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Issue 1 en
Industrial & Marine Engines

Scania DEC2 control system

Work description
Diagnostics and fault finding

Part. No.
1 588 593 ©
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
Engine protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Fault finding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Main indicator lamp (operator’s lamp) . . . . . . . . . . . . . . . . . . . . . . . . .4
Lamp test/fault code switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Fault finding procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
LED indications at operation if a fault arises. . . . . . . . . . . . . . . . . . . .5
Critical faults that cause shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Necessary actions on POWER - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Necessary actions on SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Failure of input signal to speed throttle/trim interface . . . . . . . . . . . . .7
Setting functions with DIP switches in control unit . . . . . . . . . . . . . . .8
Obtaining readouts of fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

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Engine protection Diagnostics
The control unit contains monitoring functions to Diagnostics capabilities are integrated with the
protect the engine in the event of a fault which control unit and allows the system to detect and
would otherwise damage it. adjust for a variety of faults.
If such a fault condition is detected, the control Through a diagnosticts port, authorized service
unit will take steps to alter the control program to personnel are able to connect a computer (PC) to
ensure acceptable power output and to reduce the investigate the cause of most problems.
possibility of damage to the engine. The control unit contains a fault memory which
If this is not possible, the system will for some retains important information regarding detected
faults provide only enough power to move a vehi- faults.
cle or vessel to a location where service assistance
can be obtained. Note The COMM/DIAG port is for use by
Only when there is a risk of excessive damage to authorized personnel only.
the engine or the engine cannot be safely control-
led, the engine will be switched off automatically.
The most important fault conditions that the con-
trol unit provides protection against are:
• overspeed
• low oil pressure
• high coolant temperature
• high air inlet temperature.
The control unit is also constantly monitoring
itself to detect faults in its own operation.
All these features work together to allow maxi-
mum power output and at the same time reduce
the possibility of engine damage.

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 Fault finding

Even though the control provides sophisticated Lamp test/fault code switch
fault detection and correction, this does not make
it too complex for the operator to determine minor This switch should be installed close to the DEC2
problems without test equipment and to take control unit.
appropriate measures. The recommended type of switch is a spring
Any fault that is field correctable will be dis- return switch with - (minus) in the rest position.
played on the LED display on the control unit Before reading off the fault on the LEDs on the
when performing a fault finding procedure. control panel, this switch must be depressed.
In order to read fault indications on the LEDs, a The lamp test function will then turn on all LEDs
lamp test/fault code switch must be mounted close for a short moment and then the LED fault code
to the control unit so that the LEDs can be viewed will be displayed.
when the switch is activated. See page 9 for the complete fault code reading
procedure.
Main indicator lamp (operator’s lamp)
If a fault arises, the main indicator lamp installed
at the operator’s panel will come on.
- If the main indicator lamp comes on with a
constant red light, the DEC2 control unit has
detected a fault, indicating that a warning
threshold has been reached (POWER- status).
- If the main indicator lamp comes on with a
flashing red light, the DEC2 control unit has
detected a fault, indicating that a shutdown
threshold has been reached. Engine is stopped
if DIP switch 4 is in OFF position.

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 Fault finding procedure

LED indications at operation if a

fault arises

Note Indication is given by the main indi-

cator lamp on the operator instru-
ment panel. The lamp test/fault code
switch should not be depressed.

CONTROL STATUS
✹ The LED continues to flash even if a fault
has arisen and this indicates that the control
unit is functioning normally.

POWER -
✹ If the LED comes on, the control unit has
detected a fault condition which could result
in engine damage if allowed to continue.
The control unit automatically reduces
engine power output to a certain level.
See page 6 for appropriate action.

SHUTDOWN
✹ The LED comes on and the engine is
switched off automatically if a fault of such
seriousness has arisen that the engine could
be damaged if it continues to run.
See page 6 for a listing of critical faults.
See page 7 for appropriate action.

