III IV V

DDEC
DDEC
DDEC
DDEC
DDEC
Detroit Diesel
Electronic Controls
WITH EXHAUST GAS RECIRCULATION
 DDEC AGENDA

• Pre-Test
• Objectives
• Review Manuals
• Features & Components
• System Hardware
• Repair Tools
• Basic Electricity
• System Operation
• Trouble Shooting
• DDEC Reprogramming
• Post-Test, Evaluations

25ST0072-2
Rev. 04/4/00 2
 What is DDEC?

An advanced electronic fuel injection control system

that can be integrated into many applications

DDEC Consists of:

• Sensors and switches
• Conductors and connections
• ECM (computer)
– Hardware
– Software
• Injectors

25ST0072-2
Rev. 04/4/00 3
 DDEC History

• DDEC I Introduced in 1985 on 92 Series

• Series 60 Introduced in 1987 As the First Engine
Ever Designed Exclusively for Electronic Controls
• DDEC II Introduced in 1987
• DDEC III Introduced April, 1993
• DDEC III Full Production January, 1994
• DDEC IV Initial Release, August, 1997
• DDEC IV Full Production, January, 1998
• DDEC IV Series 60 EGR, October, 2002
• DDEC V Series 60 EGR, December, 2003

25ST0072-2
Rev. 04/4/00 4
 Electronic Engine Advantages

• Engine Protection
• Engine Diagnostics
• Reduced Maintenance
• Improved Engine Governing
• Fuel Economy Optimization
• Enhanced Cold Starting
• Smoke Control
• Reduced Emission Levels

25ST0072-2
Rev. 04/4/00 5
 DDEC IV Features

• Four New ECM’s

ECM Description
Standard Truck 6 12 Volt 23519307
Cylinder
Universal 8 12/24 Volt 23519308
Cylinder
S4000 8 12/24 Volt 23519309
Cylinder
Natural Gas 8 12/24 Volt 23519310
Cylinder

• Increased Memory - 57% Over DDEC III

• Faster Processing Time - 50% Over DDEC III
• J1939 Communication Link - Standard
• Battery Backed Real Time Clock & Calendar
 • DDEC Data ( Enhanced ECM Data Pages )
Standard
25ST0072-2
Rev. 04/4/00 6
 DDEC Necessities

Ignition

Electronic
EUI
Control Module (ECM)

Synch Reference

Timing Reference

EEPROM

- +
Battery

25ST0072-2
 Electronic Control Module

25ST0072-2
Rev. 04/4/00 8
 Electronic Control Module

OEM responsibility DDC

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

25ST0072-2
 Schematic Diagram DDEC III / IV

Electronic
Control Module (ECM)

EEPROM

- +
Battery

25ST0072-2
Rev. 04/4/00 10
 Power Supply

• DDEC II - 12 Volt
• DDEC III – 12 / 24 Volt
• DDEC IV- 12 or 24 Volt
• Source must be Isolated from any other Vehicle Accessory
• The ECM Power Source must be Fused with the Proper Amp
• The ECM Must Be Incorporated with a 5 Amp Fuse on
the 440 wire going into the 439 wire.
• The ECM Case Must be Electrically Isolated from
any Chassis Ground

25ST0072-2
Rev. 04/4/00 11
 Power Supply DDEC III / IV with or without EGR

25ST0072-2
Rev. 04/4/00 12
 Schematic Diagram DDEC III / IV

EUI
Electronic
Control Module (ECM)

EEPROM

- +
Battery

25ST0072-2
Rev. 04/4/00 13
 Electronic Unit Injectors

Series 50/60 EUI

25ST0072-2
Rev. 04/4/00 14
 Voltage in Series 50/60
Rocker Arm Injector
Solenoid Animation
Cam

Poppet
Valve
Plunger

Fuel out

Fuel in

Needle Valve
 Top Of Stroke

Fuel
In

Fuel
Out

Injector
Tip

25ST0072-2
Rev. 04/4/00 16
 Start Of Injection

Fuel
In

Fuel
Out

Injector
Tip

25ST0072-2
Rev. 04/4/00 17
 End Of Injection

Fuel
In

Fuel
Out

Injector
Tip

25ST0072-2
Rev. 04/4/00 18
 Injection Sequence

Fuel Fuel Fuel

In In In
Fuel Fuel Fuel
Out Out Out

Injector Injector Injector

Tip Tip Tip
25ST0072-2
Rev. 04/4/00 19
 Injector Calibration Codes

• DDEC II No Calibration Codes

• DDEC III/ IV Calibration Codes From 00-99

Part Number

Calibration Code
25ST0072-2
Rev. 04/4/00 20
 Injector Cycle Terminology

 IRT Injector Response Time - Length of Time (ms)

required to close the Control Valve

 PW Pulse Width - Degrees of Crankshaft Rotation

when Fuel is Injected

 BOI Beginning Of Injection – When Fuel Injection

Starts in Crankshaft Degrees (Not Available in DDEC III-
IV Systems)

25ST0072-2
Rev. 04/4/00 21
 Injector Response Times

25ST0072-2
Rev. 04/4/00 22
 Cylinder Cut-Out

25ST0072-2
Rev. 04/4/00 23
 Injection Cycle
BAT

V_REG, 5V
0V
Voltage

(Inflection Point)
0A Current
Control Valve Lift
Closed
Open

Injection Rate
IRT PW
BOE BOI EOE EOI

Time
25ST0072-2
Rev. 04/4/00 24
 Typical EUI Fuel Injection Systems

Injection Events Occur as Shown

2200 bar Peak Pressure
Injection Pressure

Injection Injection
Begins 345 bar Ends

Crank Angle Degrees

Pulse Width
25ST0072-2
Rev. 04/4/00 25
 Sensor types
•Two wire sensors are called Thermistors
 Common return wire is #452

 Range -40* to +150* C

•As the temperature increases the resistance decreases.

•Three wire sensors are called Piezoresistive.

 These are pressure sensors.

 Voltage is proportional to pressure.

•Also, two other sensors with twisted wires

and a two pin connector are the TRS and
SRS called Variable Reluctance

25ST0072-2
Rev. 04/4/00 26
 5 Volt Sensor Operation

0 .25 VOLTS 4.75 5

Low Voltage Normal Operating Range High Voltage

25ST0072-2
Rev. 04/4/00 27
 2- wire Sensors

5V Supply

Signal

Return

ECM Sensor
Open = HIGH VOLTAGE
Short = LOW VOLTAGE

25ST0072-2
Rev. 04/4/00 28
 3- wire Sensors

ECM Sensor
5V Supply

Signal

Return

Open Supply = LOW VOLTAGE

Open Signal = LOW VOLTAGE
Open Return = HIGH VOLTAGE
Supply short to Signal = HIGH VOLTAGE
Supply short to Return = LOW VOLTAGE
Signal short to Return = LOW
VOLTAGE

Rev. 04/4/00 29
25ST0072-2
 Electrical System

Definitions
• Open Circuit
– An “open” describes a complete break in the
path of current at some point in the circuit.
The result of an “open” is that one or more
loads in the circuit do not work.

452
120 Open
High voltage
code

25ST0072-2
Rev. 04/4/00 30
 Electrical System

452 Cavity A
432 Cavity B
416 Cavity C

Open
Low voltage code

Definitions
• Open Circuit
– An “open” describes a complete break in the path of
current at some point in the circuit. The result of an
“open” is that one or more loads in the circuit do
not work.

25ST0072-2
Rev. 04/4/00 31
 Electrical System

452 Cavity A
432 Cavity B
416 Cavity C

Short High Voltage Code

Definitions
• Short Circuit
– A “short” occurs when a load in the circuit is accidentally
bypassed. Electricity will always take the path of least resistance.
The result of a “short” is that higher current flows, causing
excessive heat or action from a device protecting the circuit (blown
fuse or activated circuit breaker).

25ST0072-2
Rev. 04/4/00 32
 Electrical System

452 Cavity A
432 Cavity B
416 Cavity C

Ground
Low Voltage Code

Definitions
• Grounded Circuit
– A “ground” is similar to a “short” because current accidentally
bypasses a load in the circuit. The difference is that the bypass
connects directly to the negative terminal of the power source by
way of the chassis ground path.

25ST0072-2
Rev. 04/4/00 33
 SRS/TRS Sensors

• SRS/TRS: Magnetic pickup sensors generate

alternating current (A.C.). The frequency will change
dependent on the speed of the pulse wheel (RPM of
engine).

