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MID: Autodesk_Design_Suite_Ultimate_2012_64bit_SWL_ENU_C009_EXE1
Product Name: Autodesk Design Suite Ultimate 2012
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Part Number: 769D1-05Y001-P503E, 769D1-05Y001-P504E

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See Also:

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5 DDECFEATURESSectionPage5.1 AIR COMPRESSOR CONTROL ............................................................. 5-55.2 ANTI-LOCK BRAKE SYSTEMS .............................................................. 5-115.3 CRUISE CONTROL ................................................................................ 5-155.4 DIAGNOSTICS ........................................................................................ 5-235.5 ELECTRONIC FIRE COMMANDER ....................................................... 5-275.6 ENGINE BRAKE CONTROLS ................................................................ 5-315.7 ENGINE PROTECTION .......................................................................... 5-375.8 ENGINE RATINGS .................................................................................. 5-495.9 ETHER START ........................................................................................ 5-535.10 FAN CONTROL ....................................................................................... 5-575.11 FUEL ECONOMY INCENTIVE ............................................................... 5-735.12 HALF ENGINE IDLE ............................................................................... 5-755.13 IDLE SHUTDOWN TIMER AND VEHICLE POWER SHUTDOWN ........ 5-775.14 IRIS ......................................................................................................... 5-835.15 LOW GEAR TORQUE LIMITING ............................................................ 5-955.16 MAINTENANCE ALERT SYSTEM .......................................................... 5-975.17 MANAGEMENT INFORMATION PRODUCTS ........................................ 5-1175.18 OPTIMIZED IDLE .................................................................................... 5-1395.19 PASSMART ............................................................................................. 5-1455.20 PASSWORDS ......................................................................................... 5-1495.21 PRESSURE SENSOR GOVERNOR ...................................................... 5-1535.22 PROGRESSIVE SHIFT ........................................................................... 5-1595.23 TACHOMETER DRIVE ............................................................................ 5-165All information subject to change without notice. (Rev. 3/05) 5-17SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURES5.24 THROTTLE CONTROL/GOVERNORS ................................................... 5-1675.25 TRANSMISSION INTERFACE ................................................................ 5-1855.26 TRANSMISSION RETARDER ................................................................ 5-2015.27 VEHICLE SPEED LIMITING ................................................................... 5-2035.28 VEHICLE SPEED SENSOR ANTI-TAMPER .......................................... 5-2055-2 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONNOTE:Your engine is equipped with DDEC software. This software generally assures optimalengine performance. The installation of software upgrades may cause minor changes infeatures and engine performance.All information subject to change without notice. (Rev. 3/05) 5-37SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESTHIS PAGE INTENTIONALLY LEFT BLANK5-4 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.1 AIR COMPRESSOR CONTROLAir Compressor Control is an optional DDEC feature that allows DDEC to regulate enginespeed and load/unload a valve in order to maintain a requested compressor outlet air pressure forair compressor applications.5.1.1 OPERATIONThe ECM monitors the air outlet pressure while varying the engine speed and operatingload/unload a valve. The valve will be opened or closed. The desired operating pressure may bevaried by the operator, within limits preset by the OEM.The ECM will activate the Air Compressor Governor Controls when the digital input “AirCompressor Load Switch” is grounded. Engine speed is governed based on the actual aircompressor outlet pressure versus the desired output pressure. The Air Compressor PressureSensor provides a pressure signal to the ECM.The engine response to various pressure conditions is listed in Table 5-1.Pressure Set PointCurrent outlet pressure is below the pressure setpointPressure in the system continues to increase anda threshold pressure is exceededCurrent outlet pressure is above the pressure setpointResultEngine speed increases as required up to PTOmaximum speed*The air compressor solenoid digital output isenabled† (opened)Engine speed decreases as required down to theminimum PTO speed.* The engine will continue to run at PTO maximum speed until the outlet pressure matches the sensorpressure.† DDEC will open and close the loading valve as a function of pressure with hysteresis. When the pressurereaches 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 airpressure has dropped to a lower programmable limit, the digital output will be open circuited whichwill either close the vent or open the air linlet.Table 5-1Engine Operation with Air Compressor ControlsEach horsepower rating has an associated pressure range. Horsepower ratings are defined at timeof order entry. The minimum and maximum pressure setting for each of the horsepower curves isset with the DDDL/DDR, Vehicle Electronic Programming System (VEPS), or DRS. The initialpressure set point is saved between ignition cycles.Increase (Resume/Acceleration On)Momentarily toggling and releasing the Increase Switch (grounding the "Resume/AccelerationOn" digital input) increases set point pressure by a configured air compressor pressure increment(4% default) of the pressure range. Holding the switch in the increase position (grounding thedigital input), will increase the set point pressure at a rate of two increments per second. Releasingthe switch sets the compressor controls to the higher setting.All information subject to change without notice. (Rev. 3/05) 5-57SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESDecrease (Set/Coast On)Momentarily toggling and releasing the decrease switch decreases set point pressure by aconfigured air compressor pressure increment (4% default) of the pressure range. Holding theswitch in the decrease position (grounding the digital input), will decrease the set point pressureat a rate of two increments per second. Releasing the switch sets the compressor controls tothe lower setting.Air Compressor Load SwitchClosing (grounding) the air compressor load switch digital input activates the air compressorcontrol system. Opening the air compressor load switch digital input deactivates the aircompressor control system.Air Compressor SolenoidWhen the pressure reaches a programmable limit above the pressure set point the DDEC digitaloutput will be grounded. This output may be used to either open an air compressor vent or closethe air inlet. Once the air pressure has dropped to a lower programmable limit, the digital outputwill be open circuited which will either close the vent or open the air inlet.Air Compressor ShutdownDDEC will respond to a proprietary immediate engine shut down message sent over the SAEJ1587/J1708 data link by the Electronic Display Module (EDM). This feature requires both anEDM and an Auxiliary Information Module (AIM).Multiple Pressure RatingsThe pressure ranges are linked to the engine ratings. A pressure range can be associated witheach rating. The maximum number of engine ratings and pressure ranges is three. Choosing therating, with the DDR/DDDL or rating switches will automatically select the associated pressurerange. The proper 6N4D group with multiple 6N4M groups must be specified. For additionalinformation, contact your DDC Applications Engineer.5-6 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.1.2 INSTALLATIONSee Figure 5-1 for the Air Compressor Control Harness.Figure 5-1Air Compressor Control HarnessAll information subject to change without notice. (Rev. 3/05) 5-77SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURES5.1.