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Issue 2 en

Scania DEC2 control system

V7.0 and V8.1
Tuning and calibration
Dealer version

Part No.
1 588 739 ©
Scania CV AB, Sweden, 2001-06:2
 Important information

• Changes must not be made to the DEC2 control unit or sensors and wiring. Doing so
may affect the control unit safety system and cause injuries to the operator and
damage to the engine or driven equipment.
• Never splice a damaged cable. Renew the entire cable, otherwise the safety and
operation of the system could be impaired.
• Sensors for the DEC2 control system are intended only for use in the DEC2.

The following points must be observed to ensure that the DEC2 control
unit is not damaged:
• Check that cables to the battery and generator are properly connected before the
engine is started.
• Before disconnecting the cable to the control unit, switch off all power supply to the
unit.
• Disconnect the DEC2 control unit when rapid charging the battery.
• Disconnect the battery during electric welding and remove the control unit.

Contents
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tuning: single speed or all speed engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Explanation of the other parameters shown on the Tuning screen . . . . . . . . . 6
Explanation of the function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Governor Configuration: All speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Explanation of the other parameters shown on the Configuration screen: . . . 8
Governor Configuration: Single speed engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Changing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Governor Calibration: All speed and single speed engines . . . . . . . . . . . . . . . . 10
Calibration procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Saving the calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Calibration has failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Final check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Possible error messages that can occur during calibration . . . . . . . . . . . . . . 18

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 Start-up procedure
Note: The PC should only be connected to the control unit using a special cable marked
DEC at one end and PC at the other, after the cover over the COMM/DIAG PORT has
been removed. The cable part no. is 1434119 for length=4 m and 1413708 for
length=10 m. The program can only be started if the PC is connected to a powered
control unit. However, the program menu below can be reached without powering
the control unit.
All Dealer program versions with instructions are collected on a CD with part No.
1589210 with subscription and part No. 1588695 without subscription.

- Log in and open the file manager. V7.0:

- Open the program for control unit with V7.0:
- 1002d701)A.EXE for all speed engines GOVERNOR DIAGNOSTIC SYSTEM V4.0
DEALER Version
- 1002d70S.EXE for single speed engines ALL SPEED Application

- or for control unit with V8.1: or

- 1002d81A.EXE for all speed engines
- 1002d81S.EXE for single speed engines GOVERNOR DIAGNOSTIC SYSTEM V4.0
DEALER Version
- When the program starts, it first states the SINGLE SPEED Application
application version and type: all speed or single
speed.
V8.1:
- Press any key to continue.
1)
70 is the version number for the V7.0 program. GOVERNOR DIAGNOSTIC SYSTEM V4.1
All illustrations in this booklet show that program DEALER Version
version in the heading, but the illustrations are also
valid for version V8.1. ALL SPEED Application

or

GOVERNOR DIAGNOSTIC SYSTEM V4.1

DEALER Version
SINGLE SPEED Application

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- In the Main Menu there are three alternatives
for adjusting the governor function: Tuning,
Configuration and Calibration.
- Press the T, K or C key according to which
alternative is required.
- Alternative I (Maintenance Information)
contains the accumulated operating time and
information from the factory, engine number
and date of test run.
- Under the heading PC Software, information
can be stored about the specific OEM.
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Governor
<T> Tuning
<K> Configuration
<C> Calibration
<I> Maintenance Information
General
Once the required menu appears, the following
applies when changing values:
- The Tab key is used to move the cursor
forwards between the modifiable parameter
fields. See illustration on next page.
- When the cursor hits a new field, this field is
highlighted.
- With Shift+Tab the cursor is moved backwards
between the modifiable parameter fields.
- When the space bar is pressed, the user is
prompted to enter a new value.
- Enter the new chosen value.
- Confirm by pressing Enter.
- Save by pressing F2. See page 7 for a
description of the use of the function keys.
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 Tuning: single speed or all speed engine

Cntl Gain 15 CNT

Cntl Stability 15 CNT Act Gain 7 CNT
Cntl Deadtime 1 CNT Act Stability 15 CNT

Changing parameters Approximate values for these five parameters are:

