Complete Service Manual for your Detroit Diesel DDEC V Application and Installation Manual on CD
Everything needed to work on your Specified Detroit Engine is right here.
TABLE OF CONTENTS
INTRODUCTION
1.1 FEATURES
1.2 ADVANTAGES
1-2
1.3 TYPICAL INSTALLATION
1-2
1.4 APPLICATION FLEXIBILITY
1-3
1.5 DIAGNOSTICS AND TOOLS
1-3
1.6 ELECTRONIC DISPLAYS
1-4
1.7 THE BASICS
1-6
2
SAFETY PRECAUTIONS
2-1
2.1 STANDS
2-1
2.2 GLASSES
2-1
2.3 WELDING
2-2
2.4 WORK PLACE
2-2
2.5 CLOTHING
2-3
2.6 ELECTRIC TOOLS
2-3
2.7 AIR
2-4
2.8 DIAGNOSTIC TOOLS
2-4
2.9 FLUIDS AND PRESSURE
2-4
2.10 BATTERIES
2-5
2.11 FIRE
2-6
2.12 PAINT
2-6
2.13 FLUOROELASTOMER
2-6
2.14 OPTIMIZED IDLE
2-7
3
HARDWARE AND WIRING
3-1
3.1 SUPPLIED HARDWARE
3-3
3.1.1 OEM-SUPPLIED HARDWARE 3-3
3.1.2 DDC-SUPPLIED HARDWARE 3-3
3.2 ELECTRONIC CONTROL UNIT
3-5
3.2.1 CONNECTOR SHROUD 3-8
3.2.2 ECU PART NUMBERS 3-9
3.2.3 ENVIRONMENTAL CONDITIONS 3-10
TEMPERATURE 3-10
ATMOSPHERIC PRESSURE 3-10
WATER INTRUSION 3-10
3.3 ENGINE HARNESS
3-11
3.3.1 EH CONNECTOR AND TYPICAL REQUIRED FUNCTIONS 3-11
3.4 VEHICLE INTERFACE HARNESS 3-15
3.4.1 VIH CONNECTOR AND TYPICAL REQUIRED FUNCTIONS 3-16
3.4.2 VIH DESIGN GUIDELINES 3-24
FREQUENCY INPUTS 3-25
ANALOG INPUTS 3-26
PULSE WIDTH MODULATED OUTPUT 3-28
FREQUENCY OUTPUT 3-28
DIGITAL OUTPUTS 3-29
IGNITION 3-29
3.4.3 VIH POWER WIRING 3-30
WIRE RESISTANCES 3-31
3.4.4 COMMUNICATION WIRING 3-32
3.4.5 VIH INSTALLATION 3-34
3.5 POWER SUPPLY 3-35
3.5.1 AVERAGE CURRENT DRAW 3-35
3.5.2 MAIN POWER SHUTDOWN 3-36
3.6 FUSES ........... 3-37
3.7 CONNECTORS 3-39
3.7.1 ECU VEHICLE INTERFACE HARNESS CONNECTOR 3-40
3.7.2 ECU ENGINE HARNESS CONNECTOR 3-49
3.7.3 DATA LINK CONNECTOR 3-52
3.7.4 FCI CONNECTORS 3-53
3.8 WIRES AND WIRING 3-55
3.8.1 GENERAL WIRE RECOMMENDATIONS 3-55
3.8.2 ECU CONNECTOR WIRE INTO SHROUD INSTALLATION . 3-56
3.8.3 TERMINAL INSTALLATION AND REMOVAL ............. 3-58
WIRE AND TERMINAL INSTALLATION - TYCO ECU CONNECTOR . 3-58
WIRE AND TERMINAL REMOVAL - TYCO ECU CONNECTOR 3-58
DEUTSCH TERMINAL INSTALLATION GUIDELINES
3-60
DEUTSCH TERMINAL REMOVAL 3-63
3.8.4 FCI APEX TERMINAL INSTALLATION AND REMOVAL 3-65
FCI APEX MALE TERMINAL INSTALLATION .....
3-65
FCI APEX MALE TERMINAL REMOVAL ............. 3-66
FCI APEX FEMALE TERMINAL INSTALLATION . 3-68
FCI APEX FEMALE TERMINAL REMOVAL ........
3-69
3.8.5 SPLICING GUIDELINES 3-71
CLIPPED AND SOLDERED SPLICING METHOD 3-71
SPLICING AND REPAIRING STRAIGHT LEADS-ALTERNATE METHOD 1 ......
