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5 DDEC FEATURES - Wanderlodge Gurus

1. 5V SUPPLY BATTERY 12V GROUND TO CAVITY B 953 TO CAVITY NOTE WIRE PAIRS MUST BE TWISTED A MINIMUM OF 12 TURNS PER FOOT MAS DISPLAY WIRE WIRE CONNECTOR LABEL NO COLOR CAVITY GROUND 953 BLKANHT BATTERY 12V RED IGNITION 12V ONLY 439 PNK J 1587 DATA LINK 901 DK GRN J 1587 DATA LINK 900 DK GRN YEL SENSOR SUPPLY 916 RED BLK Figure 5 63 Maintenance Alert System Display Harness 5 21 3 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION The DDR can set options for the CEL and SEL indication of MAS codes as listed in Table 5 58 DDEC IV APPLICATION AND INSTALLATION MANUAL Parameter Description Choices Action Determines if the CEL SEL will NO FLASH NO no illumination or flashing Filters flash a maintenance alert for CONTINUOUS FLASH flash at ignition on filters BOTH CONTINUOUS Light will stay Determines if the CEL SEL will NO FLASH ae LM E Levels bos a alert for a tata BOTH light will flash at
2. T 1 S0 m i 5X 6 0 20 24 E 48 30 mm 48 30 mm 1 90 in 1 90 in Figure 5 90 ProDriver DC Surface Mount 5 166 All information subject to change without notice Rev 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 NOT TO SCALE 6 00 mm 0 24 in 5 HOLES 48 3 mm 48 3 mm 1 90 in 1 90 in NOTE ALL DIMENSIONS IN MILLIMETERS INCHES Figure 5 91 ProDriver DC Surface Mount Bracket All information subject to change without notice Rev Rev 3 02 5 167 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 2TO BATTERY TO GROUND CONNECTOR P N 12064978 TERMINAL T
3. reduced 62 XXX 3 Low range solenoid short to battery 62 XXX 4 Low range solenoid open circuit ESS is disabled Range control is 62 XXX 3 High range solenoid short to battery lost towards the bad solenoid 62 XXX 4 High range solenoid open circuit 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 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 Seiting 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
4. TO FAN NOTE DIGITAL OUTPUT 1224 V WHEN FAN IS NOT RUNNING FAN CONTROL 1 THE FAN WILL SPIN DUE TO AIR FLOW VAR a ieee d CONTINUOUS TRANSIENT SUPPRESSED RELAYS 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 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 TRANSMISSION DIGITAL INPUT RETARDER 953 BATTERY OPTIONAL GROUND DIGITAL INPUT OVERRIDE 953 BATTERY ___ OPTIONAL GROUND DIGITAL OUTPUT FAN CONTROL 1 INDEX CONTROL 12 24 VDC MODULE INDEX P N CM 811 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT
5. Fan PWM AIC Input Override Jake Brake Primate Control State Output P Input Status y On Modulated Grounded Open Not in High Mode barca ensors Off Open Grounded Open Not in High Mode ELI M E ensors 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 Jake Brake in High Mode and Air Temperature Above Limit Transmission Retarder Active and Coolant Temperature Above Limit 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 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 DIGITAL INPUT 953 BATTERY A C FAN STATUS GROUND FAN CONTROL L 440 24 VDC SOLENOID PWM DIGITAL OUTPUT Figure 5 37 Series 4000 Fan Control Inputs and Outputs All information subject to change without notice Rev Rev 3 02 5 81 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES For additional information contact the clutch manufacturer Rockford Powertrain Inc 1200 Windsor Road Rockford I 61132 2908 Phone 815 633 7460 5 14 7 PROGRAMMING REQUIREMENTS AND FLEXIBI
6. ON NOLLNG Qno 3Nnsas ON NOLLNG Qno SONM LJIHS WNOLLdOJ SS3N3VH ASINYO LAs Engine Synchro Shift Schematic Figure 5 128 5 249 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION All information subject to change without notice Rev Rev 3 02 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 Results ESS is disabled Manual shifting r can be performed with the clutch If i 151 14 Stuckin gear detected 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 73 084 12 Vehicle Speed Sensor failure system switch is OFF If the system switch is ON then the last range is used 73 297 4 Shift knob voltage below normal m D or shorted low ESS is disabled Manual shifting 73 227 3 Shift know voltage below normal can be performed with the clutch If or shorted low the system switch is ON DDEC will 73 097 9 Shift knob data erratic intermittent control the high low range or incorrect If both switches fail ESS and automatic range control is disabled The range will fail in the last 73 226 11 Neutral In Gear Switch fault selected position If one switch fails ESS operation will continue but the system performance will be
7. gt INCREASING TEMPERATURE TEMPERATURE BASED TIMED BASED 909 PROTECTION SHUTDOWN EOP IF CONFIGURED 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 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 ENGINE OPERATING TORQUE SPEED AT CEL CODE LOGGED FACTORY SET NO LIGHTS OPERATING OF ENGINE OPERATING TORQUE FAULT TORQUE SPEED AT CEL AND OR BROADCAST FACTORY SET SPEED ENGINE OVERTEMPERATURE a PROTECTION EOP IF CONFIGURED RAMPDOWN MINIMUM OF
8. All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION TWNINYAL Vig vOcL Nid MOLO3NNOO NICON 56 yovga mo _ ____ Uo Z OXY WSCOW OLYIVG LINSNVEL amad 91g oxy 9 0 OXLWSCOW NOHA VIVO SAI0SY MOTISA Glg ax zg P GINId OGAFZL GSHOLIMS O y YLOWSCOW OL Lnd nO ay vig MIO eg agen OCA vZI 6 g AlddNs YMd ANAM usa NICON NOHA LNdNI NYL g ysa tg 9 SLY WACON WOMJ LNA LAO Jidd ae SIM 8 2 SLO IN3GON WOH LNANI IHM 118 Slo 98 g IndNIGOQ HOT WSCOW Na3dHO Q OLB god 7g C d3sn 38 CINOHS SS3NHVH j BAGIENNY N AOAN XNIS APZ YL LNdLNO NAY WV LAY SgONVHO 888 1nONHVM 98 S Jenugold 41 CASN SI 439901 VYA AINO NHM MHOIVOICNI TVNSIA HO SIGN 96 C yovga t E k z TWNOIS MEW S8rSH H3OV3H CYVO yva ZIL HH 9v PFRN ETNE WNOIS MEV 987SY H3OV3H IVO GHH IMZ HlOHO SY LT LI z O13 Od N3GON 7 2SH HOF JONdH3HH NOAWOO yva S07 o W 060v0Z Nid HOLOSNNOO Pleo ueuis GES OUATEZLE y AlddNS H3MOd d i VM 3OV3HLINI SLWALOV QEN w0 CGNODd tV Od WON VIG 3AIO3H NMOUd 02 Oda ZY Od OLVING LINSNVEL ama 202 OdOaXL IY C GEN OCA re l 3 NOILONNA X01090 ON WNOIS Nid 9ELL0SEZ Nid F JHM OMd ALIAVO a ZELLOSEZ Nid TWNAMAL H 6817S LSES Nid HOLOANNOD QVO INMOd Data L
9. 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 Rev 3 02 5 89 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 90 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALL
10. OPTIONAL WIRING TO ALLOW RADIO TO OPERATE AT ALL TIMES Figure 5 95 Optimized Idle System Overview All information subject to change without notice Rev Rev 3 02 5 1 8 1 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 R 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 IDEE E TIMER Enables Disables the Idle Shutdown Feature YES Required The amount of engine idle time that is TIME min allowed before the idle shutdown feature stops fueling the engine Disables the Idle Shutdown timer OVERRIDE Override feature NO ENABLED ON VSG Allows the Idle timer to shutdown the YES engine when operating on PTO 1 100 minutes customer s choice Table 5 75 Idle Shutdown Timer Parameters Optimized Idle ins
11. 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 L Pressure Mode monitors water pump discharge pressure while varying engine speed to maintain the set pump pressure QO 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 sp
12. 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 gon alm v iiid Descnpron 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 Pro
13. MAX OVERSPEED LIMIT 0 to 127 MPH Table 5 117 Vehicle Speed Limiting Parameters 5 36 4 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 Rev 3 02 5 255 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 256 All information subject to change without notice Rev 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 int
14. Q 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 cu
15. All information subject to change without notice Rev Rev 3 02 5 27 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES L Check and Stop Indicators The AIM see Figure 5 8 is used in conjunction with the EDM to display additional equipment parameters 9 BETROI DIESEL LGcTRONIG CONTROLS Auxiliary Information Module Manufactured Exclusively for Detroit Diesel Corporation by Sturdy Controls Division Wilmington NC USA PATENTS PENDING PART NUMBER 23517175 SERIALNUMBER ec NOTICE This device contains No Serviceable Parts and is sealed against any Unauthorized Opening Any tempr te open alter or damage this device can result in improp operation of the Electronic Control System t Sil also void all warranty coverage for this device ig oh ag Figure 5 8 Auxiliary Interface Module 5 6 2 INSTALLATION For information on installing the Construction and Industrial EDM and AIM refer to the Construction amp Industrial EDM and AIM Installation and Troubleshooting manual 7S A801 5 6 3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY Refer to Construction amp Industrial EDM and AIM Installation and Troubleshooting manual 7SA801 5 28 All information subject to change without notice Rev Rev 3 02 7S
16. DDC P N 12048086 TO ACLS LABEL WIRE NO CAVITY WIRE COLOR PLUGGED AFRS PPLANHT PLUGGED SENSOR GROUND BLK SENSOR SUPPLY GRA PLUGGED ACLS ORN Figure 5 52 MAS Pigtail Connection to the Air Filter Restriction Sensor All information subject to change without notice Rev Rev 3 02 5 17 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES Air Filter Restriction Sensor The AFRS see Figure 5 53 is mounted downstream of the air filter and upstream of the turbocharger 3 8 24UNF 2B THREAD 69 5 mm 2 74 in 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 1 18 All information subject to change without notice Rev 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 CONNECTOR DDC P N 12110293 TERMINAL 3 REQ D DDC P N 12048074 SS ra SECONDARY LOCK MATES TO SSN DDC P N 12052845 MAS PIGTAIL SS E74 CABLE SEAL 3 REQID CONNECTORONESH 904 Ce DDC P N 12048086 DDC PIN 12047937 Bd TERMINAL CR DDC PIN 12048074 SECONDARY LOCK
17. 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
18. 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 DIGITAL INPUT FOR DUAL EFPA Figure 5 107 LSG Dual Electronic Foot Pedal Assembly Throttle All information subject to change without notice Rev Rev 3 02 5 219 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 Digital Input Function Number Dual EFPA 28 Table 5 96 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
19. DESCRIPTION 12 24 VDC BATTERY POSITIVE 4 BATTERY GROUND ETHER START DIGITAL OUTPUT VALVE INPUT D VALVE INPUT E NOTE BLUE 24 VDC RED BLUE 12 VDC Figure 5 28 RELAY CONNECTOR DDC Ether Start Harness CIRCUIT BREAKERS CANNOT BE USED WIRE VALVE FUSE HOLDER COLOR CONNECTOR CONNECTOR RED RED BLK GREEN RED BLUE WHT 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 All information subject to change without notice Rev 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 w
20. port and starboard One Electronic Display Module EDM for each engine L One Emergency Backup Control Panel EBCP master station only L Ignition switch master station only 5 176 All information subject to change without notice Rev 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 O L L L E 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 Rev 3 02 5 177 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION weeg xoo g 07u09 ueNwW 23adad SYOSNAS 3unss3ud FN WeasAdNsAL NOISSIASNYM L a a1gvo Ad3LIva LIOA velel ldIHS HV3O Wolvnlov uvado WNOILdO Ad3LIva LIOA bale WNOILdO J Indo SOVAYALNI WOOM 3NION3 sss nouum T3NVd dnyova AONSADYAWA SS anaon 3OV431N novis ou1Noo ESRC LIOHLBO
21. 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 ProDriver DC Flush Mount Kit P N 23525759 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 ProDriver DC Surface Mount Kit P N 23525760 Part Number Description 23525762 Data Card 23529276 ProDriver DC U
22. 12 00 0 12 00 14 00 15 14 00 16 00 16 00 18 00 18 00 20 00 20 00 22 00 22 00 24 00 N J Average Speed 49 4 OO CO O O0 WN N Date 6 18 1998 Total hh mm 08 49 07 37 07 34 Start Time 01 00 00 Hour EST Drive min Idle min Off min Odometer 57650 6 mi 00 00 02 00 61 59 02 00 04 00 61 59 04 00 06 00 61 59 Distance 418 0 Fuel 66 50 06 00 08 00 S9 Fuel Economy 6 29 08 00 10 00 44 Average Speed 474 10 00 12 00 0 12 00 14 00 30 14 00 16 00 16 00 18 00 18 00 20 00 20 00 22 00 22 00 24 00 Date 6 17 1998 Total hh mm 08 33 03 13 12 14 Start Time 08 55 59 Hour EST Drive min Idle min Off min 120 120 120 116 75 0 25 o Odometer 57233 0 i 00 00 02 00 02 00 04 00 04 00 06 00 Fuel 62 50 06 00 08 00 Fuel Economy 6 68 08 00 10 00 10 00 12 00 12 00 14 00 14 00 16 00 16 00 18 00 18 00 20 00 20 00 22 00 22 00 24 00 Distance 417 6 Average Speed 48 8 OJO N NINO O O05 a a Figure 5 65 DDEC Reports On highway Daily Engine Usage 5 1 36 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL DDEC Reports Engine Load RPM Print Date July 3 1998 08 26 AM Detroit Diesel 13400 West Outer Drive Detroit MI 48239 313 592 5500 Trip Vehicle ID Driver
23. 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 Definition Display Choice LATE CHANGE 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 SKIP SHIFT Enables disables Skip Shift feature YES NO 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 Rev 3 02 5 251 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 fa
24. 40 VEHICLE SPEED MPH 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 Figur
25. 5 78 ProDriver Flush Mount 5 152 All information subject to change without notice Rev 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 NOT TO SCALE 63 50 mm 63 50 mm 2 50 in 2 50 in pg 19 05 mm i 0 75 in ML ae zi 100 i li li 2 Lm 2 00 in GE ES i w 0 334 mm 0 21 in 2 PLACES A 38 10 mm 1 50 in 3 43 94 mm 1 73 in Y NOTE ALL DIMENSIONS IN MILLIMETERS INCHES Figure 5 79 ProDriver Flush Mount Mounting Bracket All information subject to change without notice Rev Rev 3 02 5 153 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES The flush mount display cutout template is shown in Figure 5 80 NOT TO SCALE 9 00mm 118 11mm 354in R 4 65in LZ PLACES E CUT OUT 79 00mm AREA 3 11in OUTLINE OF MODULE NOTE ALL DIMENSIONS IN MILLIMETERS INCHES Figure 5 80 ProDriver Flush Mount Display Template 5 154 All information subject to change without notice Rev 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 NOT TO
26. 50 Hz 1 Hz Low State On 1 lt Eout lt 2 0 V Sink lt 500 mA High State Off Voltage determined by PVM Leakage lt 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 lt 5 10 0 5 0 5 10 1 0 25 2 5 50 5 0 75 7 5 90 9 0 95 9 5 gt 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 2 10 All information subject to change without notice Rev 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 171 5 mm 6 75 in ____ 158 8 mm 6 25 in DETROIT DIESEL ELECTRONIC CONTROLS PVM 23522828 Manufactured Exclusively for letroit Diesel Corporation by Sturdy Corporation Wilmington NC PATENTS PE
27. ANF VIVG V ONS Ada THM GNNOYS AHSLIVS zv NOLLINSI ANd NOI Iv 40109 NOlldl OS3g ALIAVO JAM YOLOANNOD S3ONVININOO aula 5 33 Electronic Fire Commander Harness 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION All information subject to change without notice Rev Rev 3 02 Figure 5 10 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 VIRO ECM Connector Assignment Pressure RPM Mode 8 523 H1 PSG Enable 24 543 G2 Resume Accel On 22 545 G3 increase 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 Connector Assignment PSG Active 5 499 VIH to ECM Connector Cavity F3 Cruise Active 14 565 Pigtail off the Engine Sensor Harness Cavity Y3 DDC circuit numbers and port assignments show
28. AUXILIARY PEST auxiliary switch 1 INPUT on the Recever MA WARN SHUTDOWN 1 y RAMP SHTDWN ECM 1 Determines the type of engine protection with an active auxiliary switch 2 input N A will be N A WARN POER SR ORDONAS displayed if auxiliary switch 2 has not been RAMP SHTDWN configured as a switch input Table 5 26 Engine Protection 5 10 7 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 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 R
29. Allison Automatic Transmission Open Collector Speed Sensor GE Propulsion System Controller See Figure 5 120 for the PWM wiring for the GE Propulsion System TO OEM INTERFACE VIH TO ECM CONNECTOR LABEL 1 CAVITY PWM 1 J3 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 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 S Oo OOo OBS CONNECTOR DDC P N 12052848 TERMINAL DDC P N 12048074 OPYOSOOCANSS O99 ABOOS OOo VIH TO ECM CONNECTOR CAVITY J3 ZF ECOMAT CONNECTOR E Figure 5 121 DDEC IV to ZF Ecomat Transmission See Figure 5 122 for installation of the Voith transmission interface S Oo OOo OOS SSS Q89 TO PIN 8 ON VOITH CONNECTOR BPOSOANSOSS9gg 505 TO PIN 3 ON VOITH CONNECTOR CONNECTOR DDC P N 12034398 TERMINAL VIH TO ECM DDC P N 12103881 WIRE CONNECTOR WIRE LABEL NO CAVITY COLOR PWM 1 908 J3 WHT TACH DRIVE 505 K1 GRA Figure 5 122 DDEC IV to Voith Transmission All information subject to change without notice Rev Rev 3 02 5 239 7SA742 0203 Copyright 2002