Single speed All speed
In the Tuning menu the following parameters can
be changed. Cntl Gain 15 6
For the governor there are three parameters which Cntl Stability 15 3
regulates the engine control: Cntl Deadtime 1 1
• Cntl Gain controls how much the fuel supply Act Gain 7 4
is changed when there is a variation in speed.
• Cntl Stability adjusts the fuel flow to the Act Stability 15 10*)
engine until the speed error is eliminated. *) Minimum value
• Cntl Deadtime which makes a rapid change - A higher value gives faster control.
to the fuel supply when there is a rapid - A lower value gives slower control.
change of speed.
• Act Gain and Act Stability show the settings Note: Make changes in small steps
of the actuator solenoid on the injection (normally 1 or 2), if a value has to
pump and affect its sensitivity to the output be changed.
signal from the control unit.

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 Explanation of the other parameters shown on the Tuning screen
Speed Droop = Calculated speed reduction
depending on current speed droop.
Velocity = Actual speed
Starting Fuel = Maximum control rack travel
during startup (starting cycle).
Actual Fuel = Current control rack travel
Operating Mode = Shows current operating
mode
Air Temp = Air temperature in inlet manifold
Engine Temp = Coolant temperature in
engine
Load = Shows actual load at current speed.
Speed Request = Requested speed signal
from throttle position sensor.
Torque Limit = Shows maximum control rack
travel in the torque limiter map at current
speed.
Boost fuel = Shows maximum control rack
travel in the smoke limiter map at current
speed and boost pressure.
Oil Pressure = Oil pressure in engine.
Displays the same value as long as the
engine is running.
Atmospheric P = Shows the atmospheric
pressure before the starting cycle. This value
is updated before each startup.
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Boost Press = Absolute charge air pressure
after the turbocharger
Atemp LOP = Shows the limit value (warning
level) for charge air temperature when operation
can be set to switch over to limited power level
(POWER).
Etemp LOP = Shows the limit value (warning
level) for coolant air temperature when operation
can be set to switch over to limited power level
(POWER).
Eng. Shutdn = Shows limit value (shutdown
level) for coolant temperature when control unit
shuts down the engine (if DIPswitch 4 on the
control unit is set in the OFF position).
OS Limit = Shows the overspeed value at
which the engine will be shut down.
OS Time Limit = Shows the time delay
between the overspeed and engine
shutdown.
Speed Accel = Shows the acceleration time
required for the control rack to reach its
programmed maximum travel.
Speed Decel = Same as Speed Accel but
from maximum to minimum control rack
travel.
The actual ramp time will be somewhat
shorter than the value entered for Speed
Accel and Speed Decel.
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 Explanation of the function keys
F1 - Update = All recorded parameter values
in the control unit are updated and displayed
on the screen
F2 - Save = All the modifiable values shown
on the screen are saved and stored in the
permanent control unit memory.
Each value is now retrieved at every reset
(restart) until it is changed again. If a
parameter value is not saved in this way after
a change, the last value saved will be shown
at reset.
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F3 - File = When this key is pressed, the user
is prompted for a file name in order to store in
a separate file the parameters which can be
modified. This file can be printed and saved
for reference or troubleshooting.
F5 - Continuous updating = The screen is
updated approximately once every second
when this key is pressed. The function is
cancelled if F5 is pressed again.
F6 - Log = Shows the error log menu
ESC = This key will return the user to the
previous screen
7
 Governor Configuration: All speed
LOP power 79.69 %
Changing parameters
In the Governor Configuration menu the
following parameters can be changed.
- Low idle (Min Spd Req). Actual low idle is
governed by the speed droop.
- Speed droop (Droop 1 and Droop 2)
Values between 0-20 % are accepted for the
speed droop. Normally only map 2 is used to
govern the speed droop.
- The limited operating power (LOP power) in
percent can be changed. It is normally 100% on
delivery.
In order to switch between Droop 1 and Droop 2,
the position of DIPswitch 8 underneath the round
black rubber cap on the control panel must be
changed.
Position OFF means Droop 1.
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Min Spd Req 700 RPM
Droop Map 1 4.0 %
Droop Map 2 8.0 %
Explanation of the other parameters
shown on the Configuration screen:
Teeth = number of teeth on the flywheel gear
ring
Max spd Req = In the unloaded mode the
value displayed is high idle speed (DIPswitch
7 in ON position, normal position)
In the loaded position the value displayed is
full load speed (DIPswitch 7 in OFF position).
Surge time = shows the period over which the
engine can be run at a higher power level
than is programmed for this function
(power/torque map 2) (OEM only)
Recovery time = shows the period for which
the engine must be run according to
power/torque map 1 before the higher power
level (map 2) can be used again. (OEM only)
Note: It is not normal to have two torque
maps. Normally Map 1= Map 2
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 Governor Configuration: Single speed engine

