Section 17.4
Wires and Wiring

‪

Detroit Diesel Corporation recommends color coding and hot stamping wire numbers in contrasting colors at intervals of four inches or less.‪

Section 17.4.1
General Requirements

‪

Note: Avoid renumbering DDC circuits since all troubleshooting guides reference the circuit numbers shown in the schematic. DDC suggests including a prefix or suffix with the DDC circuit numbers when conflicts exist.

Section 17.4.2
General Wire

All wires used in conjunction with DDEC VI must meet the following criteria:‪

• Tape, conduit, loom or a combination thereof must be used to protect the wires. Refer to "17.6 Tape and Taping" and refer to "17.5 Conduit and Loom" .
• All wires must be annealed copper wire (not aluminum).
• All wires must comply with SAE J1128.
• All wires must be insulated with cross-link polyethylene (XLPE) such as GXL, or any self-extinguishing insulation having a minimum rating of -40°C (-40°F) to 125°C (257°F).

Section 17.4.3
Crimp tools

The part numbers for the crimp tools for working with the MCM and CPC connectors are listed in Table "Crimp Tools" .‪

Section 17.4.4
Deutsch Terminal Installation And Removal

The method of terminal installation and removal varies. The following sections cover Deutsch terminal installation and removal.‪

Section 17.4.4.1
Deutsch Terminal Installation Guidelines

Deutsch connectors have cable seals molded into the connector. These connectors are push-to-seat connectors with cylindrical terminals. The diagnostic connector terminals are gold plated for clarity. ‪

The crimp tool to use in Deutsch terminal installation is J–34182 (Kent-Moore part number).‪

Use the following instructions for installing Deutsch terminals:‪

1. Strip approximately .25 inch (6 mm) of insulation from the cable.
2. Remove the lock clip, raise the wire gage selector, and rotate the knob to the number matching the gage wire that is being used.
3. Lower the selector and insert the lock clip.
4. Position the contact so that the crimp barrel is 1/32 of an inch above the four indenters. See Figure "Setting Wire Gage Selector and Positioning the Contact" . Crimp the cable.
   

   Figure 1. Setting Wire Gage Selector and Positioning the Contact

5. Grasp the contact approximately one inch behind the contact crimp barrel. Hold the connector with the rear grommet facing you. See Figure "Pushing Contact Into Grommet " .
   

   Figure 2. Pushing Contact Into Grommet

6. Push the contact into the grommet until a positive stop is felt. See Figure "Pushing Contact Into Grommet " . A slight tug will confirm that it is properly locked into place. See Figure "Locking Terminal Into Connector" .

Figure 3. Locking Terminal Into Connector

Section 17.4.4.2
Deutsch Terminal Removal

The appropriate size removal tool should be used when removing cables from connectors. The proper removal tools are listed in Table "Removal Tools for Deutsch Terminals" .‪

Remove Deutsch terminals as follows:‪

1. With the rear insert toward you, snap the appropriate size remover tool over the cable of contact to be removed. See Figure "Removal Tool Position" .
   

   Figure 4. Removal Tool Position

2. Slide the tool along the cable into the insert cavity until it engages and resistance is felt. Do not twist or insert tool at an angle. See Figure "Removal Tool Insertion" .
   

   Figure 5. Removal Tool Insertion

3. Pull contact cable assembly out of the connector. Keep reverse tension on the cable and forward tension on the tool.

Section 17.4.5
Splicing Guidelines

The following are guidelines which may be used for splices. The selection of crimpers and splice connectors is optional. Select a high quality crimper equivalent to the Kent-Moore tool, J–38706, and commercially available splice clips.‪

The recommended technique for splicing and repairing circuits (other than power and ignition circuits) is a clipped and soldered splice. Alternatively, any method that produces a high quality, tight (mechanically and electronically sound) splice with durable insulation is considered to be acceptable. ‪

Section 17.4.5.1
Clipped and Soldered Splicing Method

The tools required are listed in Table "Recommended Splicing Tools" .‪

The criteria for splicing straight leads is:‪

• No more than one strand in a 16 strand wire may be cut or missing.
• Use Sn 60 solder with rosin core flux.
• The exposed wire must be clean before the splice is soldered.

Soldering splice connectors is optional. To solder splice connectors:‪

1. Position the leads, so one overlaps the other. See Figure "Positioning the Leads" .
   

   Figure 6. Positioning the Leads

2. Secure the leads with a commercially available clip and hand tool. See Figure "Securing the Leads With a Clip" .
   

   Figure 7. Securing the Leads With a Clip

3. Use a suitable electronic soldering iron to heat the wires. Apply the solder to the heated wire and clip (not to the soldering iron) allowing sufficient solder flow into the splice joint.
4. Pull on wire to assure crimping and soldering integrity. The criteria listed in Table "Applied Load Criteria for Terminals" must be met.

   Wire Gage‪	Must Withstand Applied Load‪
   14 AWG‪	45 lb (200 N)‪
   16 AWG‪	27 lb (120 N)‪
   18 AWG‪	20 lb (90 N)‪

   Table 9. Applied Load Criteria for Terminals
5. Loop the lead back over the spliced joint and tape. See Figure "Recommended Strain Relief of Spliced Joint" .