30. Control Application and Installation 188A372 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 Ll Seamless transfer of control from the active control station to any one of the additional control stations L Control and synchronization of two to four engines O Two levels of idle low idle and user idle L 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 L Trolling gear control optional 5 23 1 OPERATION The Engine Room Interface Module ER
31. DCPM Detroit MI 48239 Operator ID 313 592 5959 Period Time 63 49 53 Idle Time 9 46 46 Period Fuel 446 00 gal Idle Fuel 2 50 gal Fuel Consumption 6 99 gal h Idle Percent 15 32 96 Avg Operating Load 51 96 Maintenance Due Eng Hrs Projected Fuel Left Left Date gal 1 04 24 1999 250 00 39 05 04 1999 550 00 79 05 14 1999 850 00 Maintenance Limits Engine Hours 40 80 Last Maintenance Date 04 14 1999 04 14 1999 04 14 1999 Figure 5 67 DDEC Reports Nonroad Periodic Maintenance 5 1 38 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL DDEC Reports High RPM Print Date Apr 19 1999 03 52 PM DDC DDEC Lab RDI Period 04 09 1999 to 04 19 1999 13400 Outer Drive West Equipment ID PDCPM Detroit MI 48239 Operator ID 313 592 5959 Period Time 63 49 53 Idle Time 9 46 46 Period Fuel 446 00 gal Idle Fuel 2 50 gal Fuel Consumption 6 99 gal h Idle Percent 15 32 Avg Operating Load 51 96 High RPM Histogram 1800 1899 1900 1999 2000 2099 2100 2199 2200 2299 2300 2399 2400 2499 2500 2599 2600 2699 2700 an E o D D a o E o Z LLI 20 96 of Period Time Percent of Time Spent in High RPM Bands Figure 5 68 DDEC Reports Nonroad High RPM Detail All information subject to change without
32. DDC PIN 12066304 CABLE SEAL DDC P N 12048086 3 8 24 UNF AIR FILTER RESTRICTION SENSOR DDC P N 23526140 OEM s CHOICE OF FITTINGS TORQUE 10 15 in Ibs 1 8 27 NPT MAS PIGTAIL ESH TO ECM WIRE MATING WIRE AFRS CONNECTOR NO CONNECTOR COLOR CONNECTOR CAVITY 904 B PPLAWHT B L1 SENSOR GROUND 452 D BLK A Y2 SENSOR SUPPLY 416 E GRA o w1 Figure 5 54 Air Filter Restriction Wiring Diagram All information subject to change without notice Rev Rev 3 02 5 1 19 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 COLD FULL LEVEL MOUNT SECOND PROBE ATA LEVEL TO 5in 12 7 mm PROVIDE REASONABLE WARNING AERATION AT LEVEL BEGINS REPRESENTING 98 OF DRAW DOWN QUANTITY 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDE
33. DETERMINED BY LOAD amp ITS SUPPLY VOLTAGE CURRENT lt 1 0 mA LO STATE VOLTAGE lt 0 8 VOLTS CURRENT lt 500 mA I STATE VOLTAGE LO 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL HI STATE VOLTAGE DETERMINED BY LOAD amp ITS SUPPLY VOLTAGE CURRENT lt 1 0 mA LO STATE VOLTAGE lt 0 8 VOLTS CURRENT lt 500 mA I H t d Lu z ep 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 PWMI Transmission FOM informeton Duty Cycle PWM Signal Communication Sent Description Allison Hydraulic Powertrain Anne see Figure 5 123 page Eu Demand 0 100 Discrete Allison Transmission Electronic Powertrain Controls ATEC PWM 1 Demand 0 100 Modulated GE Propulsion System Oeralim on Controller PWM 1 i Cline 5 95 Modulated see Figure 5 120 page VOITH PWM 1 or SAE Powertrain o see Figure 5 122 page J1939 Demand
34. DETROIT DIESEL CORPORATION 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 WILLIAMS 7OPSI 482 KP AIR MODULATOR a P N 117 SKINNER i dE N O SOLENOID AIR SUPPLY P N C5DK1175 AIR FLOWS FROM 1 3 2 FULL THROTTLE AIR EXHAUSTED FROM 2 393 CLOSED THROTTLE DDEC III IV WIRE 908 CAVITY J 3 Figure 5 123 DDEC IV to Allison Hydraulic Transmission 5 240 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION Programming Requirements and Flexibility DDEC IV APPLICATION AND INSTALLATION MANUAL 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 Table 5 104 Transmission Types DDEC uses the transmission output shaft speed to determine vehicle speed Programming information is listed in Table 5 105 m DDEC IV Transmission DDEC IV Transmission Sensor Type Wire Wire Calibration Allison Transmission Open Collector 556 205 Open Collector Electronic Controls Allison Hydraulic Extern
35. DIESEL CORPORATION 5 73 DDEC FEATURES See Figure 5 34 for the specific connection from the ECM to the control module TRANSMISSION DIGITAL INPUT RETARDER 953 BATTERY GROUND DIGITAL INPUT OVERRIDE 953 BATTERY GROUND DIGITAL INPUT A C 953 BATTERY GROUND DIGITAL OUTPUT FAN CONTROL 1 412 24 VDC 0 N AIR SUPPLY TO FAN CLUTCH NOTE ALWAYS USE A NORMALLY CLOSED AIR SOLENOID VALVE WHEN AIR IS SUPPLIED TO FAN CLUTCH THE FAN TURNS OFF 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 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
36. 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 Rev 3 02 5 243 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 PACKARD P N 12010973 TERMINAL PACKARD P N 12089305 CABLE SEAL PACKARD P N 12015193 COMMUNICATIONS CONNECTOR DDC P N 12066317 TERMINAL DDC P N 12103881 PLUG DDC P N 12034413 COMMUNICATION CEEMAT INTERFACE CONNECTOR WIRE CONNECTOR LABEL CAVITY COLOR CAVITY J1922 DATA LINK A TANANHT A 41922 DATA LINK B TAN B 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
37. ID Odometer 6 02 98 to 6 19 98 PDCPM 58273 6 mi 5698 9 mi 831 13 gal 6 86 mpg 46 96 49 0 mph Trip Distance Trip Fuel Fuel Economy Avg Drive Load Avg Vehicle Speed Trip Time 1 Fuel Consumption Idle Time Idle Percent Idle Fuel 34 33 33 6 18 gal h 18 14 17 13 55 96 7 63 gal Engine Load Histogram 0 20 40 Engine Speed Histogram 0 699 700 999 g 1000 1199 amp 1200 1299 9 1300 1399 amp 1400 1499 B 1500 1599 in 1600 1699 1700 1799 1800 Engine Load 20 40 Percent of Trip Time Percent of Trip Time Percent of Trip Time in Load and RPM Table Engine Load Engine RPM 20 29 30 39 40 49 50 59 60 69 70 79 80 89 90 100 TOTAL ees oss 02 01 05 i Pos ere epos pos 1 5 04 Lu pu 2 ros os 1 X s Ler 22 3 07 s oz oz o7 Er A AEA is Pas ar 7 0 0 o NI 45 0 3 12 9 0 5 10 8 1200 1299 1300 1399 ieee a E EH Lu KA o a1 re gt 1515 or os 0 Lees or B ms 1 2 ojo ala 5 4 4 2 0 7 o ol N o Figure 5 66 DDEC Reports On highway Engine Load RPM 5 137 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES DDECe Reports Periodic Maintenance Print Date Apr 19 1999 03 53 PM DDC DDEC Lab RDI Period 04 09 1999 to ML 13400 Outer Drive West Equipment ID
38. 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 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 Table 5 5 Variable Speed Governor Maximum and Minimum RPM 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 Description Range Indicates the delta value above the current air LOAD PSI pressure set point that will initiate the air compressor 0 to UNLOAD PSI governor to reload the system Indicates the delta value above the current air UNLOAD PSI pressure set point that will initiate the air compressor LOAD PSI to 31 PSI 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 allow
39. N 12015323 TERMINAL DDC P N 12089188 CAVITY PLUG DDC P N 12010300 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 Rev 3 02 5 237 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES VIH TO ECM CONNECTOR P N 12034398 TERMINAL P N 12103881 TO OPEN COLLECTOR DEVICE ALLISON TRANSMISSIONS VIH VSS WIRE CONNECTOR WIRE CONNECTOR LABEL NO CAVITY COLOR CAVITY VEHICLE SPEED SENSOR 556 E2 LT BLU BLK SIGNAL VEHICLE SPEED SENSOR PLUGGED Figure 5 119
40. O O G OO SHORT SHORT PAUSE PAUSE 1 2 SEC 1 2 SEC CODE 21 ACTIVE INACTIVE 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 L 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 Rev 3 02 5 25 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 L 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 S
41. OPERATING TORQUE SPEED AT CEL gt INCREASING TEMPERATURE TEMPERATURE BASED t 0 TIMED BASED t 30S PROTECTION SHUTDOWN E IF CONFIGURED Figure 5 19 Series 60 1999 Model Year Engine Overtemperature Protection and Rampdown All information subject to change without notice Rev Rev 3 02 5 51 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES ENGINE OPERATING TORQUE SPEED AT CEL CODE LOGGED FACTORY SET NO LIGHTS OPERATING TORQUE OF ENGINE OPERATING AND OR FAULT TORQUE SPEED AT CEL SPEED BROADCAST FACTORY SET SEL ON ENGINE OVERTEMPERATURE PROTECTION EOP IF CONFIGURED f RAMPDOWN MINIMUM OF OPERATING TORQUE SPEED AT CEL SHUTDOWN gt INCREASING TEMPERATURE TEMPERATURE BASED TIMED BASED t 30S PROTECTION SHUTDOWN EOP IF CONFIGURED Figure 5 20 Series 60 1999 Model Year Engine Overtemperature Protection and Shutdown 5 52 All information subject to change without notice Rev 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
42. 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 ENGINE OPERATING TORQUE SPEED CEL AT CEL FACTORY SET OPERATING OF ENGINE OPERATING TORQUE TORQUE SPEED AT CEL SPEED FACTORY SET STOP ENGINE ENGINE OVERTEMPERATURE OVERRIDE WILL PROTECTION EOP RESET 30 1 RAMPDOWN SECOND TIMER MINIMUM OF OPERATING TORQUE SPEED AT CEL I I I I I I I I l SHUTDOWN I I I I I I I I TEMPERATURE BASED TIME BASED ieee PROTECTION SHUTDOWN NOTE SHUTDOWN WILL BE AVOIDED IF THE STOP ENGINE OVERRIDE SWITCH IS CLOSED Figure 5 22 Engine Overtemperature Protection and Shutdown Protection with Stop Engine Override 5 54 All information subject to change without notice Rev 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 shutdow
43. 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Parameter Description Choice Display ENABLED Enables or Disables the Idle Shutdown feature N A will be displayed if the parking brake has not been configured as a digital input YES NO TIME MIN The amount of engine idle time that is allowed before the Idle Shutdown feature stops fueling the engine 1 to 100 minutes OVERRIDE The override will flash the CEL 90 seconds before shutdown to allow the driver to cancel the shutdown by pressing the throttle YES NO ENABLED ON VSG Enables or disables the Idle Timer Shutdown feature when operating on the Variable Speed Governor YES NO OVERRIDE TEMP DISAB Allows choice between lower or upper limit to disable the Idle Shutdown Override feature based on ambient air temperature LOWER LIMIT UPPER LIMIT O LOWER LIMIT
44. Rev 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 Rev 3 02 5 141 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES 5 22 6 PRODRIVER REPORTS This Windows 95 compatible software sends set up parameters to extracts dat
45. S A P O Box 670 Mineola NY 11501 0670 Phone 516 742 1900 5 14 6 DDEC uses a pulse width modulated PWM output to drive a variable speed fan Presently VARIABLE SPEED SINGLE FAN available PWM outputs and specifications are listed in Table 5 37 Duty Cycle Duty Cycle o Engine Series PWM Output Frequency Minimum Fan Maximum Fan Speed 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 ata 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
46. SCALE DETROIT DIESEL ELECTRONIC CONTROLS MENU INFO DOWN M A 114 05 mm 4 y 4 49 in DET zt 5MM NUTS 18 6 Ib in ALL DIMENSIONS IN MILLIMETERS INCHES TORQUE NUT TO 2 1 N M NOTE 203 2 mm Y M 8 0 in 17 53 mm 69 in E 37 59 mm 1 48 in Y Figure 5 81 ProDriver Surface Mount All information subject to change without notice Rev Rev 3 02 5 155 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES See Figure 5 82 for bracket dimensions and characteristics of the surface mount bracket NOT TO SCALE 5 99 mm 0 236 in pee 5 HOLES 38 10 mm 1 50 in 25 40 mm 1 00 in 12 70 mm 0 50 in 0 mm 0 in 12 70 mm 0 50 in 111 0 mm 4 37 in o 14 48 mm 0 57 in 48 26 mm 1 90 in 0 375 mm 9 53 in MAX 3 96 52 mm 3 80 in NOTE ALL DIMENSIONS IN MILLIMETERS INCHES Figure 5 82 ProDriver Surface Mount Bracket 5 156 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DD
47. 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 Rev 3 02 5 9 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES CONNECTOR COMMUNICATIONS CONNECTOR DDC P N 12034398 DDC P N 12066317 TERMINAL TERMINAL DDC P N 12103881 DDC P N 12103881 PLUG DDC P N 12034413 TO PIN 29 TO PIN 28 TO PIN 13 TO PIN 14 NOTE WIRE PAIRS MUST BE TWISTED A MINIMUM OF 12 TURNS PER FOOT VIH TO ECM COMMUNICATION MERITORAWABCO WIRE CONNECTOR CONNECTOR WIRE INT
48. The lower limit of the ambient air temperature range that will disable the Idle Shutdown Override feature 40 to UPPER LIMIT F Ll UPPER LIMIT The upper limit of the ambient air temperature range that will disable the Idle Shutdown Override feature LOWER LIMIT to 167 F Table 5 46 5 18 3 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 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 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 R S 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
49. 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 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 Br
50. back to ON or by once again increasing the percent throttle greater than 1 5 92 All information subject to change without notice Rev 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 IGNITION VEHICLE S J ELECTRICAL oS X ue BATTERY SYSTEM IGNITION SWITCH DIGITAL OUTPUT VEHICLE POWER SHUTDOWN V 7 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 Disabl
51. brake set ee SUES pn g 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
52. 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 Clutch Released ae required for manual transmissions Digital Input 18 Cruise Control Active Light Digital Output T 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 Rev 3 02 5 17 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES Parameter Description Range CRUISE CONTROL Enables or disables t
53. fans for the first fan See Figure 5 35 for the specific connection from the ECM to the second fan Figure 5 35 DIGITAL OUTPUT FAN CONTROL 2 12 24 VDC All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION Fan Control Inputs and Outputs Second Fan 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 L Oil or coolant temperature above DDC factory set levels CL Air temperature and engine torque above DDC factory set levels Fan control 2 is enabled opened when one of the following conditions occur Q Oil or coolant temperature above DDC factory set levels Air temperature and engine torque above DDC factory set levels L Oll coolant or air temperature sensor fails L1 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 le
54. following conditions occur L Air oil coolant or intercooler temperatures above DDC factory set limits l 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 L Jacket coolant temperature above DDC factory set limits l 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 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
55. following software releases O DDEC III Release 4 0 only O 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 Pressure Set Point Result Current outlet pressure is below the pressure set Engine speed increases as required up to PTO point maximum speed Pressure in the system continues to increase and The air compressor solenoid digital output is a threshold pressure is exceeded enabledT opened Current outlet pressure is above the pressure set Engine speed decreases as required down to the point minimum PTO speed The engine will continue to run at PTO maximumuntil the outlet pressure matches the sensor pressure T 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 t
56. for 3 seconds while the data is displayed Green Air Filter is OK FUEL RESTRICT Red inlet restriction is high Service filter and press and hold FILTER RESET for 3 seconds while the data is displayed Green Fuel restriction is OK OIL LEVEL Red Oil level low Add 4 quarts of oil and recheck in a few minutes Yellow Oil is still draining back to the oil pan Recheck Green Oil level is OK COOLANT LEVEL Red Engine cootant level low Add cool ant and recheck Green Coolant level is OK DDEC CODES Red At least one active fault code is present Yellow At least one historical fault code is present Green No fault codes are present DDEC REPORTS PM Red At least one PM re minder needs service Green None of the PM re minders need service Figure 5 62 Maintenance Alert Display Bracket with Label 5 127 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 TO 901 SUN MAS DISPLAY CONNECTOR J 1587 DDC P N 12065425 DATA LINK TERMINAL DDC P N 12048074 PLUG DDC P N 12059168 SEAL J 1587 DDC P N 12048086 DATA LINK
