DDEGII

APPLICATION& INSTALLATIONMANUAL

SECTION
1. INTRODUCTION
A. Overview A-1
B. OE MR e q u i re me n ts......,.,,... B-1
C. SystemFeatures,... u-l

BASICINSTALLATION REQU¡R EMENTS

Assembly
Harness
A. VehicleInterface A-1
B. PowerSupply B-1
C. PowerHarne'ss Assembly.. C-1
D, ThrottleControls D-1
E. Coolant LevelSensor........,.,.... E-1
F. Tachometer Drive F-1

PROGRAMMING FEATURES

r) Engine
A. Factory Programming..............
B. EngindProlection
System......
A-1
B-1

SpeedGovernor...
D. Limi-ting D-1
E. VariableSpeedGovernor E-1
F. PWMPOrtb .. F.1

SYSTEMOPTIONS
A. CruiseControl....... A-1
B. RoadSpeedGoverning. B-1
& Retardér
C. Engine'Brake Controls .. C-1
D. PrósureGovernor System
TorqueOpt-¡on
E. Alternate E-1
F. PowerControi F-1

5. SPECIALIZED ENGINECONFIGURATIONS
A. 12l16CylinderEngines..... A-1
B. Alcohol'Fueledfn-gines B-1
Ó. -lzl SoftwareUpdate C-1

REFERENCE INFORMATION
Communications
A. Serial Link........... A-1
B. DiagnosticDataReader B-1
C. MiscellaneousWiringDiagrams.. c-1
D. Glossaryof Symbols.............., D-1
E. Glossaryof Terms E-1
Guidelines
F. Splicing F-1
t \ G-1
G. Connector Information.........."..
& Terminal
Bulletins.
H. Service& Information H-1
t-'l
Overview diagnostic checksar e m ade at igni ti on- on
and
continuethroughout all engineoperatingmodes.
DDECII The ECMilluminates a dashboardCheckEngine
Light(CEL)to alertthe operatorwhena fault is
DDECll (DetroitDieselElectronic Control)is an
detectedand storesa diagnostíccode in memory
advancedtechnologyelectronicfuel injectionand (includingintermittent
controlsystem. The systemoptimizescontrolof malfunctions lastinglonger
thantwoseconds).
criticalenginefunctions whichaffectfueleconomy,
smoke,and emissions.DDECofferssignificant The
operatingadvantagesover traditionalmechanically engine systemprovidesthe capabilityto protectthe
governed from seriousdamageresultingfromhigh
engines, enginetemperature, low oil pressure,low coolant
level,high crankcase pressure (Series149only)and
T h e m a j o r s u b s y s t e m so f D D E Ci n c l u d et h e powercontrol(optionalinput).The ECM
auxiliary
e l e c t r o n i cu ni t i n j e cto rs,th e E l e ctronic
Contr ol illuminates
Module(ECM),andenginesensors. a dashboard StopEngineLight(SEL)to
alertthe operatorof impendingenginemalfunction
Fuelis delivered and storesdiagnosticinformation in memoryfor
to the cylindersby the injectors futurerecall. An optional,
timed
whichare cam-driven to providethe mechanical featur eis availableto pr ovideeng i neshutdown
engine
inputfor pressurization of the fuel. precisefuel protection. dam age
deliveryis controlledby solenoidoperatedvalves.
The controlmodulecomputesthe fueltimingand Portable
equipment facilitates accessto DDECll's
/ ¡ quantityand actuatesthe solenoids,The module diagnostic capabilities.The Diagnostic DataReader
a d j u s t sf u e l d e l i ve ryto th e e n g i n eb asedupon (DDR)requests
and receives engine
tablesand inputsignals c o d e s , T h i se q u i p m e npt r o v i d e sm a nand
predetermined calibration data fault
fromthe sensors. yu n ique
capabilities including cylindercutout,parameter vs.
RPM (or time),printeroutput,and data snapshot.
The ECMcontinuously performsselfchecksand Industry
monitors standardserialdata linksprovidethe two
the othersystemcomponents, including way communications for the diagnostic
the injectorsolenoids, equipment,
sensors, and wiring.System vehicledisplays, andothervehiclesystems.

A-1 Sectlon1
,-

OEM Requirements
Minimum to installa Detroit
OEMsuppliedhardware
(DDEC)
Control
DieselElectronic systemincludes
thefollowing:
. Vehicle Assembly
Harness o CHECKENGINELight(CEL)
Interface mountedyellowindicatorlamp.
panel
Wiringfromthe controlstationto the engine A
mounled Module
Control
Electronic (ECM).
. STOPENGINE (SEL)
Light
. PowerHarness Assembly A mountedred indicatorlamp.
panel
Batterypower(12volts)and groundto the ECM o
fusesor circuitbreakers.
including ThrottleInput
Electronió Foot PedalAssembly(EFPA),Hand
o lgnition Throttle, throttledevice.
or alternate
Switch
Switched sense.
12or24voltignition o Coolant (CLS)
LevelSensor
A radiatortop tank remotesurgetankmounted
or
sensor.

