Operation and maintenance manual

Section 110-0030
Engine - Engine and Mounting
SM 2121 Rev 1 11-03
2
210-0000, COOLING SYSTEM.
There are two spin-on type fuel filters mounted on the
left hand side of engine (1). Primary fuel filter (4) is in
the fuel flow and acts as a strainer and secondary fuel
filter (5) filters the fuel after having passed through
primary fuel filter (4). The word 'Primary' or 'Secondary
is cast into the top of the respective adaptor to prevent
mismatching.
DETROIT DIESEL ELECTRONIC
CONTROL (DDEC)
Description
Refer to Fig. 2.
WARNING
Before any welding is done on a machine
equipped with the DDEC system, disconnect
the following in this order:
Battery earth cable, battery supply cable,
alternator earth cables, alternator supply
cables, body hydraulics joystick, transmission
(Est-37) connector, ECM interface harness
connector (30 pin RHS), ECM sensor harness
connector (30 pin LHS) and ECM engine to
transmission datalink connector (6 pin RHS).
Turn off battery master switch before
disconnecting any components.
After welding connect all of the above in the
reverse order.
The engine is equipped with DDEC which controls the
timing and amount of fuel injection by the electronic
unit injectors (EUI). The system also monitors
several engine functions using electrical sensors
which send electrical signals to the electronic control
module (ECM). The ECM then computes the
incoming data and determines the correct fuel output
and timing for optimum power, fuel economy and
emissions.
The DDEC system also takes action to prevent
damage to the engine and, provides the serviceman
with diagnostic capabilities so that problems can be
corrected quickly and easily.
1. Electronic Control Module (ECM) - Receives
electronic inputs from the driver as well as from
mounted sensors that provide information
electronically, such as oil pressure and temperature
and intake manifold pressure. This information is used
to control both the quantity of fuel injected and injection
timing.
2. Programmable Read Only Memory (PROM) -
Located in the ECM and encoded with the operating
software. Additional information is programmed into
the EEPROM. This information controls the
horsepower rating, torque curve, maximum engine
speed and engine protection devices. The ECM
processes this information and sends electronic
signals to the Electronic Unit Injectors (EUI) where the
precise amount of fuel is injected into the engine.
3. Electronic Unit Injectors (EUI) - The EUI is a
lightweight, compact unit that injects diesel fuel directly
into the combustion chamber. The amount of fuel
injected and the beginning of injection timing is
determined by the ECM. The ECM sends a command
pulse which activates the injector solenoid.
The EUI performs four functions:
a - Creates the high fuel pressure required for efficient
injection.
b - Meters and injects the exact amount of fuel
required to handle the load.
c - Atomizes the fuel for mixing with the air in the
combustion chamber.
d - Permits continuous fuel flow for component cooling.
Electronic unit injectors are self compensating and
virtually eliminate engine tune-ups.
Note: Never apply 12 V directly to terminals on the
injector or engine sensors as they will burn out. Before
removing injectors, the fuel passages must be blown
out to prevent fuel flow from entering the cylinder
head.
4. Batteries - Two 12 volt maintenance free batteries
supply the machine with electrical power to operate all
electrical components.
5. Electronic Foot Pedal - The electronic foot pedal
provides an electrical signal to the engine's fuel control
system in proportion to the degree of pedal actuation.
Note: The DDEC controlled engine will override the
electronic foot pedal position until the engine is warmed
up to the correct operating temperature. The engine
MUST be started with foot 'OFF' the electronic foot
pedal.
6. Check Engine Light - When the 'Check Engine' light
comes on, the computer has detected a fault in the