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Critical faults that cause shutdown
• Coolant temperature exceeds shutdown
threshold and DIP switch 4 is in OFF position.
• Oil pressure is below shutdown threshold and
DIP switch 4 is in OFF position.
• Accelerator sensor failure and DIP switch 5 is
in OFF position. All speed unit only.
• Actuator feed-back sensor failure.
• Actuator feedback sensor non-volatile calibra-
tion data failure.
• Engine speed exceeds overspeed threshold.
• Torque map non-volatile data failure.
• Internal self-test failures.
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Necessary actions on POWER -
The main indicator lamp is shining constantly
red and the control unit has reduced engine
power output to a certain level.
Note Do not switch off the control unit’s
power supply. The fault codes will
be reset to zero if the system’s
power supply is turned off.
- If possible, adjust engine rpm to low idle and
check the oil pressure and coolant temperature
gauges on the operator instrument panel.
- Low oil pressure always entails a danger of
engine damage. The engine should be used
only in an emergency and for as short time as
possible, keeping a sharp eye on the instru-
ment.
- If the oil pressure continues to drop, the engine
must be stopped. If DIP switch 4 is set in the
OFF position, the engine will be stopped auto-
matically.
- If the coolant temperature is abnormally high,
98 °C or above, the engine should be stopped
as soon as possible and the cooling system
inspected.
- If you have to keep the engine running, reduce
its output power still further and check the tem-
perature gauge constantly. If the temperature
continues to rise, the engine will be stopped
automatically (shutdown) if DIP switch 4 is in
the OFF position.
- Obtain a reading of the fault codes as described
on page 9. You should not switch off the
engine to do this in the case of Power- .
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Necessary actions on SHUTDOWN - Single speed units with trim pot:

The main indicator lamp shines with a flashing If the excitation (TPSE) or sensor (TPSS) sig-
red light. nal is discontinued, the control unit will use
full negative trim (approx. -90 rpm) if the trim
input is enabled with the Speed Hold switch in
Note Do not switch off the control unit’s Battery- position.
power supply. The fault codes will If the return (TPSR) is discontinued, the con-
be reset to zero if the system’s trol unit will use full positive trim (approx. +90
power supply is turned off. rpm) if the trim input is enabled with the Speed
Hold switch in Battery- position.
- Obtain a reading of fault codes on the control
unit as described on page 9.
Cable or connection failure to dis-
- The Shutdown function for too low oil pres- crete inputs
sure and too high coolant temperature can be
disconnected by setting DIP switch No. 4 in the If there is a breakage to any of the discrete inputs
ON position. The system will then automati- in the control unit or if it is not connected, there
cally go into Power- (LOP-power). See page 8. will be an automatic internal pulldown to battery-.
This possibility should be utilized only in This will result in the following function mode for
exceptional circumstances when it is absolutely each of the dicretes (switches):
necessary to move a vehicle or a boat.
Droop/Isochronous: Droop mode
- If Shutdown has occurred due to overrevving,
Power Control: Torque Map 1
the control unit must be switched off before the
engine is started again. Run/Stop: Turns off actuator
driver
Speed Hold: No speed hold
Failure of input signal to speed Lamp Test/Fault code:Running mode
throttle/trim interface
Idle/Run: Idle speed
- All speed units with APS (accelerator pedal
sensor):
If the excitation (TPSE) or sensor (TPSS) sig-
nal is discontinued, this failure of the sensor
will result in the following: The engine first
slows down to idle and then increases to a
fixed speed of 900 rpm + droop or shutdown
depending on the position of DIP switch 5.
If the return (TPSR) is discontinued, the engine
will first accelerate towards full speed and then
this sensor failure will result in the same oper-
ating mode as above.

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 Setting functions with DIP switches in control unit

There are 8 DIP switches in the control unit under The switches have the following functions in the
the black, round rubber cover. on or off positions.

No ON OFF
1 Standard position
2 Standard position
3 Standard position Calibration position (injection pump-DEC2)
4 LOP(Power-) with shutdown values for low Shutdown position for low oil pressure and
oil pressure and/or high coolant temperature high coolant temperature
5 Fixed speed operation for failed throttle input
Shutdown for failed throttle input signal
signal (900 rpm + droop)
6 All speed: Standard position
Single speed: Low speed request (1500 rpm)
Single speed: High speed request (1800 rpm)
7 Unloaded droop calculation Loaded droop calculation
8 Droop for Map 2 operation Droop for Map1 operation

- As described earlier, DIP switch 4 can be set in

the ON position to disconnect the Shutdown
function for low oil pressure and high coolant
temperature.
The engine can then be run even if the indi-
cated oil pressure is so low or the indicated
coolant temperature so high that Shutdown
would normally occur. The Power- (LOP
power) operating mode is engaged automati-
cally.