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITYAir Compressor Controls must be specified at the time of engine order or added to the ECMcalibration by Detroit Diesel Technical Service. An Application Code (6N4C) Group must beselected that is configured for Air Compressor Control at order entry or by contacting DetroitDiesel Technical Service.The digital outputs and inputs listed in Table 5-2 are required for Air Compressor Controls andmust be configured by order entry, VEPS, or the DRS.Description Type Function NumberSet/Coast On (Decrease) Digital Input 20Resume/Acceleration On(Increase)Digital Input 22Air Compressor Load Switch Digital Input 35Air Compressor Solenoid Digital Output 21Table 5-2Air Compressor Control Required Digital Inputs and OutputsAt order entry, the Application Code System (ACS) sets the default values for the parameterslisted in Table 5-3. These parameters may be modified using either VEPS or DRS.Parameter Description Choice/DisplayAir Compressor Integral Gain Integral Gain 0-128 RPM/(PSI x SEC)Air Compressor Proportional Gain Proportional Gain 0-128 RPM/PSIAir Compressor PressureIncrementPercent Pressure Increment0-50% (of fuel scale pressurerange)Table 5-3Air Compressor Control ParametersMultiple pressure ratings can be selected with the use of rating switches. The proper 6N4D groupswith multiple 6N4M groups must be specified at engine order or by Detroit Diesel TechnicalService. The digital inputs listed in Table 5-4 are required.Description Type Function NumberRating Switch #1 Digital Input 12Rating Switch #2 Digital Input 13Table 5-4Multiple Pressure Ratings Required Digital InputsThe VSG maximum and minimum RPM can be set with VEPS, DRS, DDR or DDDL aslisted in Table 5-5.5-8 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONParameter Description Choice/DisplayVSG Minimum RPM Sets the VSG minimum speed. Idle to VSG, Maximum RPMVSG Maximum RPM Sets the VSG maximum speed. VSG Minimum RPM to (Rated Speed+ LSG Droop)Table 5-5Variable Speed Governor Maximum and Minimum RPMThe minimum and maximum pressure is set with the DDDL/DDR, DRS or VEPS as listed inTable 5-6. There is a minimum and maximum pressure setting for each of the horsepower curves.Parameter Description RangeLOAD PSIIndicates the delta value above the current airpressure set point that will initiate the air compressor 0toUNLOADPSIgovernor to reload the system.UNLOAD PSIIndicates the delta value above the current airpressure set point that will initiate the air compressor LOAD PSI to 31 PSIgovernor to unload the system.MAX RAT#1 PSIIndicates the maximum allowable air pressure setpoint for engine rating #1MIN RAT#1 to 999 PSIMIN RAT#1 PSIIndicates the minimum allowable air pressure setpoint for engine rating #1.0toMAXRAT#1MAX RAT #2 PSIIndicates the maximum allowable air pressure setpoint for engine rating #2.MIN RAT#2 to 999 PSIMIN RAT#2 PSIIndicates the minimum allowable air pressure setpoint for engine rating #2.0toMAXRAT#2MAX RAT#3 PSIIndicates the maximum allowable air pressure setpoint for engine rating #3.MIN RAT#3 to 999 PSIMIN RAT #3 PSIIndicates the minimum allowable air pressure setpoint for engine rating #3.0toMAXRAT#3Table 5-6Air Compressor Parameters5.1.4 INTERACTION WITH OTHER FEATURESAir Compressor Control may not be used with Cruise Control or the Pressure Sensor Governor. Aproprietary immediate engine shut down message for immediate air compressor shutdown is sentover the SAE J1587/J1708 data link by the EDM. This feature requires both an EDM and an AIM.All information subject to change without notice. (Rev. 3/05) 5-97SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESTHIS PAGE INTENTIONALLY LEFT BLANK5-10 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.2 ANTI-LOCK BRAKE SYSTEMSAnti-lock Brake Systems (ABS) are electronic systems that monitor and control wheel speedduring braking. The systems are compatible with standard air brake systems. The systemmonitors wheel speed at all times, and controls braking during emergency situations. Vehiclestability and control are improved by reducing wheel lock during braking.5.2.1 OPERATIONThe ECM transmits engine data via SAE J1587, SAE J1922, or SAE J1939. Anti-lock brakesystems monitor data on one or more of these communication links. In the event that an excessivewheel spin is detected, the ECM receives a message from the ABS requesting a 0% output torquelimit. The message is transmitted on SAE J1922 or SAE J1939.SAE J1922 and SAE J1939 both implement the same message set. The difference being hardwareand performance. SAE J1922 transmits and receives data at 9.6 K baud while SAE J1939transmits/receives data at 250 K baud. SAE J1939 has a much higher bit rate so messages reachtheir destination very quickly nearly eliminating the latency found with SAE J1922.SAE J1922 is enabled on all DDEC IV ECMs. SAE J1939 is enabled on all DDEC IV ECMs(Release 24.0 or later). ECMs prior to Release 24.0 must be configured if SAE J1939 is required.See Figure 5-2 and Figure 5-3 for interface with Meritor/WABCO and Bosch respectively.All information subject to change without notice. (Rev. 3/05) 5-117SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESFigure 5-2Meritor/WABCO ABS/ATC Interface5-12 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONFigure 5-3Bosch ABS/ATC InterfaceAll information subject to change without notice. (Rev. 3/05) 5-137SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESTHIS PAGE INTENTIONALLY LEFT BLANK5-14 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.3 CRUISE CONTROLCruise Control is available with any DDEC engine. Cruise Control will operate in either Engineor Vehicle Speed Mode and maintain a targeted speed (MPH or RPM) by increasing or decreasingfueling. The targeted speed can be selected and adjusted with dash-mounted switches. Up to fivedigital inputs are required (four for automatic transmission) for Cruise Control operation and adigital output is optional (refer to section 4.2.1 for additional information on digital inputs). AVehicle Speed Sensor (VSS) is required for Vehicle Speed Cruise Control.5.3.1 OPERATIONThere are two types of Cruise Control: Engine Speed Cruise Control and Vehicle Speed CruiseControl. Vehicle Speed Cruise Control is available only to applications using a Vehicle SpeedSensor (VSS).Engine Speed Cruise ControlPower is varied under Engine Speed Cruise Control to maintain constant engine speed. Vehiclespeed will vary depending on powertrain components. Engine Speed Cruise Control does notneed a VSS. Engine Speed Cruise Control cannot be used with automatic transmissions.Vehicle Speed Cruise ControlVehicle Speed Cruise is enabled when "Enable Cruise" and a Vehicle Speed Sensor (VSS) areinstalled. Engine speed and power are varied under Vehicle Speed Cruise Control to maintain theset vehicle speed. The maximum Cruise Control speed cannot exceed the programmed maximumVehicle Speed Limit (when programmed). The vehicle speed must be above 20 MPH and theengine speed above 1,000 RPM.This type of Cruise Control is required when either of the following conditions exists:Vehicle Speed Limiting -- Vehicle Speed Cruise Control is mandatory if the vehicle speedlimit is programmed and Cruise Control is desired. This will prevent the ECM fromfueling the engine at speeds greater than the vehicle speed limit.Automatic Transmissions -- Vehicle Speed Cruise Control must be selected if the vehicle isequipped with an automatic transmission. This will ensure proper transmission upshiftswhile in Cruise Control. Refer to the transmission manufacturer's manual for moreinformation 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 atthe programmed Vehicle Speed Limit. For additional information about Vehicle Speed Limiting,refer to section 5.27.Smart CruiseThe 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 thedata 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. Release 