Professional Documents
Culture Documents
Level 2 –
Product
AllisonTraining
Transmission
- Detroit
C.E.C.
Diesel DDEC IVControls
2 Controls
Electronic Controls(IV)
170708
Allison Transmission
Detroit Diesel C.E.C. 2
Series 2000
S2000 – DDEC IV
Allison
DDEC IVTransmission C.E.C. 2
3
4
Allison Transmission
Electronic C.E.C. 2
Engine Advantages
• Engine Protection
• Engine Diagnostics
• Reduced Maintenance
• Improved Engine Governing
• Fuel Economy Optimization
• Enhanced Cold Starting
• Smoke Control
• Reduced Emission Levels
4
5
Allison Transmission
Wire / Cable Colours C.E.C. 2
5
N - BROWN
U - BLUE
R - RED
P - PURPLE
EXAMPLE;
R/W - RED/WHITE G - GREEN
•MAIN COLOUR RED
•WITH WHITE TRACER L - LIGHT GREEN
W - WHITE
Y - YELLOW
B - BLACK
S - SLATE (GREY)
O - ORANGE
K - PINK
5
6
Allison
WeldingTransmission
Precautions C.E.C. 2
6
Before welding on truck:
• Turn key-switch off
• Turn master switch off
Disconnect:
• Battery supply & earth cables
• Alternator earth & supply cables
• Transmission ECU
• Engine ECM
• Any other electronic options ie. rear view TV, lube
systems, etc.
6
7
Main Components
7
8
8
ENGINE MOUNTED
CTS COOLANT TEMP. SENSOR
TBS TURBO BOOST SENSOR
FTS FUEL TEMP. SENSOR DATA
ATS AIR INTAKE SENSOR LINK
FPS FUEL PRESSURE SENSOR
CPS COOLANT PRESSURE SENSOR
OTS OIL TEMP. SENSOR
OPS OIL PRESSURE SENSOR
SRS SYNCRONOUS REF. SENSOR
TRS TIMING REF. SENSOR
CLS COOLANT LEVEL SENSOR
TPS THROTTLE POSITION
VEHICLE MOUNTED 8
9
Allison
DDEC ECMTransmission C.E.C. 2
Connections
VEHICLE CONNECTIONS
ENGINE CONNECTIONS
9
10
Allison Transmission
S2000 DDEC ECMs C.E.C. 2
10
Master ECM
Receiver ECM
DDEC
10 (IV)
11
Allison
DDEC ECMTransmission
Design C.E.C. 2
11
11
12
Allison
DDEC ECMTransmission C.E.C. 2
Connectors
12
Power Connector
Allison
DDEC ECMTransmission C.E.C. 2
Connectors
13
Allison Transmission
Power Module – TR70C.E.C. 2
14
K23 A – Engine ECM Battery Power
K23 B – Engine ECM Battery Power
F42
F43
F41
F44
F46
F40
F45
K23 C – Trans. ECU Ignition Power
K59
K23 D – Trans. ECU Battery Power
K59 – Timer Relay
F40 – Main Battery Fuse
F41 – Engine ECM Battery Fuse M
F42 – Engine ECM Battery Fuse R K23 K23 K23 K23
F43 – Engine ECM Battery Fuse M A B C D
14
15
Allison Transmission
Timer Relay – K59 C.E.C. 2
Allison Transmission
Interface Module C.E.C. 2
16
K60 - Check Transmission K60 K14 K17 K14 K17
Aux Aux
K14 - Neutral Start
K17 - Reverse
K14 Aux – On Board Weighing
K52
K17 Aux – Reverse Camera
K52 – Body Hoist Hold in Range
K39 - Delta () P K39
S52 S53
To Shift Control
(S & V) Harness (VIW) To Console Harness
16
17
Allison Transmission
Main Fuse Box C.E.C. 2
17
A B C
K23 K4
K43
K34 K56
Relay Definition
K4 Flasher K15 Dipped Beam K56 Sound Power Body Raise
K23 Ignition K34 Horn K57 Sound Power 1st / Rev Gr.
