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DDEC V APPLICATION AND INSTALLATION MANUAL3HARDWARE AND WIRINGSectionPage3.1SUPPLIED HARDWARE .3-33.2ELECTRONIC CONTROL UNIT .3-53.3ENGINE HARNESS .3-113.4VEHICLE INTERFACE HARNESS .3-153.5POWER SUPPLY .3-353.6FUSES .3-373.7CONNECTORS .3-393.8WIRES AND WIRING .3-553.9CONDUIT AND LOOM .3-813.10TAPE AND TAPING .3-833.11SENSORS .3-853.12THROTTLE DEVICES . 3-1173.13LIGHTS . 3-121All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION3-1

HARDWARE AND WIRINGTHIS PAGE INTENTIONALLY LEFT BLANK3-2All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

DDEC V APPLICATION AND INSTALLATION MANUAL3.1SUPPLIED HARDWAREOriginal Equipment Manufacturer (OEM) supplied hardware and DDC supplied hardware isrequired to install DDEC V. The following sections list the minimum hardware required.3.1.1OEM-SUPPLIED HARDWAREThe minimum OEM-supplied hardware required is listed in Table 3-1.HardwareDescriptionVehicle Interface Harness (VIH)(refer to section 3.4)Connector Shroud for VIH Connector(refer to section 3.2.1)Throttle Input Device(refer to section 3.12)Ignition Switch(refer to section 3.4.2)Amber Warning Lamp (AWL)(refer to section 3.13.1)Red Stop Lamp (RSL)(refer to section 3.13.2)Engine Coolant Level Sensor (ECL Sensor)(refer to section 3.11.20)Diagnostic Connector, Cab (DCC)(refer to section 3.7.3)Table 3-13.1.2Connects the vehicle functions and battery power (12/24volts) and ground to the ECU and includes fuse(s) or circuitbreaker(s). Also connects the ECU J1939 node to othervehicle systems.The shroud protects the connectors from dirt and directspray and routes the wires in the correct orientation.An Accelerator Pedal (AP) with an Idle Validation Switch(required), hand throttle, or alternative throttle deviceSwitched 12 or 24 volt ignition sourceA panel-mounted amber indicator light.A panel-mounted red indicator light.A radiator top tank- or remote surge tank-mounted sensorCab-mounted diagnostic connectorOEM-Supplied HardwareDDC-SUPPLIED HARDWAREThe minimum DDC-supplied hardware required is listed in Table 3-2.HardwareEngine Harness(refer to section 3.3)Electronic Control Unit (ECU)Refer to section 3.2.Engine SensorsRefer to section 3.11.1.Turbo Compressor In Temperature SensorRefer to section 3.11.23.Table 3-2DescriptionFactory installed harness that facilitates the receipt of input andoutput signals, controlling the fuel injection process and enginespeed. Harness is connected to DDC installed sensors, theinjection unit and the ECU(s).Engine mounted ECU provides control logic for overall enginemanagement.Various engine mounted sensors for engine control.Sensor to measure turbo compressor inlet temperature. MUSTbe installed by the OEM. Series 60 only.Minimum DDC-Supplied HardwareAll information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION3-3

HARDWARE AND WIRINGTHIS PAGE INTENTIONALLY LEFT BLANK3-4All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

DDEC V APPLICATION AND INSTALLATION MANUAL3.2ELECTRONIC CONTROL UNITThe engine-mounted Electronic Control Unit (ECU) (see Figure 3-1) includes control logic toprovide overall engine management. The ECU continuously performs self-diagnostic checksand monitors other system components. System diagnostic checks are made at ignition-on andcontinue throughout all engine-operating modes.Figure 3-1Electronic Control UnitThe DDEC V ECU has two 68-pin Tyco connectors - one for the engine and the other for thevehicle.All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION3-5

