 and 1500 RPM depending on the hand throttle position. The Alternate Minimum VSG/Fast Idle digital input may be used to operate the engine at a higher engine idle speed. This feature is available with Release 2.0 or later. If the Alternate Minimum VSG becomes disabled when LSG is the primary governor or for any other reason, the operator must toggle the switch to re-enable fast idle unless the primary speed controller is VSG. Alternate Minimum VSG Installation Wire #510 must be wired to battery ground unless a hand throttle or voltage dividers are used in addition to Alternate Minimum VSG. Alternate Minimum VSG Programming Flexibility The digital input "Alternate Minimum VSG" (function #16) can be set by order entry, VEPS or DRS. Refer to section 4.1, "Digital Inputs," for additional information. The parameters listed in Table 5-100 can be set with DDDL/DDR, VEPS or DRS. Parameter Description Choice / Display ALT MIN VSG Sets the Alternate Minimum VSG RPM. VSG MIN RPM to VSG MAX RPM Table 5-100 Alternate Minimum VSG Programming VSG Voltage Dividers Voltage dividers can be used with the VSG input to provide a means to select a predetermined engine speed. Voltage dividers can be used to provide a fast idle operation or other engine operations where a fixed engine speed is desired. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-225 DDEC FEATURES VSG Voltage Dividers Installation The voltage divider consists of two precision resistors (+/- 1% tolerance, 1/4 watt minimum) in series between circuits 916 and 952 with a center tap connected to circuit 525. The values of the resistors determine engine speed. See Figure 5-109. Figure 5-109 Voltage Divider NOTE: The voltage divider circuit must be placed inside a weatherproof container. VSG Resistor Selection for Voltage Dividers The selection of the resistors is accomplished by using the following calculations. These calculations determine the RPM/count, which is then used to determine the counts needed to reach the desired engine speed. The counts are a direct representation of voltage. See Figure 5-110. 5-226 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 5-110 Throttle Count Profile Use the following steps to calculate resistor values: 1. Determine a value for RPM/Count as follows: 2. Solve for the counts at the desired engine speed, X: PTO Offset = 205 (Series 4000 using G.E. Frequency Input) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-227 DDEC FEATURES 3. Solve for the voltage divider resistance ratio, R: 4. Choose a value for R1 and solve for a value of R2 as follows: The standard precision resistor values are listed in Table 5-101. Standard Precision Resistor Values, 10.0 14.7 21.5 31.0 46.4 68.1 10.2 15.0 22.1 32.4 47.5 69.8 10.5 15.4 22.6 33.2 48.7 71.5 10.7 15.8 23.2 34.0 49.9 73.2 11.0 16.2 23.7 34.8 51.1 75.0 11.3 16.5 24.3 35.7 52.3 76.8 11.5 16.9 24.9 36.5 53.6 78.7 11.8 17.4 25.5 37.4 54.9 80.6 12.1 17.8 26.1 38.3 56.2 82.5 12.4 18.2 26.7 39.2 57.6 84.5 12.7 18.7 27.4 40.2 59.0 86.6 13.0 19.1 28.0 41.2 60.4 88.7 13.3 19.6 28.7 42.2 61.9 90.9 13.7 20.0 29.4 43.2 63.4 93.1 14.0 20.5 30.1 44.2 64.9 95.3 14.3 21.0 30.9 45.3 66.5 97.6 Standard precision resistors are available in the values listed and all multiples of 10 (i.e., 10.7W, 107W, 1.07kW, etc.) Table 5-101 Precision Resistor Values (+/-1%; 1/4 Watt Minimum) VSG Dual Throttle Controls Some applications require VSG controls at multiple control stations. These include fire trucks, cranes, etc. Special circuits can be designed to handle these unique requirements. A dual hand throttle implementation allows a hand throttle to be installed at two locations with one hand throttle active at any one time. Two digital inputs, Dual VSG and Dual VSG Complement, are used to transfer operation from one hand throttle to the other once station qualification is achieved. 5-228 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL DDEC monitors the switch inputs and maintains the engine speed when a station switch occurs until the newly selected station is qualified by reducing the station position to idle and then increasing it to the current engine speed position. After qualification, the engine speed is controlled by the new station. If qualification does not occur within 30 seconds, the engine speed will be ramped down from its current value to VSG minimum speed. If the new station becomes qualified, the rampdown process will be stopped and the new station will have control. VSG Dual Throttle Controls Installation See Figure 5-111 for a schematic of a dual hand throttle implementation (available with Release 2.0 or later). This allows a hand throttle to be installed at two locations with one hand throttle active at any one time. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-229 DDEC FEATURES Figure 5-111 Dual Hand Throttle Dual Throttle Controls Programming Requirements and Flexibility The digital inputs listed in Table 5-102 can be set by order entry, VEPS or DRS. 5-230 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Description Function Number VSG Station Change 33 VSG Station Change Complement 34 Table 5-102 Dual VSG Throttle Control Digital Inputs Refer to section 4.1, Digital Inputs, for additional information. VSG Dual Throttle Controls Diagnostics If the two digital inputs (VSG Station Change and VSG Station Change Complement) are in the same state for two seconds, a fault (Flash code 11, PID 187 FMI 7) is logged. The engine will ramp to idle and neither station can control engine speed until the fault is inactive. VSG Frequency Input A frequency input can be used to control the VSG. This frequency is connected to the vehicle speed input or the Aux Timed Input. The VSS input offers better resolution than the Aux Timed Input. The Aux Timed Input must be used for frequency control when vehicle speed is required in the application. VSG Frequency Input Installation The digital input, External Engine Synchronization, must be grounded for frequency control. See Figure 5-112. Figure 5-112 Frequency Input Diagram All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-231 DDEC FEATURES The following specifications need to be followed when using the frequency input feature. These specifications apply when using the Aux Timed Input or the VSS in open collector mode. See Figure 5-113. High State Input Voltage: Low State Input Voltage: Input Frequency: Vin>4.0 Volts DC Vin<0.4 Volts DC 80<freq <480 Hz Q1 Off Impedance: >10 k Q1 On Impedance: <100 Resolution: 5 RPM/Hz NOTE: The VSS in open collector mode offers better resolution than Aux timed Input. Figure 5-113 Frequency Input Diagram Using Aux Timed Input VSG Frequency Input Programming Flexibility The digital input "External Engine Synchronization" (function #10) must be configured by order entry, VEPS or the DRS. This feature must be enabled by the appropriate application code. 5-232 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.34 TRANSMISSION INTERFACE DDEC IV communicates to transmissions using the following: Pulse Width Modulated Signal (PWM 1) SAE J1587 Data Link SAE J1922 Powertrain Control Data Link SAE J1939 Powertrain Control Data Link Digital Inputs/Digital Outputs 5.34.1 PWM1 OPERATION The PWM 1 port's output can be a 50 Hz modulated signal or a discrete on/off signal representing the powertrain demand with the corresponding duty cycle. Powertrain demand is the ratio of operating torque over available torque at the current speed where operating torque: Includes torque generated by the driver (accelerator pedal) Includes torque generated by the Cruise Control Governor Includes torque reduction by the Vehicle Speed Governor Does not include torque generated by the Variable Speed Governor Does not include torque reduction due to emission control or engine protection Does not include torque generated by the Idle Governor Does not include torque reduction by the Rated Speed Governor NOTE: Percent load on the SAE J1587 link (PID 92) is current torque over the maximum torque at current engine speed; includes all internal torque reductions and governors. Modulated Signal The PWM signal duty cycle range can cover 0-100% or be limited to 5-95% (representing full range). PWM sample duty cycles can be seen in the next three illustrations. See Figure 5-114 for a 10% duty cycle. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-233 DDEC FEATURES Figure 5-114 PWM Output - 10% Duty Cycle See Figure 5-115 for a 50% duty cycle. Figure 5-115 PWM Output - 50% Duty Cycle See Figure 5-116 for a 90% duty cycle. 5-234 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 5-116 PWM Output - 90% Duty Cycle Discrete On/Off signal The PWM output can be used as a discrete on/off signal. The on trigger point and hysteresis are DDC calibrated parameters. The signal turns on (ground) once the powertrain demand reaches 80% and turns off (opens) once powertrain demand falls below 60%. 5.34.2 PWM1 INSTALLATION The transmissions listed in Table 5-103 communicate with the ECM using PWM1. Transmission Allison Hydraulic (see Figure 5-123, page ) Allison Transmission Electronic Controls (ATEC) GE Propulsion System Controller (see Figure 5-120, page ) VOITH (see Figure 5-122, page ) ZF Transmissions AVS™ or Ecomat™ (see Figure 5-121, page ) Table 5-103 ECM Communication PWM 1 PWM 1 Information Sent Powertrain Demand Powertrain Demand Duty Cycle PWM Signal Description 0-100% Discrete 0-100% Modulated PWM 1 Operation on Load Curve 5-95% Modulated PWM 1 or SAE J1939 Powertrain Demand 5-95% Modulated PWM 1 Powertrain Demand 5-95% Modulated Transmissions Communicating with PWM1 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-235 DDEC FEATURES Allison Interface Modules The Allison Throttle Interface Module (see Figure 5-117) translates the powertrain demand signal broadcast by the DDEC IV ECM into a signal which is recognized by the transmission. Figure 5-117 Throttle Interface Module, Allison Transmission The Allison Maximum Feature Interface Module translates the powertrain demand signal broadcast by the DDEC IV ECM into a signal which is recognized by the transmission (see Figure 5-118). 5-236 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 5-118 Maximum Feature Throttle Interface Module, Allison Transmission The module communicates the transmission output speed signal back to DDEC for use in Cruise Control/vehicle speed limiting. It also incorporates an integral engine speed switch which is sent to Allison Electronic Control as an input signal for the logic preventing shifting into a range above preset engine speeds. All Allison Electronic Control transmissions require this module or the throttle interface module when connected to DDEC IV. DDEC IV uses the open collector sensor type to integrate with the Allison Automatic Transmission to calculate vehicle speed (see Figure 5-119). NOTE: For Allison Transmission Electronic Controls refer to Allison Automatic Transmissions General Book #1, Page AS00-138, for world transmission refer to Allison Automatic Transmissions World Transmission WT Controls And General Information, Page Sa07-040. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-237 DDEC FEATURES Figure 5-119 Allison Automatic Transmission Open Collector Speed Sensor GE Propulsion System Controller See Figure 5-120 for the PWM wiring for the GE Propulsion System. Figure 5-120 DDEC IV to GE Propulsion System Controller Refer to section 5.25, "Optimum Load Signal," for additional information. 5-238 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL ZF Ecomat and Voith Transmissions See Figure 5-121 for installation of the ZF Ecomat transmission interface. Figure 5-121 DDEC IV to ZF Ecomat Transmission See Figure 5-122 for installation of the Voith transmission interface. Figure 5-122 DDEC IV to Voith Transmission All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-239 DDEC FEATURES Allison Hydraulic Transmission See Figure 5-123 for a schematic of the Allison Hydraulic Transmission and DDEC IV. NOTE: The exception to the following schematic is Allison HT750DR. Refer to "Allison Watch" #145 for DDECIV to HT750DR. Figure 5-123 5-240 DDEC IV to Allison Hydraulic Transmission All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Programming Requirements and Flexibility The correct transmission type, listed in Table 5-104, must be programmed by VEPS or DRS. Transmission Transmission Type Allison Hydraulic 1 Allison Transmission Electronic Controls (ATEC) 9 GE Propulsion System (AC) 32 Voith 3 Z-F Transmissions 4 Table 5-104 Transmission Types DDEC uses the transmission output shaft speed to determine vehicle speed. Programming information is listed in Table 5-105. Transmission Sensor Type DDEC IV Wire Transmission Wire DDEC IV Calibration Allison Transmission Electronic Controls Open Collector 556 205 Open Collector Allison Hydraulic External Magnetic 556 557 -- -- ZF Ecomat™ Open Collector 556 714 Open Collector or Magnetic Voith Magnetic 556 557 pin 5 Blue wire pin 6 Brown wire Magnetic Table 5-105 VSS Information for Various Transmissions For additional information on Vehicle Speed Sensors, refer to section 3.13.2.12. 5.34.3 COMMUNICATION LINKS OPERATION The serial communication links SAE J1587, SAE J1922, and SAE J1939 communicate control information from the engine to various vehicle systems such as transmissions. SAE J1587 defines the recommended format of messages and data being communicated between microprocessors used in heavy-duty vehicle applications. SAE J1922, and SAE J1939 transmit to the powertrain the messages assigned to both the engine and the transmission retarder. 5.34.4 COMMUNICATION LINKS INSTALLATION The transmissions listed in Table 5-106 communicate with the ECM using the data links. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-241 DDEC FEATURES Transmission ECM Communication Allison World Transmission (see Figure 5-124 on page ) SAE J1587 Allison WTEC III SAE J1939 & SAE J1587 ® Eaton CEEMAT™ (see Figure 5-126 on page ) SAE J1922 VOITH PWM 1 or SAE J1939 SAE J1939 Transmissions SAE J1939 Table 5-106 Transmissions Communicating with the Data Links Allison World Transmission The Allison World Transmission Series utilizes the SAE J1587 data link to obtain transmission control information. See Figure 5-124 for installation instructions. Figure 5-124 5-242 DDEC IV to Allison WT-Series Transmission All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL DDEC IV uses the open collector sensor type to integrate with the Allison Automatic Transmission to calculate vehicle speed (see Figure 5-125). Figure 5-125 Allison Automatic Transmission Open Collector Speed Sensor NOTE: For Allison Transmission Electronic Controls refer to Allison Automatic Transmissions General Book #1, Page AS00-138, for world transmission refer to Allison Automatic Transmissions World Transmission WT Controls And General Information, Page Sa07-040. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-243 DDEC FEATURES Eaton CEEMAT Transmission The Eaton CEEMAT™ transmission utilizes the SAE J1922 powertrain control link to obtain transmission control information. See Figure 5-126. Figure 5-126 DDEC IV to CEEMAT Transmission SAE J1939 Transmissions The SAE J1939 powertrain control link is designed to communicate control information between the engine and the transmission. Refer to section 3.5, "Communication Harness," for additional information. Programming Requirements and Flexibility The correct transmission type, listed in Table 5-107, must be programmed by VEPS or DRS. Transmission Transmission Type Allison World Transmission 12 Allison WTEC III 12 or 16 Eaton CEEMAT 14 Voith 16 SAE J1939 Transmissions 16 Table 5-107 5-244 Transmission Types All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.34.5 DIGITAL INPUT AND DIGITAL OUTPUT TRANSMISSIONS The transmissions supported by DDEC IV that communicate using digital inputs and outputs are listed in Table 5-108. Transmission ® Eaton Top2™ Meritor™ESS™ Table 5-108 5.34.6 Transmission Models RTLO-xx610B-T2 ( Release 4.01 or later) RTL-xx710B-T2 ( Release 21.0 or later) RTLO-xx713A-T2 ( Release 22.0 or later) RTLO-xx718B-T2 ( Release 22.0 or later) RS9 RSX9-A RSX9-B RSX9-R RS10 RSX10 RSX10-C ECM Communication 2 Digital Outputs 2 Digital Inputs 2 Digital Outputs Transmissions Communicating with Digital Inputs and Digital Outputs EATON TOP2 OPERATION The Top2system automatically shifts between the top two gears of the Eaton Top2 Transmission to optimize drivetrain for best fuel economy or performance. Shifting between the two highest gears in the transmission is done by the ECM and requires no driver interaction. The system works with engine brakes and Cruise Control during automatic shifts. The torque demand from throttle or Cruise Control is smoothly ramped down before the shift and ramped up after the shift allowing the driver to keep his foot on the throttle during shifts. Cruise Control is automatically resumed after the shift. When the transmission is shifted out of the two top gears, the driver has full manual control over the transmission. The engine will also detect skip shifts into the auto mode and still take control of the transmission's top two gears. Installation See Figure 5-127 to install Top2. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-245 DDEC FEATURES Figure 5-127 Top2 Transmission Programming Requirements and Flexibility The Top2 feature is enabled when the Top2 Shift Solenoid (function #30) and the Top2 Lockout Solenoid (function #31) digital outputs, listed in Table 5-109 are configured. The digital outputs must be configured by order entry, VEPS or DRS. Description Function Number Top2 Shift Solenoid 30 Top2 Lockout Solenoid 31 Table 5-109 Digital Outputs Used by Top2 Once Top2 is enabled, the logic will default to support the Super 10 Overdrive Transmission RTLO-xx610B-T2 unless one of the transmissions listed in Table 5-110 is selected. Table 5-110 Transmission Transmission Type RTLO-XX610B-T2 27 RTL-XX710B-T2 28 RTLO-XX713A-T2 29 RTLO-XX718B-T2 30 Top2 Transmission Types DRS, the DDR, or VEPS (Release 26.0) allow you to enable/disable Top2 functionality as listed in Table 5-111. 5-246 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL * On-screen Definition Choice TOP2 CRUISE SW* Enables or disables Top2 functionality. ON, OFF This feature is available for Release 8.0 or higher of DDEC III, Release 21.0 or higher for DDEC IV. Table 5-111 Top2 Reprogramming Choices Diagnostics If a fault is detected on either the shift solenoid or shift lockout digital output, the ECM will leave the transmission in manual mode until the fault is repaired. When there is a fault in any of the following sensors, the driver will be left with manual control of the transmission and the ECM will turn ON the check engine light. Vehicle Speed Sensor Synchronous Reference Sensor/Timing Reference Sensor (SRS/TRS) failure Lockout and shift solenoid failures When there is a fault in any of the following features, the driver will be left with manual control of the transmission. The Check Engine Light (CEL) will be turned ON for these conditions. Failed splitter engagements Failed splitter disengagements Failed synchronizing attempts (possible in-gear) 5.34.7 MERITOR ENGINE SYNCHRO SHIFT OPERATION ESS is a Meritor transmission feature that aids the driver. The ESS system automatically synchronizes the transmission by matching the engine RPM speed to the road speed of the vehicle which eliminates the need to use the clutch pedal for shifting gears. ESS eliminates the need to use the clutch and accelerator pedal for sequential shifts as DDEC automatically sets engine speed to the proper synchronous RPM for the next gear. The system simplifies power downshifts where matching speeds require increasing engine RPM. The system automatically performs the necessary range shifts at the appropriate place in the shift pattern. The driver indicates his intentions to the controller via the intent switch, a four position switch mounted on the side of the shift knob. The clutch is used for starting and stopping. To initiate ESS, the clutch remains engaged and the transmission is shifted into neutral. The operator must release torque on the drivetrain via the break torque "over-travel" on the four position switch or manually via the accelerator pedal. Cruise Control (if operating) will be suspended when the transmission is shifted into neutral. The current gear is calculated by DDEC using the current engine RPM and the transmission output RPM from the Vehicle Speed Sensor (VSS). The ESS logic in the DDEC ECM calculates the next desired gear ratio based on the current sensed gear ratio and the shift intent switch. It then uses this ratio to command the engine to a speed synchronous with the next gear. Control of the engine returns to the Throttle Position Sensor (TPS) when the driver shifts back into gear, uses the clutch, or the ESS system times out. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-247 DDEC FEATURES The system allows traditional manual shifting without automatic engine speed control. When the ESS system switch is ON, the driver can make manual shifts by pressing the clutch during shifting. Switching between high and low range is controlled automatically by DDEC. The ESS system can also be turned OFF entirely with the system switch. Manual shifting is done with the use of the clutch. The shift intent switch locked in the up position (ON) selects the high range gear box and in the low position (OFF) selects the low range gear box. The Shift-n-Cruise™ option is an ESS shift knob with integrated cruise control switches. The PAUSE, SET, and RESUME buttons are located on the transmission shift knob. There are four options that can be programmed using the DDDL/DDR, VEPS, or DRS. These are: Late Change Second Chance Eng Brake Shift Skip Shift The parameters for these options are listed in Table 5-115 in the section "Programming Requirements and Flexibility" on page 5-251. 5-248 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Installation The ECM must be programmed with a software level of Rel. 5.03 or higher. For installation, see Figure 5-128. Figure 5-128 Engine Synchro Shift Schematic All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-249 DDEC FEATURES Diagnostics The faults that can occur in the system and the associated results are listed in Table 5-112. Flash Code SID FMI Description 73 151 14 Stuck in gear detected 73 084 12 Vehicle Speed Sensor failure 73 227 4 73 227 3 73 227 2 Results ESS is disabled. Manual shifting can be performed with the clutch. If the system switch is ON, DDEC will control the high/low range. ESS and automatic range control is disabled. Only manual range control is available providing the system switch is OFF. If the system switch is ON, then the last range is used. Shift knob voltage below normal or shorted low Shift know voltage below normal or shorted low Shift knob data erratic intermittent or incorrect ESS is disabled. Manual shifting can be performed with the clutch. If the system switch is ON, DDEC will control the high/low range. If both switches fail, ESS and automatic range control is disabled. The range will fail in the last selected position. If one switch fails, ESS operation will continue, but the system performance will be reduced. 73 226 11 Neutral/In Gear Switch fault 62 *xxx 3 Low range solenoid-short to battery 62 *xxx 4 Low range solenoid-open circuit 62 *xxx 3 High range solenoid-short to battery 62 *xxx 4 High range solenoid-open circuit ESS is disabled. Range control is lost towards the bad solenoid. * System Identifier (SID) dependent on output cavity item to which item is assigned. Table 5-112 ESS Faults For more diagnostic and troubleshooting information, refer to the Engine Synchro Shift™ Troubleshooting manual (6SE498). 5-250 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Programming Requirements and Flexibility The ECM must be programmed with software Release 5.03 or later. The correct transmission type, listed in Table 5-113, must be programmed with VEPS or DRS. Transmission Type Setting RS9 (M-XXG9A-DXX) 17 RSX9-A (MO-XXG9A-DXX) 18 RSX9-B (MO-XXG9B-DXX) 19 RSX9-R 20 RS10 (M-XX-G10A-DXX) 21 RSX10 (MO-XX-G10A-DXX) 22 RSX10-C (MO-XX-G10C-DXX) 23 Table 5-113 ESS Transmission types The digital outputs and digital inputs listed in Table 5-114 must be configured by order entry, VEPS or DRS. Description Type Function Number Low Range Solenoid Digital Output 28 High Range Solenoid Digital Output 29 Clutch Switch Digital Input 18 In Neutral Digital Input 38 In Gear Digital Input 39 Table 5-114 Digital Inputs and Digital Outputs Used by ESS DDDL/DDR, VEPS, or DRS can be used to change parameters in the ECM calibration. Parameters specific to ESS are listed in Table 5-115. On-screen LATE CHANGE Definition Display/Choice Enables/disables Late Change feature. YES, NO SECOND CHANCE Enables/disables Second Chance feature. YES, NO ENG BRAKE SHIFT Enables/disables Eng Brake Shift feature. YES, NO Enables/disables Skip Shift feature. YES, NO SKIP SHIFT Table 5-115 Programmable Parameters Late Change - Late Change allows the driver, who has forgotten to change the shift direction intent switch, to correct the switch position while in neutral. The ECM will then recalculate the desired next gear and re-synchronize the engine speed to allow the driver to complete the shift into the newly revised gear. The default is YES. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-251 DDEC FEATURES Second Chance - When activated, Second Chance allows the ECM to calculate the best gear in which to shift and synchronizes the engine to that speed. The driver must find that selected gear. This feature can only be used while the system switch in ON, the clutch switch is ON, the vehicle has been shifted into NEUTRAL, there are no VSS faults, no shift knob fault, no neutral switch faults, no in gear switch faults, and the vehicle is at speed that will be conducive to shifting. If an ESS shift had been attempted, then the shift must have been aborted and/or timed out. The default is YES. Eng Brake Shift - The engine brakes can be actuated during an ESS shift operation. The use of engine brakes allows the engine speed to drop to the synchronous speed quicker than it would be able to spool down on its own. Normally the throttle pedal must be released for engine brake operation to go active, but for ESS the driver is allowed to have his foot on the throttle and still get engine brake operation. The default is YES. Skip Shift - The driver can skip any number of gears by pressing the break torque switch multiple times in the direction of the desired shift which signals the ECM. The number of times the switch is toggled equals the number of gears to skip. Skip shifting is only allowed while the vehicle is in neutral. The default is YES. 5-252 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.35 TRANSMISSION RETARDER A hydraulic transmission retarder is a device used to slow an engine by applying a torsional resistance to the engine output shaft. This resistance is achieved by the flow of hydraulic fluid against a rotating wheel, within an enclosed cavity. Energy is absorbed by the fluid, and is transferred as heat to an auxiliary cooler. 5.35.1 OPERATION A digital output is switched to battery ground whenever the throttle is in the 0% position and Cruise Control is inactive. This signal, in conjunction with a relay, may be used to control a transmission retarder. The retarder option must be specified at the time of engine order. This output will also be enabled if a SAE J1922 data link message is received requesting transmission retarder. 5.35.2 PROGRAMMING REQUIREMENTS AND FLEXIBILITY The transmission retarder option must be specified at the time of engine order. The digital output listed in Table 5-116 must be configured by order entry, VEPS, or DRS. Function Number Type Description 9 Digital Output Transmission Retarder Table 5-116 5.35.3 Transmission Retarder Digital Outputs INTERACTION WITH OTHER FEATURES A deceleration light can be used to warn that the vehicle is slowing down. A digital output is switched to ground whenever the percent throttle is zero and Cruise Control is inactive. This output is typically used to drive a relay, which drives the deceleration lights. Refer to section 4.2 , "Digital Outputs," for additional information. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-253 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-254 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.36 VEHICLE SPEED LIMITING The Vehicle Speed Limiting feature is available on all DDEC engines equipped with a Vehicle Speed Sensor. 5.36.1 OPERATION Vehicle Speed Limiting discontinues engine fueling at any vehicle speed above the programmed limit. DDEC stops fueling when maximum vehicle speed is reached. The Fuel Economy Incentive option will increase the Vehicle Speed Limit (refer to section 5.15, "Fuel Economy Incentive"). 5.36.2 INSTALLATION An OEM supplied Vehicle Speed Sensor or output shaft speed over the SAE J1939 Data Link is required. Refer to section 3.14.25, "Vehicle Speed Sensor," for additional information. 5.36.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY The Vehicle Speed Limit is programmable at engine order entry or with the DDR, DDDL, VEPS or DRS as listed in Table 5-117. Parameter Description Choice / Display VEHICLE SPEED LIMIT ENABLE Enables or disables vehicle speed limiting feature. YES, NO, N/A MAX VEHICLE SPD Sets the maximum vehicle speed in MPH. 20 MPH to (rated speed/VSS ratio) MAX OVERSPEED LIMIT MAX SPEED NO FUEL Table 5-117 5.36.4 Sets the vehicle speed above which a diagnostic code will be logged if the driver fuels the engine and exceeds this limit. Entering a zero (0) will disable this option. Sets the vehicle speed above which a diagnostic code will be logged if the vehicle reaches this speed without fueling the engine. Entering a zero (0) will disable this option. 0 to 127 MPH 0 to 127 MPH Vehicle Speed Limiting Parameters INTERACTION WITH OTHER FEATURES The Cruise Control maximum set speed cannot exceed the Vehicle Speed Limit. Fuel Economy Incentive will increase the Vehicle Speed Limit. When Vehicle Speed Limiting is enabled and a VSS code is logged, the engine speed in all gears will be limited for the duration of the ignition cycle to engine speed at the Vehicle Speed Limit in top gear. A vehicle can be set up with both PasSmart and Fuel Economy Incentive, but the extra speed increments provided by the two features do not add together. For example, if Fuel Economy Incentive is set up to give 7 MPH of extra speed when the driver hits the maximum fuel economy target and the PasSmart increase is 5 MPH the resulting speed increase is 7 MPH, not 12 MPH. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-255 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-256 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5.37 VEHICLE SPEED SENSOR ANTI-TAMPERING VSS Anti-tampering can be used to detect fixed frequency oscillators or devices which track engine RPM and produce fewer pulses per revolution than a VSS wheel. These devices are used to trick the ECM into believing that vehicle speed is low. A VSS fault will be logged if the sensor appears to be working improperly but the vehicle speed is not zero. The engine speed in all gears will be limited for the duration of the ignition cycle to the engine speed at the Vehicle Speed Limit in top gear. NOTE: Enabling VSS anti-tampering for use with SAE J1939, automatic, semi-automatic, or torque converter transmissions such as Meritor ESS or Eaton Top2 may cause false codes. 5.37.1 PROGRAMMING FLEXIBILITY The DDR, DDDL, or the DRS can enable VSS anti-tampering. Vehicle Speed Limiting must also be enabled. The parameters are listed in Table 5-118. Parameter Description Choice/Display VSS Anti-tamper Enables or Disables VSS Anti-tamper Feature YES/NO Vehicle Speed Limit Enable Enables or Disables Vehicle Speed Limiting YES/NO Max Vehicle Speed Sets the Max Vehicle Speed in MPH 20 MPH to (rated speed/VSS ratio) Table 5-118 VSS Anti-tampering Parameters All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 5-257 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5-258 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 6 COMMUNICATION PROTOCOLS Section Page 6.1 OVERVIEW ............................................................................................. 6-3 6.2 SAE J1587 .............................................................................................. 6-5 6.3 SAE J1922 .............................................................................................. 6-35 6.4 SAE J1939 .............................................................................................. 