25ST0072-2
Rev. 04/4/00 34
 Schematic Diagram DDEC III / IV

Synch Reference
EUI
Timing Reference Electronic
Control Module (ECM)

EEPROM

-+
Battery

25ST0072-2
Rev. 04/4/00 35
 Series 50/60
SRS/TRS Sensors

SRS/TRS

Timing Wheel
DDEC II

DDEC II Bull Gear

25ST0072-2
Rev. 04/4/00 36
 Series 50/60
SRS/TRS Sensors

SRS/TRS

Timing Wheel
Bull Gear
DDEC III/ IV
DDEC III/ IV
25ST0072-2
Rev. 04/4/00 37
Series 60
Sensor
Locations
 Schematic Diagram DDEC IV

Synch Reference Timing Reference

Electronic Foot Pedal Assembly
EUI
Electronic
Control Module (ECM)

EEPROM

- +
Battery

25ST0072-2
Rev. 04/4/00 39
 Schematic Diagram DDEC IV

Synch Reference
EUI
Timing Reference Electronic
Electronic Foot Pedal Assembly
Control Module (ECM)
Turbo Boost Pressure

EEPROM

- +
Battery

25ST0072-2
Rev. 04/4/00 40
 Turbo Boost Sensor

Series 50/60 DDEC IV

Series
50/60 DDEC
IV V W/EGR

Series 50/60 DDEC

III
25ST0072-2
Rev. 04/4/00 41
 Schematic Diagram DDEC III / IV

Synch Reference
EUI
Timing Reference Electronic
Electronic Foot Pedal Assembly
Control Module (ECM)
Turbo Boost Pressure Fuel / Oil / Coolant/ Air
Temperature

EEPROM

- +
Battery

25ST0072-2
Rev. 04/4/00 42
 Temperature Sensors

Coolant Temperature Sensor Air Temperature Sensor

Series 50/60 Series 50/60

Fuel/Oil/Coolant Temperature Sensor

Series 50/60

25ST0072-2
 Schematic Diagram DDEC III / IV

Synch Reference
EUI
Timing Reference Electronic
Electronic Foot Pedal Assembly
Control Module (ECM)
Turbo Boost Pressure

Fuel / Oil / Coolant Temperature

Oil / Fuel Pressure

EEPROM

- +
Battery

25ST0072-2
Rev. 04/4/00 44
 Pressure Sensors

Series 50/60
Oil Pressure

25ST0072-2
Rev. 04/4/00 45
 Schematic Diagram DDEC III / IV

Synch Reference
EUI
Timing Reference Electronic
Electronic Foot Pedal Assembly
Control Module (ECM)
Turbo Boost Pressure

Fuel / Oil / Coolant Temperature

Oil / Fuel Pressure

EEPROM
Oil level/Fuel Restriction

- +
Battery

25ST0072-2
Rev. 04/4/00 46
Schematic Diagram DDEC III / IV non EGR

Synch Reference

EUI
Timing Reference
Electronic Foot
Electronic Optimized Idle
Pedal Assembly
Control Fan Controls
Engine Brake

Turbo Boost Pressure

Module ISD / Vehicle
Power Down
(ECM) Communication
Fuel / Oil / Coolant DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
Check Stop
Oil / Fuel Pressure

MASS Engine Engine

EEPROM
Oil level/Fuel Restriction
Crankcase Pressure

Cruise Control
Coolant Level Vehicle Speed Limiting
Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
DDR Communication- On Highway

DDEC II or III
12-Pin DDEC III/ IV
6-Pin
25ST0072-2
Rev. 04/4/00 48
 DDR Communication- On Highway

DDEC IV
9 Pin

25ST0072-2
Rev. 04/4/00 49
 Diagnostic Socket

Pin- Outs for On-Highway Cable

6 Pin Deutsche 9 Pin Deutsche
C 12V B 12V
E Ground A Ground
A J1587 + F J 1587 +
B J1587 – G J 1587 –
C J 1939 +
D J 1939 –
25ST0072-2
Rev. 04/4/00 50
 DDR Interface with MPSI Printer

25ST0072-2

Rev. 04/4/00 51
Diagnostics
 Flash Codes

25ST0072-2
Rev. 04/4/00 53
 Troubleshooting Tools

 To properly probe terminals use

Kentmoore jumper wire kit number J39197.
Within this kit the proper leads are provided.

 The use of the lead ends of the volt ohm

meter to probe the terminal ends will
damage the DDEC connectors and will cause
intermittent codes.
DVOM w/jumper wire kit J39197
VEHICLE INTERFACE MODULE
BREAK OUT BOX
Volt-Ohm Meter DDEC SENSOR TESTER

25ST0072-2
 Troubleshooting Tools

Breakout Box (30 Pin)

DDEC III/IV Interface
J35634
J41005

DDEC II III IV DDEC V with J-41005-5

CABLE

25ST0072-2
 Diagnostic Tools

• DDEC II- III- IV- V Electronic Tools

Pro-Link Suite 8
Detroit Diesel Diagnostic Link
6.2
25ST0072-2
Rev. 04/4/00 56
 Detroit Diesel Diagnostic Link

• HARDWARE KIT # J-42384-GCD

• SOFTWARE KIT # J-DDDL-6.2 CD

25ST0072-2
Rev. 04/4/00 57
 DDDL Information

• New PC based DDEC service tool

– Release 6.2
» Windows 95 / 98 / 2000
» VGA color monitor
» Pentium, 300MHz, 128MB RAM
» Supports all DDEC Systems including EGR &
MBE On-Highway
» Support Data Extractions & Trip Reporting
Features

25ST0072-2
Rev. 04/4/00 58
 Detroit Diesel
Diagnostic Link

25ST0072-2
Rev. 04/4/00 59
 Detroit Diesel
Diagnostic Link

25ST0072-2
Rev. 04/4/00 60
 Detroit Diesel
Diagnostic Link

25ST0072-2
Rev. 04/4/00 61
 • Volts
• Amps
• Ohms
• Shorts
• Open
• Grounds
• Resistance
• DVOM
• Soldering
• Shrink Tube
• Wiring Schematics

25ST0072-2
62
Wire Crimping Exercise
 Wire Crimping Tools

25ST0072-2
Rev. 04/4/00 64
 Wire Crimping Tools

25ST0072-2
Rev. 04/4/00 65
 Wire Crimping Tools

25ST0072-2
Rev. 04/4/00 66
 Wire Crimping Tools

25ST0072-2
Rev. 04/4/00 67
 Wire Crimping

25ST0072-2
Rev. 04/4/00 68
Wire Splicing
 Wire Splicing Tools

25ST0072-2
Rev. 04/4/00 70
 DDEC IV
Additional EGR Sensors and Circuits
 DDEC IV EGR Electronics

• Utilizes New Tyco/AMP Connectors for Improved

Harness Design and Reliability
• Uses Framatome (FCI) Connectors for Sensors
– Connectors were introduced for EGR engines in Oct 2002
• Has Full Support for J1587 and J1939 Data Links
(J1922 is not supported)
• Maintains Same Footprint as DDEC III / IV
• Application and Installation Manual Now Available
on the DDC Extranet

25ST0072-2
Rev. 04/4/00 72
 Series 60 EGR
EGR System Sensors

• New Sensors
– Barometric Pressure
– Turbo Compressor Inlet
Temperature & Relative
Humidity
– EGR
Differential
Pressure/Delta
– Turbo Compressor Outlet
Temperature
– Turbocharger Speed
– EGR Temperature

• New Software
– AECD Controls DDEC IV System
– Diagnostics
25ST0072-2

Rev. 04/4/00 Series 50 EGR Sensors

 Right Side View
Oil Temp Sensor

25ST0072-2
Rev. 04/4/00 74
Auxiliary Emission
Control Device
 AECD Function

• Shuts Off EGR Flow to Protect Engine from Damage

when Conditions Produce High Levels of
Condensation.
• AECD’s are EPA Approved
• High Altitude above 6500 ft.
• High Humidity / Low Ambient Temperature
• Low Engine Temperature

25ST0072-2
Rev. 04/4/00 76
 Schematic Diagram DDEC III / IV
Additional EGR Sensors and Circuits
AECD

Electronic RH / TCITS
OEM
Control Engine Brake
Module 10 Pin Connector

Turbo
(ECM)
Speed EGR
Temperature
EGR Delta

EEPROM

Barometric
Pressure

TCOTS

12-24 Volt
VPODS

EGR VNT
25ST0072-2
Rev. 04/4/00 77
 Schematic Diagram DDEC III / IV with EGR

Synch Reference
AECD
EUI
Timing Reference
Electronic Foot
Electronic Optimized Idle
RH / TCITS
OEM
Pedal Assembly
Control Fan Controls
Engine Brake
Module ISD / Vehicle 10 Pin Connector
Turbo Boost Pressure Power Down
Turbo
(ECM) Communication
Speed Fuel / Oil / Coolant / EGR DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
EGR Delta Oil / Fuel Pressure Stop
Check
Engine Engine
MASS EEPROM
Oil level/Fuel Restriction
Barometric Crankcase Pressure
Pressure
Cruise Control
Coolant Level Vehicle Speed Limiting
TCOTS Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery 12-24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
Rev. 04/4/00 78
 Schematic Diagram DDEC III / IV with EGR