K38 Main Beam K43 Radio
17
18
18
Power Up
18
19
19
Electronic
Control
Module
(ECM)
EEPROM
- +
Battery
Ignition
19
20
Allison
Typical Transmission
Power Start UpC.E.C. 2
Circuit
MAIN FUSE BOX POWER MODULE
20
N - Gear
AR
GE TER
ENGINE ECM IF
SH
K23 F3
V
To K59
E.C.U.
Ignition Sense
S
Battery Power
From F40
K14
K1 - ENGINE
STARTER RELAY
INTERFACE
MODULE
S2 - KEY SWITCH
20
21
21
21
22
Allison Transmission
Power Start Up CircuitC.E.C.
– TR702 (T913)
22
Keyswitch
Master Disconnect
Solenoid
Neutral Start Relay
Starter
Solenoid
Batteries
Ignition
Alternator Sense Relay
Main Fuse
Starter Motor Box
22
23
Allison Transmission
Power Start Up CircuitC.E.C.
– TR702 (T913)
23
From Batteries
To Keyswitch
Timer Relay
23
H2
To Tachometer M Engine Diagnostic Stop Lamp
P Engine Diagnostic Check Lamp
Allison
Diagnostic Switch
Power Start
Transmission
Accelerator Pedal
Up CircuitC.E.C.
24
2
– Ignition
Diagnostic Switch
24
24
25
Allison Transmission
Power Start Up CircuitC.E.C.
– TR702 (T913)
25
K23 A – Engine ECM Battery Power
K23 B – Engine ECM Battery Power
F42
F43
F41
F44
F46
F40
F45
K23 C – Trans. ECU Ignition Power
K59
K23 D – Trans. ECU Battery Power
K59 – Timer Relay
F40 – Main Battery Fuse
F41 – Engine ECM Battery Fuse M
F42 – Engine ECM Battery Fuse R K23 K23 K23 K23
F43 – Engine ECM Battery Fuse M A B C D
Allison Transmission
Main Power ConnectorC.E.C. 2 Module
at Power
26
A - 150 (M) B
B - 150 (M) B
C - 150 (R) B
D - 150 (R) B
E - Spare
F - Spare
G - 240 (M) R
H - 241 (M) R
J - 240 (R) R
K - 241 (R) R
L - Spare
M - Spare
N - Spare
P - 150 (M) B
R - Spare
S - Spare
Cavity - Wire# (Master/Receiver) Colour
26
27
Allison Transmission
VIH at Power Module C.E.C. 2
27
1 - W/K
1 Ignition Signal
8
2 - 439 K
2 7 Ignition Signal to DDEC
3 - 953 B/W
DDEC Common Earth
4 - Spare
3 6 5 - Spare
6 - Spare
7 - Spare
4 5
8 - Spare
Allison Transmission
VIH at ECM – Ignition C.E.C.
Sense 2
28
28
29
29
Injector Harness
29
30
Allison Transmission
Electronic Unit Pump C.E.C.
Power 2Harness
30
Electronic EUP
Control
Module Electronic Unit Pump
(ECM)
EEPROM
- +
Battery
Ignition
30
31
Allison
InjectorTransmission C.E.C. 2
Harness Connector
31
31
32
Allison Transmission
Electronic Unit Pump C.E.C.
