Gas Engine OC9 G02 Function and Work Description: en-GB

01:01-07
Issue 2 en-GB
Gas engine
OC9 G02
Function and work description
©
1 715 995 Scania CV AB 2011, Sweden
Contents
Contents
Function description .................................................................................. 3
General ..................................................................... 3
Overview .................................................................. 6
Engine and ignition system .................................... 13
Gas control system ................................................. 18
Chassis and gas system........................................... 29
Electrical system..................................................... 34
Work description ................................................................................ 37

Safety precautions .................................................. 37
Action prior to repair .............................................. 37
MAP sensor, renewal.............................................. 38
TIP sensor, renewal ................................................ 41
Atmospheric pressure sensor, renewal ................... 42
Gas mixer, renewal................................................. 43
Gas mixer diaphragm, renewal............................... 46
Gas panel bracket, modification ............................. 48
Gas panel, leak test ................................................. 49
Low pressure regulator, gas valve leak test............ 50
Electric throttle linkage, adjustment....................... 51
Troubleshooting ................................................................................ 52
Troubleshooting diagram........................................ 52
Fault codes.............................................................. 61
HD ECM for workshop .......................................... 91
Field information .................................................. 103
2 ©
Scania CV AB 2011, Sweden 01:01-07
Function description
General
Specification
Engine type plate
O Combustion principle, O = Otto
C Cooling, C = Charge air cooled
9 Cubic capacity, litres
G Fuel type, G = Gas
02 Version number
Specification and limits

Production period 2006-2008
Engine power, 2,000 rpm 260 hp
Torque, 1,000-1,400 rpm 1,100 Nm
Combustion type Lean burn
Emission control type Oxidation catalytic converter
Lambda value 1.55
Efficiency, full load Approx. 40%
Gas control system Lambda feedback system
Exhaust emission certification EEV
CNG standard H, European Standard ISO/DIS 15403 and/or
Biogas, Swedish Standard SS 155438.
Gas tank, assembly, number of gas bottles 4 off
Gas tank, assembly, volume 320 l
Gas tank, pressure 200 bar
Turbocharger Wastegate valve (charge air pressure control)
ADR Limited
TC No
Opticruise No
Exhaust brake No
Gas-fired auxiliary heater No. A fuel heater can be fitted
01:01-07 ©
Scania CV AB 2011, Sweden 3
Gas specification Combustion

The vehicle can use two types of gas: The engine is an Otto engine that operates
according to the lean burn principle.
• Natural gas (fossil gas) containing varying
amounts of methane, ethane, butane or Lean burn means a fuel/air mixture containing
propane gas depending on the type of gas. more air than is required for complete
Natural gas must be processed and cleaned. combustion. The fuel - air ratio is approx. 1:26.
• Biogas (renewable and organically The high proportion of air raises efficiency and
extracted) containing methane gas purified results in reduced exhaust temperatures,
to 97% with the remainder being carbon reduced nitrogen oxide values and reduced
dioxide and odorants. carbon dioxide emissions.
Gas engines can handle gas grades with a During combustion the lambda value controls
class H Wobbe index in line with the European the fuel and oxygen mixture using the amount
standard ISO/DIS 15403. of oxygen remaining after combustion. When
the lambda value = 1, there is a complete
Wobbe index 46.1-56.5 MJ/m3 combustion of all available fuel and oxygen.
Temperature 288.15 Kelvin
Pressure 101.325 kPa
4 ©
Emission control
Catalytic emission control has two principles:
Catalytic oxidation Three way catalysis (lambda=1)
IN OUT IN OUT
HC + O2 H2O, CO2, HC HC + NOx H2O, N2
CO + O2 CO2 CO + NOz CO2, N2
NOx + O2 NOx
Following combustion there is carbon dioxide
Following combustion there are hydrocarbons (CO2), carbon monoxide (CO) and nitrogen
(HC), carbon monoxide (CO), nitrogen oxides oxides (NOx) and water. During emission
(NOx) and water (H2O). During emission control the exhaust gases are reduced to water
control oxygen (O2) is added; this oxidises the (H2O), carbon dioxide (CO2) and nitrogen (N2).
exhaust gases to water (H2O) and carbon The emission control of a three-way catalytic
dioxide (CO2). During catalytic oxidation a converter is greater than catalytic oxidation and
also reduces nitrogen oxides (NOx).
limited amount of hydrocarbons (HC) are
reduced but no nitrogen oxides (NOx).
01:01-07 ©
Overview
Engine and ignition system

