S2000 Ddec Iv 170708

1
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Second level
Product Training
Third level Rigid Dump Truck (RDT)
Fourth level TR70 : TR100
TEREX Equipment Limited Detroit Diesel S2000
Fifth level
TEREX Equipment Limited
Level 2 –
Product
AllisonTraining
Transmission
- Detroit
C.E.C.
Diesel DDEC IVControls
2 Controls
Electronic Controls(IV)
170708
Terex Centre of Excellence

TEREX CENTRE OF EXCELLENCE
Terex Equipment Limited
TEREX Equipment
Newhouse IndustrialLimited
Estate
TEREX Equipment Limited
Newhouse Industrial
Motherwell, ML1 Estate
5RY
Motherwell,
Newhouse ML1
Industrial
United Kingdom 5RY
Estate
See Us At - www.terex.co.uk 1 United Kingdom

Technical Online Assistance: http://constructionsupport.terex.com
2
Allison Transmission
Detroit Diesel C.E.C. 2
Series 2000
TR70 T913 – 12V2000

TR100 T883 – 16V2000
S2000 – DDEC IV
Detroit Diesel Electronic Controlled Engines (Version 4)

2
3
Allison
DDEC IVTransmission C.E.C. 2
DETROIT DIESEL ELECTRONIC CONTROLS (IV)

An advanced electronic fuel injection control system.
DDEC Consists of:

• Sensors and switches
• Conductors and connections
• ECM (computer)
– Hardware
– Software
• Injectors
3
4
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
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
Allison Transmission C.E.C. 2
Main Components
7
8

DDEC Necessities
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
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
• 1 ECM has capacity to power up to 8 electronic unit pumps (EUP).

• 12V2000 master & receiver ECMs powers 6 EUPs each.
• 16V2000 master & receiver ECMs powers 8 EUPs each.
• S2000 master ECM is hardwired for all sensor data + TRS/SRS.
• S2000 receiver ECM is hardwired for TRS/SRS only.
11
12
Allison
Connectors
12
Power Connector
Vehicle Interface Connector - VIH

Communication Connector 12
13
Allison
Connectors
13
Injector Harness Connector M
Sensor Harness Connector

Injector Harness Connector R
13
14
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
F44 – Engine ECM Battery Fuse R

F45 – Trans. ECU Battery Fuse
14
15
Timer Relay – K59 C.E.C. 2
Control Fuse to Timer (15)

15
Ignition Signal (B2)
Control Fuse to Timer (A1)
30 Second Shut-Down Delay
Timer Output to Relays (18) Timer Earth (A2)

15
16
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
K25 – Lock Up Drop Out

F60
(TR100 F64) K25
K20 – Converter Drive
F60 - Ignition Signal 10A
S52 - Manual/Automatic Key
K20
S53 - Power/Economy Key
S52 S53
To Shift Control
(S & V) Harness (VIW) To Console Harness
16
17
Main Fuse Box C.E.C. 2
17
A B C
K23 K4
K43
K34 K56
K15 K38 K57
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

DDEC Schematic
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

Power Harness
21
* Cavity B on Master ECM Only
21
22
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
– 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
Coolant Level Sensor

Sense
Diagnostic Switch
24
24
25
– 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
F44 – Engine ECM Battery Fuse R

Engine VIH Main Power Harness

25
26
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
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

27
28
VIH at ECM – Ignition C.E.C.
Sense 2
28
28
29
29
Injector Harness
29
30
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
Electronic Unit Pump C.E.C.
Harness2
RIGHT HAND BANK

32
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
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
S2000 Typical C.E.C. 2Nozzle
EUP & Injector
35
35
36
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
S2000 EUP InstallationC.E.C. 2
37
Inje
Pre ctor H
ssu i
EUP re F gh
Pip uel
e
Injector
Nozzle
37
38
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
S2000 EUP C.E.C. 2
Injection Cycle
Injection Line
39
Solenoid
EUP
Cam Injection
Nozzle
39
40
S2000 EUP CalibrationC.E.C.
Code 2
40
40
41
41
Sensors
41
42
DDEC Sensor Wiring C.E.C. 2
42
• Common Return Circuit. #452

• Thermistor
• Piezoresistive Pressure sensor

• Voltage is Proportional to Pressure
42
43
DDEC Sensor Rating C.E.C. 2
43
0.25V - 4.75V
Working Range
Fail Fail
0 Volt 5 Volt
43
44
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
Open Supply = LO VOLTAGE

Open Signal = LO VOLTAGE
Open Return = HI VOLTAGE
Supply short to Signal = HI VOLTAGE
Supply short to Return = LO VOLTAGE
Signal short to Return = LO VOLTAGE
46
47
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
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
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
Reference Sensors
S2000 SRS/TRS 51
Synchronous Reference Sensor
1/Cam Revolution
SRS
TRS
Timing Reference Sensor