6-43 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-1 COMMUNICATION PROTOCOLS THIS PAGE INTENTIONALLY LEFT BLANK 6-2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 6.1 OVERVIEW Key components of the DDEC IV system are the serial communication links SAE J1587, SAE J1922, and SAE J1939. Using these communication links allows DDEC IV to offer the following functionality: Transmitting sensor information from the ECM via the data link at regular intervals and/or upon request to obtain data and to monitor for failures Sharing information between stand-alone modules used in the system via the data link Sharing engine data with electronic dashboard displays and vehicle management information systems via the data link Transmitting and performing diagnostic procedures from external instrumentation such as the hand-held diagnostic data readers or DDDL via the data link Transmitting customer requested changes to the ECM from external instrumentation via the data link Transmitting to the powertrain the messages assigned to both the engine and the transmission retarder. The following industry standard Society of Automotive Engineers (SAE) documents can be used as a reference: SAE J1587 MAR96 , Electronic Data Interchange Between Microcomputer Systems In Heavy Duty Vehicle Applications SAE J1708 OCT93, Serial Data Communications Between Microcomputer Systems In Heavy Duty Vehicle Applications SAE J1922, DEC89, Powertrain Control Interface For Electronic Controls Used In Medium And Heavy Duty Diesel On-highway Vehicle Applications SAE J1939, Recommended Practice for a Serial Control and Communication Vehicle Network SAE J1939/71, AUG97, Vehicle Application Layer To obtain a copy of the above documents contact the Society of Automotive Engineers (SAE). SAE International 400 Commonwealth Drive Warrendale, PA 15096 Attention: Publications Phone: (412) 776-4970 DDEC IV complies with the interface definition of the SAE J1708 OCT93. DDEC IV complies with the standard diagnostic messages defined by SAE J1587 MAR96. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-3 COMMUNICATION PROTOCOLS THIS PAGE INTENTIONALLY LEFT BLANK 6-4 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 6.2 SAE J1587 SAE RP J1587 defines the recommended format of messages and data being communicated between microprocessors used in heavy-duty vehicle applications. Circuits 900 (Data Link +) and 901 (Data Link -) as shown on the Vehicle Interface Harness schematic are used as the J1587 communication link. These circuits also exist in the DDEC six-pin diagnostic connector for use with the DDR. NOTE: The maximum length for the SAE J1587 Data Link is 40 m (130 ft). 6.2.1 MESSAGE FORMAT A complete description of the DDEC IV parameters is provided within this section of the manual. DDEC IV transmits parametric data at SAE J1587 recommended rates in packed message form. The first byte or character of each message is the Message Identification character (MID). The MID identifies which microcomputer on the serial communication link originated the information. Each device in the system originating messages must have a unique MID. The assignment of MIDs should be based on those listed in SAE RP J1587. The primary MID for DDEC IV is 128. Engines with 12 and 16 cylinders use MID 128 and MID 175. Engines with 20 cylinders use MID 128, MID 175 and MID 183. The ProDriver display uses MID 171. Off-board diagnostic tools like hand-held readers should be identified by MID 172. Off-board programming stations like Vehicle Engine Programming Station (VEPS) should be identified by MID 182. Messages using MIDs as recommended by SAE RP J1587 will be responded to by the ECM. Subsystems also require identifiers. The subsystem identifier character (SID) is a single byte character used to identify field-repairable or replaceable subsystems for which failures can be detected or isolated. SIDs are used in conjunction with SAE standard diagnostic codes defined in J1587 within PID 194. The identifiers used by DDEC are defined and listed in Table 6-1. Description Identifier Failure Mode Identifier (FMI) Message Identification Character (MID) Parameter Identification Character (PID) Subsystem Identification Character (SID) Table 6-1 The FMI describes the type of failure detected in the subsystem and identified by the PID or SID. The MID is the first byte or character of each message that identifies which microcomputer on DDEC 1587 serial communication link originated the information. A PID is a single byte character used in DDEC 1587 messages to identify the data byte(s) that follow. PIDs identify the parameters transmitted. A SID is a single byte character used to identify field-repairable or replaceable subsystems for which failures can be detected or isolated. Identifiers Used by DDEC All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-5 COMMUNICATION PROTOCOLS 6.2.2 1708/1587 MESSAGE PRIORITY Each message sent by DDEC is assigned a priority on a scale of 1 to 8, in compliance with the message priority assignment specified in SAE RP J1708. The most critical message has a priority of one. The message assignments are listed in Table 6-2. All devices transmitting messages across DDEC's 1708/1587 Data Link must be prioritized and transmitted in this manner. Priority Description 1 and 2 Reserved for messages that require immediate access to the bus. 3 and 4 5 and 6 7 and 8 Table 6-2 Reserved for messages that require prompt access to the bus in order to prevent severe mechanical damage. Reserved for messages that directly affect the economical or efficient operation of the vehicle. All other messages not fitting into the previous priority categories. Message Priority Assignments SAE J1587 Parameters Available with DDEC IV DDEC IV supports the J1587 parameter identifiers (PIDs) listed in Table 6-3 and Table 6-4. NOTE: Data is transmitted only if the source has been configured for the engine. PID Description PID Description 243 Device Identification 249 Total Engine Revolution 244 Trip Miles 250 Total Fuel Used 245 Total Miles 251 Clock Module 247 Total Engine Hours 252 Clock Module 248 Total VSG Hours 404 Turbo Compressor Table 6-3 6-6 SAE J1587 PIDs Provided by DDEC IV All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PID Description PID Description 3 Extended Range Cylinder Head Temperature 109 Coolant Pressure 18 Extended Range Fuel Pressure 110 Coolant Temperature 19 Extended Range Oil Pressure 111 Coolant Level 20 Extended Range Coolant Pressure 113 Engine Governor Droop 44 Attention/Warning Indicator Lamps Status 121 Engine Retarder Status 48 Extended Range Barometric Pressure 122 Engine Retarder Percent 51 Throttle Position 153 Crankcase Pressure 52 Engine Intercooler Temperature 154 Auxiliary Input & Output Status #2 62 Retarder Inhibit Status 155 Auxiliary Input & Output Status #1 65 Service Brake Switch Status 162 Transmission Range Selected 68 Torque Limiting Factor 163 Transmission Range Attained 70 Parking Brake Switch Status 164 Injection Control Pressure Idle Shutdown Timer Status 166 Rated Engine Power 168 Battery Potential (Voltage) 171 Ambient Air Temperature 71 72 73 Blower Bypass Valve Position/Blower Bypass Door Position Extended Range Auxiliary Water Pump Pressure 74 Vehicle Speed Set Limit 172 Air Inlet Temperature 81 Exhaust Back Pressure 173 Exhaust Temperature 83 Vehicle Speed Limit Status 174 Fuel Temperature 84 Vehicle Speed 175 Engine Oil Temperature 85 Cruise Control Switch Status 182 Trip Fuel 86 Cruise Control Set Speed 183 Fuel Rate 87 Cruise Control High Limit 184 Instantaneous Fuel Economy, (mile/gal) 88 Cruise Control Low Limit 185 Average Fuel Economy, (mile/gal) 89 VSG Switch Status 187 188 91 Percent Throttle 188 Idle Engine Speed 92 Percent Engine Load 189 Rated Engine Speed 93 Output Torque 190 Engine Speed 94 Fuel Delivery Pressure 191 Transmission Output Shaft Speed 95 Fuel Filter Differential Pressure 192 Multi-sectioned Parameter 98 Engine Oil Level 194 Transmitter System Diagnostic Code and Occurrence Count Table 99 Oil Filter Differential Pressure 196 Diagnostic Data/Count Clear Response 100 Engine Oil Pressure 222 Anti-Theft 101 Crankcase Pressure 228 Speed Sensor Calibration 102 Turbo Boost Pressure 233 Unit Number 103 Turbo Speed 234 Software Identification 105 Intake Manifold Temperature 235 Total Idle Hours 106 Air Inlet Pressure 236 Total Idle Fuel Used 107 Air Filter Differential Pressure 237 Vehicle Identification Number (VIN) 108 Barometric Pressure 240 Last Customer Calibration Change Hours Table 6-4 SAE J1587 PIDs Provided by DDEC IV (continued) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-7 COMMUNICATION PROTOCOLS 6.2.3 SAE J1587 PIDS REQUIRING DDEC ACTION DDEC will respond to data requests per the J1587 PID requests shown in the next sections. Data Request The format for a data request is shown below. PID 0 Data a a - Parameter number of the requested parameter Component Specific Request The format for a component specific request is shown below. PID 128 Data ab a - Parameter number of the requested parameter b - MID of the component from which the parameter data is requested NOTE: DDEC responds with the appropriate data provided the MID in byte (b) matches the MID stored in calibration. The primary MID for DDEC III/IV is 128. Engines with 12 and 16 cylinders use MID 128 and MID 175. Engines with 20 or 24 cylinders use MID 128, MID 175 and MID 183. Retarder Status Request Electronic transmissions may indicate the status of the transmission output retarder to DDEC by using the following message: PID 47 comments: 6-8 Data a a - Transmission output retarder status Bits 2-1 Output retarder status 00 = off 10 = error 01 = on 10 = error Bits 8-3 Reserved, Bits set to 1 This parameter is supported in Release 4.00 or later. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Transmitter Data Request / Clear Count The format for a transmitter data request is shown below. PID 195 Data nabc n - Number of parameter data characters = 3 a - MID of the device to which the request is directed b - SID or PID of a standard diagnostic code c - Diagnostic code number Bits: 1 - 4 Bit: 5 Failure mode identifier (FMI) of a standard diagnostic code Byte (b) identifier 1 - Byte (b) is a Subsystem Identifier (SID) 0 - Byte (b) is a Parameter Identifier (PID) Bit: 6 Type of diagnostic code 1 - Standard diagnostic code 0 - Reserved for expansion diagnostic codes Bit: 7, 8 Request an ASCII descriptive message for the given diagnostic code. Request count be cleared for the given diagnostic code on 01 the device with the given MID. Request counts be cleared for all diagnostic codes on the 10 - device with the given MID. The diagnostic code given in this transmission is ignored. Request additional diagnostic information for the given 11 - diagnostic code, the content of which is defined under PID 196. -- NOTE: DDEC responds with the appropriate data using PID 196. source: ECM calculated; outputs represent intended state All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-9 COMMUNICATION PROTOCOLS J1587 Outputs - Single Byte Parameters PID 18 - Extended Range Fuel Pressure update rate: 1 time/s resolution: 4 kPa/Bit (Uns/SI) source: Fuel Pressure Sensor comments: This PID is used to provide a wider range of pressure values than that provided with PID 94. This parameter is available with Release 24.00 software or later. PID 19 - Extended Range Engine Oil Pressure update rate: 1 time/s resolution: 4 kPa/Bit (Uns/SI) source: Engine Oil Pressure Sensor sensor range: 0 to 145 psi comments: This PID is used to provide a wider range of pressure values than that provided with PID 100. This parameter is available with Release 24.00 software or later. PID 20 - Extended Range Coolant Pressure update rate: 1 time/s resolution: 2 kPa/Bit (Uns/SI) source: Coolant Pressure Sensor comments: This PID is used to provide a wider range of pressure values than that provided with PID 109. This parameter is available with Release 24.00 software or later. 6-10 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PID 44 - Attention/Warning Indicator Lamps Status update rate: 10 time/s or 1 time/s when changing format: Bit: 1,2 Stop Engine Light Status 00 - off 01 - on 10 - error 11 - Not Available Bit: 3,4 Check Engine Light Status 00 - off 01 - on 10 11 - Not Available Bit: 5-8 Reserved, All Bits set to 1 PID 48 - Extended Range Barometric Pressure update rate: 1 time/s resolution: 0.6 kPa/Bit (Uns/SI) source: Barometric Pressure Sensor or Turbo Boost Pressure Sensor PID 51 - Throttle Position update rate: 5 time/s resolution: 0.4%/Bit (Uns/SI) source: Throttle Position Sensor comments: This parameter identifies the position of the value used to regulate the supply of a fluid, usually air or fuel/air mixture, to an engine - 0% represents no supply. PID 52 - Engine Intercooler Temperature update rate: 1 time/s resolution: 1 F/Bit (Uns/SI) source: Engine Intercooler Temperature Sensor All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-11 COMMUNICATION PROTOCOLS PID 62 - Retarder Inhibit Status update rate: On request format: Bits: 1, 2 source: comments: Retarder Inhibit Status 00 - Off (not Inhibited) 01 - On (Inhibited) Bits: 3-8 Uncommitted, all Bits set to 1 Digital output for Engine Brake Enable Used with the Engine Brake outputs. PID 65 - Service Brake Status update rate: 1 time/s format: Bits: 1, 2 source: Service Brake Status 00 - off 01 - on Bits: 3-8 Uncommitted, all Bits set to 1 Bits 3-8 = 1 Service Brake Switch PID 68 - Torque Limiting Factor update rate: 1 time/s resolution: 0.5%/Bit (Uns/SI) source: ECM calculated. comments: This parameter indicates the amount of engine protection torque reduction that is in effect. PID 70 - Parking Brake Switch Status update rate: 1 time/s format: Bits: 8 Parking Brake Switch Status 0 - off 1 - on Bits: 1-7 Uncommitted, all Bits set to 0 source: Parking Brake Switch 6-12 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PID 71 - Idle Shutdown Timer Status update rate: 1 time/s format: Bit: 1 Bit: 2 Bit: 3 Bit: 4 Bit: 8 source: Bits: 5-7 ECM calculated Idle Shutdown Override ("Driver Alert") 1 - Active Engine Has Shutdown by Idle Timer to 1 - Yes Idle Timer Shutdown Override 1 - Active (Idle Shutdown has been overridden) Idle shutdown timer function 1 - Enabled in calibration 0 - Disabled in calibration Idle Shutdown Timer Status 1 - Active All Bits set to 0 PID 72 - Blower Bypass Valve Position update rate: 2 times/s resolution: 0.4%/Bit (Uns/SI) source: Blower Bypass Valve Position sensor comments: Electronically controlled blower bypass valves are used on Methanol engines. PID 73 - Auxiliary Water Pump Pressure update rate: 1 time/s resolution: 2 psi/Bit (Uns/SI) source: Water Pump Pressure Sensor comments: The auxiliary Water Pump Pressure system is used on fire trucks with DDEC pressure control. The transmitted value is gage pressure. PID 74 - Vehicle Speed Set Limit (Road Speed Limiting) update rate: On request only resolution: 0.5 mph/Bit (Uns/SI) source: Calibration value (customer defined) comments: Vehicle Speed Limiting is a customer option. PID 81 — Exhaust Back Pressure update rate: 0.1 times/sec. resolution: 0.169 kPa/Bit All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-13 COMMUNICATION PROTOCOLS PID 83 - Vehicle Speed Limit Status update rate: 1 time/s format: Bit: 8 source: comments: Vehicle Speed Status 1 - Active All Bits set to 0 Bits: 1-7 ECM calculated Vehicle Speed Limiting is a customer option. PID 84 - Vehicle Speed update rate: 10 times/s resolution: 0.5 mph/Bit (Uns/SI) source: Vehicle Speed Sensor input comments: Transmitted only if the Vehicle Speed Sensor is configured. 6-14 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PID 85 - Cruise Control Switch Status update rate: 10 times/s format: On/Off Switch Bit: 1 1-On 0-Off Set Switch Bit: 2 1-Off 0-On Coast Switch Bit: 3 1-Off 0-On Resume Switch Bit: 4 1-Off 0-On Accel Switch Bit: 5 1-Off 0-On Brake Switch Bit: 6 1-Off 0-On Clutch Switch Bit: 7 1-Off 0-On Cruise Active Bit: 8 1-On 0-Off source: Cruise Control switch inputs comments: Cruise Control status (Bit 8) is not cleared if Cruise Control is active but being overridden by the throttle. PID 86 - Cruise Control Set Speed update rate: 0.1 times/s, 5 times/s when the set speed is changing resolution: 0.5 mph/Bit (Uns/SI) source: Cruise Control switch inputs comments: Transmitted if Vehicle Speed Cruise control is enabled. PID 87 - Cruise Control High Set Limit update rate: On request only resolution: 0.5 mph/Bit (Uns/SI) source: Calibration value (customer define) comments: Transmitted if Vehicle Speed Cruise control is enabled. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-15 COMMUNICATION PROTOCOLS PID 88 - Cruise Control Low Set Limit update rate: On request only resolution: 0.5 mph/Bit (Uns/SI) source: Calibration value comments: Transmitted if Vehicle Speed Cruise control is enabled. PID 89 - VSG Switch Status update rate: 1 time/s format: Bit: 1 source: comments: On/off switch 0-Off 1-On Bit: 2 Set switch 0-Off 1-On Bit: 3 Coast switch 0-Off 1-On Bit: 4 Resume switch 0-Off 1-On Bit: 5 Accel switch 0-Off 1-On Bit: 6 Brake 0-Off 1-On Bit: 7 Clutch 0-Off 1-On Bit: 8 VSG 0-Off 1-On VSG switch inputs/ECM calculated Transmitted when either the Pressure Sensor Governor, Cruise-Switch VSG or analog VSG is configured. PID 91 - Percent Throttle update rate: 10 times/s resolution: 0.4%/Bit (Uns/SI) source: Throttle Sensor input 6-16 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PID 92 - Percent Engine Load update rate: 10 times/s resolution: 0.5%/Bit (Uns/SI) source: ECM calculated comments: Percent engine load is the ratio of actual torque and the minimum of the requested torque and digital torque limit. PID 93 - Output Torque update rate: 1 time/s resolution: 20 ft-lb/Bit (S/SI) source: ECM calculated PID 94 - Fuel Delivery Pressure update rate: 1 time/s resolution: 0.5 psi/Bit (Uns/SI) source: Fuel Pressure Sensor PID 95 - Fuel Filter Differential Pressure update rate: 0.1 time/s resolution: 0.25 psi/Bit (Uns/SI) source: Fuel Filter Differential Pressure Sensor comments: This parameter is available with Release 24.00 software or later. PID 98 - Engine update rate: resolution: source: Oil Level 0.1 time/s 0.5%/Bit (Uns/SI) Oil Level Sensor PID 99 - Oil Filter Differential Pressure update rate: 0.1 time/s resolution: 0.0625 psi/Bit (Uns/SI) source: Oil Filter Differential Pressure Sensor comments: This parameter is available with Release 24.00 software or later. PID 100 - Engine Oil Pressure update rate: 1 time/s resolution: 0.5 psi/Bit (Uns/SI) source: Oil pressure sensor sensor range: 0 to 65 psi All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-17 COMMUNICATION PROTOCOLS PID 101 - Crankcase Pressure update rate: 1 time/s resolution: 0.125 psi/Bit (Uns/SI) source: Crankcase pressure sensor comments: Some engine applications use a discrete switch in place of a full range sensor. In these applications, the crankcase pressure data transmitted on the J1587 data link is not a true representation of crankcase pressure. PID 102 - Turbo Boost Pressure (Gage) update rate: 2 times/s resolution: 0.125 psig/Bit (Uns/SI) source: Turbo Boost Pressure Sensor PID 103 - Turbo update rate: resolution: source: Speed 1 time/s 500 rpm/Bit (Uns/SI) Turbo Speed Sensor PID 105 - Intake Manifold Temperature update rate: 1 time/s resolution: 1 F/Bit (Uns/SI) source: Intake Manifold Temperature Sensor PID 106 - Air Inlet Pressure update rate: 1 time/s resolution: 0.25 psi/Bit (Uns/SI) source: Air Inlet Pressure Sensor or Boost Pressure Sensor (Series 2000 and Series 4000 only before Release 21.0, Series 50 and Series 60 beginning with Release 21.0) PID 107 - Air Filter Differential Pressure update rate: 0.1 time/s resolution: 0.2 in.H2O/Bit (Uns/SI) source: Air Filter Differential Pressure Sensor comments: This parameter is available with Release 24.00 software or later. PID 108 - Barometric Pressure update rate: 1 time/s resolution: 0.0625 psi/Bit (Uns/SI) source: Barometric Pressure Sensor or ECM calculated 6-18 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PID 109 - Coolant Pressure update rate: 1 time/s resolution: 0.125 psi/Bit (Uns/SI) source: Coolant Pressure Sensor PID 110 - Coolant Temperature update rate: 1 time/s resolution: 1 F/Bit (Uns/SI) source: Coolant Temperature Sensor sensor range: 0 to 300 F PID 111 - Coolant Level update rate: 10 times/s resolution: 0.5%/Bit (Uns/SI) (or full = 100%, low = 0%) source: Coolant Level Sensor comments: If the Add Coolant Level Sensor (ACLS) is installed with the Engine Protection Coolant Level Sensor (CLS), the coolant level will be: 100% When both sensors are in coolant 50% When the ACLS is out of the coolant 0% When both sensors are out of the coolant If only the CLS is configured: 100% Full 0% Low PID 113 - Engine Governor Droop update rate: On request only resolution: 2 rpm/Bit (Uns/SI) source: Calibration value PID 121 - Engine Retarder Status update rate: 1 time/s (5 times/s when changing) format: Bit: 1 1 - 2 cylinders active Bit: 2 1 - 3 cylinders active Bit: 3 1 - 4 cylinders active Bit: 4 1 - 6 cylinders active Bit: 5 1 - 8 cylinders active Bit: 8 1 - Retarder active comments: Transmitted only if engine brakes are configured. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-19 COMMUNICATION PROTOCOLS PID 122 - Engine Retarder Percent update rate: 1 time/s resolution: 0.5%Bit (Uns/SI) source: ECM calculated comments: This parameter is available with Release 5.00 or later Double Byte Parameters PID 153 - Crankcase Pressure update rate: 1 time/s resolution: 0.0078125 kPa/Bit (S/I) comments: Some engine applications use a discrete switch in place of a full range sensor. In these applications, the crankcase pressure data transmitted on the J1587 data link is not a true representation of crankcase pressure. This PID is used to provide crankcase pressure with better resolution then that provided with PID 101. This parameter is available with Release 3.00 software or later. 6-20 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PID 154 - Auxiliary Input and Output status #2 update rate: On request format: PID Data 154 ab aAuxiliary Input Status Bit: 1, 2 Torque/RPM Limiting Switch 00 - Off 01 - On 10 - Error Condition 11 - Not Available Bit: 4-3 Stop Engine Override Switch 00 - Off 01 - On 10 - Error Condition 11 - Not Available Bit: 5, 6 A/C Disengaged 00 - Off 01 - On 10 - Error Condition 11 - Not Available Bit: 8-7 Reserved bAuxiliary Output Status Bit: 1, 2 Fan Control #2 00 - Off 01 - On 10 - Error Condition 11 - Not Available Bit: 3, 4 Reserved Bit: 5, 6 Reserved Bit: 7, 8 Reserved source: ECM calculated; outputs represent intended state All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-21 COMMUNICATION PROTOCOLS PID 155 - Auxiliary Input and Output status #1 update rate: On request format: PID Data 154 ab aAuxiliary Input Status Bit:1, 2 Jake Brake Low Switch 00 - Off 01 - On 10 - Error Condition 11 - Not Available Bit: 3, 4 Jake Brake Medium Switch 00 - Off 01 - On 10 - Error Condition 11 - Not Available Bit: 5, 6 Idle Validation Switch 00 - Off 01 - On b- 6-22 10 - Error Condition 11 - Not Available Bit: 7, 8 Throttle Inhibit Switch 00 - Off 01 - On 10 - Error Condition 11 - Not Available Auxiliary Output Status Bit: 1, 2 Vehicle Power Shutdown 00 - Off 01 - On 10 - Error Condition 11 - Not Available Bit: 3, 4 Starter Lockout 00 - Off 01 - On 10 - Error Condition 11 - Not Available Bit: 5, 6 Coolant Level Low Light 00 - Off 01 - On 10 - Error Condition 11 - Not Available All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Bit: 7, 8 source: Fan Control #1 00 - Off 01 - On 10 - Error Condition 11 - Not Available ECM calculated; outputs represent intended state PID 162 - Transmission Range Selected update rate: 2 times/s format: aa - Transmission Range Selected (ASCII) comments: Transmitted only when the transmission type is a Meritor ESS (17-22). Characters sent will be 0, L, 1, 2, ..., 15. If only one character is required, the second character will be used and the first character will be a space. Whenever a target gear is not selected a "0" will be transmitted. PID 163 - Transmission Range Attained update rate: 2 times/s format: aa - Transmission Range Attained (ASCII) comments: Transmitted only when the transmission type is a Meritor ESS (17-22). Characters sent will be 0, L, 1, 2, ..., 15. If only one character is required, the second character will be used and the first character will be a space. Whenever a target gear is not selected a "0" will be transmitted. PID 164 - Injection Control Pressure update rate: 1 time/s resolution: 1/256 MPa (Uns/I) source: Injection Pressure Sensor PID 166 - Engine Horsepower Rating update rate: On request only resolution: 1 bhp/Bit (Uns/I) source: Calibration value PID 168 - Battery Voltage update rate: 1 time/s resolution: 0.05 volts/Bit (Uns/I) source: Battery voltage measured at input to ECM comments: The ECM input battery voltage does fluctuate as injectors fire and will require filtering if used for display purposes. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-23 COMMUNICATION PROTOCOLS PID 171 - Ambient Air Temperature update rate: 1 time/s resolution: 0.25 F/Bit (S/I) source: ECM estimated comments: This parameter is available with Release 2.00 software or later. PID 172 - Air Inlet Temperature update rate: 1 time/s resolution: 0.25 F/Bit (S/I) source: Air Temperature Sensor sensor range: -40 to 175 F comments: Location of air temperature sensor depends on engine series. PID 173 — Exhaust Temperature update rate: 1 time/sec resolution: 0.25 F/Bit (S/I) PID 174 - Fuel Temperature update rate: 1 time/s resolution: 0.25 F/Bit (S/I) source: Fuel Temperature Sensor sensor range: -40 to 175 F comments: Location of air temperature sensor depends on engine series. PID 175 - Engine Oil Temperature update rate: 1 time/s resolution: 0.25 F/Bit (S/I) source: Oil temperature sensor sensor range: -40 to 300 F comments: Location of air temperature sensor depends on engine series. PID 182 - Trip Fuel update rate: 0.1 times/s resolution: 0.125 gal/Bit (Uns/I) source: ECM calculated PID 183 - Fuel Rate update rate: 5 times/s resolution: 1/64 gal/hour/Bit (Uns/I) source: ECM calculated 6-24 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PID 184 - Instantaneous Fuel Economy (MPG) update rate: 5 times/s resolution: 1/256 mpg/Bit (Uns/I) source: ECM calculated comments: Transmitted only if the Vehicle Speed Sensor is configured. PID 185 - Average Fuel Economy (MPG) update rate: 0.1 times/s resolution: 1/256 mpg/Bit (Uns/I) source: ECM calculated comments: Trip information from DDEC requires that the Vehicle Speed Sensor is enabled. PID 187 - VSG update rate: resolution: source: comments: Set Speed 0.1 times/s, 5 times per s when the set speed is changing 0.25 rpm/Bit (Uns/I) VSG switch input Used to indicate the current set speed from: Analog VSG Cruise Switch VSG Engine Speed Cruise Control Pressure Governor Mode - RPM or pressure Engine Sync. Mode (marine applications) PID 188 - Idle Set Speed update rate: On request only resolution: 0.25 rpm/Bit (Uns/I) source: Calibration value PID 189 - Rated Engine Speed update rate: On request only resolution: 0.25 rpm/Bit (Uns/I) source: Calibration value PID 190 - Engine Speed update rate: 10 times/s resolution: 0.25 rpm/Bit (Uns/I) source: ECM calculated All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-25 COMMUNICATION PROTOCOLS PID 191 - Transmission Output Shaft Speed update rate: 10 times/s resolution: 0.25 rpm/Bit (Uns/I) source: Transmitted when configured for Meritor ESS transmissions only. PID 404 - Turbo Compressor Temperature Out update rate: 1 times/s resolution: 0.25 F/Bit (S/I) Variable Length Parameters PID 192 - Multi-Section Parameter update rate: Used to transmit messages that are greater than 21 bytes in length. format: PID Data 192 n a b c/d c c c c c Byte count of data that follows this character. This excludes ncharacters MID, PID 192 and n but it includes a, b, c, or d type character. aPID specifying the parameter that has been sectioned. The last section number (total number of sections minus ONE) and the current section number. The upper nibble contains the current section number (1 to 15). The lower nibble contains bthe current section number and is limited to the range 0 to 15. Section numbers are assigned in ascending order. Data portion of the sectioned parameter. May be 1 to 14 ccharacters in the first packet. May be 1 to 15 characters in the middle and ending packets. Byte count of the total data portion. This character is sent only din the first packet. The values are limited to 239 or less but must be greater than 17. comment: PID 192 is used to section any DDEC message that exceeds 21 bytes while the engine is running, in particular PID 194, PID 196, and PID 243. If the engine is stopped, DDEC may transmit messages up to 40 bytes in length. 6-26 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PID 194 - Transmitter System Diagnostic Code / Occurrence Count Table update rate: On Request only format: PID Data 194 n a b c a b c a b c a b c a b c... nByte count of data that follows this character. This excludes characters MID, PID 194 and n but includes a, b, c type characters. aSID or PID of a standard diagnostic code. b- Diagnostic code character Bits: 1-4 Bit: 5 source: comment: FMI of a standard diagnostic code Byte (a) Identifier 1 - Byte (a) is a SID 0 - Byte (a) is a PID Bit: 6 Type of Diagnostic Code 1 - standard diagnostic code 0 - expansion diagnostic codes (PID/SID from page 2) Bit: 7 Current Status of Fault 1 - fault is inactive 0 - fault is active Bit: 8 Occurrence count 1 - count is included 0 - count is not included cOccurrence count for the diagnostic code defined by the preceding 2 characters. The maximum occurrence count is 255. Bit 8 of byte (b) of the diagnostic code is used to determine if it is included. ECM calculated comments: Diagnostic codes are transmitted periodically while active. When the active code becomes inactive, the code is transmitted once to indicate that the fault became inactive. Inactive diagnostic codes are available by request of PID 194. If more than 6 codes are active at any point, PID 194 is sectioned as described in PID 192. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-27 COMMUNICATION PROTOCOLS PID 196 - Diagnostic Data/count clear response update rate: On Request only format: PID Data 196 nabccccc Byte count of data that follows this character. This excludes n - characters MID, PID 194 and n but includes a, b, and c type characters. a - SID or PID of a standard diagnostic code b- Diagnostic Code Character Bits 1-4 Bit 5 - c= 6-28 FMI of a standard diagnostic code Byte (a) identifier 1 - Byte (a) is a SID 0 - Byte (a) is a PID Bit 6 Type of diagnostic code 1 - standard diagnostic code expansion diagnostic codes (PID/SID from 0page 2) Bit 7-8 Action - Message is an ASCII descriptive message for the given diagnostic code. 01 - The count has been cleared for the given diagnostic code. 10 - All clearable diagnostic counts have been cleared for this device. - Message is additional diagnostic information for the given diagnostic code, as defined below. Additional information (if applicable) c1-c5 - ATA/VMRS (DTDSC) c6, c7 - Engine hours the code was first logged (LSB first) format: 1 h/Bit. range - 0-65535 hours. c8, c9 - Calendar date (Month, Day) the code was first logged, if available. c10, c11 - Clock time the code was first logged (hours, minutes), if available. c12, c13 - Engine hours the code last became active (LSB first). c14, c15 - Calendar date (Month, Day) the code last became active, if available. c16, c17 - Clock time the code last became active (hours, minutes), if available. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PID 196 - Diagnostic Data/count clear response update rate: On Request only format: PID Data c18, c19 - Number of ss the code has been active (LSB first). format: ss = 1 s/Bit range = 0-65535 (18.2 hours) Value remains at 65535 ss once it has been reached. c20 - Number of Stop Engine Override Switch restarts while the code was active. The value remains at 255 once it has been reached. c21+ = Optional associated parameter value (scaled as defined in J1587) For temperatures, pressures, and voltages with FMI 0 - Highest value achieved For temperatures, pressures, and voltages with FMI 1 - Lowest value achieved For engine speed with FMI 0 - Highest speed achieved For vehicle speed with FMI 0 or 11 - Highest speed achieved Last byte = checksum source: ECM calculated The date and time that the code last became inactive (bytes c14-c17) will comment: be transmitted as zero if the code is currently active. This data may be sectioned using PID 192. PID 228- Speed Sensor Calibration update rate: On Request only format: PID Data 228 naaaa n = number of bytes: 4 a= Speed Sensor Calibration 1 pulse/mi (Uns/LI) source: Calculated from calibration values comment: This parameter is available with Release 5.00 or later All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-29 COMMUNICATION PROTOCOLS PID 233- Unit Number (Power Unit) update rate: On Request only format: PID Data 231 naaa. . . n = number of bytes: 10 a = unit number in alphanumeric ASCII characters comment: This parameter is available with Release 20.00 software or later PID 234- Software Identification update rate: On Request only format: PID Data 234 naabcc n = number of bytes: 5 a = Major software release level in ASCII b = ASCII "." b = Minor software release level in ASCII Example: "01.05" is interpreted as Major release 1, Minor release 5 source: ECM calculated comment: This parameter is available with Release 3.00 software or later PID 235- Total Idle Hours update rate: On Request only format: PID Data 235 naaaa n = number of bytes: 4 a = Total idle hours; scaled 0.05 hours/Bit (Uns/LI) source: ECM calculated comment: Accumulates time while the engine is operating at idle. 6-30 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PID 236- Total Idle Fuel Used update rate: On Request only format: PID Data 236 naaaa n = number of bytes: 4 a = Idle fuel used; scaled 1/8 hours/Bit (Uns/LI) source: ECM calculated comment: Accumulates while the engine is operating at idle. PID 237- Vehicle Identification Number (VIN) update rate: On Request only format: PID Data 237 n a a a ... n = number of bytes: up to 17 a = VIN in ASCII characters source: Calibration value PID 240- Last Customer Calibration Change Hours update rate: On Request only format: PID Data 240 naaaa n = number of bytes: 4 a = Last customer calibration change hours; scaled 0.05 h/Bit (Uns/LI) source: ECM calculated comment: Used to identify the last customer reprogramming occurrence, stored in engine hours. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-31 COMMUNICATION PROTOCOLS PID 243- Device Identification update rate: On Request only format: PID Data 243 nabbbbbcddddddddeffffffffff n = number of bytes a = component ID = MID b = ATA/VMRS manufacturer ID (5 bytes) c = delimiter: ASCII ‘*' d = engine model number (8 bytes) e= source: comment: delimiter: ASCII ‘*' f= engine serial number (10 bytes) Calibration value This parameter may be sectioned using PID 192. PID 244- Trip Miles update rate: 0.1 times/s format: PID Data 244 naaaa n = number of bytes: 4 a= trip miles 0.1 mile/Bit (Uns/LI) source: ECM calculated comment: Transmitted only if the vehicle speed sensor is configured. PID 245- Total Miles update rate: 0.1 times/s format: PID Data 245 naaaa n = number of bytes: 4 a = trip miles, 0.1 mile/Bit (Uns/LI) source: ECM calculated comment: Transmitted only if the vehicle speed sensor is configured. 6-32 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PID 247- Total Engine Hours update rate: On request only format: PID Data 247 naaaa n = number of bytes: 4 a = total engine hours 0.05 hour/Bit (Uns/LI) source: ECM calculated comment: Used to identify the total hours that the engine is operating. Time accumulated while the engine speed is above 60 rpm. PID 248- Total VSG Hours update rate: On request only format: PID Data 248 naaaa n = number of bytes: 4 b = total VSG hours 0.05 hour/Bit (Uns/LI) source: ECM calculated comment: Used to identify total engine hours the engine is operating in the following modes: -Hand throttle VSG -High idle using cruise switches -Pressure governor mode: either RPM or pressure PID 249- Total Engine Revolutions update rate: On request only format: PID Data 249 naaaa n= number of bytes: 4 a= total engine revolutions 1000 revolutions/Bit (Uns/SI) comment: This parameter is available with Release 20.00 software or later All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-33 COMMUNICATION PROTOCOLS PID 250- Total Fuel Used update rate: On request only format: PID Data 250 naaaa n= number of bytes: 4 a= total fuel used 0.125 gal/Bit (Uns/LI) source: ECM calculated PID 251- Clock update rate: On request only format: PID Data 251 nabc n = number of bytes: 3 a = Seconds 0.25 sec/Bit, range 0 to 59.75 seconds b = Minutes 1.0 min/Bit, range 0 to 59 minutes c = Hours 1.00 hour/Bit, range 0 to 23 hours comment: Transmitted if clock data is considered valid. The time is broadcast in Greenwich Mean Time. This parameter is available with Release 20.00 software or later. PID 252- Date update rate: On request only format: PID Data 252 nabc n = number of bytes: 3 a = Day 0.25 day/Bit, range 1 to 31.75 days b = Month 1.0 month/Bit, range 1 to 12 months c = Year - 1985 1.00 year/Bit, range 0 to 99 comment: Day of the month is scaled such that 0 is a null value, values 1, 2, 3, and 4 are the first day of the month, 5, 6, 7, 8, are the second day of the month, etc. Transmitted if clock data is considered valid. This parameter is available with Release 20.00 software or later. 6-34 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 6.3 SAE J1922 Circuits800 (Data Link +) and 801 (Data Link-) as shown on the communications harness schematic are used as the J1922 communication link. 6.3.1 MESSAGE FORMAT A complete description of the DDEC III/IV parameters is provided within this section of the manual. DDEC III/IV transmits parametric data at SAE J1922 recommended rates in packed message form. The first byte or character of each J1922 message is the Message Identification Character (MID). The MID is used to identify the source of a data transmission and identify the type of data being transmitted. 6.3.2 SAE J1922 PARAMETERS AVAILABLE WITH DDEC III/IV DDEC III/IV supports the J1922 message identifiers (MIDs) listed in Table 6-5. MID 69 Engine to powertrain message 70 Engine to powertrain initialization message 74 Transmission to powertrain message 76 Transmission to powertrain initialization request message 79 ABS/traction control to powertrain message 81 ABS/traction control to powertrain initialization request message 83 Retarder to powertrain message 84 Retarder to powertrain initialization message Table 6-5 6.3.3 Description SAE J1922 MIDs Supported by DDEC SAE J1922 MIDS The following sections identify the MIDs supported by DDEC. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-35 COMMUNICATION PROTOCOLS Engine to Powertrain Byte 1 Byte 2 069 --- Byte 3 --- Byte 4 --Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Bit 8 Byte 5 Byte 6 Byte 7 ------- MID - Engine to powertrain Percent torque value scaled 1% of peak torque/Bit - S/SI Accelerator pedal position scaled 0.392%/Bit (100/255%/Bit) Uns/SI Control/status byte Cruise control status 1: cruise control active 0: cruise control inactive VSG control status 1: VSG active 0: VSG inactive Road speed limit status 1: road speed limit active 0: road speed limit inactive Retarder control status 1: engine retarder enabled 0: engine retarder not enabled AP kickdown switch 1: in kickdown position 0: not in kickdown position AP low idle switch 1: in low idle position 0: not in low idle position Engine parameter change Reserved 1: parameters have changed 0: current parameters valid Engine's desired RPM scaled 16 rpm/Bit - Uns/SI Desired RPM asymmetry adjustment scaled as a ratio - Uns/SI Checksum If either the transmission messages or the ABS messages are enabled, DDEC shall transmit this message 20 times per second. 6-36 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Engine Initialization Response Byte 1 070 Byte 2,3 --- Byte 4 --- Byte 5,6 --- Byte 7 --- Byte 8,9 --- Byte 10 --- Byte 11,12 --- Byte 13 --- Byte 14,15 --- Byte 16 --- Byte 17,18 --- Byte 19 --- Byte 20,21 --- Byte 22 --- Byte 23 --- MID - Engine initialization response Engine speed at idle (warm condition) scaled 0.0625 rpm/Bit - Uns/I Percent of peak torque at idle scaled 1% of peak torque/Bit - S/SI Rated engine speed scaled 0.0625 rpm/Bit - Uns/I Percent of peak torque at rated engine speed scaled 1% of peak torque/Bit - S/SI Engine speed at point 3 scaled 0.0625 rpm/Bit - Uns/I Percent of peak torque at point 3 scaled 1% of peak torque/Bit - S/SI Engine speed at point 4 scaled 0.0625 rpm/Bit - Uns/I Percent of peak torque at point 4 scaled 1% of peak torque/Bit - S/SI Engine speed at point 5 scaled 0.0625 rpm/Bit - Uns/I Percent of peak torque at point 5 scaled 1% of peak torque/Bit - S/SI Engine speed at peak torque scaled 0.0625 rpm/Bit - Uns/I Peak torque of engine scaled 10 lb·ft/Bit - Uns/SI Engine speed at high idle scaled 0.0625 rpm/Bit - Uns/I Maximum engine override speed scaled 16 rpm/Bit - Uns/SI Checksum DDEC transmits this message in response to the initialization request messages defined in "Transmission Initialization Request" and "ABS/Traction Control Initialization Request." All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-37 COMMUNICATION PROTOCOLS Transmission to Powertrain Message Byte 1 Byte 2 074 --Bit 1,2 Bit 3 Bit 4 Bit 5 Bit 6 Byte 3 Bit 7,8 --- Byte 4 --- Byte 5 Byte 6 ----- MID - transmission to powertrain Control/status byte Override control mode 00: override disabled 01: engine speed control 10: engine torque control 11: engine speed/torque limit Retarder enable 1: enable retarder 0: disable retarder Momentary high idle enable 1: override enabled 0: override disabled Driveline engaged (ignored by DDEC) 1: driveline engaged 0: driveline disengaged Transmission retarder status (ignored by DDEC) 1: retarder active 0: retarder inactive Reserved When mode is as follows 00: Not broadcast 01: Desired engine speed (LSB) scaled 0.0625 rpm/Bit - Uns/I 10: Not broadcast 11: Engine speed upper limit scaled 16 rpm /Bit - Uns/SI When mode 00: Not broadcast 01: Desired engine speed (MSB) - scaled 0.0625 rpm/Bit - Uns/I 10: Desired torque value scaled 1% of peak torque/Bit - S/SI 11: Percent torque upper limit scaled 1% of peak torque/Bit - S/SI Output shaft speed scaled 16 rpm/Bit - Uns/SI Checksum The desired speed request requires a zero droop operation, regardless of the droop calibrated for either the rated speed governor or the VSG governor. While the transmission is requesting an override control mode other than override disabled (00), the messages are expected to be repeated on a continuous basis. DDEC will maintain the most recent requested control mode until a request to disable override (00) is received or a time-out period has elapsed without any request from the transmission, at which point DDEC will revert to its normal (override disabled) state. 6-38 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Requests to disable the retarder (Bit 3 of byte 2) and override momentary high idle (Bit 4 of byte 2) follow the same strategy. DDEC will maintain the most recent requested state until a new request is received or a time-out period has elapsed without any request from the transmission. The default state for the retarder is enabled and for override momentary high idle is disabled. NOTE: This message has a variable length. Transmission Initialization Request Byte 1 Byte 2 076 Bit 1 Bit 2 Bit 3 Byte 3 Bit 4 Bit 5-7 Bit 8 --- MID - transmission initialization request Status/enable byte 1 = request engine initialization message 1 = request trans. initialization message (ignored by DDEC) 1 = request ABS initialization message (ignored by DDEC) 1 = request retarder initialization message Reserved 1 = progressive shift disable Checksum If enabled, DDEC responds to this request with the initialization messages defined in "Engine Initialization Response" and "Retarder Initialization Response" as appropriate. Once a progressive shift indication (allow or disallow) is transmitted, this state is maintained until a subsequent request from the transmission changes the state or a new ignition cycle begins. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-39 COMMUNICATION PROTOCOLS ABS/Traction Control To Powertrain Byte 1 Byte 2 079 --Bit 1,2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 Byte 3 Bit 8 --- Byte 4 --- MID - ABS/Traction control to powertrain Control/status byte Override control mode 00: override disabled 01: engine speed control 10: engine torque control 11: engine torque limit Retarder or engine control select 1: retarder control 0: engine fueling control Gear shift disable (ignored by DDEC) 1: Inhibit gear shifts 0: allow shifts Retarder disable 1: disable retarders 0: enable retarders Torque converter lock up disable (ignored by DDEC) 1: disable lock up clutch 0: enable lock up clutch Request to neutral (ignored by DDEC) 1: request de-clutch to neutral 0: allow normal operation Reserved When mode is as follows: 00: Not broadcast 01: Desired engine speed value scaled 16 rpm/Bit - Uns/SI 10: Desired % peak torque value scaled 1% of peak torque/Bit - S/SI 11: Percent torque upper limit scaled 1% of peak torque/Bit - S/SI Checksum While the traction control system is requesting a override control mode other than override disabled (00), the messages are expected to be repeated on a continuous basis. DDEC will maintain the most recent requested engine control mode and/or retarder control mode until a request to disable override (00) is received or a time-out period has elapsed without any request from the traction control system, at which point DDEC will revert to its normal (override disabled) state. 6-40 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Requests to disable the retarder (Bit 5 of byte 2) follow the same strategy. DDEC will maintain the most recent requested state until a new request is received or a time-out period has elapsed without any request from the traction control system. The default state for the retarder is enabled. The retarder request is honored independent of the particular control select (Bit 3 of byte 2) in effect. NOTE: The retarder disable request applies to all retarder types; external engine retarder, DDEC controlled engine retarder, and transmission retarder. DDEC will ignore requests from the ABS system when the transmission type is a Meritor ESS and the transmission is performing a shift. DDEC will honor requests for both retarder control (Bit 3 of byte 2 = 1) and engine control (Bit 3 of byte 2 = 0). For retarder control, the percent of peak torque request will be translated into engine brake low, medium and high as follows: 0% 1% to 33%: 34% to 66%: 67% to 100%: no braking or disable retarder low braking medium braking high braking Low, medium and high braking modes only apply when DDEC controls the engine brake directly. A request of 0% torque may apply to either direct engine brake control by DDEC or indirect engine brake control. NOTE: This message has a variable length. ABS/Traction Control Initialization Request Byte 1 Byte 2 081 Status/enable byte Bit 1 Bit 3 1 = request engine initialization message 1 = request transmission initialization message (ignored by DDEC) 1 = request ABS initialization message (ignored by DDEC) Bit 4 1 = request retarder initialization message Bit 5-8 --- Reserved Bit 2 Byte 3 MID - ABS/Traction control initialization request --- Checksum If enabled, DDEC responds to this request with the initialization messages defined in "Engine Initialization Response" and "Retarder Initialization Response" as appropriate. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-41 COMMUNICATION PROTOCOLS Retarder to Powertrain Byte 1 Byte 2 083 --Bit 1 Bit 2 Bit 3,4 Bit 5-8 Byte 3 --- MID - Retarder to powertrain Retarder status byte Retarder active/inactive 1: retarder active 0: retarder inactive Retarder operational status 1: retarder selected 0: not selected For future use Retarding level status 0000: Off 0101: Active in low (33%) 1010: Active in medium (66%) 1111: Active in high (100%) Checksum If either the transmission messages or the ABS/ASR messages are enabled and digital outputs are configured for DDEC controlled engine brake operation, DDEC shall transmit this message 10 times per second. Retarder Initialization Response Byte 1 Byte 2 Byte 3 Byte 4 084 --Bit 1 Bit 2 Bit 3-7 Bit 8 ----- MID - Retarder initialization response Type of retarder Reserved - sent as 0 1 = Engine compression release Not applicable for DDEC - sent as 0 Reserved - sent as 0 Peak torque of retarder (10 lb·ft/Bit) - Uns/SI Checksum If either the transmission messages or the ABS/ASR messages are enabled and digital outputs are configured for DDEC controlled engine brake operation, DDEC transmits this message in response to the initialization request messages defined in "Transmission Initialization Request" and "ABS/Traction Control Initialization Request." 6-42 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 6.4 SAE J1939 Circuits 925 (CAN_H/J1939 [+]), 926 (CAN_L/J1939 [-]) and 927 (CAN_SHLD/J1939 Shield) as shown on the communications harness schematic are used as the J1939 communication link. See Figure 6-1. Figure 6-1 6.4.1 Communication Harness MESSAGE FORMAT The message format uses the parameter group number as the label for a group of parameters. Each of the parameters within the group can be expressed in ASCII, as scaled data, or as function states consisting of one or more Bits. Alphanumeric data will be transmitted with the most significant byte first. Other parameters consisting of two or more data bytes shall be transmitted least significant byte first. The type of data is also identified for each parameter. The following sections identify the parameters that are supported by DDEC, parameter group number response definitions (refer to section 6.4.2) and parameter group number command definitions (refer to section 6.4.3). All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-43 COMMUNICATION PROTOCOLS 6.4.2 SAE J1939/71 APPLICATION LAYER The Application Layer Parameter Group Number (PGN) response definitions are described in the following sections. Electronic Engine Controller #1 – EEC1 Transmission Rate: Data Length: Data Page: PDU format: PDU specific: Default priority: PGN: Byte : 1 Status_EEC1 Bits: 8-5 Bits: 4-1 Byte: 2 Byte: 3 Bytes: 4,5 Bytes: 6-8 6-44 engine speed dependent 8 bytes 0 240 4 3 61,444 (0x00F004) Not Defined Engine / Retarder Torque Mode 0000: Low Idle Governor/No Request (Default Mode) 0001: Accelerator Pedal/Operator Selection 0010: Cruise Control 0011: PTO Governor 0100: Road Speed Governor 0101: ASR Control 0110: Transmission Control 0111: ABS Control 1000: Torque Limiting 1001: High Speed Governor 1010: Braking System 1011: Remote Accelerator - N/A 1100: Not Defined 1101: Not Defined 1110: Other 1111: Not Available Drivers Demand Engine - Pct Torque Resolution: 1% / Bit, -125% offset Actual Engine - Percent Torque Resolution: 1% / Bit, -125% offset Engine Speed Resolution: 0.125 rpm / Bit, 0 rpm offset Not Defined All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Electronic Engine Controller #2 – EEC2 Transmission Rate : Data Length: Data Page: PDU format: PDU specific: Default priority: PGN: Byte: 1 Status_EEC2 Bits: 8-5 Bits: 4-3 Byte: 2 Byte: 3 Bytes: 4-8 50 ms 8 bytes 0 240 3 3 61,443 (0x00F003) Not Defined (Transmitted as 1111) AP Kickdown Switch 00: Kickdown Passive 01: Kickdown Active 11: Not Configured Bits: 2,1 AP Low Idle Switch 00: Not In Low Idle Condition 01: In Low Idle Condition 11: Not Configured Accelerator Pedal Position (TPS) Resolution: 0.4% / Bit, 0% offset Percent Load At Current Speed Resolution: 1% / Bit, 0% offset Not Defined Idle Operation Transmission Rate : On Request Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 220 Default priority: 8 PGN: 65,244 (0x00FEDC) Bytes: 1-4 Total Idle Fuel Used Resolution: 0.5 L / Bit, 0 L offset Bytes: 5-8 Total Idle Hours Resolution: 0.05 hr / Bit, 0 hr offset All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-45 COMMUNICATION PROTOCOLS Turbocharger Transmission Rate : 1 sec Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 221 Default priority: 6 PGN: 65, 245 (0x00FEDD) Byte: 1 Turbo Oil Pressure - N/A Bytes: 2,3 Turbo Speed Resolution: 4 rpm / Bit, 0 rpm offset Bytes: 4-8 Not Defined Electronic Engine Controller #3 – EEC3 Transmission Rate : 250 ms Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 223 Default priority: 6 PGN: 65,247 (0x00FEDF) Byte: 1 Nominal Friction - Percent Torque Resolution: 1% / Bit, -125% offset Bytes: 2,3 Engine's Desired Operating Speed Resolution: 0.125 rpm / Bit, 0 rpm offset Byte 4: Engine's Desired Operating Speed Asymmetry Adjustment ratio 0 to 250 Bytes: 5-8 Not Defined 6-46 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Vehicle Distance Transmission Rate : On Request Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 224 Default priority: 6 PGN: 65,248 (0x00FEE0) Bytes: 1-4 Trip Distance Resolution: 0.125 km / Bit, 0 km offset Bytes: 5-8 Total Vehicle Distance Resolution: 0.125 km / Bit, 0 km offset Idle Shutdown Transmission Rate : 1 sec Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 228 Default priority: 6 PGN: 65,252 (0x00FEE4) Byte: 1 Idle shutdown_1 Bits: 8,7 Idle Shutdown Timer State 00: Inactive 01: Active Bits: 6,5 Idle Shutdown Timer Override 00: Inactive 01: Active Bits: 4,3 Driver Alert Mode 00: Inactive 01: Active Bits: 2,1 Engine Has Shutdown by Idle Shutdown 00: Engine has not shutdown by idle shutdown 01: Engine has shutdown by idle shutdown Byte: 2 Idle shutdown_2 Bits: 8,7 Idle Shutdown Timer Function. 00: Disabled in Calibration 01: Enabled in Calibration Bits: 6-1 Not Defined Byte: 3 Refrigerant_press_1 - N/A Byte: 4 Lamp_commands - N/A All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-47 COMMUNICATION PROTOCOLS Transmission Rate : Byte: 5 Bits: 8,7 Bits: 6,5 Bits: 4,3 Bits: 2,1 Byte: 6 Bits: 8,7 Bytes: 7-8 Bits: 6-1 Not Defined 1 sec Engine shutdown_1 Engine Protection Shutdown Timer State 00:Timer not Active 01:Timer Active Engine Protection Shutdown Override 00:Override Off 01:Override On Engine Shutdown Approaching - N/A Engine Has Shutdown By Engine Protection System 00:Not Shutdown 01:Has Shutdown Engine shutdown_2 Engine Protection System Configured 00:Not Enabled In Calibration 01:Enabled In Calibration Not Defined Engine Hours, Revolutions Transmission Rate : On Request Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 229 Default priority: 6 PGN: PGN:65,253 (0x00FEE5) Bytes: 1-4 Total Engine Hours Resolution: 0.05 h / Bit, 0 h offset Bytes: 5-8 Total Engine Revolutions Resolution: 1000 revs / Bit, 0 revs offset 6-48 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Time/Date Transmission Rate : Data Length: Data Page: PDU format: PDU specific: Default priority: PGN: Byte: 1 Seconds Resolution: Byte: 2 Minutes Resolution: Byte: 3 Hours Resolution: Byte: 4 Month Resolution: Byte: 5 Day Resolution: Byte: 6 Year Resolution: Bytes: 7,8 Not Defined On Request 8 bytes 0 254 230 6 65,254 (0x00FEE6) 0.25 sec / Bit, 0 sec offset 1 min / Bit, 0 min offset 1 hour / Bit, 0 h offset 1 month / Bit, 0 month offset 0.25 day / Bit, 0 day offset 1 year / Bit, 1985 year offset Vehicle Hours Transmission Rate : On Request Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 231 Default priority: 6 PGN: 65,255 (0x00FEE7) Bytes: 1-4 Total Vehicle Hours -N/A Bytes: 5-8 Total Power Takeoff Hours Resolution: 0.05 h / Bit, 0 h offset All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-49 COMMUNICATION PROTOCOLS Fuel Consumption Transmission Rate : Data Length: Data Page: PDU format: PDU specific: Default priority: PGN: Byte: 1-4 Trip Fuel Resolution: Bytes: 5-8 Total Fuel Used Resolution: On Request 8 bytes 0 254 233 6 65,257 (0x00FEE9) 0.5 L / Bit, 0 L offset 0.5 L / Bit, 0 L offset Cruise Control / Vehicle Speed Setup Transmission Rate : On Request Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 237 Default priority: 6 PGN: 65,261 (0x00FEED) Byte: 1 Maximum Vehicle Speed Limit Resolution: 1 km/h / Bit, 0 km/h offset Byte: 2 Cruise Control High Set Limit Speed. Resolution: 1 km/h / Bit, 0 km/h offset Byte: 3 Cruise Control Low Set Limit Speed Resolution: 1 km/h / Bit, 0 km/h offset Bytes: 4-8 Not Defined 6-50 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Engine Temperature Transmission Rate : Data Length: Data Page: PDU format: PDU specific: Default priority: PGN: Byte: 1 Byte: 2 Bytes: 3,4 Bytes: 5,6 Byte: 7 Byte 8: 1 sec 8 bytes 0 254 238 6 65,262 (0x00FEEE) Engine Coolant Temperature Resolution: 1 C / Bit, -40 C offset Fuel Temperature Resolution: 1 C / Bit, -40 C offset Engine Oil Temperature Resolution: 0.03125 C / Bit, -273 C offset Turbo Oil Temperature -N/A Engine Intercooler Temperature Resolution: 1 C / Bit, -40 C offset Not Defined All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-51 COMMUNICATION PROTOCOLS Engine Fluid Level/Pressure Transmission Rate : 0.5 sec Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 239 Default priority: 6 PGN: 65,263 (0x00FEEF) Byte: 1 Fuel Delivery Pressure Resolution: 4 kPa / Bit, 0 kPa offset Byte: 2 Not Defined Byte: 3 Engine Oil Level Resolution: 0.4% / Bit, 0% offset Byte: 4 Engine Oil Pressure Resolution: 4 kPa / Bit, 0 kPa offset Byte: 5,6 Crankcase Pressure Resolution: 0.0078125 kPa / Bit (1/128 kPa / Bit), -250 kPa offset Byte: 7 Coolant Pressure Resolution: 2 kPa / Bit, 0 kPa offset Byte: 8 Coolant Level Resolution: 0.4% / Bit, 0% offset 6-52 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Power Takeoff Information Transmission Rate : 100 ms Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 240 Default priority: 6 PGN: 65,264 (0x00FEF0) Byte: 1 Power Takeoff Oil Temperature - N/A Byte: 2,3 Power Takeoff Speed - N/A Byte: 4,5 Power Takeoff Set Speed Resolution: 0.125 rpm / Bit, 0 rpm offset Byte: 6 Measured_PTO_1 Bits: 8,7 Not Defined Bits: 6,5 Remote PTO Variable Speed Control Switch - N/A Remote PTO Preprogrammed Speed Control Bits: 4,3 Switch 00: Switch Off 01: Switch On 11: Not Configured Bits: 2,1 PTO Enable Switch 00: Switch Off 01: Switch On 11: Not Configured Byte: 7 Measured_PTO_2 Bits: 8,7 PTO Accelerate Switch 00: Switch Off 01: Switch On 11: Not Configured Bits: 6,5 PTO Resume Switch 00: Switch Off 01: Switch On 11: Not Configured Bits: 4,3 PTO Coast/Decelerate Switch 00: Switch Off 01: Switch On 11: Not Configured Bits: 2,1 PTO Set Switch 00: Switch Off 01: Switch On 11: Not Configured Byte: 8 Not Defined All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-53 COMMUNICATION PROTOCOLS Cruise Control / Vehicle Speed Transmission Rate : Data Length: Data Page: PDU format: PDU specific: Default priority: PGN: Byte: 1 Measured_SW1 Bits: 8-5 Bits: 4,3 Byte: 2,3 Byte: 4 Byte: 5 6-54 100 ms 8 bytes 0 254 241 6 65,265 (0x00FEF1) Not Defined Parking Brake Switch 00: Park Brake Not Set 01: Park Brake Set 11: Not Configured Bits: 2,1 Two Speed Axle Switch - N/A. Wheel Based Vehicle Speed 1/256 km/h / Bit, 0 km/h offset (1/412 mph / Bit, Resolution: 0 mph offset) Measured_CC_SW1 Bits: 8,7 Clutch Switch 00: Clutch Pedal Released 01: Clutch Pedal Depressed 11: Not Configured Bits: 6,5 Brake Switch 00: Brake Pedal Released 01: Brake Pedal Depressed 11: Not Configured Bits: 4,3 Cruise Control Enable Switch 00: Cruise Control Disabled 01: Cruise Control Enabled 11: Not Configured Bits: 2,1 Cruise Control Active 00: Cruise Control Off 01: Cruise Control On 11: Not Configured Measured _CC_SW2 Bits: 8,7 Cruise Control Accelerate Switch 00: Accelerate Switch Off 01: Accelerate Switch On 11: Not Configured Bits: 6,5 Cruise Control Resume Switch 00: Resume Switch Off All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Bits: 4,3 Bits: 2,1 Byte: 7 Byte: 8 Byte: 6 Resolution: State_CC Bits: 8–6 01: Resume Switch On 11: Not Configured Cruise Control Coast Switch 00: Coast Switch Off 01: Coast Switch On 11: Not Configured Cruise Control Set Switch 00: Set Switch Off 01: Set Switch On 11: Not Configured Cruise Control Set Speed 1 km/h / Bit, 0 km/h offset Cruise Control State 000: Off/Disabled 001: Hold 010: Accelerate 011: Decelerate/Coast 100: Resume 101: Set 110: Accelerator Override 111: Not Available Bits: 5-1 PTO State - N/A Measured_idle_SW1 Bits: 8,7 Not Defined Bits: 6,5 Engine Test Mode Switch - N/A Bits: 4,3 Idle Decrement Switch - N/A Bits: 2,1 Idle Increment Switch - N/A All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-55 COMMUNICATION PROTOCOLS Fuel Economy Transmission Rate : 100 ms Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 242 Default priority: 6 PGN: 65,266 (0x00FEF2) Bytes: 1,2 Fuel Rate Resolution: 0.05 L/h / Bit, 0 L/h offset Data Range: 0 to 3212.75 L/h Bytes: 3,4 Instantaneous Fuel Economy Resolution: 1/512 km/L / Bit, 0 km/L offset Data Range: 0 to 125.5 km/L Bytes: 5,6 Average Fuel Economy Resolution: 1/512 km/L / Bit, 0 km/L offset Data Range: 0 to 125.5 km/L Bytes: 7,8 Not Defined Ambient Conditions Transmission Rate : 1 sec Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 245 Default priority: 6 PGN: 65,269 (0x00FEF5) Byte: 1 Barometric Pressure Resolution: 0.5 kPa / Bit, 0 kPa offset Byte: 2 Cab Interior Temperature - N/A Bytes: 4,5 Ambient Air Temperature Resolution: 0.03125 C / Bit, -273 C offset Byte: 6 Air Inlet Temperature Resolution: 1 C / Bit, -40 C offset Bytes: 7,8 Road Surface Temperature - N/A 6-56 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Inlet / Exhaust Conditions Transmission Rate : 0.5 sec Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 246 Default priority: 6 PGN: 65,270 (0x00FEF6) Byte: 1 Particulate Trap Inlet Pressure - N/A Byte 2: Boost Pressure Resolution: 2 kPa / Bit, 0 kPa offset Byte 3: Intake Manifold Temperature Resolution: 1 C / Bit, -40 C offset Byte 4: Air Inlet Pressure Resolution: 2 kPa / Bit, 0 kPa offset Byte 5: Air Filter Differential Pressure Resolution: 0.05 kPa / Bit, 0 kPa offset Bytes: 6,7 Exhaust Gas Temperature Resolution: 0.03125 C / Bit, -273 C offset Byte: 8 Coolant Filter Differential Pressure - N/A All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-57 COMMUNICATION PROTOCOLS Exhaust Port Temperature #1 Transmission rate: 1 sec Data Length: 8 bytes Data Page: 0 PDU Format: 254 PDU Specific 163 Default Priority: 7 PGN: 65,185 (Ox00FEA3) Byte: 1, 2 Exhaust Gas Port 1 Temperature Resolution: 0.03125 C/bit, —273 C offset Byte: 3, 4 Exhaust Gas Port 2 Temperature Resolution: 0.03125 C/bit, —273 C offset Byte: 5, 6 Exhaust Gas Port 3 Temperature Resolution: 0.03125 C/bit, —273 C offset Byte: 7, 8 Exhaust Gas Port 4 Temperature Resolution: 0.03125 C/bit, —273 C offset 6-58 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Exhaust Port Temperature #2 Transmission Rate: 1 sec Data Length: 8 bytes Data Page: 0 PDU Format: 254 PDU Specific: 162 Default Priority: 7 PGN: 65, 186 (Ox00FEA2) Bytes: 1, 2 Exhaust Gas Port 5 Temperature Resolution: 0.03125 C/bit, —273 C offset Byte: 3, 4 Exhaust Gas Port 6 Temperature Resolution: 0.03125 C/bit, —273 C offset Byte: 5, 6 Exhaust Gas Port 7 Temperature Resolution: 0.03125 C/bit, —273 C offset Byte: 7, 8 Exhaust Gas Port 8 Temperature Resolution: 0.03125 C/bit, —273 C offset All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-59 COMMUNICATION PROTOCOLS Exhaust Port Temperature #3 Transmission Rate: 1 sec Data Length: 8 bytes Data Page: 0 PDU Format: 254 PDU Specific: 162 Default Priority: 7 PGN: 65, 186 (Ox00FEA1) Byte: 1, 2 Exhaust Gas Port 9 Temperature Resolution: 0.03125 C/bit, —273 C offset Byte: 3, 4 Exhaust Gas Port 10 Temperature Resolution: 0.03125 C/bit, —273 C offset Byte: 5,6 Exhaust Gas Port 11 Temperature Resolution: 0.03125 C/bit, —273 C offset Byte: 7, 8 Exhaust Gas Port 12 Temperature Resolution: 0.03125 C/bit, —273 C offset 6-60 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Exhaust Port Temperature #4 Transmission Rate: 1 sec Data Length: 8 bytes Data Page: 0 PDU Format: 254 PDU Specific: 160 Default Priority: 7 PGN: 65, 184 (Ox00FEA0) Byte: 1, 2 Exhaust Gas Port 13 Temperature Resolution: 0.03125 C/bit, —273 C offset Byte: 3, 4 Exhaust Gas Port 14 Temperature Resolution: 0.03125 C/bit, —273 C offset Byte: 5, 6 Exhaust Gas Port 15 Temperature Resolution: 0.03125 C/bit, —273 C offset Byte: 7, 8 Exhaust Gas Port 16 Temperature Resolution: 0.03125 C/bit, —273 C offset Vehicle Electrical Power Transmission Rate : 1 sec Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 247 Default priority: 6 PGN: 65,271 (0x00FEF7) Byte: 1 Net Battery Current - N/A Byte: 2 Alternator Current - N/A Bytes: 3,4 Alternator Potential (voltage) - N/A Bytes: 5,6 Electrical Potential (voltage) Resolution: 0.05 V / Bit, 0 V offset Bytes: 7,8 Battery Potential (Voltage), Switched - N/A All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-61 COMMUNICATION PROTOCOLS Alternate Fuel #1 Transmission Rate : 500 ms Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 253 Default priority: 6 PGN: 65,277 (0x00FEFD) Byte: 1 Blower Bypass Valve Position Resolution: 0.4% / Bit, 0% offset Bytes: 2,3 Gas Supply Pressure - N/A Bytes: 4-8 Not Defined Auxiliary Water Pump Pressure Transmission Rate : 1 sec Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 254 Default priority: 6 PGN: 65,278 (0x00FEFE) Byte: 1 Auxiliary Pump Pressure Resolution: 16 kPa / Bit, 0 kPa offset Byte: 2-8 Not Defined Engine Fluid Level/Pressure #2 Transmission Rate : 0.5 sec Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 219 Default priority: 6 PGN: 65,243 (0x00FEDB) Bytes: 