The engine is basically a DSC9 11 diesel engine
equipped with new cylinder heads with spark
plugs and new pistons. The ignition system
consists of inductive sensors on the camshaft
and flywheel, a control unit and separate
ignition coils for each spark plug.
Overview engine, ignition system
1 Ignition coil
2 Ignition cable
3 Spark plug
4 Cylinder head
The OC9 G02 is a 6-cylinder, 9 litre Otto engine

with the partially mechanical control of gas
supply and a lambda feedback system, i.e. a
system that can handle variations in gas grade
without manual adjustment. Calibration takes
place automatically.
The engine is fitted with a MegaJector that
controls the gas/air mixture to the engine. This
helps achieve low fuel consumption along with
smooth operation and low exhaust emissions.
The engine speed is controlled by an electric
throttle via the accelerator pedal.
6 ©
Combustion generates exhaust gases that are

expelled from the cylinders at high pressure and
carried to the turbine wheel in the turbocharger.
The exhaust gases drive the turbine wheel which
is connected to the compressor impeller through
a shaft. Air is sucked in through the air filter by
the compressor impeller, compressed and forced
out into the inlet pipe. When the air is
compressed it becomes hot and expands. The air
passes the charge air cooler before being carried
into the engine making combustion more
efficient.
The charge air pressure is controlled by the
proportional valve. When the charge air pressure
gets too high the proportional valve opens the
wastegate valve on the side of the turbine wheel;
this releases the exhaust gases and reduces the
rotational speed of the compressor impeller,
reducing the charge air pressure.
The throttle valve is acted on by the driver’s
accelerator pedal, which in turn acts on the
electric throttle which provides the engine with
the quantity of air and fuel required to give the
engine the desired power. The minimum load
valve, which reduces the charge air pressure
when the throttle valve is closed rapidly, is
located on the intake manifold by the throttle
valve.
There is a bypass valve on the pressure side of
the turbocharger to reduce the charge air
pressure when the driver releases the
accelerator.
01:01-07 ©
Overview engine, right-hand side
1 Minimum load valve

2 Gas mixer
3 Electric throttle
4 Throttle valve
Overview engine, from behind
1 Bypass valve
2 Turbocharger
3 Wastegate valve
8 ©
Gas control system

The gas equipment consists of tanks, mechanical
shut-off valves, solenoid valves, high and low
pressure regulators, a MegaJector, a manometer,
heat exchanger and gas mixer. The components
work together to provide the engine with the
correct amount of gas at the correct pressure.
The gas is carried at high pressure, approx.
200 bar, from the gas tanks on the high pressure
side to the gas panel. The gas is filtered and its
pressure regulated in the gas panel before being
carried to the engine through the MegaJector.
Two regulators on the high pressure side reduce
the gas pressure from approx. 200 bar to approx.
10 bar and carry the gas on to a regulator on the
low pressure side. Between the high pressure
side and low pressure side there is a solenoid
valve that shuts off the gas on the low pressure
side when the engine is switched off.
The regulators are connected to the gas mixer air
intake via pressure pipes. Reference values
control the high pressure regulators, low
pressure regulator and the MegaJector. In the
low pressure regulator and MegaJector the gas
pressure is further reduced to approx. 2-12 mbar
above the turbocharger charge air pressure. The
gas pressure must always be greater than the
charge air pressure.
The high pressure regulator and heat exchanger
are connected to the engine cooling system. The
gas is cooled drastically when it expands and
must therefore be heated by the cooling system.
The gas is carried from the low pressure
regulator through the MegaJector to the gas
mixer to be mixed with cleaned air from the
charge air cooler and provides the engine with
the correct fuel/air mixture. The MegaJector
regulates the gas/air ratio in the gas mixer using
a number of sensors connected to it.
01:01-07 ©
Overview, gas control system
1 Throttle valve 8 Pressure pipe to air intake

2 Minimum load valve 9 MegaJector
3 Gas/air mixture to the engine 10 Gas to gas mixer
4 MAP sensor 11 Gas mixer
5 Sensor, coolant temperature 12 Pressure pipe to wastegate valve
6 Coolant pipe from engine 13 Air to gas mixer
7 Coolant pipe to engine 14 TIP sensor
10 ©
Overview, gas control system
1 Sensor, wastegate valve (charge air

pressure)
2 Proportional valve
3 MAP sensor
4 Atmospheric pressure sensor
5 Control unit, engine management system
01:01-07 ©
Principle drawing of gas panel
1 Gas intake 200 bar

2 Manual high pressure shut-off valve
3 Manometer, high pressure
4 Coolant outlet
5 Safety valves
6 High pressure regulators
7 Solenoid valve
8 Pressure pipe, charge air (reference value)
9 Gas outlet to gas mixer
10 Coolant inlet
11 Low pressure regulator
12 Voltage supply 24 V
13 Heat exchanger
14 Pressure sensor
15 MegaJector
12 ©
Engine and ignition

system
General
The ignition system is of the inductive type.
Control unit
The control unit receives information about the
engine crankshaft position and camshaft
position through sensors. The control unit is
located on the cylinder block and provides a
voltage (24 V) to each ignition coil.
Ignition coil
WARNING!
The spark plugs are supplied with 25,000 V.