/ \

B-1 Section1
f-l

System Features Twelveand sixteencylinderenginesoperatewith

two ECMs,One ECMis calledthe master,whilethe
Detroit Diesel Electronic Gontrol (DDECI otheris refenedto as the receiver.ThemasterECM
is the primarycontrollerof the engine.lt receives
The DDECsystemconsistsof the Electronic Control inputfromthe varioussensors,then determines
Module(ECM),the Electronic UnitInjectors (EUls), propertimingand communicates this information to
systemsensors,and interfaces,The ECMis the the sixor eightinjectorsit controls.ThemasterECM
"brain"of the systemreceiving
electronicinputsfrom sendsthis information to the receiverECMso it can
the operator,engine,and vehicle, Fuelis delivered instructits six or eight injectorsto operatein the
to thecylinders by theEUls. samemanner.Redundant capabilityexistto enable
independent operation of eachhalfof the enginein
t h e u n l i k e l ye v e n t t h a t t h e m a s t e r / r e c e i v e r
Hardware Description communication fails.
Electronic Gontrol Module (ECMI TheECMcontainsa backupmicroprocessor thattakes
I TheenginemountedECMincludescontrollogicto over contr ol in the unlikelyevent that the m ai n
provideoverallenginemanagement.The ECM microprocessor systemexperiencesa malfunction.
containsan Electronically ErasableProgrammable Thisfeatureallowsthe engineto remainrunning
R e a dO n l y M e m o r y ( E E P R O M )T. h e E E P R O M althoughnotall operating functionswouldbe available.
controlsthe basicenginefunctionssuchas rated Engine operation in backupmodeis signaledby the
speedand power, timingof fuel injection, engine illumination
of the Check Engine Light(CEL).
(-¡ governing, torqueshaping,coldstartlogic,transient
fuelcontrol,diagnostics, and engineprotection.The Electronic Unit lnjectors lEUll
c o n t r o l o g i cde te rmi n eds u ra ti o na n d tim ingof TheEUlsoperateon the samebasicprincipleas the
fueling,whichresultsin precisefuel deliveryand m e c h a n i c aul n i t i n j e c t o r sw h i c h h a v e b e e n
improved fueleconomy. incorporated in DetroitDieselenginesfor over fifty
years. The EUIutilizesa solenoidoperatedvalveto
controlinjection timingand metering.Thesourcefor
high pressure fuel deliveryis the cam/rockerarm
system.Fuelinjectionbeginswhenthe solenoid
valveis closed. Openingthe solenoidvalveends
injection.The durationof valveclosuredetermines
thequantityof fuelinjected.

= = -

l-i
qlq*
Sectlon1
( r

DDECEngine Sensorc
DDECsensorsprovideinformation to the ECM
regardingvariousengineandvehicleperformance
characteristics.
Theinformation
sentto the ECMis
usedto regulateengineandvehicleperformance,
providediagnosticinformation,
and activatethe
engineprotection
system,DDECsensors include:
TimingandSynchronous
Reference
Sensors
(rRs,sRs)
-TRS indicates
crankposition
of everycylinder.
- SRSindicatesa specif
ic cylinderin thefiring
order.

6-71
SFS/IBSAssembly-
P/N:23502874
^

Series60
SRS- P/N:8929387
TRS- P/N: 8929388

Series149,12V-92,16VA2 ( ) ,
TRS- P/l{:23503011
6V-92,8V-92,12V-71 SRS- P/N:23503010
SBS/IBSAssembly- P/N:23503240
Sectlon1 c-2
;..
1l
t:r

Throttle Position Sensor {TPSI Fuel Temperature Sensor

- OEMsupplied. - Measuresfuel temperaturefor fuel consumption
- Convertsthe operator's
handthrottleand/orfoot andfuelinputcompensation.
calculation
pedalinputintoa signaltotheECM.

l^t
P/N:25036693

Fuel PressureSensor
Tl¡rbo Boost Sensor (TBSI - Construction
& lndustrial
EnginesOnly
- Monitorsfuelpressureto warnthe operator
of
- Pr o v i d e sd a ta to th e E C Mfo r u se in smoke impendingpowerloss.
control.
\i,¡,¡i;
. :,lti\r,

'.]

P/N:1607068 P/N:898184

c-3 Sectlon1
/-f

Goolant Level Sensor ÍCLSI Oil Pressure Sensor

- OEMsupplied. -Activates the engineprotectionfeatureif the oil
-Activates the engine protectionfeatureif the pressurefallsoutsidethe specifiedlimits.
coolantlevelis low.

i
Sensor-P/N:23503509
P/N:23503510 P/N:89A184
Module- P/N:23505264
Grankcase PressureSensor
(Series149 Onlyl
Engine Temperature Sensor -Activatesthe engineprotection
featureif the
- Coolant Temperature - Coaches/Motorhomes pressure
crankcase ishigh.
- O ¡ l T e m p e r a t u r- eO n - H i g h w a F y ,i r e t r u c k ,
Construction & Industrial
- P r o v i d e ss i g n atl o e n h a n c e i d l es p e e da n d
i n j e c t i o tni m i n gr e s u l t i n g i m p r o v ecdo l d
i n
startability andreduced whitesmoke,
-Activates the engineprotection featureif the
enginetemperature exceeds thespecified limits.

a'
P/l,l:25036693 P/l,l:23503842

Sectlon1 C4
Pressure Sensor {Firetrucks Onlyl - Performance Features
Optional
- Providesa fire pumppressuresignalto the ECM, Engine Governing
which modulates enginefuelingto maintaina DDECprovidesboth Limitingand VariableSpeed
pumppressure.
constant governingfeaturesidenticalin functionto that of
governed
mechanically DDCengines.

