18SP546Rev
Contents
1. POWER HARNESS ADAPTOR ENGINE SENSOR f j 123517986 HARNESS ASSEMBLY 7 23517553 i O ee WEHICLE EN HARNES m oo a135 Figure1 DDEC IV ECM and Wiring Harness Locations AIR TEMP SENSOR AIR INLET MANIFOLG 24447 Figure2 Air Temperature Sensor Location 18SP546 Rev Page 2 of 8 Powernet Engine Order Entry Change Unit Information In order for the newly installed DDEC IV ECM to be programmed a mainframe file must be established To ensure that the ability to program the DDEC IV ECM is established the attached FAX form See Figure 5 must be filled out and sent to the DDC Customer Support Center at 313 592 5888 See Table 2 for the appropriate 6N4D and 6N4M groups Important Information Please read You must use the updated fax request in these instructions or request the mainframe update to DDEC IV otherwise the wrong calibration could be assigned The DDEC IV ECM in this kit is only for use with 12 volt systems Within the ratings listed you will find the original DDEC II III ratings and a cross reference to the comparable DDEC IV version With the following features now found within the DDEC system it is possible to cover a wide variety of requests with fewer ratings e Low gear torque limiting will modify the max torque for the application e Progressive shift will limit the max RPM for the user NOTE Vehicle speed sensors must be used for th2. 35 5235605 N A 6N4M 6214 414 365 1800 1350 1200 N A 6N4M 6215 413 350 1800 1350 1200 N A 6N4M 6203 371 325 1800 1350 1200 N A 6N4M 6216 415 325 350 1800 1350 1200 6N4D 7275 6N4D 6311 5234935 5235605 N A 6N4M 6154 240 320 1800 1150 1200 N A 6N4M 6157 243 285 1800 1150 1200 N A 6N4M 6371 478 285 320 1800 1150 1200 6N4D 7275 6N4D 6312 5234935 5235605 N A 6N4M 6148 234 320 2100 350 1800 1250 1200 6N4D 7275 6N4D 7127 5234935 5235605 6N4M 7815 6N4M 6916 1261 357 2100 400 1800 1350 1200 6N4D 7274 6N4D 6313 5234935 5235605 6N4M 7811 6N4M 6374 433 450 2100 1800 1450 1500 1200 6N4M 7812 6N4M 6211 416 430 2100 1800 1450 1500 1200 6N4M 7813 6N4M 6200 253 425 2100 1800 1450 1200 6N4M 7814 6N4M 6372 479 425 450 2100 1800 1450 1200 6N4D 7272 6N4D 6314 5234970 5235695 6N4M 7804 6N4M 6212 417 430 1800 1450 1500 1200 6N4M 7805 6N4M 6164 250 400 1800 1450 1200 6N4M 7806 6N4M 6166 252 365 1800 1450 1200 N A 6N4M 6213 359 365 400 1800 1450 1200 6N4D 7272 6N4D 6315 5234940 5235600 6N4M 7804 6N4M 6212 417 430 1800 1450 1500 1200 6N4M 7805 6N4M 6164 250 400 1800 1450 1200 6N4M 7806 6N4M 6166 252 365 1800 1450 1200 6N4M 7807 6N4M 6213 418 365 430 1800 1450 1200 6N4D 7273 6N4D 6316 5234940 5235600 6N4M 7808 6N4M 6161 247 400 2100 425 1800 1450 1200 6N4M 7809 6N4M 6165 251 365 2100 1450 1200 6N4M 7810 6N4M 6202 373 365 400 2100 1450 1200 Table 2 1991 1993 Series 60 DDEC II to DDEC IV Conv
3. DETROIT DIESEL Installation Instructions S 18SP546 Install DDEC II to DDEC IV Wire Harness and Hardware Conversion Kit on 1991 1993 Series 60 On Highway Manual Transmission Trucks Revision 12 14 04 Introduction Service kit R23529490 permits conversion of a Detroit Diesel Series 60 DDEC II engine to a DDEC IV configuration The kit includes the items listed in Table 1 Kit Part Number R23519307 ECM 23512307 Isolator 23513558 Engine Harness 23517986 Power Harness Adaptor 23518358 Injector Harness Jake Brake 23520380 Coolant Level Sensor CLS 1 4 18 NPTF 23520381 Coolant Level Sensor CLS 3 8 18 NPTF 23518206 Adaptor Module Coolant Level Sensor 23518359 Harness Asm Coolant Level Sensor Jumper Liner 23515251 Coolant Temperature Sensor CTS in brass 23519124 Heat Shield Exh Manifold 23509744 Stud Bolt M10 1 5x120 11506101 Nut M10 23515250 Air Temperature Sensor ATS 23517875 Intake Manifold Gasket 18SP546 Installation Instructions 6SE483 and the DDEC III IV SECM Troubleshooting Guide 6SE497 for instructions on removing installing and testing the other parts required for kit installation DDEC II ECM Removal Remove the ECM as follows WARNING PERSONAL INJURY To avoid injury from hot surfaces wear protective gloves or