Synch Reference

Timing Reference Electronic

Control Module (ECM)

EEPROM

25ST0072-2
Rev. 04/4/00 79
 Series 60 EGR Cam Gear

25ST0072-2
Rev. 04/4/00 80
 Series 60 EGR SRS Sensor

25ST0072-2
Rev. 04/4/00 81
 Schematic Diagram DDEC III - IV with EGR

Synch Reference Timing Reference

Electronic Foot Pedal Assembly
Electronic
Control Module (ECM)

EEPROM

25ST0072-2
Rev. 04/4/00 82
 Schematic Diagram DDEC III / IV w/EGR

Synch Reference

Timing Reference
Electronic Foot Pedal Assembly
Electronic
Control Module (ECM)
Turbo Boost Pressure

EEPROM

25ST0072-2
Rev. 04/4/00 83
 Schematic Diagram DDEC III / IV with EGR

Synch Reference

Timing Reference
Electronic Foot Pedal Assembly
Electronic
Control Module (ECM)
Turbo Boost Pressure

Turbo Speed

EEPROM

25ST0072-2
Rev. 04/4/00 84
 TSS

• Turbo Speed Sensor

• Measures Shaft Speed in 500 RPM Increments
• Protects Turbo and Charge Air Cooler
• Magnetic Pick Up Signals From Turbo Shaft
• Displays Shaft Speed in k-rpm

25ST0072-2
Rev. 04/4/00 85
 Turbo Speed Sensor

25ST0072-2
Rev. 04/4/00 86
 Variable Nozzle Turbocharger
• Turbo Speed Sensor Spacer
• Flat on Shaft Generates Pulse
• DDEC Limits Turbo Speed
• 98k @ Sea Level

25ST0072-2
Rev. 04/4/00 87
 Schematic Diagram DDEC III / IV with EGR
Synch Reference

Timing Reference Electronic

Electronic Foot Pedal Assembly
Control Module (ECM)
Turbo Boost Pressure

Turbo Speed
Fuel / Oil / Coolant / EGR Temperature

EEPROM

25ST0072-2
Rev. 04/4/00 88
 EGR Temperature Sensor

25ST0072-2
Rev. 04/4/00 89
 Schematic Diagram DDEC III / IV with EGR
Synch Reference

Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control
Module
Turbo Boost Pressure

Turbo
(ECM)
Fuel / Oil / Coolant / EGR
Speed
Temperature
EGR Delta

EEPROM
25ST0072-2
Rev. 04/4/00 90
 EGR Delta Pressure Sensor

• Provides DDEC With Measurements Resulting In

EGR Flow Rate
• Pressure Differential (Delta P) Between Venturi Inlet and
Throat, Along with EGR Temperature, Are Converted to
Mass Flow Rate in DDEC
• Actual Rate is Displayed as in.H2O and Counts
• A Temperature sensor allows DDEC to correct for density
variations that result from temperature changes.
• This feedback is used only in the EGR mode

25ST0072-2
Rev. 04/4/00 91
 Delta Pressure Sensor

25ST0072-2
Rev. 04/4/00 92
 Delta P Sensor

25ST0072-2
Rev. 04/4/00 93
 Schematic Diagram DDEC III / IV with EGR
Synch Reference

Timing Reference
Electronic
Electronic Foot Pedal Assembly
Control Module (ECM)
Turbo Boost Pressure

Turbo Speed
Fuel / Oil / Coolant / EGR Temperature
Oil / Fuel Pressure
EGR Delta

EEPROM

Barometric
Pressure

25ST0072-2
Rev. 04/4/00 94
 Barometric Pressure Sensor

• Used to Calculate Fuel Tables at Various Altitudes and AECD Controls

25ST0072-2
Rev. 04/4/00 95
 BARO

• Barometric Pressure Sensor

• Smoke Control
• Fuel Table Calculation
• High Altitude Turbo Protection

25ST0072-2
Rev. 04/4/00 96
 Schematic Diagram DDEC III / IV with EGR

Synch Reference

Timing Reference Electronic

Electronic Foot Pedal Assembly
Control Module (ECM)
Turbo Boost Pressure

Turbo Speed
Fuel / Oil / Coolant / EGR Temperature
Oil / Fuel Pressure
EGR Delta MASS
Oil level/Fuel Restriction
EEPROM

Barometric Pressure

TCOTS

25ST0072-2
Rev. 04/4/00 97
 Turbo Compressor Outlet Temp Sensor

• CAC Protection

25ST0072-2
Rev. 04/4/00 98
 Turbo Compressor Outlet Temperature Sensor

• TCOTS
• Protects Charge Air Cooler
• Located in Turbo Compressor Outlet Housing
• Used for AECD Controls

25ST0072-2
Rev. 04/4/00 99
 Schematic Diagram DDEC III / IV with EGR
Synch Reference

Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control
Module
Turbo Boost Pressure

Turbo
(ECM)
Fuel / Oil / Coolant / EGR
Speed
Temperature
EGR Delta Oil / Fuel Pressure
MASS EEPROM
Oil level/Fuel Restriction
Barometric
Pressure
Coolant Level
TCOTS
VSG Control

Progressive Shift - +
Pressure Governor Battery 12 or 24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
 Variable Pressure Operating Device

• VPOD
• VPOD Signal is PWM Output from DDEC
• Electric Proportional Solenoid Valve
• 12V and 24V Options
• Modulates Air Pressure to VNT and EGR Valve
• VPODS Regulate EGR Valve and VNT Positions
• VPODS are Slewable

25ST0072-2
Rev. 04/4/00 101
 VPOD

• PWM 4 VNT
Control/Left VPOD
• PWM 2 EGR
Control/Right VPOD
• Rear Mount VPOD Option

25ST0072-2
Rev. 04/4/00 102
 Series 60 EGR Components
Variable Nozzle Turbocharger

• Uses Exhaust Energy To Provide

Intake Boost And Exhaust
Pressure To Drive EGR

– Pneumatically Actuated Vane Set

– Turbo Speed Sensor (TSS)
– Turbocharger Compressor Outlet
Temperature Sensor (TCOTS)

25ST0072-2
Rev. 04/4/00 103
 Series 60 EGR
Variable Nozzle Turbocharger

• Provides the means to drive EGR by a set of moveable

vanes which increase the exhaust manifold pressure
• Can be varied to change EGR rate in EGR mode or boost
level when in the boost mode
• Controlled via PWM signal from ECM to a
Variable Pressure Operating Device (VPOD)

25ST0072-2
Rev. 04/4/00 104
 Series 60 EGR
Variable Nozzle Turbocharger

• Garrett GT 42

25ST0072-2
Rev. 04/4/00 105
 Variable Nozzle Turbocharger

Vane set Exhaust Turbine

Unison Ring
25ST0072-2
Rev. 04/4/00 106
 EGR Valve & Actuator

Oct 2002 thru 2003:

Pneumatic Actuator & Control Valve

25ST0072-2
Rev. 04/4/00 107
 Series 60 EGR Components
EGR Hot pipe

25ST0072-2
Rev. 04/4/00 108
 Series 60 EGR Components
EGR Butterfly Valve

Valve Actuator
25ST0072-2
Rev. 04/4/00 109
 Schematic Diagram DDEC III / IV with EGR
Synch Reference

Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control
Module
Turbo Boost Pressure

Turbo
(ECM)
Fuel / Oil / Coolant / EGR
Speed
Temperature
EGR Delta Oil / Fuel Pressure
MASS EEPROM
Oil level/Fuel Restriction
Crankcase Pressure
Barometric
Pressure Cruise Control
Coolant Level Vehicle Speed Limiting
TCOTS Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery 12-24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
 Crankcase Pressure

Series 60 CCM

25ST0072-2
Rev. 04/4/00 111
 Schematic Diagram DDEC III / IV with EGR
Synch Reference

Timing Reference
Electronic Foot
Electronic RH / TCITS
OEM
Pedal Assembly
Control
Module 10 Pin Connector
Turbo Boost Pressure
Turbo
(ECM) Communication
Speed Fuel / Oil / Coolant / EGR DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
EGR Delta Oil / Fuel Pressure Stop
Check
Engine Engine
MASS EEPROM
Oil level/Fuel Restriction
Barometric Crankcase Pressure
Pressure
Cruise Control
Coolant Level Vehicle Speed Limiting
TCOTS Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery 12-24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
Rev. 04/4/00 112
 Relative Humidity and
Compressor Inlet Temperature Sensor
• Reports Humidity and Compressor Inlet Temperature for
AECD Controls
• OEM Installed in Air Intake System
•Connects to Ten Pin Engine Sensor Harness Pigtail for
OEM Interface

25ST0072-2
Rev. 04/4/00 113
 Schematic Diagram DDEC III / IV with EGR
Synch Reference

