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en

Scania DEC2 control system

Tuning and calibration
Dealer version

Part. No.
1 588 594 ©
Scania CV AB, Sweden, 1999-01:1
 Important information

• Changes must not be made to the DEC2 control unit or sensors and wiring. Doing so
may effect the control unit’s safety system and cause damage to the operator, the
engine or driven equipment.
• The sensors for the DEC2 control system are dedicated for use in DEC2 only.
• Check that the cables for the battery and alternator/s are properly connected before
starting the engine as otherwise the DEC2 control unit might be damaged.
• Before disconnecting the cable to the control unit, all power to the unit should first
be switched off. If not, the DEC2 control unit may be damaged.
• Disconnect the DEC2 control unit when boost charging the battery to avoid damag-
ing the control unit.
• Never splice a damaged cable. Change the entire cable, otherwise the safety and
operation of the system could be impaired.
• Disconnect the battery if arc welding in order to avoid damage to the DEC2 control
unit.

Contents
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Tuning: All speed or single speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Change of parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Explanation of the other parameters shown on the Tuning screen . . .6
Explanation of the Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Governor Configuration: All speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Change of parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Governor Configuration: Single speed . . . . . . . . . . . . . . . . . . . . . . . . . .9
Change of parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Governor Calibration: All speed and single speed . . . . . . . . . . . . . . . .10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Calibration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Saving the calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Calibration has failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Final check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Possible fault messages that can occur during calibration . . . . . . . .15

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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 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.

- Log in and open the file manager. GOVERNOR DIAGNOSTIC SYSTEM V4.0
- Open the program directory DEALER. - DEALER Version
ALL SPEED Application
- Open the appropriate program:
- 1002DXX1)A.EXE for all speed engines or
- 1002DXXS.EXE for single speed engines
GOVERNOR DIAGNOSTIC SYSTEM V4.0
- 1002DXXC.EXE for all speed engines DEALER version
(OEM only) SINGLE SPEED Application
- When the program starts, it first states version
and type of application: all speed or single or
speed.
- Press any key to continue. GOVERNOR DIAGNOSTIC SYSTEM V4.0
DEALER version
1) ALL SPEED with J1939 Communication Application
XX is a version number of the program that is
changed at program changes e.g. 61.

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 - In the Main Menu there are three alternatives:
Tuning, Configuration and Calibration. Governor
<T> Tuning
- Press the T, K or C key for wanted alternative. <K> Configuration
<C> Calibration

Tuning: All speed or single speed

Cntl Gain 6 CNT

Cntl Stability 4 CNT Act Gain 5 CNT
Cntl Deadtime 2 CNT Act Stability 8 CNT

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General • Cntl Deadtime which gives a quick change of
the fuel supply at a quick change of the
When the chosen menu appears, the following speed.
applies when changing values: • Act Gain and Act Stability show the setting
- The Tab key moves the user forward between of the solenoid on the injection pump and
the modifiable parameter fields. See picture. affects its sensitivity to the output signal from
the control unit.
- When the cursor hits a new field, this is high-
lighted. Approximate values for these five parameters are:
Single speed All speed
- With Shift+Tab the cursor is moved backwards
between the modifiable parameter fields. Cntl Gain 15 6
- When pressing the space bar, the user is Cntl Stability 15 3
prompted for a new value.
Cntl Deadtime 1 1
- Enter the new chosen value.
Act Gain 7 4
- Confirm by pressing Enter.
Act Stability 15 10*)
- Save by pressing F2. See page 7.
*) Never choose a value less than 10.
- A higher value gives a faster governing.
Change of parameters
- A lower value gives a slower governing.
In the menu for Tuning the following parameters
can be changed. Note Make changes in small steps (nor-
For the governor there are three alternatives that mally 1 or 2), if change is necessary.
control the governing of the engine:
• Cntl Gain governs the magnitude of the fuel
supply change at a deviation in speed.
• Cntl Stability adjusts the quantity of fuel to
the engine until the speed error is eliminated.