1,2 Injection Control Pressure - N/A Bytes: 3,4 Injector Metering Rail Pressure Resolution: 1/256 MPa / Bit, 0 MPa offset Bytes: 5-8 Not Defined 6-62 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL High Resolution Vehicle Distance Transmission Rate : 1 sec Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 193 Default priority: 6 PGN: 65,217 (0x00FEC1) Bytes: 1-4 High Resolution Total Vehicle Distance Resolution: 5 m / Bit, 0 m offset (16.4 ft/Bit, 0 ft offset) Bytes: 5-8 High Resolution Trip Distance Resolution: 5 m / Bit, 0 m offset (16.4 ft/Bit, 0 ft offset) Electronic Engine Controller #4 : EEC4 Transmission Rate : On Request Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 190 Default priority: 7 PGN: 65,214 (0x00FEBE) Bytes: 1,2 Rated Engine Power 0.5 kW / Bit, 0 kW offset (0.67 hp / Bit, 0 hp Resolution: offset) Bytes: 3,4 Rated Engine Speed Resolution: 0.125 rpm / Bit, 0 rpm offset Bytes: 5-8 Not Defined All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-63 COMMUNICATION PROTOCOLS Fan Drive Transmission Rate : 1 sec Data Length: 8 bytes Data Page: 0 PDU format: 254 PDU specific: 189 Default priority: 6 PGN: 65,213 (0x00FEBD) Byte: 1 Estimated Percent Fan Speed Resolution: 0.4% / Bit, 0% offset Byte: 2 State_Fan_Drive Bits: 8-5 Not Defined Bits: 4-1 Fan Drive State 0000: Fan Off 0001: Engine System - General 0010: Excessive Engine Air Temperature 0011: Excessive Engine Oil Temperature 0100: Excessive Engine Coolant Temperature 0101-1000: Not Defined 1001: Manual Control 1010: Transmission Retarder 1011: A/C System 1100: Timer 1101: Engine Brake 1110: Other 1111: Not Available Bytes: 3-8 Not Defined 6-64 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Electronic Retarder Controller #1 - ERC1 Transmission Rate : Data Length: Data Page: PDU format: PDU specific: Default priority: PGN: Byte : 1 Status_ERC1 Bits: 8,7 Bits: 6,5 Bits: 4-1 100 ms 8 bytes 0 240 0 6 61,440 (0x00F000) Retarder Enable - Shift Assist Switch - N/A Retarder Enable - Brake Assist Switch - N/A Engine/Retarder Torque Mode 0000: No Request (Default Mode) 0001: Accelerator Pedal/Operator Selection 0010: Cruise Control 0011: PTO Governor 0100: Road Speed Governor - N/A 0101: ASR Control 0110: Byte: 2 Byte: 3 Byte: 4 Bytes: 5-8 Transmission Control 0111: ABS Control 1000: Torque Limiting - N/A 1001: High Speed Governor - N/A 1010: Braking System 1011: Remote Accelerator - N/A 1100: Not Defined 1101: Not Defined 1110: Other 1111: Not Available Actual Retarder - Percent Torque Resolution: 1% / Bit, -125% offset Intended Retarder Percent Torque - N/A Coolant Load Increase - N/A Not Defined All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-65 COMMUNICATION PROTOCOLS Software Identification Transmission Rate : On Request Data Length: 31 bytes Data Page: 0 PDU format: 254 PDU specific: 218 Default priority: 6 PGN: 65,242 (0x00FEDA) Byte: 1 Number of Software Identification Fields - 7 Byte: 2 1st digit of Cal Major Version - ASCII Byte: 3 2nd digit of Cal Major Version - ASCII Byte: 4 3rd digit of Cal Major Version - ASCII Byte: 5 * - Delimiter Byte: 6 1st digit of Cal Minor Version - ASCII Byte: 7 2nd digit of Cal Minor Version - ASCII Byte: 8 3rd digit of Cal Minor Version - ASCII Byte: 9 * - Delimiter Byte: 10 1st Digit of Cal Edit Version - ASCII Byte: 11 2nd Digit of Cal Edit Version - ASCII Byte: 12 3rd Digit of Cal Edit Version - ASCII Byte: 13 * - Delimiter Byte: 14 1st Digit of Edit Build Version - ASCII Byte: 15 2nd Digit of Edit Build Version - ASCII Byte: 16 3rd Digit of Edit Build Version - ASCII Byte: 17 * - Delimiter Byte: 18 Software Release Type - ASCII X - Experimental T - Pre-production R - Production Byte: 19 * - Delimiter DDEC Hardware Version - ASCII Byte: 20 3 – DDEC III, 4 – DDEC IV, 5 – DDEC V Byte 21: * - Delimiter Bytes: 22-29 ECM Serial Number - ASCII Byte: 30 * - Delimiter 6-66 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Component Identification Transmission Rate : On Request Data Length: 37 bytes Data Page: 0 PDU format: 254 PDU specific: 235 Default priority: 6 PGN: 65,259 (0x00FEEB) Bytes: 1-5 DTDSC - ASCII Byte: 6 * - Delimiter Byte: 7-14 Engine Model Number - ASCII Byte: 15 * - Delimiter Byte: 16-25 Engine Serial Number - ASCII Byte: 26 * - Delimiter Byte: 27-36 Unit Number (VIN) - ASCII Byte: 37 * - Delimiter All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-67 COMMUNICATION PROTOCOLS Retarder Configuration Transmission Rate : On Request Data Length: 19 bytes Data Page: 0 PDU format: 254 PDU specific: 225 Default priority: 6 PGN: 65,249 (0x00FEE1) Byte: 1 Type And Location Bits: 8-5 Retarder Location 0000: Primary Engine Retarder For Compression Brakes 0001: Primary Engine Retarder For Exhaust Brakes Bits: 4-1 Retarder Type 0011: Compression Release (Engine Retarder) 0100: Exhaust Byte: 2 Retarder Control Method 255 - when not configured 0 - DVB 1 - Konstantdrossel 2 - Low/High Compression 3 - Low/Med/High Compression Bytes: 3, 4 Retarder Speed At Idle, Point 1- N/A Byte: 5 Percent Torque At Idle, Point 1 - N/A Bytes: 6, 7 Maximum Retarder Speed, Point 2 - N/A Byte: 8 Percent Torque At Maximum Speed, Point 2 - N/A Bytes: 9, 10 Retarder Speed At Point 3 - N/A Byte: 11 Percent Torque At Point 3 - N/A Bytes: 12, 13 Retarder Speed At Point 4 - N/A Byte: 14 Percent Torque At Point 4 - N/A Bytes: 15,16 Retarder Speed At Peak Torque, Point 5 - N/A Bytes: 17,18 Reference Retarder Torque - N/A Bytes: 19 Percent Torque At Peak Torque, Point 5 - N/A Engine Configuration Transmission Rate : Data Length: Data Page: PDU format: PDU specific: 6-68 on change of torque/speed points of more than 10% since last transmission, or every 5 s 28 bytes 0 254 227 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Default priority: 6 PGN: 65,251 (0x00FEE3) Bytes: 1,2 Engine Speed At Idle, Point 1 Resolution: 0.125 rpm / Bit, 0 rpm offset Byte: 3 Percent Torque At Idle, Point 1 Resolution: 1% / Bit, -125% offset Bytes: 4, 5 Engine Speed At Point 2 Resolution: 0.125 rpm / Bit, 0 rpm offset Byte: 6 Percent Torque At Point 2 Resolution: 1% / Bit, -125% offset Bytes: 7,8 Engine Speed At Point 3 Resolution: 0.125 rpm / Bit, 0 rpm offset Byte: 9 Percent Torque At Point 3 Resolution: 1% / Bit, -125% offset Bytes: 10, 11 Engine Speed At Point 4 Resolution: 0.125 rpm / Bit, 0 rpm offset Byte: 12 Percent Torque At Point 4 Resolution: 1% / Bit, -125% offset Bytes: 13, 14 Engine Speed At Point 5 Resolution: 0.125 rpm / Bit, 0 rpm offset Byte: 15 Percent Torque At Point 5 Resolution: 1% / Bit, -125% offset Bytes: 16, 17 Engine Speed At High Idle, Point 6 Resolution: 0.125 rpm / Bit, 0 rpm offset Bytes: 18, 19 (KP) Of Endspeed Governor - N/A Bytes: 20, 21 Reference Engine Torque Resolution: 1 Nm / Bit, 0 Nm offset Byte: 22, 23 Maximum Momentary Engine Override Speed, Point 7 Resolution: 0.125 rpm / Bit, 0 rpm offset Byte: 24 Maximum Momentary Engine Override Time Limit Resolution: 0.1 s / Bit, 0 s offset Byte: 25 Requested Speed Control Range Lower Limit - 300 RPM Resolution: 10 rpm / Bit, 0 rpm offset Byte: 26 Requested Speed Control Range Upper Limit Resolution: 10 rpm / Bit, 0 rpm offset Byte: 27 Requested Torque Control Range Lower Limit Resolution: 1% / Bit, -125% offset Byte: 28 Requested Torque Control Range Upper Limit Resolution: 1 % / Bit, -125% offset All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-69 COMMUNICATION PROTOCOLS Adaptive Cruise Control Transmission rate : Data length: PDU format: PDU specific: PGN: Byte : 1 Byte : 2 Byte : 3 Byte : 4 Byte : 5 Byte : 6-8 Note: 6-70 100 ms 8 bytes 0 254 111 0x00FE6F Speed of Forward Vehicle - N/A Distance to Forward Vehicle - N/A Adaptive Cruise Control Set Speed - N/A ACC Status 1 Bits: 8,7 Not Defined Bits: 6-4 Adaptive Cruise Control Set Distance Mode - N/A Bits: 3-1 Adaptive Cruise Control State 110: Error 111: Not Available Road Curvature - N/A Not Defined This message is received only from an ACC device. It is not transmitted by the ECM. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Torque Speed Control - TSC1 Transmission Rate : Data Length: Data Page: PDU format: PDU specific: Default priority: PGN: Byte : 1 Control Bits Bits: 8,7 Bits: 6,5 Byte: 2,3 Byte: 4 Bytes: 5-8 10 ms 8 bytes 0 0 Destination Address 3 0 (0x000000) Not Defined Override Control Mode Priority 00: Highest 01: High 10: Medium 11: Low Bits: 4,3 Requested Speed Control Conditions - N/A Bits: 2,1 Override Control Modes 00: Override Disabled 01: Speed Control 10: Torque Control 11: Speed/Torque Limit Requested Speed / Speed Limit Resolution: 0.125 rpm / Bit, 0 rpm offset Requested Torque / Torque Limit Resolution: 1% / Bit, -125% offset 0-125% for engine torque requests -125-0% for retarder torque requests Not Defined All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-71 COMMUNICATION PROTOCOLS Electronic Transmission Controller #1 – ETC1 Transmission Rate : Data Length: Data Page: PDU format: PDU specific: Default priority: PGN: Byte : 1 Status_ETC1 Bits: 8,7 Bits: 6,5 Byte: 2,3 Byte: 4 Byte: 5 Bytes: 6,7 Byte: 8 6-72 10 ms 8 bytes 0 240 2 3 61,442 (0x00F002) Not Defined Shift in Progress 00: shift is not in process 01: shift in process 11: N/A Bits: 4,3 Torque Converter Lockup Engaged - N/A Bits: 2,1 Driveline Engaged 00: Driveline Disengaged 01: Driveline Engaged 11: N/A Output Shaft Speed Resolution: 0.125 rpm / Bit, 0 rpm offset Percent Clutch Slip - N/A Command_ETC1 Bits: 8-5 Not Defined Bits: 4-3 Progressive Shift Disabled 00: Progressive Shift Is Not Disabled 01: Progressive Shift Is Disabled 11: N/A Bits: 2,1 Momentary Engine Overspeed Enable 00: Momentary Engine Overspeed Is Disabled 01: Momentary Engine Overspeed Is Enabled 11: N/A Input Shaft Speed - N/A Not Defined All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 6.4.3 SAE J1939/21 DATA LINK LAYER The Data Link Layer Parameter Group Number (PGN) response definitions are described in the following sections. Acknowledge / Negative Acknowledge Transmission Rate As Needed : Data Length: 8 bytes Data Page: 0 PDU format: 232 PDU specific: Destination Address Default priority: 6 PGN: 0x00E800 Byte : 1 Control Byte 0: Positive Acknowledgment (ACK) 1: Negative Acknowledgment (NACK) 2: Access Denied (PGN supported but access denied) Byte: 2 Group Function Value (if applicable)- N/A Bytes: 3-5 Not Defined Bytes: 6 Least Significant Byte of PGN of Requested Information Byte: 7 Middle Byte of PGN of Requested Information Byte: 8 Most Significant Byte of PGN of Requested Information All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-73 COMMUNICATION PROTOCOLS Requests Transmission Rate : As Needed Data Length: 3 bytes Data Page: 0 PDU format: 234 PDU specific: Destination Address Default priority: 6 PGN: 59,904 (0x00EA00) Byte : 1 Least Significant Byte of PGN Byte: 2 Byte 2 of PGN Byte: 3 Most Significant Byte of PGN NOTE: It is recommended that requests occur no more than 2 or 3 times per second. NOTE: For any unsupported PGN that are destination specific DDEC will transmit a NACK. DDEC will not transmit a NACK to a global request. Transport Protocol Broadcast Announce (TP.CM_BAM) Transmission Rate: As Required Data Length: 8 bytes Data Page: 0 PDU Format: 236 PDU Specific: 255 Default Priority: 7 Byte: 1 Control Byte — set to 32 for CM_BAM Byte: 2, 3 Total Message Size, number of bytes Byte: 4 Total number of packets Byte: 5 Not Defined Byte: 6–8 PGN of packeted message 6-74 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Transport Protocol Data (TP.DT) Transmission Rate: As Required Data Length: 8 bytes Data Page: 0 PDU Format 235 PDU Specific: 255 Default Priority: 7 Byte: 1 Sequence Number Byte 2–8 Packetized Data (7 bytes) NOTE: The last packet of a multi-packet parameter group may require less than eight data bytes. The extra bytes will be filled with 255. NOTE: The data packets are spaced between 50 and 200 ms. Transport Protocol Request to Send (TP.CM_RTS) Transmission Rate: As Required Data Length: 8 bytes Data Page: 0 PDU Format: 236 PDU Specific: Destination Address Default Priority: 7 Byte: 1 Control Byte 16 — Designation Specific Request_To_Send (RTS) Bytes: 2, 3 Total Message Size, number of bytes Byte: 4 Total Number of Packets, zero not allowed Byte: 5 Not Defined Bytes: 6–8 Parameter group Number (PGN) NOTE: The ECM does not support incoming multi-placket messages and will ignore TP.CM_RTS messages. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-75 COMMUNICATION PROTOCOLS Transport Protocol Connection Abort (TP.ConnAbort) Transmission Rate: As Required Data Length: 8 bytes Data Page: 0 PDU Format: 236 PDU Specific: Destination Address Default Priority: 7 Byte: 1 Control Byte 255 — Connection Abort Byte: 2–5 Not Defined Bytes: 6–8 Parameter Group Number (PGN) NOTE: This message is sent if any of the time outs occurs or an invalid packet request occurs. Transport Protocol End of Message (TP.EndofMsgACK) Transmission Rate: As Required Data Length: 8 bytes Data Page: 0 PDU Format: 236 PDU Specific: Destination Address Default Priority: 7 Byte: 1 Control Byte 19–End_of_Message Acknowledge Bytes: 2, 3 Total Message Size, number of bytes Byte: 4 Total Number of Packets, zero not allowed Byte 5: Not Defined Bytes: 6–8 Parameter Group Number (PGN) 6-76 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Transport Protocol Clear to Send (TP.CM_CTS) Transmission Rate: As Required Data Length: 8 bytes Data Page: 0 PDU Format: 236 PDU Specific: Destination Address Default Priority: 7 Byte: 1 Control Byte 17 — Destination Specific Clear_to_Send (CTS) Byte: 2 Number of packets that can be sent Byte: 3 Next packet number to be sent Bytes: 4-5 Not Defined Bytes: 6-8 Parameter Group Number (PGN) TP.DT Transmission Rate: As Required Data Length: 8 bytes Data Page: 0 PDU Format 235 PDU Specific: Destination Address Default Priority: 7 Byte: 1 Sequence Number Bytes: 2–8 Packetized Data (7 Bytes) NOTE: The last packet of a multi-packet parameter group may require less than eighty data bytes. The extra bytes will be filled with 255. The data packets will be spaced no more than 200 ms. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-77 COMMUNICATION PROTOCOLS 6.4.4 SAE J1939/73 DIAGNOSTIC LAYER The Diagnostic Layer Parameter Group Number (PGN) response definitions are described in the following section. Stop Start Broadcast Transmission Rate : As Needed Data Length: 8 bytes Data Page: 0 PDU format: 223 PDU specific: Destination Address Default priority: 3 PGN: 57,008 (0x00DF00) Byte : 1 SAE Primary Links Bits: 8,7 Current Data Link 00: Stop Broadcast 01: Start Broadcast 11: Don't Care Bits: 6,5 J1587 * 00: Stop Broadcast 01: Start Broadcast 11: Don't Care Bits: 4,3 J1922 † 00: Stop Broadcast 01: Start Broadcast 11: Don't Care Bits: 2,1 J1939 Network #1, Primary Vehicle Network ‡ 00: Stop Broadcast 01: Start Broadcast 11: Don't Care Byte: 2 Other Networks #1 Bits: 8,7 J1939 Network #2 - N/A Bits: 6,5 ISO 9141 - N/A Bits: 4,3 J1850 - N/A Bits: 2,1 Other, Manufacture Specified Port - N/A Byte: 3 Other Networks #2 Bits: 8,7 J1939 Network #3 - N/A Bits: 6-1 Not Defined Bytes: 4 Control Flags Bits: 8-5 Hold Signal 0000: All Devices 6-78 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 0001: Devices whose broadcast state has been modified 0010-1110: Not Defined 1111: N/A Bytes: 5-8 Not Defined * Only the broadcast data for the J1587 data link will be shutdown. The ECM will still respond to requests for data. † Only the broadcast data for the J1922 data link will be shutdown. The ECM will still respond to commands from other devices. ‡ Only the broadcast data for the J1939 data link will be shutdown. The ECM will still respond to requests for data. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 6-79 COMMUNICATION PROTOCOLS THIS PAGE INTENTIONALLY LEFT BLANK 6-80 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7 TOOLS Section Page 7.1 DIAGNOSTIC REQUEST SWITCH ........................................................ 7-3 7.2 VEHICLE ELECTRONIC PROGRAMMING SYSTEM ............................ 7-5 7.3 DIAGNOSTIC DATA READER ................................................................ 7-7 7.4 DETROIT DIESEL DIAGNOSTIC LINK .................................................. 7-27 7.5 DDEC REPROGRAMMING SYSTEM .................................................... 7-29 7.6 DDEC ENGINE PROTECTION SIMULATION KIT .................................. 7-35 7.7 DDEC MANUALS .................................................................................... 7-37 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-1 TOOLS THIS PAGE INTENTIONALLY LEFT BLANK 7-2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.1 DIAGNOSTIC REQUEST SWITCH The Diagnostic Request Switch is used to activate the CEL/SEL lights to flash codes. Active codes are flashed on the SEL and inactive codes are flashed on the CEL (see see Figure 5-6). Inactive codes are flashed in numerical order, active codes are flashed in the order received, most recent to least recent. The Diagnostic Request Switch can be used as the SEO switch also. The codesare flashed out of the ECM connected to the switch. Figure 7-1 Flash Codes NOTE: For multi-ECM installations, the Diagnostic Request Switch and SEO are combined on the master ECM. All receiver ECMs have a separate Diagnostic Request Switch. The Diagnostic Request Switch is used to flash codes in the following circumstances: The engine is not running and ignition is on The engine is idling and not in an "engine protection" condition In both circumstances activating and holding the Diagnostic Request Switch will flash out the diagnostic codes. For additional information, refer to section 5.5, "Diagnostics." All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-3 TOOLS THIS PAGE INTENTIONALLY LEFT BLANK 7-4 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.2 VEHICLE ELECTRONIC PROGRAMMING SYSTEM The purpose of the DDEC Vehicle Electronics Programming System (VEPS) is to give OEMs the ability to configure many ECM parameters. This allows DDEC features to be tailored to the specific customer requirements when the vehicle is assembled. Some of the features which may be configured by VEPS are the transmission type, cruise control, vehicle speed limit, idle shutdown, rating switches, digital inputs, and digital outputs. VEPS requires the Windows 95 operating system. 7.2.1 SOFTWARE The VEPS PC software package consists of the several files which are extracted when the software installation program is executed. A System Users Manual which defines the available parameters is included with the software package at the time of purchase. The PC interface utilizes a communications driver which is defined in the TMC Recommended Practice RP1210A. The RP1210A software is used to translate the datalink signal of the ECM to the format required by Windows programs. The RP1210A communications driver is included as part of the VEPS software package. 7.2.2 HARDWARE The hardware portion of the VEPS programming package includes the interface module and cables. The components that are included in the package are listed in Table 7-1. Part Description Part Number 100 Foot Cable 23512893 SAE J1708 6-Pin Dash Connector 23515957 J1708/RS-232 Translator Box 23512415 6 foot Cable 23515869 Table 7-1 VEPS Hardware A cable kit, listed in Table 7-2, is also available. Part Description Part Number Cable Kit (includes the 100 foot cable and the 6-pin dash connector) 23512980 Table 7-2 VEPS Cable Kit A translator and cable kit, listed in Table 7-3, is also available. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-5 TOOLS Part Description Part Number Translator Kit (includes the J1708/RS-232 translator box, 100 foot cable and the 6-pin dash connector) 23512895 Table 7-3 VEPS Translator and Cable Kit The VEPS software kit, listed in Table 7-4, is available. Part Description Part Number Software Kit (includes the RP1202 Software and the VEPS Software) Contact DDC Application Engineering Table 7-4 7.2.3 VEPS Software Kit OPTIONAL PARTS KITS DDC offers vehicle repower kits to aid in the installation of DDEC III/IV. NOTE: This is a repower kit for DDEC II to DDEC III only. There are no repower kits for NOTE: DDEC IV. The kits listed in Table 7-5and Table 7-6 include all of the necessary wiring for the installation of the DDEC III/IV engine and the following parts: Table 7-5 Table 7-6 Part Description Part Number Terminal Kit 23515326 Vehicle Harness - 30 foot 23515152 Power Harness - 22 foot 23515151 Light and Switch Kit 23501634 DDEC Repower Kit - DDC P/N: 23515327 Part Description Part Number Terminal Kit 23515326 Vehicle Harness - 70 foot 23515153 Power Harness - 22 foot 23515151 Light and Switch Kit 23501634 DDEC Repower Kit - DDC P/N: 23515328 The harnesses come with ECM connectors on one end and no connections on the other end. These harnesses are intended to be cut to length by the OEM. The harnesses come with all the connections in the ECM connector. Wires can be removed if not used in a specific application. 7-6 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.3 DIAGNOSTIC DATA READER The hand-held DDR plugs into the Diagnostic Data Link Connector located in the Vehicle Interface Harness (refer to section 3.10.7). This connection allows the DDR to receive data from the ECM. The DDR is used to display: Engine Description via the ENGINE DATA LIST menu Codes via the DIAGNOSTIC CODES menu View/reprogram certain operating parameters A printout of the information displayed on the DDR can be obtained by attaching a printer. 7.3.1 REQUIREMENTS The components required to receive data from the DDEC system can be seen in the next illustration (see Figure 7-2). The components and part numbers are listed in Table 7-7. Component Part Number Pro-Link Main Unit J 38500-1A Multi Protocol Cartridge (MPC) J 38500-1500C Detroit Diesel Application Suite PC Card, DDEC III/IV J 38500-2300D Table 7-7 6 pin Deutsch Adapter J 38500-60A 6 pin to 9 pin Deutsch Adapter J 38500-96A Pro-Link Reprogramming Cable J 38500-925 Pro-Link Portable Printer J 38480-A Diagnostic Data Reader Components and Part Numbers NOTE: Printers used in Europe must use a European power supply as listed in Table 7-8. Do not substitute an AC adapter for the European power supply. Table 7-8 Component Part Number Printer (U.S.A.) J 38480-A Printer with European Power Supply J 38699 European Power Supply only J 38480-220 DDR Printers and Power Supply All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-7 TOOLS To avoid injury from loss of vehicle/vessel control, the operator of a DDEC equipped engine must not attempt to use or read the Diagnostic Data Reader when the vehicle/vessel is moving. The DDR must be used by personnel other than the vehicle operator. The vehicle operator must maintain control of the vehicle while an assistant performs the diagnostic evaluations. Figure 7-2 Diagnostic Data Reader Kit Plus DDEC Cartridge and PCMCIA Card The DDR can be purchased from: 7-8 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Kent-Moore 28635 Mound Road Warren, MI 48092 Phone: 1-800-328-6657 See Figure 7-3 for a DDR menu options map. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-9 TOOLS Figure 7-3 7-10 DDR Menu Options (Release 24.0 Software) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.3.2 ENGINE DATA LIST The DDR can be used to view operational data and parameter settings, via the Engine Data List feature. View operational data as follows: 1. Turn the ignition ON. 2. Press until ENGINE DATA LIST is shown on the screen. 3. Scroll through the data list by pressing is shown on the screen. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION and until the desired parameter 7-11 TOOLS 7.3.3 DIAGNOSTIC CODES The DDR can be used to view active and inactive codes. Active Codes View the (active) codes as follows: 1. Press until the SELECT DESIRED MENU appears on the screen. 2. Select ENGINE and press 3. Press until DIAGNOSTIC CODES is shown on the screen. 4. Then press 5. Press . until ACTIVE CODES is shown on the screen. 6. Then press 7. Press . to view the first active code. and to scroll through the active codes. NOTE: Refer to Appendix A for a list of all DDEC codes and code descriptions. 7-12 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Inactive Codes View the inactive codes as follows: 1. Press until the SELECT DESIRED MENU appears on the screen. 2. Select ENGINE and press 3. Press until DIAGNOSTIC CODES is shown on the screen. 4. Then press 5. Press . until INACTIVE CODES is shown on the screen. to view the first inactive code. 6. Then press 7. Press . and to scroll through the inactive codes. NOTE: Refer to Appendix A for a list of all DDEC codes and code descriptions. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-13 TOOLS Clearing Codes With A DDR The diagnostic codes stored in the ECM's memory can be cleared with a DDR, via the DIAGNOSTIC CODES menu. To clear the codes perform the following: 1. Press until the SELECT DESIRED MENU appears on the screen. 2. Select ENGINE and press 3. Press 4. Then press 5. Press . until DIAGNOSTIC CODES is shown on the screen. . until CLEAR CODES is shown on the screen. . 6. Then press 7. Use 7-14 to select YES to clear the codes. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.3.4 VIEW CALIBRATION Perform the following steps to view the calibration data stored within the ECM: 1. Press until the SELECT DESIRED MENU appears on the screen. 2. Select ENGINE and press 3. Press until VIEW CALIBRATION is shown on the screen. 4. Then Press 5. Use the data. . . and to scroll through the VIEW CALIBRATION menu to view The following information can be viewed with the DDR under the VIEW CALIBRATION menu: Engine Configuration Idle Shutdown VSG Configuration Engine Protection Cruise Control Progressive Shift ECM Input and Output Air Compressor Function Lockout All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-15 TOOLS Engine Configuration See Figure 7-4 for an Engine Configuration menu options map. Figure 7-4 7-16 Engine Configuration Menu All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.3.5 FUEL INJECTOR Perform the following steps to view the Fuel Injection information stored within the ECM: 1. Press until the SELECT DESIRED MENU appears on the screen. 2. Select ENGINE and press 3. Press . until FUEL INJECTOR INFO is shown on the screen. 4. Then Press . 5. Use the and to scroll through the FUEL INJECTOR INFO menu to view the required data or perform a function. The following information can be viewed/modified with the DDR under the FUEL INJECTOR INFO menu: Cylinder Cutout Response Times Cal Update Change Injector Password Change Injector Description Option (Series 2000 and Series 4000 only) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-17 TOOLS 7.3.6 ENGINE/TRIP DATA Perform the following steps to view the Engine/Trip data stored within the ECM: 1. Press until the SELECT DESIRED MENU appears on the screen. 2. Select ENGINE and press 3. Press until ENGINE/TRIP DATA is shown on the screen. 4. Then Press 5. Use the . . and to scroll through the ENGINE/TRIP DATA menu. The following information can be viewed with the DDR under the ENGINE/TRIP DATA menu: TOTAL ENGINE DATA ENGINE TRIP DATA RESET TRIP DATA 7-18 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.3.7 CALIBRATION CHANGES Perform the following steps to change calibration values stored within the ECM: 1. Press until the SELECT DESIRED MENU appears on the screen. 2. Select ENGINE and press 3. Press until CALIBRATION CHANGE is shown on the screen. 4. Then press 5. Use . . and to scroll through the CALIBRATION CHANGE menu. The following menus are available under CALIBRATION CHANGE: Reprogram Calibration View Calibration Change History Change Password All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-19 TOOLS Reprogram Calibration This selection offers a list of ECM calibrations that can be modified. See Figure 7-5. Figure 7-5 7-20 Reprogram Calibration Selections All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.3.8 SWITCH/LIGHT STATUS Perform the following steps to view the Switch/Light status stored within the ECM: 1. Press until the SELECT DESIRED MENU appears on the screen. 2. Select ENGINE and press 3. Press 4. Then press . until SWITCH/LIGHT STATS is shown on the screen. . The switch/light status lists the current status of each of the ECM digital inputs and outputs. This list will also display the receiver ECM #1 and receiver ECM #2 digital input and output status. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-21 TOOLS 7.3.9 ACTIVATE OUTPUTS 1. Press until the SELECT DESIRED MENU appears on the screen. 2. Select ENGINE and press 3. Press 4. Then press . until ACTIVATE OUTPUTS is shown on the screen. . The Activate Outputs menu option allows each of the digital outputs and PWM outputs to be toggled to the opposite state. This will allow testing of lights and relays to ensure proper operation. 7-22 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.3.10 MIDS RECEIVED 1. Press until the SELECT DESIRED MENU appears on the screen. 2. Select ENGINE and press . until MIDS RECEIVED is shown on the screen. 3. Press 4. Then press . The MIDS RECEIVED will display the current device that the DDR is receiving messages from as listed in Table 7-9. Display MID 128: ENGINE Description Single ECM Applications MID 175: ENGINE R1 Dual ECM Application - first Receiver ECM MID 183: ENGINE R2 Triple ECM Application - second Receiver ECM Table 7-9 7.3.11 MIDS RECEIVED Display and Description RESET COMPONENTS This function is only available for DDEC III engines. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-23 TOOLS 7.3.12 TRANSMISSIONS Perform the following steps to view/change the Transmission information stored within the ECM: 1. Press until the SELECT DESIRED MENU appears on the screen. 2. Select ENGINE and press 3. Press until TRANSMISSIONS is shown on the screen. 4. Then press 5. Use . . and to scroll through the TRANSMISSIONS menu. The menus are available under TRANSMISSIONS are: ESS TRANSMISSION TOP 2 TRANSMISSION 7.3.13 RESET AFR TABLE This function is used on natural gas engines to reset the Air Fuel Ratio (AFR) Learn table. 7-24 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.3.14 MAINTENANCE STATUS Perform the following steps to view the Maintenance Status menu: 1. Press until the SELECT DESIRED MENU appears on the screen. 2. Select ENGINE and press 3. Press until MAINTENANCE STATUS is shown on the screen. 4. Then press 5. Use . . and to scroll through the MAINTENANCE STATUS menu. The menus are available under MAINTENANCE STATUS are: MAINTENANCE STATUS CLEAR MAINTENANCE CODES All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-25 TOOLS THIS PAGE INTENTIONALLY LEFT BLANK 7-26 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.4 DETROIT DIESEL DIAGNOSTIC LINK The Detroit Diesel Diagnostic Link™ (DDDL) is a sophisticated PC software package supporting the setting up, maintenance and repair of engines using the DDEC IV ECM. For additional information, refer to the on-line Help within the program. 7.4.1 CALIBRATION You can use the DDDL to: Read and display the current calibration from an ECM. Create a calibration for the ECM on an individual engine. Save a single calibration with an ECM password so that the same calibration can be used conveniently for a fleet of vehicles with the same password, or can be used by a technician who does not have access to the password. Change the engine rating of a vehicle. Set the injector calibration when you replace the injectors. View an audit trail of ECM and injector calibration changes. 7.4.2 DIAGNOSTICS AND MAINTENANCE You can use the Detroit Diesel Diagnostic Link to: Monitor a wide range of parameters while connected live to the ECM . Select a group of these parameters and plot how they have varied over the last two minutes. Take and save a snapshot of how the parameters vary over a period of time, so that you can replay the snapshot for detailed analysis. Monitor fault codes as they occur while connected live to the ECM. You can also clear any inactive fault codes stored in the ECM. Take a snapshot recording the fault codes occurring over a period of time, and relate their occurrence to the values of measurements made by the ECM. Test for the effect on performance of cutting out individual cylinders. View a record of the injector timings. Set the ECM output functions to particular values to support troubleshooting. Display specific troubleshooting help for any fault codes that occur, or have occurred. View engine and trip totals, and reset the trip counters in the ECM. Reset the ECM counters monitoring component usage when you replace the components. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-27 TOOLS THIS PAGE INTENTIONALLY LEFT BLANK 7-28 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.5 DDEC REPROGRAMMING SYSTEM The DDEC Reprogramming System (DRS) is composed of Programming Software, DDECcomm Mainframe Communications software, all the hardware required to connect a Personal Computer to the ECM, and a user manual explaining the use of the software. The DRS software is used to reprogram calibrations, modify customer calibration values, upgrade ECM software versions, update injector calibration codes, and program blank ECMs. The DDECcomm software is used to communicate via modem to the DDC Mainframe computer which stores all the DDEC Calibrations. 7.5.1 REQUIREMENTS The DRS and DDECcomm software require a Personal Computer which meets certain minimum requirements. These minimum requirements include a 80486 - 33 MHz microprocessor with 8 MB of RAM and at least 530 KB of DOS conventional memory, a modem, and the Windows 95 Operating System. DDC also sells kits which include a Laptop PC, please contact your Detroit Diesel representative for current Laptop specifications. The part numbers for the kits are listed in Table 7-10. Kit Part Number DDEC Reprogramming System MRS7500 DDEC Reprogramming System with Laptop PC MRS7500-L Table 7-10 7.5.2 Mini Reprogramming System Part Numbers DRS PROGRAMMING SOFTWARE The DRS software requires that the PC be started in the DOS mode of operation. It is not possible to reprogram an ECM by starting a DOS session from within Windows. 7.5.3 ECM PROGRAMMING MENU There are several menu choices on the ECM Programming Menu. A menu option is selected by using the up and down arrows to highlight the choice and then pressing the space bar or the enter key to actuate it. The following sections describe these menu options. Program ECM Reprogram ECMs with a customer calibration that has previously been downloaded from the DDC mainframe computer. The customer configurable parameters are retained through this type of a reprogramming. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-29 TOOLS Program Fleet ECM Reprogram fleet units from a single customer calibration that has previously been downloaded from the DDC mainframe computer. The customer configurable parameters are retained through this type of a reprogramming. Program ECM With Mainframe Data Reprogram ECMs with a customer calibration that has previously been downloaded from the DDC mainframe computer. Unlike the standard Program ECM option, this option will overwrite the customer configurable parameters, resulting in a calibration exactly like the one created by the factory. Display Available ECM S/W Versions Displays ECM software versions that are available on the PC. These versions are used to electronically upgrade ECM software for DDEC III and IV. Display Customer Calibration Displays electronic parameter settings currently programmed in an ECM. Update Calibration at DDC This function is used to store the ECM's electronic parameters on the PC. After performing this option, the Upload History function in the DDEC Mainframe Communications Program (DDECcomm) can be used to send the ECM data to the DDC mainframe computer. Display Station Log File Displays a file containing system usage information. Update Customer Calibration Similar to the Display Customer Calibration option, this option allows the electronic parameters to be updated. A customer password is required to perform this function. The following groups of information, listed in Table 7-11, can be modified. 7-30 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Parameters That Can Be Updated Air Compressor Output Config VSG Configuration Auto Cruise Resume Idle Adjustment Vehicle Number CLS Polarity Idle Shutdown Function Lockout Cruise Control Rating Lockout Password Cruise Switch VSG Rating Receiver #1 Fan Timer Customer Password Rating Receiver #2 Engine Brakes Droop Rating Password ESS Config Dynamic Braking Progressive Shift Half Engine Idle Engine Protection Transmission TOP 2 Switch Receiver Protection Vehicle Spd Limiting Fuel Quality Factor Fire Truck Vehicle Spd Sensor Low Gear Torque Limiting Fuel Econ Incentive Vehicle ID Number Sensor Configuration Input Config __ __ Table 7-11 Parameters that can be Updated with the Update Customer Calibration Option Update Logon Parameters This option was used to configure the communication parameters when the DOS communications package was used. The only parameter used by the Windows DDECcomm software is the Logon ID. Upgrade ECM Software New versions of DDEC ECM software may be programmed into customer's ECMs with this option. There is a nominal charge each time this function is performed. Update Injector Calibration This option displays a graphical representation of the engine allowing the injector calibration code to be updated. An injector password is required. Display Downloaded Units This menu item displays the Unit Numbers of the engines which have been downloaded from the mainframe and are available for programming. Update ECM Accumulators Update ECM with engine data such as idle hours, engine hours, cruise hours, miles, etc. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-31 TOOLS Print ECM Parameters This menu item queries the ECM for the Customer Calibration information and formats it into a report which can be printed out on a printer attached to the parallel port on the computer. DDC Mainframe Interface Menu This option was used to select the DOS-based DDC Mainframe Interface Menu which loaded a separate communications program to communicate to the DDC server. This functionality has been replaced by the Windows 95 program DDECcomm which uses the quicker File Transfer Protocol to communicate with the server. 7.5.4 DDECCOMM DDECcomm is a Win95 program which can be invoked by selecting the DDEC Server Interface icon on the Windows desktop or through the Start button via Programs | DDEC Electronic Controls | DDEC Communications. The following menu options are available in this program. Download Engine Serial Calibration(s) This option is used to download any changed or desired unit calibrations from the DDC mainframe computer. These calibrations are stored on the PC for a maximum of 14 days, after that period they are automatically deleted. Download Fleet Calibration(s) This option allows the download of a single "fleet" unit from the mainframe to the PC. This "fleet" unit calibration may be used to program multiple units in a fleet via the Program Fleet ECM option discussed above. Upload History This option takes the programming history on the PC and uploads it to the DDC mainframe. This allows DDC to maintain a current image of the calibration status should further service be required. The history file must first be created by running the Update Calibration at DDC menu option in the DRS Programming Software. Display Available ECM S/W Versions Displays ECM software versions that are available on the PC. These versions are used to electronically upgrade ECM software for DDEC III and IV. Display Station Log File Displays a file containing system usage information. 7-32 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Display Downloaded Units This menu item displays the Unit Numbers of the engines which have been downloaded from the mainframe and are available for programming. Update Logon Parameters This option is used to configure the system. All user information may be updated when this option is selected. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-33 TOOLS THIS PAGE INTENTIONALLY LEFT BLANK 7-34 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.6 DDEC ENGINE PROTECTION SIMULATION KIT The DDEC Engine Protection Simulation Kit is used to reduce diagnostic troubleshooting time for DDEC sensors. The normal use for these false sensors is to simulate an engine fault that would result in the engine protection system triggering a code in the DDEC ECM. This kit can also be used for testing and verification of the engine shutdown system, fan control outputs, and coolant level outputs. This will also be useful in simulating an engine protection fault to show customers how the DDEC protection system will react in the event of a failure that would normally cause damage to the engine. To use, plug the simulator into the connector currently used for the appropriate sensor. Start and run the engine and DDEC will trigger the appropriate code for that fault. The DDEC Engine Protection Simulation Kit components and part numbers are listed in Table 7-12. Component Part Number Coolant Low Level Simulator 23524785 High Oil/Coolant Temperature Simulator 23524787 Low Oil Pressure Simulator 23524786 Table 7-12 DDEC Engine Protection Simulation Kit, P/N: 23526923 The High Crankcase Pressure Simulator (P/N: 23524784) is for the Series 4000 only and is not included in kit. 7.6.1 COOLANT LEVEL LOW SIMULATOR This simulator is preset to advise the ECM that the coolant is low. Use only for DDEC III or IV. This simulator can be used to: Verify protection function. Test low coolant level light output to ensure it is configured to the correct output and correct polarity (activates the output). Determine if the actual sensor is bad/shorted. A bad/shorted CLS can result in other fault codes. 7.6.2 HIGH OIL/COOLANT TEMPERATURE SIMULATOR This simulator is preset to provide a 250 F (121 C) signal to the ECM. Use for any DDEC. This simulator can be used to: Test coolant temperature shutdown logic/protection. Test oil temperature shutdown logic/protection. Test coolant temperature high output. Test oil temperature high output. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-35 TOOLS Fake coolant temperature high to test fan control circuit. Fake oil temperature high to test fan control circuit. 7.6.3 LOW OIL PRESSURE SIMULATOR This simulator is preset to provide oil pressure signal of 0 psi (0 kPa). This simulator can be used to: Provide a known pressure (oil pressure) for engine protection testing. Provide a known pressure (fuel pressure) for fault code testing. Provide a known pressure (coolant pressure) for engine protection testing. Verify if correct output is configured for low oil pressure (activates the output). Test current OPS to determine if a shorted sensor is causing other codes. Test current FPS to determine if a shorted sensor is causing other codes. Test current CPS to determine if a shorted sensor is causing other codes. 7.6.4 HIGH CRANKCASE PRESSURE SIMULATOR (SERIES 4000 ONLY) The High Crankcase Pressure Simulator (P/N: 23524784) is not included in the kit. This simulator is preset to provide a crankcase pressure signal of 12 psi / 83 kPa. 7-36 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 7.7 DDEC MANUALS The following DDC manuals provide more information about troubleshooting and specific DDEC features: Construction & Industrial EDM and AIM Installation and Troubleshooting (7SA801) Construction & Industrial EDM and AIM User Manual (6SE710) ProDriver User Manual (6SE701) ProDriver DC User Manual (6SE703) Electronic Fire Commander Installation and Troubleshooting(6SE476) Engine Synchro Shift™ Troubleshooting (6SE498) Optimized Idle - DDEC III/IV - Installation and Troubleshooting(7SA741) DDEC III/IV Single ECM Troubleshooting (6SE497) DDEC III/IV Multi-ECM Troubleshooting (6SE496) IRIS User and Installation Guide (6SE36) Ether Start Installation(7SA727) Data Hub User Manual (6SE704) Data Hub RDI User Manual (6SE714) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 7-37 TOOLS THIS PAGE INTENTIONALLY LEFT BLANK 7-38 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8 APPLICATIONS Section Page 8.1 APPLICATION CODE SYSTEM .............................................................. 8-3 8.2 TYPICAL ON-HIGHWAY APPLICATION ................................................. 8-11 8.3 TYPICAL INDUSTRIAL APPLICATION - UNDERGROUND HAUL TRUCK .................................................................................................... 8-13 8.4 TYPICAL INDUSTRIAL APPLICATION - AIR COMPRESSOR .............. 8-15 8.5 TYPICAL INDUSTRIAL APPLICATION - ON-HIGHWAY CRANE .......... 8-17 8.6 TYPICAL GENSET APPLICATIONS ....................................................... 8-19 8.7 TYPICAL FIRE TRUCK APPLICATION .................................................. 8-23 8.8 DDEC REQUIREMENTS FOR GASEOUS HAZARDOUS ENVIRONMENTS ................................................................................... 8.9 8-25 TYPICAL INDUSTRIAL APPLICATION - HAZARDOUS ENVIRONMENT PETROLEUM .......................................................................................... All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-47 8-1 APPLICATIONS THIS PAGE INTENTIONALLY LEFT BLANK 8-2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8.1 APPLICATION CODE SYSTEM DDC Application Engineering, Product Engineering, and DDEC Engineering work together to establish and define the Electronic Control Module (ECM) functions and the electronic parameters that are maintained by the DDEC Application Code System (ACS). DDC Application Engineering creates application codes (6N4C groups) that define defaults and validation ranges for the ECM features. ACS provides the flexibility to customize engine speed governing and control, engine protection, and communications. DDC Product Distribution and Distributors use the application codes to process and further customize customers' orders. This section contains a blank copy of the "DDEC ACS Worksheet." This worksheet may be used by the OEM, or distributor, to specify desired DDEC parameters and help determine the proper 6N4C group. These parameters include: Type of transmission or powertrain Engine speed governing Idle speed High idle speed Droop Cruise Control options Engine protection strategy DDEC digital inputs DDEC digital outputs All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-3 APPLICATIONS DDEC Nonroad Application Specification 6N4C Group (To be assigned by DDC Application Engineering) Transmission (The transmission codes are listed in Table 8-1on page 8-7.) Transmission Code: Governing Type (Circle One) VSG Only LSG Only VSG & LSG Number of VSG Throttle Locations (0, 1, or 2) Number of LSG Throttle Locations (0, 1, or 2) VSG MAX RPM 400 to 2500 RPM VSG MIN RPM 400 to 2500 RPM VSG ALT MIN RPM 400 to 2500 RPM VSG DROOP 0 to 300 RPM HOT IDLE 400 to 2500 RPM COLD IDLE 750 to 1050 RPM LSG DROOP Idle Operation at Zero VSG 0 to 300 RPM Yes No Note: VSG ALT MIN RPM must be greater than VSG MIN RPM. LSG DROOP must be greater than or equal to VSG DROOP. Cruise Switch VSG Cruise Switch VSG (Circle One) Initial Speed RPM Increment Yes No Yes No Idle Only Idle & VSG Yes No 400 to 2500 0 to 250 Idle Timer Shutdown Idle Timer Shutdown (Circle One) Time Operates On Override 8-4 1 to 99 Minutes All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL DDEC Nonroad Application Specification Engine Protection (Circle required option) Coolant Temperature Shutdown Rampdown Warning Coolant Level Shutdown Rampdown Warning Coolant Pressure Shutdown Rampdown Warning Oil Pressure Shutdown Rampdown Warning Oil Temperature Shutdown Rampdown Warning Aux. Stop 1 Shutdown Rampdown Warning Aux. Stop 2 Shutdown Rampdown Warning Crankcase Pressure Shutdown Rampdown Warning Intercooler Temperature Shutdown Rampdown Warning Engine Overtemperature Protection Yes No Air Temperature Reduction Yes No Continuous Override Yes No Fan Controls (Circle required options) Digital Fan Type: None Single Dual 2-Speed PWM None Jake Brake KD Brake DVB Engine Brakes (circle required option) Engine Brake Type: Engine Brake Cruise Engine Brake Cruise (Circle One) Engine Brake Low 1 to 10 MPH Increment 1 to 5 MPH Yes No Vehicle Speed Sensor Vehicle Speed Sensor (VSS) (Circle One) Yes No VSS Sensor Type (Circle One) Transmission Wheel VSS Signal Type (Circle One) Open Collect Magnetic Number of Teeth Tire Revolutions Per Mile 2 to 200 100 to 1000 Axle Ratio: Final Gear Ratio: All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-5 APPLICATIONS DDEC Nonroad Application Specification Vehicle Speed Limit Vehicle Speed Limit (Circle One) Yes Max. Speed 20 to 127 MPH Overspeed with Fuel 0 to 127 MPH Overspeed w/o Fuel 0 to 127 MPH No Cruise Control Cruise Control (Circle One) Yes No Auto Resume (Circle One) Yes No Min. Speed 20 to 127 MPH Max. Speed 20 to 127 MPH Air Compressor Controls Air Compressor Controls (Circle One) Yes No Load Pressure Unload Pressure Range 1 Min. Pressure Range 1 Max. Pressure Range 2 Min. Pressure Range 2 Max. Pressure Range 3 Min. Pressure Range 3 Max. Pressure Other Options (Circle required options) Fuel Economy Incentive Yes No Pressure Governor System Yes No Progressive Shift Yes No 8-6 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL DDEC Nonroad Application Specification Configuration Of Digital Inputs (A list of Digital Input options and codes is listed in Table 8-2 on page 8-7.) VIH Pin Number VIH Wire Number E1 451 F1 542 G1 528 H1 523 J1 541 F2 544 G2 543 H2 524 J2 531 K2 583 G3 545 K3 979 Customer Selection Configuration Of Digital Outputs (A list of Digital Output options and codes is listed in Table 8-3 on page 8-8.) VIH Pin Number VIH Wire Number A1 988 A2 555 F3 499 Sensor Harness Pin Number Sensor Harness Wire Number W3 563 X3 564 Y3 565 Customer Selection Customer Selection Refer to section 5.34, "Transmission Interface," for further details of the transmission definition. Transmission Type Transmission Type Code Code Manual 00 RS9 17 Allison Hydraulic 01 RSX9-A 18 Voith 03 RSX9-B 19 Z-F Ecomat 04 RSX9-R 20 Allison Electronic 09 RS10 21 Allison WT 12 RSX10 22 Other Automatic 14 RSX10-C 23 GE Statex III 15 GE Propulsion System 31 Autoshift / J1939 16 Note: If application has no transmission enter code "00" Table 8-1 Transmission Options and Codes Refer to section 4.1, "Digital Inputs," for a detailed description of each digital input option. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-7 APPLICATIONS Description Description Code Code None 00 Resume / Accel On 22 Engine Brake Low 01 Cruise Enable 23 Engine Brake High 02 PGS System Enable 24 Aux. Shutdown # 1 03 SEO / Diagnostic Request 25 Aux. Shutdown # 2 04 Engine Brake Disable 26 Park Brake Interlock 05 Transmission Retarder Status 27 Idle Validation 06 Dual Throttle 28 Throttle Kickdown 07 A/C Fan Status 29 Pressure RPM Mode 08 N/A 30 Throttle Inhibit 09 Aux CLS 31 External Engine Synchronization 10 Fan Control Override 32 RPM Freeze 11 VSG Station Change 33 Rating Switch # 1 12 VSG Station Complement 34 Rating Switch # 2 13 Air Load Switch 35 Limiting Torque Curve 14 N/A 36 Diagnostic Request 15 N/A 37 Alt Min VSG / Fast Idle 16 In Neutral Switch (ESS) 38 Service Break Release 17 In Gear Switch (ESS) 39 Clutch Released 18 KD Brake 40 Set / Coast On 20 VSG Inhibit 42 Table 8-2 Digital Input Options and Codes Refer to section 4.2, "Digital Outputs," for a detailed description of each digital output option. 8-8 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Description Description Code Code No Function 00 Coolant Temp. High Light 20 N/A 01 Air Compressor Solenoid 21 N/A 02 Crankcase Pressure High 22 Low DDEC Voltage 03 Coolant Pressure Low Light 23 External Engine Synchronization Active 04 Ether Start 24 PSG Pressure Mode Light 05 N/A 25 Vehicle Power Shutdown 06 Optimized Idle Light 26 Starter Lockout 07 N/A 27 External Engine Brake Enable 08 ESS Low Range 28 Transmission Retarder Enable 09 ESS High Range 29 Coolant Level Low Light 10 Shift Solenoid (TOP2) 30 Cruise Active Light 11 Shift Lockout (TOP2) 31 N/A 12 Gas Throttle Actuator 32 Fan Control # 1 13 Fuel Supply Solenoid 33 Fan Control # 2 14 KD Brake Solenoid 34 Deceleration Light 15 Sequential Turbo 35 Engine Brake Active 16 Natural Gas Knock Shutdown 36 VSG Active Indication 17 Cold Engine Signal (S4000) 37 Oil Pressure Low Light 18 Engine Overspeed Signal 39 Oil Temperature High Light 19 Table 8-3 Digital Output Options and Codes All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-9 APPLICATIONS THIS PAGE INTENTIONALLY LEFT BLANK 8-10 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8.2 TYPICAL ON-HIGHWAY APPLICATION This section contains typical parameter settings for on-highway truck applications and the pin assignments for the Vehicle Interface Harness and the Engine Sensor Harness as listed in the Verification Report on the following pages. The Digital Input and Digital Output ports can be configured for a variety of software options. The location of the connector pin for each software option can be specified at the time of engine order, by VEPS or the Distributor Reprogramming Station. For more information on software options, refer to section 4.1, "Digital Inputs" and section 4.2, "Digital Outputs." All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-11 APPLICATIONS DATE: VERIFICATION REPORT SALES ORDER NUMBER: ---------------------------------------------------------------------------------------------------------DDEC III/IV ENGINE SUMMARY Series I60 DDEC Appl Group 06N04C0126 DDEC IV HIGHWAY TRK EPL W/O JAKE BRAKE Base group 06N04D6437 370-430 HP STD RAT 1999 DDEC IV LINE HAUL 12L S60 Hp Group 06N04M7109 400HP@1800RPM 1056 1999 LINE HAUL TRK 12L S60 (155OFTLB) PWM Trans 0 MANUAL VSG Cruise Switch Init Speed RPM Increment YES 1000 25 IDLE SHUTDOWN YES Maximum Security Minimum Security ENGINE PROTECTION Coolant Temp Coolant Level Coolant Pressure R1 Coolant Prs Crankcase Prs Override Intercool Temp Oil Press Override Oil Temp R1 Oil Temp Aux Stop 1 Aux Stop 2 Vehicle Speed Sensor VSS Sensor Type VSS Signal Type Num Teeth Tire Rev/Mile Axle Ratio Final Gear Ratio Vehicle Speed Limit Max Speed Overspeed with Fuel Overspeed w/o Fuel PROGRESSIVE SHIFT Low Gear #1 Max MPH Low Gear #2 Max MPH High Gear Max MPH Air Comp. System Load Pressure Unload Pressure Pressure Increment NO NO PIN E1 F1 G1 H1 J1 F2 G2 H2 J2 K2 G3 K3 8-12 WIRE# #451 #542 #528 #523 #541 #544 #543 #524 #531 #583 #545 #979 Fn 32 29 25 03 20 23 17 05 18 00 22 00 SHUTDOWN SHUTDOWN DISABLED DISABLED YES DISABLED SHUTDOWN SHUTDOWN SHUTDOWN SHUTDOWN YES TRANS MAGNETIC 16 500 3.55 1 YES 68 0 0 NO NO VSG Max RPM VSG Min RPM VSG Alt Min RPM VSG is Primary 1600 600 600 NO Hot Idle Cold Idle Max Droop LSG Droop VSG Droop Time Operates On Override Min Temp Digital Fan PWM Fan Dynamic Brk Engine Brakes Eng Brake Cruise Eng Brake Low Increment 5 MIN IDLE & VSG GOVERNOR NO 75 DEGC Max Temp 75 DEGC SINGLE FUEL ECONOMY INCENTIVE NONE Min MPG N/A NO Max MPH 0 Conv. Factor N/A NONE Calc. Type N/A NO 3 2 Data Pages Optimized Idle Fan Timer NO NO 180 SEC Full Power Override Cruise Control AutoResume Min Speed Max Speed NO YES NO 30 65 ATI Port NONE Press Gov System Cavitation Timeout Pump Press Incr Eng Spd Incr Integral Gain Prop Gain Digital Torque Curve Starter Lockout Enable Speed Starter Lockout Disable Speed 1 500 60 Max RPM Max RPM Max RPM R1 Min Pressure R2 Min Pressure R3 Min Pressure % Integral Gain Turn-off RPM Turn-off RPM FAN CONTROL OVERRIDE A/C FAN STATUS SEO/DIAGNOSTIC REQUEST AUX SHUTDOWN #1 SET/COAST ON CRUISE ENABLE SERVICE BRAKE RELEASED PARK BRAKE INTERLOCK CLUTCH RELEASED NONE RESUME/ACCEL ON NONE 600 2500 150 125 0 NO R1 Max Pressure R2 Max Pressure R3 Max Pressure Prop Gain VIH PIN A1 A2 F3 Wire# #988 #555 #499 Fn 10 13 06 Reverse Polarity NO COOLANT LEVEL LOW LIGHT YES FAN CONTROL #1 NO VEHICLE POWER SHUTDOWN ESH PIN W3 X3 Y3 Wire# #563 #564 #565 Fn 00 00 00 Reverse Polarity NO NO FUNCTION NO NO FUNCTION NO NO FUNCTION All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8.3 TYPICAL INDUSTRIAL APPLICATION - UNDERGROUND HAUL TRUCK This section contains typical parameter settings for a Series 2000 underground haul truck industrial application and the pin assignments for the Vehicle Interface Harness and the Engine Sensor Harness as listed in the Verification Report on the following pages. The Digital Input and Digital Output ports can be configured for a variety of software options. The location of the connector pin for each software option can be specified at the time of engine order, by VEPS or the Distributor Reprogramming Station. For more information on software options, refer to section 4.1, "Digital Inputs" and section 4.2, "Digital Outputs." All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-13 APPLICATIONS DATE: VERIFICATION REPORT SALES ORDER NUMBER: ---------------------------------------------------------------------------------------------------------DDEC III/IV ENGINE SUMMARY Series 2000 DDEC Appl Group 06N04C0721 DDEC III/IV APPL OFF-HWY WITH LSG ONLY S2000 Base group 06N04D0292 575 HP STD RATING 1997 8V S2000 INDUSTRIAL Hp Group 06N04M1211 575HP@2100 18435 1997 MINE DDEC3 8V S2000 INDUSTRIAL PWM Trans 9 VSG Cruise Switch Init Speed RPM Increment NO 1000 25 IDLE SHUTDOWN NO Maximum Security Minimum Security ENGINE PROTECTION Coolant Temp Coolant Level Coolant Pressure R1 Coolant Prs Crankcase Prs Override Intercool Temp Oil Press Override Oil Temp R1 Oil Temp Aux Stop 1 Aux Stop 2 Vehicle Speed Sensor VSS Sensor Type VSS Signal Type Num Teeth Tire Rev/Mile Axle Ratio Final Gear Ratio Vehicle Speed Limit Max Speed Overspeed with Fuel Overspeed w/o Fuel PROGRESSIVE SHIFT Low Gear #1 Max MPH Low Gear #2 Max MPH High Gear Max MPH Air Comp. System Load Pressure Unload Pressure Pressure Increment NO NO PIN E1 F1 G1 H1 J1 F2 G2 H2 J2 K2 G3 K3 8-14 WIRE# #451 #542 #528 #523 #541 #544 #543 #524 #531 #583 #545 #979 Fn 00 00 25 00 01 03 09 04 00 00 02 28 RAMPDOWN RAMPDOWN RAMPDOWN DISABLED YES DISABLED RAMPDOWN YES RAMPDOWN SHUTDOWN RAMPDOWN NO NO VSG Max RPM VSG Min RPM VSG Alt Min RPM VSG is Primary 2100 600 600 NO Hot Idle Cold Idle Max Droop LSG Droop VSG Droop Time Operates On Override Min Temp Digital Fan PWM Fan Dynamic Brk Engine Brakes Eng Brake Cruise Eng Brake Low Increment 5 MIN IDLE GOVERNOR ONLY NO 75 DEGC Max Temp 75 DEGC NONE FUEL ECONOMY INCENTIVE NONE Min MPG N/A NO Max MPH 0 Conv. Factor N/A NONE Calc. Type N/A NO 2 1 Data Pages Optimized Idle Fan Timer YES NO 180 SEC Full Power Override Cruise Control Auto Resume Min Speed Max Speed YES NO ATI Port NONE Press Gov System Cavitation Timeout Pump Press Incr Eng Spd Incr Integral Gain Prop Gain Digital Torque Curve Starter Lockout Enable Speed Starter Lockout Disable Speed 1 500 60 Max RPM Max RPM Max RPM R1 Min Pressure R2 Min Pressure R3 Min Pressure % Integral Gain Turn-off RPM Turn-off RPM 600 700 150 150 125 NO NO NO NONE NONE SEO/DIAGNOSTIC REQUEST NONE ENGINE BRAKE LOW AUX SHUTDOWN #1 THROTTLE INHIBIT AUX SHUTDOWN #2 NONE NONE ENGINE BRAKE MED DUAL THROTTLE (LSG) R1 Max Pressure R2 Max Pressure R3 Max Pressure Prop Gain VIH PIN A1 A2 F3 Wire# #988 #555 #499 Fn 20 08 07 Reverse Polarity NO COOLANT TEMP HIGH LIGHT NO EXT BRAKE ENABLE NO STARTER LOCKOUT ESH PIN W3 X3 Y3 Wire# #563 #564 #565 Fn 00 00 00 Reverse Polarity NO NO FUNCTION NO NO FUNCTION NO NO FUNCTION All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8.4 TYPICAL INDUSTRIAL APPLICATION - AIR COMPRESSOR This section contains typical parameter settings for a Series 60 air compressor industrial application and the pin assignments for the Vehicle Interface Harness and the Engine Sensor Harness as listed in the Verification Report on the following pages. The Digital Input and Digital Output ports can be configured for a variety of software options. The location of the connector pin for each software option can be specified at the time of engine order, by VEPS or the Distributor Reprogramming Station. For more information on software options, refer to section 4.1, "Digital Inputs" and section 4.2, "Digital Outputs." All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-15 APPLICATIONS DATE: VERIFICATION REPORT SALES ORDER NUMBER: --------------------------------------------------------------------------------------------------------DDEC III/IV ENGINE SUMMARY Series DDEC Appl Group 06N04C0726 DDEC III APPL AIR COMPRESSOR I60 Base group 06N04D6396 450/475 HP DDEC IV NON-ROAD 12L S60 Hp Group 06N04M7079 475HP@2100RPM 5012 1998 DDEC IV NON-ROAD S60 (1550 FTLB) PWM Trans 0 VSG Max RPM 2100 Hot Idle 1000 VSG Cruise Switch NO VSG Min RPM 600 Cold Idle 2500 Init Speed 1000 VSG Alt Min RPM 600 Max Droop 150 RPM Increment 25 VSG is Primary YES LSG Droop 150 VSG Droop 125 IDLE SHUTDOWN NO Time 5 MIN Operates On IDLE GOVERNOR ONLY Maximum Security NO Override NO Minimum Security NO Min Temp 75 DEGC Max Temp 75 DEGC ENGINE PROTECTION Digital Fan NONE FUEL ECONOMY INCENTIVE Coolant Temp SHUTDOWN PWM Fan NONE Min MPG N/A Coolant Level SHUTDOWN Dynamic Brk NO Max MPH 0 Coolant Pressure DISABLED Conv. Factor N/A R1 Coolant Prs Engine Brakes NONE Calc. Type N/A Crankcase Prs DISABLED Eng Brake Cruise NO Override YES Eng Brake Low 2 Intercool Temp DISABLED Increment 1 Oil Press SHUTDOWN Override YES Data Pages YES Oil Temp SHUTDOWN Optimized Idle NO R1 Oil Temp Fan Timer 180 SEC Aux Stop 1 SHUTDOWN Aux Stop 2 SHUTDOWN Full Power Override NO Vehicle Speed Sensor NO Cruise Control NO Press Gov System NO VSS Sensor Type Auto Resume Cavitation Timeout VSS Signal Type Min Speed Pump Press Incr Num Teeth Max Speed Eng Spd Incr Tire Rev/Mile Integral Gain Axle Ratio ATI Port NONE Prop Gain Final Gear Ratio Vehicle Speed Limit NO Digital Torque Curve 1 Max Speed Starter Lockout Enable Speed 500 Overspeed with Fuel Starter Lockout Disable Speed 60 Overspeed w/o Fuel PROGRESSIVE SHIFT NO Low Gear #1 Max MPH Max RPM Turn-off RPM Low Gear #2 Max MPH Max RPM Turn-off RPM High Gear Max MPH Max RPM Air Comp. System YES R1 Min Pressure 60 R1 Max Pressure 135 Load Pressure 7 R2 Min Pressure 60 R2 Max Pressure 150 Unload Pressure 14 R3 Min Pressure 30 R3 Max Pressure 60 Pressure Increment 4 % Integral Gain 64 Prop Gain 32 PIN E1 F1 G1 H1 J1 F2 G2 H2 J2 K2 G3 K3 8-16 WIRE# #451 #542 #528 #523 #541 #544 #543 #524 #531 #583 #545 #979 Fn 00 35 00 12 00 13 00 00 22 00 20 00 NONE AIR LOAD SWITCH NONE RATING SWITCH #1 NONE RATING SWITCH #2 NONE NONE RESUME/ACCEL ON NONE SET/COAST ON NONE VIH PIN A1 A2 F3 Wire# #988 #555 #499 Fn 00 00 21 Reverse Polarity NO NO FUNCTION NO NO FUNCTION NO AIR COMP SOLENOID ESH PIN W3 X3 Y3 Wire# #563 #564 #565 Fn 00 00 00 Reverse Polarity NO NO FUNCTION NO NO FUNCTION NO NO FUNCTION All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8.5 TYPICAL INDUSTRIAL APPLICATION - ON-HIGHWAY CRANE This section contains typical parameter settings for on-highway crane applications and the pin assignments for the Vehicle Interface Harness and the Engine Sensor Harness as listed in the Verification Report on the following pages. The Digital Input and Digital Output ports can be configured for a variety of software options. The location of the connector pin for each software option can be specified at the time of engine order, by VEPS or the Distributor Reprogramming Station. For more information on software options, refer to section 4.1, "Digital Inputs" and section 4.2, "Digital Outputs." All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-17 APPLICATIONS DATE: VERIFICATION REPORT SALES ORDER NUMBER: ---------------------------------------------------------------------------------------------------------DDEC III/IV ENGINE SUMMARY Series I60 DDEC Appl Group 06N04C0760 DDEC IV CRANE W/JAKE EPL Base group 06N04D6431 370-430 HP STD RAT 1999 LINE HAUL 11L S60 Hp Group 06N04M7103 400HP@2100RPM 1053 1999 LINE HAUL TRK 12L S60 (1450FTLB) PWM Trans 0 VSG Cruise Switch Init Speed RPM Increment NO 1000 25 IDLE SHUTDOWN NO Maximum Security Minimum Security ENGINE PROTECTION Coolant Temp Coolant Level Coolant Pressure R1 Coolant Prs Crankcase Prs Override Intercool Temp Oil Press Override Oil Temp R1 Oil Temp Aux Stop 1 Aux Stop 2 Vehicle Speed Sensor VSS Sensor Type VSS Signal Type Num Teeth Tire Rev/Mile Axle Ratio Final Gear Ratio Vehicle Speed Limit Max Speed Overspeed with Fuel Overspeed w/o Fuel PROGRESSIVE SHIFT Low Gear #1 Max MPH Low Gear #2 Max MPH High Gear Max MPH Air Comp. System Load Pressure Unload Pressure Pressure Increment NO NO PIN E1 F1 G1 H1 J1 F2 G2 H2 J2 K2 G3 K3 8-18 WIRE# #451 #542 #528 #523 #541 #544 #543 #524 #531 #583 #545 #979 Fn 01 02 18 23 20 22 17 12 13 25 16 09 WARNING WARNING DISABLED DISABLED YES DISABLED WARNING YES WARNING WARNING WARNING YES TRANS MAGNETIC 16 501 5.87 1.0 NO VSG Max RPM VSG Min RPM VSG Alt Min RPM VSG is Primary 2100 700 1500 NO Hot Idle Cold Idle Max Droop LSG Droop VSG Droop Time Operates On Override Min Temp Digital Fan PWM Fan Dynamic Brk Engine Brakes Eng Brake Cruise Eng Brake Low Increment 5 MIN IDLE & VSG GOVERNOR ONLY NO 75 DEGC Max Temp 75 DEGC SINGLE FUEL ECONOMY INCENTIVE NONE Min MPG N/A NO Max MPH 0 Conv. Factor N/A JAKE Calc. Type N/A YES 5 2 Data Pages Optimized Idle Fan Timer YES NO 180 SEC Full Power Override Cruise Control AutoResume Min Speed Max Speed NO YES YES 30 60 ATI Port NONE Press Gov System Cavitation Timeout Pump Press Incr Eng Spd Incr Integral Gain Prop Gain Digital Torque Curve Starter Lockout Enable Speed Starter Lockout Disable Speed 1 500 60 Max RPM Max RPM Max RPM R1 Min Pressure R2 Min Pressure R3 Min Pressure % Integral Gain Turn-off RPM Turn-off RPM 700 2500 125 100 0 NO NO NO ENGINE BRAKE LOW ENGINE BRAKE MED CLUTCH RELEASED CRUISE ENABLE SET/COAST ON RESUME/ACCEL ON SERVICE BRAKE RELEASED RATING SWITCH #1 RATING SWITCH #2 SEO/DIAGNOSTIC REQUEST ALT MIN VSG/FAST IDLE THROTTLE INHIBIT R1 Max Pressure R2 Max Pressure R3 Max Pressure Prop Gain VIH PIN A1 F3 A2 Wire# #988 #555 #499 Fn 00 24 13 Reverse Polarity NO NO FUNCTION NO ETHER START YES FAN CONTROL #1 ESH PIN W3 X3 Y3 Wire# #563 #564 #565 Fn 00 00 00 Reverse Polarity NO NO FUNCTION NO NO FUNCTION NO NO FUNCTION All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8.6 TYPICAL GENSET APPLICATIONS This section contains typical Verification Reports parameter settings and pin assignments for generator sets. For 1,500 RPM genset applications, refer to section 8.6.1 and for 1,800 RPM genset applications, refer to section 8.6.2. For more detailed information on the engine governors, refer to section , "Throttle Control/Governors." 