00:03-13

Issue 4 en

Checking performance and fuel

consumption

PGRT and FKN series

Work description

© Scania CV AB 2009, Sweden

Contents

Contents
Introduction .................................................................................. 3

Procedure .................................................................................. 5

Preparations .................................................................................. 6

Asking the customer .................................................................................. 7

Analysing tacho charts ............................................. 8

Checking how the vehicle is driven

and the pulling power ................................................................................ 10
SCOP ...................................................................... 11
Stored operational data ........................................... 15
Acceleration test on a flat road ............................... 26
Hill test ................................................................... 28

Troubleshoot the vehicle ................................................................................ 31

High fuel consumption ........................................... 31
Low power output or poor pulling power............... 32
Abnormal smoke emission ..................................... 32
Troubleshooting the vehicle, trailer and
powertrain............................................................... 34
Troubleshooting the fuel and fuel system .............. 35
Troubleshooting the electronic control system....... 36
Troubleshooting the charge air system................... 37
Troubleshooting the EGR system........................... 38
Troubleshooting the exhaust system ...................... 39

2 © Scania CV AB 2009, Sweden 00:03-13

 Introduction

Checking performance

Introduction
High fuel consumption and poor pulling power are not always
caused by a technical fault in the vehicle. The fuel consumption
and pulling power are greatly influenced by the following factors
for example.
• How the driver operates the vehicle
• The total weight of the vehicle
• Use of the power take-off
• The energy content of the fuel
• The air resistance of the vehicle
• The rolling resistance of the vehicle
• The road surface
• The topography
• The weather conditions
The following describes a timesaving and efficient procedure to
check performance and fuel consumption.

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Introduction

4 © Scania CV AB 2009, Sweden 00:03-13

 Procedure

Procedure Analyse the stored operational data that

A technical investigation of the vehicle is both
expensive and time consuming. Therefore, first
ensure that the problem is not caused by any of
the factors on the preceding page.
This is achieved by following steps 1-3 below.
Note that the actions described in the first three
steps are not exact methods of measurement.
You will however gain an indication of
whether the fault is due to the vehicle or due to
other circumstances.
IMPORTANT! Allow the customer to be
present when you carry out step 3 so that the
customer understands what your conclusion is
and how you reached it.
Allow the vehicle to remain outside the
workshop until you are ready to carry out
step 4.
you obtained. Compare this with the
information obtained from SCOP.
If the customer claims that the vehicle
seems to have poor pulling power, this can
be checked by carrying out a performance
test. You can carry out an acceleration test
or a hill test.
4 Troubleshoot the vehicle
If the above analysis indicates that the fault
is with the vehicle - troubleshoot the
vehicle.
The above steps are described in more detail in
this booklet.

1 Preparations
Note down any fault codes.
Save and print the vehicle’s stored
operational data using SDP3.
If high fuel consumption is the problem -
request information from the tachograph
and driver’s log-book in order to carry out
a correct performance check. The longer
the time period being reviewed, the greater
the accuracy.
2 Asking the customer
Find out everything that the customer
knows about the problem.
3 Checking how the vehicle is driven and
the pulling power
Analyse the vehicle in SCOP.
You can prepare yourself before meeting
the customer by accessing the vehicle
specification in SCANIA MULTI and then
entering this information into SCOP. You
must however check that this information
corresponds to the vehicle.

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Preparations

Preparations
There are many things that can be investigated
before beginning to troubleshoot the vehicle.
Therefore, allow the vehicle to remain outside
the workshop.
At this point you should only carry out the
steps below.
• Note down any fault codes stored in the
vehicle.
• Obtain the vehicle’s stored operational
data.
• If high fuel consumption is the problem,
the following points should also be carried
out.

• Request to see a driver’s log-book that

describes the fuel consumption.
• Request information from the
tachograph for different driving
situations.
• Measure the fuel density by weighing
1 litre (= 1 dm3 ) of the vehicle’s fuel or
use measuring equipment 588 158. In
SCOP, density is indicated using the
unit kg/m3.

Lower density results in lower engine

power output. The power output of our
engines is stated for a fuel density of
840 kg/m3 at 15°C.