31.0 or latersoftware will not illuminate the CEL for Smart Cruise faults.All information subject to change without notice. (Rev. 3/05) 5-157SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESThis feature is available with Release 27.0 or later. Smart Cruise must be configured by VEPS(Release 27.0 or later), WinVeps (Release 2.0 or later) or the DRS. For additional informationon Smart Cruise, contact Eaton Corporation.Auto ResumeThe Auto Resume feature will resume Vehicle Speed Cruise Control if the clutch has been pushedtwice and released within three (3) seconds.Cruise PauseCruise Pause saves the current Cruise Control Set Point (vehicle speed) when the Cruise ControlEnable input is opened. The set point is saved for 10 seconds. This feature is intended towardtransmissions with shift knobs that do not have to be moved to shift every gear and have the CruiseControl switches on the knob. the Resume/Accel Switch must be momentarily switched to sensorreturn to resume the saved vehicle speed after the Cruise Enable is switched to sensor return again.Cruise PowerCruise Power is an optional engine rating which operates on a higher horsepower during CruiseControl. The ECU automatically switches to the cruise power rating when Cruise Controlis turned on. This extra power gives the driver incentive to run in Cruise Control wheneverpossible and gain the additional fuel economy it provides. Cruise Power can be selected withDDDL, VEPS, or with an engine rating switch provided it is part of the engine rating package.Refer to section 4.2.4.2 for additional information on engine rating switches.Cruise EnableCruise Control is enabled, but not active when the Cruise Control Enable digital input is switchedto battery ground.Set / Coast OnSet:Coast:Cruise Speed is set by momentarily contacting the switch to the ON position(switching the digital input to battery ground). Cruise Control will becomeactive and maintain the engine or vehicle speed present at the time.When Cruise Control is active, the Set/Coast input can be used to reducepower and speed by toggling the switch. Momentarily toggling and releasingthe Set/Coast switch will decrease the set point by 1 MPH increments forVehicle Speed Cruise Control and 25 RPM increments for Engine SpeedCruise Control. Holding the Set/Coast will decrease the set point by 1 MPHper 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.5-16 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONResume / Accel OnResume:Accel: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.When Cruise Control is active, the Resume/Accel input can be used to increasepower and speed by toggling the switch. Momentarily toggling and releasing theResume/Accel switch will increase the set point by 1 MPH increments for VehicleSpeed 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 releasedthe Cruise Control set point will be at the new speed.Clutch Released (Manual Transmissions)This input indicates that the clutch is released and is used for suspending Cruise Control andAuto Resume.When the clutch is released, the input is at battery ground. Cruise Control is suspended if theclutch is depressed once. If the clutch is depressed twice within three seconds, Cruise Controlis automatically resumed.NOTE:When engine brake is configured and auto resume is enabled, the first time the clutchis depressed to suspend Cruise Control, the engine brakes will be delayed for threeseconds.The digital input logic for the Clutch Switch disables Cruise Control in the unlikely event of abroken 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 isactivated, then the input is not grounded and Cruise Control is suspended. Cruise Control isresumed by using the Resume/Accel Switch.The input logic for the Brake Switch disables Cruise Control in the unlikely event of a brokenbrake switch wire.All information subject to change without notice. (Rev. 3/05) 5-177SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURES5.3.2 INSTALLATIONThe following is a list of switches that are required for Cruise Control operation.Cruise Enable SwitchBrake SwitchClutch Switch -- optional for automatic transmissionsSet/Coast SwitchResume/Accel SwitchCruise Active Light -- optionalSee Figure 5-4 for a diagram of the Cruise Control circuit.Figure 5-4Cruise Control Circuit5-18 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.3.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITYTo configure an engine for Cruise Control, the digital inputs, output and VSS settings listed inTable 5-7 must be selected either with the Vehicle Electronic Programming System (VEPS), theDDEC Reprogramming System (DRS) or on engine order entry. The required and optionaldigital inputs and outputs are listed in Table 5-7.Description Type Function NumberService Brake Released Digital Input 17Set/Coast Digital Input 20Resume/Accel Digital Input 22Cruise Control Enable Digital Input 23Clutch Released(required for manual transmissions)Digital Input 18Cruise Control Active Light(optional for Cruise Control)Digital Output 11Table 5-7Cruise Control Related Digital Input and Output SignalsAVehicle 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 beenabledbyVEPSorDRS.Parameter Description ChoiceAdaptive Cruise Control(Smart Cruise)Enables or disables the Smart Cruise Control feature.YES, NOTable 5-8Smart Cruise ParameterAll information subject to change without notice. (Rev. 3/05) 5-197SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESThe Cruise Control parameters listed in Table 5-9 can be set by order entry, DDR, DDDL, theDRS, or VEPS.Parameter Description RangeCRUISE CONTROLEnables or disables the vehicle speed CruiseControl feature.YES, NOMIN CRUISE SPEED Sets the maximum cruise speed in MPH or KPH.20 MPH to MAXCRUZ SPDMAX CRUISE MPH or KPH Sets the maximum cruise speed in MPH or KPH.MIN CRUZ to VehicleSpeed Limit or 127 mphif VSL = NOAUTO RESUMEEnables or disables the automatic Cruise Controlset speed resume feature.YES, NOCRUISE SWITCH VSGEnables or disables the cruise switch VSG setspeed feature.YES, NOINITIAL VSG SET SPEED Sets the cruise switch VSG initial set speed.VSG MIN RPM toVSG MAX RPMRPM INCREMENT Sets the cruise switched VSG RPM increment. 1to255RPMCRUISE/ENGINE BRAKEFEATURECRUISE/ENGINE BRAKEACTIVATION SPEEDENG BRAKE INCREMENTMPH or KPHMAX OVERSPEED LIMITMAX SPEED NO FUELEnables or disables the feature that allows theengine brake to be used while on Cruise Controlif the vehicle exceeds the cruise set speed.Sets the additional speed before the enginebrake is applied to slow down the vehicle. Theengine brake is activated at low level unless theoperator has turned off the engine brakes withthe dash board switches.Sets the additional incremental speed that mustbe reached before the engine brake will activatethe medium and/or high level of retardation.Sets the vehicle speed above which a diagnosticcode will be logged if the driver fuels the engineandexceedsthislimit. Enteringa0willdisablethis option.Sets the vehicle speed above which a diagnosticcode will be logged if the vehicle reaches thisspeed without fueling the engine. Entering a 0will disable this option.YES, NO0to10MPH1to5MPH0to127MPH0to127MPHTable 5-9Cruise Control Parameters5.3.4 DIAGNOSTICSTwo faults (SID 216 FMI 14 and PID 86 FMI 14) will be logged simultaneously if Smart Cruiseis enabled and the data is not being received, the received data is bad or the Smart Cruise unit hasbeen removed.If these faults are received in addition to an SAE J1939 Data Link failure (SID 231 FMI 12), thenthe problem is with the SAE J1939 Data Link itself.5-20 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.3.5 INTERACTION WITH OTHER FEATURESThe 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 5.21 for moreinformation on the Pressure Sensor Governor. DDEC can be configured to allow the enginebrakes to activate during Cruise Control operation.NOTE:Cruise Control maximum speed cannot exceed the vehicle speed limit.All information subject to change without notice. (Rev. 3/05) 5-217SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESTHIS PAGE INTENTIONALLY LEFT BLANK5-22 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.4 DIAGNOSTICSDiagnostics