8.6.1 1,500 RPM GENSET The Verification Report on the following pages contains typical parameter settings for 1,500 RPM genset applications, the pin assignments for the Vehicle Interface Harness and the Engine Sensor Harness. The Digital Input and Digital Output ports can be configured for a variety of software options. The location of the connector pin for each software option can be specified at the time of engine order, by VEPS or the Distributor Reprogramming Station. For more information on software options, refer to section 4.1, "Digital Inputs" and section 4.2, "Digital Outputs." All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-19 APPLICATIONS DATE: VERIFICATION REPORT SALES ORDER NUMBER: ---------------------------------------------------------------------------------------------------------DDEC III/IV ENGINE SUMMARY Series S2000 DDEC Appl Group 06N04C0742 APPLCATION DDEC IIV GEN SET 1500 RPM Base group 06N04D0377 730 HP STD RATING 1997 12V S2000 INDUSTRIAL Hp Group 06N04M1169 730HP@1500RPM 8413 1997 DDEC III INDUSTRIAL S2000 PWM Trans 0 VSG Cruise Switch Init Speed RPM Increment NO 1000 25 IDLE SHUTDOWN NO Maximum Security Minimum Security ENGINE PROTECTION Coolant Temp Coolant Level Coolant Pressure R1 Coolant Prs Crankcase Prs Override Intercool Temp Oil Press Override Oil Temp R1 Oil Temp Aux Stop 1 Aux Stop 2 Vehicle Speed Sensor VSS Sensor Type VSS Signal Type Num Teeth Tire Rev/Mile Axle Ratio Final Gear Ratio Vehicle Speed Limit Max Speed Overspeed with Fuel Overspeed w/o Fuel PROGRESSIVE SHIFT Low Gear #1 Max MPH Low Gear #2 Max MPH High Gear Max MPH Air Comp. System Load Pressure Unload Pressure Pressure Increment NO NO PIN E1 F1 G1 H1 J1 F2 G2 H2 J2 K2 G3 K3 8-20 WIRE# #451 #542 #528 #523 #541 #544 #543 #524 #531 #583 #545 #979 Fn 00 16 00 00 00 00 00 25 00 00 00 00 SHUTDOWN SHUTDOWN DISABLED DISABLED DISABLED YES DISABLED SHUTDOWN YES WARNING DISABLED WARNING WARNING NO NO VSG Max RPM VSG Min RPM VSG Alt Min RPM VSG is Primary 1575 1425 1500 YES Hot Idle Cold Idle Max Droop LSG Droop VSG Droop Time Operates On Override Min Temp Digital Fan PWM Fan Dynamic Brk Engine Brakes Eng Brake Cruise Eng Brake Low Increment 5 MIN IDLE GOVERNOR ONLY NO 75 DEGC Max Temp 75 DEGC SINGLE FUEL ECONOMY INCENTIVE NONE Min MPG N/A NO Max MPH 0 Conv. Factor N/A NONE Calc. Type N/A NO 2 1 Data Pages Optimized Idle Fan Timer YES NO 180 SEC Full Power Override Cruise Control Auto Resume Min Speed Max Speed NO NO ATI Port NONE Press Gov System Cavitation Timeout Pump Press Incr Eng Spd Incr Integral Gain Prop Gain Digital Torque Curve Starter Lockout Enable Speed Starter Lockout Disable Speed 1 500 60 Max RPM Max RPM Max RPM R1 Min Pressure R2 Min Pressure R3 Min Pressure % Integral Gain Turn-off RPM Turn-off RPM 600 2500 120 120 0 NO NO NO NONE ALT MIN VSG/FAST IDLE NONE NONE NONE NONE NONE SEO/DIAGNOSTIC REQUEST NONE NONE NONE NONE R1 Max Pressure R2 Max Pressure R3 Max Pressure Prop Gain VIH PIN A1 A2 F3 Wire# #988 #555 #499 Fn 18 13 00 Reverse Polarity NO OIL PRESSURE LOW LIGHT YES FAN CONTROL #1 NO NONE ESH PIN W3 X3 Y3 Wire# #563 #564 #565 Fn 19 00 20 Reverse Polarity NO OIL TEMP HIGH LIGHT NO NO FUNCTION NO COOLANT TEMP HIGH LIGHT All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8.6.2 1,800 RPM GENSET The Verification Report on the following pages contains typical parameter settings for 1,800 RPM genset applications, the pin assignments for the Vehicle Interface Harness and the Engine Sensor Harness. The Digital Input and Digital Output ports can be configured for a variety of software options. The location of the connector pin for each software option can be specified at the time of engine order, by VEPS or the Distributor Reprogramming Station. For more information on software options, refer to section 4.1, "Digital Inputs" and section 4.2, "Digital Outputs." All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-21 APPLICATIONS DATE: VERIFICATION REPORT SALES ORDER NUMBER: ---------------------------------------------------------------------------------------------------------DDEC III/IV ENGINE SUMMARY Series S2000 DDEC Appl Group 06N04C0725 APPLICATION DDEC IV GEN SET 1800 RPM Base group 06N04D0376 910 HP STD RATING 1997 12V S2000 INDUSTRIAL Hp Group 06N04M1168 910HP@1800RPM 8412 1997 DDEC III INDUSTRIAL S2000 PWM Trans 0 VSG Cruise Switch Init Speed RPM Increment NO 1000 25 IDLE SHUTDOWN NO Maximum Security Minimum Security ENGINE PROTECTION Coolant Temp Coolant Level Coolant Pressure R1 Coolant Prs Crankcase Prs Override Intercool Temp Oil Press Override Oil Temp R1 Oil Temp Aux Stop 1 Aux Stop 2 Vehicle Speed Sensor VSS Sensor Type VSS Signal Type Num Teeth Tire Rev/Mile Axle Ratio Final Gear Ratio Vehicle Speed Limit Max Speed Overspeed with Fuel Overspeed w/o Fuel PROGRESSIVE SHIFT Low Gear #1 Max MPH Low Gear #2 Max MPH High Gear Max MPH Air Comp. System Load Pressure Unload Pressure Pressure Increment NO NO PIN E1 F1 G1 H1 J1 F2 G2 H2 J2 K2 G3 K3 8-22 WIRE# #451 #542 #528 #523 #541 #544 #543 #524 #531 #583 #545 #979 Fn 00 16 00 00 00 00 00 00 00 00 25 00 SHUTDOWN SHUTDOWN DISABLED DISABLED DISABLED YES DISABLED SHUTDOWN YES WARNING DISABLED WARNING WARNING NO NO VSG Max RPM VSG Min RPM VSG Alt Min RPM VSG is Primary 1890 1710 1800 YES Hot Idle Cold Idle Max Droop LSG Droop VSG Droop Time Operates On Override Min Temp Digital Fan PWM Fan Dynamic Brk Engine Brakes Eng Brake Cruise Eng Brake Low Increment 5 MIN IDLE GOVERNOR ONLY NO 75 DEGC Max Temp 75 DEGC SINGLE FUEL ECONOMY INCENTIVE NONE Min MPG N/A NO Max MPH 0 Conv. Factor N/A NONE Calc. Type N/A NO 2 1 Data Pages Optimized Idle Fan Timer YES NO 180 SEC Full Power Override Cruise Control Auto Resume Min Speed Max Speed NO NO ATI Port NONE Press Gov system Cavitation Timeout Pump Press Incr Eng Spd Incr Integral Gain Prop Gain Digital Torque Curve Starter Lockout Enable Speed Starter Lockout Disable Speed 1 500 60 Max RPM Max RPM Max RPM R1 Min Pressure R2 Min Pressure R3 Min Pressure % Integral Gain Turn-off RPM Turn-off RPM 600 2500 120 120 0 NO NO NO NONE ALT MIN VSG/FAST IDLE NONE NONE NONE NONE NONE NONE NONE NONE SEO/DIAGNOSTIC REQUEST NONE R1 Max Pressure R2 Max Pressure R3 Max Pressure Prop Gain VIH PIN A1 A2 F3 Wire# #988 #555 #499 Fn 18 13 20 Reverse Polarity NO OIL PRESSURE LOW LIGHT YES FAN CONTROL #1 NO COOLANT TEMP HIGH LIGHT ESH PIN W3 X3 Y3 Wire# #563 #564 #565 Fn 19 00 00 Reverse Polarity NO OIL TEMP HIGH LIGHT NO NO FUNCTION NO NO FUNCTION All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8.7 TYPICAL FIRE TRUCK APPLICATION This section contains typical parameter settings for Fire Truck applications and the pin assignments for the Vehicle Interface Harness and the Engine Sensor Harness as listed in the Verification Report on the following pages. The Digital Input and Digital Output ports can be configured for a variety of software options. The location of the connector pin for each software option can be specified at the time of engine order, by VEPS or the Distributor Reprogramming Station. For more information on software options, refer to section 4.1, "Digital Inputs" and section 4.2, "Digital Outputs." All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-23 APPLICATIONS DATE: VERIFICATION REPORT SALES ORDER NUMBER: --------------------------------------------------------------------------------------------------------DDEC III ENGINE SUMMARY Series DDEC Appl Group 06N04C0507 DDEC III/IV APPL FIRETRUCK W/PGS/EOP OFF JB I60 Base group 06N04D6429 470/500 HP PREM RAT 1999 DDEC IV LINE HAUL 12L S60 Hp Group 06N04M7095 470HP@2100RPM 1045 1999 LINE HAUL PREM 12L S60 (155OFTLB) PWM Trans 12 ALLISON WT VSG Max RPM 2100 Hot Idle 600 VSG Cruise Switch NO VSG Min RPM 600 Cold Idle 750 Init Speed 1000 VSG Alt Min RPM 600 Max Droop 150 RPM Increment 25 VSG is Primary NO LSG Droop 125 VSG Droop 0 IDLE SHUTDOWN NO Time 5 MIN Operates On IDLE GOVERNOR ONLY Maximum Security NO Override NO Minimum Security NO Min Temp 75 DEGC Max Temp 75 DEGC ENGINE PROTECTION Digital Fan SINGLE FUEL ECONOMY INCENTIVE Coolant Temp WARNING PWM Fan NONE Min MPG N/A Coolant Level WARNING Dynamic Brk NO Max MPH 0 Coolant Pressure DISABLED Conv. Factor N/A R1 Coolant Prs Engine Brakes JAKE Calc. Type N/A Crankcase Prs DISABLED Eng Brake Cruise NO Override YES Eng Brake Low 2 Intercool Temp DISABLED Increment 1 Oil Press WARNING Override YES Data Pages NO Oil Temp WARNING Optimized Idle NO R1 Oil Temp Fan Timer 180 SEC Aux Stop 1 WARNING Aux Stop 2 WARNING Full Power Override NO Vehicle Speed Sensor NO Cruise Control NO Press Gov system YES VSS Sensor Type AutoResume Cavitation Timeout 5 VSS Signal Type Min Speed Pump Press Incr 4 Num Teeth Max Speed Eng Spd Incr 25 Tire Rev/Mile Integral Gain 10 Axle Ratio ATI Port NONE Prop Gain .75 Final Gear Ratio Vehicle Speed Limit NO Digital Torque Curve 1 Max Speed Starter Lockout Enable Speed 500 Overspeed with Fuel Starter Lockout Disable Speed 60 Overspeed w/o Fuel PROGRESSIVE SHIFT NO Low Gear #1 Max MPH Max RPM Turn-off RPM Low Gear #2 Max MPH Max RPM Turn-off RPM High Gear Max MPH Max RPM Air Comp. System NO R1 Min Pressure R1 Max Pressure Load Pressure R2 Min Pressure R2 Max Pressure Unload Pressure R3 Min Pressure R3 Max Pressure Pressure Increment % Integral Gain Prop Gain PIN E1 F1 G1 H1 J1 F2 G2 H2 J2 K2 G3 K3 8-24 WIRE# #451 #542 #528 #523 #541 #544 #543 #524 #531 #583 #545 #979 Fn 15 16 00 08 20 26 24 09 05 02 22 01 DIAGNOSTIC REQUEST ALT MIN VSG/FAST IDLE NONE PRESSURE/RPM MODE SET/COAST ON ENGINE BRAKE DISABLE PGS SYSTEM ENABLE THROTTLE INHIBIT PARK BRAKE INTERLOCK ENGINE BRAKE MED RESUME/ACCEL ON ENGINE BRAKE LOW VIH PIN A1 A2 F3 Wire# #988 #555 #499 Fn 16 11 05 Reverse Polarity NO ENGINE BRAKE ACTIVE NO CRUISE ACTIVE LIGHT NO PGS ACTIVE LIGHT ESH PIN W3 X3 Y3 Wire# #563 #564 #565 Fn 10 08 07 Reverse Polarity NO COOLANT LEVEL LOW LIGHT NO EXT BRAKE ENABLE NO STARTER LOCKOUT All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8.8 DDEC REQUIREMENTS FOR GASEOUS HAZARDOUS ENVIRONMENTS A hazardous environment DDEC package has been developed that meets North American, European, and Asian hazardous environment certification requirements. The DDEC system has been certified for operation in Class 1 Division 2 or Group II Zone 2 (Category 3) hazardous gaseous environments for all gas groups. The means used to obtain compliance vary somewhat between engine series due to engine hardware differences. Engine series currently available for Class I Division 2 and Group II Zone 2 hazardous environments include Series 60, Series 50 and Series 2000. The information provided is necessary to install a DDEC IV engine certified and/or listed for Class 1 Division 2 or Group II Zone 2 (Category 3) categories hazardous environments. The information is intended to supplement current DDEC requirements as listed in this manual. This section is written for those familiar with hazardous environment applications. It is the responsibility of the installer to procure the standards that are discussed in this section in order to ensure their compliance with the appropriate standard. Explosion Hazard — Substitution of components may impair suitability for Class 1 Division 2. UL1604 Explosion Hazard — Do not connect or disconnect equipment unless power has been switched off or the area is known to be non-hazardous. Explosion Hazard — Substitution of components may impair suitability for Group II Zone 2 (Category 3). EN 50021, EN 50014, and EN 50028 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-25 APPLICATIONS 8.8.1 HAZARDOUS GASEOUS ENVIRONMENT OVERVIEW The following information should be used to provide a broad overview of Hazardous Environments only, it is not intended to be a definitive reference guide. Hazardous Environment Classification - North America Class I: Hazardous location due to the presence of flammable substances such as gases or vapors. Division 1: Danger can be present during normal functioning, during repair or maintenance, or where a fault may cause the simultaneous failure of electrical equipment. Division2: Combustible material is present but confined to a closed container or system, or an area adjacent to a Division 1 location. Hazardous Environment Classification - Europe Group II: Hazardous location due to the presence of flammable substances such as gases or vapors. Zone 1 (Category 2): An area in which an explosive air/gas mixture is LIKELY to occur in normal operation. Zone 2 (Category 3): An area in which an explosive air/gas mixture is UNLIKELY to occur; but, if it does, only for short periods of time. Gas Classification Gas classifications are made on the basis of the gas or vapors ease of ignition. North America: Groups A - D A Is Most Stringent (readily ignitable) D Is Least Stringent ( more difficult to ignite) Europe: Groups C - A C Is Most Stringent (readily ignitable) A Is Least Stringent ( more difficult to ignite) Refer to section 3.18 for the DDC-supplied hardware IP code. Ingress Protection Ingress protection specifies the degree of protection: From contact with live or moving parts Against the intrusion of solid foreign bodies or liquid into a component The codes for the level of protection is listed in Table 8-4. 8-26 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Degree of Protection Solid Bodies Degree of Protection 0 No Protection 0 No Protection 1 Objects > 50 mm 1 Vertically Dripping Water 2 Objects > 12mm 2 Angled Dripping Water 3 Objects > 2.5 mm 3 Sprayed Water 4 Objects > 1.0 mm 4 Splashed Water 5 Dust Protected 5 Water Jets 6 Dust Tight 6 Heavy Seas 7 Effects of Immersion 8 Indefinite Immersion Table 8-4 Liquid Ingress Protection Codes Example: Protection degree is specified by a code such as IP64. The first numeral (6) defines the degree of protection against contact with live or moving parts and against the intrusion of solid foreign bodies. The second numeral (4) defines the degree of protection against the intrusion of liquid. Therefore, IP64 is a dust tight device that is resistant to splashed water. Temperature Classification The maximum surface temperature must be lower than the minimum ignition temperature of the gas present. Temperature classifications are listed in Table 8-5. Maximum Surface Temperature ( C) Temperature Classification 450 C T1 300 C T2 200 C T3 135 C T4 100 C T5 85 C T6 Table 8-5 Temperature Classification Detroit Diesel provides two options, which have been certified by both Nemko and Underwriters Laboratories for use in Group II Zone 2 (Category 3) and Class 1 Division 2 for all types of combustible gases. Refer to section 8.8.2 for certification information. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-27 APPLICATIONS 8.8.2 DDEC IV SYSTEM CERTIFICATION Detroit Diesel has been awarded Class I Division 2 and Group II Zone 2 (Category 3) certification for the DDEC IV System for all gas groups. Class I Division 2 Certification The DDEC IV System has been investigated by Underwriters Laboratories Inc.® in accordance with the following standards for safety as indicated on the certificate of compliance (see Figure 8-1): UL 508 UL 1604 CSA C22.2 No. 14 CSA C22.2 No. 213 A copy of these standards can be obtained from Underwriters Laboratories Inc. 8-28 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 8-1 Certificate of Compliance from Underwriters Laboratories Inc. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-29 APPLICATIONS Group II Zone 2 (Category 3) Certification Detroit Diesel has been awarded the product conformity certificates for the DDEC IV System by Nemko®, the Test Laboratory accredited by the Norwegian Metrology and Accreditation Service, for compliance with the following harmonized European Standard(s): CENELEC EN 50021: 1999 for the DDEC IV Electronic Control Module (see Figure 8-2and Figure 8-3) CENELEC EN 50019; 1994 and CENELEC EN 50014; 1997 + A1:1999 + A2:1999 for the top of the cylinder head with rocker cover (see Figure 8-4, Figure 8-5 and Figure 8-6) CENELEC EN 50014; 1997 + A1:1999 + A2:1999 and CENELEC EN 50019; 1994 and CENELEC EN 50028; 1987 for the Electronic Unit Injector (EUI) and the Electronic Unit Pump (EUP) (see Figure 8-7 and Figure 8-8) The DDEC IV System and electronic components have been certified for the Group II Zone 2 (Category 3) T4, and Groups A, B, and C hazardous environments. Detroit Diesel has been awarded the Type Approval Certificate for the DDEC IV System by Det Norske Veritas (DNV) for compliance with Det Norske Veritas Rules for Classification of Ships and Mobile Offshore Units (see Figure 8-9, Figure 8-10, Figure 8-11). 8-30 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 8-2 Nemko Component Certificate for ECM All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-31 APPLICATIONS Figure 8-3 8-32 Annex for Nemko Component Certificate for ECM All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 8-4 Nemko Component Certificate for Diesel Engine Top of Cylinder Head with Rocker Cover for Series 60 and Series 50 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-33 APPLICATIONS Figure 8-5 8-34 Annex for Nemko Component Certificate for Diesel Engine Top of Cylinder Head with Rocker Cover for Series 60 and Series 50 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 8-6 Supplement 1 for Nemko Component Certificate for Diesel Engine Top of Cylinder Head with Rocker Cover for Series 60 and Series 50 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-35 APPLICATIONS Figure 8-7 8-36 Nemko Component Certificate for EUI and EUP Solenoids All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 8-8 Annex for Nemko Component Certificate for EUI and EUP Solenoids All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-37 APPLICATIONS Figure 8-9 8-38 DNV Type Approval Certificate, Page 1 of 3 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 8-10 DNV Type Approval Certificate, Page 2 of 3 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-39 APPLICATIONS Figure 8-11 8-40 DNV Type Approval Certificate, Page 3 of 3 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8.8.3 PRODUCT MARKINGS The certified system and/or components must have labels that identify the system/components as certified. The labels needed are listed in Table 8-6. Hazardous Environment Classification Class I Division 2 Group II Zone 2 (Category 3) Group II Zone 2 (Category 3) Group II Zone 2 (Category 3) Group II Zone 2 (Category 3) Group II Zone 2 (Category 3) Table 8-6 Placement DDEC IV ECM (see Figure 8-12) DDEC IV ECM (see Figure 8-13) Top of the Cylinder Head with the Aluminum Rocker Cover (Series 60/Series 50 only) (see Figure 8-14) Top of the Cylinder Head with the Vinyl Rocker Cover (Series 60 only) (see Figure 8-15) DDEC IV ECM (see Figure 8-16) Top of the Cylinder Head with the Vinyl Rocker Cover (Series 60 only) (see Figure 8-17) Part Number 23528426 23528451 23528427 23528955 23528908 23528907 Temperature Classification Class I Division 2 This label for the ECM has a UL Recognized Component marking for the U.S. and Canada which includes the "US" and "C" identifiers, UL Recognized Component symbol, and Detroit Diesel's product designation "Detroit Diesel Electronic Control System (DDEC IV)" (see Figure 8-12). The part number is 23528426 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-41 APPLICATIONS Figure 8-12 Class 1 Division 2 UL Label for the ECM Group II Zone 2 (Category 3) There are five Group II Zone 2 (Category 3) labels with specific codes to be placed on the following components: DDEC IV ECM: EEx nAL IIC T4 (see Figure 8-13) - P/N: 23528451 Diesel Engine Top of the Cylinder Head with Aluminum Rocker Cover (Series 60 and Series 50): EEx em II T4 (see Figure 8-14) - P/N: 23528427 Diesel Engine Top of the Cylinder Head with Vinyl Rocker Cover (Series 60): EEx em II T4 (see Figure 8-15) - P/N: 23528955 DDEC IV ECM Warning (see Figure 8-16) - P/N: 23528908 Diesel Engine Top of Cylinder Head with Vinyl Rocker Cover (Series 60) Warning (see Figure 8-17) - P/N: 23528907 8-42 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 8-13 Group II Zone 2 (Category 3) DDEC IV ECM Label Figure 8-14 Group II Zone 2 (Category 3) Top of the Cylinder Head with Aluminum Rocker Cover Label — Series 60 and Series 50 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-43 APPLICATIONS Figure 8-15 Group II Zone 2 (Category 3) Top of the Cylinder Head with Vinyl Rocker Cover Label — Series 60 Figure 8-16 DDEC IV ECM Warning Label 8-44 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure 8-17 Diesel Engine Top of the Cylinder Head with Vinyl Rocker Cover Warning Label – Series 60 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-45 APPLICATIONS 8.8.4 APPLICABLE STANDARDS The following standards are applicable to Division 2 and to Zone 2. Class I Division 2 UL 508-Industrial Control Equipment UL 1604 - Electrical Equipment for Use in Class I and II, Division 2, and Class III Hazardous (Classified) Locations CSA C22.2 No. 14 CSA C22.2 No. 213 Group II Zone 2 (Category 3) CENELEC EN 50014; 1997 + A1:1999 + A2:1999 Electrical apparatus for potentially explosive atmospheres – General Requirements CENELEC EN 50021; 1999 Electrical apparatus for potentially explosive atmospheres – TYPE N CENELEC EN 50019; 1994 Electrical apparatus for potentially explosive atmospheres Increased safety ‘e' CENELEC EN 50028; 1987 Electrical apparatus for potentially explosive atmospheres Part 8. Encapsulation ‘m' 8.8.5 TEMPERATURES Ambient Temperature rating for DDEC System: -40 C ≤ Ta ≤ +55 C. DDEC engines shall not be installed in environments requiring temperature classifications exceeding T4 (i.e. T5 or T6). 8-46 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 8.9 TYPICAL INDUSTRIAL APPLICATION - HAZARDOUS ENVIRONMENT PETROLEUM This section contains typical parameter settings for a Series 60 hazardous environment petroleum industrial application. The pin assignments for the Vehicle Interface Harness and the Engine Sensor Harness are listed in the Verification Report on the following pages. Many ACS/6N4C groups can be used for Hazardous Environment Petroleum applications depending on customer requirements. However, a unique ACS/6N4C group, 06N04C0784, has been created for Series 60 Offshore for Hazardous Environments. 8.9.1 HAZARDOUS ENVIRONMENT PETROLEUM UNIQUE 6N4C GROUP The unique 06N04C0784 group includes: Engine Overtemperature Protection Exhaust Temperature Sensor Configuration Engine Overspeed Digital Output High Coolant Temperature Light and Low Oil Pressure Light Digital Outputs Engine Overtemperature Protection (EOP) is additional logic programmed into the ECM and used in conjunction with standard temperature protection. When EOP is part of the engine calibration, engine power and /or speed is reduced as a function of temperature. The CEL illuminates and a fault code is logged when the EOP calibrated temperature is reached. If the temperature does not decrease as power/speed is reduced, the SEL will illuminate when a still higher temperature is reached. The subsequent action taken by the ECM depends on customer selection of one of the following: Warning Only 30 Second Rampdown Shutdown Power reduction is based on the average power/speed in use prior to the fault condition. Refer to section 4.1.3, "Engine Protection," for more information. Exhaust Temperature Sensor configuration is included in 06N04C0784. The DDEC Exhaust Temperature Sensor, available in an OEM installed kit, has previously been available for certain applications such as buses. The Exhaust Temperature Sensor configuration for hazardous environments is available only as part of the unique 06N04C0784 group. The Exhaust Temperature Sensor helps prevent damage by providing early warning of excessive exhaust temperature. The Exhaust Temperature Sensor, placed in the exhaust gas cooler of a hazardous environment DDEC engine, will provide torque reduction if the exhaust gas temperature approaches 200 C. The torque reduction may bring the exhaust temperature down low enough for the operator to continue running the engine and complete a job. If the temperature does not drop below 200 C, DDEC will shut down the engine. Refer to section 3.14.22, "Exhaust Temperature Sensor," for installation information. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-47 APPLICATIONS The Engine Overspeed digital output provides a signal when a calibrated enable engine speed is exceeded. The digital output remains grounded until the engine speed reaches or drops below another calibrated speed. The battery ground output signal can be used to drive a warning light or alarm and/or control a shutdown device. A code will be logged. The enable speed is set to 2310 rpm and the disable speed is set to 600 rpm. Refer to section 4.2, "Digital Outputs," for additional information. The digital output for a High Coolant Temperature Light is switched to battery ground with the CEL when the coolant temperature is above the Check Engine Code value (212 F). The Low Oil Pressure Light digital output is switched to battery ground with the CEL and SEL when the oil pressure is below the Stop Engine Code value. Refer to section 4.2 , "Digital Outputs," for additional information. The Digital Input and Digital Output ports can be configured for a variety of additional software options. The location of the connector pin for each software option can be specified at the time of engine order, by the Vehicle Electronic Programming System (VEPS) or the DDEC Reprogramming Station. For more information on software options, refer to section 4.1, "Digital Inputs," and section 4.2, "Digital Outputs." 8-48 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL DATE: VERIFICATION REPORT SALES ORDER NUMBER: ---------------------------------------------------------------------------------------------------------DDEC III/IV ENGINE SUMMARY Series DDEC Appl Group 06N04C0784 DDEC III/IV APPL OFF-HWY WITH LSG ONLY S60 I60 Base group 06N04D7067 500 HP PREMIUM RAT 2000 DDEC IV WAT CLD INDST S60 Hp Group 06N04M7303 500HP@2100RPM 5030 2000 DDEC IV WAT CLD INDST S60 (1650 FTLB) PWM Trans Manual VSG Max RPM 2100 Hot Idle 600 VSG Cruise Switch NO VSG Min RPM 600 Cold Idle 700 Init Speed 1000 VSG Alt Min RPM 600 Max Droop 150 RPM Increment 25 VSG is Primary YES LSG Droop 150 VSG Droop 125 IDLE SHUTDOWN NO Time 5 MIN Operates On IDLE GOVERNOR ONLY Maximum Security NO Override NO Minimum Security NO Min Temp 75 DEGC Max Temp 75 DEGC ENGINE PROTECTION Digital Fan NONE FUEL ECONOMY INCENTIVE Coolant Temp RAMPDOWN PWM Fan NONE Min MPG N/A Coolant Level RAMPDOWN Dynamic Brk NO Max MPH 0 Coolant Pressure Conv. Factor N/A R1 Coolant Prs Engine Brakes NONE Calc. Type N/A Crankcase Prs DISABLED Eng Brake Cruise NO Override YES Eng Brake Low 2 Intercool Temp DISABLED Increment 1 Oil Press RAMPDOWN Override YES Data Pages YES Oil Temp RAMPDOWN Optimized Idle NO R1 Oil Temp Fan Timer 180 SEC Aux Stop 1 SHUTDOWN Aux Stop 2 RAMPDOWN Full Power Override YES Vehicle Speed Sensor NO Cruise Control NO Press Gov System NO VSS Sensor Type Auto Resume Cavitation Timeout VSS Signal Type Min Speed Pump Press Incr Num Teeth Max Speed Eng Spd Incr Tire Rev/Mile Integral Gain Axle Ratio ATI Port NONE Prop Gain Final Gear Ratio Vehicle Speed Limit NO Digital Torque Curve 1 Max Speed Starter Lockout Enable Speed 500 Overspeed with Fuel Starter Lockout Disable Speed 60 Overspeed w/o Fuel PROGRESSIVE SHIFT NO Low Gear #1 Max MPH Max RPM Turn-off RPM Low Gear #2 Max MPH Max RPM Turn-off RPM High Gear Max MPH Max RPM Air Comp. System NO R1 Min Pressure R1 Max Pressure Load Pressure R2 Min Pressure R2 Max Pressure Unload Pressure R3 Min Pressure R3 Max Pressure Pressure Increment % Integral Gain Prop Gain PIN E1 F1 G1 H1 J1 F2 G2 H2 J2 K2 G3 K3 WIRE# #451 #542 #528 #523 #541 #544 #543 #524 #531 #583 #545 #979 Fn 00 00 25 00 00 03 00 04 33 34 00 20 NONE NONE SEO/DIAGNOSTIC REQUEST NONE NONE AUX SHUTDOWN #1 NONE AUX SHUTDOWN #2 VSG STATION CHANGE VSG STATION COMPLEMENT NONE NONE VIH PIN A1 A2 F3 Wire# #988 #555 #499 Fn 00 00 00 Reverse Polarity NO NO FUNCTION NO NO FUNCTION NO NO FUNCTION ESH PIN W3 X3 Y3 Wire# #563 #564 #565 Fn 00 00 00 Reverse Polarity NO HIGH COOLANT TEMP NO LOW OIL PRESSURE NO ENGINE OVERSPEED SIGNAL All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION 8-49 APPLICATIONS THIS PAGE INTENTIONALLY LEFT BLANK 8-50 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL APPENDIX A: CODES The codelisted may not be used in all applications. A default value in the normal operating range is used by the ECM to provide for engine operation if a sensor failure is present. DDC Code # (Flashed) PID SID FMI -- 240 -- 2 Fram Checksum Incorrect -- 251 -- 10 Clock Module Abnormal Rate -- 251 -- 13 Clock Module Fault/Failure -- -- 253 13 Incompatible Calibration Version -- -- 254 0 External Failed RAM -- -- 254 1 Internal Failed RAM Description -- -- 254 6 Entered Boot Via Switches 11 187 -- 4 Variable Speed Governor Sensor Voltage Low 11 187 -- 7 Variable Speed Governor Switch System Not Responding 12 187 -- 3 Variable Speed Governor Sensor Voltage High 13 111 -- 4 Coolant Level Sensor Input Voltage Low 13 111 -- 6 Add Coolant Level Sensor Input Voltage Low 14 52 -- 3 Intercooler Coolant Temperature Sensor Input Voltage High 14 110 -- 3 Coolant Temperature Sensor Input Voltage High 14 175 -- 3 Oil Temperature Sensor Input Voltage High 15 52 -- 4 Intercooler Coolant Temperature Sensor Input Voltage Low 15 110 -- 4 Coolant Temperature Sensor Input Voltage Low 15 175 -- 4 Oil Temperature Sensor Input Voltage Low 16 111 -- 3 Coolant Level Sensor Input Voltage High 16 111 -- 5 Add Coolant Level Sensor Input Voltage High 17 72 -- 3 Throttle Plate Position Sensor Input Voltage High 17 51 -- 3 Throttle Position Sensor Input Voltage High 18 72 -- 4 Bypass Position Sensor Input Voltage Low 18 51 -- 4 Throttle Plate Position Sensor Input Voltage Low 21 91 -- 3 Throttle Position Sensor Input Voltage High 22 91 -- 4 Throttle Position Sensor Input Voltage Low 23 174 -- 3 Fuel Temperature Sensor Input Voltage High 23 -- 65 3 Oxygen Content Circuit Input Voltage High 24 174 -- 4 Fuel Temperature Sensor Input Voltage Low 24 -- 65 4 Oxygen Content Circuit Input Voltage Low 25 -- -- -- Reserved for ‘‘No Codes" 26 -- 25 11 Aux. Shutdown #1 Active 26 -- 61 11 Aux. Shutdown #2 Active 27 171 -- 3 Ambient Air Temperature Sensor Input Voltage High (Release 2.00 or later only) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION A-1 APPENDIX A: CODES DDC Code # (Flashed) PID SID FMI 27 172 -- 3 27 105 -- 3 28 171 -- 4 28 172 -- 4 Air Temperature Sensor Input Voltage Low 28 105 -- 4 Intake Manifold Temperature Sensor Input Voltage Low 31 -- 51 3 Aux. Output #3 Open Circuit (High Side) - S3 31 -- 51 4 Aux. Output #3 Short To Ground (High Side) - S3 31 -- 51 7 Aux. Output #3 Mechanical System Fail - S3 31 -- 52 3 Aux. Output #4 Open Circuit (High Side) - T3 31 -- 52 4 Aux. Output #4 Short To Ground (High Side) - T3 31 -- 52 7 Aux. Output #4 Mechanical System Fail - T3 32 -- 238 4 SEL Open Circuit 32 -- 238 3 SEL Short to Battery (+) 32 -- 239 3 CEL Short to Battery (+) 32 -- 239 4 CEL Open Circuit 33 102 -- 3 Turbo Boost Pressure Sensor Input Voltage High 34 102 -- 4 Turbo Boost Pressure Sensor Input Voltage Low 35 100 -- 3 Oil Pressure Sensor Input Voltage High 35 19 -- 3 High Range Oil Pressure Sensor Input Voltage High 36 100 -- 4 Oil Pressure Sensor Input Voltage Low 36 19 -- 4 High Range Oil Pressure Sensor Input Voltage Low 37 94 -- 3 Fuel Pressure Sensor Input Voltage High 37 18 -- 3 High Range Fuel Pressure Sensor Input Voltage High 37 95 -- 3 Fuel Restriction Sensor Input Voltage High 38 94 -- 4 Fuel Pressure Sensor Input Voltage Low 38 18 -- 4 High Range Fuel Pressure Sensor Input Voltage Low 38 95 4 Fuel Restriction Sensor Input Voltage Low 39 -- 152 7 39 -- 153 7 41 -- 21 0 Too Many SRS (missing TRS) 42 -- 21 1 Too few SRS (missing SRS) 43 111 -- 1 Coolant Level Low 44 52 -- 0 Intercooler Coolant Temperature High 44 110 -- 0 Coolant Temperature High 44 172 -- 0 Air Inlet Temperature High 44 175 -- 0 Oil Temperature High 44 105 -- 0 Intake Manifold Temperature High 45 100 -- 1 Oil