Harness2
Receiver ECM
Master ECM
LEFT HAND
32 BANK
33
Allison
InjectorTransmission C.E.C. 2
Bank Identification
33
A1-B2-A5-B4-A3-B1-A6-B5-A2-B3-A4-B6
33
34
Allison Transmission
EUP & Injector C.E.C. 2
Schematic
34
1 FUEL FILTER
2 FUEL PUMP
3 FUEL FILTER
4 REGULATOR/RELIEF VALVE
5 JUNCTION BOX
6 INJECTION NOZZLE
7 HIGH PRESSURE FUEL LINE
8 ELECTRONIC UNIT PUMP (EUP)
SCHEMATIC BASED
34 ON 16V2000
35
Allison Transmission
S2000 Typical C.E.C. 2Nozzle
EUP & Injector
35
35
36
Allison Transmission
EUP Drive C.E.C. 2
off Camshaft
36
• EUPs on Camshaft
– Near EUI Performance
Yet Less Space
• Injection Nozzles in Head
– Pumping Forces in Block
– Lower Engine Height
• Roller Cam Followers
– Reduced Friction & Wear
• Short Pre-Stressed
Fuel Lines
– Increased Fatigue Strength
36
37
Allison Transmission
S2000 EUP InstallationC.E.C. 2
37
Inje
Pre ctor H
ssu i
EUP re F gh
Pip uel
e
Injector
Nozzle
37
38
Allison Transmission
S2000 EUP InstallationC.E.C. 2
38
1. CAMSHAFT ROLLER4. SOL. PLUNGER 1. EUP 3. FUEL LINE NUT 5. INJECTION NOZZLE CLAMP
2. EUP BODY 5. SPRING 2. INJECTION LINE 4. INJECTION NOZZLE
3. SOLENOID 6. PLUNGER 38
39
Allison Transmission
S2000 EUP C.E.C. 2
Injection Cycle
Injection Line
39
Solenoid
EUP
Cam Injection
Nozzle
39
40
Allison Transmission
S2000 EUP CalibrationC.E.C.
Code 2
40
40
41
41
Sensors
41
42
Allison Transmission
DDEC Sensor Wiring C.E.C. 2
42
42
43
Allison Transmission
DDEC Sensor Rating C.E.C. 2
43
0.25V - 4.75V
Working Range
Fail Fail
0 Volt 5 Volt
43
44
Allison Transmission
DDEC Sensor Rating C.E.C. 2
DDEC Sensor Electrical Terms 44
• Open Circuit
An “open” describes a complete break in the path of current at some
point in the circuit.
• Short Circuit
A “short” occurs when a load in the circuit is accidentally bypassed.
Electricity will always take the path of least resistance.
• Grounded Circuit
A “ground” is similar to a “short” because current accidentally bypasses
a load in the circuit. The difference is that the bypass connects directly
to the negative terminal of the power source by way of the chassis
ground path.
44
45
Allison
DDEC 2Transmission
Wire Sensor C.E.C. 2
45
5V Supply
Signal
Return
ECM Sensor
Open = HI VOLTAGE
Short = LO VOLTAGE
45
46
Allison
DDEC 3Transmission
Wire Sensor C.E.C. 2
46
ECM Sensor
5V Supply
Signal
Return
46
47
Allison Transmission
S2000 Sensor HarnessC.E.C. 2
47
47
48
Allison
Sensor Transmission
Locations C.E.C. 2
48
1 OIL TEMP. SENSOR (OTS)
2 OIL PRESS. SENSOR (OPS)
3 TIMING REFERENCE SENSOR (TRS)
4 FUEL TEMP. SENSOR (FTS)
5 CHARGE AIR TEMP. SENSOR (ATS)
6 TURBO BOOST SENSOR (TBS)
7 FUEL PRESSURE SENSOR (FPS)
8 COOLANT TEMP. SENSOR (CTS)
9 COOLANT PRESS. SENSOR (CPS)
10 SYNCHRONOUS REFERENCE SENSOR (SRS)
48
49
Allison Transmission
Synchronous / TimingC.E.C. 2
Reference Sensors
DDEC Schematic Diagram 49
Synch Reference
Electronic EUI
Timing Reference
Control
Module
(ECM)
EEPROM
- +
Battery
Ignition
49
50
Allison Transmission
Synchronous / TimingC.E.C. 2
Reference Sensors
(TRS / SRS) 50
SRS/TRS: Magnetic pickup sensors generate alternating current (AC). The frequency will
change dependent on the speed of the pulse wheel (RPM of Engine).