Max Spd Req 1800 RPM

LOP power 100.00 % Min Spd Req 1500 RPM
Idle Speed 1000 RPM Droop Map 1 4.0 %
Droop Map 2 2.5 %

Changing parameters
In the single speed version, two operating speeds This applies if speed droop has been selected. For
can be adjusted. further information on switching between
- The two most common speeds for generating isochronous and droop operation, see installation
instructions.
sets, 1500 or 1800 rpm can be preprogrammed
by Scania. The minimum and maximum speeds There is an option for externally switching
are programmed at the same level when between low idle and operating speed with an
delivered from Scania. extra switch connected to the control unit.
- If both 1500 and 1800 rpm are required, this When the Run/Idle input on the control unit is
must be specified separately when ordering the switched to Battery-, the engine runs at idle and
engine. when it is switched to Battery+ the engine will
run at the required operating speed. See
If the speed needs to be switched, DIPswitch no. 6 installation instructions.
underneath the round black rubber cap on the
control unit must be changed.
- Normally the speed is 1800 rpm with the
switch in the ON position and 1500 rpm in the
OFF position.
- Values of between 0-20 % are accepted for the
speed droop. When the engine is delivered
from Scania, Map 1 is used to set the speed
droop. The basic value is 4.0%

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 Governor Calibration: All speed and single speed engines

Calibration procedure
The menu for calibrating the governor (A) gives
an option to calibrate and match the injection
pump to the control unit.
This calibration must be carried out when the
control unit or injection pump have been replaced.
- Make sure that power to the control unit has
been switched off.
- Remove the round, black, rubber cap over the
DIPswitches in the control unit. Set DIP switch
3 in the OFF position. See illustrations on next
page.
- Remove the red warning (Caution) label on the
control unit carefully, so that the label is not
damaged, to expose the calibration hole. After
the calibration the label should be put back to
cover the hole.
- Remove the cover over the COMM/DIAG
PORT and connect the computer cable with the
DEC end to this port.

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 DIP switch 3

Control unit, version V7.0

Control unit for single speed engines, version 8.1

DIP switch 3

Control unit for all speed engines, version V8.1

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V7.0:
- Connect a multimeter with + (plus) to the
measuring pin (1) in the control unit and with –
(minus) to the brown cable marked TPSR
(A7=pin 7 in row A, cable C36-11) in the main
connector. See illustration below.

Note It is important to use a calibrated

multimeter in order to obtain
accurate voltage readings.

2 1

A
1

7 3
12

12

Control unit, version V7.0

1. Measuring pin (+)

2. Trimpotentiometer
3. Trimpotentiometer
7. Pin 7 in row A (-)

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V8.1:
- Connect a multimeter with + (plus) to the
measuring pin (1) in the control unit and with –
(minus) to the yellow cable marked OPSR
(B7=pin 4 in row B, cable C44-2) in the main
connector. See illustration below.

Note It is important to use a calibrated

multimeter in order to obtain
accurate voltage readings.

2 1 2 1

B
B
1

1
1

3
4 4
12

12

12

12

Control unit for single speed engines, Control unit for all speed engines,
version V8.1 version V8.1

1. Measuring pin (+)

2. Trimpotentiometer
3. Trimpotentiometer
4. Pin 4 in row B (-)

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 20.3

The calibration procedure involves the adjustment

of two voltage levels:
- at control rack travel = 0 mm and
- at control rack travel = 20.3 mm.
This is done with the two trim pots located at
positions 2 and 3 in the control unit illustrations
on pages 12 and 13.
Both trim pots are adjusted in the same way.
When they are turned clockwise the voltage
reading will increase and vice versa.
However, the resulting effects are different.
- trim pot 2 shifts the entire measuring range, i.e.
both values are increased or decreased.
- trim pot 3 increases or decreases the measuring
range between the two values.
Normally only very small adjustments are
required.