Timing Reference
Electronic Foot
Electronic RH / TCITS
OEM
Pedal Assembly
Control Engine Brake
Module ISD / Vehicle 10 Pin Connector
Turbo Boost Pressure Power Down
Turbo
(ECM) Communication
Speed Fuel / Oil / Coolant / EGR DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
EGR Delta Oil / Fuel Pressure Stop
Check
Engine Engine
MASS EEPROM
Oil level/Fuel Restriction
Barometric Crankcase Pressure
Pressure
Cruise Control
Coolant Level Vehicle Speed Limiting
TCOTS Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery 12-24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
Rev. 04/4/00 114
 DDEC III/IV Engine Brakes (NON EGR)

• DDEC III/IV controls engine brake operation

• If configured for “cruise control engine brake”
the ECM will automatically turn on the brake if
the set speed is exceeded.
• Two digital inputs and two ‘positive’ outputs are
used to control the brake.
25ST0072-2
 Schematic Diagram DDEC III / IV with EGR
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic Optimized Idle
RH / TCITS
OEM
Pedal Assembly
Control Fan Controls
Engine Brake
Module ISD / Vehicle 10 Pin Connector
Turbo Boost Pressure Power Down
Turbo
(ECM) Communication
Speed Fuel / Oil / Coolant / EGR DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
EGR Delta Oil / Fuel Pressure Stop
Check
Engine Engine
MASS EEPROM
Oil level/Fuel Restriction
Barometric Crankcase Pressure
Pressure
Cruise Control
Coolant Level Vehicle Speed Limiting
TCOTS Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery 12-24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
Rev. 04/4/00 116
 Schematic Diagram DDEC III / IV with EGR
Synch Reference AECD

Timing Reference
Electronic Foot
Electronic Optimized Idle
EUI RH / TCITS
OEM
Pedal Assembly
Control Fan Controls
Engine Brake
Module ISD / Vehicle 10 Pin Connector
Turbo Boost Pressure
Turbo
(ECM) Power Down
Communication
Speed Fuel / Oil / Coolant / EGR DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
EGR Delta Oil / Fuel Pressure Stop
Check
Engine Engine
MASS EEPROM
Oil Level/Fuel Restriction
Barometric Crankcase Pressure
Pressure
Cruise Control
Coolant Level Vehicle Speed Limiting
TCOTS Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery 12-24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
Rev. 04/4/00 117
 Maintenance Alert Sensors System

• Designed to Provide Preventative Maintenance

Information to Mechanics and Operators
• Reduces Unexpected Downtime
• Optimizes Normal Routine Service
• Used on Highway Trucks only at this time
• CANNOT Be Used with DDEC IV
EGR Programming

25ST0072-2
Rev. 04/4/00 118
 Maintenance Alert System

• Overview
– Based on Inputs from Customers, the Maintenance Alert
System Provides Preventative Maintenance Information to
Mechanics and Drivers to Reduce Unexpected Downtime
and to Assist Normal Routine Service Scheduling
• Features
– Uses DDEC IV ECM
– New DDEC Software Processes Information
– Incorporates Four New Sensors (Both On and Off Engine)
– Optional Remote Mounted Monitor Display Unit Available

25ST0072-2
Rev. 04/4/00 119
 Maintenance Alert System

Oil Level Sensor Air Filter Restriction Sensor 2nd Coolant Level Sensor

Fuel Restriction Sensor Monitor Display Unit

25ST0072-2
 On Engine Components

• Oil Level Sensor

– Mounts in Front Sump Non-
metal Oil Pan
– Utilizes Optical Technology
to "See" Oil Level
– Engine Must Be Off (Zero
RPM ) for "X" Minutes
(Based on Oil Temp.) to
Drain Oil Back to the Pan
– Switches at Four Quart
Low Level
– OEM Impact
» Order Maintenance Alert
System on the Engine

25ST0072-2
Rev. 04/4/00 121
 On Engine Components

• Fuel Restriction Sensor

– Measures Fuel System
Restriction at Fuel Pump
Inlet
– Sensor Measures Actual
Inlet Restriction
– OEM Impact
» Order Maintenance Alert
System on the Engine

Rev. 04/4/00 122

25ST0072-2
 DDC Installed Components

• Includes Two Maintenance Alert System Sensors

– Oil Level Sensor (Requires Front Sump Non-metal
Oil Pan) Will not work on Rear Sump Applications

– Fuel Restriction Sensor

25ST0072-2
Rev. 04/4/00 123
 OEM Installed Components

• 2nd Coolant Level Sensor (CLS)

– Separate Sensor from Current Primary
CLS
– Mounted in Coolant Surge Tank Above
Primary CLS
– Requires Interface Module
– OEM Impact
» Order Engine Mounted Sensors
» Purchase CLS Sensor and Module from
PDC
» Mount Sensor in Surge Tank
» Mount Interface Module
» Provide Wiring Between the
Sensor/Module/Engine Harness
» Use VEPS( Vehicle Engine Program
Station) to "Turn On” OEM Only

25ST0072-2
Rev. 04/4/00 124
OEM Installed Components

• Air Filter Restriction Sensor

– Electronic Version of the
Mechanical Filter
Minder®
– Switch Points at 15 and
20 Inches of Water
– OEM Impact
» Order Engine Mounted Sensors
» Purchase Sensor from
Engineered Products or PDC
» Install into Turbo Inlet Tube
» Provide Wiring from Sensor to
Engine Harness Pigtail
» Use VEPS to "Turn On"
25ST0072-2
 OEM Installed Components

• Monitor Display Unit

– 2 Buttons and 8 LEDs (Green, Red,
& Yellow)
– Mounted in Cab
– Reads Engine J1587 Data Link for
Information
– Can Access Maintenance Information
with Ignition On or Up to 2 Hours
After Ignition Off
– Stores Status after 2 Hours for
Later Display
– OEM Impact
» Order Engine Mounted Sensors
» Purchase Display from PDC
» Design and Install Display Bracket
» Provide Wiring to Display

25ST0072-2
Rev. 04/4/00 126
 Service Tools

• Diagnostic Data Reader-(DDR) (Version 24.0 and higher

• Detroit Diesel Diagnostic Link (DDDL) - Version 3.0
and higher

– Sensor Alerts Due to Failed Sensors

– Quick Access Screen to Show Maintenance Alert System
Alerts
» Clear Maintenance Alert System (MAS) Filter Alerts
– Maintenance Alert System sensors added to Data List
– Warning Light Option Programming

25ST0072-2
Rev. 04/4/00 127
 Summary

• Monitors and Displays Service Requirements

– Oil Level
– Fuel System Restriction Engine
– Air Filter Restriction
– 2nd Coolant Level Vehicle
– Monitor Display Unit - in Cab
– DDR and DDDL

• Engine Only or Engine and Any Vehicle Sensors

• Oil Level Requires Front Sump Plastic Plan
• Display is Optional

Rev. 04/4/00 128

25ST0072-2
 Schematic Diagram DDEC III / IV with EGR

Synch Reference

Timing Reference Electronic

Electronic Foot Pedal Assembly
Control Module (ECM)
Turbo Boost Pressure

Turbo Speed
Fuel / Oil / Coolant / EGR Temperature
Oil / Fuel Pressure
EGR Delta MASS
Oil level/Fuel Restriction
EEPROM

Barometric Pressure

Coolant Level
TCOTS

25ST0072-2
Rev. 04/4/00 129
 Coolant Level Sensor

DDEC II/ III Coolant Level Sensor

DDEC III-IV-V
Coolant Level Sensor

25ST0072-2
Rev. 04/4/00 130
 Schematic Diagram DDEC III / IV with EGR
Synch Reference

Timing Reference Electronic

Electronic Foot Pedal Assembly
Control Module (ECM)
Turbo Boost Pressure

Turbo Speed
Fuel / Oil / Coolant / EGR Temperature
EGR Delta Oil / Fuel Pressure
MASS
Oil level/Fuel Restriction
EEPROM

Barometric Pressure

Coolant Level
TCOTS
VSG Control

25ST0072-2
Rev. 04/4/00 131
 Progressive Shift

25ST0072-2
Rev. 04/4/00 132
 VSG Control

• Variable Speed Governor

– Throttle Position Controls RPM
• Droop
– Difference in RPM Between Full Load
(Rated Speed) and Maximum Engine
RPM (No Load)
– Allows the engine to overrun the rated
or governed engine speed.