HARDWARE AND WIRINGDDEC V supports three independent data links. There are two links on the Vehicle InterfaceHarness (VIH). One link is based on SAE J1708, and the second is SAE J1939. The other link,on the Engine Harness, is CAN based and will be used for proprietary communications such asmulti-ECU applications and DDC factory programming.The following warning label is found on the ECU (see Figure 3-2).Figure 3-23-6ECU Warning LabelAll information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

DDEC V APPLICATION AND INSTALLATION MANUALConnector shrouds protect the two 68-pin Tyco connectors (see Figure 3-3).Figure 3-3Electronic Control Unit with Connector ShroudsThe shrouds are fastened to the ECU studs with lock nuts.See Figure 3-4 for the ECU outline and dimensions.The DDEC V ECU has the same footprint as DDEC II, III, and IV.Figure 3-4Dimensions of Electronic Control Unit with Connector ShroudsAll information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION3-7

HARDWARE AND WIRING3.2.1CONNECTOR SHROUDThe shroud is used to protect the connectors from dirt and direct spray and to route the wires inthe correct orientation. The shroud is designed for 25-30 mm conduit. The shroud is REQUIRED.Different views of the connector shroud may be seen in the next illustration (see Figure 3-5).Figure 3-5Electronic Control Unit Connector ShroudTwo lock nuts are required to attach the shroud to the ECU studs. The torque specification forthe lock nuts is 30 in.·lb (3.4 N·m).3-8All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

DDEC V APPLICATION AND INSTALLATION MANUAL3.2.2ECU PART NUMBERSPart number for the DDEC V ECU is listed in Table 3-3.DescriptionPart NumberVoltageNo. of CylindersDDEC V – ECU2353080212/24 Volts6Table 3-3ECU Part NumbersThe part numbers for the ECU connectors are listed in Table 3-4.DescriptionDDC Part NumberTyco Part NumberVehicle Interface HarnessConnector Assembly23528252776315-1Engine Harness Connector ud Lock Nuts(M6x1.0 Nylon Insert Lock NutPlated with Yellow Zinc)23533607—ECU 28255—23528254—2352827477636414 AWG Terminal (Large)(Terminal only)18 AWG Terminal (Standard)(Terminal only)14 AWG Terminal (Large)(crimped with 12 in. wire)18 AWG Terminal (Standard)(crimped with 12 in. wire)Cavity PlugTable 3-4ECU Connector Part NumbersAll information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION3-9

HARDWARE AND WIRING3.2.3ENVIRONMENTAL CONDITIONSThe following environmental conditions must be considered.TemperatureThe ambient operating temperature range is -40 F (-40 C) minimum and 221 F (105 C)maximum.Atmospheric PressureThe engine-mounted ECU can withstand atmospheric pressures ranging from 62.0 to 120 kPaabsolute that result from altitude and weather changes in the operating and non-operatingconditions.Water IntrusionThe ECU can be exposed to steam cleaning and pressure washing. Care should be taken not topressure spray the connectors.3-10All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