DIP switches shown in ON position

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 Obtaining readouts of fault codes
Note If the engine has stopped or lost power
but the operator’s lamp is out and nei-
ther POWER- nor SHUTDOWN are on,
the fault is outside the control unit’s
sensing area. Probable causes: fuel
shortage, temporary overload, mechan-
ical fault.
- Activate the lamp test/fault code switch and
keep it depressed.
- All LEDs will then light up for 2 seconds to
indicate that they are intact and in working
order. This also applies to the main indicator
lamp on the control panel. Make a note of any
LED that is defective.
- Following this, a fault code will be flashed on
one of the LEDs for 5 seconds. Note which
LED it is.
- Operating mode will then be shown for 2 sec-
onds.
- The first fault code to be flashed indicates the
most serious engine fault or operating fault. If
the lamp test/fault code switch remains
depressed, the process will be repeated auto-
matically as above.
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- After having made a note of the fault code
shown, reset the lamp test/fault code switch
and the control unit by turning off its power
supply momentarily.
- The most probable cause of the fault can then
be found in the trouble shooting schedule on
the next page.
- When the fault or faults have been rectified the
engine can be restarted.
- If the control system still gives a fault indica-
tion (operator’s lamp still on or flashing), other
faults may be registered. The fault code test
must then be repeated as above since the sys-
tem can only show one fault code at a time.
- The fault or faults will be logged in a special
memory in the control unit where the operating
time concerned is recorded. This log cannot be
deleted and can only be accessed by authorized
service personnel.
9
10
LED code indicated when lamp test/fault
code switch is activated

Probable cause of fault Action

ON CONTROL PANEL
MAIN INDICATOR LAMP
CONTROL STATUS LED
SHUTDOWN
STARTING
RUNNING
TORQUE LIMIT
BOOST LIMIT
POWER -
POWER +
Send in the control unit for repair at a suitable
✹ ❍ ❍ ❍ ❍ ❍ ❍ ❍ DEC2 has detected an internal fault in the control unit.
opportunity.

©
Intake air temperature has reached warning level or Check the intake system. Check the temperature sensor
❍ ❍ ❍ ❍ ✹ ❍ ❍ ❍ charge air temperature sensor has become inoperative. and wiring.

Engine speed potentiometer or idling safety switch has Check the wiring, connectors and cables.
❍ ❍ ❍ ❍ ❍ ❍ ✹ ❍ become inoperative. Change the engine speed sensor.

Fixed
Engine temperature has reached warning level or temper- Check the cooling system. Check the temperature
❍ ✹ ❍ ❍ ❍ ❍ ❍ ❍ ature sensor has become inoperative. sensor and wiring.

✹ ❍ ❍ ❍ ❍ ❍ ❍ ❍ DEC2 has detected an internal fault in the control unit. Send in the control unit for repair as soon as possible.

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Engine temperature has reached the engine-stopping Check the cooling system. Check the temperature
❍ ✹ ❍ ❍ ❍ ❍ ❍ ❍ level or the temperature sensor has become inoperative. sensor and wiring.

Engine has reached the overspeed limit or engine speed Check the wiring and connector.
❍ ❍ ✹ ❍ ❍ ❍ ❍ ❍ sensor is inoperative. Change the engine speed sensor.

❍ ❍ ❍ ✹ ❍ ❍ ❍ ❍ Control rack position sensor inoperative. Check connectors and leads to governor.

Flashing
DEC2 has registered absence of charge air pressure. Send in the control unit for repair at a suitable
❍ ❍ ❍ ❍ ❍ ✹ ❍ ❍ Boost pressure sensor has failed. opportunity.

Oil pressure has dropped to engine-stopping level or oil Check oil level, connector and lead.
❍ ❍ ❍ ❍ ❍ ❍ ❍ ✹ pressure sensor has become inoperative. Change the oil pressure sensor.

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❍ = LED off ✹ = LED on