25ST0072-2
Rev. 04/4/00 133
 Pressure Governor

•Fire Commander and

Mastermind use the same digital
inputs and outputs as cruise
control

High Pressure
Sensor

Fire Commander

25ST0072-2
Mast
ermin
d
 Electronic Fire Commander

Control Buttons
Engine Data

System Status

Message Window

25ST0072-2
Rev. 04/4/00 135
 Diagnostic Request
and Stop Engine Override

25ST0072-2
Rev. 04/4/00 136
 Schematic Diagram DDEC III / IV with EGR
Synch Reference

Timing Reference Electronic

Electronic Foot Pedal Assembly
Control Module (ECM)
Turbo Boost Pressure

Turbo Speed
Fuel / Oil / Coolant / EGR Temperature
Oil / Fuel Pressure
EGR Delta MASS
Oil level/Fuel Restriction
EEPROM

Barometric Pressure

Coolant Level
TCOTS
VSG Control

-+
Progressive Shift Pressure Governor
Diagnostic Request Battery

Stop Engine Override

25ST0072-2
Rev. 04/4/00 137
 Power Supply

• DDEC II - 12 Volt
• DDEC III - 12/24 Volt
• DDEC IV- 12 or 24 Volt
• Source must be Isolated from any other Vehicle Accessory
• The ECM Power Source must be Fused with the Proper Amp
• The ECM Must Be Incorporated with a 5 Amp Fuse on
the 440 wire going into the 439 wire.
• The ECM Case Must be Electrically Isolated from
any Chassis Ground

25ST0072-2
Rev. 04/4/00 138
 Power Supply DDEC III / IV with or without EGR

25ST0072-2
Rev. 04/4/00 139
 Multiple Horsepower Ratings

• Three Independent Ratings

• One Dependent Cruise Power Rating

• Switch Power Options (C&I)

– Max. Power for Fully Loaded Engine
– Min. Power for a Lightly Loaded Engine

25ST0072-2
Rev. 04/4/00 140
 Cruise Control

• Determined by vehicle speed (VSS) or engine speed

(RPM) DDEC IV changed
• Must be above 20 MPH or 1100 RPM to set
• Cruise Power can provide higher HP while in cruise
control by using the C. P. rating.
• Uses up to 5 digital inputs and one digital output
• VSG can be controlled by the cruise switch
• Use cruise switches to set PTO high idle and lower
high idle..

25ST0072-2
Rev. 04/4/00 141
 Vehicle Speed Sensor

• Revs per Mile (Tires)

High Gear Ratio (Transmission)
Rear End Ratio (Ring & Pinion)
Sensor Type (Magnetic or
Switched)
# of teeth on Pulse Wheel (Trans. or Wheel End)

• Vehicle Speed Limit

• Vehicle Overspeed with Fuel (typically set 3-4 mph
above road speed limit)
• Vehicle Overspeed without Fuel (typically set 5-6 mph
above road speed limit)
• VSS Antitamper
– Will not go above Idle
– Code will be logged
25ST0072-2
 Diagnostic Request
and Stop Engine Override

25ST0072-2
Rev. 04/4/00 143
 Check Engine / Stop Engine Lights

External Fault Internal Fault

25ST0072-2
Rev. 04/4/00 144
 Engine Protection

• Warning- Illumination of CEL,SEL only

• Rampdown- Immediate reduction to 70% power,

ramping down to 40% over 30 seconds and
maintains 40% power.

• Shutdown- Same as rampdown except engine is

shutdown at the end of 30 seconds.
• ENGINE PROTECTION NOT AVAILABLE ON
ALL APPLICATIONS

25ST0072-2
Rev. 04/4/00 145
 Pulse Width Modulated Outputs

• Signals sent by the ECM to other microprocessor

controlled systems

Signal High 20% 50% 80%

Signal Low
1 Hz 1 Hz 1 Hz

• 50 Hz duty cycle modulated

• Four ports available-- circuits 908, 909, 910, 911
• Factory programmed only

Rev. 04/4/00 146

25ST0072-2
 NON EGR PWM CIRCUTS

Circuit Wire
No. Color
• PWM #1 Output - VIH (Transmission) 908 White
• PWM #2 Output - ESH (Throttle/GAS) 909 Lt. Green
• PWM #3 Output - ESH (Gas Valve/GAS) 910 Orange
• PWM #4 Output - ESH (Fan Control) 911 Pink

• ESH = Engine Sensor Harness

• VIH = Vehicle Interface Harness

25ST0072-2
Rev. 04/4/00 147
 EGR PWM CIRCUTS

Circuit Wire
No. Color
• PWM #1 Output - VIH (Transmission) 908 White
• PWM #2 Output - ESH (EGR Control) 909 Lt. Green
• PWM #3 Output - ESH (OI STARTER) 910 Orange
• PWM #4 Output - ESH (VNT Control) 911 Pink

• ESH = Engine Sensor Harness

• VIH = Vehicle Interface Harness

25ST0072-2
Rev. 04/4/00 148
DDEC III / IV / V
Reprogramming
 Reprogramming Station

25ST0072-2
Rev. 04/4/00 150
 Software

• Software is programmable
• Numbered like computer software
– Major version changes number before dot ( X.00 )
– Minor version changes number after dot ( 9.XX )
• DDEC III software will be 19.XX or lower
– Current DDEC III software is 9.00
• DDEC IV software will be 20.00 or higher
– Current DDEC IV software is 36.00
• Software level can ONLY go UP, it can NEVER
go back down

25ST0072-2
Rev. 04/4/00 151
 Reprogramming Station
Windows Based for Download

25ST0072-2

Rev. 04/4/00 152

 Reprogramming Station
Windows Based for Download
Rev. 04/4/00 153

25ST0072-2
 Reprogramming Station
Windows Based for Download

25ST0072-2
Rev. 04/4/00 154
 Idle Shut Down
(ISD) / Vehicle Power Shutdown
• Idle Shut Down (ISD): Turns engine off after programmed idle time
has elapsed (optional “override” disables idle timer if the engine
speed is increased by 100 during last 90 seconds of ISD
sequence. The check engine light (CEL) will flash during this 90
seconds.
• Vehicle Power Shutdown relay (optional/OEM) turns off electrical
power to the vehicle as well as stopping the engine

2 - 100 Minutes
25ST0072-2
Rev. 04/4/00 155
 Fan Control

• Four fan configurations can be used

– Single fan
– Dual fans
– Two speed fan
– Variable speed fan (PWM) # 4 Hydraulically
Operated (Coach)
• Fan controlled by digital output(s)
• “Fan override” & “air conditioning active” digital
inputs can force the fan on
• Series 4000 uses (PWM) #2 To Operate a Rockford
Fan

25ST0072-2
Rev. 04/4/00 156
 Fan Control

• Conditions which activate the fan;

– High Oil, Coolant, or Air Inlet Temp
– Circuit fault codes (HI VOLT, LO VOLT) on any of
these three sensors
– A/C Compressor On
– Fan Override input
– Dynamic Braking (Fan is Activated During Engine
Overspeed to Help Slow The Vehicle)

25ST0072-2
Rev. 04/4/00 157
 DDEC Fan Controls
Normal
High Temperatures
Temperatures Allow
Turn FanFan
On Off
Air Supply
Temp sensor
Temp sensor Inputs
Inputs
Optional Fan # 2
Output Output
“off”
ECM “off”
“on”

Ign. + Fan “on”

Fan“off”
“on”

Fan Override (Input Off)

#953 (-)
Aux. Fan Control (Input On)
Off)
Air Conditioning
Air Conditioning -- On
off
(Fan on for at least 3 minutes)
 Optimized Idle
7SA741 I&T Manual

• Automatic Starting and Stopping of the Engine

• Maintains Engine Temperature and / or Battery
Voltage
• Optional Sleeper Thermostat
• Truck Skin Temperature Sensor is used for
continuous run
• Saves Fuel by Running the Engine Only When
Needed
• Warm Engines Start Much Easier With Less Exhaust
Emissions
• Engine Mode – Thermostat Mode – Customer Mode

25ST0072-2
Rev. 04/4/00 159
 Requirements for Optimized Idle

 Cruise Enable Switch

Hood Switch
 Idle Shutdown Enabled
Under-hood Alarm
 Vehicle Power
Start Relay
Down Relay
Overlay Relay
 Op Idle light on dash
VSS Enabled
 Park Brake Switch
Optional Sleeper Thermostat
 Transmission Neutral
Switch (Some
transmissions
require high range in
Neutral)
25ST0072-2
Rev. 04/4/00 160
 Optimized Idle Shutdown Sequence

 Park Brake set with hood closed and transmission in

Neutral supplies ground to the Park Brake input and the
Overlay Relay. Idle Timer starts and the Overlay Relay
closes supplying power to the Start Relay.

 Optimized Idle is activated by turning on the Cruise

Enable Switch which supplies ground on the Cruise
Enable input.

 Optimized Idle Light flashes until the engine shuts

down then remains on.

Rev. 04/4/00 161

25ST0072-2
 Optimized Idle Shutdown Sequence

 With Battery Voltage above 12.2V, Oil Temp between

15ºC/60ºF and 40ºC/104F, and Sleeper Temp within limits,
the Idle Timer shuts the engine down.

 Vehicle Power Down Relay opens powering down the

vehicle Ignition Circuit.