6 © Scania CV AB 2009, Sweden 00:03-13

 Asking the customer

Asking the customer • Select information from the tachograph

that represents how the vehicle is used.
If the vehicle has a tachograph with
Note: Before carrying out the following steps graph charts - analyse the tacho charts
you should first follow the instructions in the according to the section Analysing tacho
section Preparations. charts. If the vehicle has a digital
tachograph - print the information from
the tachograph.
Find out as much as you can about how the
customer experiences the problem, by going • Using the driver’s log-book, find out the
through the following list together. fuel consumption for the same days
covered by the tachograph.
Find somewhere quiet and undisturbed to sit
down with the customer. Enter the following data - obtained using
the tachograph - into SCOP.
Use the information to build up a picture of the
problem and the troubleshooting to follow. • The cruising speed. The speed the driver
attempts to maintain for most of the
• What is the problem? High fuel journey.
consumption? Poor pulling power?
• The number of stops (include those
• Is the problem based on a comparison with times when the vehicle has had a speed
another vehicle? If so, are the conditions the below 20 km/h).
same for both vehicles? For example,
compare the rear axle gear ratio, engine • Road distance.
power output and total weight of both
vehicles. • The average speed. Calculate the
average speed by dividing the driven
• Has the problem always been present or did distance by the time it took to cover that
it arise at a certain time? distance. Disregard longer stops such as
rest stops.
If the problem arose at a certain time, it
could be due to a technical fault or
something else being changed at that time.
Analyse any fault codes that were retrieved
and see if they can indicate what the cause
of the problem could be. Note down your
conclusions and save them for any
troubleshooting of the vehicle that may be
required.
• How is the vehicle maintained?
Could poor maintenance be the cause of the
problem?
• Have they changed the trailer to check
whether the problem is related to that?
• Have they checked by having the vehicle
driven by different drivers?
• If high fuel consumption is the problem, the
following points should also be carried out.

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Asking the customer

Analysing tacho charts

Interpret the tacho chart as follows.

A tacho chart.
1 Time scale in hours
2 Vehicle speed
3 One stop
4 Road distance. The distance between each peak on the curve indicates that the vehicle has
travelled 10 km.

8 © Scania CV AB 2009, Sweden 00:03-13

 Asking the customer

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Checking how the vehicle is driven and the pulling power

Checking how the vehicle is driven and the pulling power

Note: Before carrying out the following steps

you should first follow the instructions in the
sections Preparations and Asking the customer.

IMPORTANT! Let the customer be present

when you follow this section so that the
customer understands what your conclusions
are and how you reached them.

This section describes how to check if the

vehicle actually consumes too much fuel or has
poor pulling power.
The section is subdivided as follows.
• SCOP - the information which should be
entered into the SCOP program is
described here.
In SCOP there are features such as power
and torque diagrams, information for
acceleration and hill tests, plus an
indication of how much fuel the vehicle
should consume and the most economical
road speed range and engine speed range
for the vehicle.
• Stored operational data - explains how to
analyse the stored data you obtained.
• Acceleration test - explains how to check
the pulling power of the vehicle by
carrying out an acceleration test.
• Hill test - explains how to check the
pulling power of the vehicle by carrying
out a hill test.

10 © Scania CV AB 2009, Sweden 00:03-13

 Checking how the vehicle is driven and the pulling power

SCOP
In the SCOP program you can specify the
vehicle and obtain the information below.
• Power and torque diagrams - the power
and torque curves indicate, among other
things, within which engine speed range
the engine achieves maximum torque and
the engine speed at which torque
breakaway begins. If the vehicle is driven
at an engine speed where breakaway has
started the engine will have poor pulling
power.
The stored operational data of the vehicle
shows the the engine speed ranges in which
the vehicle was driven. Compare with the
SCOP power and torque diagram.
• Data from an acceleration test on a flat
road
• Data from a hill test
• Fuel consumption - compare the SCOP
value with the fuel consumption you
calculated using the figures from the
driver’s log-book. Compare with the
calculated value obtained from the stored
operational data.

IMPORTANT! The fuel consumption from

SCOP only gives an indication of what the fuel
consumption should be. It should not be
regarded as a precise fuel consumption value.

• The most economical vehicle speed

range - compare with the cruising speed
shown by the tachograph. Also compare
with the vehicle speed shown in the stored
operational data.
• Recommended engine speed intervals -
compare with the engine speeds at which
the vehicle has been driven according to
the stored operational data.
The following is a short description of the
information to be entered into SCOP. The
SCOP user manual gives a more detailed
description of how to use the program.

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Checking how the vehicle is driven and the pulling power

General information for SCOP

Below is a description of which information
must be entered, irrespective of whether the
problem concerns high fuel consumption or
poor pulling power.
Enter information about:
• Engine type
You do not need to choose an exhaust
brake.
Allow the Power output factor to remain
as 1.
• Gearbox and whether the customer uses the
retarder, if fitted.
• Rear axle gear and gear ratio.
• Tyres.
• Fuel temperature and density.