3-74
SPLICING AND REPAIRING STRAIGHT LEADS - ALTERNATE METHOD 2 .... 3-76
SHRINK WRAP 3-78
STAGGERING WIRE SPLICES
3-79
3.9 CONDUIT AND LOOM 3-81
3.10 TAPE AND TAPING 3-83
3.11 SENSORS ...... 3-85
3.11.1 FACTORY-INSTALLED SENSORS 3-87
3.11.2 BAROMETRIC PRESSURE SENSOR 3-88
3.11.3 EGR DELTA PRESSURE SENSOR 3-88
3.11.4 EGR TEMPERATURE SENSOR 3-89
3.11.5 ENGINE COOLANT TEMPERATURE SENSOR ...... 3-89
3.11.6 ENGINE OIL LEVEL SENSOR 3-90
3.11.7 ENGINE OIL PRESSURE SENSOR 3-90
3.11.8 ENGINE OIL TEMPERATURE SENSOR 3-91
3.11.9 FUEL RESTRICTION SENSOR 3-91
3.11.10 INTAKE AIR TEMPERATURE SENSOR 3-92
3.11.11 INTAKE MANIFOLD PRESSURE SENSOR ............. 3-92
3.11.12 SYNCHRONOUS AND TIMING REFERENCE SENSORS 3-93
3.11.13 SUPPLY FUEL TEMPERATURE SENSOR 3-93
3.11.14 TURBO COMPRESSOR TEMPERATURE OUT SENSOR 3-94
3.11.15 TURBO SPEED SENSOR 3-94
3.11.16 OEM-INSTALLED SENSORS 3-95
3.11.17 ACCELERATOR PEDAL SENSOR 3-96
3.11.18 AIR FILTER RESTRICTION SENSOR 3-96
3.11.19 AMBIENT AIR TEMPERATURE SENSOR . 3-98
AMBIENT AIR TEMPERATURE SENSOR INSTALLATION 3-99
3.11.20 ENGINE COOLANT LEVEL SENSOR 3-100
3.11.21 ADD ENGINE COOLANT LEVEL SENSOR 3-103
3.11.22 FIRE TRUCK PUMP PRESSURE SENSOR .............. 3-106
3.11.23 TURBO COMPRESSOR IN TEMPERATURE SENSOR 3-107
3.11.24 VEHICLE SPEED SENSOR 3-109
MAGNETIC PICKUP 3-110
OPEN COLLECTOR 3-111
SAE J1939 DATA LINK 3-112
VSS ANTI-TAMPER 3-112
3.11.25 AFTERMARKET INSTALLED SENSORS . 3-113
3.11.26 AMBIENT AIR TEMPERATURE SENSOR . 3-113
AMBIENT AIR TEMP SENSOR KIT INSTALLATION 3-115
3.12 THROTTLE DEVICES 3-117
3.12.1 ACCELERATOR PEDAL ASSEMBLY 3-118
3.12.2 CRUISE CONTROL SWITCHES 3-118
3.12.3 HAND THROTTLE 3-119
3.12.4 FAST IDLE SWITCH (ALTERNATE MINIMUM VSG) . 3-119
3.12.5 VOLTAGE DIVIDERS 3-119
3.12.6 FREQUENCY INPUT 3-119
3.13
LIGHTS .......... 3-121
3.13.1 AMBER WARNING LAMP 3-121
AWL AND MAINTENANCE INTERVALS .............. 3-121
AWL AND PASSMART 3-121
AWL AND THE MAINTENANCE ALERT SYSTEM 3-122
AMBER WARNING LAMP REQUIREMENTS AND GUIDELINES 3-122
WIRING REQUIREMENTS 3-123
3.13.2 RED STOP LAMP 3-124
RED STOP LAMP REQUIREMENTS AND GUIDELINES
RED STOP LAMP WIRING
INPUTS AND OUTPUTS
DIGITAL AND ANALOG INPUTS
AIR COMPRESSOR CONTROL
AIR COMPRESSOR LOAD SWITCH
AIR COMPRESSOR PRESSURE SENSOR ........
INCREASE
DECREASE
PROGRAMMING REQUIREMENTS AND FLEXIBILITY .
4-7
4.1.2 CRUISE CONTROL
4-8
CRUISE CONTROL ENABLE
4-8
SET / COAST ON
RESUME / ACCEL ON
CLUTCH RELEASED (MANUAL TRANSMISSIONS)
SERVICE BRAKE RELEASED (AUTOMATIC AND MANUAL TRANSMISSIONS)
PROGRAMMING REQUIREMENTS AND FLEXIBILITY .
INTERACTION WITH OTHER FEATURES
ENGINE BRAKE 4-10
ENGINE BRAKE DISABLE 4-10
ENGINE BRAKE LOW 4-10
ENGINE BRAKE MEDIUM 4-10
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-11
4.1.4 ENGINE PROTECTION 4-12
AUXILIARY SHUTDOWN #1 AND #2 . 4-12
DIAGNOSTIC REQUEST SWITCH 4-12
DIAGNOSTIC REQUEST SWITCH/STOP ENGINE OVERRIDE SWITCH
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-13
DIAGNOSTICS 4-13
4.1.5 ENGINE RATINGS 4-14
LIMITING TORQUE CURVE 4-14
RATING SWITCH #1 AND #2 4-14
PROGRAMMING REQUIREMENTS AND FLEXIBILITY .