 With Ignition key on, the ECM is still awake and it

continuously monitors Battery Voltage, Oil Temperature
and Sleeper Temperature.

25ST0072-2
Rev. 04/4/00 162
 Optimized Idle Start Sequence

• With the hood closed, Transmission in Neutral, Park

Brake set, and the Optimized Idle dash light ON,the
ECM supplies ground on PWM #2, wire 909 which
activates the under-hood alarm.

• ECM then supplies ground on PWM #3, wire 910

which closes the Start Relay.

• After the engine starts, the ECM supplies ground to

the Vehicle Power Down relay which closes to
supply Ignition power to the vehicle
25ST0072-2
Rev. 04/4/00 163
 Communication

• J1587
– 9600 Baud Rate, used to transmit sensor and engine data
(electronic dash display, vehicle management systems
and electronic transmissions). MPSI readers, DDDL
• J1922
– 9600 Baud Rate, controls Transmissions, braking
systems and retarders
• J1939
– 250k Baud Rate, controls Transmissions, braking
systems and retarders also used as the proprietary data
link in multi ECM engines

25ST0072-2
Rev. 04/4/00 164
Infrared Information System
 Infrared Information System

• The IRIS System Consists of Simple Infrared

Transceivers
• One Transceiver is Mounted on the Vehicle &
Another Transceiver is Mounted at the Location
where the Vehicle Owner Wants to Extract
Information
• Once the Vehicle is in Position, an Indicator Light
Lets the Driver Know the Infrared Connection has
Been Made
• Information Can Then Begin to Flow

25ST0072-2
Rev. 04/4/00 166
 Schematic Diagram DDEC III / IV

Synch Reference

Timing Reference
Electronic Foot
Electronic EUI
Pedal Assembly
Control
Turbo Boost Pressure
Module
(ECM) Communication
DDR Interface/ DDDL/ Reprogramming
Fuel / Oil / Coolant
PWM Ports
Temperature
Oil / Fuel Pressure Stop
Check
Engine Engine
EEPROM
Oil level/Fuel Restriction
Crankcase Pressure

Coolant Level Cruise Control Vehicle Speed Limiting

Vehicle Speed Sensor
VSG Control
Engine Rating / Cruise Power / Switch Power
Progressive Shift - +
Pressure Governor Battery
Diagnostic
Request Stop Engine
Override
25ST0072-2
 Communication

• J1587
– 9600 Baud Rate, used to transmit sensor and engine data
(electronic dash display, vehicle management systems
and electronic transmissions). MPSI readers, DDDL
• J1922
– 9600 Baud Rate, controls Transmissions, braking
systems and retarders
• J1939
– 250k Baud Rate, controls Transmissions, braking
systems and retarders also used as the property data
link in multi ECM engines

25ST0072-2
Rev. 04/4/00 168
 Schematic Diagram DDEC III / IV

Synch Reference

Timing Reference
Electronic Foot
Electronic EUI
Pedal Assembly
Control
Turbo Boost Pressure
Module Idle Shut Down/Vehicle Power Down

(ECM) Communication
DDR Interface/ DDDL/ Reprogramming
Fuel / Oil / Coolant
PWM Ports
Temperature
Oil / Fuel Pressure Stop
Check
Engine Engine
EEPROM
Oil level/Fuel Restriction
Crankcase Pressure

Coolant Level Cruise Control Vehicle Speed Limiting

Vehicle Speed Sensor
VSG Control
Engine Rating / Cruise Power / Switch Power
Progressive Shift - +
Pressure Governor Battery
Diagnostic
Request Stop Engine
Override
25ST0072-2
 Schematic Diagram DDEC III / IV

Synch Reference

Timing Reference
Electronic Foot
Electronic EUI
Pedal Assembly
Control Engine Brake

Turbo Boost Pressure

Module Idle Shut Down/Vehicle Power Down
(ECM) Communication
DDR Interface/ DDDL/ Reprogramming
Fuel / Oil / Coolant
PWM Ports
Temperature
Oil / Fuel Pressure Stop
Check
Engine Engine
EEPROM
Oil level/Fuel Restriction
Crankcase Pressure

Coolant Level Cruise Control Vehicle Speed Limiting

Vehicle Speed Sensor
VSG Control
Engine Rating / Cruise Power / Switch Power
Progressive Shift - +
Pressure Governor Battery
Diagnostic
Request Stop Engine
Override
25ST0072-2
Rev. 04/4/00 170
 Schematic Diagram DDEC III / IV

Synch Reference

EUI
Timing Reference
Electronic Foot
Electronic Optimized Idle
Pedal Assembly
Control Fan Controls
Engine Brake

Turbo Boost Pressure

Module ISD / Vehicle
Power Down
(ECM) Communication
Fuel / Oil / Coolant DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
Oil / Fuel Pressure Check Stop
Engine Engine
EEPROM
Oil level/Fuel Restriction
Crankcase Pressure

Cruise Control
Coolant Level Vehicle Speed Limiting
Vehicle Speed Sensor
VSG Control
Engine Rating / Cruise Power / Switch Power
Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Digital Inputs
 Digital Input Functions

• External Switch Requests Function from the ECM

• 37 Options to Choose from
• 12 pins Available on the 30 Pin Vehicle Harness
Connector for Input Functions
• Functions are Assignable to any of these
Pins through the use of a “Reprogramming
Station”

Rev. 04/4/00 173

25ST0072-2
 DDEC III – IV Digital Inputs

No Function
ECM No Function No Function
Cruise Enable Fan Override

#953
EEPROM
#150
_
+
Battery

25ST0072-2
Rev. 04/4/00 174
 DDEC III – IV Digital Inputs

• Air Compressor Controls • Engine Protection

– Air Compressor Load Switch – Auxiliary Input Protection #1
• Cruise Control ( Uses Up – Auxiliary Input Protection #2
to Five Inputs ) – Diagnostic Request Switch
– Cruise Enable – SEO/Diagnostic Request
– Clutch Released Switch
– Service Brake Released • Engine Ratings
– Set / Coast On ( Decrease – Limiting Torque Curve
) – Rating Switch #1
– Resume / Acceleration On – Rating Switch #2
( Increase )
• Engine Brake • Fan Control
– Engine Brake Disable – Transmission Retarder Status
– Engine Brake Low ( Release 2.00 or Later only )
– Engine Brake Medium – Air Conditioner Status
– Fan Control Override
25ST0072-2
Rev. 04/4/00 175
 DDEC III – IV Digital Inputs (Cont’d)

• Throttle Control • Pressure Governor System

– Alternate Minimum (PGS) (Uses Five Inputs)
VSG/Fast Idle – Pressure Governor System
(Release Enable
2.00 or Later Only) – Pressure/RPM Mode Switch
– Dual Throttle (LSG) – Set/Coast On (Decrease)
– Idle Validation Switch – Resume/Acceleration On
(Increase)
– Throttle Inhibit
– VSG Station Change
• Additional Functions
– Auxiliary Coolant Level
– VSG Station Sensor
Complement – Parking Brake Interlock
25ST0072-2
Rev. 04/4/00 176
Digital Outputs
 DDEC III – IV Digital Output Functions

• ECM Commands ( Internal Switches ) Action of

some External Device- Fan Control
• 32 Output Options
• 6 Pins Available, 3 on the 30 pin Vehicle Connector,
3 on the 30 Pin Engine Harness Connector
( Auxiliary Outputs )
• Configurable with the Distributor or Dealer
Reprogramming Station

25ST0072-2
Rev. 04/4/00 178
 Outputs

SEL

ECM
To Jake brake

Ignition
#439

25ST0072-2
Rev. 04/4/00 179
 DDEC III – IV – Digital Outputs

• Coolant Level Low Light • VSG Active Indication

• Cruise Control Active Light • Low Oil Pressure Light
• Deceleration Light • High Oil Temperature Light
• Engine Brake Active • High Coolant Temp. Light
• Fan Control #1 • Ether Injection
• Fan Control #2 • Low Coolant Pressure Light
• Low DDEC Voltage • High Crankcase Pressure
• Pressure Mode Light Light
• Starter Lockout • Optimized Idle Active Light
• Transmission Retarder • Gas Solenoid Shutdown
• Vehicle Power Shutdown • Fuel Regulator Solenoid
25ST0072-2
Rev. 04/4/00 180
 DDEC –III – IV Digital Outputs (Cont’d)

• Air Compressor Solenoid • Turbo Recirculation Valve

• Exhaust Brake Enabled • Cold Engine Signal
• Fuel Supply Solenoid • Rpm Synchronize Light
• Low Range Solenoid • Shift Lockout
• High Range Solenoid • Shift Solenoid
25ST0072-2
Rev. 04/4/00 181
 Fuel Economy Incentive

• Encourages better driving habits by rewarding good

fuel economy with extra road speed
• If driver exceeds the target fuel economy extra road
speed will automatically be added to his maximum
vehicle speed

25ST0072-2
Rev. 04/4/00 182
 Fuel Economy Incentive

Parameter Range Example

Min MPG 5-10 mpg 7.0
Max MPH 0-10 mph 4
Scaler MPH/MPG 0.1-20 mph/mpg 10.0
Calc Type Filtered/Trip Trip
If Scaler is set at:
20.0 = 1 extra mph for every .05 mpg above target mpg
10.0 = 1 extra mph for every .1 mpg above target mpg
5.0 = 1 extra mph for every .2 mpg above target mpg
2.0 = 1 extra mph for every .5 mpg above target mpg
1.0 = 1 extra mph for every 1.0 mpg above target mpg
If Calc Type is set at:
Filtered - Calculates using Total Engine Data
Trip - Calculates using Trip Data

25ST0072-2
Rev. 04/4/00 183
 PasSmart

• Electronically Controlled Increased Passing Speed

– PasSmart is an electronic feature that enables a fleet
manager to enable a second Vehicle Speed Limit (VSL)
to assist drivers during passing.