is a standard feature of the DDEC system. The purpose of this feature is to provideinformation for problem identification and problem solving in the form of a code. The ECMcontinuously performs self diagnostic checks and monitors the other system components.Information for problem identification and problem solving is enhanced by the detection of faults,retention of fault codes and separation of active from inactive codes.5.4.1 OPERATIONThe engine-mounted ECM includes control logic to provide overall engine management. Systemdiagnostic checks are made at ignition on and continue throughout all engine operating modes.Sensors provide information to the ECM regarding various engine and vehicle performancecharacteristics. The information is used to regulate engine and vehicle performance, providediagnostic information, and activate the engine protection system.Instrument panel warning lights (see Figure 5-5) the Check Engine Light (CEL) and the StopEngine Light (SEL) warn the engine operator. The CEL is an amber light and the SEL is ared light.Figure 5-5Typical Diagnostic Request/SEO Switch and Warning LightsAll information subject to change without notice. (Rev. 3/05) 5-237SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESThe CEL is illuminated and a code is stored if an electronic system fault occurs. This indicatesthe problem should be diagnosed as soon as possible. The ECM illuminates the CEL and SELand stores a malfunction code if a potentially engine damaging fault is detected. These codescan be accessed in one of four ways:Using the Diagnostic Data Reader (DDR)Flashing the CEL and SEL with the Diagnostic Request Switch (may be combined withStop Engine Override switch, see Figure 5-5)Using the Detroit Diesel Diagnostic Link (DDDL) PC software packageBy ProDriver ® , Electronic Fire Commander ® , Electronic Display Module (EDM), orother displayThere are two types of diagnostic codes:An active code - a fault present at the time when checking for codesAn inactive code - a fault which has previously occurred; inactive codes are logged intothe ECM and time stamped with the following information:First occurrence of each diagnostic code in engine hoursLast occurrence of each diagnostic code in engine hoursTotal time in seconds that the diagnostic code was activeDiagnostic Request SwitchThe Diagnostic Request Switch is used to activate the CEL/SEL to flash codes. Active codes areflashed on the SEL and inactive codes are flashed on the CEL (see Figure 5-6). Inactive codes areflashed in numerical order, active codes are flashed in the order received, most recent to leastrecent. 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.5-24 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONFigure 5-6Flash CodesNOTE:For multi-ECM installations, the Diagnostic Request Switch and SEO are combined onthe 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 ONThe engine is idlingIn both circumstances, activating and holding the Diagnostic Request Switch will flash out thediagnostic codes.Diagnostic Request Switch/Stop Engine OverrideIf no separate Diagnostic Request Switch is configured, the SEO Switch serves as both aDiagnostic Request Switch and an SEO Switch.The Diagnostic Request/Stop Engine Override Switch is used to flash codes in the followingcircumstances:The engine is not running and ignition is onThe engine is idlingIn 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 diagnosticcodes. Codes will also cease flashing if the engine is no longer at idle. The codes are flashed outof the ECM connected to the switch.NOTE:For multi-ECM installations, the Diagnostic Request Switch and SEO Switch arecombined on the master ECM. All receiver ECMs have a separate Diagnostic RequestSwitch.All information subject to change without notice. (Rev. 3/05) 5-257SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURES5.4.2 DEFINITIONS AND ABBREVIATIONSParameter Identification Character (PID): A PID is a single byte character used in SAE J1587messages to identify the data byte(s) that follow. PIDs in the range 0-127 identify single bytedata, 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 identifyfield-repairable or replaceable subsystems for which failures can be detected or isolated. SIDs areused 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 subsystemand identified by the PID or SID. The FMI and either the PID or SID combine to form a givendiagnostic code defined in SAE J1587 within PID 194.Flashing Codes: Provides a two digit number (see Figure 5-6). This code may cover severalspecific faults. It is provided to advise the operator of the general severity of the fault so theoperator 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 numberand a description of each code.5-26 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.5 ELECTRONIC FIRE COMMANDERThe Detroit Diesel Electronic Fire Commander ® (EFC) is designed to support DDEC IVengines in the fire fighting and emergency services market. It combines the DDEC PressureSensor Governor (PSG), a system monitor, and a pump panel display for vital engine operatingparameters into one compact, durablepackage(seeFigure5-7).Refer to Electronic Fire Commander Installation and Troubleshooting (6SE476) for additionalinformation.EFC replaces the PSG switches, as well as many pump panel gauges as it provides completecontrol and monitoring of DDEC IV systems on the fire truck.Figure 5-7 Electronic Fire Commander Pump Panel DisplayRPM, Oil Pressure, Oil or Coolant Temperature, and ECM Voltage are displayed continuously inthe Engine Data section of the EFC.Messages and any known diagnostic code accompanying a Check Engine or Stop Enginecondition will be displayed on the Information Center message display. The external alarmoutput will also be activated when the engine is running. The EFC displays the PSG status inthe Information Center whenever the OEM interlocks are met. The real time of day will alsobe displayed. The EFC logs the time that the pump is engaged and that time can be displayedusing the Information Center.5.5.1 OPERATIONThe Electronic Fire Commander has two modes of operation:RPM Mode (engine speed)Pressure Mode (water pump pressure, psi)All information subject to change without notice. (Rev. 3/05) 5-277SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESRPM Mode controls engine speed to a desired RPM and Pressure Mode controls engine speed tomaintain a desired discharge manifold pressure.The operating modes are selectable and may be changed by pressing the MODE button providingthe appropriate interlocks have been met. The engine will continue to run at the same speed whenthe mode switch is toggled between the RPM and Pressure modes.The maximum preset pressure for EFC is 200 psi.5.5.2 INSTALLATIONThe Electronic Fire Commander Harness schematic shows the minimum requirements for thePSG to operate (see Figure 5-8). Additional functions and interlocks may be used. Refer to theElectronic Fire Commander Installation and Troubleshooting manual (6SE476).EFC may be powered from a 12/24 volt supply.5.5.3 ORDERING EFCThe hardware listed in Table 5-10 is needed for Pressure Governor installation with EFC.ComponentPart NumberElectronic Fire Commander 23519655Pressure Sensor 23520795Electronic Fire Commander Harness (seeFigure 5-8)OEM InterlocksOEM SuppliedOEM SuppliedTable 5-10Electronic Fire Commander and Pressure SensorHardware available from the DDC Parts Distribution Center for installation of Electronic FireCommander (EFC) is listed in Table 5-10 as a complete kit. The 6N4C group must be specified atengine order entry or through Detroit Diesel Technical Service.ComponentElectronic Fire Commander Kit(contains Electronic Fire Commander and the pressure sensor)Part Number23520139Table 5-11Electronic Fire Commander Kit5-28 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONFigure 5-8Electronic Fire Commander Harness5.5.4 PROGRAMMING REQUIREMENTS AND FLEXIBILITYThe digital inputs listed in Table 5-12 are required for use with EFC and can be configured atorder entry, by VEPS, or DRS. Refer to section 4.2, "Digital Inputs," for additional information.All information subject to change without