Carelessness can cause lethal injuries.
The purpose of the ignition coils is to raise the

voltage from 24 V to approx. 25,000 V in order
to generate a spark across the spark plug
electrodes.
01:01-07 ©
Spark plug
The spark plug produces an electric spark
between the spark plug electrodes on receiving a
signal from the ignition pulse sensor; this ignites
the gas mixture in the combustion chamber.
Each spark plug has its own ignition coil.
Type: NGK IRIFR7U4D

Electrode gap: 0.35 mm nominal value
Tightening torque: 35-40 Nm
Ignition pulse sensor

The ignition pulse sensors are located on the
camshaft gear. There is also a position sensor
which detects the position of the flywheel. Both
of these sensors must work for the engine to
start. If the engine has started only one position
sensor is used for the flywheel. At a preset
position the control system transmits a signal to
the spark plug to produce a spark.
Note: The firing position cannot be changed in

the OC9 G02. The position is determined by the
control unit and position sensors for the
camshaft and flywheel.
14 ©
Wastegate valve
The wastegate valve acts as a charge air pressure
control valve for the turbocharger.
Wastegate valve component parts and flow
1 Air in
2 Air to the engine
3 Exhaust gases from the engine
4 Exhaust gases out
5 Wastegate valve
6 Bypass duct
7 Compressor impeller
8 Turbine wheel
The engine exhaust gases are expelled from the

cylinders at high pressure. The exhaust gases are
carried to the turbine wheel in the turbocharger
which starts to rotate. The turbine wheel is
connected to the compressor impeller via a
shaft.
The compressor impeller sucks air via the air
filter and forces the air into the inlet pipe. An
increased load on the engine produces a higher
pressure on the exhaust gases and higher
pressure on the intake air which increases the
At a set charge air pressure the wastegate valve
opens, releasing a proportion of the exhaust
gases past the turbocharger turbine wheel so that
the charge air pressure does not get too high.
The charge air pressure is controlled so that the
engine has the correct torque curve.
See Scania Multi 01-30 Wastegate.
01:01-07 ©
Proportional valve
The proportional valve controls the charge air
pressure via the pressure to the wastegate valve.
The charge air pressure is measured in the intake
manifold.
At a low charge air pressure the proportional
valve is closed. The wastegate valve pressure
sensor detects the reduced charge air pressure
and closes the wastegate valve. At a high charge
air pressure the proportional valve opens and the
wastegate valve pressure sensor responds by
opening the wastegate valve and regulating the
The proportional valve is a three-way valve
which is controlled by PWM signals (Pulse
Width Modulated) from the engine control unit.
Bypass valve
The purpose of the bypass valve is to reduce the
pressure against which the turbocharger is
working and slowly reduce the speed of the
turbocharger when the driver releases the
accelerator pedal. This prevents cavitation that
could damage the turbocharger.
The bypass valve is located on the inlet pipe
downstream of the turbocharger and is
controlled by the vacuum between the throttle
valve and intake valve. The bypass valve
controls the intake air back to the inlet pipe
upstream of the turbocharger.
16 ©
Minimum load valve 1 2 3 4 5 6

The minimum load valve is located on the
throttle valve housing. When the throttle valve
closes rapidly the vacuum in the intake manifold
increases and the charge air pressure increases
because the turbocharger continues to spin due
to the moment of inertia. A spring-loaded valve
is opened mechanically when the vacuum
downstream of the throttle valve becomes too
great and the charge air pressure decreases.
Component parts and function
1 Throttle valve housing 7

2 Minimum load valve
3 Valve
4 Spring
5 Cover
6 Open throttle valve
7 Closed throttle valve
317 245
Electric throttle
The electric throttle is an electronic control for
increasing and decreasing the engine speed. It
replaces mechanical control using a control
wire. For further information, see the booklet
Electric throttle 14:02-55.
01:01-07 ©
Gas control system

Gas panel
The gas panel is a unit in which gas from the gas
tanks is filtered and its pressure regulated before
being carried to the engine fuel system.
Gas panel overview
1 Sensor, gas pressure 6 Test connection

2 Manometer 7 High pressure regulator
3 Heat exchanger 8 Safety valve, high pressure
4 Solenoid valve, low pressure 9 Shut-off valve
5 Low pressure regulator 10 Fuel filter
18 ©
Manometer
The manometer indicates the gas pressure in the
tanks before the gas has passed through the high
pressure regulators.
Heat exchanger
The temperature of the gas drops sharply when
the pressure is reduced and the gas expands.
When the gas is cooled there is a risk of damage
to components as they become brittle at low
temperatures.
The high pressure regulators and heat exchanger
downstream of the low pressure regulator are
connected to the engine cooling system. Coolant
from the engine is carried through the regulators
to heat up the gas. A constant gas temperature
provides better lambda control.
Solenoid valves
The purpose of the solenoid valves is to open
and shut off the gas flow when starting or
stopping the engine.
The solenoid valves open when the starter key is
turned to the start position and the starter motor
turns. The valves are kept open by the voltage
from the alternator charge control output.
There is a solenoid valve between the high
pressure side and low pressure side which acts
to shut off the connection between high and low
pressure.
01:01-07 ©
Low pressure regulator