TheLimiting
SpeedGovernor(LSG)fuelstheengine
basedon the percentthrottlerequestedby the
operator.
The Var iableSpeedGover nor( VSG)hol dsthe
engineat a requestedconstantspeedregardless of
(withinengineoutputcapabilities).
loadfluctuation

Smoke Gontrol
Enginesteadystateand transientsmokeis limited
fuel deliveryas a functionof throttle
by controlling
positionandturboboostpressure.TheECMadjusts
the timingand quantityof fuel deliveryaccordingto
programlogicandrequires no maintenance.
P/N:23505962 Cold Starting
Vehicle Speed Sensor (VSSI - where Optimuminjectiontimingand fuel inputbasedon
applicable t e m p e r a t u r ep, r o v i d e su n a i d e ds t a r t s a t a n
approximate 1SoFlowerambientair temperature
- OEMsupplied. t h e n e q u i v a l e nm t e c h a n i c ael n g i n e s . S o m e
- Providesa vehiclespeedsignalfor usein cruise applications have an automaticincreasein idle
controlandroadspeedgoverning. speedand advancedinjectiontimingto achieve
rapidwhitesmokeclean-up. The idlespeedreturns
to pr ogr am m edvaluesas the engi ner eac hes
operating temperatures.

Engine Protection
DDECprovidesa warningof enginemalfunctions.
TheECMcontinually monitorsthe DDECsystemand
if a faultis detected, the CELor SELare illuminated.
The CELis illuminated if a minorfaultoccurs.This
indicatesthe problemshouldbe diagnosedas soon
as convenient and does not r equir ei m m edi ate
engineshutdown. TheSELis illuminated if a major
faultoccurs. This is an indication that the engine
shouldbe shutdownimmediately. Automaticengine
s h u t d o w ni s a n a v a i l a b l eo p t i o n .A s h u t d o w n
overrideswitchis providedto allowthe vehicleto be
m oved to a safe location dur ing autom ati c
shutdown.

c-5 Sectlon1
Data Link DDEC Tbst Module
A data link is providedto transmitsensor(s)and TheDDECTestModuleis a controlpanelfortesting
enginedata to othervehiclemodules,for example: DDECll engines.The panelfunctionsas a control
electronic dashboarddisplays,vehicle management consoleand allowsoperation of the engineon a test
information systems,and electronictransmissions. standor in a vehiclereplacingall OEMinterfaces.
The linkis used to transmitand performdiagnostic
proc e d u r e sw i t h e xte rn a il n stru me n tation.
The
c a t aR e a d e r(D D R )u se sth e linkto
Dia g n o s t i D
changecalibration valuesstoredin theEEPROM.

Engine Diagnostics
Anyfaultsthatoccurare storedas numerical codes
i n t h e E C M ' sm e m o r y . T h e s ec o d e s c a n b e
accessedin oneof threeways:

1. A DDRcanbe usedto readthecodes.

2, The CEL will flashout the codeswhentwo pins
areshortedin thediagnostic connector.
3. A microprocessor
connectedto thesystem.
Therearetwotypesof codes:
1. Active- A faultpresentat the time of the check.
The code is immediately storedas an historic
code. The aboveservicetoolsmay be purchasedfrom
2, Historic- Faultswhichhaveoccurredpreviously. Kent-Moore. PartNumbersarelistedbelow.

KentMoore
DDEC Service 29784LittleMack
Michigan48066-2299
Roseville,
Diagnostic Data Reader (DDRI (800)328-6657
The hand-heldDDRis used on DDECenginesto (313)558-7375(FAX)
displayenginedescription,diagnosticdata,error
DataReaderKit
c o d e s , a n d t o c h a n g e f e a t u r e so f t h e E C M Diagnostic P/N:J385ffi-A
calibration. A printoutof the information displayed - IncludesReader, Cable,CarryingCase,DDEC
canbe obtainedby attachinga printer, Manual,12PinAdapter
Cartridge,

DDECTestModule P/N:J386a0-A

ReplacementParts
Cable P/N:J38500-2
CarryingCase P/N:J38500-25
DDECCarIridgell2PinAdapter P/N:J38500-203
Manual P/N:J38500-10A
12PinAdapter P/N:J34812

Sectlon1 c-6
Vehicle lnterface Harness - Vehicle
SpeedSensor(VSS)
Assembly Circuits
556and557