notice. (Rev. 3/05) 5-297SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESDescription Function Number Circuit Number*VIH-to-ECMConnector Assignment*Pressure/RPM Mode 8 523 H1PSG Enable 24 543 G2Resume/Accel On(increase)22 545 G3Set/Coast On (decrease) 20 541 J1* DDC circuit numbers and port assignments shown are default settings but can differ from applicationto application.Table 5-12Required Digital Inputs for EFCThe digital outputs required for use with EFC are listed in Table 5-13 and can be configured atorder entry, by VEPS, or DRS. Refer to section 4.3, "Digital Outputs," for additional information.Description Function Number Circuit Number* Connector Assignment*PSG Active 5 499VIH-to-ECM Connector-CavityF3Cruise Active 11 565Pigtail off the Engine SensorHarness - Cavity Y3* DDC circuit numbers and port assignments shown are default settings but can differ from applicationto application.Table 5-13Required Digital Outputs for EFCThe correct 6N4C group must be specified at engine order entry or through Detroit DieselTechnical Service. More information is available in the manual Electronic Fire CommanderInstallation and Troubleshooting (6SE476).5-30 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.6 ENGINE BRAKE CONTROLSThe Engine Brake option converts a power-producing diesel engine into a power-absorbing aircompressor. This is accomplished by opening the cylinder exhaust valves near the top of thenormal compression stroke and releasing the compressed cylinder charge to exhaust. The releaseof the compressed air to atmospheric pressure prevents the return of energy to the engine pistonon the expansion stroke, the effect being a net energy loss. Fueling is cut off when this occurs.5.6.1 OPERATIONA dash mounted On/Off Switch is used to enable the Engine Brake option. DDEC IV will directlycontrol the engine brake solenoids using an intensity switch to select three or six cylinders toproduce low, medium, or high braking power on a Series 60. The engine brakes are engaged everytime the foot pedal is brought back to the idle position and Cruise Control is not active.The following are seven options for Engine Brake:Cruise Control with Engine BrakeEngine Brake DisableEngine Brake ActiveEngine Fan BrakingClutch Released InputService Brake Control of Engine BrakesMin. MPH for Engine BrakesCruise Control with Engine BrakeThe Engine Brake option can also provide Engine Brake capability when the vehicle is in CruiseControl. For example, if the vehicle is going down hill in Cruise Control while the engine brake isselected, the ECM will control the amount of Engine Brake with respect to the Cruise Control setspeed. The level of Engine Brake (low, medium, high) selected with the dash switches will be themaximum amount of engine braking the ECM allows. Cruise Control with Engine Brake canbe set with DDDL/DDR, VEPS, and DRS.Engine Brake DisableThe Engine Brake Disable option uses a digital input which is switched to ground whenever avehicle system, such as a traction control device, does not allow engine braking to occur. Thisoption is required for most automatic transmissions.Engine Brake ActiveThe Engine Brake Active option uses a digital output that can be used to drive an Engine BrakeActive Light. This output is switched to battery ground whenever the engine brake is active.All information subject to change without notice. (Rev. 3/05) 5-317SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESEngine Fan BrakingThe Engine Fan Braking option turns on the cooling fan when the engine brake level is high andDDEC fan control is enabled. This creates about 20 to 40 hp additional engine braking powerdepending on the size of the cooling fan. This option is selected at the time of engine order or setby DDDL/DDR, VEPS or DRS. For additional information, refer to section 5.10, "Fan Controls."Clutch Released InputThe Clutch Released digital input will prevent the engine brakes from being turned on when theclutch is pressed. This input is required for use with manual transmissions. Refer to section 4.2,"Digital Inputs," for additional information.Service Brake Control of Engine BrakesThis option will allow the dash-mounted engine brake switch to be set to the ON position butnot engage the engine brakes until the service brake pedal is pressed. A digital input must beprogrammed for service brake. Refer to section 4.2, Digital Inputs for additional information.VEPS, DDR/DDDL or DRS can set this function.Min MPH for Engine BrakesThis option will disable the engine brakes until a minimum vehicle speed is reached. Thisparameter 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.5.6.2 INSTALLATIONSee Figure 5-9 for a schematic of the internal engine brake for the DDEC IV ECM andsee Figure 5-10 for a schematic of the internal engine brake for the DDEC IV ECM WorldTransmission interface.5-32 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONFigure 5-9Internal Engine Brake for DDEC IV ECMAll information subject to change without notice. (Rev. 3/05) 5-337SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESFigure 5-10Internal Engine Brake for DDEC IV ECM World TransmissionInterface5-34 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.6.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITYEngine Brake must be specified at the time of engine order or by contacting Detroit DieselTechnical Service. This enables the two digital outputs required.The digital inputs listed in Table 5-14 must be configured by order entry, VEPS, DRS:DescriptionFunction NumberEngine Brake Low 1Engine Brake Medium 2Engine Brake Disable(required for most automatic transmissions)Clutch Switch(required for manual transmissions)2618Table 5-14Required Digital Inputs for Engine Brake ControlsThe parameters listed in Table 5-15 can be set by order entry, VEPS, DDDL/DDR or DRS for theCruise Control Engine Brake option.Parameter Description Choice / DisplayCRUISE CONTROL ENGINEBRAKECRUISE ENGINE BRAKEACTIVATION SPEEDENGINE BRAKE INCREMENTEnables or disables the feature thatallows the engine brake to be used whileon cruise control if the vehicle exceedsthe cruise set speed.Sets the delta speed that the enginebrake should be applied to slow thevehicle while in cruise control.Sets the additional incremental speed thatmust be reached before the engine brakewill activate the medium and/or high levelof retardation.YES, NO1to10MPH1to5MPHTable 5-15Cruise Control Engine Brake ParametersThe optional digital output listed in Table 5-16 can be configured by order entry, VEPS or DRS. Itcan be used to drive an Engine Brake Active Light.Description Type Function NumberEngine Brake Active Digital Output 16Table 5-16Optional Digital Output for Engine BrakesThe Engine Fan Braking option as shown in Table 5-17 can be configured at the time of engineorder, VEPS, DDR, DDDL or DRS.All information subject to change without notice. (Rev. 3/05) 5-357SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESParameter Description Choice/DisplayDYNAMIC BRAKINGProvides additional engine brakingby activating the DDEC controlledfan whenever the engine brakesareactiveinhigh. Thisfunctionrequires both DDEC engine brakecontrols and DDEC fan controls.YES, NOTable 5-17Optional Fan Braking for Engine BrakesThe parameter listed in Table 5-18 can be set by order entry, VEPS, DDDL/DDR or DRS for theService Brake Control of the Engine Brakes option.Parameter Description Choice / DisplaySERVICE BRAKE ENABLEWhen this function is enabled, an inputfrom the service brake is required in orderto activate the engine brake.YES, NOTable 5-18Service Brake Control of Engine Brakes ParameterThe parameter listed in Table 5-19 can be configured by order entry, VEPS, DDR, and DDDLfor the Minimum Vehicle Speed for engine braking to occur.Parameter Description Choice/DisplayENGINE BRAKE MIN MPHThe minimum vehicle speedrequired before engine braking willoccur.0-40 MPHTable 5-19Minimum MPH for Engine Brakes Option5.6.4 INTERACTION WITH OTHER FEATURESDDEC will respond to requests from other vehicle systems via SAE J1939 data link or SAEJ1922 data link to disable the engine brakes.5-36 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.7 ENGINE