The low pressure regulator further reduces the
gas pressure from the high pressure side from
approx. 10 bar to a gas pressure approx.
2-12 mbar above charge air pressure.
Low pressure regulator, component parts
1 Gas inlet
2 Valve, stage 1
3 Diaphragm
4 Outlet from the reference pressure pipe
5 Outer spring
6 Diaphragm
7 Inner spring
8 Reference pressure to the MegaJector
9 Valve, stage 2
10 Gas outlet
20 ©
Pressure reduction in the low pressure regulator

takes place in two stages.
In the first stage the gas reaches a valve with a
leaf spring and rubber seal design. When
unpressurised the valve is open. The pressure in
the first stage acts on a diaphragm and
counteracts the force of the spring, closing the
valve when the pressure is too high. The
connection between the first and second stages
is controlled by the second stage valve which is
acted on by the second stage diaphragm and its
spring.
The second stage of the regulator is connected,
via the MegaJector, to the gas mixer on the
engine intake manifold by a hose. The vacuum
from the gas mixer acts on the second stage
diaphragm which opens allowing the gas to be
sucked into the gas mixer and then on into the
engine.
The reference pressure pipe is connected to the
air pipe on the gas mixer. When the
turbocharger is charging a positive pressure
arises in the air pipe. In order to compensate for
this pressure in the gas mixer the pressure is
carried through the reference pressure pipe to
the outside of the diaphragm. This increases the
positive gas pressure in proportion to the charge
air pressure creating the correct ratio of gas to
air.
01:01-07 ©
High pressure regulator

There are two high pressure regulators on the
gas panel. The regulators reduce the gas
pressure from the tanks on the high pressure side
from approx. 200 bar to approx. 10 bar. In the
event of a fault leading to high pressure, the
safety valve releases gas through a gas pipe to
reduce the overpressure.
Shut-off valve, high pressure

At the fuel filter on the high pressure pipe
upstream of the gas panel there is a manual
valve for shutting off the gas from the gas tanks,
when renewing the fuel filter for example.
Fuel filter
The fuel filter is a throughflow filter which
mainly cleans the gas of oil. The filter is located
on the high pressure pipe from the gas tanks
upstream of the gas panel.
22 ©
Engine management system

The engine management system is an electronic
system for controlling the amount of gas,
ignition and charge air pressure. The control
system consists of a control unit which is
connected to the MegaJector and a number of
sensors. The ignition coils and proportional
valve are also connected to the control unit.
The control system has a diagnostic socket for
connecting equipment used when changing
settings and troubleshooting.
Control unit
Factors that influence the engine are engine
speed, air temperature, pressure and the lambda
value in the exhaust system. Sensors on the
engine and chassis transmit information to the
control unit which controls the amount of gas,
ignition and charge air pressure.
The control unit has adaptive learning and
receives information from the sensors to
automatically adjust the amount of gas to the gas
mixer. The amount of gas and the gas/air
mixture are adjusted for complete combustion
using information from the lambda sensor about
combustion. The lambda system with feedback
manages variations in gas grade without the
need for manual adjustment.
Information in the control unit is saved in maps.
The amount of gas and gas/air mixture are
regulated by the information in the Lambda,
Ignition and Charge air pressure maps. See
Section Troubleshooting, HD ECM for
workshop.
01:01-07 ©
MegaJector
The MegaJector contains a damper that
regulates the amount of gas to the gas mixer and
the gas/air ratio to the engine. The amount of
gas from the MegaJector is controlled by the
differential pressure sensor downstream of the
gas mixer. The sensor controls the damper so
that the engine receives the correct amount of
gas.
MegaJector, overview
1 Differential pressure sensor

2 Gas in from the low pressure regulator
3 Gas out to the gas mixer
4 Damper
5 Chamber with gas
24 ©
Sensors
A number of sensors are connected to the
control unit to collect information and control
the amount of gas, ignition and charge air
pressure.
1 Accelerator pedal 6 Low pressure valve

2 Diagnostic socket 7 High pressure valve
3 MegaJector 8 Proportional valve
4 Control unit 9 Spark plugs 1-6
5 Sensor for filler flap and collision
01:01-07 ©
Lambda sensor Wastegate valve (pressure sensor)

Sensor T1013. The sensor is located on the Sensor T604. The sensor is located on the three-
exhaust pipe downstream of the turbocharger way valve.
and measures the amount of oxygen in the
exhaust gases following combustion. During
Coolant temperature sensor
combustion the lambda sensor controls the
lambda value, i.e. the ratio of air to gas. The Sensor T33. The sensor is located on the engine
control system delivers more or less fuel in and measures the coolant temperature.
order to keep the lambda value constant.
Complete combustion occurs when the lambda
Rotational speed sensor
value = 1. The OC9 G02 has a lambda value
of =1.55. In other words 55% more air than that Sensors T74 and T75. Sensor T74 is located in
required for complete combustion. the flywheel housing at cylinder 6. Sensor T75
is located in the timing gear casing at cylinder 1.
MAP sensor
The sensors measure engine speed.
MAP sensor (Manifold Air Pressure) T605. The