57. in general alignment to the base transceiver handshaking will take place and establish the infrared link see Figure 5 44 r 25 FT OUTDOORS E ER 50 FT INDOORS Figure 5 44 IRIS Infrared Two way Communication 40633 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 08 All information subject to change without notice Rev 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 SIDE VIEW TOP VIEW VERTICAL ALIGNMENT HORIZONTAL ALIGNMENT IS NOT CRITICAL IS NOT CR
58. notice Rev Rev 3 02 5 1 39 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES DDECe Reports Diagnostic Record 1 Print Date Apr 19 1999 03 53 PM DDC DDEC Lab RDI Period 04 09 1999 to ioo 13400 Outer Drive West Equipment ID DCPM Detroit MI 48239 Operator ID 313 592 5959 Period Time 63 49 53 Idle Time 9 46 46 Period Fuel 446 00 gal Idle Fuel 2 50 gal Fuel Consumption 6 99 gal h Idle Percent 15 32 96 Avg Operating Load 51 96 Diagnostic Code 43 Coolant Level Low Diagnostic Time 01 17 00 09 34 18 EST Time Engine Speed Boost Press Fuel Press Fuel Temp Oil Press RPM F PSI 09 34 18 823 46 8 09 34 13 824 0 0 0 0 46 8 09 34 08 825 47 0 09 34 03 823 47 5 09 33 58 824 47 8 09 33 53 824 48 5 09 33 48 825 49 3 09 33 43 827 50 5 09 33 38 825 51 5 09 33 33 533 09 33 28 0 40 0 09 33 23 0 40 0 OoOoOooooooo oooolooooo oOooojoooo oooo ooooo Time Coolant Temp Air Temp EngineLoad Throttle i Eng Brake F F cylinders 09 34 18 70 0 50 0 19 0 0 0 09 34 13 69 0 18 5 09 34 08 69 5 i 17 5 09 34 03 68 8 09 33 58 68 8 09 33 53 68 5 09 33 48 68 5 09 33 43 69 5 09 33 38 68 0 09 33 33 67 8 09 33 28 40 0 09 33 23 40 0 oo e oO oOooO ooodc o oOoooloooo jooo Figure 5 69 DDEC Reports Nonroad Diagnostic Record 5 140 All information subject to change without notice
59. notice Rev Rev 3 02 5 179 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 se
60. or for a maximum of 15 minutes after OK ADD N A UNKNOWN FAIL shutting down the engine oil level will be UNKNOWN Indicates the coolant level in the COOL LEVEL FULL ADD LOW N A FAIL reservoir AIR FILTER Indicates the condition of the air inlet OK PLUGGED ERROR N A filter FUEL FILTER es the condition of the fuel OK PLUGGED ERROR N A Table 5 52 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 1 12 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Parameter Description Choices Indicates the engine oil level NOTE While the engine is running OIL LEVEL or for a maximum of 15 minutes after OK ADD N A UNKNOWN FAIL shutting down the engine oil level will be UNKNOWN COOL LEVEL Indicates the coolant level in the FULL ADD LOW N A FAIL reservoir AIR FILT RS Indicates the relative amount of 0 0 to 99 9 H2O H2O or kPa restriction measured at the air inlet 0 0 to 99 9 kPa filter FAIL N A FUEL IN RES Indicates the restriction measured at 0 0 taro Fg 7 i 0 0 to 99 9 kPa HG or kPa the fuel pump inlet FAIL N A Table 5 53 DDR Main Data List MAS Parameters NOTE After replacing the filter PLUGGED will be displayed on the DDR until i
61. 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 Rev 3 02 5 21 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES 5 4 2 PROGRAMMING REQUIREMENTS amp 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 Setting Cruise Control Enable Enables the engine speed cruise control feature YES Alternate Minimum VSG Sets the Alternate Minimum VSG speed 650 RPM set above the idle speed Table 5 10 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 I
62. 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 Rev 3 02 5 63 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES ETHER INJECTION RELAY CONNECTOR CONNECTOR PIN 12034342 16 ga TERMINAL P N 12124580 GXL SEAL P N 12015323 SXL SEAL P N 12010293 18 ga TERMINAL P N 12089188 VALVE CONNECTOR CONNECTOR PIN 12010973 TERMINAL P N 12124582 SXL SEAL P N 12010293 GXL SEAL P N 12015323 O DDEC ETHER START OUTPUT FUSE HOLDER CONNECTOR FUSE HOLDER P N 12033769 TERMINAL P N 12066614 COVER P N 12033731 GXL 16 ga SEAL P N 12034364 15 AMP FUSE FOR 12 VDC SYSTEMS 10 AMP FUSE FOR 24 VDC SYSTEMS ECM DIGITAL OUTPUT WIRE IS 18 gaGXL ALL OTHER WIRES ARE AT LEAST 16 ga XLPE SXL OR GXL ETHER INJECTION
63. 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 i EE BS Il Dual Throttle Controls C 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 lt 0 68 volts before it can be reactivated 5 220 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL L When faul
64. 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 Ex eps dp Sey de Does not include torque generated by the Idle Governor Q 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 Rev 3 02 5 233 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES HI STATE VOLTAGE DETERMINED BY LOAD amp ITS SUPPLY VOLTAGE CURRENT lt 1 0 mA LO STATE VOLTAGE lt 0 8 VOLTS CURRENT lt 500 mA I STATE VOLTAGE r O Figure 5 114 PWM Output 10 Duty Cycle See Figure 5 115 for a 50 duty cycle HI STATE VOLTAGE
65. 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 Ll Air temperature and engine torque above DDC factory set levels CL Air temperature sensor fails Ll 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 L Fan engine brake enabled and engine brake level is active at high level and air temperature is above DDC factory set levels L Fan control override switch is enabled Pressure governor system is active Fan control 2 is enabled opened when one of the following conditions occur L Oil or coolant temperature above DDC factory set levels Oil or coolant temperature sensor fails L Fan engine brake enabled and engine brake level is active at high level and air temperature is above DDC factory set levels O Fan control override switch is enabled Ll Transmission retarder is active and coolant temperature above DDC factory set level Release 2 00 or later onl
66. to change without notice Rev Rev 3 02 5 217 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 417 gt 952 ZEN 952 2 LOW ENGINE SPEED HIGH ENGINE SPEED 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION
67. 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 Ll Warning only see Figure 5 16 C 30 second rampdown see Figure 5 17 L 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 Rev 3 02 5 47 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES ENGINE OPERATING TORQUE SPEED AT CEL FACTORY SET OPERATING TORQUE OF ENGINE OPERATING AND OR TORQUE SPEED AT CEL SPEED FACTORY SET SEL ON ENGINE OVERTEMPERATURE PROTECTION EOP IF CONFIGURED MINIMUM OF OPERATING TORQUE SPEED AT CEL _ INCREASING TEMPERATURE TEMPERATURE BASED t 0 PROTECTION EOP IF CONFIGURED Figure 5 16 Engine Overtemperature Protection and Warning Only EOP can be disab
68. 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 Rev 3 02 5 15 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 MAS PIGTAIL Figure 5 51 Location of MAS Pigtail 5 1 16 All information subject to change without notice Rev 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 DDC P N 12047937 TERMINAL 4 REQ D DDC P N 12048074 SECONDARY LOCK DDC P N 12066304 CABLE SEAL 4 REQ D
69. 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL RPM VSG MAX COUNTS DESIRED RPM VSG MIN l l l l l l l l l l i X 0 INITIAL 968 COUNTS Figure 5 110 Throttle Count Profile Use the following steps to calculate resistor values 1 Determine a value for RPM Count as follows VSG Max Speed VSG Min Speed RPM Count Divisors Divisor 775 all applications not using VSG foot pedal Divisor 512 all applications using VSG foot pedals 2 Solve for the counts at the desired engine speed X Desired Speed VSG Min Speed RPM Count X PTO Offset T T PTO Offset 140 all applications not using VSG foot pedal PTO Offset 205 all applications using VSG foot pedals PTO Offset 205 Series 4000 using G E Frequency Input All information subject to change without notice Rev Rev 3 02 5 227 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES 3 Solve for the voltage divider resistance ratio R X R 1024 4 Choose a value for R1 and solve for a value of R2 as R2 Rizk R R 4kpsR1 R2s10kC TRET 1 R ki s 25 10k follows The standard precision resist
70. x R0 25 1 00 in g 54 99 mm g 76 20 mm gt 2 17 in 3 00 in i SECTION B B lrzzz774 NOTE ALL DIMENSIONS po mm 1 n IN MILLIMETERS INCHES 1 93 in pla a 127 0 mm ___ gt 5 00 in SECTION A A Figure 5 88 ProDriver DC Flush Mount Mounting Bracket 5 164 All information subject to change without notice Rev 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 NOT TO SCALE 9 00mm 118 11mm 354in R 4 65in iP PLACES CUT OUT 79 00mm AREA 3 11in m OUTLINE OF MODULE NOTE ALL DIMENSIONS IN MILLIMETERS INCHES Figure 5 89 ProDriver DC Flush Mount Display Template All information subject to change without notice Rev Rev 3 02 5 165 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 NOT TO SCALE PnoDniven DC DETROIT DIESEL MENU INFO TASK A 135 90 mm 5 35 in d 50 80 mm 2 00 in 62 20 mm 166 90 mm 2 45 in 6 57 in Y 25 40 mm 1 00 in
71. 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 Date Jul 14 94 To Jul 31 94 Driver 18 Tom Philips Driver GradingReport 1 per 0 1 Overall Fuel Economy below 6 70 MPG 2 per 0 1 Overall Fuel Economy above 6 70 MPG Delete Edit Select Grading Criteria e e Value Brake Avg day Target Cruise Percentage Cruise time i Units Days Working Driving fuel Economy O Percent Driving Percentage Driving Time Hard Brake Appls points per 1 Store Cancel Changes Changes Figure 5 72 ProManager Screen 5 144 All information subject to change without notice Rev 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 Manageme
72. 203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES WALSAS Nolssadddns JH WOH 0706807 N d NNIIAHHAL 260L0ZL Nid HOLOJNNOO ic OP06807L Nid NNIIAHAL 60102L Nid HOLOJNNOO f r3 Z62GLOZL Nid HOLOJNNOO E b fe gt a vo Oly lt a gasn LON SI ALINDUID NOISSdHddris zl Jl GaYINOAY dd Tan OMLOATA OL AlddNS YaMOd dd Tana Avec dV Torrid MOTO HOLLIAAS 3ORHJAO 09 Ave e Ov06802L Nid NAV WNIWYAL v20vcOZL Nid HOLOJNNOO STN a NHO 906 8ZESLOZL Nid HOLOJNNOO b lt fe INDYIO NOISSJ YddNS JHld dAW1 SNTd MOIS aA S06 pros SYOOTHAINI IN3O IVNOLLdO LINHO GONG IOS UAVS SLIDAZL O3HOLIAS sod AYALIVE 3AUNON OL ALORIA CHOMf0S 38 isn ANNOYS AHBILIV 88168021 N d NNIIAHAL 26 SV02L Nid HOLOJNNOO 260 L0ZL Nid HOLOJNNOO Idd 896 LINDYID LIGIHNI H3 LHVILS ANNOYS AMALIE IHAA T8 LSL Nd 0S SLIOA L GAHOLIMS ON HO105 FAIM LYLOL LOZ 29h0 Nid WNIWYAL SOL S 9L GH Nd HOLOJNNOO HOSLNAd 6826802 Nid TNNIIARHALL O0vvtOZL Nid HO
73. 229 Modulateg ZF Transmissions Powertrain AVS or Ecomat PWM 1 Demand 5 95 Modulated see Figure 5 121 page Table 5 103 Transmissions Communicating with PWM1 5 235 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 THROTTLE INTERFACE MODULE TO ALLISON TRANSMISSION ELECTRONIC CONTROLS cic j oos TO DDEC III IV ENGINE CONTROLS CONNECTOR DDC P N 12015791 SEAL DDC P N 12015323 TERMINAL DDC P N 12089188 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL CONNECTOR DDC P N 12015791 SEAL DDC P N 12015323 TERMINAL DDC P N 12089188 ALLISON MAXIMUM TRANSMISSION FEATURE DDEC III IV ELECTRONIC THROTTLE INTERFACE CONTROLS MODULE CONNECTOR DDC P N 12015799 SEAL DDC P
74. 38 Glow Plug Controller Power Supply All information subject to change without notice Rev Rev 3 02 5 85 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 l
75. 43 MOBILE BASE TRANSCEIVER TRANSCEIVER DDC TRANSLATOR SS IR LINK ProDriver DC ProDriver OPTIONAL POWER SUPPLY WIN 95 98 2000 NT XP PC SOFTWARE DIAGNOSTIC LINK ProDrivere REPORTS DDEC REPORTS DDEC Il V DATA SUMMARIES DDEC REPROGRAMMING STATION OTHER DIAGNOSTIC SOFTWARE CORRECT TRANSLATOR OTHER DEVICES IS REQUIRED FOR NON DDC SOFTWARE Figure 5 43 IRIS Configuration All information subject to change without notice Rev Rev 3 02 5 97 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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
76. 6 Table 5 21 Optional Digital Output for Engine Brakes All information subject to change without notice Rev Rev 3 02 5 43 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 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 DYNAMIC BRAKING 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 When this function is enabled an input SERVICE BRAKE ENABLE from the service brake is required in order YES NO to activate the engine brake 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 The minimum vehicle speed ENGINE BRAKE MIN MPH required before engine braking will 0 40 MPH occur Table 5 24 Minimum MPH for Engine Brakes Option 5 9 4 IN
77. A NOISSINSNVYL JIM CTYOM OL Q3 18VSIO 3MV88 ANIONS 7 LAdNI TIVLIDIO xHOLIMS HOLATO OL G3svarmu HOLM LINEN WLISIG OQNNOYD ee WNOIS OALM M L9L dNOYO HOLIMS ze vs O Adis M2vg qug dNION3 HO C IHM LNdNI WNICAW 7 LAdNI TIVLIOIQ LNATWAINDA HO S 0020 N d S HOOVTP d 1OHO HOLIMS MO1 LAdNI IVLIDIG g man es log LO GSW SW ONI y NHOI l z 19MO13NH8 9NI NNOO H0100 ALIAVO N 739V1 JNISNI 38lM tur LE E se 4 LeecoLzL Nid Odd GAYINOAN TWNINYAL v108v0Z Nid OQQ OOrrE0ZL Nid Odd TWNINMSLL MOLOZNNOD JEZE SS3NHVH YOSNAS 3NION3 L38 0LZL N d O00 WNIWYSL 86EPEOT N d OCG YOLOANNOOD cl wLOI x mamononu 3OVJHALNI l SS3NHVH JOHTA LroZcsSOZL N d O00 YOLOJNNOO 3NION3 HLIM Q3ddlHS Internal Engine Brake for DDEC III IV ECM World Trans Interface 13 Figure 5 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 5 42 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 co
78. A742 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 amp Industrial EDM and AIM Installation and Troubleshooting manual 7SA801 All information subject to change without notice Rev Rev 3 02 5 29 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 30 All information subject to change without notice Rev 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 DETROIT DIESEL A ELECTRONIC FIRE COMMANDER oO IDLE ENG
79. ATION 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 C Vehicle Power Shutdown L Variable Speed Governor VSG Shutdown Q Ambient Air Temperature Override Disable 5 18 1 OPERATION There are two types of idle shutdown L 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 L Engine temperature above 104 F 40 C L Engine operation at idle or VSG minimum The parking brake interlock digital input switched to battery ground Q OEM supplied interlocks enabled Ll 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 consid
80. C RED BLUE FOR 12 VDC M d d ALWAYS WHITE j RED BLUE DIESELMATIC VALVE ETHER METERING INJECTION E ORIFICE RELAY INJECTOR NOZZLE FUSE HOLDER 15 Amp FUSE 12V NEGATIVE BATTERY INPUT 10 Amp FUSE 24V POSITIVE BATTERY INPUT yx Figure 5 26 DDEC Ether Start System All information subject to change without notice Rev Rev 3 02 5 61 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 A caution To avoid injury from flames explosion and toxicants when using ether the following precautions must be taken L 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 O 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 preferab
81. C 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 MATES TO MAS PIGTAIL ON ESH CONNECTOR DDC P N 15300030 Se MINNS Rer d TERMINAL P N 12077411 SECONDARY LOCK P N 12066304 CABLE SEALS P N 12015323 5 REQ D CABLE SEAL P N 12048086 SECONDARY LOCK P N 15300017 PLUG P N 12059168 ACLS MODULE DDC P N 23524054 METALPRCK CONNECTOR eS COOLANT LEVEL P N 15300027 aes SENSOR TERMINAL P N 12077411 SECONDARY LOCK P N 15300014 CABLE SEAL P N 12015323 COOLANT LEVEL PROBE 3 8 in NPT P N 23520381 1 4 in NPT P N 23520380 9 16 in UNF P N 23522855 COOLANT LEVEL MODULE ESH MAS PIGTAIL ESH TO ECM WIRE CONNECTOR WIRE CLS CONNECTOR CONNECTOR LABEL NO CAVITY COLOR CAVITY CAVITY CAVITY ADD COOLANT LEVEL 116 ORN GROUND 953 BLK WHT GROUND 953 BLK WHT ACLS 906 BATTERY 12V RED Figure 5 56 Add Coolant Level Sensor Installation All information subject to change without notice Rev Rev 3 02 5 121 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 l
82. 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 l An active code a fault present at the time when checking for codes Ll An inactive code a fault which has previously occurred inactive codes are logged into the ECM and time stamped with the following information O First occurrence of each diagnostic code in engine hours 1 Last occurrence of each diagnostic code in engine hours L1 Total time in seconds that the diagnostic code was active 5 24 All information subject to change without notice Rev 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 RED SEL YELLOW CEL 1 FLASH 3 FLASHES 2 FLASHES 1 FLASH O