T h eVe h i c l eI n te rfa ce H a rn e ss (V l H )connects all - DataLink

e x t e r n aD
l D ECa cce sso ri eto s th e E CM.These Circuits
900and901
include: ignition, governors, instrument panel,cruise
control,coolantlevelsensor,diagnostic connector, 2. CONNECTORS
a n d m i s c e l l a n e o uf es a t u r e sV. e h i c l eI n t e r f a c e
Harness schematic (SK-9744) is included at theend Connectors and terminalsmay be purchasedfrom
of thissection. DDC PartsDistributionCenter.Partnumbersare
listedbelow.
Design Guidelines
NOTE:Donotsolderterminal crimos.
T h ef o l l o w i n ag r e g u i d e l i n efso r d e s i g n i n tgh e
Vehiclelnterface Harness. ElectronicControlModule(ECM)Connector
1 .W I R E - ConnectorAssembly P/N:12034398
- Terminal
(FEMALE) P/N:12089289
a.TheVIHconnector is designedto accept18Ga. - CavityPlug P/N:12034413
(.80 mm2)standardwallcable.Largercable
wirewillpresentinstallation
problems. ElectronicFootPedalAssembly(EFPA)
Connector
b .T h e a c c ep ta b l eca b l ei n su l a ti o ns
ar e Teflon
(EFTE), cross-link polyethylene (XLPE)or any - ConnectorAssembly P / N :1 2 0 1 5 7 9 3
equivalent self-extinguishing insulation havinga - Terminal
(FEMALE) P/N:12089188
m i n i m u mr a t i n go f - 4 0 ' C t o 1 2 5 " C . A n - Seal P/N:12015323
equivalent insulation mustmeetthe acceptable
cablediameters 2.00- 2.42mm. CoolantLevelSensor(CLS)Connector
c. The conductormustbe annealedcoppernot - Connector Assembly P/N:1530@30
aluminum an d mu stco mp l yw i ththe industr y - Terminal (FEMALE) PIN:12077a11
standard SAEJ1128document. - Seal P/N:12015323
- SecondaryLock P/N:15300017
d. DetroitDieselCorporation (DDC)requiresboth
colorcodingand hot stamping wirenumbersin Diagnostic Connector
contrasting colorsat intervals of four inchesor
ICSS. - ConnectorAssembly P/N:12020043
- Terminal
(FEMALE) P/N:12034046
A v o i dr e n u m b e r i nDg D Cc i r c u i t ss i n c ea l l - Lock(2 Required) P/N:12020219
t r o u b l e s ho o ti nggu i d e sre fe re n cethe cir cuit
n u m b e r ss h o w ni n t h e s c h e m a t i cD. D C Crimptoolsmaybe purchased fromKent-Moore.
a p re fi xo r su ffixwiththe
s u g g e s t sin cl u d i n g
DDCcircuitnumbers whenconflicts exist. Kent-Moore
29784LittleMack
e.Twisting of thefollowing wirepairsa minimum of Michigan48066-2298
Roseville,
1 2 t u r n sp e r f o o t ( 3 0 5 m m )i,s r e q u i r e dt o (800)328-6657
minimize electromagnetic fieldcouplingeffects:

A-1 Sectlon2
ECMConnector Normaloperatingvoltagesare between7 and
- CrimpTool P /N :J35123 28voltsDC.

EFPAConnector b. lgnitionpowerm ustbe pr ovidedin r un and

- CrimpTool P/N:J35606 crankmodes.

CLSConnector 5. GOVERNORS
- CrimpTool P/N:J35606
governorsectionin this
Referto the appropriate
Diagnostic
Connector manual.
- CrimpTool P/N:J35688
PANEL
6. INSTRUMENT
3. SWITCHES
a .T h e C H E C KE N G I N EL I G H T( C E L )i s O E M
a .S w i t c h e sd r a w 1 0 m A e x c e p tt h e o p t i o n a l s u p p l i e da n d m u s tb e i n t e g r a t e idn t ot h e
interlock switchin theVariable SpeedGovernor instrument panel.Thelenscolormustbe yellow
(VSG)circuit510 and 525 whichdraws1SmA. andthewordsCHECKENGINE mustappearto
Specify500mAswitches forDDECinstallation. identify the display. A 12or 24 voll,5 wattlamp
is required, depending ontheignition source.
b. SwitchGround(Circuit953)mustonlybe used
t o p r o v i d eg r o u n df o r t h e f o l l o w i n gD D E C b . T h eS T O PE N G I N EL I G H T( S E L )i s O E M
features and mustbe sourceddirectlvfromthe s u p p l i e da n d m u s tb e i n t e g r a t e idn t ot h e
Battery - terminal: instrument panel.The lenscolormustbe red
and the wordsSTOPENGINEmustappearto
- StopEngineOverrideSwitch identify thedisplay.A 12or 24 volt,5wattlamp
- PowerControlSwitch is required, depending ontheignition source.
- CruiseControl
ON/OFF Switch
- Alternate
TorqueOptionSwitch c, Referto the EngineProtection
sectionof this
- DiagnosticConnector
Ground. manualforStopEngineOvenideswitch.