Rotation speed sensor, electric throttle
sensor is located on the engine by the ignition
coils and measures the intake pressure The electric throttle sensor is located on the
downstream of the throttle. flywheel housing and measures the engine speed
for the electric throttle.
TIP sensor
TIP sensor (Throttle Inlet Pressure) T1019. The Diagnostic socket

sensor is located on the inlet pipe for air to the The diagnostic socket is located in the engine
gas mixer and measures the pressure and compartment at the upper edge of the engine
temperature upstream of the throttle. compartment door. Troubleshooting and
changing settings can be carried out using
Atmospheric pressure sensor special equipment. See Section
Troubleshooting, HD ECM for workshop.
Sensor T1018. The sensor is located by the
control unit and measures the atmospheric
pressure.
Note: The sensor is not operational and if

necessary can be used as a spare part when
renewing the MAP sensor.
26 ©
Gas mixer
The purpose of the gas mixer is to mix gas and
air according to current values from the
MegaJector control unit.
Gas mixer, component parts
1 Gas flow adjusting screw (factory set)

2 Diaphragm
3 Support washer
4 Idling mixture shim (factory set)
5 Air/gas valve
6 Idling speed adjusting screw (factory set)
7 Variable gas passage
8 Variable air passage
9 Pressure connection to diaphragm chamber
Note: The adjusting screw, 1, is factory set to

position R and must not be changed.
Note: The idling speed adjusting screw, 6, is

factory set and must not be changed.
01:01-07 ©
Gas mixer, gas flow
1 Gas intake
2 Air inlet 1
3 Gas/air mixture outlet
A. Mixing chamber B
B. Diaphragm C
C. Pressure connection to the diaphragm

chamber
A
317 248
D. Gas valve 2
D
When air is pressed into the confined passages
in the gas mixer its speed and dynamic pressure
increases because the volume decreases in the
narrow passages. The increased throughflow
creates a vacuum and the static pressure drops
behind the diaphragm through a connection to
the diaphragm chamber through the holes in the
air/gas valve and diaphragm.
Because the pressure is lower on one side of the
diaphragm, in the chamber, the air will try to
even out the pressure differential between the
two sides. The spring-loaded valve is then
pressed back by the positive pressure, which in
turn presses back the valve and opens for the gas
to be mixed with the air. The gas pressure is
always greater than the charge air pressure so
that the air does not go back into the gas line.
The gas valve opens in proportion to an
increased charge air pressure and the gas/air
mixture is routed to the engine.
28 ©
Chassis and gas system

The gas system consists of the gas tank package,
gas panel and gas lines. The gas tank package is
located on the front section of the roof. The gas
filling point is located by the front headlamp or
above the hatch for the gas panel on the right-
hand side of the vehicle.
Gas system
1 Gas tank package

2 Gas panel
3 Gas filling point
01:01-07 ©
Gas tank package

The bus gas tank package consists of four tanks.
The tanks are located on stands which are
certified according to regulations governing
their attachment and for possible acceleration
forces, e.g. in the case of a collision. A
certificate from the manufacturer of the tank
equipment must accompany the vehicle on
delivery.
Gas tank package
1 Gas tank
2 Shut-off valve, gas tank
3 Fusible link
4 Main valve, gas tank package
5 Filler nipple
6 Check valve
Main valve, gas tank package

There is a main valve on the vehicle for
manually shutting off the gas from the entire
tank package.
Filler nipple
There is a check valve in the filler nipple that
prevents the gas leaking out of the tanks to the
filler nipple when filling the gas tanks.
30 ©
Gas tank
The gas tanks are made of a composite material
and hold 320 l. The tanks are marked with their
date of manufacture and how many fillings for
which they are approved. The gas tanks have
solenoid valves, manual shut-off valves, flow
limiters and fusible links.
Shut-off valve, gas tank

The gas tank has a shut-off valve for manually
shutting off the gas from the individual tank,
when renewing the gas tank for example.
There is a solenoid valve in the shut-off valve
which starts and shuts off the supply of gas to
the gas panel from the high pressure side when
the engine is started and stopped.
The solenoid valve also acts as a pipe break
valve (flow limiter) to limit the speed of the gas
outflow following the rupture of a pipe on the
high pressure side for example.
The shut-off valve contains a fusible link that
blows if the temperature exceeds 110°C.
01:01-07 ©
Gas system
Principle drawing Scania Omni
32 ©
1. Gas tank S1. Lambda sensor