DDEC V APPLICATION AND INSTALLATION MANUAL3.3ENGINE HARNESSThe Engine Harness (EH) is installed at the factory and is delivered connected to all enginesensors, the fuel injection system and the ECU.3.3.1EH CONNECTOR AND TYPICAL REQUIRED FUNCTIONSThe EH 68-pin Tyco connector pinout for the Series 60 is listed in Table 3-5 and Table 3-6.PinWire ColorSignal TypeFunctionE-1BlkPWM Output – Low SideEGR Hydraulic ValveControlE-2WhtAnalog Input – 1.5k Pull-upAir TempE-3—Analog Input – 51k Pull-downSpareE-4BlkPWM Output – Low SideVGT VPOD ControlE-5YelAnalog Input – 1.5k Pull-upCoolant TempE-6—Analog Input – 51k Pull-downSpareE-7TanAnalog Input – 1.5k Pull-upOil TempE-8—PWM Output – Low SideSpareE-9OrnAnalog Input – 1.5k Pull-upFuel TempE-10—Analog Input – 1.5k Pull-upEGR TempE-11—PWM Output – Low SideSpareE-12GraSensor Supply #3Sensor SupplyE-13—Digital Output – Low SideSpareE-14BlkSensor Return #4Sensor ReturnE-15BlkSensor Return #3Sensor ReturnE-16YelAnalog Input – 51k Pull-downFuel Restriction (MAS)E-17PplTRS (CKP) (-)TRS (CKP) (-)E-18Dk GrnTRS (CKP) ( )TRS (CKP) ( )E-19Lt BluSRS (CMP) ( )SRS (CMP) ( )E-20WhtSRS (CMP) (-)SRS (CMP) (-)E-21Dk GrnAnalog Input – 51k Pull-downOil Level (MAS)Analog Input – 1.5k Pull-upTurbo Compressor OutTempE-22Dk BluE-23—Analog Input – 1.5k Pull-upSpareE-24—Analog Input – 51k Pull-downSpareE-25—Analog Input – 51k Pull-downSpareE-26GraSensor Supply #4Sensor SupplyE-27—Analog Input – 1.5k Pull-upSpareE-28—Ground PinSpareE-29—Ground PinSpareE-30—Ground PinSpareE-31BrnAnalog Input – 51k Pull-downOil PressureE-32—Frequency Input ( ) — Aux 3SpareTable 3-5ConnectorShroud Side of ConnectorSeries 60 Engine Harness Connector - Pins E-1 Through E-32All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION3-11

HARDWARE AND WIRINGPinWire ColorSignal TypeFunctionConnectorE-33—Frequency Input (-) – Aux3SpareE-34BrnFrequency Input (-) – Aux2Turbo Speed Sensor ( )E-35BlkFrequency Input ( ) – Aux2Turbo Speed Sensor (-)E-36—Analog Input – 1.5k Pull-upSpareE-37PnkAnalog Input – 51k Pull-downBarometric PressureE-38—Analog Input – 51k Pull-downEGR Delta PressureE-39Lt GrnAnalog Input – 51k Pull-downTurbo BoostE-40Dk BlueCAN2 ( )CAN2 ( )E-41—Analog Input – 51k Pull-downSpareE-42BkGround PinVGT VPOD GndE-43BkGround PinSpareE-44—Ground PinSpareE-45—Ground PinSpareSwitched Battery ( )– VGTE-46Lt GrnDigital Output – High SideE-47—Digital Output – High SideSpareE-48RedDigital Output – High SideJake Med/HighE-49OrnDigital Output – High SideJake LowE-50—Digital Output – High SideSpareE-51YelDigital Output – High SideSwitch Battery ( ) — EGRE-52RedDigital Output – High SideSpareE-53—Digital Output – High SideSpareE-54PnkCAN2 (-)CAN2 (-)E-55BlkCAN2SCAN2 ShieldE-56—Analog Input – 51k Pull-downSpareE-57—Analog Input – HWOLSNo ConnectionE-58—Analog Input – 1.5k Pull-upSpareE-59—RTC BATT External RTC Battery ( )E-60—Ground PinSpareE-61WhtInjector High CommonS60 Common Cyl #1,2,3E-62WhtInjector High CommonS60 Common Cyl #4,5, 6E-63WhtInjector A – LO1S60 Cylinder #1E-64WhtInjector A – LO2S60 Cylinder #3E-65WhtInjector A – LO3S60 Cylinder #2E-66WhtInjector B – LO1S60 Cylinder #5E-67WhtInjector B – LO2S60 Cylinder #6E-68WhtInjector B– LO3S60 Cylinder #4Table 3-63-12Shroud Side of ConnectorSeries 60 Engine Harness Connector - Pins E-33 Through E-68All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