– This second Vehicle Speed Limit (VSL) is programmed

for a limited duration during a given period This feature
is available with DDEC IV Software version R28.00.

– As and example: If the fleet policy is 65 Miles Per Hour

(MPH) the fleet manager can increase the Vehicle Speed
Limit (VSL) an additional 5-20 MPH for 1- 255 minutes
per day.

25ST0072-2
Rev. 04/4/00 184
 Series 60 EGR
Electrical Schematic

W1 416 1.5KΩ W1 416 1

ECM ECM
EGR 1.5KΩ DPS
R2907 2 Temp Sensor M2 958 2

Y2 1 Y2 452 3
452

25ST0072-2
Rev. 04/4/00 185
DDEC V
 History of DDEC V

• 1999 - Kick off for use with EGR in Oct 2002

– Designed for Common Rail Injection
• 2001 - Removed Common Rail and Went back to
Unit Injectors
• 2002-2003 – Field Test
– SOP Dec. 1 2003

25ST0072-2
Rev. 04/4/00 187
 DDEC V Features

• DDEC V Electronic Control

Module (ECU)
– 4 Times More Memory
– Two 68 Pin Connectors Instead of
Current Six Connectors
• Benefits
– Ability to Add Options to
EGR Engines
» Maintenance Alert System
– New Connectors With Improved
Seals to Prevent Water Intrusion
– Improved Vehicle Integration
With Other Control Systems

25ST0072-2
Rev. 04/4/00 188
 DDEC V Improvements Over DDEC IV

• More Terminal Pins (136 vs. 81)

• More Flexible Inputs
– Frequency Inputs: 6 vs. 4
» OEM has 2 Frequency Inputs
• Digital Outputs: 19 (8 Hi),B+ (11 Lo)B- vs. 10 (2 Hi, 8
Lo)
» OEM has 10 Low Side Digital Inputs – 2 are used for CEL/SEL
• PWM Outputs: 6 vs. 4 (Low Side)
» OEM has 2 PWM Outputs

25ST0072-2
Rev. 04/4/00 189
 DDEC V Improvements over DDEC IV (cont.)

• Memory:
– DDEC IV: 512 kB Flash, 66 kB RAM, 32 kB EEPROM
– DDEC V: 2496 kB Flash, 282 kB RAM, No EEPROM
• High Speed Programming
– New DDEC Multilink Translator (J1708, CAN & J1939)
» Uses Same J1708 Cables as DDC RP1202 Translator
» Translator Now Available: P/N 23528022

25ST0072-2
Rev. 04/4/00 190
 DDEC V ECU

25ST0072-2
Rev. 04/4/00 191
 DDEC V ECU

25ST0072-2

Rev. 04/4/00 192

 DDEC V – Hardware changes

• Stud thread is M6 x
1, stud height
above the shroud
will be about 12 mm
• Corrosion resistant,
plated, nylon insert
or prevailing torque
lock-nuts are
recommended

25ST0072-2
Rev. 04/4/00 193
 DDEC V Electronics

• Utilizes New Tyco/AMP Connectors for Improved

Harness Design and Reliability
• Uses Framatome (FCI) Connectors for Sensors
– Connectors were introduced for EGR engines in Oct 2002
• Has Full Support for J1587 and J1939 Data Links
(J1922 is not supported)
• Maintains Same Footprint as DDEC II / III / IV
• Application and Installation Manual Now Available
on the DDC Extranet

25ST0072-2
Rev. 04/4/00 194
 DDEC V ECU Connectors

Terminal Side of Connector

Pins 1 to 60 are for 18 gauge wire
Pins 61 to 68 are for 14 gauge wire
Both the wire end and the terminal
end are different sizes
On the Engine Harness Connector,
EHC, pins 61- 68 are used for the
EUI’s
On the Vehicle Harness Connector,
VHC, pins 61- 68 are used for the
25ST0072-2
Battery connection
Rev. 04/4/00 195
 DDEC V Software

• First Release for December 2003

– R 1.0 Includes all DDEC IV Software Features
» Return of Maintenance Alert System
– J1939 ECU Programming
– J1708 Diagnostics

25ST0072-2
Rev. 04/4/00 196
 DDEC V – Software changes

• Fan control
– The fan control outputs will stay on when the ignition
is turned off until the engine speed is zero
– Requirement for FL – must wire the fan controls to
+12V for feature to work
» If switched +12V is used, fan will turn off with ignition and
freewheel

25ST0072-2
Rev. 04/4/00 197
 DDEC V A&I Manual

• First Official Complete Edition

– Publication Number: 7SA821

– Available on the DDC Extranet

25ST0072-2
Rev. 04/4/00 198
 DDEC V Codes

Sensor Function
Barometric Pressure Senses barometric pressure.
Sensor (Baro Sensor)

Camshaft Position Senses crankshaft position and engine speed for

Sensor (CMP Sensor) functions such as fuel control strategy.

Crankshaft Position Indicates a specific cylinder in the firing order.

Sensor (CKP Sensor)

Engine Coolant Senses coolant temperature for functions such as

Temperature Sensor engine protection, fan control and engine fueling.
(ECT Sensor)
Engine Oil Level Detects oil level at four quarts low. Used in the
(EOL Sensor) Maintenance Alert System.

25ST0072-2

Rev. 04/4/00 199

 DDEC V Codes (cont.)

Sensor Function
Engine Oil Pressure Senses gallery oil pressure for functions such as
Sensor (EOP Sensor) engine protection.

Engine Oil Senses oil temperature for functions such as

Temperature Sensor reducing variation in fuel injection and fan control.
(EOT Sensor)
Fuel Restriction Detects fuel restriction for replacement of fuel filter.
Sensor Used in the Maintenance Alert System.

Intake Air Temperature Senses air temperature for functions such as fan
Sensor (IAT Sensor) control and engine fueling.

Intake Manifold Senses turbo boost for functions such as smoke

Pressure Sensor control and engine protection.
(IMP Sensor)

25ST0072-2
Rev. 04/4/00 200
 DDEC V Codes (cont.)

Sensor Function
Supply Fuel Senses fuel temperature for functions such as engine
Temperature Sensor fueling.
(SFT Sensor)
Turbo Compressor Senses turbo out air temperature.
Temperature Out
Sensor
Turbo Speed Sensor Senses turbo speed for over-speed conditions.
(TSS)

25ST0072-2

Rev. 04/4/00 201

 Schematic Diagram DDEC V

Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic Optimized Idle
TCITS OEM

Pedal Assembly
Control Fan Controls
Engine Brake
Module ISD / Vehicle
Turbo Boost Pressure Power Down
Turbo
(ECM) Communication
Speed Fuel / Oil / Coolant / EGR (ECU) DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
EGR Delta
Oil / Fuel Pressure V Check Stop
Engine
Engine
MASS
Oil level/Fuel Restriction
Barometric Crankcase Pressure
Pressure
Cruise Control
Coolant Level Vehicle Speed Limiting
TCOTS Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery 12-24 Volt VPOD
Diagnostic Stop Engine
 Request Override Hydraulic EGR VNT
25ST0072-2
Rev. 04/4/00
Valve

202
 Schematic Diagram DDEC V

Synch Reference

Timing Reference
Electronic Foot
Electronic
Pedal Assembly
Control
Module
Turbo Boost Pressure

Turbo
(ECM)
Speed Fuel / Oil / Coolant / EGR (ECU)
Temperature
EGR Delta Oil / Fuel Pressure V
MASS
Oil level/Fuel Restriction

Barometric
Pressure
Coolant Level
TCOTS
VSG Control

Progressive Shift - +
Pressure Governor
12-24 Volt VPOD
Diagnostic Stop Engine
Request Override Hydraulic EGR VNT
25ST0072-2
Valve
 DDEC V Hydraulic EGR Valve

• Current Controlled from DDEC

• Actual Current Displayed in DDDL Using Mill volts
• Increasing Current Allows More Oil Flow
to Hydraulically Open EGR Valve

25ST0072-2
Rev. 04/4/00 204
 EGR Valve & Actuator

December 2004
Hydraulic Actuator & Control Valve

25ST0072-2
Rev. 04/4/00 205
 Series 60 ‘04 EGR

• New EGR Valve Design

• Electronically Controlled
Hydraulic Valve Actuation
– Utilizes Engine Oil to
“Power” the Valve With
Supply Line from the Oil
Cooler Adapter
– Direct DDEC Input
– Reduced Linkage “Parts”
• Replaces Pneumatic
Actuator, Air Lines and
EGR VPOD

Rev. 04/4/00 206

25ST0072-2
 EGR Valve Assy.