SRS
Camshaft
Timing
Pins
SRS/TRS
Cam Gear/
SRS
36
1
50 TRS Crank Timing Wheel
51
Allison Transmission
Synchronous / TimingC.E.C. 2
Reference Sensors
S2000 SRS/TRS 51
Synchronous Reference Sensor
1/Cam Revolution
SRS
TRS
Allison Transmission
Electronic Foot Pedal C.E.C. 2
52
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot
Pedal Assembly Control
Module
(ECM)
EEPROM
- +
Battery
Ignition
52
53
Allison Transmission
Electronic Foot Pedal C.E.C. 2
Assembly
53
Terex ID
B19
Allison
ThrottleTransmission C.E.C.
Position Sensor 2 TR70
– TPS
54
54
55
Allison Transmission
Electronic Foot Pedal C.E.C. 2
Assembly
55
0 VOLTS 0.25 VOLTS 4.75 VOLTS 5 VOLTS
LO
VOLT BUFFER 0% BUFFER
100% Hi VOLT
CODE ZONE THROTTLE THROTTLE ZONE CODE
OPERATING RANGE
DDEC IV
Allison Transmission
Turbo Boost Sensor - C.E.C.
TBS 2
56
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot
Pedal Assembly Control
Module
Turbo Boost Pressure
(ECM)
EEPROM
- +
Battery
Ignition
56
57
Allison Transmission
Turbo Boost Sensor - C.E.C.
TBS 2
57
TBS
57
58
Allison Transmission
Temperature C.E.C.
& Pressure 2
Sensors
58
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot
Pedal Assembly Control
Module
Turbo Boost Pressure
(ECM)
Fuel / Oil / Coolant/ Air
Temperature
- +
Battery
Ignition
58
59
Allison Transmission
Temperature C.E.C.
& Pressure 2
Sensors
59
AIR INTAKE TEMPERATURE SENSOR
ATS
ATS
59
60
Allison Transmission
Temperature C.E.C.
& Pressure 2
Sensors
60
FTS FPS
Allison Transmission
Temperature C.E.C.
& Pressure 2
Sensors
61
CPS
OPS
OTS
61
62
Allison
PressureTransmission
Sensors C.E.C. 2
62
Coolant
Oil / Fuel
Pressure
Pressure
Series 60
Series 2000
Different Harness Connectors
Series 2000
62
63
Allison
CoolantTransmission
Level Sensor C.E.C. 2
63
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot
Pedal Assembly Control
Module
Turbo Boost Pressure
(ECM)
Fuel / Oil / Coolant
Temperature
Oil / Fuel Pressure
EEPROM
Coolant Level
- +
Battery
Ignition
63
64
Allison
CoolantTransmission
Level Sensor C.E.C. 2
64
DDEC IV
Coolant Level Sensor
OEM Responsible - Coolant level sensor (S47) signal to VIH connector 115-H3
64
65
65
Diagnostics
65
66
66
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot
Pedal Assembly Control
Module DDR Interface/ DDDL/
Reprogramming
Turbo Boost Pressure
(ECM)
Stop
Fuel / Oil / Coolant Engine
Temperature
Coolant Level
- +
Ignition Battery
Diagnostic Stop Engine
Request Override
66
67
Allison
On BoardTransmission
DiagnosticsC.E.C. 2
Engine Diagnostic / Engine Override Switch 67
10. Master Diagnostic Request & Engine
Override Switch (S68)
11. Receiver Diagnostic Request Switch (S68)
10 11
68
DiagnosticsC.E.C. 2
68
68
69
Allison
On BoardTransmission
DiagnosticsC.E.C. 2
Diagnostic Lights 69
2 FLASHES 5 FLASHES
Allison Transmission
Diagnostic C.E.C. 2
Code Summary
71
Diagnostic Connector
S2000
Allison
D.D.D.L.Transmission
Interface C.E.C. 2
DDDL Package
72
73
Allison
D.D.D.L.Transmission
Interface C.E.C. 2
DDDL Interface Tool No.s 73
15501306 DDDL Complete Kit - Includes Software, Cables,
Translator box
Spares
15501455 Translator Box
15501458 PC to Translator Box Cable
15501460 Translator Box to Vehicle Cable
15501457 Vehicle Cable
15501454 Extension Cable
15501379 6 to 9 Pin Adaptor Cable - DDEC V Engines Only
73
74
Allison Transmission
Engine Protection C.E.C.