DDEC V APPLICATION AND INSTALLATION MANUALThe EH 68-pin Tyco connector pinout for Series 60 non-road equipment is listed in Table 3-7and Table 3-8.PinWire ColorSignal TypeFunctionE-1—PWM Output – Low SideSpareE-2WhtAnalog Input – 1.5k Pull-upAir TempE-3—Analog Input – 51k Pull-downSpareE-4—PWM Output – Low SideSpareE-5YelAnalog Input – 1.5k Pull-upCoolant TempE-6—Analog Input – 51k Pull-downSpareE-7TanAnalog Input – 1.5k Pull-upOil TempE-8—PWM Output – Low SideSpareE-9OrnAnalog Input – 1.5k Pull-upFuel TempE-10—Analog Input – 1.5k Pull-upSpareE-11—PWM Output – Low SideSpareE-12GraSensor Supply #3Sensor SupplyE-13—Digital Output – Low SideSpareE-14BlkSensor Return #4Sensor ReturnE-15BlkSensor Return #3Sensor ReturnE-16YelAnalog Input – 51k Pull-downSpareE-17PplTRS (CKP) (-)TRS (CKP) (-)E-18Dk GrnTRS (CKP) ( )TRS (CKP) ( )E-19Lt BluSRS (CMP) ( )SRS (CMP) ( )E-20WhtSRS (CMP) (-)SRS (CMP) (-)E-21Dk GrnAnalog Input – 51k Pull-downSpareE-22—Analog Input – 1.5k Pull-upSpareE-23—Analog Input – 1.5k Pull-upSpareE-24—Analog Input – 51k Pull-downSpareE-25—Analog Input – 51k Pull-downSpareE-26GraSensor Supply #4Sensor SupplyE-27—Analog Input – 1.5k Pull-upSpareE-28—Ground PinSpareE-29—Ground PinSpareE-30—Ground PinSpareE-31BrnAnalog Input – 51k Pull-downOil PressureE-32—Frequency Input ( ) — Aux 3SpareTable 3-7ConnectorShroud Side of ConnectorSeries 60 Engine Harness Connector for Non-Road Equipment - PinsE-1 Through E-32All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION3-13

HARDWARE AND WIRINGPinWire ColorSignal TypeFunctionE-33—Frequency Input (-) – Aux3SpareE-34—Frequency Input (-) – Aux2SpareE-35—Frequency Input ( ) – Aux2SpareE-36—Analog Input – 1.5k Pull-upSpareE-37PnkAnalog Input – 51k Pull-downSpareConnectorE-38—Analog Input – 51k Pull-downSpareE-39Lt GrnAnalog Input – 51k Pull-downTurbo BoostE-40Dk BlueCAN2 ( )CAN2 ( )E-41—Analog Input – 51k Pull-downSpareE-42—Ground PinSpareE-43BkGround PinSpareE-44—Ground PinSpareE-45—Ground PinSpareE-46—Digital Output – High SideSpareE-47—Digital Output – High SideSpareE-48RedDigital Output – High SideJake Med/HighE-49OrnDigital Output – High SideJake LowE-50—Digital Output – High SideSpareE-51YelDigital Output – High SideSpareE-52RedDigital Output – High SideSpareE-53—Digital Output – High SideSpareE-54PnkCAN2 (-)CAN2 (-)E-55BlkCAN2SCAN2 ShieldE-56—Analog Input – 51k Pull-downSpareE-57—Analog Input – HWOLSNo ConnectionE-58—Analog Input – 1.5k Pull-upSpareE-59—RTC BATT External RTC Battery ( )E-60—Ground PinSpareE-61WhtInjector High CommonS60 Common Cyl #1,2,3E-62WhtInjector High CommonS60 Common Cyl #4,5, 6E-63WhtInjector A – LO1S60 Cylinder #1E-64WhtInjector A – LO2S60 Cylinder #3E-65WhtInjector A – LO3S60 Cylinder #2E-66WhtInjector B – LO1S60 Cylinder #5E-67WhtInjector B – LO2S60 Cylinder #6E-68WhtInjector B– LO3S60 Cylinder #4Table 3-83-14Shroud Side of ConnectorSeries 60 Engine Harness Connector for Non-Road Equipment PinsE-33 Through E-68All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