2. Tank frame S2. Engine speed flywheel
3. Tank valve S3. Engine temperature
4. Fusible link S4. Camshaft position
5. Check valve S5. Inlet pipe, pressure and temperature
6. Filler nipple S6. Charge air pressure
7. Manometer S7. Atmospheric pressure sensor
8. Shut-off valve S8. Wastegate pressure
9. Filler nipple
10. Line 12 mm
11. Line 16 mm
12. Line 8 mm
13. Threaded fitting
14. Safety line
A1. Spark plug and ignition coil
15. Fuel filter
A2. Valve, wastegate control
16. High pressure regulator
A11. Actuator, VDO electric throttle
17. Solenoid valve
18. Heat exchanger
19. Low pressure regulator
20. MegaJector
E1. Sensor, emergency gas shut-off
21. Low pressure line
22. Gas mixer
23. Low pressure line
24. Pressure sensor, instrument panel A. ECUI
25. Gas mixer (throttle) B. Electric throttle
01:01-07 ©
Electrical system
Communication electrical cable
X. Scania connection (view from behind)

1. RX
2. TX
3. 5 V
4. RTN
Y. IMPCO connection (view from behind)
(9). PIN number 9 (black/green)
(12). PIN number 12 (green)
(13). PIN number 13 (orange)
(14). PIN number 14 (green/brown)
Part numbers for electrical cables:

1901764 (RS232 connection)
1901767 (USB connection)
34 ©
Engine
01:01-07 ©
36 ©
Work description
Work description
Safety precautions
Prepare the vehicle according to the regulations
contained in Safety and fire protection in service
workshops, see Scania Multi 00:01-02.
Note: Use only ECE R110 approved

components.
Action prior to repair

• Always check that the electric throttle is
correctly set prior to starting a repair.
• Adjust the setting if necessary and test drive
the vehicle.
• Continue with the planned repairs if the
problem persists.
01:01-07 ©
Work description
MAP sensor, renewal

In order to simplify the renewal of the sensor,
the bracket for the ignition coils by the MAP
sensor is to be modified.
This work description describes the workflow
after the modification. The workflow for
modifying the bracket is described in brackets,
this can be ignored after the modification has
been carried out.
Removal
workshops, 00:01-02.
1 Remove the seat above the engine
compartment door to give space in which to
work.
2 Open the door to the engine compartment.
3 Disconnect the three (six) ignition cables, 1
from the spark plugs.
4 Disconnect the three (six) ignition coil
connectors, 2.
5 Remove the screw (the three screws), 3
securing the hose clamp (the three hose
clamps) and the hose on the fuel manifold.
6 Remove the two (three) screws, 4 securing
the bracket at the front and the screw (the
three screws) holding the bracket at the
back.
7 Remove the bracket, 5.
38 ©
Work description
8 Disconnect the sensor connector and

cable, 6.
9 Remove the two screws, 7 securing the
sensor.
10 Remove the sensor, 8.
11 (Split the bracket, 9 at the marking.)
01:01-07 ©
Work description
Fitting
1 Fit the new sensor and a new O-ring.
2 Tighten the two screws securing the sensor.
3 Connect the sensor connector and cable.
4 Fit the bracket (the two brackets).
5 Tighten the two (three) screws, 4 securing
the bracket (brackets) at the front and the
screw (the three screws) holding the bracket
at the back.
6 Tighten the screw (the three screws), 3
securing the hose clamp (the three hose
clamps) and the hose on the bracket.
7 Connect the three (six) ignition coil
connectors, 2. Check that the locking parts
snap into position.
8 Connect the three (six) ignition cables, 1 to
the spark plugs.
9 Close the engine compartment door.
10 Refit the seat.
40 ©
Work description
TIP sensor, renewal

Removal
1 Disconnect the sensor cable.

2 Remove the two screws securing the sensor
to the inlet pipe upstream of the gas mixer.
3 Remove the sensor.
Fitting
3 Connect the sensor cable.
01:01-07 ©
Work description
Atmospheric pressure sensor, renewal

Note: If the sensor is being used as a spare part a
new sensor should be fitted as soon as possible
to avoid problems such as the oxidation of
contacts.
Removal
1 Disconnect the sensor cable.
2 Remove the two screws securing the sensor.
3 Remove the sensor.
Fitting
3 Connect the sensor cable.
42 ©
Work description
Gas mixer, renewal

Special tools
Description Measurements
Socket 3/8 inch
Removal
1 Remove the air cleaner, 1, to give space in
which to work.
2 Remove the four screws, 2, securing the

steel plate with the gas mixer onto the intake
manifold.
3 Remove the latch clamp securing the
throttle valve linkage, 3, on the ball joint
and detach the linkage.
4 Remove the throttle valve spring. The
spring is located on the back of the intake
manifold between the throttle valve and gas
mixer.
01:01-07 ©
Work description
5 Remove the two front screws, 4, securing