Supply Port

Return Port

25ST0072-2
Rev. 04/4/00 207
Series 60 2004 DDEC V
Reprogramming Station
 Factory/Distributor Tools DDEC V

• Distributor Reprogramming System

– V3.61 Released to key distributors on Aug 24
» Supports engineering test calibrations
» Supports most customer features, not fully functional
• Production release of DRS on Dec 15

25ST0072-2
Rev. 04/4/00 209
 Distributor Reprogramming DDEC V

• DDEC V Electronic Tools

Distributor Reprogramming Kit
DDEC V Hardware Components
for Programming Station (DRS)
DDEC V Programming
Software Supporting Test
Vehicles
Production Version Scheduled
for Release 12/1/03
New High Speed Kit
Features J-1939 Connection
25ST0072-2
Rev. 04/4/00 210
 Schematic Diagram DDEC V

Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic Optimized Idle
TCITS OEM

Pedal Assembly
Control Fan Controls
Engine Brake
Module ISD / Vehicle
Turbo Boost Pressure Power Down
Turbo
(ECM) Communication
Speed Fuel / Oil / Coolant / EGR (ECU) DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
EGR Delta
Oil / Fuel Pressure V Check Stop
Engine
Engine
MASS
Oil level/Fuel Restriction
Barometric Crankcase Pressure
Pressure
Cruise Control
Coolant Level Vehicle Speed Limiting
TCOTS Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power

Progressive Shift - +
Pressure Governor Battery 12-24 Volt VPOD
Diagnostic Stop Engine
 Request Override Hydraulic EGR VNT
25ST0072-2
Rev. 04/4/00
Valve

211
 Bosch N-3 Fuel Injector

25ST0072-2
Rev. 04/4/00 212
 Bosch N3

• Removal Force Applied to this Surface Only !

Insert pry bar

Copper Gasket
25ST0072-2
Rev. 04/4/00 213
 Bosch N3

• Electronic Fuel Injector

– Internal Solenoid
– Reduced Internal Fuel Volume
– Utilize Electrical Connector Instead of
Ring Terminals
– Designed to Accept SS Injector Sleeve
• Benefits
– Improved Reliability Due to Higher
Design Factor of Safety ( 1.6 )
» Less Susceptible to Tip and Body Cracks
– Crisper Injection Event (Efficiency)

25ST0072-2
Rev. 04/4/00 214
 Bosch N-3 Injector

• Improved Response Times .7-.9ms

• Continue to Utilize High Injection

Pressure for Optimization of
Emissions and Efficiency Tradeoffs
– 2200 bar Peak Injection Pressure

25ST0072-2
Rev. 04/4/00 215
N3 Advantages over S60 N2

Reliability
40% Improved Strength
•
• Reduced External Leakage
Potential
• Improved Nut Design

Performance
• Reduced Trapped Volume
•Faster Response Time
•Improved End of
Injection
Behavior
• Reduced Weight (~15 lb.
per engine)
25ST0072-2
Rev. 04/4/00 216
 DDEC V
Sensor Wiring
 DDEC V ESH Schematic

25ST0072-2
Rev. 04/4/00 218
 DDEC V TRS/SRS Sensor

ECU

TRS -
E-17 1
TRS +
E-18 2

SRS -
E-20 1
SRS +
E-19 2

EHC

25ST0072-2
Rev. 04/4/00 219
 DDEC V On-Highway Governors

ECU
TPS
Signal A
V-13/14
V-11 5 Volt B .
V-60 Return C
D

V-16 IVS, Closed @ Idle E

Return
V-59

VHC
F .
13: ALSG
14: VSG
25ST0072-2
 DDEC V Turbo Speed Sensor

ECU

TSS -
E-35 1
TSS +
E-34 2

EHC

25ST0072-2
Rev. 04/4/00 221
 DDEC V Temperature Sensor

ECU

Return
E-15 1
Signal
XX 2

XX is
CTS: E-5
OTS: E-7 2 seconds to set a high temp. code
EHC
EGR: E-10

25ST0072-2
Rev. 04/4/00 222
 DDEC V Three Wire Engine Sensors

ECU

Return
E-15 1
Signal
XX 2
5 Volt
E-12 3

XX is
OPS: E- 7 seconds to set a low pressure code
EHC 31 BPS:
E-37 TBS:
E-39
25ST0072-2
Rev. 04/4/00 223
 DDEC V Coolant Level Sensors

ECU

Signal
V-37/38 A
Return
V-60 B

37: ACLS (MAS)

38: CLS, Shutdown 15 seconds to set a low coolant code
VHC

25ST0072-2
 DDEC V Three Wire Vehicle Sensor

ECU

V-60 Return A
V-11 V-29 5 Volt Signal
B PGS
C

Pressure Governor
VHC

25ST0072-2
Rev. 04/4/00 225
 Diagnostic Test Mode/Stop Engine Override
DDEC V Switch - DTM/SEO
ECU

Diag. Request
V-24
V-59 Return

VHC

25ST0072-2
Rev. 04/4/00 226
 DDEC V Diagnostic Connector

ECU
Ground A
Power B D
J1939 + C E
V-43 C
J1939 -
V-58 D
J1939 Shield F A B
V-44 E
J1587 +
V-56 F J
J1587 - G
V-57 G H
Plug
H
Plug
J
VHC
J 1587 & 1939
25ST0072-2
Rev. 04/4/00 227
 DDEC V Power, Ground, and Ignition
ECU

V-15 . . 10 Amp

V-61
V-62
V-65 30 Amp .
V-66 Pos.
Batt.
V-63
V-64
V-67
V-68
.Neg.

VHC
25ST0072-2
Rev. 04/4/00 228
 DDEC V VNT VPOD

ECU

Switched Power
E-46 1 V
PWM Control
E-4 2 P
E-42
Ground
3
O
D

EHC

25ST0072-2
Rev. 04/4/00 229
 DDEC V Cruise Control
ECU
Input, Cruise On/Off
V-9
Input, Set/Coast
V-47
Input, Resume/Accel
V-8
Input, Clutch Released
V-10
Input, Service Brake Released
V-3
V-59 Sensor Return
Low Output, Cruise Light Ignition
V-XX
VSS +
V-17
VSS -
V-18
VHC
25ST0072-2
Rev. 04/4/00 230
 DDEC V Warning Lights

ECU

V-1 CEL/AWL Ignition

V-2 SEL/RSL Ignition

V-X Indicator Ignition

VHC
Max current to be grounded per output 2.0 A.
Max total current for all 10 low-side D.O.’s is 10.0 A.
25ST0072-2
 DDEC V ISD and Vehicle Power Shutdown
ECU
PB Sw Neutral Sw
PB Input
V-50 Sensor return
V-59

To Veh. Systems
Ign. Sw
Low Output, VPS
V-7

VHC

25ST0072-2
Rev. 04/4/00 232
 DDEC V Jakes

ECU
Analog Input, Brake Low
V-39

V-51 Analog Input, Brake Med

V-59 Sensor return

Digital Output, High Side. Low/High Brake

E-49

E-48 Digital Output, High Side. Med/High Brakes

EHC/VHC

25ST0072-2
 DDEC V Series 60 Injector Wiring
ECU
E-63
1
E-65
Bank 1 Return 2
E-61
E-64
3
E-68
4
E-66
Bank 2 Return
5
E-62
E-67
EHC 6
25ST0072-2
Rev. 04/4/00 234
 DDEC V VIH Schematic

25ST0072-2
Rev. 04/4/00 235
 DDEC V
Service Tools
 Service Tools

Test Sensors

DDEC V Test ECM

DDEC V Harness Repair Kit
25ST0072-2
 Summary of Major Benefits

• Improved Component Reliability

– EGR Cooler
– Injector
– Overhead
– EGR Valve
• Reduced Ring/Liner Wear and Oil Soot Loading
• Eliminated Compressor Surge at Altitude
• Enhanced Technology With DDEC V
• Reduced Engine Weight
• Potential for Fuel Economy Improvements From
2003 Depending on Current Driveline Gearing
25ST0072-2
Rev. 04/4/00 238
We Define Performance