Note: The fuel density and temperature are

important for the result obtained, and it is
therefore necessary that this information is
entered.

• Air temperature.
If an acceleration test or a hill test is to be
performed, enter the current air
temperature.
To check fuel consumption indicate the
average temperature for the days to be
analysed.
• Gross train weight of the vehicle.
• Weight on the driving axle.
• Frontal area information.
• Information about the road surface.
If poor pulling power is the problem, you
only need to select the type of road surface.
If high fuel consumption is the problem,
you should also select the type of
topography.
• Click on the calculator.
The following pages describe how to proceed,
depending on whether the pulling power is
poor or whether the fuel consumption is high.

12 © Scania CV AB 2009, Sweden 00:03-13

 Checking how the vehicle is driven and the pulling power

Information in SCOP when the

pulling power is poor
It is not necessary to enter more information
into SCOP if you only want to check the
pulling power.
You can obtain the following information.
1 Engine power and torque diagram.
The torque curve indicates, among other
things, within which engine speed range
the engine achieves maximum torque and
the engine speed at which torque
breakaway begins. If the vehicle is driven
at an engine speed where breakaway is
activated, the engine will have poor pulling
power.
The vehicle’s stored operational data can
be used to check in which engine speed
ranges the vehicle has been driven.
Compare with the power and torque
diagram.
2 Data from an acceleration test on a flat
road and hill test.
The information in the group box Acc.
should be used when you carry out an
acceleration test.
The information in the group box Hill test
should be used when you carry out a hill
test. There you must also enter the gradient
of the hill. In the section Hill test is an
explanation of how to measure the
gradient.
Enter the data in the group boxes and then
follow the instructions in the sections
Acceleration test and Hill test.

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Checking how the vehicle is driven and the pulling power

Information for SCOP when the

fuel consumption is high
If high fuel consumption is the problem you
should continue to enter the information into
SCOP as described below.
Note: First you must enter the information as
described in the section General information
for SCOP.
Enter the following information:
1 Whether the vehicle has been subjected to
power driving, i.e. outside the green engine
speed range. Check this by looking at the
vehicle’s stored operational data.
2 Whether the power take-off has been used
on the vehicle.
Select power take-off and then enter
information about the power output, power
take-off speed and operating time.
3 A stretch of road which corresponds with
information from the tachograph.
4 The number of stops according to the
tachograph.
5 The cruising speed according to the
tachograph.
When you have entered all the information.
1 Click on the calculator.
2 Compare the average vehicle speed you
calculated using the information from the
tachograph with the average speed that
SCOP has calculated. The speeds should
correspond.
3 You can now see the fuel consumption
figure that SCOP has calculated.
There are many factors affecting fuel
consumption. It is important that all data in
SCOP is entered as correctly as possible so
that the calculated fuel consumption
corresponds. This gives an indication of
how much fuel the vehicle should
consume.
If the actual fuel consumption of the
vehicle is lower than or equal to the
calculated consumption, there is no
problem with the fuel consumption.
If the actual fuel consumption of the
vehicle is higher than the calculated
consumption - continue according to the
section Stored operational data.
14 © Scania CV AB 2009, Sweden 00:03-13
 Checking how the vehicle is driven and the pulling power

Stored operational data

According to the section Preparations you
should have obtained the vehicle’s stored
operational data. It is now time to analyse this
data.
The engine control unit is one of the control
units which stores operational data. When
vehicle information is stored using SDP3 the
operational data can be read off from the control
unit’s total running time.
If the operational data from a vehicle has been
stored on several occasions the two files can be
compared, providing operational data for a
particular period.
This section describes the operational data that
is useful when analysing vehicle performance
and fuel consumption.
Go through the operational data of the vehicle
with the customer and compare it with the
results you obtained from SCOP.

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Checking how the vehicle is driven and the pulling power

Speed

The bar chart shows an example of operational

data for vehicle speed. In the bar chart it is
possible to see for what part of the operational
time the vehicle has been driven within the
different speed ranges.
Compare the vehicle speed with the most
economical vehicle speed range that you
obtained using SCOP.
At cruising speed the engine speed should be
within the green engine speed range.
If the bar chart indicates that the vehicle has
been driven a lot at low speed, but this is not the
case, there may be an error in the message from
the tachograph to the engine control unit
regarding the vehicle speed. If the vehicle speed
signal is incorrect the engine control unit
registers a preset speed value of 15 km/h.