Figure 8. Recommended Strain Relief of Spliced Joint

Section 17.4.5.2
Splicing and Repairing Straight Leads-Alternate Method 1

The tools required are listed in Table "Recommended Splicing Tools" .‪

Note: When splicing straight leads, no more than one strand in a 16 strand wire may be cut or missing.

The recommended method to splice straight leads follows:‪

1. Locate broken wire.
2. Remove insulation as required; be sure exposed wire is clean and not corroded.
3. Insert one wire into the splice clip until it butts against the clip. Stop and crimp (see Figure "Splicing Straight Leads - Alternate Method 1" , A).
4. Insert the other wire into the splice clip until it butts against the clip stop (see Figure "Splicing Straight Leads - Alternate Method 1" , B).

   NOTICE:
   Any terminal that is cracked or ruptured is unacceptable as malfunctions may occur.‪

5. Visually inspect the splice clip for cracks, rupture, or other crimping damage. Remove and replace damaged clips before proceeding.
6. Pull on wire to ensure the splice integrity. The criteria listed in Table "Applied Load Criteria for Terminals" must be met.

   Wire Gage‪	Must Withstand Applied Load‪
   14 AWG‪	45 lb (200 N)‪
   16 AWG‪	27 lb (120 N)‪
   18 AWG‪	20 lb (90 N)‪

   Table 12. Applied Load Criteria for Terminals

7. Shrink the splice clip insulative casing with a heat gun to seal the splice (see Figure "Splicing Straight Leads - Alternate Method 1" , C).‪

   NOTICE:
   Splices may not be closer than 12 in. (.3 m) apart to avoid degradation in circuit performance. Replace wire to avoid having splices closer than 12 in. (.3 m) apart.‪

8. Loop the lead back over the spliced joint and tape. See Figure "Recommended Strain Relief of Spliced Joint" .

Figure 9. Splicing Straight Leads - Alternate Method 1

Section 17.4.5.3
Splicing and Repairing Straight Leads - Alternate Method 2

This method is not allowed or recommended for power or ignition circuits. The tools required are listed in Table "Recommended Splicing Tools" .‪

Note: When splicing straight leads, no more than one strand in a 16 strand wire may be cut or missing.

An acceptable option for splicing straight leads is:‪

1. Locate broken wire.
2. Remove insulation as required; be sure exposed wire is clean and not corroded.
3. Slide a sleeve of glue lined, shrink tubing (Raychem HTAT or equivalent) long enough to cover the splice clip on the wire and overlap the wire insulation, about .25 in. (6 mm) on both sides (see Figure "Splicing Straight Leads - Alternate Method 2" , A).

4. Insert one wire into splice clip until it butts against the splice clip. Stop and crimp (see Figure "Splicing Straight Leads - Alternate Method 2" , B). ‪

5. Insert the remaining wires into the splice clip one at a time until each butts against the splice clip; stop and crimp (see Figure "Splicing Straight Leads - Alternate Method 2" , B).‪

   NOTICE:
   Any terminal that is cracked or ruptured is unacceptable as malfunctions may occur.‪

6. Visually inspect the terminal for cracks, rupture, or other crimping damage. Remove and replace damaged terminal before proceeding.
7. Slide the shrink tubing over the crimped splice clip (see Figure "Splicing Straight Leads - Alternate Method 2" , C).
8. Shrink tubing with a heat gun to seal the splice (see Figure "Splicing Straight Leads - Alternate Method 2" , D).

   NOTICE:
   A minimum of two layers of heat shrink tubing must be applied to splices that have more than one lead in or out.‪

9. Loop the lead back over the spliced joint and tape. See Figure "Recommended Strain Relief of Spliced Joint" .

Figure 10. Splicing Straight Leads - Alternate Method 2

Section 17.4.5.4
Shrink Wrap

Shrink wrap is required when splicing non insulated connections. Raychem HTAT or any equivalent heat shrink dual wall epoxy encapsulating adhesive polyolefin is required. Shrink wrap must extend at least .25 in. (6 mm) over wire insulation past splice in both directions.‪

To heat shrink wrap a splice:‪

1. Select the correct diameter to allow a tight wrap when heated.
2. Heat the shrink wrap with a heat gun; do not concentrate the heat in one location, but apply the heat over the entire length of shrink wrap until the joint is complete.
3. Repeat step 2 to apply a second layer of protection (if required by splicing guidelines).

Section 17.4.5.5
Staggering Wire Splices

Position spliced wires properly as follows:‪

1. Stagger the position of each splice (see Figure "The Correct and Incorrect Method of Staggering Multiple Splices" ) so there is at least a 2.5 in. (65 mm) separation between splices.
   

   Figure 11. The Correct and Incorrect Method of Staggering Multiple Splices

   NOTICE:
   A minimum of two layers of heat shrink tubing extending .25 in.‪ (6 mm) past the splice must be used to complete the splice.‪

2. Heat shrink a minimum of two layers of heat shrink tubing.
3. Tape the spliced wires to each other. Refer to "17.5 Conduit and Loom" .