4-14
4.1.6 FAN CONTROL 4-15
AIR CONDITIONER STATUS 4-15
FAN CONTROL OVERRIDE 4-15
TRANSMISSION RETARDER STATUS 4-15
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-15
4.1.7 MAINTENANCE ALERT SYSTEM 4-16
AIR FILTER RESTRICTION SENSOR . 4-16
ADD ENGINE COOLANT LEVEL SENSOR ......... 4-16
PROGRAMMING REQUIREMENTS AND FLEXIBILITY .
4-16
DIAGNOSTICS 4-17
4.1.8 OPTIMIZED IDLE 4-18
CRUISE ENABLE/OPTIMIZED IDLE ENABLE ....
4-18
PARKING BRAKE INTERLOCK 4-18
OPTIMIZED IDLE THERMOSTAT 4-18
PROGRAMMING REQUIREMENTS AND FLEXIBILITY .
4-18
4.1.9 PRESSURE SENSOR GOVERNOR 4-19
PRESSURE SENSOR GOVERNOR ENABLE ..... 4-19
PRESSURE/RPM MODE
4-19
SET/COAST (DECREASE) 4-19
RESUME/ACCEL (INCREASE) 4-19
FIRE TRUCK PUMP PRESSURE SENSOR
PROGRAMMING REQUIREMENTS AND FLEXIBILITY
INTERACTION WITH OTHER FEATURES
THROTTLE CONTROL
ALTERNATE MINIMUM VSG SPEED/FAST IDLE
DUAL THROTTLE (ALSG)
EXTERNAL ENGINE SYNCHRONIZATION/FREQUENCY INPUT ACTIVE
IDLE VALIDATION
THROTTLE INHIBIT
VSG STATION CHANGE AND VSG STATION CHANGE COMPLEMENT
VSG INHIBIT
PROGRAMMING REQUIREMENTS AND FLEXIBILITY
DDITIONAL FUNCTIONS
AUXILIARY ENGINE COOLANT LEVEL SWITCH
PARK BRAKE INTERLOCK
RPM FREEZE 4-25
TWO-SPEED AXLE RATIO SWITCH 4-25
PROGRAMMING REQUIREMENTS AND FLEXIBILITY OF ADDITIONAL
FUNCTIONS 4-25
4.2 DIGITAL OUTPUTS 4-27
4.2.1 AIR COMPRESSOR LOAD SOLENOID 4-29
INSTALLATION 4-29
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-29
4.2.2 CRUISE CONTROL ACTIVE LAMP (PRESSURE SENSOR GOVERNOR ACTIVE
LAMP) ........ 4-29
INSTALLATION 4-29
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-29
INTERACTION WITH OTHER FEATURES .......... 4-29
4.2.3 DECELERATION LAMP 4-30
INSTALLATION 4-30
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-30
4.2.4 ENGINE BRAKE ACTIVE 4-30
INSTALLATION 4-30
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-30
4.2.5 ENGINE COOLANT LEVEL LOW LAMP 4-31
INSTALLATION 4-31
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-31
INTERACTION WITH OTHER FEATURES .......... 4-31
4.2.6 ENGINE OVERSPEED 4-32
INSTALLATION 4-32
PROGRAMMING REQUIREMENTS & FLEXIBILITY 4-32
4.2.7 ETHER START 4-33
INSTALLATION 4-33
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-33
DIAGNOSTICS 4-33
4.2.8 EXTERNAL ENGINE BRAKE ENABLE 4-33
INSTALLATION 4-33
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-33
4.2.9 EXTERNAL ENGINE SYNCHRONIZATION/FREQUENCY INPUT ACTIVE ............. 4-34
INSTALLATION 4-34
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-34
4.2.10 FAN CONTROL #1 & #2 4-35
INSTALLATION 4-35
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-35
4.2.11 HIGH ENGINE COOLANT TEMPERATURE LAMP .. 4-36
INSTALLATION 4-36
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-36
DIAGNOSTICS 4-36
4.2.12 HIGH ENGINE OIL TEMPERATURE LAMP ............. 4-37
INSTALLATION 4-37
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-37
DIAGNOSTICS 4-37
4.2.13 LOW DDEC VOLTAGE WARNING LAMP 4-38
INSTALLATION 4-38
PROGRAMMING REQUIREMENTS AND FLEXIBILITY .
4-38
DIAGNOSTICS 4-38
4.2.14 LOW ENGINE OIL PRESSURE LAMP 4-39
INSTALLATION 4-39
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-39
DIAGNOSTICS 4-39
4.2.15 OPTIMIZED IDLE ACTIVE LAMP 4-40
INSTALLATION 4-40
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-40
DIAGNOSTICS 4-40
4.2.16 OPTIMIZED IDLE ALARM 4-41
INSTALLATION 4-41
PROGRAMMING REQUIREMENTS AND FLEXIBILITY .