Thiscircuitcan not be usedto providegroundfor 7. CRUISE

CONTROL
nonDDECll OEMsuppliedelectronics.
Referto the Cr uiseContr oland Roa dSpeed
4.IGNITION Governingsectionsin thismanual.

a.The ignitionsensemay be either12 or 24 volI. 8. COOLANT LEVELSENSOR (CLS)

The ignitionsupplymustbe sourceddirectly
fromthe batterypostvia a 5 amp weatherproof Referto the CoolantLevelSensorsectionin this
bladetype fuse,circuitbreaker,or equivalent. manual.
F u s eh o l d e r sma y b e p u rch a se d
fro m DDC
PartsDistribution Center. Partnumbers arelisted 9. DIAGNOSTIC CONNECTOR
below.
sectioninthismanual.
Referto theDiagnostic
FuseHolder PIN:12033769
Cover P/N:12033731 10.MISCELLANEOUS
Terminals P/N:12066614
sectionin thismanual.
Referto theappropriate
12 or 24 volt(depending on ignitionsource),5
wattlampsmustbe usedforanylightdisplay.

Section2 A-2
lnstallation Guidelines Welding Precaution
Thefollowingconceptshaveprovento be effective Systempowerand groundand theVehiclelnterface
in installing theVlH. Harness priorto anywelding
mustbe disconnected
onthevehicle.
1.Provrde maximum physicalseparation of the VIH
fromothervehicleelectrical systems.Do not run The OEMmustapply precautionary
labelson the
"SERIOUS DAMAGE TOTHE
o t h e re l e c t r i c asl y s t e mc a b l e sw i t h i nc l o s e vehicleindicating,
proximity andparallelto theVlH. ECM(s)AND DDECCOMPONENTS RESULT MAY
FROMW ELDING IF THEPOW ER HAR N ESS AN D
2. Usethe following precautions wheninstalling the VEHICLE INTERFACE HARNESS ARE N OTD IS-
VIH: CONNECTED ATTHEECM.''

a. Do not routeharnessnearany vehiclemoving

parts.

b. Do not routethe harnessnearexhaustor anv

highheatsource.

c. Use a protectivesheathto preventwiresfrom

b e i n g c u t o r fra ye dw h e nw e a vi nghar ness
throughtheframe.

A-3 Sectlon2
VEHICLE
I N T E R F A CHEA R N E S S VEHICLEINTERFACE
HARNESS
CONNECTOR

ALL UNUSED
C A V IT I E S
R E O U I R EP L U G S JO fAY CONNECTOR
P/N 12034398
fERMINAL
P/N | 208928I

I-953 BA' Il- R\ GROú\D

= G O E ST O A 6 0 , C s I , F 4 2 ,
D32, G23, 823 ANDD r 3
t 2 3
LABEL WIRE CAVITY COLOR G O E ST O
E D E D l C A T E DI 2 , /
C O O L A N TL E V E L l | 5 H 3 LT BLU D32 I4USTBE SOURC
L I M I T I N G S P E E DG O V E R N O R 4 t l D 2 DK BLUI,/BLK H60 f ] R O I .B
4ATTERY
C H E C KE N G I N E L I G H T 419 B I PPLlWHT trs 1
I G N ITI O N 439 B 3 PNK I42,F5t,866
D I A G N O S T I CR E O U E S T 45 I E-t LT GREEN c23,E23
T A C H O M E I E R# I 505 K-l GRA,/WHT Gr3
ENGINE BRAKE,/RETARDER 508 A-l GRA Fr3
STOP ENG]NELIGHT 509 B-2 PPL G 5l
V A R ] A B L E S P E E DG O V E R N O R 5 l o D-l BRN c60
A L T E R N A T ET O R O U EO P T H-l GRA,/RED 860
P O W E RC O N T R O L 524 H 2 GRA,/BLK Dt3 S W II C H E D
I G N II I O N
STOP ENGINEOVERRIDE 528 G I BRN,/RED D 5l
ERAKE ,/ CLUTCH ON 53 1 ORN D42
SET / COAST ON 541 u - l YEL,/RED H42
SEI / COAST OFF 542 F-l YEL H42
B R A K E , / C L U T C HO F F 543 G-2 ORN,/BLK E42
R E S U M E / A C C EO L FF 544 F 2 BRN,/WHT G42
RESUME,/ ACCEL ON G-3 LT BLUE,/YEL G42 MUST PRO\
CRUISE ACTIVE 555 A-2 TAN I42
V E H I C L ES P E E D ( + ) 556 E-2 LT BLUE,/BLK c 4 2 , 4 4 2 If'l RUN Al
V E H I C L ES P E E D( ' ) 557 E-3 L T B L U E / O R N 842
D A T AL I N K ( + ) 900 D K G R E E N / Y E L E23
D A T AL I N K ( _ ) 90 1 c-l DK GREEN c-a DO NOT S(
VEHICLESPEEDOPENCOLLECTOR 9O3 F-3 L T B L U E / W H T 442 ACCESSOR
PWM # I OUTPUT 908 J-3 WHT Gt3
S E N S O RS U P P L Y ( s V D C ) 9t6 RED,/BLK F60, 160
SENSORRETURN 952 c-3 BLK F60,H60
K-3
TACHOMETER
NOT USED
#2
?!? D-3
TAN,/BLK Gr3
t20344 r 3 PLUG R E O U I R E D
NOT USED K-2 t2a344 I 3 PLUG R E O U I R E D
]NITION GOVERNOR