4. ENABLE O ON SWITCH RELEASED OFF A DEPRESSED ON CLUTCH SWITCH BRAKE SWITCH 44735 Figure 4 Cruise Control Wiring Schematic after Modification Testing of Cruise Control Switch and Wiring To speed up the testing of cruise control switches quick check tables have been developed These tests are to be run with the ignition ON and the engine not running A DDR DDDL must be plugged into the connector All three quick check tables must be completed to properly check the cruise control wiring and switches See Tables 3 4 and 5 NOTE When all tests pass the unit is ready for road testing A CAUTION LOSS OF VEHICLE CONTROL To avoid injury from the loss of vehicle control do Not use cruise control under these conditions e When it is not possible to keep the vehicle at a constant speed on winding roads in heavy traffic in traffic that varies in speed etc e Onslippery roads wet pavement ice or snow covered roads loose gravel etc 18SP546 Rev Page 5 of 8 Cruise ad Enable SEE to Sec 10 7 of DDEC HIV SECM TS Manual Cruise Refer to Sec 10 7 of DDEC Enable Se SECM TS Manual Table 3 Cruise Control Quick Check Table Testing Cruise Enable Switch and a Cruise Enable Brake Clutch DDR DDDL DDR DDDL Okay Go To Switch Pedal Pedal Readout EET Service Yes eS to Sec 10 7 of Released Released Brake Off No DDEC III
5. IV SECM Release TS Manual Service Refer to Sec 10 7 of 2 On Depressed Released Brake On No PREC SECM Release TS Manual of Yes _ Clutch Refer to Sec 10 7 of 3 On Released Released Release DDEC III IV SECM TS Manual Refer to Sec 10 7 of Clutch DDEC III IV SECM 4 On Released Depressed Release TS Manual Table 4 Cruise Control Quick Check Table Testing Brake and Clutch Switch and Wiring Cruise Enable Res DoRDDDL ppRIDDDL Okay Switch Coast Accel Readout Displa Go To Switch Switch play 1 On off orf Serenas PE No Refer to Sec 10 7 of DDEC TIVIV SECM TS Manual Refer to Sec 10 7 of DDEC III IV 2 On On Grr Rees SECM TS Manual P Ont Yes oC CST Off Cruise Enable Ct Res ppRIDDDL DDR DDDL Okay Coast Accel Go To Switch Readout Display Switch Switch Refer to Sec 10 7 of DDEC III IV SECM TS Manual Oof Yes On No Off No Refer to Sec 10 7 of DDEC III IV 4 On Off On Res Accel SECM TS Manual E On 2 ves li a Table 5 Cruise Control Quick Check Table Testing Set Coast and Resume Accel Switches and Wiring 18SP546 Rev Page 6 of 8 FACSIMILE COVER SHEET To Customer Support Center Company Detroit Diesel Corporation Phone 313 592 5800 FAX 313 592 5888 From Company Phone FAX Date We have scheduled or completed the conversion of a Series 60 engine from DDEC I to DDEC IV We require a Powernet Entry Change for the engine serial number listed belo
6. allow engine to cool before removing any component WARNING PERSONAL INJURY To avoid injury from accidental startup while servicing the engine disconnect the starting system 1 With the engine at ambient temperature cool to the touch and the starting system disconnected disabled disconnect the power harness from vehicle batteries 2 Loosen the wire harness connector hold down screws and gently disengage the connectors from ECM sockets Table 1 DDEC II to DDEC IV Conversion Kit P N 23529490 3 Remove the DDEC Il injector and engine sensor harness from the engine Following are instructions for installing the parts in the kit Refer to the current Series 60 Service Manual 18SP546 Rev Page 1 of 8 4 Loosen the wire harness connector hold down screws gently disengage connectors and remove DDEC II ECM from vehicle DDEC IV ECM Installation Conversion kit components are listed in Table 1 Refer to the Series 60 Service Manual and install parts as follows 1 Install the Engine Sensor Harness P N 23513558 included in the kit See Figure 1 Refer to Section 8 6 of Service Manual 2 Install the Injector Jake Brake harness P N 23518358 included in the kit 3 Install new Coolant Level Sensor CLS either P N 23520380 or 3 8 P N 23520381 Refer to Section 2 34 of Service Manual 4 Install the CLS adaptor module P N 23518206 and jumper adaptor P N 23518359 5 Install t