PROTECTIONThe DDEC engine protection system monitors all engine sensors and electronic components, andrecognizes system malfunctions. If a critical fault is detected, the Check Engine Light (CEL) andStop Engine Light (SEL) illuminate. The malfunction codes are logged into the ECM's memory.The standard parameters which are monitored for engine protection are:Low coolant levelHigh coolant temperatureLow oil pressureHigh oil temperature5.7.1 OPERATIONEngine protection is a vital part of ECM programming and software. The ECM monitorscoolant level, various pressures and temperatures, and compares these parameters against theallowable limits to determine when a critical fault is reached. The CEL is illuminated and a codelogged if there is an electronic system fault. This indicates the problem should be diagnosed assoon as possible. The ECM illuminates the CEL and SEL and stores a malfunction code if apotentially engine damaging fault is detected. Once a critical fault is reached, the CEL and SELare 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 slightlyfrom one engine model to another.Engine protection consists of different protection levels:Warning OnlyRampdownShutdownWarning OnlyThe CEL and SEL will illuminate if a fault is detected. There is no power and/or speed reductionwhen "Warning Only" is selected. The resulting engine protection is at the discretion of theengine operator.NOTE:The operator has the responsibility to take action to avoid engine damage.NOTE:A diagnostic switch is not required but applications using one, must have a separatediagnostic switch for each ECM on the engine.The Diagnostic Request switch is used to activate the CEL and SEL to flash codes.All information subject to change without notice. (Rev. 3/05) 5-377SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESRampdownThe CELand SEL will illuminate if a fault is detected. The ECM reduces torque and/or speedover a 30 second period after the SEL illuminates. The initial torque/speed, which is used forreduction, is the operating torque or speed prior to the SEL fault condition. See Figure 5-11.Figure 5-11 RampdownA Stop Engine Override (SEO)/Diagnostic Request switch is required when this engine protectionoption is selected. The SEO options are available to prevent engine shutdown at the operator'sdiscretion.ShutdownThis option operates in the same manner as rampdown, except the engine shuts down 30 secondsafter the SEL is illuminated (see Figure 5-12). (The initial torque and/or speed which is used forreduction, is the torque and/or speed which occurred immediately prior to the fault condition.) TheStop Engine Override options are available to prevent engine shutdown at the operator's discretion.5-38 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONFigure 5-12 Engine ShutdownA SEO/Diagnostic Request Switch is required when this engine protection option is selected.Refer to section 5.7.3. The SEO options are available to prevent engine shutdown at the operator'sdiscretion.5.7.2 ENGINE OVERTEMPERATURE PROTECTIONEngine Overtemperature Protection (EOP) is additional logic programmed into the ECM and usedin 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 afault code is logged when the EOP calibrated temperature is reached. If the temperature doesnot decrease as torque/speed is reduced, the SEL will illuminate when a still higher temperatureis reached.The subsequent action taken by the ECM depends on customer selection of one of the following:Warning only (see Figure 5-13)30 second rampdown (see Figure 5-14)Shutdown (see Figure 5-15)Torque reduction is based on the average torque/speed in use prior to the fault condition.All information subject to change without notice. (Rev. 3/05) 5-397SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESFigure 5-13Engine Overtemperature Protection and Warning Only5-40 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONFigure 5-14Engine Overtemperature Protection and RampdownAll information subject to change without notice. (Rev. 3/05) 5-417SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESFigure 5-15 Engine Overtemperature Protection and ShutdownSeries 60 engines have additional logic to start the overtemperature torque reduction logic earlierwithout alerting the driver. Engine torque and/or speed is reduced as a function of temperature. Acode will be logged and torque reduction will begin when the first EOP calibrated temperature isreached. The CEL will illuminate and a fault code is logged when the second higher temperaturelimit is reached. If the temperature does not reduce as torque/speed is reduced, the SEL willilluminate when a still higher temperature is reached.The subsequent action taken by the ECM is the 30 second rampdown (see Figure 5-16) orshutdown (see Figure 5-17) depending on the customer selection. Torque reduction is based onthe average torque/speed in use prior to the fault condition.5-42 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONFigure 5-16Series 60 Engine Overtemperature Protection and RampdownAll information subject to change without notice. (Rev. 3/05) 5-437SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESFigure 5-17Series 60 Engine Overtemperature Protection and Shutdown5.7.3 ENGINE PROTECTION SWITCHESThe SEO/Diagnostic Request switch can be combined. A separate Diagnostic Request switch isan option.NOTE:EOP is active even if engine protection is configured for Warning only for the Series60 and Series 50, and engines.Diagnostic Request SwitchThe Diagnostic Request switch is used to activate the CEL and SEL to flash codes (seeFigure 5-18). The SEL will flash the active codes and the CEL will flash the inactive codes.Refer to section 4.2.3.5-44 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONFigure 5-18 Typical SEO Switch, Diagnostic Request Switch and WarningLightsThe Diagnostic Request switch is used to flash codes when:The engine is not running and ignition is onThe engine is idling and not in an "engine protection" conditionActivating 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 diagnosticcodes. 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 receiverECMs use a separate Diagnostic Request Switch.5.7.4 STOP ENGINE OVERRIDE OPTIONSTwo types of stop engine overrides are available, Momentary Override and ContinuousOverride. Continuous Override has two options. These types are dependent upon specificengine applications. The ECM will record the number of times the override is activated aftera fault occurs.Momentary Override - An SEO switch is used to override the shutdown sequence. This overrideresets 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 5-19.NOTE:The operator has the responsibility to take action to avoid engine damage.All information subject to change without notice. (Rev. 3/05) 5-457SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESFigure 5-19 Engine Overtemperature Protection and Shutdown Protection withStop Engine OverrideContinuous Override, Option 1 - This option is used when the vehicle needs full power during ashutdown 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 theshutdown sequence. This is primarily used in construction and industrial applications. Furtherengine protection is disabled until the ignition key is cycled. See Figure 5-20.5-46 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONFigure 5-20Engine Overtemperature Protection and Shutdown ProtectionwithContinuous Override, Option 25.7.5 INSTALLATIONSome application require two sets of warning lights (CEL and SEL) at different control stations.5.7.6 PROGRAMMING FLEXIBILITYAll ECMs are programmed with pressure, temperature, and level protection limits. The level ofprotection 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 anyof the available service tools, VEPS, DRS, DDR, or DDDL.The DDEC engine protection system monitors all engine sensors and electronic components, andrecognizes system malfunctions. The choices listed in Table 5-20 are available for reprogrammingEngine Protection.All information subject to change without notice. (Rev. 3/05) 5-477SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESParameter Definition RangeOIL PRESSUREOIL LEVELCOOLANT