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 Checking how the vehicle is driven and the pulling power

Coolant temperature

The bar chart shows an example of operational

data for engine coolant temperature. In the bar
chart it is possible to see for what part of the
operational time the engine coolant temperature
has been within different ranges.
A cold engine consumes more fuel than a warm
engine.
On certain engines, the engine power output is
reduced slightly at coolant temperatures
exceeding 100°C.

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Checking how the vehicle is driven and the pulling power

Engine speed

The bar chart shows an example of operational

data for engine speed. In the bar chart it is
possible to see for what part of the operational
time the engine speed has been within different
ranges.
The engine speed ranges differ between
different control units.
When the vehicle is driven at engine speeds
within the green zone on the tachometer the
vehicle consumes the least fuel.

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 Checking how the vehicle is driven and the pulling power

Charge air temperature

The bar chart shows an example of operational

data for charge air temperature. In the bar chart
it is possible to see for what part of the
operational time the vehicle has been driven
within the different charge air temperature
ranges.
Under normal circumstances, the charge air
temperature should be approximately 10°C
higher than the outside temperature. If the
charge air temperature is too high, the engine
output will be reduced and the fuel consumption
will increase.

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Checking how the vehicle is driven and the pulling power

Fuel supply pressure (HPI)

The bar chart shows an example of operational

data for fuel supply pressure. The bars show for
what part of the operating time the supply
pressure deviation has been within different
ranges in comparison with the expected value.
If the supply pressure is lower than it should be,
a fault code is generated and the engine torque is
reduced by approximately 30%.

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 Checking how the vehicle is driven and the pulling power

Load

95 0 0 0 0 1 2 1 0 0 0 0 0
95 0 0 0 0 0 0 0 0 0 0 0 0
90 0 0 0 0 0 1 1 0 0 0 0 0
80 0 0 0 0 0 1 1 0 0 0 0 0
70 0 0 0 0 1 1 2 0 0 0 0 0
60 0 0 0 0 1 2 2 0 0 0 0 0
50 0 0 0 0 1 3 4 0 0 0 0 0
40 0 0 0 0 2 4 5 0 0 0 0 0
30 0 0 0 1 2 4 7 0 0 0 0 0
20 0 2 1 1 2 3 5 0 0 0 0 0
10 0 13 3 3 4 6 7 0 0 0 0 0

142 365
450 450 650 650 950 950 1100 1100 1250 1250 1400 1400 1550 1550 1700 1700 1850 1850 2000 2000 2500 2500

rpm

Above is an example of the what the load matrix Use SCOP to find out which engine speed
can look like for a vehicle. The table shows for range(s) is(are) optimum for each engine type.
how much of the operational time the vehicle has Because the recommended engine speed ranges
been driven with a particular load in the different are different for each engine type, it is not
engine speed ranges. The control unit only stores possible to draw up a general table dividing
the operating time when the engine speed engine speeds into ranges.
exceeds 0 rpm.
Compare the stored operational data from SVAP
When the vehicle is driven within the optimum with the data obtained from SCOP to see if the
engine speed range it uses the least amount fuel. vehicle has been driven within the recommended
ranges.
The higher the load, the higher the fuel
consumption.

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Checking how the vehicle is driven and the pulling power

Analysing the vehicle

A high fuel consumption is often due to the fact
that the vehicle has been incorrectly specified
and it is therefore driven outside the
recommended (green) engine speed ranges for a
large part of the time.
Two examples are provided below, depicting an
incorrectly and correctly specified vehicle with
engine DT1203.

Engine type: DT1203 Rear axle tab in SCOP

Rear axle ratio: 3.08 3.40
3.27
Tyres: 295/60 R22.5
Gearbox: GRS900 3.08
2.92
When information about the vehicle is entered
in SCOP, it indicates that the vehicle has been 2.71
incorrectly specified. The speed falls in the 1480
B
range between the green engine speed ranges. 1415
For those engines that have two green engine 1
speed ranges, when specifying a vehicle it is 1240
possible to select which engine speed range the A
1160
vehicle should fall within during normal
operation. The low engine speed range is used in
order to optimise a vehicle for low fuel

147 975
consumption. The recommended engine speed 40 50 60 70 80 90 100 km/h
range is used in order to obtain better
driveability, resulting in a slightly higher fuel
consumption. A = Low engine speed range
B = Recommended engine speed range

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 Checking how the vehicle is driven and the pulling power

When the vehicle’s stored operational data is

viewed, this confirms the fact that the vehicle
has been driven outside the green engine speed
ranges for a large part of the operating time.