83. 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 446 throttle VSG may be disabled when a predetermined set by ACS LSG percent throttle is exceeded as listed in Table 5 95 Application 96 Throttle On highway Trucks 496 Transit Bus 100 Fire Truck 100 Motor Coach 100 Crane 4 Table 5 95 Predetermined LSG Throttle All information subject to change without notice Rev Rev 3 02 5 215 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 VSG 510 ae roti INHIBIT DIGITAL INPUT LSG OPERATION Pid VSG OPERATION 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 Engin
84. 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 OEM CONTROL SYSTEM 556 VEHICLE SPEED DIGITAL INPUT EXTERNAL ENGINE SYNCHRONZATION 910 VARIABLE SPEED GOVERNOR Figure 5 112 Frequency Input Diagram All information subject to change without notice Rev Rev 3 02 5 231 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES The following specifications need to be followed
85. 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 DETROIT DIESEL ALARM OFF ENGINE CHECK feel DRIVETRAIN SCROLL auge pampa F E TA z 230 F oL auunguma Tg ele 380 a lobes CODE ee EFPR ENGINE HOURS SELECT CLEAR LIGHT ELECTRONIC CONTROLS 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 Ll Oil Temperature only when coolant temperature is unavailable from the ECM Q Engine Oil Pressure ECM Battery Voltage or Auxiliary Current Requires AIM Battery Voltage display L Vehicle Speed or Auxiliary Pump Pressure or Engine Load CL Equipment Temperature or Pressure Requires AIM Equipment Temperature or Pressures Requires AIM or Engine Turbo Boost Pressure Fuel Level Requires AIM
86. DDEC IV APPLICATION AND INSTALLATION MANUAL 5 DDEC FEATURES Section Page 51 AIRCOMPRESSORCONTROL iiinis apii heer auium au idea sce 5 3 52 ANTHLOCK BRAKE SYSTEMS sical nine 5 9 BB CRUREGCONIROL JtevenuisbdM R 5 13 5 4 CRUISE CONTROL FOR DRILLING PUMPING APPLICATIONS WITH OPTIONAL DUAL STATION CONTROL 1 aeenacacacnna spp espagne 5 21 m DAGNO TICO qr TEN 5 23 zn EDM AND AIN erei nina tne Da ELM ub doc usa een Ed 5 27 57 ELECTRONIC FIRE COMMANDER spccicccivcictuantessterriensnrtticladsbiuamacients 5 31 58 ELECTRON SPEED SWITCH sciannninmeniiininanncninus 5 35 58 ENGINE BRAKE CONTROLS cctehiccseeisnccisteccciscuducnetasinecosomecessencwsmenbness 5 39 510 ENGINE PROTECTION 2251 1 d depu ee aae E 5 45 Bat ENGINE RATINGS sinneuiiaeirnidindaskiiei ded b nderit ach 5 57 512 EINER GTART xoudentdcsakosniaatdieueteci aca imas dae ue eaten eae 5 61 5 13 EXTERNAL ENGINE SYNCHRONIZATION sccvcctecscsiccscnssanseccdecoionsendaenved 5 65 mie BAMGUNIB ENL siiani 5 69 5 15 FUEL ECONOMY INCENTIVE 5uuuuidou cect cece cetiset ee a cas 5 83 5 18 GLOW PLUG CONTROLLER sae statins nannaa aaa Ea 5 85 517 HALF ENGINE n5 5 89 5 18 IDLE SHUTDOWN TIMER AND VEHICLE POWER SHUTDOWN 5 91 SIS IPIS seran p HQ 5 97 520 LOW GEAR TORQUE LIMITING wicessseseniisinarinerinsararieaanianmudrmeteass 5 105 5 21 MAINTENANCE ALERT SYSTEM sess 5 107 5 22 MANAGEMENT INFORMATION PRODUCTS 2 eoo ra reed ainanars
87. DEC 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 Rev 3 02 5 229 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES STATION 2 STATION 1 DIGITAL INPUT VSG STATION CHANGE AX DIGITAL INPUT 953 STATION 42 953 VSG STATION CHANGE COMPLIMENT pl A 953 STATION 1 12 24 VDC 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 Rev 3 02 7SA742 0203
88. DL can set the group lockouts listed in Table 5 82 Parameter Description Choice ENGINE VEHICLE OPTIONS Enables Disables lockout for Engine Vehi YES NO cle parameters 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 Enables Disables lockout for Engine Pro YES NO tection parameters AIR COMPRESSOR Enables Disables lockout for Air Compres YES NO sor parameters PROGRESSIVE SHIFT Enables Disables lockout for Progressive YES NO Shift parameters ESS TOP2 Enables Disables lockout for ESS Top2 parameters YES NO MAINTENANCE ALERT SYSTEM Enables Disables lockout for Maintenance YES NO Alert System parameters 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 Rev 3 02 5 195 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 196 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL
89. DYID M3HIO EM 139v1 m MO 91 IM l LINDYID OL Q3 18VSIO 3MV88 ANIONS 7 LAdNI TIVLIDIO HOLIMS SS3NHVH YOSNAS 3NION3 Wd HOL TIO OL OI3S V3 HH HOLNI LAdNI IVLIOICI d N S6 n 3 u dnow D d HOLMS 40 3 lS MOVv8 4 M s WNICAW 7 LAdNI TVILIOTG hy IN3TIVAQO3HO 97 4L10 N d SOW d nioMWo HOLIMS ANO T LAdNI WLISIG SS3NHVH 3OVJHALNI FTOIHSA L38 0LZL N d 900 WNIWYSL 86E PENT N d OCG YOLOANNOOD ect wor qooaw N Lv9 S0Zl N d O00 YOLOANNOO 3NION3 H LIM Q3ddlHS Internal Engine Brake for DDEC III IV ECM 12 Figure 5 5 41 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION All information subject to change without notice Rev Rev 3 02 DDEC FEATURES LE8LE AOVAYALNI NOISSINSNYV HL Q THOM INO23 Aii 930d OJ ZV88 3NION3 IVNHA3LENI NOLIVeI3dO T1OH INOO ASINYD 3dOd Od ON OHO AH3LIVH OLO31OS3NNOO 38 LSNW LI GSYNSISNOO SI _LAdNI IVLIOIG T38V3 TH HOLNTO 3H JI 43A3MOH NOISSIINSNV LG THOM SH LHIIM CHICYOH LON SI CS V3 TH8 HOLAT LAGNI TWLSIC Gas va 38 HOLMIO 3OVJH3LNI WIA NI wield aaavsid ave 9NI HO 318VN3 NI WLISId aan AV ONA SVU 3NIDN3 NI NLISIG WOT Was Ne Andino WLIOIO ON BEEN
90. Driver Without Description All information subject to change without notice Rev Rev 3 02 5 109 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 DETROIT DIESEL IGN KEY ON OIL LEVEL AIR FILTER COOLANT LEVEL FUEL RESTRICT DDEC CODES DDEC REPORT PM FILTER RESET SPECK ELECTRONIC CONTROLS 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 1 10 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL Parameter Green Amber Flashing Red Blank Air Filter OK N A Filter restriction is high S amp sor fault or not configured Coolant Level is low Sensor fault or not Coolant Level OK NIA Add coolant configured Inactive sensor fault c des Active sensor fault DDEC Codes No sensor fault codes present No N A code is present Active sensor fault codes Preventive Preventive a Maintenance Maintenance Preventive DDEC Reports N A Mainten
91. EC IV APPLICATION AND INSTALLATION MANUAL See Figure 5 83 for the bolt pattern layout which defines mounting without the adjustable bracket 57 02 mm 2 245 in NOT TO SCALE 38 1 mm 1 50 in 17 53 mm 0 68 in OS 0 795 in 2x 26 35 mm 20 25 in 231 75 mm 91 25 in 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 of
92. EO 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION
93. ERFACE LABEL NO CAVITY CAVITY COLOR CONNECTOR 41587 DATA LINK 900 C2 DK GRN YEL 14 41587 DATA LINK 901 C1 DK GRN 13 41922 DATA LINK 800 TANANHT 29 41922 DATA LINK 801 TAN 28 Figure 5 2 Meritor WABCO ABS ATC Interface 5 10 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL CONNECTOR COMMUNICATIONS CONNECTOR DDC P N 12034398 DDC P N 12066317 TERMINAL TERMINAL DDC P N 12103881 DDC P N 12103881 PLUG DDC P N 12034413 TO PIN 30 TO PIN 29 NOTE WIRE PAIRS MUST BE TWISTED A MINIMUM OF 12 TURNS PER FOOT VIH TO ECM COMMUNICATION WIRE CONNECTOR CONNECTOR WIRE LABEL NO CAVITY CAVITY COLOR TO PIN 12 TO PIN 14 BOSCH INTERFACE CONNECTOR J1587 DATA LINK 900 C2 DK GRN YEL 41587 DATA LINK 901 C1 DK GRN 41922 DATA LINK 800 TANANHT 41922 DATA LINK 3801 TAN Figure 5 3 Bosch ABS ATC Interface All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 29 30 12 14 5 11 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 12 All information subject to change without notice Rev 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 a
94. GENERATOR MAGNETIC PICK UP OPERATING TEMPERATURE ALTERNATOR IGNITION COIL GAS ENGINES 40 C TO 85 C 40 F TO 185 F RATION SPECIFY STANDARD OR REVERSE RELAY LOGIC S FROM 20 TO 500 HZ SPECIFY SPEED RANGE 1 OR 2 SPEED RANGE SELECTIONS TTED ELECTRONICS FOR ENVIRONMENTAL PROTECTION STANDARD IGNITION KEL PLATED TERMINALS HUMIDIT Y AND SALT SPRAY RESISTANT INPUTS INPUTS GHT 80 2500 HZ 10 250 HZ 9 LBS 0 9 KG 325 10 000 HZ 20 500 HZ Figure 5 11 Electronic Speed Switch Installation 5 36 All information subject to change without notice Rev 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 Es 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 8 40 VDC 40 80 VDC Max Operating At 40 V 250 MA At 80 V 115 MA At 24 V 220 MA At 64 V 100 MA Current At 12 V 200 MA At 40 V 50 MA At 40 V 70 MA At 80 V 75 MA Max Standby At 40 V 45 MA At 64 V 60 MA Current At 40 V 30 MA At 40 V 50 MA Relay C
95. HOM T3INvd NOWINS GSE LIMS NOLLINSI CSHOLIMS guter ola SAS OCAZII AlddnS CEHOLIMSNR 9 3 Pon erica YNN VINO S021 P aN SM1d TWNINYSL 60SLSES Nid dvO AAILOSLOYd 9ELLOSES Nid DM 1d ALIAVO ZELLOSES Nid TWNIWYSL i H 687SLSEC N d HOLOANNOO YOLOANNOD QVO INMOd 0607021 Nid po NOLOSNNOO YYA vd gt ANY Pleo Hews mr p i PLSLPOZL Nd ad MOLOSNNOO CHV 140d NICON uw MNT VIVO 8044 P b SLOSLSES Nid ASN sIJeAucolg N3HAA Gasn LON HOIVOIONI WASIA YO FTE IGN JEAUGOd NAMOQ ED OdNI ANS STOUINO JINOULIS15 135310 LiOHLl3C 989902L Nid YOLOANNOD vL8S9021 Nid YOLOANNOD Nic Z 6679071 Nid YOLOANNOD QV vd Ov SvOCL Nid YOLOANNOD QHVMOVQ p SEIS Wadow u3MOd X39901 viva Management Information System 85 5 igure F 5 159 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION All information subject to change without notice Rev Rev 3 02 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 Oth
96. HSII3ALLOV 9Sd lndlno TvLIOIG V GSV3Ho30 1SvOO 13S LAdNI WLISIG I 3SV3sOND T329v 3Wnsds Junssdead LAdNI TWLISIG o Ep et 10313S AOW LAdNI IVLIOIG 318VN3 WALSAS 9Sd LAdNI IVLIOIQ IVNOILLdO LISIHNI 31 1 LOHH L LAdNI WLISIG Pressure Sensor Governor System Vehicle Interface Harness Connector Figure 5 97 5 199 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION All information subject to change without notice Rev Rev 3 02 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 Entr ee VIH to ECM T Function Numbi Circuit Number Connector Assignment ROR Deseription 8 523 H1 Pressure RPM Mode 24 543 G2 PSG Enable 22 545 G3 a pn 20 541 Ji 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 Circuit Number Connector Assignment DDR Description Function Number 5 499 VIH to ECM Connector PSG Active Cavity F3 Pigtail off the Engine Sensor Harness Cavity Y3 11 565 Cruise Active DDC circuit
97. ILITY 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 Range The Overall Governor Gain can be changed between the minimum and maximum governor gain The value is set by the Base Overall Governor Gain Calibration and varies by engine series values Table 5 77 Overall Governor Gain All information subject to change without notice Rev Rev 3 02 5 1 87 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 1 88 All information subject to change without notice Rev 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 pe
98. IM 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 C Coordinates the transfer of control from one station to another Routes ECM outputs to each control station L 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 Rev 3 02 5 175 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES Ll 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 compone
99. INE RPM VOLTS RPM OIL PRESSURE ENG TEMP GOVERNOR ENGLISH PSI F METRIC kPa C CONTROL ENGINE DATA PUMP ENGAGED OKAY TO PUMP THROTTLE READY MENU PSG Ready 2 00 INFORMATION CENTER 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 Rev 3 02 5 31 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES 5 7 1 OPERATION The Electronic Fire Commander has two modes of operation O 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
100. ITICAL Figure 5 45 Horizontal and Vertical Alignment is not Critical Use the following guidelines when installing IRIS Ll The control module should be mounted in a cab environment L The transceiver can be shaded to obtain more distance O Do not shine electronic ballast fluorescent lights into the transceiver O 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 Rev 3 02 5 99 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 MOBILE UNIT MODULE P N 23528557 DETROIT DIESEL POWER O DATA LINK U S PATENT NO 6 064 299 AND 6 111 524 AND PATENT S PENDING TRANSCEIVER P N 23528558 TO za 5 TRUCK 8 FTIN T WIRING LENGTH MOBILE UNIT HARNESS 8 FT IN LENGTH P N 23528561 Figure 5 46 IRIS Mobile Unit The Mobile Unit Module can be mounted anywhere i
101. Jake Brake in High Mode Transmission Retarder Not in Active and Coolant High Open Open Don t Care Don t Care High Mode Temperature Above Limit Table 5 36 Two speed Fan Digital Inputs and Outputs 5 78 All information subject to change without notice Rev 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 DIGITAL INPUT OVERRIDE 953 BATTERY GROUND DIGITAL INPUT A C 953 BATTERY GROUND TRANSMISSION DIGITAL INPUT RETARDER 953 BATTERY GROUND FAN CLUTCH BATTERY BATTERY POSITIVE GROUND DIODE IS NEEDED FOR SOFTWARE PRIOR TO REL 5 05 DIGITAL OUTPUT FAN CONTROL 1 BATTERY POSITIVE BATTERY POSITIVE DIGITAL OUTPUT FAN CONTROL 2 NOTE WHEN FAN IS NOT RUNNING THE FAN WILL SPIN DUE TO AIR FLOW Figure 5 36 Fan Control Inputs and Outputs Electro Magnetic Two Speed Fans Linnig All information subject to change without notice Rev Rev 3 02 5 79 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES For additional information contact the fan vendor Linnig U
102. L 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 ae Or gi ablesvenicle speed limiting YES NO N A MAX VEHICLE SPD Sets the maximum vehicle speed in MPH eo Ee Malad speed VSS ratio 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 MAX SPEED NO FUEL vehicle reaches this speed without fueling 0 to 127 MPH the engine Entering a zero 0 will disable this option
103. LITY 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 Description Choices The minimum duration of time the fan will remain ON after the AC sta
104. LOJNNOO NId 0 HA S06 Tdd 896 LHW 1d LSL Nd 0S dV T19rild MO TO JIBIHNI YALLYWLS ONDIOHO AMAL IVa SITOA ZLHOLIMS ON HOIOD ALIO JAIM T38vi SS3NSVH SHATIOHLNOO ON 1d MOTO vo IM Oly NHO IN 906 OCA 9 AlddS HOSN3S NNOIS HOSN3S ON X07100 ALO JHM 138v1 HOLO3NNOO SS3NHVH HOSN3S 3NION3 All information subject to change without notice Rev 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 DDR Parking Vehicle Engine HEI Allowed Configuration Brake Speed Limit Default Allowed Required Series 50 No
105. LY Figure 5 25 Rotary Switch for Multiple Engine Ratings All information subject to change without notice Rev Rev 3 02 5 59 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 ent
106. Ll mom o o EE SHOSN3S 3unssaud 3n vadat NOISSIASNY L 3l8gvo ldIHS HV39 gt YOIWNLOV aygo Ed Two Engine Marine Application All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES AW1dSI0 Waa ldIHS HV3O ldIHS HV39 HO HO SalLioHHL JOuLNOO S31LI HHL AN Id SI WQS Figure 5 94 5 178 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 L 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
107. MOLIS EIS ignition on then stay on Table 5 58 DDR Options 5 21 4 DIAGNOSTICS The codes that will be logged are listed in Table 5 59 goes ae ei EMI DeseripBon 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 an
108. NDING 39 0 mm 1 54 in 28 7 mm 1 13 in 9 PWM INPUT SIGNAL r 10 PLUGGED 8 15VDC 11 0 TO 10V OUTPUT SIGNAL 13 18 PLUGGED 12 PLUGGED 7 sonon A i MATING CONNECTOR REAR VIEW 1 6 PLUGGED Figure 5 101 Pulse to Voltage Module Installation All information subject to change without notice Rev Rev 3 02 5 21 1 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 8 15 VOLTS 9 PWM INPUT SIGNAL 10 Plugged 11 0 TO 10 VOLT OUTPUT 12 18 Plugged Table 5 91 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 Table 5 92 Connector Part Numbers A kit containing all parts as listed in Table 5 93 is available Table 5 93 PVM Connector Kit P N 23530079 5 2 12 All information subject to change without notice Rev 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 engi
109. O P N 12089649 IGNITION LOCK P N 12066170 WIRE LENGTH TO INTENSITY IS DETERMINED CONTROL BY APPLICATION POTENTIOMETER TO J 1587 DATA LINK TO J 1587 DATA LINK PRODRIVER DC CONNECTOR WIRE LABEL WIRE NO CAVITY COLOR BATTERY 12VDC 251 RED GROUND 953 BLK IGNITION 12VDC 439 PNK PANEL LIGHT 751 GRA J 1587 DATA LINK 900 DK GRN YEL J 1587 DATA LINK 901 DK GRN 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 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 CONNECTOR P N 12064978 TERMINAL P N 12089649 LOCK P N 12066170 CONNECTOR MATES TO P N 12065873 PRODRIVER DC UE MATES TO EXISTING PRODRIVER VEHICLE HARNESS EXISTING PRODRIVER DC WIRE PRODRIVER CONNECTOR LABEL WIRE NO COLOR CONN CAVITY CAVITY BATTERY 251 RED 4 1 GROUND 953 BLK 7 2 IGNITION 439 PNK 5 3 PANEL LIGHT 751 GRA 6 4 J 1587 DATA LINK 900 DK GRN YEL 2 5 J 1587 DATA LINK 901 DK GRN 3 6 38355 Figure 5 93 ProDriver DC Jumper Harness All information subject to change without notice Rev Rev 3 02 5 169 7SA742 0203 Copyright 2002 DETROIT DIESEL CORP