LEVELOIL TEMPCOOLANT TEMPAUXILIARY SHUTDOWN #1AUXILIARY SHUTDOWN #2Determines the type of engine protection with lowoil pressure. N/A will be displayed if the sensor isnot present.Determines the type of engine protection with lowoil level. N/A will be displayed if the sensor is notpresent.Determines the type of engine protection with lowcoolant level. N/A will be displayed if the sensoris not present.Determines the type of engine protection with highoil temperature. N/A will be displayed if the sensoris not present.Determines the type of engine protection with highcoolant temperature. N/A will be displayed if thesensor is not present.Determinesthetypeofengineprotectionwithan active auxiliary switch #1 input. N/A will bedisplayed if auxiliary switch #1 has not beenconfigured as a switch input.Determinesthetypeofengineprotectionwithan active auxiliary switch #2 input. N/A will bedisplayed if auxiliary switch #2 has not beenconfigured as a switch input.N/A; WARN,RAMP,SHTDWNN/A; WARN,RAMP,SHTDWNN/A; WARN,RAMP,SHTDWNN/A; WARN,RAMP,SHTDWNN/A; WARN,RAMP,SHTDWNN/A; WARN,RAMP,SHTDWNN/A; WARN,RAMP,SHTDWNTable 5-20Engine Protection5.7.7 INTERACTION WITH OTHER FEATURESCruise 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 whenEngine Protection is enabled.5-48 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.8 ENGINE RATINGSEngine ratings are designated by horsepower rating and engine speed. For on-highwayapplications, three independent engine ratings and an additional dependent rating (cruise power)are provided. For construction and industrial applications, up to three independent ratings areprovided. Although multiple ratings are stored in the ECM, only one rating is in operation atany time.5.8.1 OPERATIONThe 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 5-21.Example #1 Example #2430 bhp @ 2100 RPM Rating #0 470 bhp @ 2100 RPM Rating #0400 bhp @ 2100 RPM Rating #1 470 bhp @ 1800 RPM Rating #1370 bhp @ 2100 RPM Rating #2 430 bhp @ 1800 RPM Rating #2370/430 bhp @ 2100 RPM Rating #3 430/370 bhp @ 1800 RPM Rating #3Table 5-21Examples of Engine RatingsDetroit Diesel can provide additional security to prevent the ECM rating selection from beingmodified with the DDR or DDDL. The additional security is not available with the use of ratingswitches. The Maximum Rating Security or the Rating Password (if configured) will protectDDEC IV engine ratings.Engine Rating SwitchesEngine 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 groupratings. The rating switches must be used in conjunction with up to two digital inputs, RatingSwitch #1 and Rating Switch #2.Rating Switch #1 selects between Engine Rating #0 and Engine Rating #1 when used withoutRating Switch #2 as listed in Table 5-22.RatingEngine Rating #0Engine Rating #1Switch #1 PositionOFFONTable 5-22Rating Selections with One Rating SwitchAll information subject to change without notice. (Rev. 3/05) 5-497SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESRating Switch #2, in conjunction with Rating Switch #1, is used to select any of the four engineratings (three independent and one dependent) as listed in Table 5-23.Rating Switch #1 Switch #2Engine Rating #0 OFF OFFEngine Rating #1 ON OFFEngine Rating #2 OFF ONEngine Rating #3 ON ONTable 5-23Rating Selections with Two Rating SwitchesCruise PowerCruise Power is an optional engine rating which operates on a higher horsepower curve duringCruise Control operation. The ECM provides the higher horsepower when Cruise Control is ONand not being overridden with the foot pedal. The additional power provides an incentive for thedriver 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 torquecurve when the appropriate digital input is enabled. Limiting torque curve tables are generatedby Applications Engineering and can either be selected at the time of engine order or selectedafter engine order by DDC Technical Service.The Limiting Torque Curve option use is shown in the following examples:Articulated Coach - The Limiting Torque Curve option is used to limit torque in an extremearticulated condition, which could occur during reverse operation.Transmission - The Limiting Torque Curve option provides a customized reduced torquecurve during conditions which would otherwise exceed the maximum allowable torquelimit set by the transmission manufacturer.Locomotive - The Limiting Torque Curve option provides a reduced torque to reducewheel slip at low vehicle speed.The following must be considered when using the Limiting Torque Curve option:The DDEC system cannot detect or display a malfunction of the digital input wiring.Limiting vehicle speed is best accomplished by utilizing DDEC's Vehicle Speed Limitingfeature. Refer to section 5.27.The % Load display on the DDR / DDDL is a function of the main rating torque curve.LSG Droop is added to the speed limit.5-50 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.8.2 INSTALLATIONThe rating switches must be used in conjunction with up to two digital inputs, Rating Switch #1and Rating Switch #2. Refer to section 4.2, "Digital Inputs," for additional information. SeeFigure 5-21 for an installation using one rating switch.Figure 5-21 Simple Engine Rating SwitchSee Figure 5-22 for an installation using two rating switches.Figure 5-22Rotary Switch for Multiple Engine RatingsAll information subject to change without notice. (Rev. 3/05) 5-517SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURES5.8.3 PROGRAMMING REQUIREMENTS AND FLEXIBILITYThe Maximum Rating Security to protect DDEC IV engine rating must be enabled at the timeof engine order. Maximum Rating Security locks out all other ratings and will only operate onthe rating selected at order entry. The DDR or DDDL cannot change a rating selection if therating is maximum security protected.The Rating Password is a four digit alphanumeric password that may be set at the time of engineorder, by the DDR, DDDL, or VEPS. This offers additional protection above and beyond thestandard DDR, DDDL password protection.Rating SwitchesThe Rating Switches option and the digital inputs listed in Table 5-24 must be configured byorder entry, VEPS, or DRS.Description Type Function #Rating Switch #1 Digital Input 12Rating Switch #2 Digital Input 13Table 5-24Rating Switches Digital Input RequirementsCruise PowerCruise Power may be selected at the time of engine order, by VEPS, DDR, DDDL or usingthe engine rating switches.Limiting Torque OptionLimiting Torque Curves must be selected at the time of engine order or selected after engineorder by Technical Service.The digital input listed in Table 5-25 must be configured by order entry, VEPS, or DRS.Description Type Function NumberLimiting Torque Curve Digital Input 14Table 5-25Limiting Torque Curve Option Digital Input Requirements5-52 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.9 ETHER STARTThe DDEC Ether Start ® System is a fully-automatic engine starting fluid system used to assist aSeries 50 or Series 60 diesel engine in cold starting conditions. The amount of ether is properlycontrolled to optimize the starting process and prevent engine damage. DDEC will control etherinjection using standard sensors to control the ether injection hardware.5.9.1 OPERATIONEther Start will occur in two modes, preload (before cranking) and block load (during and aftercranking). The mode and duration of injection is determined by DDEC based on engine speedand coolant, air and oil temperatures. Since excessive preloading could be harmful to enginecomponents, DDEC will not allow multiple preloads. The engine speed must exceed 1500 RPMto 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 miscellaneoushardware (see Figure 5-23).Figure 5-23DDEC Ether Start SystemAll information subject to change without notice. (Rev. 3/05) 5-537SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESIt will be necessary to configure a DDEC digital output to control the relay module. Batterypower and ground must also be supplied to the module.To avoid injury from flames, explosion, and toxicants whenusing ether, the following precautions must be taken:Do not smoke when servicing ether system.Work in well-ventilated area.Do not work near open flames, pilot