Load
Load matrix
95 0 0 0 0 1 2 1 0 0 0 0 0
90 95 0 0 0 0 0 0 0 0 0 0 0 0
80 90 0 0 0 0 0 1 0 0 0 0 0 0
70 80 0 0 0 0 1 1 0 0 0 0 0 0
60 70 0 0 0 0 1 1 0 0 0 0 0 0
50 60 0 0 0 0 1 2 0 0 0 0 0 0
40 50 0 0 0 1 1 5 0 0 0 0 0 0
30 40 0 0 1 1 2 7 0 0 0 0 0 0
20 30 0 0 4 1 3 10 0 0 0 0 0 0
10 20 0 3 2 2 3 7 1 0 0 0 0 0
10 0 8 3 6 7 7 3 0 0 0 0 0

147 976
450 650 950 1100 1250 1400 1550 1700 1850 2000
450 650 950 1100 1250 1400 1550 1700 1850 2000 2500 2500
rpm
A B C

A = 20% of the operating time

B = 43% of the operating time
C = 5% of the operating time
This indicates that only 25% of the operating
time is within the green engine speed range.

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Checking how the vehicle is driven and the pulling power

Here the gearbox and the rear axle ratio have Rear axle tab in SCOP
been modified.
Engine type: DT1203
3.40
Rear axle ratio: 2.92
3.27
Tyres: 295/60 R22.5
3.08
Gearbox: GRSO900 1480 2.92
B
When information about the vehicle is entered 1400 2.71
in SCOP, it indicates that the vehicle has been
correctly specified. The speed falls within one of
the green engine speed ranges. 1240
A
For those engines that have two green engine
1160 1
speed ranges, when specifying a vehicle it is
possible to select which engine speed range the

147 973
40 50 60 70 80 90 100 km/h
vehicle should fall within during normal
operation. The low engine speed range is used in
order to optimise a vehicle for low fuel A = Low engine speed range
consumption. The recommended engine speed
B = Recommended engine speed range
range is used in order to obtain better
driveability, resulting in a slightly higher fuel
consumption.

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 Checking how the vehicle is driven and the pulling power

When the vehicle’s stored operational data is

viewed, this confirms the fact that the vehicle
has been driven within the green engine speed
ranges for a large part of the operating time.

Load matrix
Load
95 0 0 0 0 3 2 2 0 0 0 0 0
90 95 0 0 0 0 0 0 0 0 0 0 0 0
80 90 0 0 0 0 1 0 2 0 0 0 0 0
70 80 0 0 0 0 2 0 2 0 0 0 0 0
60 70 0 0 0 0 3 1 2 0 0 0 0 0
50 60 0 0 0 1 5 1 0 0 0 0 0 0
40 50 0 0 0 1 9 1 0 0 0 0 0 0
30 40 0 1 0 1 13 1 0 0 0 0 0 0
20 30 0 3 0 1 7 1 0 0 0 0 0 0
10 20 0 5 1 1 6 1 1 0 0 0 0 0
10 0 0 1 4 11 2 1 0 0 0 0 0

147 974
450 650 950 1100 1250 1400 1550 1700 1850 2000
450 650 950 1100 1250 1400 1550 1700 1850 2000 2500 2500
rpm
A B C
A = 60% of the operating time
B = 10% of the operating time
C = 10% of the operating time
This indicates that 70% of the operating time is
within the green engine speed ranges.

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Checking how the vehicle is driven and the pulling power

Acceleration test on a flat

road

Preparations
The acceleration test can be performed with
either SDP3 or SCOP.
If using SCOP, obtain the information for the
acceleration test as indicated in the section
SCOP.
The fuel density and temperature are important
for the result obtained, and it is therefore
necessary that this information is entered.
Choose a level road with no traffic. You can
use a Clinometer (see below) to check that the
road is level.
The test requires two people - one to drive the
vehicle and one to run the program.
Run the engine until it reaches normal
operating temperature before the test is carried
out.

Tools

Clinometer Part no. 1 593 822

Acceleration test using SDP3

1 Connect SDP3 to the vehicle. The test is
found under User functions in SDP3.
Select Externally controlled engine
functions from the menu and then
Regulating engine speed with accelerator
pedal. The test is found under the Test tab.
2 Follow the instructions in SDP3 to carry
out the test.