the flange onto the gas mixer.
6 Remove the two rear screws securing the
bracket for the gas spring and gas mixer
onto the flange and remove the bracket for
the spring.
7 Remove the gas mixer from the flange.
8 Remove the two screws, 5, and washers
securing the steel plate with the electric
throttle onto the bracket and remove the
electric throttle to give space in which to
work.
9 Undo the nut, 6, on the gas line from the
MegaJector and remove the line.
10 Remove the gas mixer.
44 ©
Work description
Fitting
1 Fit the gas line to the gas mixer and tighten
the nut, 6.
2 Fit the new gas mixer. Check that the gasket
is correctly positioned between the flange
and gas mixer.
3 Fit the bracket for the spring and tighten the
two rear screws securing the gas mixer to
the flange.
4 Tighten the two front screws, 4, securing the
gas mixer onto the flange.
5 Fit the spring for the throttle valve, between
the bracket on the throttle valve and the
bracket on the gas mixer.
6 Fit the steel plate with the electric throttle
and tighten the four screws, 2, securing the
gas mixer onto the plate at the intake
manifold.
7 Tighten the two screws, 5, securing the steel
plate with the electric throttle to the bracket.
8 Fit the throttle valve linkage, 3, to the ball
joint and lock it with the latch clamp.
9 Fit the air cleaner, 1.
01:01-07 ©
Work description
Gas mixer diaphragm, renewal

Removal
1 Remove the gas mixer. See Gas mixer,

renewal.
Note: Mark the parts and make a note of their

location so that they can be refitted in the same
position.
2 Remove the five screws, 1, securing the

cover on the gas mixer.
3 Remove the spring.
Note: Take care when handling the diaphragm

so as not to damage the rubber.
4 Remove the diaphragm unit.
46 ©
Work description
Fitting
Note: Refit the parts in their original position.
Note: Take care when handling the diaphragm

unit so as not to damage the rubber.
5 Fit a new diaphragm unit.

6 Fit the spring.
7 Fit the cover and tighten the five screws, 1.
8 Fit the gas mixer. See Gas mixer, renewal.
01:01-07 ©
Work description
Gas panel bracket, modification

In order to simplify the removal of the low
pressure regulator the gas panel bracket is to be
modified.
Note: The bracket must not be shortened by

more than the specified measurement as there is
a risk that its strength could be impaired.
1 Make a recess in the bracket by cutting two

grooves perpendicular to surface C in
accordance with markings A and B. The
angle of the cut should be at least 90° and a
maximum of 95°.
2 Remove the loose bit of the bracket.
Note: During regular inspections of the vehicle

the bracket must be checked for cracks in the
area of modification.
48 ©
Work description
Gas panel, leak test

• Gas under pressure (nitrogen or air) can be

connected to the high pressure gas inlet of
the gas panel without risk of overload.
• Gas under pressure may not be connected to
the reference (charge air pressure) pressure
connection. During actual operation the gas
pressure is raised to about the same level as
the reference pressure so that the pressure
differential between both sides of the
regulator diaphragm is very small. If the
regulator is tested using a reference pressure
of one bar the force on the diaphragm will
be approx. 1,650 N (165 kp) which is too
great.
• The pressure out downstream of the gas
panel is slightly higher than the reference
pressure. If no reference pressure is
connected the nitrogen (or air) will flow out
through the outlet on the low pressure side
with a slight pressure. This means that the
function of the solenoid valves can easily be
checked.
• Check the function of the valves. Gently
press your hand against the low pressure
outlet. The flow should stop.
• If a valve is leaking the pressure will
increase after several seconds which you
will be able to feel clearly with your hand.
01:01-07 ©
Work description
Low pressure regulator, gas valve leak test
When idling, if the engine lambda setting varies

for no reason, the fault can be due to a leaking
valve in the low pressure regulator. The integrity
of the gas valves in the low pressure regulator
can be checked using compressed air.
1 Disconnect the connection for high pressure

gas to the gas panel and connect compressed
air at a pressure of approx. 1-10 bar.
2 Disconnect the gas line from the low
pressure outlet of the regulators.
3 Open the solenoid valve between the high
and low pressure regulators by connecting
24 V to the solenoid valve, using the
connection in the lines in the gas panel.
(Alternatively, the engine can be cranked by
the starter motor to open the valves.) Air,
together with residual gas (which can be
noticed by its smell), will now flow out
through the low pressure outlet at a slight
pressure.
4 Stop the air flow with your hand gently
pressed against the low pressure outlet.
Keep your hand in place for 10-20 s. If you
feel no pressure against your hand the
valves in the low pressure regulator are
leaktight. If you can feel a clearly increasing
pressure on your hand then one of the valves
is leaking.
5 Rectify the fault and check all gas
connections using leak detection spray.
50 ©
Work description
Electric throttle linkage, adjustment

For other work descriptions regarding the
electric throttle, see Electric throttle, Work
description 14:02-56.
1 Run the engine until it reaches normal Note: The throttle linkage must be
operating temperature. disconnected.
2 Disconnect the throttle linkage.