WI R E COLOR GOES
_TÓ-
g
9t6 RED/BLI'<
--.---7L H76 1 ^
4t1 DK BLU
--------_-?
H76 .. - L I M I T I N G S P E E DG O V E R N O R
ó ( T H R O T T L EP O S I T I O N S E N S O R )
952 BLK H76
>A

V D C B A T T E R YP O W E R
D] R E C T L Y
ST
9t6 RLD/BLK H76 --"----rL \ n
5 V A R I A B L E S P E E DG O V E R
( P O W E RT A K E _ O F FC O N T
BLK H-76

W T R F -C O T O R -E-
=ño- GOES

439 PNK D32

F5 I
H76

DE IGNITION POWER OPTIONAL

) C R A N KM O D E S . I N T E R L O C KS W I I C H ( E S )

J R C EA N Y N O N _ D D E C
F R 0 l . 4T H I S t I N E . 523 GRA/RED J-76
ALTERNATETOROUE
OPTION SWITCH
953 BLKIWHT H73
I N S I R U M T N TP A N I L -E
WIRE

439 t
^ÁÁ
.=--:Y---

rED GOVERNOR
]SITION SENSOR) -__94? ,
-E
,{IRE COLOR -E-
GOES
-_l4l )
509 PPL Hl6
STOP ENG]NELIGHT 544 t
RED
t,,1ñ |

4I9 PPL,/WHT H76

CI-]ECK
ENGINELIGHT
YELLO14
A R I A B L E S P E E DG O V E R N O R 439 PNK H]6
P O W E RT A K E _ O F FC O N T R O L , )

Á/ 7

53 1

528 BRN,/RED J]6

INAL S T O P E N G I N E O V E R R I D ES W I T C H
, L O C K S W I T C H( E S )
953 BLK,/WHT H73 ( MO[4ENTARY )

?NATE TOROUE
]N SWITCH
GOES CRUISECONTROT COOLANT
-E
I{IRE COLOR
E- D A S HP A N E L
439 PNK H-76 CRUISE
ENABLE
TAN H-76 LIGHT
GREEN
#B TERM
542 YEL J-76
SET/COAST
54 I YEL,/RED J-76 S}{ITCH

544 BRN/WHT J-76

RESUME/ACCEL
545 L T B L U / Y E LJ 7 6 SI{ITCH

CRUISE
953 BLKIWHT H73 ENABLE
SWlTCH

CLUTCH SWITCH WIRE

---ñ1ñ- C A VI T Y COLOR GOE
=
543 oRN,/BLK J76 I - RRLELLLEAAS
SLEU
D
I sn¡xr swrrcH 68 YEL G3
l B BLK H3
J-76 953 C BLK,/WHT HI
53 | ORN
| | 5 D LT BLU J]
E RED SW
VEHICLE SPEEDSENSOR

LT 8LU/BLK H76 REOUIREDFOR ROADSPEED

MAGNETIC GOVERNINGAND AUTOMATIC
PICKUP TRANSMISSlON,/CRUISE
557 LT BLU,/ORNH76 CONTROLAPPLICATION
NOTE.903 NOTUSED
OR
556 LT 8LU/BLK H76 ;r TO 0PEN
I coLLEcToR DEVTCE
903 LT BLU/}JHI J76 - JI A L L I S O N A T E C I
CIRCUIT 2O5
NOTE: 557 NOTUSED
C O O L A N TL E V E T S E N S O R D I A G N O S T I CC O N N I C T

#8 TERN4INAL

-;+El L L ) PROBE
P,/N 2 3 5 0 3 5 0 9 -
l,.lIRE CAVITY C O L O R -E-
GOES LABfL
-JTilT.LJ
I
P/N 2 J 5 0 3 5 t O -
3/8" NPT
t / 4 " NPT
E
953 BLK,/!{FT
#IO ILRM]NAL
B l'1 B A T T E R YG R O U

C
D
E
F
G
H Sll +12 VDC
900 J GRN,/YEL Árl SERIAL DATA
90 1 K GRN SERIAL DATA
-a¡yll_Y. coLoR -T0--
GOES 1,6_
M L T G R E E NH f 6 D I A G N O S T I CR
A YEL G30 I
B BLK H30 u
C BLK,/WHT H73 I
D LT BLU J/6 I
E RED Sl'l + l2 VDC u -E
WIRE COLOR GOES
E_
45 1 LT GREEN Hl6
CLS CONNECTOR CLS MODULE
P./N t5300030 P/N 23505264
COLORBLACK BLK,/WHT H73
TERMINAL
P / N 1 2 0 - / f4 t I
D I A G N O S T I CC O N N f C T C R M IS C E L L A N