4-41
DIAGNOSTICS 4-41
4.2.17 OPTIMIZED IDLE STARTER RELAY 4-42
INSTALLATION 4-42
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-42
DIAGNOSTICS 4-42
4.2.18 PRESSURE SENSOR GOVERNOR PRESSURE MODE LAMP 4-43
INSTALLATION 4-43
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-43
4.2.19 STARTER LOCKOUT 4-44
INSTALLATION 4-44
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-44
4.2.20 TOP2 SHIFT SOLENOID 4-44
INSTALLATION 4-44
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-44
DIAGNOSTICS
4-44
4.2.21 TOP2 SHIFT LOCKOUT SOLENOID 4-45
INSTALLATION 4-45
PROGRAMMING REQUIREMENTS AND FLEXIBILITY .
DIAGNOSTICS 4-45
4.2.22 TRANSMISSION RETARDER 4-45
INSTALLATION 4-45
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-45
4.2.23 VEHICLE POWER SHUTDOWN 4-46
INSTALLATION 4-46
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-47
DIAGNOSTICS 4-47
INTERACTION WITH OTHER FEATURES .......... 4-47
4.2.24 VSG ACTIVE INDICATION 4-47
INSTALLATION 4-47
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 4-47
INTERACTION WITH OTHER FEATURES .......... 4-47
4.3 PWM OUTPUTS 4-49
4.3.1 PWM TRANSMISSION 4-49
4.3.2 PWM FAN .. 4-49
5
DDEC FEATURES
5-1
5.1 AIR COMPRESSOR CONTROL
5-3
5.1.1 OPERATION 5-3
INCREASE SWITCH (RESUME/ACCELERATION ON)
5-3
DECREASE SWITCH (SET/COAST ON) .............
5-4
AIR COMPRESSOR LOAD SWITCH
5-4
AIR COMPRESSOR SOLENOID
5-4
AIR COMPRESSOR SHUTDOWN
5-4
MULTIPLE PRESSURE RATINGS
5-4
5.1.2
INSTALLATION 5-5
5.1.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY
5-6
5.1.4
INTERACTION WITH OTHER FEATURES 5-7
5.2 ANTI-LOCK BRAKE SYSTEMS
5-9
5.2.1 OPERATION 5-9
5.3 CRUISE CONTROL
5-11
5.3.1 OPERATION 5-11
ENGINE SPEED CRUISE CONTROL
5-11
VEHICLE SPEED CRUISE CONTROL
5-11
SMART CRUISE 5-12
CRUISE ENABLE 5-12
SET / COAST ON 5-12
RESUME / ACCEL ON 5-13
CLUTCH RELEASED (MANUAL TRANSMISSIONS) 5-13
SERVICE BRAKE RELEASED (AUTOMATIC AND MANUAL TRANSMISSIONS)
5-13
AUTO RESUME 5-13
CRUISE PAUSE 5-14
CRUISE POWER 5-14
5.3.2
INSTALLATION 5-15
5.3.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-16
5.3.4 DIAGNOSTICS 5-17
5.3.5
INTERACTION WITH OTHER FEATURES 5-17
5.4 DIAGNOSTICS 5-19
5.4.1 OPERATION 5-19
DIAGNOSTIC REQUEST SWITCH 5-20
DIAGNOSTIC REQUESTSWITCH/STOP ENGINE OVERRIDE 5-21
5.5 EDM AND AIM 5-23
5.5.1 OPERATION 5-23
5.5.2
INSTALLATION 5-24
5.5.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-24
5.5.4
INTERACTION WITH OTHER FEATURES 5-25
5.5.5 DIAGNOSTICS 5-25
5.6 ELECTRONIC FIRE COMMANDER 5-27
5.6.1 OPERATION 5-28
5.6.2
INSTALLATION 5-28
5.6.3 ORDERING EFC 5-28
5.6.4 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-30
5.7 ENGINE BRAKE CONTROLS 5-31
5.7.1 OPERATION 5-31
CRUISE CONTROL WITH ENGINE BRAKE ...... 5-31
ENGINE BRAKE DISABLE 5-31
ENGINE BRAKE ACTIVE 5-32
ENGINE FAN BRAKING 5-32
CLUTCH RELEASED INPUT 5-32
SERVICE BRAKE CONTROL OF ENGINE BRAKES 5-32
MIN MPH FOR ENGINE BRAKES 5-32
5.7.2
INSTALLATION 5-32
5.7.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-33
5.7.4
INTERACTION WITH OTHER FEATURES 5-35
5.8 ENGINE PROTECTION 5-37
5.8.1 OPERATION 5-37
WARNING ONLY 5-37
RAMPDOWN 5-38
SHUTDOWN 5-38
5.8.2 ENGINE OVERTEMPERATURE PROTECTION ....... 5-39
5.8.3 ENGINE PROTECTION SWITCHES 5-44
DIAGNOSTIC REQUEST SWITCH 5-44