110. ORATION 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 Management Information Surface Mount Kit P N 23516620 Kit P N 23516619 Part Number 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 23516459 Management Information 23515915 Audible External Warning Alarm
111. 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 Description Choice Display 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 Passing Speed Duration 0 to 255 minutes Passing Speed Interval 1 to 24 hours Passing Speed Increment 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 PasSmart Parameters 5 27 4 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 n
112. Reference Card Management Information Management Information 23916460 User Manual 23916193 Reference Card 23516591 Download Connector Bracket 23516460 Managemen IMormaign User Manual 23516976 Management niormaton 23516591 Download Connector Bracket Warranty Booklet 018SP365 Management Information 23516976 Management Information Installation Instruction Warranty Booklet 018SP365 Management Information 23519866 RDI Driver Card 7SE0424 Installation Instruction 23519866 RDI Driver Card 7SE0424 Table 5 64 Management Information Kits The harnesses are listed in Table 5 65 Part Number Description 23515655 Vehicle to ProDriver Display Harness 23515651 Data Logger Modem Harness 23515650 Data Logger Power Harness Table 5 65 Management Information Harnesses 5 170 All information subject to change without notice Rev 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 Part 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 Con
113. SB Data Card Reader 23529277 ProDriver DC PCMCIA Data Card Reader Table 5 71 Other ProDriver DC Parts 5 172 All information subject to change without notice Rev 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 23525745 ProDriver DC Display Unit 23525872 ProDriver DC Flush Mount Bracket 23524862 ProDriver DC Adapter Harness Table 5 72 OEM ProDriver DC Flush Mount Kit P N 23525753 23525745 ProDriver DC Display Unit 23525873 ProDriver DC Surface Mount Bracket 23524862 ProDriver DC Adapter Harness Table 5 73 OEM ProDriver DC Surface Mount Kit P N 23525754 All information subject to change without notice Rev Rev 3 02 5 173 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 174 All information subject to change without notice Rev 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
114. SG PTO Percentage YSG PTO Fuel Total Alerts Total Driver Incidents Driver Incident Records J 1587 Timeouts Engine Hour of Interrupt Duration of Interrupts il Monitor Interval Interval Left Percent Left 6 18 98 2 58 PM 2475 5 389 43 1 25 07 0 0 00 31 58 0 5 68 428 11 28 34 98 4 63 15000 Miles 5 250 Miles 350 Figure 5 70 ProDriver Reports Trip Page 5 142 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL ProDriver Reports 1 00 Detailed Incident Report ProDriver 3 00 Hard Brake Incident 1 Report date 9 28 98 Driver 83 Extracted 6 18 98 2 58 PM Detroit Diesel Vehicle ID 2475 13400 West Outer Drive Odometer 5 389 Detroit MI 48239 Engine Hr 43 Vehicle Speed MPH 50 45 40 20 A40 100 050 040 0 30 0 20 010 ONIN 020 4030 Engine RPM 1400 1300 1200 1100 1000 900 300 70D 600 00 120 1 10 1 00 0 50 040 0 30 0 20 0 10 0 00 010 020 30 30 Percent LS 120 1 10 1 00 0 50 040 0 30 0 20 0 10 0 00 30430 020 30 30 Brake Engaged Released Clutch Engaged Released Figure 5 71 ProDriver Hard Brake Incident Report All information subject to change without notice Rev Rev 3 02 5 143 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES 5 22 7 PROMANAGER 2
115. TERACTION 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 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 Q Low coolant level Q High coolant temperature Ll Low oil pressure L High oil temperature The additional parameters for Series 4000 and Series 2000 which are monitored for engine protection are Q Low coolant pressure Ll High crankcase pressure Ll High intercooler temperature L Low intercooler coolant pressure C1 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 diag
116. 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 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 Rev 3 02 5 149 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION LOCLE SS3NHVH IN3OOIN 39901 VIVO NOLIVO lddV Ag CSNIINHSLLSG SI HLONG T3MIAA SVESPOSL Nid Vd L YVegvOcL Nid Vd 67968021 N d IWNIINSHAL 9v 8VOCL Nid HOLOS3NNOO LS9SLSES N d d3H 6trvvgOcL Nid
117. 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 Ibs 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 8 1 65 1 27 10 1 00 Table 5 47 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 Provides a limit on the available torque 0 to 65535 ft Ibs POW ee TORQUE if the ratio of vehicle speed to engine 65535 ft lbs disables this LIMITING Y speed is below a set point 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 notic
118. Type Allison World Transmission 12 Allison WTEC III 12 or 16 Eaton CEEMAT 14 Voith 16 SAE J1939 Transmissions 16 Table 5 107 Transmission Types 5 244 All information subject to change without notice Rev 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 ECM Transmission Transmission Models a fos Communication 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 Meritor MESS TM RSX9 R RS10 RSX10 RSX10 C Eaton Top2 2 Digital Outputs 2 Digital Inputs 2 Digital Outputs Table 5 108 Transmissions Communicating with Digital Inputs and Digital Outputs 5 34 6 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
119. a 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 ProDriver Reports 1 00 Activity Report ProDriver 3 00 Trip Page Report date 6 18 98 Driver 83 Detroit Diesel 13400 West Guter Drive Detroit MI 45239 Trip Distance Y Miles Trip Fuel Gal Trip Time Overall Economy 6 89 MPG Fleet Goal 00 MPG Driving Time Driving Percentage Driving Fuel Driving Economy Load Factor Cruise Time Cruise Percentage Cruise Distance Cruise Fuel Cruise Economy Top Gear Time Top Gear Percentage Top Gear Distance Top Gear Fuel Top Gear Economy Coasting Time Coasting Percentage Hard Braking gt 5 MPH Sec Total Hard Braking Incidents Power Interrupts Engine Hour of Interrupt Duration of Interrupts Optimized Idle Active Time Opt Idle Time dle Time Saved Est Fuel Savings Extracted Vehicle ID Odometer Engine Hr Speeding Time gt 60 MPH Speeding Percentage Speeding Time gt 62 MPH Speeding Percentage Highest Speed Average Speed Idle Time Idle Percentage Idle Fuel Fleet Idle Goal Over Rev Time gt 1800 RPM Over Rev Percentage Highest RPM VSG pron Time V
120. able air pressure set point for engine rating 3 MAX RAT 1 PSI MIN RAT 1 to 999 PSI MIN RAT PSI 0 to MAX RAT 1 MAX RAT 2 PSI MIN RAT 2 to 999 PSI MIN RAT 2 PSI 0 to MAX RAT 2 MAX RAT 3 PSI MIN RAT 3 to 999 PSI MIN RAT 3 PSI 0 to MAX RAT 3 Table 5 6 Air Compressor Parameters 5 1 4 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 Rev 3 02 5 7 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 8 All information subject to change without notice Rev 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
121. age 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 a ccoo coocoo TO OEM INTERFACE O 29O9Q0YNWNOoOoOOo VIH TO ECM WIRE CONNECTOR WIRE NO CAVITY COLOR 908 J3 WHT Figure 5 96 Optimum Load Signal Interface 5 25 3 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 Rev 3 02 5 1 85 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 1 86 All information subject to change without notice Rev 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 amp FLEXIB
122. age when the CEL and SEL are illuminated PnoDniven DC Fuel Economy Incentive 4 10 mph i L 0 10 DATA CARD DETROIT DIESEL SLOT EJECT BUTTON 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 Data Card Functions Assigned to a specific driver Driver Card 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 Upgrade ProDriver DC features as new software Reprogramming Card becomes available Table 5 63 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 Rev 3 02 5 161 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 Intensi
123. ake 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 Esp HE eg ss dts Cruise Active Light optional All information subject to change without notice Rev Rev 3 02 5 15 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES See Figure 5 4 for a diagram of the Cruise Control circuit WIRE NO COLOR DASH PANEL 12 24 VDC DIGITAL OUTPUT CRUISE DIGITAL INPUT ENABLE SWITCH RESUME ACCEL DIGITAL INPUT SWITCH SET COAST DIGITAL INPUT SWITCH DIGITAL INPUT ON BRAKE ONE SWITCH A OFF ON CLUTCH pe um SWITCH A OFF DIGITAL INPUT 953 BLKANHT VEHICLE SPEED SENSOR 556 LT BLUE BLK SIGNAL 557 LT BLU ORN 3 Figure 5 4 Cruise Control Circuit 5 16 All information subject to change without notice Rev 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
124. al Magnetic ZF Ecomat Open Collector 556 714 Open Collector or Magnetic 556 pin 5 Blue wire Voith Magnetic 557 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 Rev 3 02 5 241 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES Transmission ECM Communication Allison World Transmission see Figure 5 124 on page Allison WTEC Ill SAE J1939 amp SAE J1587 Eaton CEEMAT SAE J1587 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 Tra
125. al revolutions per mile AXLE RATIO Rear Axle ratio TOP GEAR RATIO Gear ratio in top gear Table 5 87 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 Rev 3 02 5 207 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES 5 30 6 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 PROGRAMMING REQUIREMENTS AND FLEXIBILITY Parameter Description RANGE ENABLED Indicates the enabled disabled status of the progressive shift feature YES NO N A LG 1 OFF SPD Indicates the low gear 1 turn off spe
126. ance limits EXPIRED NOT EXPIRED NOT CONFIGURED PREVENTATIVE MAINTENANCE STATUS SERVICE B Indicates the status of preventative maintenance limits EXPIRED NOT EXPIRED NOT CONFIGURED PREVENTATIVE MAINTENANCE STATUS SERVICE C Indicates the status of preventative maintenance limits EXPIRED NOT EXPIRED NOT CONFIGURED Table 5 55 5 114 DDDL Maintenance Alert Menu List of MAS Parameters All information subject to change without notice Rev 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 Description Choices Indicates the engine oil level NOTE While the engine is running OIL LEVEL or for a few minutes after shutting OK ADD N A UNKNOWN FAIL down the engine oil level will be UNKNOWN COOLANT LEVEL Indicate the coolant levelin the FULL ADD LOW N A FAIL reservoir Indicates the relative amount of 0 0 to 99 9 H2O AIR VE P T restriction measured at the air inlet 0 0 to 99 9 kPa filter FAIL N A FUEL FILTER DIFFEREN Indicates the restriction measured ue i He s TIAL PRESSURE at the fuel pump inlet FAIL N A Table 5 56 DDDL Instrumentation Menu List of MAS Parameters NOTE After replacing the filter DDDL will display PLUGGED
127. ance not configured no configured and needs configured maintenance required service fuel RESTRICT OK N A Filter restriction is high S2 sor fault or not configured ECM asleep memory ECM active current ON SY ON NA NA data displayed data displayed Oil Level OK Oil is still draining Low oil level Sensor fault or not to the oil pan minimum of 4 quarts configured Table 5 51 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 All LEDs turn off very briefly All LEDs turn on and are red for approximately one 1 second The current information from memory will turn the LEDs to their appropriate color 2 3 4 All LEDs turn off very briefly 5 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 da
128. ating 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 Rev 3 02 5 57 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 lis
129. ation and Troubleshooting manual 7SA741 for installation requirements DIGITAL OUTPUT OPTIMIZED IDLE SYSTEM ACTIVE LIGHT BATTERY VOLTAGE 439 CRUISE ENGINE TEMPERATURE MASTER SWITCH ENGINE SPEED VEHICLE SPEED THERMOSTAT ANALOG INPUT 5 958 DIGITAL OUTPUT A PWM OUTPUT 2 VEHICLE POWER SHUTDOWN 439 ALARM 909 DDEC III IV VEHICLE NOTE ELECTRICAL MAINTAIN ISOLATION ECM SYSTEM BETWEEN SEPARATE l i PWM OUTPUT 3 POWER SOURCES STARTER RELAY 910 NOTE MUST BE v CONNECTED TO fv Ree Y BLOWER FAN CIRCUITS FUSE SIZE DETERMINED BY APPLICATION Se NSE OPTIONAL OEM HOOD TILT NEUTRAL PARK BRAKE SUPPRESSED INTERLOCKS SWITCI SWITCH RELAY DIGITAL INPUT PARK BRAKE INTERLOCK PIN 86 OPTIMIZED IDLE STARTER RELAY PIN 30 ic EXISTING TO STARTER LZ BATTERY NS 439 TO STARTER SOLENOID PIN PIN FUSE SIZE p HA DETERMINED xX 6 CN APPLICATION BATTERY OPTIMIZED IDLE ON OVERLAY RELAY CONTINUOUS OPTIONAL OPTIMIZED IDLE THERMOSTAT TRANSIENT UPPRESSE TO DETROIT DIESEL RELAY px vestem FUSE SIZE qn ii DETERMINED BY iu APPLICATION v ELECTHONIC CONTROLS TEMPERATURE SENSOR 439 953 PERATURE SENSOR EHIGLE RADIO
130. ation subject to change without notice Rev 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 SS3NMNVH 3 TOIH3A IN3O WO3 930d NMOHS SLNAWNOISSYV TVOIdAL NOLL3MOSIG IN3O LY ON Nid ed OSSA zg t SSA ed Ac 1 NOILINSI Q3HOLIMS E JVNOIS TVHLOSN LH TYN IS V39O NI IVNOIS w WHLNAN Nl 31VIS 3344 NI NNMOHS AlaiN3ssv HOLIMS d LY GION3 IOS MOI t CION3 IOS HOIH CION3 108 MOT GION3IOS HOIH SS3N3SVH NIHIM ed TWNOIS MS 9OTVNVY v A89 AlddNS SO TVNV NOLLISOd LNO dN 1va3d B HOLIMS TvCO3d mM dsnvd MS 3InsaW i AAS LAS NOLLONNA WSO NOILSYOSIG IY SHOLOS3NNOO Os SSANYVH HJA31IN3O SONM LAIHS SSASNYVH ONVIAINOO d ANS 1S3no34 JOooL ce NOILISOd NO WALSAS NI NMOH ole ddO NO Mv3sda V WNOIS OL 3S0 o AN ba NOILISOd l3IHSd n NI NMOHS NMOd dN ON NOLLASHSNd MS OU asnvd
131. 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 L Progressive Shift should be used with 2100 RPM rated engines in fleet applications where the reduced driveability will not impede trip times or productivity C 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 Rev 3 02 5 203 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES LOW RANGE 1 BEI LOW RANGE 2 1 amp 2 TURN OFF HIGH GEAR MAX SPEED 2000 1500 1 MAX SPEED 1000 500 a o a m Lu A o Tm o z ui
132. c components and recognizes system malfunctions The choices listed in Table 5 26 are available for reprogramming Engine Protection Parameter Definition Range RECEIVER 1 OIL Determines the type of engine protection with high N A WARN TEMPERATURE oil temperature on the Receiver ECM 1 RAMP SHTDWN Determines the type of engine protection with low N A WARN OIL PRESSURE oil pressure N A will be displayed if the sensor is RAMP SHTDWN not present Determines the type of engine protection with high N A WARN CRANKCASE PRESSURE crankcase pressure N A will be displayed if the RAMP SHTDWN sensor is not present Determines the type of engine protection with low N A WARN COOLANT PRESSURE coolant pressure N A will be displayed if the sensor RAMP SHTDWN is not present RECEIVER 1 COOLANT Determines the type of engine protection with low N A WARN PRESSURE coolant pressure on the Receiver ECM 1 RAMP SHTDWN Determines the type of engine protection with low N A WARN OIL LEVEL oil level N A will be displayed if the sensor is not RAMP SHTDWN present Determines the type of engine protection with low N A WARN COOLANT LEVEL coolant level N A will be displayed if the sensor RAMP SHTDWN is not present Determines the type of engine protection with an active auxiliary switch 1 input N A will be N A WARN DEACIAPTERETDONIN S displayed if auxiliary switch 1 has not been RAMP SHTDWN configured as a switch input RECEIVER 1
133. ced 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 L 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 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 ENGINE RATING ENABLE DIGITAL INPUT RATING SWITCH 1 Figure 5 24 Simple Engine Rating Switch See Figure 5 25 for an installation using two rating switches h DIGITAL INPUT RATING SWITCH 1 DIGITAL INPUT RATING SWITCH 2_ RATING SWITCH GRAYHILL P N 44MGS0 01 1 04N FOR CONSTRUCTION AND INDUSTRIAL ENGINES ON
134. conds 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 1 80 All information subject to change without notice Rev 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 Install
135. cument 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 Ll 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 Q 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 mid DDEC IV DDEC IV R21 DDEC Reports Version Pages R20 or Later Required Trip Activity X X 2 0 or Later Vehicle Speed RPM X X X 2 0 or Later Overspeed Over Rev X X 2 0 or Later Engine Load RPM X X 2 0 or Later Vehicle C