D I A G I \ O SITC
CONNECTOR

WIRE CAVITY
NO.
-E-
C O L O R - GOES LABEL WI R E COLOR -E-
GOES
NO.
953 BLK/VIFT
B !'1 B A T T E R YG R O U N D 908 WHT Jf6

C 505 GRA,/WHT Jf 6
D
E 9-72 I AN,/BLK Jf 6
F
5O8 GRA H76
G
n SW+12 VDC
900 J GRN,/YEL irl SERIAL DATALINK (+}
K GRN SERIAL DATA LIN[< ( _)
L 1,6_
/ q I
M L T G R E E NH f 6 D I A G N O S T I CR E O U E S T

CONNECTOR
P/N | 2020043
COLORBLACK
TERMINAL 524 GRA/BLK J /6
P/N t2034046
-E
WIRE COLOR GOES
E- 953 BLK,/WHT H73
451 H-/6

D I A G N O S T I CR E O U E S TS h / I T C H
( MOI.4ENTARY )
M IS C E L L A N f O U S

Pf^/M# |
#I
TACHOMETER
#2
TACHOI'4ETER
TO ENGINE
BRAKE,/RETAF,DER
I N T E R F A C EC I R C U I T

P O W E RCOI.ITROL
S|,¿ITCH
953 BLK,/WHT H73
Power Supply VannerInc.
745HanisonDrive
to 24 volts
DDECoperateson 12 volts.Connection Columbus.Ohio43204
polarity
or reverse willcausedamage. (614)771-2718

The OEMmustapply"THEprecautionary labelson

Operating Voltages EQUALIZER MUST
indicating:
thevehicle
Normaloperatingvoltagesof DDECare 11 to 16 BE DISCONNECTED BEFORE W ELD IN ON
G
voltsDC,measuredat theECM. THEVEHICLE. ALW AYS DISCO N N ECTTH E
EQUALIZER GROUND TERMINALS FIRST TO
Operating t h e e n g i n eo v e r 1 6 v o l t so r r e v e r s e AVOIDREVERSE POLARITY DAMAGE WHEN
polarity
willcausedamage. DISCONNECTING BATTERIES OR W ELD IN G
ONTHE VEHICLE. RECONNECTTHE GROUND
O p e r a t i n gb e tw e e n7 a n d 1 1 vo l tsw i ll r esultin TERMINALS L A S T , A F T E R W ORK IS
improper operation. COMPLETE.''
Requirements for l2 Volt System b. SurePowerEqualizer
T h e b a t t e r y s i z e m u s t b e s u i t a b l ef o r t h e
amountof currentdraw.Referto thechartat theend SK-10477 showsthe correctwrringfor a Sure
PowerEqualizer installation. Thepowerharness
of thissection.
leadsmustbe connected BatteryA in the
to
Requirements for Systems Other Than l2 schematic. Neverpull 12 voltsdirectlyfromthe
12 volt post on the equalizer. Alwaysconnect
Volts
D D E Ca c r o s st h e b a t t e r y For additional
.
S o e c i a lc o n s i d e r a t i o nms u s t b e u t i l i z e df o r informationcontact Sure Power Industries.
installations wherevoltagesin excessof 12voltsare
used.Thefollowing arerequired on24voltsystems. SurePowerIndustries
10189 S.W.AverY
1.BatteryEqualizer - An equalizer is requiredina24 Tualatin,Oregon97062
volt(dual12 voltbattery)systemto insureproper (800)845-626e
chargingof thebatteries. Thisdevicemonitors the
TheOEMmustapply labelson the
precautionary
v o l t a g eo f b o th b a tte ri e sa n d ch a r gesthem "THEEQUALIZER M U STBE
appropriately. vehicleindicating:
D I S C O N N E C TB
EEDF O R W
E ELDING ONTHE
VEHICLEHE24VOLTIGNITION SWITCH MUST
DDECmustbe connectedto the batteryposts
neverto theequalizer. BEOFF' '
- shouldnot
DDCacknowledges twosources fortheequalizer: 2. BatteryConvertersBatteryconverters
b e u s e do n D D E Cp o w e r e de q u i p m e n tT. h e
following problemsmay be encountered whena
a. VannerEqualizer is used:
converter
SK-10475 showsthecorrectwiringfora Vanner
installation. Thepowerharnessleads r a y r e s u l ti n t h e
a . F a i l u r eo f t h e c o n v e r t e m
Equalizer
m u s t b e c o n n e c t e dt o B a t t e r yA i n t h e following:
schematic. Neverpull 12voltsdirectlyfromthe - totalpowerlossto the DDECsystemand
12 volt post on the equalizer. Always-connect
immediate engineshutdown
DDECacrossthe battery.Forfurtherinformation
contactVannerInc' - highvoltagemay be directlyappliedto the
ECMresulting in damage.