5.8.4 STOP ENGINE OVERRIDE OPTIONS 5-46
5.8.5
INSTALLATION 5-48
5.8.6 PROGRAMMING FLEXIBILITY 5-48
5.8.7
INTERACTION WITH OTHER FEATURES 5-49
5.9 ENGINE RATINGS 5-51
5.9.1 OPERATION 5-51
ENGINE RATING SWITCHES
5-51
CRUISE POWER 5-52
LIMITING TORQUE CURVE OPTION (DIGITAL TORQUE LIMITING) 5-52
5.9.2
INSTALLATION 5-52
DDEC V APPLICATION AND INSTALLATION MANUAL
5.9.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-54
RATING SWITCHES 5-54
CRUISE POWER 5-54
LIMITING TORQUE OPTION 5-54
5.10 ETHER START 5-55
5.10.1 OPERATION 5-55
5.10.2 INSTALLATION 5-56
INJECTOR NOZZLE 5-57
VALVE AND CYLINDER ASSEMBLY 5-58
ETHER INJECTION RELAY 5-62
TUBING AND METERING ORIFICE 5-64
WIRING HARNESS 5-65
5.10.3 PARTS ....... 5-68
OEM -- ETHER START KITS FOR THE SERIES 60 ENGINES 5-68
AFTER-MARKET ETHER START KITS FOR THE SERIES 50 AND SERIES 60
ENGINES 5-69
5.10.4 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-73
5.10.5 DIAGNOSTICS 5-73
5.11 FAN CONTROL 5-75
5.11.1 OPERATION 5-75
5.11.2 INSTALLATION 5-75
5.11.3 SINGLE FAN 5-77
INSTALLATION 5-79
5.11.4 DUAL FANS 5-82
INSTALLATION - DUAL FANS 5-83
5.11.5 TWO-SPEED FAN 5-84
INSTALLATION -TWO-SPEED FANS 5-86
5.11.6 VARIABLE SPEED SINGLE-FAN 5-87
INSTALLATION - VARIABLE SPEED SINGLE-FAN 5-89
5.11.7 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-90
5.12 FUEL ECONOMY INCENTIVE 5-93
5.12.1 OPERATION 5-93
5.12.2 PROGRAMMING FLEXIBILITY 5-94
5.12.3 INTERACTION WITH OTHER FEATURES. 5-94
5.13 HALF ENGINE IDLE 5-95
5.13.1 OPERATION 5-95
5.13.2 INSTALLATION 5-95
5.13.3 PROGRAMMING FLEXIBILITY 5-95
5.13.4 DIAGNOSTICS 5-95
5.14 IDLE SHUTDOWN TIMER AND VEHICLE POWER SHUTDOWN 5-97
5.14.1 OPERATION 5-97
IDLE SHUTDOWN OVERRIDE - OPTIONAL ...... 5-98
VEHICLE POWER SHUTDOWN - OPTIONAL .... 5-98
ENABLED ON VARIABLE SPEED GOVERNOR (VSG) - OPTIONAL . 5-99
AMBIENT AIR TEMPERATURE OVERRIDE DISABLE - OPTIONAL . 5-100
AMBIENT AIR TEMPERATURE AUTOMATIC OVERRIDE 5-100
INACTIVE SHUTDOWN 5-100
5.14.2 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-101
5.14.3
INTERACTION WITH OTHER FEATURES 5-101
5.15
IRIS 5-103
5.15.1 OPERATION 5-103
5.15.2
INSTALLATION 5-106
MOBILE UNIT INSTALLATION 5-107
IRIS HARDWARE AND KITS 5-111
5.16 LOW GEAR TORQUE LIMITING 5-115
5.16.1 OPERATION 5-115
5.16.2 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-115
5.17 MAINTENANCE ALERT SYSTEM 5-117
5.17.1 OPERATION 5-117
ECU POWER DOWN BEHAVIOR 5-118
AWL/RSL FLASHING 5-118
PRODRIVER DC 5-119
MAINTENANCE ALERT SYSTEM DISPLAY MODULE 5-119
DETROIT DIESEL DIAGNOSTIC LINK 5-121
5.17.2
INSTALLATION 5-123
AIR FILTER RESTRICTION SENSOR . 5-123
ADD ENGINE COOLANT LEVEL SENSOR ......... 5-125
ENGINE FUEL RESTRICTION SENSOR ............ 5-126
ENGINE OIL LEVEL SENSOR 5-127
MAINTENANCE ALERT SYSTEM DISPLAY MODULE INSTALLATION ............. 5-128
MAINTENANCE ALERT SYSTEM DISPLAY HARNESS . 5-132
5.17.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-132
5.17.4 DIAGNOSTICS 5-133
5.17.5
INTERACTION WITH OTHER FEATURES 5-133
5.18 MANAGEMENT INFORMATION PRODUCTS 5-135
5.18.1 OPERATION 5-135
5.18.2 DDEC DATA 5-136
5.18.3 DETROIT DIESEL DATA SUMMARIES 5-136
5.18.4 DDEC REPORTS 5-137
5.18.5 PRODRIVER DC 5-144
PRODRIVER DC INSTALLATION 5-145
5.18.6 MANAGEMENT INFORMATION PRODUCT KITS .... 5-153