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 Checking how the vehicle is driven and the pulling power

Acceleration test using SCOP

1 Drive the vehicle to the chosen stretch of
road.
2 In SCOP you were given a number of gears
that the test could be performed in. Select a
gear which will give a time between 15 and
25 seconds.
There are two engine speeds given for each
gear. You should measure the time
between these two engine speeds.
Use the stop watch in SCOP to record the
time.
3 Drive the vehicle at an engine speed of
between 800 and 900 rpm.
4 Select the previously chosen gear and fully
depress the accelerator pedal until you
have reached the highest engine speed
stated in SCOP. Measure the time between
the two engine speeds stated in SCOP.
5 Carry out the test several times in both
directions.
6 Calculate the average time and compare it
with the time calculated in SCOP. A
difference of 1 second is considered
normal.
If the average time is the same as the time
according to SCOP, this indicates that the
vehicle pulling power is OK.
If the average time is longer than the time
according to SCOP - troubleshoot the
vehicle.
If the average time is shorter than the time
according to SCOP, this indicates that the
vehicle is more powerful than expected.

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Checking how the vehicle is driven and the pulling power

Hill test

Preparations
The hill test can be performed with either
SDP3 or SCOP.
If using SCOP, obtain the information for the
hill test as indicated in the section SCOP.
The fuel density and temperature are important
for the result obtained, and it is therefore
necessary that this information is entered.
Find an empty stretch of road. Check the slope
of the road, preferably via information from the
local authorities, or by using a Clinometer (see
below).
The test requires two people - one to drive the
vehicle and one to run the program.
Run the engine until it reaches normal
operating temperature before the test is carried
out.

Tools

Clinometer Part no. 1 593 822

Hill test using SDP3

1 Connect SDP3 to the vehicle. The test is
found under User functions in SDP3.
Select Externally controlled engine
functions from the menu and then
Regulating engine speed with accelerator
pedal. The test is found under the Test tab.
2 Follow the instructions in SDP3 to carry
out the test.

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 Checking how the vehicle is driven and the pulling power

Hill test using SCOP

1 Drive the vehicle to the chosen stretch of
road.
2 In SCOP you were given a number of gears
that the test could be performed in. Choose
a gear.
There is one engine speed given for each
gear. The vehicle should be able to
maintain this speed during the whole
climb.
3 Before you reach the hill you should ensure
that the chosen gear is selected and that
you are maintaining the engine speed
stated in SCOP. The engine speed can best
be maintained by engaging cruise control.
4 Apply full throttle just before reaching the
hill.
5 Maintain full throttle until you have
reached the top of the hill. Observe
whether the engine speed changes.
6 Carry out the test several times.
7 If the engine speed was constant then there
is no problem with the pulling power of the
vehicle.
If the engine speed decreases -
troubleshoot the vehicle.
If the engine speed increases then the
vehicle is more powerful than expected.

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Checking how the vehicle is driven and the pulling power

Example of acceleration tests

Below are results from acceleration tests
carried out with a tractor unit, with and without
a trailer. The tests were carried out with a
virtually identical gross weight.
Two tests were carried out with only the tractor
loaded with weights.
Two tests were carried out with the same
tractor with the trailer loaded to the same gross
weight.

Weight Gear Time (s), test 1 Time (s), test 2

(tonnes)
18.38 6L 12.6 13.0

18.69 6L 14.3 14.5

Difference (s) 1.7 1.5

Here it is possible to see how the rolling

resistance of the trailer affects the result. The
trailer was approximately 6 months old at the
time of the test. The tyres had no signs of being
unevenly worn. The trailer was tested, without
remarks, on a roller brake tester to check the
rolling resistance.
The example shows why a tolerance of +/- 1
second is necessary.
For further information see the section
Troubleshoot the vehicle under the heading
Troubleshooting the vehicle, trailer and
powertrain.

30 © Scania CV AB 2009, Sweden 00:03-13


Troubleshoot the vehicle
Note: Before carrying out the following steps
you should first follow the instructions in the
sections Preparations, Asking the customer and
Checking how the vehicle is driven and the
pulling power.
The following pages describe how to
troubleshoot the vehicle.
Troubleshooting can be used if you have one of
the following problems:
• High fuel consumption
• Low power output and poor pulling power
• Abnormal smoke emission
High fuel consumption
If the fuel consumption is high, you should
troubleshoot as described in the following
sections. Troubleshoot in the following order.
1 Vehicle, trailer and powertrain
2 Fuel and the fuel system
3 The electronic control system
4 Charge air system
5 EGR system
6 Exhaust system
00:03-13 © Scania CV AB 2009, Sweden
Troubleshoot the vehicle
The section is subdivided into troubleshooting
of the following areas:
• Vehicle, trailer and powertrain
• Fuel and the fuel system
• The electronic control system
• Charge air system
• Exhaust system
The following vehicle characteristics are of
great importance to the fuel consumption of the
vehicle.
• The vehicle specification
• The vehicle and trailer bodywork
• The optional equipment
• The wheel and axle settings
• The brakes
• The function of the entire powertrain
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Troubleshoot the vehicle