DDEC V APPLICATION AND INSTALLATION MANUAL3.4VEHICLE INTERFACE HARNESSThe OEM supplied Vehicle Interface Harness (VIH) connects the ECU to other vehicle systems asshown in the VIH illustration (see Figure 3-6). Refer to Appendix B for a harness schmatic.Figure 3-6Typical On-highway Vehicle Interface HarnessAll information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION3-15

HARDWARE AND WIRING3.4.1VIH CONNECTOR AND TYPICAL REQUIRED FUNCTIONSThe VIH 68-pin Tyco connector pinout for the Series 60 is listed in Table 3-9 and Table 3-10.PinWireColorSignal TypeFunctionReq/TypicalV-1Dk Grn/BlkDigital Output - Low SideAWLRequiredV-2Blk/YelDigital Output - Low SideRSLRequiredService BrakeReleasedRequiredV-3Wht/Dk GrnAnalog Input - 1.5k Pull-upV-4Blk/Lt BluDigital Output - Low SideFan Control #1Typical: FanV-5Blk/Lt grnDigital Output - Low SideTop2 Shift SolenoidTypical: Top2V-6Blk/OrnDigital Output - Low SideTop2 LockoutSolenoidTypical: Top2V-7Blk/WhtDigital Output - Low SideVehicle Power ShtdnTypicalV-8Wht/OrnAnalog Input - 1.5k Pull-upResume/AccelTypical: CCV-9Ppl/WhtAnalog Input - 1.5k Pull-upCruise EnableTypical: CCV-10Lt Grn/WhtAnalog Input - 1.5k Pull-upClutch ReleasedTypical: CCV-11Yel/RedSensor Supply #1Sensor Supply #1RequiredV-12Wht/ RedSensor Supply #2Sensor Supply #2RequiredV-13Lt Blu/YelAnalog Input - 300k Pull-downThrottle PositionRequiredV-14Ppl/YelAnalog Input - 300k Pull-downVSG or No Red/WhtAnalog Input - 1.5k Pull-upIdle ValidationRequiredV-17Lt Blu/ OrnFrequency Input ( ) VSSVehicle Speed ( )RequiredV-18Lt Blu/ BlkFrequency Input (-) VSSVehicle Speed (-)RequiredV-19—No ConnectionNo ConnectionNo ConnV-20—No ConnectionNo ConnectionNo ConnV-21—No ConnectionNo ConnectionNo ConnV-22Yel/Lt BluAnalog Input – 51k Pull-downAir Filter RestrictionTypical: MASV-23Yel/Dk GrnAnalog Input - 1.5k Pull-upExhaust Temp(Bus/Coach)TypicalV-24Dk Grn/WhtAnalog Input - 1.5k Pull-upSEO/Diag RequestRequiredV-25Grey/WhtAnalog Input - 1.5k Pull-upA/C StatusTypical: FanEngine BrakeDisableTurbo CompressorIn TempV-26Yel/Lt GrnAnalog Input - 1.5k Pull-upV-27Yel/WhtAnalog Input - 1.5k Pull-upV-28—No ConnectionNo ConnectionNo ConnTypicalRequiredV-29Wht/YelAnalog Input – 51k Pull-downV-30—No ConnectionNo ConnectionNo ConnV-31TanFrequency OutputTachometerTypical3-16Shroud Side ofConnectorTypicalExhaust Back Pressor Water Pump Pressor Air CompressorPressTable 3-9ConnectorSeries 60 VIH Connector On-highway Trucks – Pins V-1 – V-31All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION

DDEC V APPLICATION AND INSTALLATION MANUALPinWire ColorSignal TypeFunctionReq/TypicalV-32Dk Blu/OrnFrequency Input ( ) Aux 1Spare—V-33Dk Blu/BlkFrequency Input (-) Aux 1Spare—V-34—No ConnectionNo ConnectionNo ConnV-35—No ConnectionNo ConnectionNo ConnV-36—No ConnectionNo ConnectionNo ConnV-37Orn/YelAnalog Input – 120k Pull-upAdd Coolant LevelTypical: MASV-38Lt Gr/YelAnalog Input – 120k Pull-upCoolant LevelShtdnReqV-39Lt Blu/WhtAnalog Input – 1.5k Pull-upEngine Brake LowTypical: JakeV-40Orn/BlkDigital Output – Low SideOI AlarmTypical: OIV-41Dk Grn/YelAnalog Input – 1.5k Pull-upAux Shtdn #1—V-42Grey/YelAnalog Input – 1.5k Pull-upOI ThermostatTypical: OIV-43Dk Blu/RedJ1939 J1939 ReqV-44Dk Blu/YelJ1939SJ1939 ShieldRequiredV-45—No ConnectionNo ConnectionNo ConnV-46Dk Grn/BrnPWM Output - Low SideVariable Speed Fan—V-47Wht/Lt BluAnalog Input - 1.5k Pull-upSet/CoastTypical; CCV-48Tan/ YelAnalog Input - 1.5k Pull-upThrottle InhibitTypicalTypicalV-49Pink/WhtAnalog Input - 1.5k Pull-upFan ControlOverrideV-50Tan/ WhtAnalog Input - 1.5k Pull-upPark BrakeTypicalV-51Dk Blu/WhtAnalog Input - 1.5k Pull-upEngine BrakeMediumTypical: JakeV-52Dk Grn/OrnPWM Output Low SideTrans % Load—V-53Blk/RedDigital Output - Low SideEther Start—V-54Blk/PnkDigital Output - Low SideOI StarterTypical: OIV-55Lt Grn/BlkDigital Output - Low SideOI Active LampTypical: OIV-56Dk Grn/ GreyJ1587 ( )J1587 ( )RequiredV-57Dk GrnJ1587(-)J1587 (-)RequiredV-58Dk BluJ1939 (-)J1939 (-)RequiredV-59Dk BluSensor Return #2Sensor ReturnRequiredV-60Yel/ BlkSensor Return #1Sensor ReturnRequiredV-61Red/BlkBattery ( ) 12V / 24VRequiredV-62Red/ Lt BluBattery ( ) 12V / 24VRequiredV-63Brn/BlkBattery (-)GroundRequiredV-64Brn/ Lt GrnBattery (-)GroundRequiredV-65Red/ Lt GrnBattery ( ) 12V / 24VRequiredV-66Red/ PnkBattery ( ) 12V / 24VRequiredV-67Brn/WhtBattery (-)GroundRequiredV-68Brn/YelBattery (-)GroundRequiredTable 3-10ConnectorShroud Side of ConnectorSeries 60 VIH Connector On-highway Trucks – Pins V-32 – V-68All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION3-17

HARDWARE AND WIRINGThe VIH 68–pin Tyco connector pinout for Series 60 Bus/Coach applications is listed in Table3-11 and Table 3-12.PinWireColorSignal TypeFunctionReq/TypicalV-1Dk Grn/BlkDigital Output - Low SideAWLRequiredV-2Blk/YelDigital Output - Low SideRSLRequiredRequiredV-3Wht/Dk GrnAnalog Input - 1.5k Pull-upService BrakeReleasedV-4Blk/Lt BluDigital Output - Low SideFan Control #1Typical: FanV-5Blk/Lt grnD

DDEC V APPLICATION AND INSTALLATION MANUAL 3.3 ENGINE HARNESS The Engine Harness (EH) is installed at the factory and is delivered connected to all engine sensors, the fuel injection system and the ECU. 3.3.1 EH CONNECTOR AND TYPICAL REQUIRED FUNCTIONS The EH 68-pin Tyco connector pinout for the Series 60 is listed in Table 3-5 and Table 3-6.

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