B-1 Section2
b. Electrical
noisecausedby the converter
may
interfere
withDDECoperation. ENGINE CONDMON CURRENT
Averaqe DC
c. A directconnection
to thebatterysourcecannot
be achieved. SingleECM lgnition
Off 10mA
SingleECM lgnition
On & 500mA
Battery lsolator EngineStopped
DualECM lgnition
Off 20 mA
S o m ea p p l i c a t i o n rse q u i r ea b a t t e r yt h a t i s DualECM lgnition
On& 1000mA
dedicatedto the engineand completelyisolated EngineStopped
f romt h e r e s to f th e ve h i cl e .S K -1 0 5 0 s1howsa
c i r c u i tt h a t c a n b e u s e d f o r t h i s r e q u i r e m e n t . 4-Cycle
Co m m e r c i a lal yva i l a b l eb a tte ryi so l a to rcans be
used. Series60 ldle 10A
Series60 1800RPM,FullLoad 3.2A
Welding Precaution Series60 2100RPM.FullLoad 3.5A
Systempowerand groundandtheVehicleInterface
Harness mustbe disconnected priorto anywelding 2-Cycle
onthevehicle.
6-Cylinder ldle 2 . 0A
The OEMmustapplyprecautionary labelson the 6-Cylinder 1500 RPM, FullLoad 5.1A
" S
v e h i c l ei n d i c a t i n g , E R I O U S
DAMAGE 6-Cylinder 1800 RPM. FullLoad 60A
TOTHE
ECM(s)AND DDECCOMPONENTS MAYRESUL| 6-Cylinder 1900 RPM, Full Load 6 1A
F R O MW E L D I NG IF T H EP OWE R H A R NESS AND 6-Cylinder 2100 RPM, Full Load 6.5A
V E H I C L EI N T E R F A C H E A R N E S SA R E N O T
DISCONNECTED ATTHEECM.'' 8-Cylinder ldle 2 . 7A
8-Cylinder 1500RPM,FullLoad 7.0A
Gurrent Draw 8-Cylinder 1800RPM,FullLoad 80A
8-Cylinder 1900RPM,FullLoad 8 1A
T h e f o l l o w i n gc ha rt sh o w sth e cu rre n tdr awfor 8-Cylinder 2100RPM,FullLoad 8.5A
different typesof engines.
12-Cylinder ldle 40A
12-Cylinder 1500RPM.FullLoad 10.2A
12-Cylinder 1800RPM.FullLoad 12.0A
12-Cylinder 1900RPM,FullLoad 12.2A
12-Cylinder 2 1 0 0R P M ,F u l lL o a d 1 3 . 0A

16-Cylinder ldle 54A

16-Cylinder 1500RPM,FullLoad 14.0A
16-Cylinder 1800RPM.FullLoad 16 0 A
16-Cylinder 1900RPM.FullLoad 16.2A
16-Cylinder2100RPM.FullLoad 17.OA

Section2 B-2
TYPICALWIRII{GDAGRAM
\ANNER BATTERYEOUALUER

BATTERY
EOUALI ZER
NOTE:ALWAYSDISCONNECTTHE
EOUALIZERGROUNDTERMINAL
FIRST TO AVOID REVERSE
POLARITY DAMAGEb/HEN
DISCONNECTING BATIERIES.
24V)C

I2VDC

+ +
B A T T E R YA B A T T E R YB
I2V DC I2V DC

t50 24A 241

S E E P O W E RH A R N E S S
A S S E M B L YS E C T I O N
FOR FURTHER
INFORMATION

N O T E : D D E CC I R C U I T S 1 5 0 , 2 4 0 &
24 I ARE TO BE CONNECTED
D I R E C T L YT O T E R M I N A L SO F D E T R O I TD I E S E L C O R P .
B A T T E R Y" A " A S S H O W N .N O
OTHER,CIRUITS ARE TO BE a v - |' A
.-,r\ t r -A
r . - -+ I7 7J
SOURCED F R O MT H E S EW ] R E S . L A T E SR
T E V .D A T E .2 J J N 9 I
D R A W I NDGA T E , 2 I J N 9 I
DRAWNBY, J .PINSONNEAULT

B-3 Section2
TYPICAL WlRll.lG DIAGRA¡u|
SURE POWERBATTERYEOUALUER

B AT T E R Y
EAUAL I ZER
24V
SVlITCHED
IGNITION
24VDC

I 2VDC

-t
+
B A T T E R YA E A T T E R YE
I2V DC I2V DC

r50 t50 240 241

'l
l'

S E E P O W E RH A R N E S S
ASSEMBLY SECTION
FOR FURTHER
INFORMATION

N O T E : D D E CC I R C U I T S 1 5 0 , 2 4 0 &
241 ARE TO BE CONNECTED
D I R E C T L YT O T E R M ] N A L SO F D E T R O I TD I E S E L C O R P .
B A T T E R Y' A ' A S S H O I I I NN . O /-\l,/ | t'\ A
-1 -7
O T H E R .C I R U I T S A R E T O B E ) n - l U 4 / t
SOURCED F R O MT H E S E| ' I I R E S . L A T E S TR E V . D A T E 2 I J N g I
D R A W I N GD A T E . 2 I J N g I
D R A V J NB Y . J P I N S O N N E A U L T

B-4 Section2
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B-5 Section2