Pressure Low A-2 Description Air Temperature Sensor Input Voltage High Intake Manifold Temperature Sensor Input Voltage High Ambient Air Temperature Circuit Failed Low (Release 2.00 or later only) EGR Valve Not Responding (Release 29.0 or later) VNT Vanes Not Responding (Release 29.0 or later) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL DDC Code # (Flashed) PID SID FMI 45 19 -- 1 High Range Oil Pressure Low 46 168 -- 1 ECM Battery Voltage Low 46 -- 214 1 RTC Backup Battery Voltage Low (Release 29.0 or later) 46 -- 232 1 Sensor supply Voltage Low 47 94 -- 0 Fuel Pressure High 47 102 -- 0 Turbo Boost Pressure High 47 106 -- 0 Air Inlet Pressure High 47 164 -- 0 Injection Control Pressure High 47 18 -- 0 High Range Fuel Pressure High 48 18 -- 1 High Range Fuel Pressure Low 48 94 -- 1 Fuel Pressure Low 48 106 -- 1 Air Inlet Pressure Low 48 154 1 EGR Temperature Low (Release 29.0 or later) 48 155 1 EGR Delta Pressure Low (Release 29.0 or later) Description 48 164 -- 1 Injection Control Pressure Low 52 -- 254 12 A/D Conversion Fail 53 -- 253 2 Nonvolatile Checksum Incorrect 53 -- 253 12 EEPROM Write Error 53 -- 253 13 Out of Calibration 54 84 -- 12 Vehicle Speed Sensor Fault 55 -- 216 14 Other ECU Fault (Release 27.0 or later) (This fault is logged in conjunction with another fault to indicate missing information from another ECU.) 55 -- 231 12 J1939 Data Link Fault 55 -- 248 8 Proprietary Data Link Fault (Master) 55 -- 248 9 Proprietary Data Link Fault (Receiver) 56 -- 250 12 J1587 Data Link Fault 57 -- 249 12 J1922 Data Link Fault 58 92 -- 0 Torque Overload 61 -- xxx 0 Injector xxx Response Time Long 62 -- 26 3 Aux. Output #1 Short to Battery (+) - F3 62 -- 26 4 Aux. Output #1 Open Circuit - F3 62 -- 40 3 Aux. Output #2 Short to Battery (+) - A2 62 -- 40 4 Aux. Output #2 Open Circuit - A2 62 -- 53 3 Aux. Output #5 Short to Battery (+) - W3 62 -- 53 4 Aux. Output #5 Open Circuit - W3 62 -- 54 3 Aux. Output #6 Short to Battery (+) - X3 62 -- 54 4 Aux. Output #6 Open Circuit - X3 62 -- 55 3 Aux. Output #7 Short to Battery (+) - Y3 62 -- 55 4 Aux. Output #7 Open Circuit - Y3 62 -- 56 3 Aux. Output #8 Short to Battery (+) - A1 62 -- 56 4 Aux. Output #8 Open Circuit - A1 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION A-3 APPENDIX A: CODES DDC Code # (Flashed) PID SID FMI 62 -- 26 7 62 -- 40 7 62 -- 53 7 62 -- 54 7 62 -- 55 7 62 -- 56 7 63 -- 57 3 PWM #1 Short to Battery (+) 63 -- 57 4 PWM #1 Open Circuit 63 -- 58 3 PWM #2 Short to Battery (+) 63 -- 58 4 PWM #2 Open Circuit 63 -- 59 3 PWM #3 Short to Battery (+) 63 -- 59 4 PWM #3 Open Circuit 63 -- 60 3 PWM #4 Short to Battery (+) 63 -- 60 4 PWM #4 Open Circuit 63 -- 57 0 PWM #1 Above Normal Range 63 -- 57 1 PWM #1 Below Normal Range 63 -- 58 0 PWM #2 Above Normal Range 63 -- 58 1 PWM #2 Below Normal Range 63 -- 59 0 PWM #3 Above Normal Range 63 -- 59 1 PWM #3 Below Normal Range 63 -- 60 0 PWM #4 Above Normal Range 63 -- 60 1 PWM #4 Below Normal Range 64 103 -- 8 Turbo Speed Sensor Input Failure 64 103 -- 0 Turbo Overspeed 65 51 -- 0 Throttle Plate Position Above Normal Range 65 51 -- 1 Throttle Plate Position Below Normal Range 65 51 -- 2 Throttle Plate Position Erratic 65 51 -- 7 Throttle Plate Not Responding 65 107 -- 3 Air Filter Restriction Sensor Voltage High 65 107 -- 4 Air Filter Restriction Sensor Voltage Low 66 -- 76 0 Engine Knock Level Above Normal Range 66 -- 76 3 Engine Knock Level Sensor Input Voltage High 66 -- 76 4 Engine Knock Level Sensor Input Voltage Low 66 -- 76 7 Engine Knock Level Sensor Not Responding 66 99 -- 3 Oil Filter Restriction Sensor Voltage High 66 99 -- 4 Oil Filter Restriction Sensor Voltage Low 67 109 -- 3 Coolant Pressure Sensor Input Voltage High 67 109 -- 4 Coolant Pressure Sensor Input Voltage Low A-4 Description Aux. Output #1 Mechanical System Not Responding Properly -F3 Aux. Output #2 Mechanical System Not Responding Properly -A2 Aux. Output #5 Mechanical System Not Responding Properly - W3 Aux. Output #6 Mechanical System Not Responding Properly - X3 Aux. Output #7 Mechanical System Not Responding Properly - Y3 Aux. Output #8 Mechanical System Not Responding Properly - A1 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL DDC Code # (Flashed) PID SID FMI 67 106 -- 3 Air Inlet Pressure Sensor Input Voltage High 67 106 -- 4 Air Inlet Pressure Sensor Input Voltage Low 67 20 -- 3 67 20 -- 4 68 -- 230 6 TPS Idle Validation Circuit Fault (short to ground) 68 -- 230 5 TPS Idle Validation Circuit Fault (open circuit) 71 -- xxx 1 Injector xxx Response Time Short 72 84 -- 0 Vehicle Overspeed 72 84 -- 11 Vehicle Overspeed (Absolute) 72 -- 65 0 Oxygen Content Too High 72 -- 65 1 Oxygen Content Too Low 73 -- 151 14 ESS Transmission Stuck in Gear 73 -- 226 11 73 -- 227 2 73 -- 227 3 73 -- 227 4 73 -- 77 0 Gas Valve Position Above Normal Range 73 -- 77 1 Gas Valve Position Below Normal Range 73 -- 77 3 Gas Valve Position Input Voltage High 73 -- 77 4 Gas Valve Position Input Voltage Low 73 -- 77 7 Gas Metering Valve Not Responding 73 107 -- 0 Air Filter Restriction High 74 99 -- 0 Oil Filter Restriction High 74 70 -- 4 Optimized Idle Safety Loop Short to Ground 75 168 -- 0 ECM Battery Voltage High 75 -- 214 0 RTC Backup Battery Voltage High (Release 29.0 or later) 75 -- 232 0 Sensor Supply Voltage High 76 121 -- 0 Engine Overspeed With Engine Brake 77 3 – 0 77 19 – 0 77 20 – 0 77 72 – 0 77 72 – 1 77 73 – 1 Description High Range Coolant Pressure Sensor Input Voltage High High Range Coolant Pressure Sensor Input Voltage Low Transmission Neutral Switch Failure (ESS Transmission) Aux Analog Input Data Erratic, Intermittent, or Incorrect (ESS Transmission) Aux Analog Input #1 Voltage High (ESS Transmission) Aux Analog Input #1 Voltage Low (ESS Transmission) Cylinder Head Temperature Above Range (Release 31.0 or later) Extended Range Oil Pressure Above Range (Release 31.0 or later) Extended Range Coolant Pressure Above Range (Release 31.0 or later) Bypass Blower Door Position Above Range (Release 31.0 or later) Bypass Blower Door Position Below Range (Release 31.0 or later) Pump Pressure Below Range (Release 31.0 or later) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION A-5 APPENDIX A: CODES DDC Code # (Flashed) PID SID FMI 77 81 – 0 77 81 – 1 77 81 – 3 77 81 – 4 77 81 – 12 77 95 – 1 77 99 – 1 77 100 – 0 77 102 – 1 77 105 – 1 77 107 – 1 77 108 – 0 77 108 — 1 77 109 — 0 77 110 — 1 77 110 — 0 77 171 — 0 77 171 — 1 77 172 — 1 77 174 — 0 Fuel Temperature Above Range 77 174 — 0 Fuel Temperature Below Range 77 175 — 1 77 177 — 0 77 177 — 1 77 177 — 3 77 177 — 4 77 222 — 14 Anti-Theft Fault Present (Release 31.0 or later) 77 251 — 10 Clock Module Abnormal Rate of Change (Release 31.0 or later) A-6 Description Exhaust Back Pressure Above Range (Release 31.0 or later) Exhaust Back Pressure Below Range (Release 31.0 or later) Exhaust Back Pressure Failed High (Release 31.0 or later) Exhaust Back Pressure Failed Low (Release 31.0 or later) Exhaust Back Pressure at Rampdown Threshold (Release 31.0 or later) Fuel Filter Differential Pressure Below Range (Release 31.0 or later) Oil Filter Differential Pressure Below Range (Release 31.0 or later) Engine Oil Pressure Above Range (Release 31.0 or later) Turbo Boost Pressure Below Range (Release 31.0 or later) Inlet Manifold Temperature Below Range (Release 31.0 or later) Air Filter Differential Pressure Below Range (Release 31.0 or later) Barometric Pressure Above Range (Release 31.0 or later) Barometric Pressure Below Range (Release 31.0 or later) Coolant Pressure Above Range (Release 31.0 or later) Coolant Temperature Below Range (Release 31.0 or later) Coolant Level Above Range (Release 31.0 or later) Ambient Air Temperature Above Range (Release 31.0 or later) Ambient Air Temperature Below Range (Release 31.0 or later) Air Inlet Temperature Below Range (Release 31.0 or later) Engine Oil Temperature Below Range (Release 31.0 or later) Transmission Oil Temperature Above Range (Release 31.0 or later) Transmission Oil Temperature Below Range (Release 31.0 or later) Transmission Oil Temperature Failed High (Release 31.0 or later) Transmission Oil Temperature Failed Low (Release 31.0 or later) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL DDC Code # (Flashed) PID SID FMI 77 251 — 13 Clock Module Failure (Release 31.0 or later) 77 252 — 10 Clock Module Abnormal Rate of Change (Release 31.0 or later) 77 252 — 13 Clock Module Failure (Release 31.0 or later) 78 86 -- 14 Cruise Control/Adaptive Cruise Control Fault (Release 27.0 or later) 81 -- 20 3 Timing Actuator (Dual Fuel) Input Voltage High 81 98 -- 3 Oil Level Sensor Input Voltage High 81 101 -- 3 Crankcase Pressure Sensor Input Voltage High 81 153 -- 3 81 154 -- 3 81 155 -- 3 81 164 -- 3 Injection Control Pressure Circuit Voltage High 81 173 -- 3 Exhaust Temperature Sensor Input Voltage High 82 -- 20 4 Timing Actuator (Dual Fuel) Input Voltage Low 82 98 -- 4 Oil Level Sensor Input Voltage Low 82 101 -- 4 Crankcase Pressure Sensor Input Voltage Low 82 153 -- 4 82 154 -- 4 82 155 -- 4 82 164 -- 4 82 173 -- 4 Exhaust Temperature Sensor Input Voltage Low 83 98 -- 0 Oil Level High 83 101 -- 0 Crankcase Pressure High 83 153 -- 0 Extended Crankcase Pressure High (Release 27.0 or later) 83 154 -- 0 EGR Gas Temperature High 83 155 -- 0 EGR Delta Pressure High 83 173 -- 0 Exhaust Temperature High 83 73 -- 0 Pump Pressure High 84 98 -- 1 Oil Level Low 84 101 -- 1 Crankcase Pressure Low 84 153 -- 1 Extended Crankcase Pressure Low (Release 27.0 or later) 85 190 -- 0 Engine Overspeed 85 190 -- 14 Engine Overspeed Signal (Release 28.0 or later) 86 73 -- 3 Pump Pressure Sensor Input Voltage High 86 108 -- 3 Barometric Pressure Sensor Input Voltage High 87 73 -- 4 Pump Pressure Sensor Input Voltage Low Description Extended Crankcase Pressure Input Voltage High (Release 27.0 or later) EGR Temperature Input Voltage High (Release 29.0 or later) EGR Delta Pressure Input Voltage High (Release 29.0 or later) Extended Crankcase Pressure Input Voltage Low (Release 27.0 or later) EGR Temperature Input Voltage Low (Release 29.0 or later) EGR Delta Pressure Input Voltage Low (Release 29.0 or later) Injection Control Pressure Sensor Input Voltage Low All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION A-7 APPENDIX A: CODES DDC Code # (Flashed) PID SID FMI 87 108 -- 4 Barometric Pressure Sensor Input Voltage Low 88 109 -- 1 Coolant Pressure Low 88 20 -- 1 High Range Coolant Pressure Low 89 95 -- 0 Fuel Restriction High 111 -- 12 Maintenance Alert Coolant Level Fault 89 A-8 Description All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL A.1 PIDS The codes listed are sorted by PID. PID FMI DDC Code # (Flashed) 3 0 77 Cylinder Head Temperature Above Range (Release 32.0 or later) 18 0 47 High Range Fuel Pressure High 18 1 48 High Range Fuel Pressure Low 18 3 37 High Range Fuel Pressure Sensor Input Voltage High 18 4 38 High Range Fuel Pressure Sensor Input Voltage Low 19 0 19 1 45 High Range Oil Pressure Low 19 3 35 High Range Oil Pressure Sensor Input Voltage High 19 4 36 High Range Oil Pressure Sensor Input Voltage Low 20 0 20 1 88 High Range Coolant Pressure Low 20 3 67 High Range Coolant Pressure Sensor Input Voltage High 20 4 67 High Range Coolant Pressure Sensor Input Voltage Low 51 0 65 Throttle Plate Position Above Normal Range 51 1 65 Throttle Plate Position Below Normal Range 51 2 65 Throttle Plate Position Erratic 51 3 17 Throttle Plate Position Sensor Input Voltage High 51 4 18 Throttle Plate Position Sensor Input Voltage Low 51 7 65 Throttle Plate Not Responding 52 0 44 Intercooler Coolant Temperature High 52 3 14 Intercooler Coolant Temperature Sensor Input Voltage High 52 4 15 Intercooler Coolant Temperature Sensor Input Voltage Low 70 4 74 Optimized Idle Safety Loop Short to Ground 72 0 77 Bypass Blower Door Position Above Range (Release 31.0 or later) 72 1 77 Bypass Blower Door Position Below Range (Release 31.0 or later) 72 3 17 Bypass Position Sensor Input Voltage High 72 4 18 Bypass Position Sensor Input Voltage Low 73 0 83 Pump Pressure High 73 1 77 Pump Pressure Below Range (Release 31.0 or later) 73 3 86 Pump Pressure Sensor Input Voltage High 73 4 87 Pump Pressure Sensor Input Voltage Low 81 0 77 Exhaust Back Pressure Above Range (Release 31.0 or later) 81 1 77 Exhaust Back Pressure Below Range (Release 31.0 or later) 81 3 77 Exhaust Back Pressure Failed High (Release 31.0 or later) 81 4 77 Exhaust Back Pressure Failed Low (Release 31.0 or later) 81 12 77 Exhaust Back Pressure at Rampdown Threshold (Release 31.0 or later) 84 0 72 Vehicle Overspeed Description Extended Range Oil Pressure Above Range (Release 31.0 or later) Extended Range Coolant Pressure Above Range (Release 31.0 or later) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION A-9 APPENDIX A: CODES PID FMI DDC Code # (Flashed) 84 11 72 Vehicle Overspeed (Absolute) 84 12 54 Vehicle Speed Sensor Fault 86 14 78 Cruise Control/Adaptive Cruise Control Fault (Release 27.0 or later) 91 3 21 Throttle Position Sensor Input Voltage High 91 4 22 Throttle Position Sensor Input Voltage Low 92 0 58 Torque Overload 94 0 47 Fuel Pressure High 94 1 48 Fuel Pressure Low 94 3 37 Fuel Pressure Sensor Input Voltage High 94 4 38 Fuel Pressure Sensor Input Voltage Low 95 0 89 Fuel Restriction High 95 1 77 Fuel Filter Differential Pressure Below Range (Release 31.0 or later) 95 3 37 Fuel Restriction Sensor Input Voltage High 95 4 38 Fuel Restriction Sensor Input Voltage Low 98 0 83 Oil Level High 98 1 84 Oil Level Low 98 3 81 Oil Level Sensor Input Voltage High 98 4 82 Oil Level Sensor Input Voltage Low 99 0 74 Oil Filter Restriction High 99 1 77 Oil Filter Differential Pressure Below Range (Release 31.0 or later) 99 3 66 Oil Filter Restriction Sensor Voltage High 99 4 66 Oil Filter Restriction Sensor Voltage Low 100 0 77 Engine Oil Pressure Above Range (Release 31.0 or later) 100 1 45 Oil Pressure Low 100 3 35 Oil Pressure Sensor Input Voltage High 100 4 36 Oil Pressure Sensor Input Voltage Low 101 0 83 Crankcase Pressure High 101 1 84 Crankcase Pressure Low 101 3 81 Crankcase Pressure Sensor Input Voltage High 101 4 82 Crankcase Pressure Sensor Input Voltage Low 102 0 47 Turbo Boost Pressure High 102 1 77 Turbo Boost Pressure Below Range (Release 31.0 or later) 102 3 33 Turbo Boost Pressure Sensor Input Voltage High 102 4 34 Turbo Boost Pressure Sensor Input Voltage Low 103 0 64 Turbo Overspeed 103 8 64 Turbo Speed Sensor Input Failure 105 0 44 Intake Manifold Temperature High 105 1 77 Inlet Manifold Temperature Below Range (Release 31.0 or later) 105 3 27 Intake Manifold Temperature Sensor Input Voltage High 105 4 28 Intake Manifold Temperature Sensor Input Voltage Low 106 0 47 Air Inlet Pressure High A-10 Description All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PID FMI DDC Code # (Flashed) 106 1 48 Air Inlet Pressure Low 106 3 67 Air Inlet Pressure Sensor Input Voltage High 106 4 67 Air Inlet Pressure Sensor Input Voltage Low 107 0 73 Air Filter Restriction High 107 1 77 Air Filter Differential Pressure Below Range (Release 31.0 or later) 107 3 65 Air Filter Restriction Sensor Voltage High 107 4 65 Air Filter Restriction Sensor Voltage Low 108 0 77 Barometric Pressure Above Range (Release 31.0 or later) 108 1 77 Barometric Pressure Below Range (Release 31.0 or later) 108 3 86 Barometric Pressure Sensor Input Voltage High 108 4 87 Barometric Pressure Sensor Input Voltage Low 109 0 77 Coolant Pressure Above Range (Release 31.0 or later) 109 1 88 Coolant Pressure Low 109 3 67 Coolant Pressure Sensor Input Voltage High 109 4 67 Coolant Pressure Sensor Input Voltage Low 110 0 44 Coolant Temperature High 110 0 77 Coolant Temperature Below Range (Release 31.0 or later) 110 1 77 Coolant Temperature Above Range (Release 31.0 or later) 110 3 14 Coolant Temperature Sensor Input Voltage High 110 4 15 Coolant Temperature Sensor Input Voltage Low 111 1 43 Coolant Level Low 111 3 16 Coolant Level Sensor Input Voltage High 111 4 13 Coolant Level Sensor Input Voltage Low 111 5 16 Add Coolant Level Sensor Input Voltage High 111 6 13 Add Coolant Level Sensor Input Voltage Low 111 12 89 Maintenance Alert Coolant Level Fault 121 0 76 Engine Overspeed With Engine Brake 153 3 81 153 4 82 153 0 83 Extended Crankcase Pressure High (Release 27.0 or later) 153 1 84 Extended Crankcase Pressure Low (Release 27.0 or later) 164 0 47 Injection Control Pressure High 164 1 48 Injection Control Pressure Low 164 3 81 Injection Control Pressure Circuit Voltage High 164 4 82 Injection Control Pressure Sensor Input Voltage Low 168 0 75 ECM Battery Voltage High 168 1 46 ECM Battery Voltage Low 171 0 77 Ambient Air Temperature Above Range (release 31.0 or later) 171 1 77 Ambient Air Temperature Below Range (release 31.0 or later) 171 3 27 Ambient Air Temperature Sensor Input Voltage High (Release 2.00 or later only) Description Extended Crankcase Pressure Sensor Input Voltage High (Release 27.0 or later) Extended Crankcase Pressure Sensor Input Voltage Low (Release 27.0 or later) All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION A-11 APPENDIX A: CODES PID FMI DDC Code # (Flashed) 171 4 28 Ambient Air Temperature Circuit Failed Low (Release 2.0 or later only) 172 0 44 Air Inlet Temperature High 172 1 77 Air Inlet Temperature Below Range (Release 31.0 or later) 172 3 27 Air Temperature Sensor Input Voltage High 172 4 28 Air Temperature Sensor Input Voltage Low 173 0 83 Exhaust Temperature High 173 3 81 Exhaust Temperature Sensor Input Voltage High 173 4 82 Exhaust Temperature Sensor Input Voltage Low 174 0 77 Fuel Temperature Above Range 174 1 77 Fuel Temperature Below Range 174 3 23 Fuel Temperature Sensor Input Voltage High 174 4 24 Fuel Temperature Sensor Input Voltage Low 175 0 44 Oil Temperature High 175 1 77 Engine Oil Temperature Below Range (Release 31.0 or later) 175 3 14 Oil Temperature Sensor Input Voltage High 175 4 15 Oil Temperature Sensor Input Voltage Low 177 0 77 Transmission Oil Temperature Above Range (Release 31.0 or later) 177 1 77 Transmission Oil Temperature Below Range (Release 31.0 or later) 177 3 77 Transmission Oil Temperature Failed High (Release 31.0 or later) 177 4 77 Transmission Oil Temperature Failed Low (Release 31.0 or later) 187 3 12 Variable Speed Governor Sensor Voltage High 187 4 11 Variable Speed Governor Sensor Voltage Low 187 7 11 Variable Speed Governor Switch System Not Responding 190 0 85 Engine Overspeed 190 14 85 Engine Overspeed Signal (Release 28.0 or later) 222 14 77 Anti-Theft Fault Present (Release 31.0 or later) 240 2 -- Fram Checksum Incorrect 251 10 77 Clock Module Abnormal Rate of Change (Release 31.0) 251 13 77 Clock Module Failure (Release 31.0) 252 10 77 Clock Module Abnormal Rate of Change (Release 31.0) 252 13 77 Clock Module Failure (Release 31.0) A-12 Description All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL A.2 SIDS The codes listed are sorted by SID. SID FMI DDC Code # (Flashed) xxx 0 61 Injector xxx Response Time Long xxx 1 71 Injector xxx Response Time Short 20 3 81 Timing Actuator (Dual Fuel) Input Voltage High 20 4 82 Timing Actuator (Dual Fuel) Input Voltage Low 21 0 41 Too many SRS (missing TRS) 21 1 42 Too few SRS (missing SRS) 25 11 26 Aux. Shutdown #1 Active 26 3 62 Aux. Output #1 Short to Battery (+) - F3 26 4 62 Aux. Output #1 Open Circuit - F3 26 7 62 Aux. Output #1 Mechanical System Not Responding Properly - F3 40 3 62 Aux. Output #2 Short to Battery (+) - A2 40 4 62 Aux. Output #2 Open Circuit - A2 40 7 62 Aux. Output #2 Mechanical System Not Responding Properly - A2 51 3 31 Aux. Output #3 Open Circuit (High Side) - S3 51 4 31 Aux. Output #3 Short To Ground (High Side) - S3 51 7 31 Aux. Output #3 Mechanical System Fail - S3 52 3 31 Aux. Output #4 Open Circuit (High Side) - T3 52 4 31 Aux. Output #4 Short To Ground (High Side) - T3 52 7 31 Aux. Output #4 Mechanical System Fail - T3 53 3 62 Aux. Output #5 Short to Battery (+) - W3 53 4 62 Aux. Output #5 Open Circuit - W3 53 7 62 Aux. Output #5 Mechanical System Not Responding Properly - W3 54 3 62 Aux. Output #6 Short to Battery (+) - X3 54 4 62 Aux. Output #6 Open Circuit - X3 54 7 62 Aux. Output #6 Mechanical System Not Responding Properly - X3 55 3 62 Aux. Output #7 Short to Battery (+) - Y3 55 4 62 Aux. Output #7 Open Circuit - Y3 55 7 62 Aux. Output #7 Mechanical System Not Responding Properly - Y3 56 3 62 Aux. Output #8 Short to Battery (+) - A1 56 4 62 Aux. Output #8 Open Circuit - A1 56 7 62 Aux. Output #8 Mechanical System Not Responding Properly - A1 57 0 63 PWM #1 Above Normal Range 57 1 63 PWM #1 Below Normal Range 57 3 63 PWM #1 Short to Battery (+) 57 4 63 PWM #1 Open Circuit 58 0 63 PWM #2 Above Normal Range 58 1 63 PWM #2 Below Normal Range 58 3 63 PWM #2 Short to Battery (+) Description All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION A-13 APPENDIX A: CODES SID FMI DDC Code # (Flashed) 58 4 63 PWM #2 Open Circuit 59 0 63 PWM #3 Above Normal Range 59 1 63 PWM #3 Below Normal Range 59 3 63 PWM #3 Short to Battery (+) 59 4 63 PWM #3 Open Circuit 60 0 63 PWM #4 Above Normal Range 60 1 63 PWM #4 Below Normal Range 60 3 63 PWM #4 Short to Battery (+) 60 4 63 PWM #4 Open Circuit 61 11 26 Aux. Shutdown #2 Active 65 0 72 Oxygen Content Too High 65 1 72 Oxygen Content Too Low 65 3 23 Oxygen Content Circuit Input Voltage High 65 4 24 Oxygen Content Circuit Input Voltage Low 76 0 66 Engine Knock Level Above Normal Range 76 3 66 Engine Knock Level Sensor Input Voltage High 76 4 66 Engine Knock Level Sensor Input Voltage Low 76 7 66 Engine Knock Level Sensor Not Responding 77 0 73 Gas Valve Position Above Normal Range 77 1 73 Gas Valve Position Below Normal Range 77 3 73 Gas Valve Position Input Voltage High 77 4 73 Gas Valve Position Input Voltage Low 77 7 73 Gas Metering Valve Not Responding 151 14 73 ESS Transmission Stuck in Gear 152 7 39 EGR Valve Not Responding (Release 29.0 or later) 153 7 39 VNT Vanes Not Responding (Release 29.0 or later) 154 1 48 EGR Temperature Low (Release 29.0 or later) 154 3 81 EGR Temperature Low (Release 29.0 or later) 154 4 82 EGR Temperature Input Voltage Low (Release 29.0 or later) 154 0 83 EGR Gas Temperature High 155 1 48 EGR Delta Pressure Low (Release 29.0 or later) 155 3 81 EGR Delta Pressure Input Voltage High (Release 29.0 or later) 155 4 82 EGR Delta Pressure Input Voltage Low (Release 29.0 or later) 155 0 83 EGR Delta Pressure High 214 1 46 RTC Backup Battery Voltage Low (Release 29.0 or later) 214 0 75 RTC Backup Battery Voltage High (Release 29.0 or later) 216 14 55 Other ECU Fault (Release 27.0 or later) (This fault is logged in conjunction with another fault to indicate missing information from another ECU.) 226 11 73 Transmission Neutral Switch Failure (ESS Transmission) 227 2 73 Aux Analog Input Data Erratic, Intermittent, or Incorrect (ESS Transmission) 227 3 73 Aux Analog Input #1 Voltage High (ESS Transmission) A-14 Description All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL SID FMI DDC Code # (Flashed) 227 4 73 Aux Analog Input #1 Voltage Low (ESS Transmission) 230 5 68 TPS Idle Validation Circuit Fault (open circuit) 230 6 68 TPS Idle Validation Circuit Fault (short to ground) 231 12 55 J1939 Data Link Fault 232 0 75 Sensor Supply Voltage High 232 1 46 Sensor supply Voltage Low 238 3 32 SEL Short to Battery (+) 238 4 32 SEL Open Circuit 239 3 32 CEL Short to Battery (+) 239 4 32 CEL Open Circuit 248 8 55 Proprietary Data Link Fault (Master) 248 9 55 Proprietary Data Link Fault (Receiver) 249 12 57 J1922 Data Link Fault 250 12 56 J1587 Data Link Fault 253 2 53 Nonvolatile Checksum Incorrect 253 12 53 EEPROM Write Error 253 13 -- Incompatible Calibration Version 253 13 53 Out of Calibration 254 0 -- External Failed RAM 254 1 -- Internal Failed RAM 254 6 -- Entered Boot Via Switches 254 12 52 A/D Conversion Fail Description All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION A-15 APPENDIX A: CODES A-16 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL APPENDIX B: HARNESS WIRING DIAGRAMS Figure B-1 Figure B-2 Figure B-3 Figure B-4 Figure B-5 Figure B-6 Figure B-7 Figure B-8 Figure B-9 Figure B-10 Figure B-11 Figure B-12 Figure B-13 Figure B-14 Figure B-15 Engine Interface Harness - Series 149 Multi-ECMs ......................................... Engine Interface Harness, Series 4000, Multi-ECM ......................................... Engine Power Harness- Series 4000, Multi-ECM ............................................. Engine Power Harness — Series 149 Multi-ECM ............................................ Optional Engine Power Harness - Series 2000 Multi-ECM .............................. Vehicle Power Harness - Series 2000, Multi-ECM ........................................... Vehicle Power Harness - Series 149 ................................................................ Vehicle Power Harness - Series 4000 ............................................................. Injector Harness Schematic - Series 92-6V ..................................................... Injector Harness Schematic -Series 92-8V and Series 149- 8V ...................... Injector Harness Schematic - Series 60 ........................................................... Injector Harness Schematic - Series 60 with Jake Brake ................................. Injector Harness Schematic - Series 50 ........................................................... Injector Harness Schematic - Series 50 with Jake Brake ................................. Injector Harness Schematic - Series 2000-8V ................................................. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION B-3 B-4 B-5 B-6 B-7 B-8 B-9 B-10 B-11 B-12 B-13 B-14 B-15 B-16 B-17 B-1 APPENDIX B: HARNESS WIRING DIAGRAMS The following harness schematics may be found on the DDC extranet: Vehicle Interface Harness Vehicle Interface Harness - Series 4000 Vehicle Interface Harness - Series 2000 Single-ECM Vehicle Interface Harness - Series 2000 Multi-ECM (1 of 2) Vehicle Interface Harness - Series 2000 Multi-ECM (2 of 2) Engine Sensor Harness - Series 60/50 Engine Sensor Harness - Series 4000-12V & 16V Engine Sensor Harness - Series 149 Engine Sensor Harness - Series 2000-8V Engine Sensor Harness - Series 2000-12V & 16V Engine Interface Harness,-Series 2000, Multi-ECM Injector Harness Schematic - Series 71-12V and Series 149-12V Injector Harness Schematic - Series 92-12V Injector Harness Schematic - Series 92-16V Injector Harness Schematic - Series 149-16V Injector Harness Schematic - Series 149-20V Injector Harness Schematic - Series 4000-12V Injector Harness Schematic - Series 4000-16V Injector Harness Schematic - Series 2000-12V Injector Harness Schematic - Series 2000-16V 12V Series 4000 Marine Exhaust Temperature Sensors 8V Series 4000 Marine Exhaust Temperature Sensors 16V Series 4000 Marine Exhaust Temperature Sensors 12V and 16V Series 4000 Marine Engine Harness B-2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure B-1 Engine Interface Harness - Series 149 Multi-ECMs All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION B-3 APPENDIX B: HARNESS WIRING DIAGRAMS Figure B-2 B-4 Engine Interface Harness, Series 4000, Multi-ECM All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure B-3 Engine Power Harness- Series 4000, Multi-ECM All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION B-5 APPENDIX B: HARNESS WIRING DIAGRAMS Figure B-4 B-6 Engine Power Harness — Series 149 Multi-ECM All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure B-5 Optional Engine Power Harness - Series 2000 Multi-ECM All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION B-7 APPENDIX B: HARNESS WIRING DIAGRAMS Figure B-6 B-8 Vehicle Power Harness - Series 2000, Multi-ECM All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure B-7 Vehicle Power Harness - Series 149 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION B-9 APPENDIX B: HARNESS WIRING DIAGRAMS Figure B-8 B-10 Vehicle Power Harness - Series 4000 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure B-9 Injector Harness Schematic - Series 92-6V All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION B-11 APPENDIX B: HARNESS WIRING DIAGRAMS Figure B-10 B-12 Injector Harness Schematic -Series 92-8V and Series 149- 8V All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure B-11 Injector Harness Schematic - Series 60 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION B-13 APPENDIX B: HARNESS WIRING DIAGRAMS Figure B-12 B-14 Injector Harness Schematic - Series 60 with Jake Brake All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure B-13 Injector Harness Schematic - Series 50 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION B-15 APPENDIX B: HARNESS WIRING DIAGRAMS Figure B-14 B-16 Injector Harness Schematic - Series 50 with Jake Brake All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Figure B-15 Injector Harness Schematic - Series 2000-8V All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION B-17 APPENDIX B: HARNESS WIRING DIAGRAMS B-18 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL APPENDIX C: SYMBOLS All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION C-1 APPENDIX C: SYMBOLS C-2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION C-3 APPENDIX C: SYMBOLS C-4 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL APPENDIX D: ACRONYMS ABS Anti-lock Braking System ACLS Add Coolant Level Sensor ACS Application Code System ACPS Air Compressor Pressure Sensor AFRS Air Filter Restriction Sensor AIM Auxiliary Interface Module ATI Aux Timed Input ATS Air Temperature Sensor CEL Check Engine Light CFPS Common Rail Fuel Pressure Sensor CLS Coolant Level Sensor CPS Coolant Pressure Sensor CTS Coolant Temperature Sensor DDC Detroit Diesel Corporation DDDL Detroit Diesel Diagnostic Link DDEC Detroit Diesel Electronic Controls DDR Diagnostic Data Reader DRS DDEC Reprogramming System ECM Electronic Control Module EDM Electronic Display Module All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION D-1 APPENDIX D: ACRONYMS EFC Electronic Fire Commander EFPA Electronic Foot Pedal Assembly EEPROM Electronically Erasable Programmable Read Only Memory EOP Engine Over Temperature Protection ESH Engine Sensor Harness ESS Engine Synchro Shift ETS Exhaust Temperature Sensor EUI Electronic Unit Injectors EUP Electronic Unit Pump FEI Fuel Economy Incentive FMI Failure Mode Identifier FPS Fuel Pressure Sensor FRS Fuel Restriction Sensor FTS Fuel Temperature Sensor HEI Half Engine Idle ICPS Intercooler Coolant Pressure Sensor ICTS Intercooler Coolant Temperature Sensor IRIS InfraRed Information System ISD Idle Shutdown LSG Limiting Speed Governor OEM Original Equipment Manufacturer OI Optimized Idle D-2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL OLS Oil Level Sensor OPS Oil Pressure Sensor OTS Oil Temperature Sensor MAS Maintenance Alert System MPG Miles Per Gallon MPH Miles Per Hour MID Message IDentification Character MUI Mechanical Unit Injector PGN Parameter Group Number PID Parameter IDentification Character PTO Power Take-off PSG Pressure Sensor Governor PVM Pulse to Voltage Module PW Pulse Width PWM Pulse Width Modulated SEL Stop Engine Light SEO Stop Engine Override SRS Synchronous Reference Sensor SID Subsystem IDentification Character TBS Turbo Boost Sensor TDC Top Dead Center All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION D-3 APPENDIX D: ACRONYMS TPS Throttle Position Sensor TRS Timing Reference Sensor VEPS Vehicle Electronic Programming System VIH Vehicle Interface Harness VIN Vehicle Identification Number VSG Variable Speed Governor VSL Vehicle Speed Limiting VSS Vehicle Speed Sensor D-4 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL APPENDIX E: VENDORS Compatible engine accessories may be obtained from several vendors. This section provides vendors FANS name, address. Single-speed fans are available from: VEHICLE SPEED SENSORS Wabash Technologies 1375 Swan Streets Linnig Corp. Huntington, Indiana 46750-0829 P.O. Box 2002 Phone: 219-356-8300 Tucker, GA 30084 Fax: 219-356-3846 Phone: (770) 414-9499 Airpax Instruments Index Sensors & Controls, Inc. Phillips Technologies 13205 Southeast 30th Street 150 Knotter Drive Bellevue, WA 98005-4433 Chesire, Connecticut 06410 Phone: (206) 746-4049 Phone: 1- 800-643-0643 Bendix (A division of Allied Signal) Electro Corporation 901 Cleveland St. 1845 57th Street P.O. Box 4016 Sarasota, Florida 34243 Elyria, OH 44036 Tel: 941-355-8411 Phone: 1-800-AIR-BRAKE Fax: 941-355-3120 Kysor ELECTRONIC FOOT PEDAL 1100 Wright Street ASSEMBLEY Cadillac, MI 49601 Phone: (616) 779-7528 Williams Controls 14100 S.W. 72nd Avenue Horton, Inc. Portland, Oregon 97223 2565 Walnut Street Phone: (503) 684-8600 Roseville, MN 55113 Phone: 1-800-621-1320 Bendix Heavy Vehicle Systems 901 Cleveland Two-speed fans are available from: Elyria, Ohio 44036 Linnig Corp Phone: 1-800-AIR-BRAKE P.O. Box 2002 Tucker, GA 30084 King Controls Phone: (770) 414-9499 5100 West 36th Street St. Louis Park, Minnesota 55416 A variable speed fan is available from: Phone: (612) 