136. d 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 Rev 3 02 5 15 1 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES NOT TO SCALE DETROIT DIESEL ALL DIMENSIONS IN umm a MILLIMETERS INCHES M 125 1 mm 4 93 in 177 8 mm 17 53 mm 7 0 in gt 0 69 in OS EM tt 37 59 mm 148 in CONNECTOR P N 12065873 TERMINAL P N 12089649 132 1 mm M 5 20 in A 47 8 mm 1 88 in 21 59 mm 0 85 in T 5MM NUTS TORQUE NUT TO 2 1 NM 18 6 Ib in Figure
137. d 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 NOT TO SCALE S 4 PANEL LIGHT ON OFF 5 J1708 DATA BUS ProDriver DC 6 J1708 DATA BUS DETROIT DIESEL M 125 1 mm 4 93 in 1 UNSWITCHED SUPPLY 12VDC 2 POWER GROUND e 3 SWITCH IGNITION A C 85 8mm 4 etc 3 38 in 37 59 mm Ee 62 20 mm 148 in 2 45 in amp 4 p 5 20 in L E A 58 50 mm 2 30 in 21 59 mm Y 0 85 in TORQUENUT PC 5 MM NUTS TO 2 1 N M NOTE 18 6 Ib in ALL DIMENSIONS IN MILLIMETERS INCHES Figure 5 87 ProDriver DC Flush Mount All information subject to change without notice Rev Rev 3 02 5 163 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES See Figure 5 88 for the mounting bracket for the flush mount ProDriver DC NOT TO SCALE 13 46 mm Hu 58 17 mm gt 0 53 in 2 29 in E 8 76 mm 0 35 in 20 32 mm 0 80 in 25 40 mm B 4
138. e 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 Rev 3 02 5 93 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 UPPER LIMIT 65 F 80 F AMBIENT AIR TEMPERATURE OVERRIDE IS OVERRIDE IS OVERRIDE IS ALLOWED DISABLED ALLOWED 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
139. e Rev Rev 3 02 5 105 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 106 All information subject to change without notice Rev 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 O Air Filter Restriction OEM installed sensor O Add Coolant Level OEM installed sensor Oil Level factory installed sensor LI 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 O CEL SEL indication CL ProDriver L Maintenance Alert System Display Modu
140. e 5 131 All information subject to change without notice Rev Rev 3 02 5 1 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES S25 MARINE CONTROLS 2215dxicuiaudud i e Eo Moi ddad a Bh dLd arc eda i 5 175 52 Heg 2g 8 i Gl Hcc 5 179 See OPTIMUM LOAD SIGNAL asrine R ES 5 185 5 26 OVERALL GOVERNOR GAIN sirimiri Ra 5 187 Sar PASSMA RT serere eE p 5 189 bue PASSWORDS dusia ee Eie ie 5 193 5 29 PRESSURE SENSOR GOVERNOR 1ueieinsniecatamisdsad t dixic amada ad 5 197 SB PROGRESSIVE SHIFT Lisez actus anian A S 5 203 Sel FULE TO VOLIAGE MODULE ccauwiininnnnieinnuninnin inna 5 209 5 32 TACHOMETER DRIVE serisinden ipn nnee eE 5 213 5 33 THROTTLE CONTROLGOVERNORS sisisi dca preach cis 5 215 5 34 TRANSMISSION INTERFACE 4 55 rER ada rade ur RED a RO OR ERR d 5 233 5 35 TRANSMISSION RETARDER 12tuicie ie pins in etu bad aae d adad dash haie aad 5 253 Becerra heel acta acto een inito cadena 5 255 5 37 VEHICLE SPEED SENSOR ANTI TAMPERING eseese 5 257 5 2 All information subject to change without notice Rev 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
141. e 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 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 engin
142. e Control 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 Idle Shutdown Timer Enable Idle Shutdown Idle Shutdown Duration Enable Idle Shutdown on VSG Idle Shutdown Min Ambient Temperature Enable Idle Shutdown Override Idle Shutdown Max Ambient Temperature Engine Protection Engine Protection on Oil Tem perature High Engine Protection on Intercooler Temperature High Engine Protection on Coolant Temperature High Engine Protection on Crankcase Pressure High Engine Protection on Oil Pressure Low Engine Protection on Auxiliary Shutdown 1 Engine Protection on Coolant Level Low Engine Protection on Auxiliary Shutdown 2 Air Compressor 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 Proportiona
143. e 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 Fan Control Override Jake Brake State Output 1 C Input Input 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 1 f Jake Brake in High Mode and On Open Don t Care Don t Care High Mode Air Temperature Above Limit Transmission Retarder Active On Open Don t Care Don t Care Not in High Mode and Coolant Temperature Above Limit Table 5 34 Single Fan Digital Inputs and Outputs All information subject to change without notice Rev Rev 3 02 5 71 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES Installation See Figure 5 32 for the specific connection from the ECM to the fan DIGITAL INPUT OVERRIDE 953 BATTERY OPTIONAL GROUND DIGITAL INPUT A C 953 BATTERY pet OPTIONAL GROUND TRANSMISSION IGITAL INPUT RETARDER 953 BATTERY OPTIONAL GROUND FAN 112 24 953 BATTERY CLUTCH VDC GROUND
144. e 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 7 7 in MAX 196 mm ry NAME PLATE EEA 4 HOLES O A Wi ET ott tan O 7 SpectreStart v PRODUCTS ING ELETTEL idg TE MS INPUT TACHI SIGNAL 4 5 6 807 131 MS HOLIAAS 0334S 2INOM123 13 0 2 196 7 00 in 177 8 mm TERMINAL BLOCK WITH 6 32 PAN HD SCREWS 6 OPTIONAL 2 PLACES MANUAL RESET PUSH BUTTON SWITCH A 1 55 in MAX 1 25 in MAX 20 mm Y 39 4 mm ESSE 2 i 1 COMPLETE THE FOLLOWING MODEL DESCRIPTIONS ESS E 2 X X SET POINTS 1 amp 2 0 25 in 64mm L LATCH UP A AUTOMATIC RESET aa ELECTRICAL L_ P AUTOMATIC ADUSTABLE RESET 8 40 VDC 40 80 VDC OPTIONAL M MANUAL RESET POINT RESET LL SWITCH MODEL TOMATIC 8096 9096 OF SETPOINT ELECTRONIC SPEED SWITCH DJUSTABLE VARIABLE AUTOMATIC 2596 9596 OF SETPOINT FIRST X REFERS TO SET POINT 1 SECOND X REFERS TO SET POINT 2 2 SPECIFY SET POINT FREQUENCY AND SIGNAL SOURCE SPECIFICATIONS MECHANICAL ENVIRONMENTAL MINGEN SIGNAL
145. e rating All information subject to change without notice Rev Rev 3 02 5 205 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES 70MPH CAN BE ACHIEVED IN DIRECT GEAR AT 2000 RPM VSL 70 ENGINE SPEED RPM ere gael CRUISE SPEED 70 10 20 30 40 50 60 70 80 90 VEHICLE SPEED MPH SHIFT SCHEDULE STANDARD PROGRESSIVE SHIFT FORCES 70 MPH INTO OVERDRIVE AT A LOWER ENGINE SPEED 2400 2000 1600 1200 800 ENGINE SPEED RPM 400 0 CRUISE SPEED 70 30 40 50 VEHICLE SPEED MPH SHIFT SCHEDULE DDEC IV PROGRESSIVE LOW RANGE 1 12 0 MPH 2100 RPM LOW RANGE 2 27 0 MPH 2100 RPM HIGH RANGE 67 0 MPH 1700 RPM Figure 5 99 Progressive Shift Corrects Problem with High and Low Gears Modified 5 206 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright O 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 Parameter Choice VSS ENABLED Yes VSS TYPE Tail Wheel VSS TEETH 8 160 VSS SIGNAL Magnetic Switched TIRES REVS MI Actu
146. e 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 ALT MIN SPD The VSG droop can be programmed between 0 and LSG droop but not greater than Vo DD 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 Rev 3 02 5 221 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 cu
147. ect 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 C 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 C Instantaneous and average fuel economy L Trip time miles fuel total fuel used economy and average speed All information subject to change without notice Rev Rev 3 02 5 1 3 1 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES Ep a ES Lay pep ST TE dp dep eC Spesa E Ean En SE L 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
148. ed 0 to Low LG 2 OFF SPD LG 1 RPM LMT Indicates the low gear 1 RPM limit 1000 to LG 1 MAX LMT LG 1 MAX LMT Indicates the low gear 1 maximum RPM limit LG 1 RPM LMT to Rated Speed LG 2 OFF SPD Indicates the low gear 2 turn off speed LG 1 OFF SPD to HG ON SPD LG 2 RPM LMT Indicates the low gear 2 RPM limit 1000 to LG 2 MAX LMT LG 2 MAX LMT Indicates the low gear 2 maximum RPM limit LG 2 RPM LMT to Rated Speed HG ON SPD Indicates the high gear turn on speed LG 2 OFF SPD to 127 MPH qum 1650 to Rated Engine HG RPM LMT Indicates the high gear RPM limit Speed N A Table 5 88 Progressive Shift Programming 5 30 7 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 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 DETROIT DIESEL ELECTRONIC CONTROLS PVM 23522828 Manufact
149. ed 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 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 DIRECT BATTERY INPUT 12 24V REQUIRED DIRECT BATTERY FEED 375 in STUD SIZE MIN 6 AWG REQUIRED DETROIT DIESEL GLOW PLUG CONTROLLER 24 VOLTS P N 23506286 Figure 5
150. eed 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 Rev 3 02 5 197 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 discha
151. eer For another example of VSG or LSG only operation using two inputs see Figure 5 105 5 2 16 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL DIGITAL INPUT VSG INHIBIT RT DIGITAL INPUT THROTTLE INHIBIT 953 GROUND LSG OPERATION d VSG OPERATION 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 L Electronic Foot Pedal Assembly EFPA Q 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
152. 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 Digital Input 22 Increase 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 Air Compressor Pressure 0 50 of fuel scale pressure Percent Pressure Increment Increment range 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
153. equired when either of the following conditions exists L 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 Q 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 Rev 3 02 5 1 3 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES This feature is available with Release 27 0 or later Smart Cruise must be configured by VEPS Release 27 0 or later
154. er 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 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 74 185 0mm 7 28in 7 50mm gt 170 0mm 60in 6 69in l 5 8mm 228in 15 5mm 61in x12 7mm 50in DETROIT DIESEL SLOT 2 PLACES ELECTRONIC CONTROLS 5 8mm 228in 2PLACES 9 A 40 4mm 1 59in HER EE Ez y Figure 5 74 Data Logger Installation All informati
155. er 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 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 mess
156. ered 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 Rev 3 02 5 91 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 OPTIONAL OEM INTERLOCKS DIGITAL INPUT vV O PARK BRAKE PARK BRAKE SWITCH 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
157. esistor 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 Ll Open circuit in either a glow or glow plug output circuit C Short circuit in either a glow plug or glow plug output circuit L 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 Rev 3 02 5 87 7SA742 0
158. ets 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL INSTALLATION 5 29 3 See Figure 5 97 G6LOCSEC N d YOSNAS JANSSJHd 6826801 N d TWNIWYSL 48 890C N d HOLOJNNOO Jdunssdsd dnd TAA AlddNS YOSNAS 198 054 Nanay YOSNAS S3HOLIMS MOO TH3 LNI HOLIMS HOLIAS ALAAVS QA9VONA dols TWNOLLIGGV dnd AONSAODYAWA 18 IVa SNDIHVd annoys A daLllvg o Paw o A E es 3GON Id NV Vaan Nl N 3dON JHNSSJHd S6 H LHS AGOW 9Sd Md N lndlno TvLIOIG AN I
159. ev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL S8cS90c N d 00d Was 68268021 N d O00 TIVNIIA3 L 49cS90c N d 900 Q Nid HIA YOLOANNOOD V Nid HIA 13A dYyNSsadd dWnd 2 Nid HIA M 18 038 Aldd n S HOSN3S 18 NL YOSN3AS nies E 86402862 HOSN3S ee HOLIMS Tad MOT aunssaud G3sn LON Yay ZH Nid HIA gus LISIHNI 3 1LLOSH L LAdNI TV LIOIG WO3 INS AH3llva8 OL SZ LM HOSLNAG N d 43001 AMVONOOAS l VvL9L LOc Z9vO HOSLO3G NOLLINSI v 990 0S z odd SIIONI diindiold Nid TYNINSAL AVIA nw SZL 901d HOSLNAG Szgozsez oad ISN dv L p MAVINS Nid HOLO3NNOO O Nid Tlv1Old ZTIN N 1ndino d ntis HSd dau 6Sd SAILOV 3SIndo 1ndno TLI WoA d f Nid HIA G3 T3A 3Svauo3d LSVOO 13S 10dNI WISI WO3 s Nld HIA Tame 3S V3HONI 1399 V S3 L dNI TV LIDIG WOJ eo NIBH WIg NYO STGVNa OSd LNdNI WLISIG NOJ 3 Nid HIA 3ALLOV DSd LNdLNO WLDIG WOA dasn LON S2i 901ad vsn ddl HOSs LNsd MOOTYALNI MOOTHALNI MOOTHALNI SVE WYVvd NOISSINSNVYL WSO TVNOLLdO SVM HOSLN3G NOILINSI AO RO A N N SOECLGEC oOdd Nid 4201 AHVONOO3S Lt L9L LOZ Z9t0 HOSLO3G 990Z0S z 2dQ RENIEN RENTA ICON Wdy SuNSSaud Sd Nid TYNINYA L 2 Sr 901d HOSLNAG LANI WLIDIG IN23 olilzsez odd Nid HOLO3NNOO L O Nid HIA NHO d INT Viva wv T Nid HIA TSAINSO MG
160. fers an audible alarm P N 23515915 All information subject to change without notice Rev Rev 3 02 5 157 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES See Figure 5 84 for the diagram to use when constructing a harness for ProDriver TO GROUND 2 TO INTENSITY CONTROL POTENTIOMETER CONNECTOR P N 12065874 TERMINAL P N 12084449 WIRE LENGTH IS DETERMINED BY APPLICATION TO IGNITION TO BATTERY se TO EXTERNAL EX ES ALERT DEVICE J 1587 DATA LINK J 1587 DATA LINK PRODRIVER CONNECTOR WIRE LABEL CAVITY COLOR EXTERNAL ALERT ORN J 1587 DATA LINK DK GRN GRAY J 1587 DATA LINK DK GRN BATTERY 12 24V RED IGNITION PNK POTENTIOMETER GRA GROUND BLK 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 80cLE WALSAS NH viva 6rrr80Z1 Nid Qv ovd ISN SHOLO3NNOO W TWA TIY Z 6968074 Nid QV OVvd ASN SHOLO3NNOO 4 IVW TIY LAdLNO WAY TV L3 IV MNIS Ave VL SILON GL6SLSEZ N d x o u3o5O0lvivd 9 Jenicioid HLIM YOLVOIONI TWASIANO S1gIONY LINDH TOXLNOD ANNONS YaMOd ALISNALNI T3NVH LNSIAIDHLSNI NIO OLAANN 44O NO L
161. 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 Ill 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 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 do
162. ge 5 75 L Two speed fan refer to section 5 14 5 page 5 76 L 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 Rev 3 02 5 69 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 TRANSMISSION DIGITAL INPUT RETARDER DIGITAL INPUT A C DIGITAL OUTPUT FAN CONTROL 1 DIGITAL OUTPUT FAN CONTROL 2 Figure 5 30 Fan Control Inputs with Two Digital Outputs TRANSMISSION DIGITAL INPUT RETARDER DIGITAL INPUT OVERRIDE DIGITAL INPUT A C 953 BATTERY GROUND 953 BATTERY GROUND 953 BATTERY GROUND TO FAN TO FAN 38682 953 BATTERY GROUND 953 BATTERY GROUND 953 BATTERY GROUND PWM OUTPUT VARIABLE SPEED FAN CONTROL Figure 5 31 Fan Control Inputs with PWM Output for Variable Speed Fan Control Compatible fans may be obtained fro
163. gram 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 Rev 3 02 5 193 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES Feature with Lockout Enabled Lockout Password Needed to Reprogram These Parameters Cruis
164. gramming 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 Sets the Alternate Minimum VSG MIN RPM to ALT MIN VSG VSG RPM 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 Rev 3 02 5 225 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 CIRCUIT GROUNDING 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
165. 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 Rev 3 02 5 223 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES 510 gt 952 EN 952 EE LOW ENGINE SPEED HIGH ENGINE SPEED 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 Inthe 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 in
166. gy 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 ET a el spp Te g 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 Crui
167. hange without notice Rev 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 IRIS MOBILE gt L IRIS INTERFACE HARNESS Figure 5 49 IRIS Mobile System on Vehicle Detailed IRIS installation information can be found in the RIS User and Installation Guide 6SE0036 All information subject to change without notice Rev Rev 3 02 5 103 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 104 All information subject to change without notice Rev 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
168. he 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 Rev 3 02 5 3 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 dec
169. he vehicle speed Cruise YES NO Control feature 20 MPH to MAX MIN CRUISE SPEED Sets the maximum cruise speed in MPH or KPH CRUZ SPD MIN CRUZ to Vehicle MAX CRUISE MPH or KPH Sets the maximum cruise speed in MPH or KPH Speed Limit or 127 mph if VSL NO AUTO RESUME Enables or disables the automatic Cruise Control YES NO set speed resume feature CRUISE SWITCH VSG Enables or disables the cruise switch VSG set YES NO speed feature l iis VSG MIN RPM to INITIAL VSG SET SPEED Sets the cruise switch VSG initial set speed VSG MAX RPM RPM INCREMENT Sets the cruise switched VSG RPM increment 1 to 255 RPM CRUISE ENGINE BRAKE Enables or disables the feature that allows the engine brake to be used while on Cruise Control YES NO FEATURE if the vehicle exceeds the cruise set speed Sets the additional speed before the engine CRUISE ENGINE BRAKE brake is applied to slow down the vehicle The engine brake is activated at low level unless the 0 to 10 MPH ACTIVATION SPEED i operator has turned off the engine brakes with the dash board switches Sets the additional incremental speed that must ENG ERASE INCREMENT be reached before the engine brake will activate 1 to 5 MPH MPH or KPH i the medium and or high level of retardation Sets the vehicle speed above which a diagnostic MAX OVERSPEED LIMIT code will be logged if the driver fuels the engine 0 to 127 MPH and exceeds this limit Entering a 0 will disable this option Sets the ve