5.19 OPTIMIZED IDLE 5-155
5.19.1 OPERATION 5-155
OPTIMIZED IDLE START UP SEQUENCE ......... 5-156
ENGINE MODE 5-156
THERMOSTAT MODE 5-158
5.19.2
INSTALLATION 5-159
INPUTS 5-161
DIGITAL OUTPUTS 5-161
5.19.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-162
5.19.4 DIAGNOSTICS 5-164
5.19.5
INTERACTION WITH OTHER FEATURES 5-164
5.20 PASSMART ... 5-165
5.20.2 INSTALLATION 5-166
5.20.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-167
5.20.4 INTERACTION WITH OTHER FEATURES 5-167
5.21 PASSWORDS 5-169
5.21.1 RATING PASSWORD 5-169
5.21.2 INJECTOR PASSWORD 5-169
5.21.3 CUSTOMER PASSWORD 5-169
PARAMETER GROUP LOCKOUT 5-169
5.21.4 PROGRAMMING REQUIREMENTS & FLEXIBILITY 5-171
5.22 PRESSURE SENSOR GOVERNOR 5-173
5.22.1 PSG OPERATION 5-173
RPM MODE 5-173
PRESSURE MODE 5-173
5.22.2 SWITCHES - INCREASE AND DECREASE ............. 5-174
INCREASE SWITCH (RESUME/ACCELERATION ON) 5-174
DECREASE SWITCH (SET/COAST ON) ............. 5-174
5.22.3 INSTALLATION 5-175
5.22.4 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-176
5.22.5 INTERACTION WITH OTHER FEATURES 5-177
5.23 PROGRESSIVE SHIFT 5-179
5.23.1 OPERATION 5-179
5.23.2 LOW RANGE #1 5-180
5.23.3 LOW RANGE #2 5-180
5.23.4 HIGH RANGE 5-181
5.23.5 INSTALLATION INFORMATION 5-183
5.23.6 PROGRAMMING FLEXIBILITY 5-183
5.23.7 INTERACTION WITH OTHER FEATURES 5-183
5.24 TACHOMETER DRIVE 5-185
5.25 THROTTLE CONTROL/GOVERNORS 5-187
5.25.1 AUTOMOTIVE LIMITING SPEED GOVERNOR- ON-HIGHWAY 5-187
ALSG PRIMARY WITH VSG AS A SECONDARY CONTROL 5-187
ALSG CONTROL OPTIONS 5-188
ALSG ACCELERATOR PEDAL 5-188
ALSG ACCELERATOR PEDAL INSTALLATION .. 5-189
ALSG ACCELERATOR PEDAL DIAGNOSTICS .. 5-190
ALSG DUAL ACCELERATOR PEDAL THROTTLE CONTROLS 5-190
ALSG DUAL THROTTLE CONTROL INSTALLATION 5-190
ALSG DUAL THROTTLE CONTROL PROGRAMMING FLEXIBILITY 5-191
ALSG DUAL THROTTLE CONTROL DIAGNOSTICS 5-191
5.25.2 VARIABLE SPEED GOVERNOR - OFF-HIGHWAY ... 5-191
VSG PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-193
CRUISE SWITCH VSG 5-193
CRUISE SWITCH VSG INSTALLATION REQUIREMENTS 5-194
CRUISE SWITCH VSG PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-194
VSG HAND THROTTLE 5-195
VSG HAND THROTTLE INSTALLATION ............. 5-195
VSG HAND THROTTLE CALIBRATION .............. 5-196
VSG ACCELERATOR PEDAL 5-196
ALTERNATE MINIMUM VSG (FAST IDLE) .......... 5-197
ALTERNATE MINIMUM VSG PROGRAMMING FLEXIBILITY 5-197
VSG VOLTAGE DIVIDERS 5-197
VSG VOLTAGE DIVIDERS INSTALLATION ......... 5-198
VSG RESISTOR SELECTION FOR VOLTAGE DIVIDERS 5-198
VSG DUAL THROTTLE CONTROLS 5-200
VSG DUAL THROTTLE CONTROLS INSTALLATION 5-201
DUAL THROTTLE CONTROLS PROGRAMMING REQUIREMENTS AND
FLEXIBILITY 5-202
VSG DUAL THROTTLE CONTROLS DIAGNOSTICS 5-202
VSG FREQUENCY INPUT 5-202
VSG FREQUENCY INPUT INSTALLATION ......... 5-203
VSG FREQUENCY INPUT PROGRAMMING FLEXIBILITY 5-203
5.26 TRANSMISSION INTERFACE 5-205
5.26.1 PWM OPERATION 5-205
MODULATED SIGNAL 5-205
DISCRETE ON/OFF SIGNAL 5-207
5.26.2 PWM INSTALLATION 5-207
5.26.3 ALLISON INTERFACE MODULES 5-208
5.26.4 ZF ECOMAT AND VOITH TRANSMISSIONS ............ 5-210
5.26.5 ALLISON HYDRAULIC TRANSMISSION 5-211
5.26.6 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-212
5.26.7 COMMUNICATION LINKS OPERATION 5-213