922-6889 Rockford Powertrain, Inc. 1200 Windsor Road Rockford, IL 61132-2908 Phone: (815) 633-7460 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION E-1 APPENDIX E: VENDORS HAND THROTTLE Morse Controls 21 Clinton Street Hudson, Ohio 44236 Phone: (330) 653-7701 Fax: (330) 653-7799 DOCUMENTATION SAE International 400 Commonwealth Drive Warrendale, PA 15096 Attention: Publications Phone: (412) 776-4970 DIAGNOSTIC DATA READER Kent-Moore 28635 Mound Road Warren, MI 48092 Phone: 1-800-328-6657 SHRINK WRAP Alpha Wire Corporation 711 Lidgerwood Ave P.O. Box 711 Elizabeth, New Jersey 07207-0711 Phone: 1-800-52ALPHA Raychem Corporation, Corporate Division 300 Constitution Drive, Bldg. B Menlo Park, CA 94025 Phone: (650)-361-2755 E-2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL GLOSSARY Add Coolant Level Sensor Provides another coolant level sensor, higher in the top tank of the vehicle cooling system. Typically, this is used to recognize the coolant is low, but not low enough to activate the DDEC engine protection. Air Temperature Sensor An intake mounted sensor which provides air temperature information to the ECM. Located in the bottom middle of the air intake manifold on the Series 50 and Series 60 Engines. Check Engine Light A panel mounted yellow indicator light, provided by the vehicle OEM as standard. Coolant Level Sensor Activates the engine protection if the coolant level is low. Coolant Temperature Sensor Provides coolant level information to the ECM. Used for engine protection. Communication Harness This OEM supplied harness connects the ECM's J1922 and J1939 ports to other vehicle systems. Cruise Control Operates in either Engine or Vehicle Speed Mode and maintain a targeted speed (MPH or RPM) by increasing or decreasing fueling to maximize fuel economy and driveability. Check Engine Light A panel mounted yellow indicator light. Provided by the vehicle OEM as standard. Customer Option Password A 4 digit alphanumeric password to protect and change customer parameters in the DDR. This password is set with the DDR. This password does not protect the horsepower rating. DDEC IV Fourth generation of Detroit Diesel Electronic Controls. Deceleration Light Illuminates on the rear of the vehicle when you take your foot off the accelerator pedal to indicate that the vehicle is slowing down. Typically, this is used on the rear of a bus that operates in the city. Diagnostic Request Switch A switch that allows the yellow and red lights to flash two digit diagnostic codes when the engine is idling or off. The yellow light flashes inactive (or historic) codes. The All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION G-1 GLOSSARY red light flashes active codes. These two digit codes are defined on the DDEC diagnostic data reader pocket card. This can be the same switch as the stop engine override. Electronic Control Module The ECM includes control logic to provide overall engine management. The ECM continuously performs self diagnostic checks and monitors other system components Electronic Fire Commander A complete pressure governor control unit for DDEC IV engines. The EFC displays engine RPM, battery voltage, engine oil pressure, and either engine oil temperature or engine coolant temperature (programmable). Electronic Unit Injector Provides fuel delivery to the engine cylinders. The EUI controls injection timing and metering using a solenoid operated valve. The duration of valve closure determines the quantity of fuel injected. Electronic Fire Commander Designed for the fire fighting and emergency services market, EFC combines the DDEC Pressure Sensor Governor (PSG), a system monitor, and a pump panel display for vital engine operating parameters into one compact, durable package. Engine Brakes Cruise Control Provides cruise control compatibility with engine brakes. While in cruise control, the engine brakes will turn on and go off automatically in order to maintain the same cruise set speed. Engine Brake LOW ON (Above Cruise Control) The additional engine speed above the driver selected cruise speed that the low engine brakes (Jake Brakes) turn on. Engine Brake Medium/High On (Increment) Sets the engine brake medium and high limits to a vehicle speed above engine brake low. Engine Fan Braking Automatically engages the cooling fan clutch when all the engine brakes are on, (HIGH). Engine Interface Harness Used in multi-ECM applications is usually installed at the factory and delivered connected to all ECMs. Ends with a quick disconnect connector. The OEM VIH connects to the quick disconnect connector. Engine Protection Provides three levels of protection to the engine if it is operating out of the limits. These three levels are warning, rampdown, and shutdown. Coolant level, G-2 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL coolant temperature, oil temperature, oil pressure, and two additional sensors provide protection to the engine. Typically, the additional sensors are used for high oil temperature in the automatic transmission, low oil level in the engine, and other vehicle systems that require the engine to shutdown. Engine Over Temperature ProtectionThe reduction in operating power from between the time the CEL and the SEL illuminates. For high coolant and/or oil temperature only. Engine Overspeed Logs diagnostic code at 2500 RPM, DDC standard. Engine Sensor Harness Connects the ECM to all engine sensors, facilitates the receipt of inputs and outputs signals, controlling the fuel injection process and engine speed. Failure Mode Identifier The FMI describes the type of failure detected in the subsystem and identified by the PID or SID. Fan Clutch Override Used to engage the cooling fan when desired. Fan Controls use the DDEC oil temperature, coolant temperature, or air temperature sensors to engage the cooling fan. Fuel Pressure Sensor Provides fuel pressure information to the ECM. Used for diagnostics. Fuel Temperature Sensor Provides fuel temperature information to the ECM. Used for determining hot fuel, and adjusting the calibration based on this temperature. Half Engine Idle The engine idles on three of the cylinders to reduce the amount of white smoke on cold engine start-up. High Range Max MPH Defines the minimum vehicle speed required to activate the high range max RPM function. This is used to encourage the driver to use high gear, while in cruise control. High Range Max RPM Limits the maximum engine speed in the top range of gears, encouraging the driver to upshift to the next higher gear to increase vehicle speed. This function will determine the vehicle speed limit, unless a slower speed limit is selected for the vehicle speed limit parameter. During the shift sequence, the high range max MPH must be reached before the high range max RPM is achieved. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION G-3 GLOSSARY Horsepower Rating Password A 4 digit alphanumeric password to protect and activate the horsepower rating in the ECM. This password is set with the DDR. Horsepower Rating Security Protects the multiple horsepower ratings in the ECM. Only one rating will be available with this feature turned on. This lock is set at the time of engine order from DDC or the OEM. Idle Shutdown Override With Throttle Allows the engine shutdown to be canceled by depressing the accelerator pedal while the yellow check engine light is flashing 90 seconds before engine shutdown. Idle Time The amount of time spent idling before the engine will automatically shutdown; set with the DDR. Idle Timer Shutdown Allows the engine to shutdown after a customer set time expires on idling (low idle or high idle or PTO). Injector Harness Installed at the factory and are delivered connected to the injection units and the ECMs. InfraRed Information System Provides infrared two-way communication between a vehicle and a PC. Limiting Speed Governor Maintains vehicle speed based on driver throttle input. The engine changes RPM to maintain a vehicle speed with the accelerator pedal. Maintenance Alert System Monitors engine fluid levels and filter restrictions and notifies the driver and/or technician when maintenance is required. Maximum Security Protects and locks out all of the programmed parameters in the ECM. This lock is set at the time of engine order from DDC or at the OEM. Feature settings cannot be changed with maximum security turned on. Oil Pressure Sensor Provides engine oil pressure to the ECM. Used for engine protection. Oil Temperature Sensor Provides the engine oil temperature to the ECM. Used for engine protection and fan controls. Parameter Identification Character A PID is a single byte character used in J1587 messages to identify the data byte(s) that follow. G-4 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL PasSmart Allows a fleet manager to enable a second Vehicle Limit Speed (VLS) above the normal VLS to assist while passing other vehicles on the highway. This second VLS is programmed for a limited duration during a given time period (interval). Power Harness Connects battery power (12 or 24 volts) and ground to the ECM and includes fuse(s) or circuit breaker(s). OEM supplied. Power Take Off A mechanical gear device used to divert engine horsepower to other machinery. Progressive Shifting Encourages the driver to shift in to a higher gear before the engine reaches governed speed. The Spec Manager program should be utilized to determine maximum vehicle speed. Typically, this is used on 2100 RPM rated engines. Pressure Sensor Governor For Fire Maintains a set water pressure on a fire truck water pump. Trucks The engine speed will vary to maintain a constant water pressure. This feature is in fire trucks. Pressure Sensor Governor Light For Fire Trucks Indicates that the Pressure Sensor Governor is active. Pulse Width The duration of time the injectors are fueling the engine, measured in degrees of rotation of the engine. Pulse Width Modulated A type of electrical signal output. SAE J1587 Communication link used for DDR, Data Hub, ABS, etc. SAE J1922 Communication link used for traction control systems and CEEMAT Fuller transmissions. SAE J1939 Communication link used for multiple block engines and other vehicle systems. Starter Lockout Prevents the starter from activating after the engine is already running. Typically, this is used in buses. Stop Engine Light A panel mounted red indicator light provided by the OEM as standard. Stop Engine Override This switch allows an override of the engine protection system when toggled in the rampdown or shutdown mode All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION G-5 GLOSSARY every 30 seconds. This can be the same switch as the diagnostic request. Subsystem Identification Character A SID is a single byte character used to identify field-repairable or replaceable subsystems for which failures can be detected or isolated. Synchronous Reference Sensor Indicates a specific cylinder in the firing order; tells the ECM when the #1 cylinder is at top dead center of its stroke. DDC standard. Timing Reference Sensor Indicates crank position of every cylinder; tells the ECM where the rotation of the engine is or when to fuel each cylinder. DDC standard. Throttle Inhibit Disables the accelerator pedal by making it unresponsive when a switch is toggled. Typically, this is used in buses for when the doors are open, or when the pressure governor system is active in a fire truck. Throttle Position Sensor Converts the operator's hand throttle and/or foot pedal input into a signal for the ECM, better known as the accelerator pedal. This pedal, located on the floor of the vehicle cab, tells the ECM how much fuel is needed based on the driver input. Provided by the OEM, standard. Top Dead Center When the piston is at the top of the stroke nearest the head of the engine. The point at which the piston stops going up and starts going down. Turbocharger Boost Sensor Provides air pressure (atmospheric and boost) information from turbocharger to the ECM. This sensor is located in the air intake manifold. Used for white smoke and emissions. DDC standard. Variable Speed Governor Maintains a constant engine speed with varying loads. A variable speed governor is referred to as: high idle, fast idle, hand throttle, Vernier, voltage divider, power take off (PTO), cruise control, or cruise switch PTO. Vehicle Electronic Programming System A PC software package used to change the parameters to be programmed into the DDEC IV ECM. OEM supplied. Vehicle Interface Harness Connects the ECM to other vehicle systems. Vehicle Power Shutdown Allows the chassis power and DDEC power to shutdown after idling on low idle, high idle, or PTO for the set G-6 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL idle time. The idle shutdown override with throttle will override the vehicle power shutdown. In addition, the vehicle power will shutdown after an engine protection shutdown. This can be overridden by the stop engine override switch. Vehicle Speed Limiting The vehicle's fastest speed. limits the vehicle from going faster than a preset limit. Vehicle Speed Maximum The fastest vehicle speed (MPH/KPH) the driver is allowed to travel on flat ground. Vehicle Speed Sensor Tells the ECM how fast the vehicle is going. This magnetic pickup is located on the tail shaft of the transmission or on the rear drive wheel of the vehicle. Provided by the OEM. Required for cruise control, vehicle speed limiting, vehicle overspeed with/without throttle, progressive shift, and engine brakes. Optional. Wire Comb A strain relief for the back of the VIH connector to prevent water from entering the connector from the back. Used in all Series 50, Series 149, and Industrial applications. All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION G-7 GLOSSARY G-8 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION INDEX A Active Codes, 5-24 Add Coolant Level Sensor (ACLS), 3-133 Aftermarket Installed Sensors, 3-146 Air Compressor Control, 5-3 decrease (set/coast on), 5-4 digital inputs, 4-19 digital outputs, 4-22 increase (resume/acceleration on), 5-3 load switch, 5-4 multiple pressure ratings, 5-4 shutdown, 5-4 solenoid, 5-4 wiring, 3-161 Circuits data link, 3-70 data link, 800 & 801, 3-70 data link, 900 & 901, 3-70 data link, 925 & 926, 3-70 return power (ground), 3-70 Codes, A-1 active flashed, 5-25 inactive flashed, 5-25 Common Rail Fuel Pressure Sensor (FPS), 3-112 Communication Harness, 3-27, connector-to-ECM, 3-59 Communication Link, J1939, 6-43 Air Compressor Pressure Sensor (ACPS), 3-126 Conduit and Loom, 3-101 Air Filter Restriction Sensor (AFRS), 3-128 Connector Removing Tools, 3-71 Air Intake Temperature Sensor, 3-129 Connectors 1708/1587 data link connector, 3-66 communication harness-to-ECM connector, 3-59 engine interface harness quick disconnect connector, 3-60 engine power harness quick disconnect connector, 3-61 ESH-to-ECM connector, 3-64 power harness-to-ECM connector, 3-58 Required Connectors, 3-53 SAE 1939/J1587 data link connector, 3-66 VIH-to-ECM connector, 3-56 Air Temperature Sensor (ATS), 3-111 Allision World Transmission Series, 5-242 Ambient Air Temperature Sensor, 3-146 Anti-Lock Brake Systems, 5-9 B Battery average drain current, 3-44–3-45 switch ground, 3-25 Coolant Level Sensor (CLS), 3-130 Battery Isolator, 3-46 Coolant Pressure Sensor (CPS), 3-112 Battery Size, 3-46 Coolant Temperature Sensor (CTS), 3-113 Bendix, E-1 Crankcase Pressure Sensor, 3-112, 3-114 Crimp Tools, 3-71 C Charge Air Temperature Sensor, 3-111 Check Engine Light (CEL) activated to flash codes, 5-53 as used in MAS, 5-108 engine overtemperature protection, 5-47, 5-50 engine protection, 5-45 flashing codes, 4-10 idle shutdown, 5-91 rampdown, 5-46 requirements and guidelines, 3-160 use in diagnostics, 5-24 Criteria, wires, 3-69 Cruise Control, 5-13 cruise power, 5-58 digital inputs, 4-6 engine brake, 5-39 engine speed, 5-13 vehicle speed, 5-13 Current amount of current draw, 3-44, 3-46 CEL requirements, 3-160 rated fuse current, 3-52 SEL requirement, 3-162 INDEX D Data Card, 5-161 Data Hub, 5-131 Data Link 1708/1587 connector, 3-66 messages, 6-6 circuits 800 & 801, 3-70 circuits 900 & 901, 3-70 circuits 925 & 926, 3-70 SAE J1587, 6-5, 3-70, anti-lock brakes, 5-9 SAE J1922, 6-35, 3-70, anti-lock brakes, 5-9 SAE J1939, 3-70, anti-lock brakes, 5-9 SAE J1939/J1587, connector, 3-66 Data Logger, 5-146, installation, 5-147 DDC, supplied hardware, 3-3 DDEC III Data Pages, 5-132 DDEC Reports, 5-133 DDEC Reprogramming System (DRS), 7-29 Deceleration Light, 4-24 Detroit Diesel Diagnostic Link (DDDL), 7-27 instrumentation menu, 5-115 maintenance alert menu, 5-113 Deutsch Connectors, 3-54, 3-79 Deutsch Terminals installation, 3-79 removal, 3-82 Diagnostic Data Reader (DDR), 7-7 maintenance status menu, 5-112 menu options, 7-10 activate outputs, 7-22 calibration changes, 7-19 diagnostic codes, 7-12 engine data list, 7-11 engine/trip data, 7-18 fuel injector, 7-17 maintenance status, 7-25 MIDs received, 7-23 reset AFR table, 7-24 switch/light status, 7-21 transmissions, 7-24 view calibration, 7-15 Diagnostic Request Switch, 7-3, 4-10, 5-25–5-26, 5-53 Diagnostics, 5-23 check engine light, 5-24 diagnostic request switch, 5-25 stop engine light, 5-24 stop engine override switch, 5-26 Index-2 Digital Inputs, 4-3 air compressor load switch, 4-19 auxiliary coolant level switch, 4-18 cruise control, 4-6 engine brake, 4-8 engine protection, 4-10 engine ratings, 4-12 engine synchro shift, 4-17 fan control, 4-13 parking brake interlock, 4-18 pressure sensor governor, 4-14 rpm freeze, 4-19 throttle control, 4-15 throttle kickdown, 4-19 Digital Outputs, 4-20 air compressor load solenoid, 4-22 coolant level low light, 4-23 cruise control active light, 4-23 deceleration light, 4-24 engine brake active, 4-24 ESS high range solenoid, 4-26 ESS low range solenoid, 4-25 ether injection, 4-26 external engine brake enable, 4-27 external engine synchronization/frequency input active, 4-27 fan control, 4-28 high coolant temperature light, 4-29 high crankcase pressure light, 4-29 high oil temperature light, 4-30 low coolant pressure light, 4-30 low ddec voltage warning light, 4-31 low oil pressure light, 4-31 optimized idle active light, 4-32 pressure sensor governor active light, 4-23 pressure sensor governor mode light, 4-32 service now lamp, 4-33 starter lockout, 4-35 Top2 shift lockout solenoid, 4-36 Top2 shift solenoid, 4-35 transmission retarder, 4-36 vehicle power shutdown, 4-37 VSG active indication, 4-38 E Edm and Aim, 5-27 EDM and AIM, 5-27 Electronic Control Module (ECM), 3-5 connections to other vehicle systems, 3-17 diagnostics, 5-23 environmental conditions, 3-7 master ECM, 3-13, 3-20 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL multi-ECMs, 3-6 engine sensor harness, 3-13 master ECM, 3-6 receiver ECM, 3-6 vehicle interface harness, 3-20 operating voltage, 3-43 receiver ECM, 3-13 Electronic Fire Commander (EFC), 1-6, 5-31 Electronic Foot Pedal Assembly (EFPA), 3-155, as OEM requirement, 3-3 Electronic Speed Switch (ESS-2), 5-35 Electronic Unit Injector (EUI), 3-30 Engine Brake, 5-39 active, 5-40 clutch released input, 5-40 cruise control, 5-39 digital inputs, 4-8 digital outputs, 4-24 disable, 5-39 engine fan braking, 5-40 minimum mph, 5-40 service brake control of, 5-40 ESH-to-ECM Connector, 3-64 Ether Start, 5-61 digital outputs, 4-26 ether start harness, 5-64 Exhaust Temperature Sensor (ETS), 3-138 F Fan Control, 5-69 digital inputs, 4-13 digital outputs, 4-28 dual fans, 5-75 single fan, 5-71 two-speed fan, 5-77 variable speed single-fan, 5-80 Ferrule, 3-86, 3-88 Fire Truck Pump Pressure Sensor, 3-140 Flash Codes, 7-3, 5-25, definition of, 5-26 FMI DDEC identifier, 6-5 definition of, 5-26 Engine Interface Harness, 3-20 Fuel Economy Incentive, 5-83 Engine Interface Harness Quick Disconnect Connector, 3-60 Fuel Pressure Sensor, 3-115 Engine Power Harness, 3-40 Engine Power Harness Quick Disconnect Connector, 3-61 Engine Protection, 5-45 diagnostic request switch, 5-53 digital inputs, 4-10 engine overtemperature protection, 5-47 rampdown, 5-46 shutdown, 5-47 stop engine override continuous override - option 1, 5-55 continuous override - option 2, 5-55 momentary override, 5-54 warning only, 5-46 Engine Ratings, 5-57 cruise power, 5-58 digital inputs, 4-12 limiting torque curve, 5-58 switches, 5-57 Engine Sensor Harness, 3-9, with multi-ecms, 3-13 Engine Synchro Shift (ESS) digital inputs, 4-17 digital outputs, 4-25–4-26 transmission interface, 5-247 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION Fuel Pressure Sensor (FPS), 3-115 Fuel Restriction Sensor (FRS), 3-116, 5-122 Fuel Temperature Sensor (FTS), 3-117 G Glow Plug Controller, 5-85, 5-87, oem connections, 5-86 Governor Droop, 5-215 Governors, 5-215 limiting speed governor, 5-215 overall governor gain, 5-187 variable speed governor, 5-220 H Half Engine Idle, 5-89 Hardware supplied by DDC, 3-3 supplied by OEM, 3-3 Harnesses ambient air temperature harness, 3-148 communication harness, 3-27 Index-3 INDEX communication Harness, 1-2 data logger modem harness, 5-150 data logger power harness, 5-148 engine interface harness, 3-20 engine power harness, 3-40 engine sensor harness, 3-9 engine sensor harness, construction and industrial, 3-11 engine sensor harness, genset, 3-12 engine sensor harness, multi-ecm, 3-13 engine sensor harness, on-highway, 3-9 ether start, 5-64 Injector Harness, 3-29 MAS display harness, 5-128 power harness, 3-33 ProDriver DC jumper harness, 5-169 ProDriver DC vehicle harness, 5-168 prodriver vehicle harness, 5-158 vehicle interface harness, construction and industrial, 3-21 vehicle interface harness, multi-ecm, 3-20 vehicle interface harness, on-highway, 3-17 vehicle power harness, 3-40 Horton Industries, Inc., E-1 Hot Idle, 5-215 I Idle Shutdown Timer, 5-91 ambient air temperature override disable, 5-93 enabled on VSG, 5-93 idle shutdown override, 5-92 vehicle power shutdown, 5-93 Ignition, ignition source, 3-25 Inactive Codes, 5-24 Index Sensors & Controls, Inc., E-1 Intercooler Coolant Pressure Sensor, 3-112 Intercooler Coolant Temperature Sensor (ICTS), 3-113 J J1939, 6-78, diagnostic layer parameter group number response definitions, 6-78 K Kent-Moore, 3-71 Kysor, E-1 Index-4 L Lights, 3-159 CEL, 3-159 SEL, 3-162 Limiting Speed Governor (LSG), 5-215 control options, 5-217 dual electronic foot pedal assembly, 5-219 electronic foot pedal assembly, 5-217 with VSG as a secondary control, 5-215 Linnig Corp, E-1 Low Gear Torque Limiting, 5-105 M Main Power Supply Shutdown, 3-48 Maintenance Alert System, 5-107 add coolant level sensor, 5-120 air filter restriction sensor, 5-118 Detroit Diesel Diagnostic Link, 5-113 diagnostic data reader, 5-112 display module, 5-110 fuel restriction sensor, 5-122 oil level sensor, 5-123 ProDriver, 5-109 Management Information Products, 5-131 data hub, 5-131 data logger, 5-146 DDEC data, 5-133 DDEC III data pages, 5-132 DDEC reports, 5-133 ProDriver, 5-151 ProDriver DC, 5-161 ProManager, 5-144 Marine Controls, 5-175 control station, 5-176 engine room, 5-177 Master ECM, 3-13, 3-20 Message Identification Character (MID), description of, 6-5 Metri-Pack Connectors 150 series, 3-54 280 series, 3-54 630 series, 3-54 MIDs DDEC identifier, 6-5 supported by DDEC, 6-35 Multi-ECM connectors, 3-60 engine interface harness, 3-60 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL vehicle interface harness, 3-53 DDC-supplied hardware, 3-3 engine interface harness, 3-20 engine power harness, 3-40 engine sensor harness, 3-13 first receiver ECM, 3-20 master ECM, 3-6, 3-20 OEM-supplied hardware, 3-3 receiver ECM, 3-6 second receiver ECM, 3-20 Series 2000 engine sensor harness, 3-15 Series 2000 vehicle interface harness, 3-22 Series 4000 engine sensor harness, 3-14 Series 4000 vehicle interface harness, 3-21 stop engine override switch, 3-20 vehicle power harness, 3-40 welding precaution, 3-50 O OEM diagnostic connector, 3-66 installed sensors, 3-125 supplied hardware, 3-3 supplied harness, 3-17, 3-27, 3-33, 3-40 supplied lights, 3-159 supplied throttle control device, 3-155 dual-fuse installation, 3-33 single-fuse installation, 3-35 Pressure Governor Light, 4-32 Pressure Mode, 5-197 Pressure Sensor Governor (PSG), 5-197 digital inputs, 4-14 digital outputs, 4-32 pressure mode, 5-197 rpm mode, 5-197 switches, 5-198 ProDriver, 1-6, 5-151 installation, 5-151, 5-163 flush mount, 5-152 surface mount, 5-155 maintenance alert system, 5-109 ProDriver reports, 5-142 ProDriver DC, 5-161 data card, 5-161 installation flush mount, 5-163 surface mount, 5-166 Progressive Shift, 5-203 high range, 5-205 low range #1, 5-204 low range #2, 5-204 Oil Level Sensor (OLS), 3-118, 5-123 ProManager, 5-144 Oil Pressure Sensor (OPS), 3-118 Pulse to Voltage Module (PVM), 5-209 Oil Temperature Sensor (OTS), 3-119 PWM 1 Port, 5-233 Optical Coolant Level Sensor, 3-136 Optimized Idle, 2-8, 5-179 digital outputs, 4-32 engine mode, 5-180 thermostat mode, 5-180 R Optimum Load Signal, 5-185 Receiver ECMs first receiver, 3-13, 3-20 second receiver, 3-13, 3-20 Overall Governor Gain, 5-187 Rockford Powertrain, Inc., E-1 RPM Mode, 5-197 P PasSmart, 5-189 PIDs, 6-6–A-9 DDEC identifier, 6-5 definition of, 5-26 double byte parameters, 6-20 single byte parameters, 6-10 variable length parameters, 6-26 Power Harness, 3-33 connector-to-ECM, 3-58 connectors, 3-39 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION S SAE J1128, 3-19 SAE J1587, 5-233 anti-lock brakes, 5-9 diagnostic connector, 3-67 message format, 6-5 PIDs, 6-6–6-8 double byte parameters, 6-20 single byte parameters, 6-10 transmitter data request, 6-9 Index-5 INDEX variable length parameters, 6-26 transmission interface, 5-241 SAE J1922, 6-35 anti-lock brakes, 5-9 communication harness design guidelines, 3-28 message format, 6-35 MIDs, 6-35 parameters available, 6-35 powertrain control data link, 5-233 transmission interface, 5-241 SAE J1939, 6-43 anti-lock brakes, 5-9 communication harness design guidelines, 3-28 data link layer parameter group number response definitions, 6-73 message format, 6-43 powertrain control data link, 5-233 transmission interface, 5-241 SAE J1939/71, application layer parameter group definitions, 6-44 Safety Precautions, 2-1 Sensors, 3-105–3-106, 3-112–3-114, 3-118–3-120, 3-125 add coolant level sensor, 3-133 air compressor pressure sensor, 3-126 air filter restriction sensor, 3-128 air intake temperature sensor, 3-129 air temperature sensor, 3-111 ambient air temperature sensor, 3-146 charge air temperature sensor, 3-111 common rail fuel pressure sensor, 3-112 coolant level sensor, 3-130 coolant pressure sensor, 3-112 coolant temperature sensor, 3-113 crankcase pressure sensor, 3-114 exhaust temperature sensor, 3-138 factory-installed sensors, 3-106, function and location, 3-106 fire truck pump pressure sensor, 3-140 fuel pressure sensor, 3-115 fuel restriction sensor, 3-116 fuel temperature sensor, 3-117 intercooler coolant pressure sensor, 3-112 intercooler coolant temperature sensor, 3-113 OEM-installed sensors, 3-125, function and guidelines, 3-125 oil level sensor, 3-118 oil pressure sensor, 3-118 oil temperature sensor, 3-119 optical coolant level sensor, 3-136 synchronous reference sensor, 3-120 throttle position sensor, 3-141 timing reference sensor, 3-120 turbo boost sensor, 3-123 vehicle speed sensor, 3-142 SEO Switch, 7-3, 4-10, 5-26 Service Now Lamp, 4-33 SIDs, A-13 DDEC identifier, 6-5 definition of, 5-26 SK-10658 Power Harness - Multi-ECMs - Series 149, E-1, B-9 Society of Automotive Engineers (SAE), 3-28 Starter Lockout, 4-35 Stop Engine Light (SEL) activated to flash codes, 5-53 as used in MAS, 5-108 engine overtemperature protection, 5-47, 5-50 engine protection, 5-45 flashing codes, 4-10 rampdown, 5-46 requirements and guidelines, 3-162 shutdown, 5-47 use in diagnostics, 5-24 wiring, 3-163 Stop Engine Override (SEO) Switch, 5-53, multi-ECMs, 3-20 Stop Engine Override Options, 5-54 Synchronous Reference Sensor (SRS), 3-120 T Tachometer Drive, 5-213 Tape and Taping, 3-103 Terminal Installation Deutsch connectors, 3-79 pull-to-seat, 3-76 push-to-seat, 3-72 quick disconnect connector, 3-83 Terminal Removal Deutsch terminals, 3-82 main VIH, 3-89 pull-to-seat, 3-79 push-to-seat, 3-75 Throttle Control, 3-155, 5-215, digital inputs, 4-15 Throttle Devices, 3-155, electronic foot pedal assembly, 3-155 Throttle Position Sensor (TPS), 3-141 Timing Reference Sensor (TRS), 3-120 Index-6 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Top2, 5-245, digital outputs, 4-35–4-36 Wire Comb, 3-56 Transmission Interface, 5-233 Allison hydraulic transmission, 5-240 Allison interface modules, 5-236 Allison world transmission, 5-242 digital input and output transmissions, 5-245 Eaton CEEMAT transmission, 5-244 Eaton Top2, 5-245 GE propulsion system controller, 5-238 Meritor engine synchro shift, 5-247 PWM1 operation, 5-233 SAE J1939 transmissions, 5-244 Voith transmission, 5-239 ZF Ecomat, 5-239 Wires criteria, 3-69 recommendations, 3-69 requirements, 3-69 Transmission Retarder, 5-253, digital outputs, 4-36 Turbo Boost Sensor (TBS), 3-123 V Variable Speed Governor (VSG), 5-220 alternate minimum VSG, 5-225 cruise switch VSG, 5-222 dual throttle controls, 5-228 electronic foot pedal assembly, 5-224 frequency input, 5-231 hand throttle, 5-223 voltage dividers, 5-225 Vehicle Electronics Programming System (VEPS), 7-5 Vehicle Interface Harness (VIH) construction and industrial, 3-21 multi-ecm, 3-20 multi-ecm, engine interface harness, 3-20 on-highway, 3-17 wire comb, 3-56 Vehicle Power Harness, 3-40 Vehicle Power Shutdown, 4-37, 5-91 Vehicle Speed Limiting, 5-255 Vehicle Speed Sensor (VSS), 3-142 magnetic pickup requirements, 3-143 open collector requirements, 3-145 VIH-to-ECM Connector, 3-56 Voith Retarder, 4-36 VSG, digital outputs, 4-38 W Weather Pack Connectors, 3-54 Wiring add coolant level sensor, 3-135 add coolant level sensor with dash-mounted light, 5-121, 3-134 air compressor pressure sensor, 3-127 air filter restriction sensor, 5-119, 3-129 Allison transmission automatic transmission open collector speed sensor, 5-238, 5-243 hydraulic transmission, 5-240 maximum feature throttle interface module, 5-237 throttle interface module, 5-236 WT-series, 5-242 CEEMAT transmission, 5-244 check engine light, 3-161 coolant level sensor, 3-131 data link circuits, 3-70 data logger modem harness, 5-150 data logger power harness, 5-148 dual hand throttle, 5-230 engine synchro shift, 5-249 fire truck pump pressure sensor, 3-141 fuel restriction sensor, 5-122 GE propulsion system controller, 5-238 magnetic pickup VSS, 3-143 management information system, 5-159 multiple warning lights, 3-164 oil level sensor, 5-123 open collector VSS, 3-144 optical coolant level sensor harness, 3-137, 3-139 optimum load signal interface, 5-185 power harness - single-ECM, dual-fuse, 3-33 power harness - single-ECM, single-fuse, 3-36 power harness wire resistance, 3-70 pressure sensor governor, 5-199 ProDriver DC jumper harness, 5-169 ProDriver DC vehicle harness, 5-168 ProDriver vehicle harness, 5-158 return power (ground) circuits, 3-70 splicing and heat shrink, 3-91 stop engine light, 3-163 tachometer, 5-213 Top2 transmission, 5-246 vehicle power harness Series 149, 3-41 Series 4000, 3-42 Voith transmission, 5-239 ZF Ecomat transmission, 5-239 Welding, 3-49–3-50 All information subject to change without notice. (Rev. 3/02) 7SA742 0203 Copyright © 2002 DETROIT DIESEL CORPORATION Index-7 ">
/
Download
Just a friendly reminder. You can view the document right here. But most importantly, our AI has already read it. It can explain complex things in simple terms, answer your questions in any language, and help you quickly navigate even the longest or most compilcated documents.
Public link updated
The public link to your chat has been updated.
Document public link
Advertisement
Key features
- Improved engine control
- Extensive range of engine and vehicle options
- Facilitates feature selection and settings
- Guides fabrication and installation of vehicle interface harness
- Explains communication between sensors and electronic control modules
- Provides tools for obtaining engine data and diagnostics
- Enables reprogramming of key parameters
- Offers application-specific recommendations
- Includes information on codes and kit availability
Frequently asked questions
DDEC IV is the fourth generation electronic engine controller from Detroit Diesel Corporation. It offers improved engine control and a more extensive range of engine and vehicle options.
This manual covers the installation and use of DDEC IV. It includes information on features, settings, communication protocols, hardware and wiring requirements, tools for obtaining engine data and diagnostics, and application-specific recommendations.
A basic understanding of electrical circuits is required for a simple installation. A more comprehensive electrical/electronics background is recommended to access all the capabilities of DDEC IV.