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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 = Max control rack travel during
start (cranking cycle).
Actual Fuel = Current control rack travel
Operating Mode = Shows actual 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 max control rack travel
in the torque limiter map at current speed .
Boost Fuel = Shows max control rack travel
in the smoke limiter map at current speed and
boost pressure.
Oil Pressure = Oil pressure in engine
Atmospheric P = Displays the atmospheric
pressure before the cranking cycle. This
value is updated before each startup.
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Boost Press = Absolute charge air pressure
after the turbo charger
Atemp LOP = Shows the limit value (warning
level) for charge air temp. when operation
turns into limited power level (POWER- ).
Etemp LOP = Shows the limit value (warning
level) for coolant temperature when operation
turns into the limited power level (POWER- ).
Eng. Shutdn = Shows limit value (shutdown
level) for coolant temperature when engine is
stopped by the control unit (if chosen by DIP
switch 4 on the control unit).
OS Limit = Shows at which overspeed value
the engine will be stopped.
OS Time Limit = Shows the time delay
between overspeed and engine shutdown.
Speed Accel = Shows the acceleration time
for the control rack to reach the programmed
max travel.
Speed Decel = Same as speed acceleration
but now from max travel down to min travel.
The actual ramp time will be somewhat
shorter than the entered value for Speed
Accel and Speed Decel .
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 Explanation of the Function keys

F1 - Refresh = All recorded parameter values
in the control unit are refreshed and
displayed on the screen
F2 - Save = All of the modifiable values, that
are displayed on the screen, are saved and
stored in the permanent (non-volatile) control
unit memory.
Each value is now retrieved at every reset
until it is changed again. If a parameter value
is not saved in this way after a change, the
last saved value will be shown at reset.
F3 - File = This key prompts the user for a file
name in order to store the parameters that
can be modified in a separate file. This file
can be printed and saved for reference or
trouble shooting
F5 - Cont = The screen is updated approx.
every second when depressed. The function
is interrupted if F5 is pressed again.
F6 - Log = Shows the fault log menu
ESC = This option will return the user to the
previous screen

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 Governor Configuration: All speed
General
When the chosen menu appears, the following
applies when changing values:
- The Tab key moves the user forward between
the modifiable parameter fields. See picture.
- When the cursor hits a new field, this is high-
lighted.
- With Shift+Tab the cursor is moved backwards
between the modifiable parameter fields.
- When pressing the space bar, the user is
prompted for a new value.
- Enter the new chosen value
- Confirm by pressing Enter.
- Save by pressing F2. See page 7.
Change of parameters
In the menu for Governor Configuration the fol-
lowing 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 for
governing of speed droop.
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Min Spd Req 700 RPM
Droop Map 1 4.69 %
Droop Map 1 10.16 %
In order to switch between Droop 1 and Droop 2,
the position of DIP-switch 8 underneath the round
black cap on the control panel must be changed.
Position OFF means Droop 1.
Explanation of the other parameters
shown on the Configuration screen:
Teeth = number of teeth on the flywheel ring
gear
Max Spd Req = In the Unloaded mode, the
given value is high idle speed (DIP switch 7 in
position ON)
In the Loaded mode, the given value is the
full load speed (DIP switch 7 in position OFF).
Surge time = shows the time period during
which the engine can be run at a higher
power level (torque map 2) (OEM only)
Recovery time = shows the time period dur-
ing which the engine must run acc. to torque
map 1 before the higher power level (torque
map 2) can be used again. (OEM only)
Note It is not standard with two different
torque maps. As standard Map1=
Map2
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 Governor Configuration: Single speed

Max Spd Req 1800 RPM

Idle Speed 700 RPM Min Spd Req 1500 RPM
Droop Map 1 4.69 %
Droop Map 2 10.16 %

Change of parameters This applies if droop has been chosen with switch
S16. For further information on switching
In the single speed version, two operation speeds between isochronous and droop operation, see
can be adjusted. installation instruction.
- The two speeds most common for gensets, There is a possibility to externally switch between
1500 or 1800 rpm can be preprogrammed. Min the low idle (Idle Speed) and operation speed
and max speed are programmed at the same (high idle) with an extra switch S24, Run/Idle,
level when delivered from Scania. connected to the control unit.
- If both 1500 and 1800 rpm are requested, this When the Run/Idle input on the control unit is
has to be specified separately when ordering switched to Battery-, the engine runs in idle and
the engine. when it is switched to Battery+, the engine will
run in the operation speed wanted.
If there is a need for switching the speeds,
DIP switch No. 6 underneath the round black 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 between 0-20% are accepted for the
speed droop. When the engine is delivered
from Scania, map 2 is used for the setting of
speed droop.