Low power output or poor pulling power

If the power output is low or the pulling power
is poor, you should troubleshoot as described in
the following sections. Troubleshoot in the
following order.
1 Vehicle, trailer and powertrain
2 Fuel and the fuel system
3 The electronic control system
4 Charge air system
5 Exhaust system
The quality of the fuel greatly affects the power
output and pulling power of the engine.
Likewise, the fuel system in general also has a
great influence.
• Also check that the white smoke limiter is
working. If it is not working properly, the
vehicle may seem to have poor pulling
power.
• Also check that the charge air pressure
sensor and charge air temperature sensor
are working. If they are not working, the
vehicle may seem to have poor pulling
power.

Abnormal smoke emission

Black smoke - the relation between the amount 5 Check the EGR system as described in the
of air and fuel supplied to the engine, and any section Checking the EGR system.
faults in the exhaust system, determine the
amount of black smoke produced. If the EGR content at high loads is too
high, black smoke is produced.
1 Check the charge air system as described in
the section Checking the charge air system. White smoke - white smoke is unburned fuel
or water that evaporates together with the fuel
Too little air in relation to the amount of in the combustion chamber.
fuel results in black smoke.
Check the fuel and the fuel system according to
2 Check the exhaust system as described in the steps below. Remedy any faults and then
the section Checking the exhaust system. check smoke emissions right after performing
the measures.
The exhaust back pressure in the complete
exhaust system and any exhaust leakage
before the last exhaust turbine (in the
direction of flow) have an effect on the
smoke emission.
3 Check the fuel and fuel system according
to section Checking the fuel and the fuel
system.
4 Check that the white smoke limiter is
working.

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 Troubleshoot the vehicle

1 Check that the white smoke limiter is

working

2 Check that the wastegate valve, if

fitted, functions correctly

3 Check that the injectors are of the

correct type and are not defective

4 Check that the cold start function, if

fitted, functions correctly

5 Check that coolant is not leaking into

the combustion chamber via the
cylinder liner or the cylinder head

6 Check whether there is water in the

charge air cooler

7 Check that the engine has the correct

compression by carrying out a
compression test using SDP3
The compression of the engine affects
the amount of white smoke.

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Troubleshoot the vehicle

Troubleshooting the vehicle, trailer and powertrain

Check the vehicle, the trailer and the
powertrain according to the steps below.
Discuss with the customer those points that
according to your conclusions may have had an
effect.
1 Use SCOP to check that the vehicle
has the correct gear ratio
Check that the vehicle has the correct
ratios for the gearbox and the rear axle
gear, and also for the vehicle’s transport
application.
2 Check that the tyres are of the correct
type and dimensions and have the
correct inflation pressure
5 Check that none of the brakes in the
vehicle combination are binding
6 Check that the vehicle and the trailer
have the correct wheel and axle
settings
If the wheel and axle settings are
incorrect, the rolling resistance of the
vehicle will be greater, leading to
increased fuel consumption.
7 Check that there is no abnormal
friction in components such as wheel
bearings or the bearings in the
powertrain

8 Check if there is any extra equipment

3 Check how much the bodywork affects fitted that affects the fuel
the air resistance of the vehicle consumption, for example, power
take-off and AC cooling fans
The bodywork affects the fuel
consumption. Check the appearance of
the bodywork.
Factors such as different heights of
tractor and trailer and long distance
between vehicle and trailer have an
effect.
Using different trailers or bodywork
from time to time may also have an
effect.
Loose tarpaulins may also have this
effect.

4 Check to see if there is any extra

equipment that affects the air
resistance of the vehicle
A vertical roof sign on the vehicle, bull
bars and decoration such as the Michelin
man all affect fuel consumption.

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 Troubleshoot the vehicle

Troubleshooting the fuel and fuel system

Check the fuel and the fuel system according to 4 Check that there are no fuel leaks
the steps below.
Repair the fault and immediately afterwards
check fuel consumption, power output, pulling
power or smoke emissions, depending on the 5 Carry out a performance test using
subject of troubleshooting. SCOP

1 Check with SDP3 to see if the engine 6 Carry out a compression test and
control unit has generated any fault check cylinder balancing using SDP3
codes