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Important! Turn on the power to the control
unit. Check that DIP switch 3 is in
the OFF position. If there is a
Run/Stop switch, it should be set in
the Run position.
- Adjustment to reach these values is carried out
with calibration screws 2 and 3.
- Repeat the procedure and check that the correct
values have been obtained.

In the first screen (page 11), the control unit will Note: The control unit may switch to
ask for a value for "control rack travel". Shutdown during the calibration. By
turning off power to the control unit
- First read off the voltage value on the
momentarily, the function is reset to
multimeter with control rack travel = 0. The
normal and the calibration
voltage should be 0.454 (0.450-0.458) volts
procedure can be resumed.
DC.
- Then insert the value 20.3 (maximum control Summary of calibration data:
rack travel) and press Enter. Refer to
illustration on page 11. Control rack Voltage value
travel mm Volts DC
- The control unit now moves the control rack
twice to maximum and back to zero. At the 0 0.454 ± 0.004
same time Sending fuel rack travel .... is
displayed on the screen. 20.3 4.54 ± 0.04
- Read off the highest voltage value when the
control rack reaches maximum travel (twice).
- The voltage should be 4.54 (4.50-4.58) volts
DC.

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 Saving the calibration

When the calibration procedure has been
completed and accepted, the message Calibration
has passed appears.
Save the calibration as follows:
- Press the space bar so that the text Enter choice
appears.
- Save the required Calibration by pressing F2.
- Check that a green text is flickering in the
bottom left hand corner, which confirms that
the save function is working.
- Set DIPswitch 3 in the control unit to the ON
position (standard position).
- Press ESC twice and confirm by pressing Y to
Exit.
Note: If an non-approved calibration is
saved, the engine cannot be started
until an approved calibration is
carried out and saved.

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Calibration has failed
- If the calibration values are outside the
approved range, the message Calibration has
failed will appear.
- If this happens, the calibration procedure must
be repeated from the beginning.
Note: The calibration may fail even if the
voltage values are correct. In this
case it is also necessary to repeat
the calibration procedure.
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Final check
Turn off the power to the control unit and then
turn on the power again.
- Open the Calibration window and check the
values for Act F/B Offset and Act F/B Range.
- Act F/B Offset should be within 81-102
CNT (RV=0).
- Act F/B Range should be within 921-942
CNT (RV=20.3).
Note: If the voltage values are correct but
the CNT values are outside the limit
values, the voltage values must be
changed to obtain the correct CNT
values and an approved calibration.
- Press F3 if you wish to store this data in a
separately named PC file.
- Exit the program as before and turn off the
power.
- Disconnect the computer cable and restore the
control unit to normal.
17
 Possible error messages that can occur during calibration
• If the calibration fails although both high and
low voltage values are correct and the CNT
values are within the tolerance range,
proceed as follows:
- Exit the DEC2 calibration program.
- Turn off the main switch for powering the
control unit.
- Put DIPswitch 3 back in the ON position.
- Resume the calibration procedure from the
start on page 11.
• If Shutdown occurs and the LED lights up on
the control unit, momentarily turn off power
to the control unit and then resume the
calibration procedure.
• If the following text appears on the screen:
Press any key to continue (blue text) and
Error communication failure, Status:
(e.g.) E000 (red text):
- Press the space bar.
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• If the following text appears on the screen:
Press any key to continue (blue text) and
Sending fuel rack travel.......0 (green text):
- Press the space bar.
• If the following text appears on the screen:
Press any key to continue (blue text) and
Calibration has failed (green text):
- Press the space bar.
• If the following text appears on the screen:
Would you like to (R)etry, (D)isable, or
(Q)uit (blue text) and Comm Error while
reading byte/word, data (e.g.) CCEF,
status = 10 (green text)
- Press the Q key and restart the calibration
procedure from the start on page 11.
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