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 Governor Calibration: All speed and single speed

General
The menu for calibration of the governor gives the
possibility to calibrate and match the injection
pump against the control unit.
2 1
This calibration should be performed when any of
these components have been exchanged.
- Remove the round black cap over the DIP
switches in the control unit.
- Remove the red CAUTION label on the control
unit, carefully not to damage the label, to ABC
expose the calibration hole. After the calibra-
tion, the label should be put back to cover the
hole.
7
1

- Remove the cover over the COMM/DIAG 3

PORT and connect the computer cable with
12
12

DEC end to this port.

- Connect a multimeter with + (plus) to the mea-
suring pin (1) in the control unit and with
– (minus) to the brown cable marked TPSR
(A7=pin 7 in row A) in the main connector.

Note It is important to use a calibrated

multimeter in order to get accurate
voltage readings.

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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 two trim pots located at posi-
tions 2 and 3 in the control unit picture on
page 10.
Both trim pots are adjusted in the same way,
meaning that when you turn them clockwise, the
voltage reading will increase and vice versa.
However, the resulting effect is different.
- trim pot 2 moves 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.
DIP switch 3
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20.3
Calibration procedure
- Turn on the power to the control unit.
- Open the appropriate program:
- 1002DXX1)A.EXE for all speed engines
- 1002DXXS.EXE for single speed engines
- 1002DXXC.EXE for all speed engines
(OEM only)
1)
XX is a version number of the program that is
changed at program changes e.g. 61
- Choose Calibration from the main menu by
pressing key C.
- Put DIP switch 3 in the OFF position. See pic-
ture below.
- Then press A for Actuator Calibration
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In the first screen picture (page 11), the control
unit will ask for a value for max. control rack
travel.
- First read off the voltage value on the multime-
ter with control rack travel = 0. The voltage
should be 0.454 (0.450-0.458) VDC.
- Then write the value 20.3 and press Enter.
See picture on page 11.
- The control unit now moves the control rack
twice to max and then back to zero. At the
same time Sending fuel rack travel .... is shown
on screen.
- Read off the highest voltage value when the
control rack reaches max travel (twice).
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- The value should be 4.54 (4.50 - 4.58) VDC.
- Adjustment to reach these values is done with
calibration screws 2 and 3.
- Repeat the procedure and check that the correct
values have been obtained.
Note It can happen that the control unit
switches to Shutdown during the
calibration. By turning off power to
the control unit momentarily, the
function is reset to normal and the
calibration procedure can be
resumed.
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 Saving the calibration

When the calibration procedure has been com-
pleted and accepted, the message Calibration has
passed appears.
Save the calibration in accordance with the fol-
lowing:
- Press the space bar so that the text Enter choice
appears.
- Save Calibration by pressing F2.
- Check that a green text flickers in the lower left
hand corner, which confirms that the save
function is working.
- Put DIP switch 3 in the control unit in the ON
position (standard position).
- Press ESC twice and confirm with Y to Exit.

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Calibration has failed
- If the calibration values are outside the
approved range, the message Calibration has
failed will appear.
- In this case the Calibration procedure has to be
repeated from the start.
Note It can happen that the calibration
fails although the voltage values are
correct. In this case it is also neces-
sary to repeat the calibration proce-
dure.
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Final check
Turn off the power to the control unit and then
power the unit 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).
- Press F3 if you want to store the data in a sepa-
rately named PC file.
- Exit the program as before and turn off power.
- Disconnect the computer cable and restore the
control unit to normal.
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 Possible fault messages that can occur during calibration
• If calibration fails although both high and
low voltage values are correct and the CNT
values are within the tolerence range,
proceed as follows:
- Exit the DEC2 calibration program.
- Turn off the main switch for powering the
control unit.
- Put back DIP switch 3 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 cali-
bration 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 Cal-
ibration 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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