36/Crankshaft Revolution 51
52
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
Assembly
53
Terex ID
B19
Supply - Red & White = 5V±1%

Idle - White & Black = 10 - 20% of Input (i.e. 5V Input = 0.5 - 1V)
Full Throttle - White & Black = 70 - 85% of Input (i.e. 5V Input = 3.5 - 4.25V)
Wired 53via VIH
54
Allison
ThrottleTransmission C.E.C.
Position Sensor 2 TR70
– TPS
54
54
55
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
0 48 102 205 717 871 968 1025

(10%) (20%) (70%) (85%) (100%)
COUNTS
DDEC IV
55 Counts can be read using DDR only

56
Turbo Boost Sensor - C.E.C.
TBS 2
56
Synch Reference
EUI
Electronic Foot
Module
Turbo Boost Pressure
(ECM)
EEPROM
- +
Battery
Ignition
56
57
Turbo Boost Sensor - C.E.C.
TBS 2
57
TBS
57
58
Temperature C.E.C.
& Pressure 2
Sensors
58
Synch Reference
EUI
Electronic Foot
Module
(ECM)
Fuel / Oil / Coolant/ Air
Temperature
Oil / Fuel Pressure

EEPROM
- +
Battery
Ignition
58
59
Temperature C.E.C.
& Pressure 2
Sensors
59
AIR INTAKE TEMPERATURE SENSOR
ATS
ATS
59
60
Temperature C.E.C.
& Pressure 2
Sensors
60
FTS FPS
FTS - Fuel Temperature Sensor

FPS - Fuel Pressure Sensor
60
61
Temperature C.E.C.
& Pressure 2
Sensors
61
OTS - Oil Temp. Sensor

CTS
CTS - Engine Coolant Temp. Sensor
T - Engine Coolant Temp. Sender
CPS - Engine Coolant Press.
Sensor
OPS - Oil Pressure Sensor
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
Electronic Foot
Module
(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

Diagnostics
66
Synch Reference
EUI
Electronic Foot
Module DDR Interface/ DDDL/
Reprogramming
(ECM)
Stop
Fuel / Oil / Coolant Engine
Temperature
Oil / Fuel Pressure

Check
EEPROM Engine
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
A - Stop Engine Light (SEL)

B - Check Engine Light (CEL)
67
H2
M Engine Diagnostic Stop Lamp
P Engine Diagnostic Check Lamp
Allison
68
DiagnosticsC.E.C. 2
68
68
69
Allison
DiagnosticsC.E.C. 2
Diagnostic Lights 69
 ECM will detect a fault on the engine.

 Either engine warning or stop lamp will illuminate depending on severity of fault.
 With ignition ON, select diagnostic request switch.
 The red warning lamp will flash out any active fault codes followed by the amber warning lamp
flashing out any inactive fault codes.
 Once all the active and inactive codes have been shown it will begin the sequence again.
 Note: Code 25 = All clear.
 Press the diagnostic switch again to exit diagnostic mode.
2 FLASHES 5 FLASHES
SHORT PAUSE LONG PAUSE

69
70
Diagnostic C.E.C. 2
Code Summary
13 COOLANT LEVEL CIRCUIT LOW 43

70
COOLANT LEVEL TOO LOW
14 INTERCOOLER, COOLANT OR OIL TEMP CIRCUIT HIGH 44 IN/COOLER, COOLANT OR OIL TEMP HIGH
15 INTERCOOLER, COOLANT OR OIL TEMP CIRCUIT LOW 45 LOW OIL PRESSURE
16 COOLANT LEVEL CIRCUIT HIGH 46 BATTERY VOLTAGE LOW
21 TPS CIRCUIT HIGH 47 FUEL PRESSURE HIGH
22 TPS CIRCUIT LOW 48 FUEL PRESSURE LOW
23 FUEL TEMP CIRCUIT HIGH 53 EEPROM WRITE OR NON VOLATILE FAIL
24 FUEL TEMP CIRCUIT LOW 55 J1939 DATA LINK FAULT
25 NO CODES (ALL CLEAR) 58 TORQUE OVERLOAD
27 AIR TEMP CIRCUIT HIGH 61 INJECTOR RESPONSE TIME TOO LONG
28 AIR TEMP CIRCUIT LOW 63 PWM OPEN OR SHORT TO BATTERY
32 SEL SHORT OR OPEN CIRCUIT 64 TURBO SPEED CIRCUIT FAILED
33 BOOST PRESSURE CIRCUIT HIGH 67 COOLANT PRESSURE CIRCUIT HIGH/LOW
34 BOOST PRESSURE CIRCUIT LOW 71 INJECTOR RESPONSE TIME TOO SHORT
35 OIL PRESSURE CIRCUIT HIGH 72 VEHICLE OVERSPEED
36 OIL PRESSURE CIRCUIT LOW 75 BATTERY VOLTAGE HIGH
37 FUEL PRESSURE CIRCUIT HIGH 76 ENGINE OVERSPEED WITH ENGINE BRAKE
38 FUEL PRESSURE CIRCUIT LOW 85 ENGINE OVERSPEED
41 TOO MANY SRS (MISSING TRS) 86 WATER PUMP PRESSURE CIRCUIT HIGH
42 TOO MANY TRS (MISSING SRS) 88 COOLANT PRESSURE LOW
70
71