7 Troubleshoot the unit injectors and

2 Check that the fuel is of an approved
quality
The quality of the fuel greatly affects the
fuel consumption. The fuel consumption
may be normal in relation to the quality
of the fuel. See the service information in
Scania Multi.
fuel system
PDE: Troubleshoot and overhaul the
unit injectors according to the section
in Scania Multi that covers unit
injectors, PDE, Checking and cleaning

HPI: Troubleshoot according to the

3 Check that the fuel supply pressure is section in Scania Multi that covers
correct troubleshooting of the Scania HPI fuel
Check the supply pressure with SDP3 or system
measure it according to the instructions
in the service information in Scania
Multi. If the supply pressure is too low
the engine will lose pulling power. This
can in turn lead to the driver changing
down, leading to power driving and
increased fuel consumption.
The following factors may affect the
supply pressure:
- The suction strainer in the tank is
blocked.
- The fuel line between the tank and the
feed pump is leaking or constricted. A
leak can be difficult to detect.
- The feed pump is not working
satisfactorily.
- The fuel filter is blocked.
- The overflow valve is faulty.

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Troubleshoot the vehicle

Troubleshooting the electronic control system

Check the electronic control system according

to the steps below.
Repair the fault and immediately afterwards
check fuel consumption, power output, pulling
power or smoke emissions, depending on the
subject of troubleshooting.

1 Check the earthing point for the

control unit
It is important for the control unit to be
earthed correctly.

2 Ensure that control unit connectors

are clean and not coated with verdigris
or oxides

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 Troubleshoot the vehicle

Troubleshooting the charge air system

Check the charge air system according to the
steps below.
Repair the fault and immediately afterwards
check fuel consumption, power output, pulling
power or smoke emissions, depending on the
subject of troubleshooting.
1 If the vehicle has a winter air intake,
check that it is correctly adjusted
Important! The winter position should
only be used when the outdoor
temperature is below +5°C.
2 Check that the intake system is of the
original design and that the air filter is
not blocked
Check the vacuum in the intake (vacuum
indicator, refer to maintenance
instructions step 1) which will indicate
whether there is a fault.
Note: Remember that SDP3 displays
absolute pressure (turbocharger pressure
plus atmospheric pressure), i.e. it should
be approximately 1 bar higher than the
pressure measured.
5 Check that the turbocharger is
working and is free from oil and soot
deposits
6 Check that the charge air cooler is not
blocked, internally or externally
The temperature after the charge air
cooler should be 5-10°C above ambient
temperature.
7 Check that the damper in the EGR
valve is not jammed and that the
venturi is working correctly

8 Check that the wastegate valve, if

3 Check the intake manifolds before the fitted, functions correctly
air filter and between the air filter and
turbocharger
Check that none of the bellows have been
squeezed together. 9 Check that the noise baffle, if fitted,
functions correctly

4 Check that all the intake manifolds are

intact and that the intake system is not
leaking
Pressure test the charge air cooler
according to the description in the
service information in Scania Multi.

4b Check the charge air pressure sensor

Measure the charge air pressure using
measuring kit 99 362 (see description in
Scania Multi) and compare it to the
charge air pressure in SDP3.

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Troubleshoot the vehicle

Troubleshooting the EGR system

Check the EGR system according to the steps

below.
Repair the fault and immediately afterwards
check fuel consumption, power output, pulling
power or smoke emissions, depending on the
subject of troubleshooting.

1 Visually check that the exhaust brake

is not applied

2 Check the charge air temperature

sensor and mass flow sensor using
SDP3

3 Check whether the water-cooled EGR

cooler is blocked
The water-cooled EGR cooler may be
blocked if the engine had a serious fault,
such as a leaking injector.
Clean the EGR cooler. Refer to
Workshop Manual, subgroup 01-65
EGR system, water-cooled EGR cooler.

4 Make sure there are no leaks in the

charge air system
Leakage in the charge air system can
cause black smoke.

38 © Scania CV AB 2009, Sweden 00:03-13

 Troubleshoot the vehicle

Troubleshooting the exhaust system

Check the exhaust system according to the

steps below.
Repair any faults, and immediately afterwards
check fuel consumption, power output, pulling
power or smoke emissions, depending on what
you are troubleshooting.

1 Check that the exhaust system is of the

original design and that the silencer is
intact.
The exhaust back pressure must not be
too high.

2 Check that there are no leaks in the

exhaust system before the gas flow
reaches the last exhaust turbine.

3 Check that the exhaust brake is correctly

adjusted, is not worn and is working
satisfactorily. Also check the
proportional valve.

4 Check that the turbine in the

turbocharger is working and not chafing
on the turbine housing.

5 Also check the power turbine in the

turbocompound unit (engines equipped
with turbocompound).

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