flames (gas or oilheaters), or sparks.Do not weld or carry an open flame near the ethersystem 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, washeyes with large quantities of clean water for 15 minutes.A physician, preferably an eye specialist, should becontacted.Contents of cylinder are under pressure. Storecylinders in a cool dry area. Do not incinerate, punctureor attempt to remove cores from cylinders.The relay module performs a number of important functions. The module will not allow etherinjection unless it receives a signal from DDEC, it will prevent ether injection in the event of afaulty signal, and it will illuminate a light on the module when the ether canister is 90% consumed.If the digital output remains grounded for longer than a factory set time, the relay module willcause an inline fuse to blow to prevent excessive ether from being injected into the cylinders. Ifthe 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 mustbe fixed before replacing the fuse.5-54 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.9.2 INSTALLATIONThe injector nozzle is installed in the intake manifold (see Figure 5-24).Figure 5-24 Series 60 Intake Manifold - Injector Nozzle LocationA red dot indicates the direction of spray, which should be pointed against the airflow. Thecylinder assembly should be mounted vertically in an accessible location away from extreme heatsuch as the exhaust system and protected from road dirt, ice and snow. If protected, it can bemounted in the engine compartment on the firewall, frame or any other convenient location. TheEther Injection Relay (EIR) should be located near the valve and cylinder assembly.The DDEC Ether Start system requires a harness (see Figure 5-25) to supply battery power,receive a signal from DDEC and control the ether injection valve. A fuse is required on the batteryinput (15 amp for 12 V systems, 10 amps for 24 V systems). Circuit breakers cannot be used.For complete information on installing Ether Start and other details of the Ether Start system,refer to the DDEC Ether Start Installation Manual (7SA0727).All information subject to change without notice. (Rev. 3/05) 5-557SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESFigure 5-25DDC Ether Start HarnessProgramming Requirements and FlexibilityTo configure an engine for Ether Injection, digital output function # 24 must be selected withVEPS, DRS, or on order entry. This feature does not have any reprogrammable parameters.5-56 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.10 FAN CONTROLThe purpose of the Fan Control feature is to electronically control engine cooling fan activationand to provide a load for vehicle retardation, when required. DDEC Fan Controls are designed tooptimally control the engine cooling fan(s) based on engine cooling requirements. Fan Controlsare designed to use other system inputs such as A/C pressure switches, transmission retarderstatus, and operator requested fan operation. Transmission Retarder Status may be received viathe 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.5.10.1 OPERATIONThe 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 storedwithin the ECM. These limits are factory configured based on application.When these temperature levels exceed the preset fan ON temperature value, the ECM will enablethe fan control digital output(s) that activate the fan. The fan will remain on, cooling the enginewith the increased air flow until the temperature levels reach the preset fan OFF temperature.At this point, the ECM will switch fan control to battery ground, which will deactivate the fan,effectively maintaining the coolant temperature between the two preset levels.DDEC IV provides fan control for four different fan configurations:Single fan (refer to section 5.10.3, page 5-58)Dual fans (refer to section 5.10.4, page 5-63)Two-speed fan (refer to section 5.10.5, page 5-65)Variable speed single fan (PWM) (refer to section 5.10.6, page 5-69)In accordance with the proposed Truck Maintenance Council (TMC) Standard, the minimumfan-on time for on-highway applications is 30 seconds.All information subject to change without notice. (Rev. 3/05) 5-577SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURES5.10.2 INSTALLATIONThis section provides a schematic of the specific connection from the ECM to the fan. SeeFigure 5-26 and Figure 5-27 for the input and outputs used for fan control.Figure 5-26Fan Control Inputs with Two Digital OutputsFigure 5-27 Fan Control Inputs with PWM Output for Variable Speed FanControlCompatible fans may be obtained from several vendors.5-58 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATION5.10.3 SINGLE FANThe single-fan control uses one digital output to drive a single-speed fan. The digital output iscalled Fan Control #1. Fan Control #1 is deactivated to turn the fan OFF. The fan remains ONfor 30 seconds when turned ON. The fan output will not be enabled until five seconds afterthe engine has started.NOTE:Digital output circuits are designed to sink no more than 1.5 A (DC) current.Fan Control #1 is enabled (opened) when at least one of the following conditions occur:Oil or coolant temperature above DDC factory set levelsAir temperature and engine torque above DDC factory set levelsAir conditioner is active (OEM supplied A/C switch is opened), the fan remains ON forthree minutes (the default) after the switch is grounded if vehicle speed is less than 20 MPHOil, coolant, or air temperature sensor failsFan engine brake enabled and engine brake is active at high level for a minimum of fiveseconds and air temperature is above factory set levelsTransmission retarder is active and coolant temperature above DDC factory set levelFan Control Override Switch is enabledPressure Sensor Governor is activeNOTE:If either the A/C or transmission retarder inactive digital input is configured, the inputmust be grounded to prevent continuous fan operation.All information subject to change without notice. (Rev. 3/05) 5-597SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESThe digital inputs and outputs for a single fan are listed in Table 5-26.FanStateFan ControlOutput 1A/C InputOverrideInputOn Open Grounded OpenOff Grounded Grounded OpenOn Open Open Don't CareOn Open Don't Care GroundedJake BrakeStatusNot in HighModeNot in HighModeNot in HighModeNot in HighModeOn Open Don't Care Don't Care High ModeOn Open Don't Care Don't CareNot in HighModePrimary ControlEngine TemperatureSensorsEngine TemperatureSensorsOEM A/C SwitchOEM Override SwitchJakeBrakeinHighModeand Air TemperatureAbove LimitTransmission RetarderActive and CoolantTemperature AboveLimitTable 5-26Single Fan Digital Inputs and Outputs5-60 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONInstallationSee Figure 5-28 for the specific connection from the ECM to the fan.Figure 5-28 Fan Control Inputs and Outputs Electro Magnetic Single-SpeedDigital Fans (Linnig)For additional information, contact the fan vendor:Linnig Corp.5131 S. Royal Atlanta DriveTucker, GA 30084Phone: (770) 414–9499www.linnig.comAll information subject to change without notice. (Rev. 3/05) 5-617SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURESSee Figure 5-29 for the specific connection from the ECM to the fan.Figure 5-29 Fan Control Inputs and Outputs Index Control ModuleFor additional information, contact the fan vendor:Index Sensors and Controls, Inc.7112 265th St NWStanwood, WA 98292Phone: 1-800-726-1737Fax: 360-629-0838www.indexsensors.com5-62 All information subject to change without notice. (Rev. 3/05)7SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDEC IV ON-HIGHWAY - EGR APPLICATION AND INSTALLATIONSee Figure 5-30 for the specific connection from the ECM to the control module.Figure 5-30 Fan Control Inputs - Normally Closed Air Solenoid Single-SpeedFan (BorgWarner ® , Bendix ® )For additional information, contact the fan vendors:Borg WarnerPhone: 1–800–828–8127www.bwinstruments.comBendix Commercial Vehicle Systems901 Cleveland StreetElyria, OH 44035Phone: 1-800-AIR-BRAKEwww.bendix.comAll information subject to change without notice. (Rev. 3/05) 5-637SA743 0503 Copyright © 2005 DETROIT DIESEL CORPORATION

DDECFEATURES