DDR Interface
71
Diagnostic Connector
S2000
Located Below Dash

Terex Tooling #
Multi-Kit (DDR, Cartridge & Cables) ; 15275098
DDEC III/IV Card ; 15275096
Spare DDR ; 15268971
Spare Multi Cartridge ; 15273084
Spare Adaptor Cable ; 15270310 71
72
Allison
D.D.D.L.Transmission
Interface C.E.C. 2
Detroit Diesel Diagnostic Link - D.D.D.L.

72
Diagnostic Link and DDEC Reports
DDDL Package
DDEC Reports DDDL
Operating Report Tool Troubleshooting &

Maintenance Tool
Comprehensive Engine Maintenance &

Information Management Troubleshooting Software
Software Programme That Performs All
of The Same Functions As
DDR and MORE
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
Engine Protection C.E.C.
/ Ramp 2
Down
74
 Warning- Illumination of CEL, SEL only.
 Rampdown- Immediate reduction to 70% power, ramping down to 40%

over 30 seconds and maintains 40% power.
Typical Parameters:
LOW COOLANT LEVEL
HIGH COOLANT TEMPERATURE
LOW OIL PRESSURE
HIGH OIL TEMPERATURE
74
75
75
Communication
75
76

Communication
76
Synch Reference
EUI
Electronic Foot Communication
Module DDR Interface/ DDDL/
Reprogramming
(ECM)
Stop
Fuel / Oil / Coolant Engine
Temperature
Oil / Fuel Pressure

Check
EEPROM Engine
Coolant Level
- +
Ignition Battery
Diagnostic Stop Engine
Request Override
76
77

Communication
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

Communication
78
A - Spare
B - Spare
C - Spare
D - 927 G J1939 (S)
E - 926 B J1939 (-)
F - 925 R J1939 (+)
Common for both Master

78 and Receiver ECMs’
79
Allison
CANBUS Transmission C.E.C.
Communication 2
– TR70
79
79
80
80
Tachometer Calibration
80
81
(P2) Tachometer C.E.C. 2
Calibration
Tachometer Calibration Input 81

TR70 (T913) 12.00 Pulses
TR100 (T883) 12.00 Pulses (70 Amp Alternator)
18.34 Pulses (100 Amp Alternator – 14 poles)
20.96 Pulses (100 Amp Alternator – 16 poles)
PULSE
The tachometer when installed as new or replaced will
require calibration prior to being put to work.
On the rear of the tachometer there is a pressure pad.
1. Hold down pressure pad.

2. Turn on ignition - Do not start engine.
3. Hold pressure pad until the word ‘PULSE’ appears
on the tachometer display.
4. Release pressure pad and a calibration figure will be
displayed, similar to above.
5. Each digit will flash for 4-5 seconds each, prior to
advancing to the next digit.
6. To alter a digit, press the pressure pad.
7. Once calibration is complete, turn off ignition.
81
82
82
General Troubleshooting
82
83
Allison
GeneralTransmission C.E.C. 2
Troubleshooting
Fuel System Troubleshooting 83
Low Power
Inspect the following:

• Fuel Supply
• Restricted Filters
• Obstructed Fuel Lines
• Fuel Pump
83
84
Allison
Troubleshooting
Air System Troubleshooting 84
Low Power
Inspect The Following:

• Intake
– Air Cleaner
– Charge Cooler
– Piping
– Turbocharger
• Exhaust
– Faulty Piping
– Obstructed Muffler
• Turbo Boost Sensor
• Low Compression
84
85
Allison
Troubleshooting
Lube System Troubleshooting 85
Low Oil Pressure
Inspect the following:

• Supply
– Low Oil Level
– Oil Quality
• Mechanical
– Stuck Regulator or Relief Valve
• Temperature
– High Coolant Temp.
– High Ambient Load
85
86
Allison
Troubleshooting

High Oil Consumption
• High Consumption
– Leaks
– Worn Components
– Checking and Filling Procedures
• Pump Speed
• Restriction to flow (worn parts)
86
87
Allison
Troubleshooting

High Oil Consumption
• 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
Troubleshooting