5.26.8 COMMUNICATION LINKS INSTALLATION 5-213
5.26.9 ALLISON WORLD TRANSMISSION 5-214
5.26.10 SAE J1939 DATA LINK TRANSMISSIONS 5-215
5.26.11 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-216
5.26.12 DIGITAL INPUT AND DIGITAL OUTPUT TRANSMISSIONS 5-216
5.26.13 EATON TOP2 OPERATION 5-217
INSTALLATION 5-217
PROGRAMMING REQUIREMENTS AND FLEXIBILITY . 5-218
DIAGNOSTICS 5-219
5.27 TRANSMISSION RETARDER 5-221
5.27.1 OPERATION 5-221
5.27.2 PROGRAMMING REQUIREMENTS AND FLEXIBILITY 5-221
INTERACTION WITH OTHER FEATURES 5-221
5.28 TWO-SPEED AXLE 5-223
5.28.1 OPERATION 5-223
PROGRAMMING FLEXIBILITY & REQUIREMENTS
VEHICLE SPEED LIMITING
OPERATION
INSTALLATION
PROGRAMMING REQUIREMENTS AND FLEXIBILITY
INTERACTION WITH OTHER FEATURES
VEHICLE SPEED SENSOR ANTI-TAMPERING
DDEC V APPLICATION AND INSTALLATION MANUAL
PROGRAMMING FLEXIBILITY
COMMUNICATION PROTOCOLS
OVERVIEW
SAE J1587 DATA LINK
MESSAGE FORMAT
SAE J1708/J1587 MESSAGE PRIORITY
SAE J1587 PARAMETERS AVAILABLE WITH DDEC V
SAE J1587 PIDS REQUIRING DDEC ACTION
DATA REQUEST
COMPONENT SPECIFIC REQUEST
RETARDER STATUS REQUEST
TRANSMITTER DATA REQUEST / CLEAR COUNT
PID 256 (255 0) PAGE 2 DATA REQUEST
J1587 OUTPUTS - SINGLE BYTE PARAMETERS
DOUBLE BYTE PARAMETERS
VARIABLE LENGTH PARAMETERS
SAE J1939 DATA LINK
MESSAGE FORMAT
SAE J1939/71 APPLICATION LAYER
ELECTRONIC ENGINE CONTROLLER #1 -- EEC1
ELECTRONIC ENGINE CONTROLLER #2 -- EEC2
IO — IDLE OPERATION
TC — TURBOCHARGER
ELECTRONIC ENGINE CONTROLLER #3 -- EEC3
VD — VEHICLE DISTANCE
SHUTDOWN — IDLE SHUTDOWN
ENGINE HOURS, REVOLUTIONS — HOURS
TD — TIME/DATE
VH — VEHICLE HOURS
FUEL CONSUMPTION (LIQUID) – LFC
CCSS – CRUISE CONTROL / VEHICLE SPEED SETUP
ENGINE TEMPERATURE #1 – ET1
ENGINE FLUID LEVEL/PRESSURE #1 – EFL/P1
PTO – POWER TAKEOFF INFORMATION
CRUISE CONTROL / VEHICLE SPEED – CCV
FUEL ECONOMY (LIQUID) – LFE
AMB – AMBIENT CONDITIONS
INLET / EXHAUST CONDITIONS – IC
TURBOCHARGER INFORMATION #6 – TCI6
EXHAUST PORT TEMPERATURE #1 – EPT1
EXHAUST PORT TEMPERATURE #2 – EPT2
EXHAUST PORT TEMPERATURE #3 – EPT3
EXHAUST PORT TEMPERATURE #4 – EPT4
VEP – VEHICLE ELECTRICAL POWER
ALTERNATE FUEL #1 – A1
AUXILIARY WATER PUMP PRESSURE – AWPP
EFL/P2 – ENGINE FLUID LEVEL/PRESSURE #2
VDHR – HIGH RESOLUTION VEHICLE DISTANCE
EEC4 – ELECTRONIC ENGINE CONTROLLER #4
FAN DRIVE – FD
ELECTRONIC RETARDER CONTROLLER #1 - ERC
SOFT – SOFTWARE IDENTIFICATION
COMPONENT IDENTIFICATION – CI
RETARDER CONFIGURATION – RC
ENGINE CONFIGURATION – EC
ACC1 – ADAPTIVE CRUISE CONTROL
ELECTRONIC BRAKE CONTROLLER #1 -- EBC1
TORQUE SPEED CONTROL — TSC1
ELECTRONIC TRANSMISSION CONTROLLER #1 -- ETC1
SAE J1939/21 DATA LINK LAYER
ACKNOWLEDGE / NEGATIVE ACKNOWLEDGE
REQUESTS
TRANSPORT PROTOCOL BROADCAST ANNOUNCE (TP.CM_BAM)
TRANSPORT PROTOCOL DATA (TP.DT)
TRANSPORT PROTOCOL REQUEST TO SEND (TP.CM_RTS)
TRANSPORT PROTOCOL CONNECTION ABORT (TP.CONNABORT)
TRANSPORT PROTOCOL END OF MESSAGE (TP.ENDOFMSGACK)
TRANSPORT PROTOCOL CLEAR TO SEND (TP.CM_CTS)
TRANSPORT PROTOCOL DATA (TP.DT)
SAE J1939/73 DIAGNOSTIC LAYER
DM1 – ACTIVE DIAGNOSTIC TROUBLE CODES
PREVIOUSLY ACTIVE DIAGNOSTIC TROUBLE CODES – DM2
DIAGNOSTIC DATA CLEAR/RESET OF PREVIOUSLY ACTIVE DTCS — DM3
DIAGNOSTIC DATA CLEAR/RESET FOR ACTIVE DTCS — DM11
STOP START BROADCAST — DM13 .