170. hicle speed above which a diagnostic code will be logged if the vehicle reaches this MAX SPEED NO FUEL R 0 to 127 MPH speed without fueling the engine Entering a 0 will disable this option Table 5 9 Cruise Control Parameters 5 3 4 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 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 Rev 3 02 5 19 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 20 All information subject to change witho
171. ight 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 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 amp 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 KQ r
172. ine 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
173. ith 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 Rev 3 02 5 65 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES euiBue BARIS 10 1eMO O BY seu1ooeq Ino pepunojf s epis JOASYSIUAA Pe 4 LNdLNO HALAWOHOVI SOS LINdNI SSA 9SS OL ONAS 3NION3 IAdNI TVLIOIQ LAdNI TVLIOIQ c WO E PS LNdNI SSA 9S9 INdLNO YALSWOHOVL SOS OL ONAS 3NION dfiMOOH 1OH NOO SNONOYHONAS ANIONS External Engine Synchronization Schematic Figure 5 29 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 5 66 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
174. l Air Compressor Min 3 Pressure Air Compressor Gain Integral Air Compressor Max 1 Pressure Progressive Shift 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 and Top2 ESS Late Change ESS Skip Shift ESS Second Chance Top2 Cruise Switch ESS Engine Brake Shift Maintenance Alert MAS CEL SEL to flash for Levels MAS CEL SEL to flash for Filters Table 5 80 Protection 5 194 Features and Parameters Selected for Additional Password All information subject to change without notice Rev 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 Fuel Economy Incentive MPH Delta Fuel Economy Incentive MPH A C Fan Timer to MPG Engine Vehicle i i g Dynamic Brake Enabled Fuel Economy Incentive Trip Mileage Fuel Economy Incentive MPG s Threshold Engine Droop LSG Droop VSG Droop VSG Minimum RPM VSG Maximum RPM Alternate Minimum VSG RPM VSG Table 5 81 Features and Parameters Selected for Additional Password Protection continued 5 28 4 PROGRAMMING REQUIREMENTS amp FLEXIBILITY VEPS DRS or DD
175. l for extracting data analyzing and printing information from the ECM A set of Marine reports is now available in DDEC Reports 3 10 5 1 34 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL DDEC Reports Daily Engine Usage Print Date July 3 1998 04 10 PM Detroit Diesel Date Range 6 02 98 to 6 19 98 13400 Outer Drive West Vehicle ID PDCPM Detroit MI 48239 4001 Driver ID 313 592 5500 Figure 5 64 DDEC Reports On highway Idle and Drive Time All information subject to change without notice Rev Rev 3 02 5 135 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES DDEC Reports Daily Engine Usage Print Date July 3 1998 08 27 AM Detroit Diesel Date Range 6 02 98 to 6 19 98 13400 West Outer Drive Vehicle ID PDCPM Detroit MI 48239 Driver ID 313 592 5500 Date 6 19 1998 Total hh mm 04 09 03 24 16 27 Start Time 01 00 00 Hour EST Drive min Idle min Off min Odometer 58068 5 i 00 00 02 00 61 59 Distance 205 1 02 00 04 00 61 59 04 00 06 00 38 82 Fuel 28 00 06 00 08 00 90 Fuel Economy 7 33 08 00 10 00 82 10 00
176. l 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 Rev 3 02
177. le DDR DDDL For mobile applications the DDR DDDL or MAS display must be used by personnel other than the vehicle operator A caution 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 Rev 3 02 5 107 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 H O and the second at 25 in H O An air filter is considered to be restricted if the AFRS reads 18 in H O and the engine is operating below 1500 RPM or the AFRS reads 25 in H O 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 fue
178. lected Transmission Transmission Type RTLO XX610B T2 27 RTL XX710B T2 28 RTLO XX713A T2 29 RTLO XX718B T2 30 Table 5 110 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 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 Ill 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 C Vehicle Speed Sensor L 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 l Failed splitter disengagements
179. led 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 Engine Series 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 Warning Only Disabled 5 48 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL ENGINE OPERATING TORQUE SPEED AT CEL FACTORY SET OPERATING TORQUE OF ENGINE OPERATING AND OR TORQUE SPEED AT CEL SPEED FACTORY SET ENGINE OVERTEMPERATURE PROTECTION EOP IF CONFIGURED MINIMUM OF OPERATING TORQUE SPEED AT CEL INCREASING TEMPERATURE TEMPERATURE BASED PROTECTION EOP IF CONFIGURED Figure 5 17 Engine Overtemperature Protection and Rampdown All information subject to change without notice Rev Rev 3 02 5 49 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES ENGINE OPERATING TORQUE SPEED AT CEL FACTORY SET OPERATING TORQUE OF ENGINE OPERATING AND OR TORQUE SPEED AT CEL SPEED FACTORY SET ENGINE OVERTEMPERATURE PROTECTION EOP IF CONFIGURED MINIMUM OF OPERATING TORQUE SPEED AT CEL SHUTDOWN
180. ly 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 9096 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 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
181. m several vendors 5 70 All information subject to change without notice Rev 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 CL Oil or coolant temperature above DDC factory set levels l Air temperature and engine torque above DDC factory set levels Ll 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 l Oil coolant or air temperature sensor fails L 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 inactiv
182. m 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 Aube A 0 i m ub AES DIAGNOSTIC REQUEST CHECK ENGINE STOP ENGINE SEO SWITCH Figure 5 5 Typical Diagnostic Request SEO Switch and Warning Lights All information subject to change without notice Rev Rev 3 02 5 23 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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
183. 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 Rev 3 02 5 201 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 202 All information subject to change without notice Rev 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
184. 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 23920139 Table 5 14 Electronic Fire Commander Kit 5 32 All information subject to change without notice Rev R
185. n 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 All information subject to change without notice Rev 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
186. n 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 ENGINE OPERATING TORQUE SPEED AT CEL CEL FACTORY SET OPERATING TORQUE SEO SPEED BUTTON OF ENGINE OPERATING ERE PED TORQUE SPEED AT CEL ENGINE OVERTEMPERATURE FACTORY SET PROTECTION EOP I 1 RAMPDOWN MINIMUM OF OPERATING TORQUE SPEED AT CEL BUTTON NOT PRESSED SHUTDOWN TEMPERATURE BASED TIME BASED Eee PROTECTION SHUTDOWN NOTE SHUTDOWN WILL BE AVOIDED IF THE STOP ENGINE OVERRIDE SWITCH IS CLOSED Figure 5 23 Engine Overtemperature Protection and Shutdown Protection with Continuous Override Option 1 5 10 5 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 Rev 3 02 5 55 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 electroni
187. nactive 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 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 54 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 Rev 3 02 5 1 13 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES Parameter Description Choices Indicates the engine oil level NOTE While the engine is running OIL LEVEL or for a few minutes after shutting OK ADD N A UNKNOWN FAIL down the engine oil level will be UNKNOWN COOLANT LEVEL Indicates the coolant level in the reservoir FULL ADD LOW N A FAIL AIR FILTER RESTRICTION Indicates the relative amount of restriction measured at the air inlet filter OK PLUGGED ERROR N A FUEL FILTER RESTRICTION Indicates the restriction measured at the fuel pump inlet OK PLUGGED ERROR N A PREVENTATIVE MAINTENANCE STATUS SERVICE A Indicates the status of preventative mainten
188. ne 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 VIH TO ECM CONNECTOR P N 12034398 TERMINAL P N 12103881 TO TACHOMETER VIH TO ECM CONNECTOR LABEL WIRE NO CAVITY TACHOMETER OUTPUT 505 K1 Figure 5 102 Tachometer Drive Installation Signal output characteristics are listed in Table 5 94 Signal Signal Characteristics PULSE RATE 12 Pulse Rev all engines DUTY CYCLE 50 30 SIGNAL LOW OV V 5V when sinking less than 50mA out SIGNAL HIGH 4 0 V V Batt sourcing less than 5mA out Table 5 94 Tachometer Drive Signal Output Characteristics All information subject to change without notice Rev Rev 3 02 5 2 1 3 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES See Figure 5 103 for the tachometer output signal T1 RISE TIME MAX 10 OF T3 T2 DECAY TIME 200 us MAXIMUM T3 PULSE WIDTH 400 us MAXIMUM VEHICLE GROUND Figure 5 103 Tachometer Output Signal 5 2 14 All information subject to change without notice Rev 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 eng
189. nector 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 ed Warranty 23516976 Management ee Warranty 018SP362 ProDriver Installation 018SP362 ProDriver Installation 23519866 Card RDI Driver 7SE0424 23519866 Card RDI Driver 7SE0424 e Ex Table 5 66 ProDriver Kits Other available Management Information and ProDriver kits are listed in Table 5 67 and Table 5 68 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 Table 5 67 ProDriver Surface Mount Kit P N 23516789 Surface Mount Kit P N 23515698 Flush Mount Kit P N 23515697 Part Number Part 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 Rev 3 02 7SA742
190. nfigured 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 MIN RPM to Rated Engine RPM LSG Droop VSG MAXIMUM RPM Sets the maximum VSG RPM Enables or disables the cruise CRUZE SWITCH VSG switch VSG set speed feature YESXNO CRUIZE SWITCH VSG INITIAL Sets the cruise switch VSG VSG MIN RPM to SET SPEED initial set speed VSG MAX RPM VSG RPM INCREMENT Sele Ne cruise Switched VSG 1 to 255 RPM RPM increment Table 5 99 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
191. ngine 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 l Single fan refer to section 5 14 3 page 5 70 L Dual fans refer to section 5 14 4 pa
192. nosed 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 Q Rampdown Shutdown All information subject to change without notice Rev Rev 3 02 5 45 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 ove
193. nput 17 Alt Min VSG Digital Input 16 Table 5 11 Digital Inputs 5 4 3 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 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 proble
194. nside 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 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 TRANSCEIVER BASE UNIT MODULE P N 23528560 P N 23528556 o o DETROIT DIESEL e x 2 POWER llo POWER SUPPLY O DATA LINK U S PATENT NO 6 064 299 AND 6 111 524 L9 AND PATENT S PENDING J H B H m P N 23528632 l 8 FT IN LENGTH Y A DDC TRANSLATOR BOX 1 FT IN LENGTH PR P N 23512415 INCLUDED WITH A THE BASE KIT P N 23528631 Li 6 FT IN LENGTH 9 PIN SERIAL CABLE P N 23520540 40629 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 in
195. nsmission Series utilizes the SAE J1587 data link to obtain transmission control information See Figure 5 124 for installation instructions 30 PIN CONNECTOR WT SERIES DDC P N 12034398 UD A TERMINAL DDC P N 12103881 30 PIN CONNECTOR DDC P N 12037398 TERMINAL DDC P N 12103771 NOTE CONNECTOR LOCATED ON TRANSMISSION CONNECTOR AMP P N 206036 3 TERMINAL AMP P N 66099 2 NOTE WIRE PAIRS MUST BE TWISTED A MINIMUM OF 12 TURNS PER FOOT WIRE DDEC WIRE WT SERIES LABEL NO CAVITY COLOR CAVITY J1587 DATA LINK 900 C2 DK GRN YEL 6 AMP CONNECTOR J1587 DATA LINK 901 C1 DK GREEN 7 AMP CONNECTOR VEHICLE SPEED 556 E2 LT BLU BLK H2 PACKARD SENSOR CONNECTOR Figure 5 124 DDEC IV to Allison WT Series Transmission 5 242 All information subject to change without notice Rev 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 VIH TO ECM CONNECTOR P N 12034398 TERMINAL P N 12103881 o o QG ooo TO OPEN COLLECTOR DEVICE ALLISON TRANSMISSIONS OOQOY NO OOo VIH VSS WIRE CONNECTOR WIRE CONNECTOR LABEL NO CAVITY COLOR CAVITY VEHICLE SPEED SENSOR 556 E2 LT BLU BLK SIGNAL VEHICLE SPEED SENSOR PLUGGED B
196. nt Overview Xxx X Exceptions X Custom X Driver Grading Driver Activity User defined X Event List Leg Stop List Event Summary X Event Analysis X KX XK OK ox x Detailed Incident Record State Activity Trends X Performance Trend Analysis Detailed Alert ECM Diagnostics Service Interval Summary X Distance Left Graph Service Schedule Speed Histogram RPM Histogram Speed vs RPM Engine Usage Profile XI XJ X OK X OK 0X 0X0 OK X OK X OK OK 0X X OK OK OK PX OK OK OK C K XK OK OK OK OK OK OK xx X X X X 5X X x Xx Table 5 62 Reports Available from ProManager 2 10 All information subject to change without notice Rev Rev 3 02 5 145 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 DETROIT DIESEL ELECTRONIC CONTROLS Figure 5 73 The Data Logg
197. nt 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 Rev 3 02 5 1 89 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 constan
198. ntacting 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 TE 26 required for most automatic transmissions Clutch Switch 18 required for manual transmissions Table 5 19 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 Description Choice Display Enables or disables the feature that CRUISE CONTROL ENGINE allows the engine brake to be used while BRAKE 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 1 to 10 MPH 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 YES NO CRUISE ENGINE BRAKE ACTIVATION SPEED ENGINE BRAKE INCREMENT 1 to 5 MPH Table 5 20 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 1
199. nts 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 L One Control Station Interface Module CSIM L One Control Button Panel CBP L One set of gear and throttle levers
200. 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 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
201. ny 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 r
202. o 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 VSS Anti tamper Enables or Disables VSS Anti tamper YES NO Feature Vehicle Speed Limit Enable Enables or Disables Vehicle Speed YES NO Limiting 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 Rev 3 02 5 257 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 258 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION
203. og a fault code at 12 in Hg CONNECTOR P N 12015793 TERMINAL P N 12089188 CONNECTOR P N 12010717 ON ENGINE SENSOR HARNESS P N 23523866 FUEL RESTRICTION SENSOR P N 23523674 ESH FRS PIGTAIL ESH TO ECM CONNECTOR CONNECTOR WIRE LABEL WIRE NO CAVITY CAVITY COLOR FUEL RESTRICTION 905 B M1 YEL SENSOR GROUND 452 A Y2 BLK SENSOR SUPPLY 416 C W1 GRA Figure 5 57 Fuel Restriction Sensor Installation 5 122 All information subject to change without notice Rev 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 CONNECTOR P N 12162280 TERMINAL P N 12103881 OLS PIGTAIL ON ENGINE SENSOR HARNESS P N 23523866 ESH OLS PIGTAIL CONNECTOR LABEL WIRE NO CAVITY OIL LEVEL 976 B SENSOR GROUND 452 A SENSOR SUPPLY 416 C Figure 5 58 Oil Level Sensor Installation All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION CABC SSS OIL LEVEL SENSOR P N 23522788 ESH TO ECM CONNECTOR CAVITY L2 Y2 W1 5 123 DDEC FEATURES Maintenance Alert System Display Module In
204. ogger Modem Harness DDEC FEATURES 76 5 Figure 5 150 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 DETROIT DIESEL DETROIT DIESEL IDLE TIME Nt ELECTRONIC CONTROLS GLECTRONIC CONTROLS MENU INFO MENU INFO FUEL ECONOMY SCREEN IDLE PERCENTAGE SCREEN 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 reporte