High Oil Pressure
• Oil Control At Cylinder

– Oil Control rings worn, broken, or improperly
installed
– Scored liners, Pistons, or oil rings
– Excessive oil in Crankcase
88
89
Allison
Troubleshooting
Blue Smoke Troubleshooting 89
• Air Cleaner
• Turbocharger seals
• Turbocharger Oil Drain
• Exhaust Valve Guides and Seals
• Piston Rings
• Oil Level
BLUE SMOKE IS CAUSED BY EXCESSIVE OIL IN THE CYLINDER
89
90
Allison
Troubleshooting
Black Smoke Troubleshooting 90
• Air Cleaner
• Turbocharger
• Exhaust Manifold Gaskets
• Muffler
• Exhaust Piping
• Charge Cooler
• Turbo Boost Sensor
BLACK SMOKE OCCURS WHEN FUEL IS NOT COMPLETELY BURNED
90
91
Allison
Troubleshooting
Black Smoke Troubleshooting 91
• Grade of Fuel
• Injector Output
• Avoid Lugging the Engine
BLACK SMOKE OCCURS WHEN FUEL IS NOT COMPLETELY BURNED
91
92
Allison
Troubleshooting
White Smoke Troubleshooting 92

• Air Cleaner
• Connections
• Grade of Fuel
• Injector Output
• Aerated Fuel
• Burnt Exhaust Valves
• Exhaust Valve Adjustment
• Compression Rings
WHITE SMOKE IS CAUSED BY MISFIRING CYLINDER
92
93
Allison
Troubleshooting
Cooling System Troubleshooting 93

Temperature Problems
• HIGH TEMP.
– Coolant level
– Fan Operation
– Hoses
– Pump Failure
– Ambient/Load
• LOW TEMP.
– Thermostats
– System Cooling Capacity
93
94
Allison
Troubleshooting
Cooling System Troubleshooting 94

Temperature Problems
• Cavitation
• Corrosion
• Scale
• Silicate Drop-out
94
95
Terex Equipment Limited

Motherwell, ML1 5RY
Scotland
+44 (0)1698 732121
+44 (0)1698 734046
Web
www.terex.com
Technical Online Assistance

http://constructionsupport.terex.com

S2000 Ddec Iv 170708

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Terex Centre of Excellence

See Us At - www.terex.co.uk 1 United Kingdom

TR70 T913 – 12V2000

Detroit Diesel Electronic Controlled Engines (Version 4)

DETROIT DIESEL ELECTRONIC CONTROLS (IV)

DDEC Consists of:

Allison Transmission C.E.C. 2

Allison Transmission C.E.C. 2

• 1 ECM has capacity to power up to 8 electronic unit pumps (EUP).

Vehicle Interface Connector - VIH

Injector Harness Connector M

Sensor Harness Connector

F44 – Engine ECM Battery Fuse R

Control Fuse to Timer (15)

Control Fuse to Timer (A1)

30 Second Shut-Down Delay

Timer Output to Relays (18) Timer Earth (A2)

K25 – Lock Up Drop Out

K15 K38 K57

Allison Transmission C.E.C. 2

Allison Transmission C.E.C. 2

Allison Transmission C.E.C. 2

* Cavity B on Master ECM Only

Coolant Level Sensor

F44 – Engine ECM Battery Fuse R

Engine VIH Main Power Harness

Cavity - Wire# (Master/Receiver) Colour

Allison Transmission C.E.C. 2

RIGHT HAND BANK

Allison Transmission C.E.C. 2

• Common Return Circuit. #452

• Piezoresistive Pressure sensor

Open Supply = LO VOLTAGE

Timing Reference Sensor

Supply - Red & White = 5V±1%

0 48 102 205 717 871 968 1025

55 Counts can be read using DDR only

Oil / Fuel Pressure

FTS - Fuel Temperature Sensor

OTS - Oil Temp. Sensor

Allison Transmission C.E.C. 2

Allison Transmission C.E.C. 2

Oil / Fuel Pressure

A - Stop Engine Light (SEL)

 ECM will detect a fault on the engine.

SHORT PAUSE LONG PAUSE

13 COOLANT LEVEL CIRCUIT LOW 43

Allison Transmission C.E.C. 2

Located Below Dash

Detroit Diesel Diagnostic Link - D.D.D.L.

Diagnostic Link and DDEC Reports

DDEC Reports DDDL

Operating Report Tool Troubleshooting &

Comprehensive Engine Maintenance &

 Warning- Illumination of CEL, SEL only.

 Rampdown- Immediate reduction to 70% power, ramping down to 40%

Allison Transmission C.E.C. 2

Allison Transmission C.E.C. 2

Oil / Fuel Pressure

Allison Transmission C.E.C. 2