TOOLS
VEHICLE ELECTRONIC PROGRAMMING SYSTEM ....
SOFTWARE
HARDWARE
DETROIT DIESEL DIAGNOSTIC LINK
7-5
7.2.1 CALIBRATION
DIAGNOSTIC DATA READER
REQUIREMENTS
DDEC REPROGRAMMING SYSTEM
REQUIREMENTS
DRS WELCOME SCREEN
PROGRAM ECM
PROGRAM FLEET ECM
7-11
PROGRAM ECM WITH MAINFRAME DATA ....... 7-11
UPDATE CALIBRATION AT DDC
ENGINE CONFIGURATION DATA
UPDATE CUSTOMER CALIBRATION
UPDATE INJECTOR CALIBRATION 7-12
UPDATE ECM ACCUMULATORS 7-12
DDC MAINFRAME COMMUNICATIONS ............. 7-12
7.4.3 DRS MENU OPTIONS 7-13
UPGRADE ECM SOFTWARE 7-13
CHANGE PASSWORDS 7-13
RANDOM CUSTOMER PASSWORD 7-13
RANDOM RATING PASSWORD 7-13
RANDOM LOCKOUT PASSWORD 7-13
ECM S/W VERSIONS 7-13
DISPLAY STATION LOG FILE 7-13
DISPLAY DOWNLOADED UNITS 7-13
COMMS SETTING 7-13
OPTIONS 7-14
7.4.4 DDECCOMM 7-14
DOWNLOAD ENGINE SERIAL CALIBRATION(S) 7-14
DOWNLOAD FLEET CALIBRATION(S) 7-14
UPLOAD HISTORY 7-14
DISPLAY AVAILABLE ECM S/W VERSIONS ....... 7-14
DISPLAY STATION LOG FILE 7-14
DISPLAY DOWNLOADED UNITS 7-14
UPDATE LOGON PARAMETERS 7-15
7.5 DDEC MANUALS 7-17
APPENDIX A: CODES
A-1
APPENDIX B: HARNESS WIRING DIAGRAMS
B-1
APPENDIX C: CUSTOMER PROGRAMMABLE PARAMETERS C-1
C.1 AIR COMPRESSOR C-1
C.2 CRUISE CONTROL C-2
C.3 ENGINE BRAKE C-3
C.4 ENGINE OVERSPEED C-3
C.5 ENGINE PROTECTION
C-4
C.6 FAN CONTROL . C-4
C.7 FUEL ECONOMNY INCENTIVE C-5
C.8
IDLE SHUTDOWN C-5
C.9 LOW GEAR TORQUE LIMITING C-5
C.10 MAINTENANCE ALERT SYSTEM C-6
C.11 MANAGEMENT INFORMATION PRODUCTS C-6
C.12 OPTIMIZED IDLE C-6
C.13 PASSMART
C.14 PASSWORD/GROUP LOCKOUT C-8
C.15 PRESSURE SENSOR GOVERNOR C-9
C.16 PROGRESSIVE SHIFT C-9
C.17 THROTTLE CONTROLS C-10
C.18 TWO-SPEED AXLE C-11
C.19 VEHICLE SPEED LIMITING C-11
C.20 VEHICLE SPEED SENSOR C-12
C.21 OTHER PARAMETERS C-12
APPENDIX D: ACRONYMS D-1
APPENDIX E: SYMBOLS E-1
APPENDIX F: VENDORS F-1
GLOSSARY G-1
INDEX INDEX-1
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