7. ersion On Highway Trucks with Manual Transmissions 18SP546 Rev Page 4 of 8 DDEC II to DDEC IV Conversion Cruise Control Switch Wiring Modifications Figure 3 illustrates a typical DDEC II cruise control wiring schematic Wiring modifications to the Cruise Enable Switch and the Set Coast Switch are required whenever a DDEC II to DDEC IV conversion is made on a vehicle using the DDEC II cruise control feature WIRE NO 542 SETICOAST 541 SWITCH RESUME ACCEL SWITCH CRUISE ENABLE SWITCH RELEASED A DEPRESSED A ON CLUTCH SWITCH BRAKE SWITCH 44734 Figure 3 Typical DDEC II Cruise Control Wiring Schematic Remove the wire identified as DDEC circuit 542 from the Set Coast Switch At a convenient point splice circuit 542 into the cruise control switched ground circuit Cruise control switched ground is the circuit that is open when the Cruise Enable Switch is turned OFF and grounded when the Cruise Enable Switch is turned ON If necessary use a volt ohm meter to verify the circuit before splicing in circuit 542 Depending on the application the switched ground circuit may be identified as DDEC circuit 558 or a branch of DDEC battery ground such as circuit 953A 953B or 953C etc See Figure 4 WIRE NO SETICOAST SWITCH OFF RESUME ACCEL ts ON SWITCH n CRUISE
8. ese two features to operate properly For example there is only one DDEC IV rating released for the 11 liter engines 6N4D7275 is a 400 357 1800 2100 1350 Ib ft To reduce the maximum torque from 1350 to 1250 Ib ft e Set the low gear torque limit to 1250 e Set the threshold to 0 1 To reduce the maximum rated speed from 2100 to 1800 rpm set progressive shift as follows e LG1 rpm limit 1800 e LG1 max rpm 1800 e LG1 max mph 12 e LG2 rpm limit 1800 e LG2 max rpm 1800 e LG2 max mph 44 e HG max rph 1800 e HG min mph 45 DDEC II to DDEC IV UPC groups are listed in Table 2 To ensure that the engine is serviced properly after being converted from DDEC II to DDEC IV and to ensure that other modifications may be made DDC s unit history file must be updated If this is not done subsequent engine service and or repair work might be done using incorrect parts Complete the attached FAX form and send it to the DDC Customer Support Center See Figure 5 18SP546 Rev Page 3 of 8 DDEC IV DDEC I III CWC Rated RPM Other RPM FT LB RPM Inj P N Inj P N HP HP 6N4D 7275 6N4D 6309 5234935 5235605 N A 6N4M 6149 235 350 1800 1250 1200 N A 6N4M 6153 239 320 1800 1250 1200 N A 6N4M 6167 354 320 350 1800 1250 1200 6N4D 7275 6N4D 6310 52349
9. he Coolant Temperature Sensor CTS P N 23515251 at right rear of head Refer to Section 2 31 of Service Manual 6 Install the heat shield P N 23519124 using stud bolts P N 23509744 and nuts P N 11506101 a Ifthe engine has current exhaust manifold install heat shield as is b Ifthe engine has former style manifold the heat shield may need to be altered prior to installation 7 Remove the air intake manifold and discard old gaskets 8 Using a drill press and a 9 16 drill drill and tap a 3 8 pipe port for the Air Temperature Sensor ATS between 3 and 4 intake air ports in manifold See Figure 2 9 Clean the air intake manifold thoroughly to remove drill chaff 10 Install ATS P N 23515250 Torque to 11 16 N m 8 12 Ib ft 11 Using new gaskets P N 23517875 install the air intake manifold WARNING PERSONAL INJURY Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm e Always start and operate an engine in a well ventilated area e If operating an engine in an enclosed area vent the exhaust to the outside e Do not modify or tamper with the exhaust system or emission control system 12 Reconnect starting power Start the engine and check for proper DDEC system operation INJECTOR HARNESS ASSEMBLY 24518458 POWER HARNESS ASSEMBLY Sa SA wre
10. w to enable reprogramming of the DDEC IV remanufactured ECM Serial Number Model Number Requested Rating Figure 5 18SP546 Rev Page 7 of 8 DETROIT DIESEL 13400 Outer Drive West Detroit Michigan 48239 4001 Telephone 313 592 5000 www detroitdiesel com Copyright 2004 Detroit Diesel Corporation Detroit Diesel DDC Series 60 and the spinning arrows design are registered trademarks of Detroit Diesel Corporation All other trademarks are the property of their respective owners 18SP546 Rev 0412 As technical advances continue specifications will change All rights reserved Printed in U S A 18SP546 Rev Page 8 of 8
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18SP546Rev