/ Ramp 2
Down
74
Typical Parameters:
LOW COOLANT LEVEL
HIGH COOLANT TEMPERATURE
LOW OIL PRESSURE
HIGH OIL TEMPERATURE
74
75
75
Communication
75
76
76
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot Communication
Pedal Assembly Control
Module DDR Interface/ DDDL/
Reprogramming
Turbo Boost Pressure
(ECM)
Stop
Fuel / Oil / Coolant Engine
Temperature
Coolant Level
- +
Ignition Battery
Diagnostic Stop Engine
Request Override
76
77
77
• J1587/J1708
– 9600 Baud Rate, used to transmit sensor and engine data to diagnostic
tools ie. DDR, DDDL
• J1939
– 250k Baud Rate, communication link between engine and transmission.
77
78
78
A - Spare
B - Spare
C - Spare
D - 927 G J1939 (S)
E - 926 B J1939 (-)
F - 925 R J1939 (+)
Allison
CANBUS Transmission C.E.C.
Communication 2
– TR70
79
79
80
80
Tachometer Calibration
80
81
Allison Transmission
(P2) Tachometer C.E.C. 2
Calibration
81
82
82
General Troubleshooting
82
83
Allison
GeneralTransmission C.E.C. 2
Troubleshooting
Fuel System Troubleshooting 83
Low Power
83
84
Allison
GeneralTransmission C.E.C. 2
Troubleshooting
Air System Troubleshooting 84
Low Power
84
85
Allison
GeneralTransmission C.E.C. 2
Troubleshooting
Lube System Troubleshooting 85
Low Oil Pressure
85
86
Allison
GeneralTransmission C.E.C. 2
Troubleshooting
• High Consumption
– Leaks
– Worn Components
– Checking and Filling Procedures
• Pump Speed
• Restriction to flow (worn parts)
86
87
Allison
GeneralTransmission C.E.C. 2
Troubleshooting
• External Leaks
– Oil Lines or connections leaking
– Gaskets or oil seal leaks
– High crank case pressure
• Internal Leaks
– Oil Cooler Leaking
– Turbocharger
– Air compressor
– Worn Valve Guides/Seats
87
88
Allison
GeneralTransmission C.E.C. 2
Troubleshooting
88
89
Allison
GeneralTransmission C.E.C. 2
Troubleshooting
Blue Smoke Troubleshooting 89
• Air Cleaner
• Turbocharger seals
• Turbocharger Oil Drain
• Exhaust Valve Guides and Seals
• Piston Rings
• Oil Level
89
90
Allison
GeneralTransmission C.E.C. 2
Troubleshooting
Black Smoke Troubleshooting 90
• Air Cleaner
• Turbocharger
• Exhaust Manifold Gaskets
• Muffler
• Exhaust Piping
• Charge Cooler
• Turbo Boost Sensor
90
91
Allison
GeneralTransmission C.E.C. 2
Troubleshooting
Black Smoke Troubleshooting 91
• Grade of Fuel
• Injector Output
• Avoid Lugging the Engine
91
92
Allison
GeneralTransmission C.E.C. 2
Troubleshooting
92
93
Allison
GeneralTransmission C.E.C. 2
Troubleshooting
• HIGH TEMP.
– Coolant level
– Fan Operation
– Hoses
– Pump Failure
– Ambient/Load
• LOW TEMP.
– Thermostats
– System Cooling Capacity
93
94
Allison
GeneralTransmission C.E.C. 2
Troubleshooting
• Cavitation
• Corrosion
• Scale
• Silicate Drop-out
94
95
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