205. on subject to change without notice Rev Rev 3 02 5 147 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 TO DATA LOGGER TO GROUND CONNECTOR P N 12064993 TERMINAL P N 12089649 TO IGNITION SECONDARY LOCK P N 12066170 TO BATTERY 12 24 VDC TERMINATE TO LOGGER J 1708 1587 DATA LINK CONNECTOR WIRE IN VEHICLE LABEL WIRE NO CAVITY COLOR INTERFACE HARNESS GROUND 953 10 BLK IGNITION 439 8 PNK BATTERY 12 24V 251 7 RED J 1587 DATA LINK 901 6 DK GRN J 1587 DATA LINK 900 5 DK GRN YEL 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
206. onfiguration X X X 2 0 or Later 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 Profile X X 2 1 or Later Monthly Activity X 2 1 or Later Daily Engine Usage X 2 1 or Later Life to Date X X 2 1 or Later Table 5 60 On highway Reports Available from DDEC Reports All information subject to change without notice Rev Rev 3 02 5 1 33 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES The nonroad reports are listed in Table 5 61 DDEG DDEC IV DDEC IV DDEC Reports Version Available Reports pua R20 R21 or Later 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 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 idea
207. ontact Ratings 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 900 VDC for 100 microseconds Exponential Decay 140 VDC for 1 milliseconds Exponential Decay 140 VDC for 1 milliseconds Exponential Decay 110 VDC for 0 45 seconds Exponential Decay 110 VDC for 0 45 seconds Exponential Decay Reverse Polarity Protection 1000 VDC 1000 VDC Table 5 18 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION ESSE 2 Electrical Input Voltage Options 5 37 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 38 All information subject to change without notice Rev 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 ener
208. or values are listed in Table 5 101 Standard Precision Resistor Values 2 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION D
209. otice Rev Rev 3 02 5 191 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 192 All information subject to change without notice Rev 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 repro
210. ptimized Idle operation No other DDEC features can be used when Optimized Idle is active All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 5 183 DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 1 84 All information subject to change without notice Rev 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 Volt
211. put 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 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 Pro
212. pyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES Figure 5 61 Maintenance Alert Display and Bracket 5 126 All information subject to change without notice Rev 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 Operating Instructions Light Definition To check the status of the maintenance parameters press the CHECK button The seven lights will flash red then green to indicate the lights are functioning The display will then show the status of the main tenance parameters DDEC codes and DDEC preventive maintenance PM alerts see description to the right if the light for IGN KEY ON is red DDC recommends that the vehicle ignition switch be turned on Do not start the engine to update the data If the engine is started you will have to wait for the oil to drain down before being able to get an oil level check DETROIT DIESEL IGN KEY ON OIL LEVEL AIR FILTER COOLANT LEVEL FUEL RESTRICT DDEC CODES DDEC REPORT PM FILTER RESET ELECTRONIC CONTROLS IGN KEY ON Blank Normal operation Red Turn on ignition to get current levet check readings AIR FILTER Red Filter restriction is high Service filter and press and hold FILTER RESET
213. r 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 Transmission Retarder Digital Outputs 5 35 3 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 Rev 3 02 5 253 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 254 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESE
214. r 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 OF ENGINE OPERATING TORQUE SPEED AT CEL 96 OPERATING FACTORY SET TORQUE AND OR SPEED CEL amp SEL ON RAMPDOWN TIME BASED SHUTDOWN 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 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 OF ENGINE OPERATING TORQUE SPEED AT CEL iS BERAANG FACTORY SET TORQUE AND OR CEL amp SEL ON SPEED RAMPDOWN TIME BASED SHUTDOWN 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
215. rease 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 mu
216. rge 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 s
217. riod 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 eve
218. rrent 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 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 co
219. rrent 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 Rev 3 02 5 247 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 L Late Change Ll Second Chance Eng Brake Shift L 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 inform
220. ry VEPS or DRS Description Type Function Number Limiting Torque Curve Digital Input 14 Table 5 31 Limiting Torque Curve Option Digital Input Requirements 5 60 All information subject to change without notice Rev 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 a PRESSURIZED FLUID CYLINDER BLUE FOR 24 VD
221. se 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 Rev 3 02 5 39 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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
222. 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL ceale LO Q3IN JAVY ON3 LO MO 1 3oIVHga ON3 T38vl GSYINDAY 7ZO8P0Z Nid Od TWNIAAL INO3 AMI O3QC OJ S Gah ce Won JAvYg 3NION3 WNYSALNI RSS OS ESN 3NION3 INIM S A xP a ee A O LE 4 NI TvLI IG Gasva1ay HOLM L88E0IZL Nid OQ NI TvS Gaiavsid Svea ONJ VNIASSL NI VLIOIG Q3IN vu SNA OOrrE0 Nid 90A SNOISSINSNVYL NI VLSC MOT IJvHa ONF A HOLOaNNOO OUVINOLCY HO N LIN
223. ss than 20 MPH L Fan engine brake enabled and engine brake level is active at high level and air temperature is above DDC factory set levels O Fan control override switch is enabled L 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 Rev 3 02 5 77 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES The digital inputs and outputs for a two speed fan are listed in Table 5 36 Fan Fan Fan Override Jake State Control Control A C Input input Brake Primary Control Output 1 Output 2 p Status Not in High Engine Temperature Off Grounded Grounded Grounded Open Mode Sensors Low Open Grounded Grounded Open Not im High engine Temperat re Mode Sensors Not in High Engine Temperature High Open Open Grounded Open Mode Sensors High Open Open Open Don t Care A OEM A C Switch High Open Open Don t Care Grounded I Override Switch High Open Open Don t Care Don t Care High Mode
224. st be specified For additional information contact your DDC Applications Engineer 5 4 All information subject to change without notice Rev 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 OEM INTERLOCKS 953 V O DIGITAL INPUT AIR COMPRESSOR LOAD SWITCH DIGITAL INPUT INCREASE DIGITAL INPUT DECREASE IGNITION 439 O cm 12 24 VDC DIGITAL OUTPUT AIR COMPRESSOR SOLENOID COMPRESSOR SOLENOID CHECK ENGINE LIGHT BATTERY GROUND DESCRIPTION CAVITY WIRE NO BATTERY GROUND 953 AIR COMPRESSOR LOAD SWITCH DIGITAL INPUT AIR COMPRESSOR SOLENOID DIGITAL OUTPUT CHECK ENGINE LIGHT B 1 DECREASE SET COAST DIGITAL INPUT IGNITION B3 INCREASE RESUME ACCEL DIGITAL INPUT STOP ENGINE LIGHT B2 Figure 5 1 Air Compressor Control Harness All information subject to change without notice Rev Rev 3 02 5 5 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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
225. stallation 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 NOT TO SCALE 157 99 mm 6 22 in 43 69 mm 1 72 in 167 64 mm 6 60 in 0 218 TYP BACK VIEW t 48 26 mm 1 90 in Figure 5 59 Maintenance Alert System Display Dimensions 5 124 All information subject to change without notice Rev 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 O 37808 Figure 5 60 Maintenance Alert Display Bracket All information subject to change without notice Rev Rev 3 02 5 125 7SA742 0203 Co
226. stallation information All information subject to change without notice Rev Rev 3 02 5 101 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 REMOTE DATA INTERFACE ProDrivere DC TRANSCEIVER iv ProDrivere E z Oa OPTIONAL rF Erg CO Busy DONE IR LINK MOBILE UNIT WIN 95 98 2000 NT PC SOFTWARE ProDriver e REPORTS DDEC Il V DDEC REPORTS DATA SUMMARIES 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 IZRIS User and Installation Guide 6SE0036 for detailed installation information 5 102 All information subject to c
227. t 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 Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC IV APPLICATION AND INSTALLATION MANUAL 5 27 3 PROGRAMMING
228. t 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 L 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 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 YSG MIN SPD 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 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 th
229. ta 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 5 111 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 Description Choices Indicates the engine oil level NOTE While the engine is running OIL LEVEL
230. tallations should have the parameters listed in Table 5 76 set to Shutdown 5 1 82 All information subject to change without notice Rev 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 based on low coolant level Parameter Description Setting OIL TEMP Indication of the type of engine protection SHTDWN based on high engine oil temp COOLANT TMP Indication of the type of engine protection SHTDWN based on high engine coolant temp OIL PRS Indication of the type of engine protection SHTDWN based on low engine oil pressure COOLANT LVL Indication of the type of engine protection SHTDWN Table 5 76 Engine Protection Parameters 5 24 4 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 O
231. ted 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 Ll 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 Ll Locomotive The Limiting Torque Curve option provides a redu
232. 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 Rev 3 02 5 245 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES 10 AMP 12V FUSE BATTERY LOCKOUT TOP2 TRANSMISSION SOLENOID DIGTAL OUTPUT c P CONNECTOR 12110293 SHIFT CABLE SEAL 12048086 SOLENOID TERMINAL 12048074 SECONDARY 12052845 j rcm TI I is In VALVE 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 se
233. 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 Rev 3 02 5 35 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES Fuses or circuit breakers should be connected in series with th
234. 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 VSS SIGNAL VSS TEETH SWITCHED Table 5 33 Vehicle Speed Sensor Parameters All information subject to change without notice Rev Rev 3 02 5 67 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 68 All information subject to change without notice Rev 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 e
235. 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 STOP ENGINE DIAGNOSTIC CHECK STOP SWITCH Cara scale X EX E OVERRIDE OPTIONAL ENGINE ENGINE 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 L 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 Rev 3 02 5 53 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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
236. tus digital input has indicated that the AC unit has turned OFF The timer starts when the input is grounded after being open AC Fan Timer 0 255 seconds Table 5 41 Fan Timer Parameter 5 82 All information subject to change without notice Rev 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 qne Conversion Factor 20 MPH MPG Target Fuel Economy 7 MPG Table 5 42 Fuel Econom
237. ty 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 CL Direct connection to a PC running Detroit Diesel Data Summaries software through a translator box O Automated direct connection with the Remote Data Interface L1 Wireless communications such as the Highway Master cellular telephone service O Extraction to a Driver Card or Extraction Card 5 162 All information subject to change without notice Rev 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 mounte
238. ults 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 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 coole
239. ured Exclusively for Detrat Diesel Corporation by Sturdy Corporation Wilmington NC PATENTS PENDING Figure 5 100 Pulse to Voltage Module 5 31 1 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 Rev 3 02 5 209 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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
240. ut notice Rev 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
241. 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 Q1 Off Impedance Q1 On Impedance Resolution NOTE V 24 0 Volts DC V lt 0 4 Volts DC 80 freq 480 Hz gt 10 kK 100 2 5 RPM Hz The VSS in open collector mode offers better resolution than Aux timed Input OEM CONTROL SYSTEM Figure 5 113 573 AUX TIMED INPUT DIGITAL INPUT EXTERNAL ENGINE SYNCHRONIZATION 510 VARIABLE SPEED GOVERNOR 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 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 Q SAE J1922 Powertrain Control Data Link Q SAE J1939 Powertrain Control Data Link l 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
242. y 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 Rev 3 02 5 75 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES Fan Fan Fan Override Jake State Control Control A C Input input Brake Primary Control Output 1 Output 2 p Status 1 On Not in High Engine Temperature 2 On Open Open Grounded Open Mode Sensors 1 On Not in High Engine Temperature 2 Off Open Grounded Grounded Open Mode Sensors 1 Off Not in High Engine Temperature 2 On Grounded Open Grounded Open Mode Sensors 1 Off Not in High Engine Temperature 2 0ff Grounded Grounded Grounded Open Mode Sensors 1 On Not in High 2 Off Open Grounded Open Don t Care Mode OEM A C Switch 1 On Not in High 2 Off Open Grounded Don t Care Grounded Mode Override Switch d Open Grounded Don t Care Don t Care High Mode Jake Brake in High Mode Transmission Retarder 1 Off i Active and Coolant 2 On Open Grounded Don t Care Don t Care High Mode Temperature Above Limit Table 5 35 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
243. y 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 Rev 3 02 5 83 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION 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 Definition Choice Indicates the minimum economy for fuel 5 to 10 MPG MINIMUM ECONOMY economy incentive 50 8 to 23 3 L 100 K MAXIMUM MPH or MAXIMUM KPH Indicates customer set maximum vehicle speed 0 to 10 MPH increase for vehicle 0 0 to 16 1 KPH CONVERT FACTOR MPH MPG or The miles per hour you want to allow for each 0 1 to 20 MPH MPG 0 4 CONVERT FACTOR KPH KPL full mile per gallon above the minimum MPG to 75 8 KPH KPL FILT ECON bases the calculations on the fuel information by periodic sampling of fuel CALC TYPE consumption recorded in the ECM TRIP TRIP ECON FILT ECON ECON bases the calculation on the trip portion of the fuel usage information Table 5 43 Fuel Economy Incentive Parameters 5 15 3 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 spe
244. y active faults as they occur 5 129 All information subject to change without notice Rev Rev 3 02 7SA742 0203 Copyright 2002 DETROIT DIESEL CORPORATION DDEC FEATURES THIS PAGE INTENTIONALLY LEFT BLANK 5 1 30 All information subject to change without notice Rev 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 L 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 ProDrivere Release 3 0 refer to section 5 22 9 ProDriver DC refer to section 5 22 10 0go g PC software for data analysis and reporting include L DDEC Reports refer to section 5 22 4 Detroit Diesel Data Summaries refer to section 5 22 5 L ProDriver Reports refer to section 5 22 6 L 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 eff

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