6 Stop the engine by shutting off the supply of
gas. Leave the ignition on.
Note: Do not change the idling speed adjusting
screw on the gas mixer. 7 Adjust the length of the linkage so that it fits
onto the ball when the lever is in the idling
position.
3 Set the idling speed to 550 rpm using the
idling screw on the throttle valve housing. 8 Depress the accelerator pedal as far as it will
go and adjust the linkage so that it travels
4 Switch off the ignition voltage with the 2-4 mm further than the wide open throttle
starter key. position on the lever. If necessary, move the
5 Start the engine and keep the accelerator upper ball pin in the slot on the electric
pedal depressed for at least 2 s. throttle motor. Adjustment in this slot will
not affect the idling position.
9 Check that the ball still fits onto the linkage

at the idling position.
10 Clear any fault codes.
01:01-07 ©
Troubleshooting
Troubleshooting
Troubleshooting diagram
Gas vehicles
The troubleshooting diagram can provide
guidance in case of engine problems. If the gas
engine is being supplied with fuel, a spark is
being generated and the lambda value is correct,
the engine should run well. Of course there may
be other faults which have nothing to do with it
being a gas engine.
Fault codes
- Check for active or historical fault codes in See Section HD ECM in the function and
the control unit. work description
- Check for active or historical fault codes in See the function description, work
the Electric throttle system. description and fault code list for the Electric
throttle 14:02-55, 14:02-56 and 14:02-57.
52 ©
Troubleshooting
0. Preparatory checks
A Under what circumstances is the engine At full load, partial load, idling, will not
running poorly? start, runs unevenly etc.
B When did the problem start? After an inspection, refuelling or washing.
Or did it start all of a sudden?
C Was there a change in the weather when Was there a frost, did it rain etc?
the problems started?
D Check the mileage. Total mileage and mileage since the last
inspection.
E Check the tank pressure and the type of gas Natural gas or biogas.
which was taken on last.
01:01-07 ©
Troubleshooting
1. Checks to be made
Symptom
The engine is running poorly at full load but well at other loads.
Possible cause Action
A Incorrect lambda value Check the variables UEGO Phi and Phi command on the
PhiNG page. See Section HD ECM.
B Low tank pressure Refuel if the pressure is lower than 30 bar.
C The gas regulator is not Close the high pressure shut-off valve, crank the engine
receiving a gas supply using the starter motor and check the manometer to see if
the pressure drops. Check that the solenoid valve on the low
pressure side opens if the pressure does not drop.
D Fault in the ignition system Check whether the engine fires on all cylinders by shutting
off each of the cylinders in turn. See Section HD ECM,
Test. Shut off the cylinders in firing order not cylinder
order. 1=cyl 1, 2=cyl 5, 3=cyl 3, 4=cyl 6, 5=cyl 2, 6=cyl 4.
Renew the spark plugs if the mileage since the last spark
plug change is greater than 30,000 km.
F Fault in the ignition system Check that all spark plugs generate a spark by
disconnecting one ignition cable at a time. Otherwise renew
the spark plug, ignition cable, ignition coil and cable
harness, in that order.
G Fault in the ignition system Check that the engine starts up the ignition system. See
Section HD ECM.
I Dirt in the gas system Check the pressure differential between the charge air
pressure and gas pressure in the low pressure regulator. The
pressure differential can be measured using a water column
in a transparent hose. The gas pressure should be
20-100 mm higher than the charge air pressure both at
idling speed and at full load. If this is not the case check for
dirt in the solenoid valve or low pressure regulator valve.
54 ©
Troubleshooting
Possible cause Action

J Dirt in the gas system Measure the pressure downstream of the high pressure
regulator by connecting a 16 bar manometer where the
safety valve on the high pressure regulator is normally
situated. The pressure should be 8-10 bar at all loads.
Check the pressure at idling speed and at full load.
K Fault in the low pressure Remove the valve cone in the solenoid valves and check
valve whether the engine runs at full load.
Note: The valve cone must be refitted after troubleshooting.
L Leakage in the 1 inch gas Check that none of the hoses or lines are damaged or kinked
hose, reference or pressure and that there is no water in the reference pressure hoses.
lines Check that the reference pressure hose nipples and hose
clamps on the gas hose are securely tightened.
O Poor gas grade Check the lambda value, see 1 A.
Q Minimum load valve Remove the three screws securing the minimum load valve.
Fabricate a steel plate cover that covers the hole in the
throttle valve housing and check whether the engine runs
well with it in place.
Note: The minimum load valve must be refitted in exactly
the same way as it was removed. Mark up the position of
the cover and count the number of turns when the cover is
unscrewed.
01:01-07 ©
Troubleshooting
2. Checking
Symptom
The engine is running poorly all the time or unevenly at moderate loads.
Possible fault Action
A Fault in the ignition system See 1 D.
B Fault in the ignition system Check that the cable harness is connected to the correct
cylinder.
D Incorrect lambda value Check the lambda sensor. See 1 A.
E Fault in the low pressure Check the pressure differential between the charge air
regulator pressure and gas pressure in the low pressure regulator.
The pressure differential can be measured using a water
column in a transparent hose. The gas pressure should be
20-100 mm greater than the charge air pressure. If the gas
pressure is lower check that the diaphragm nearest the
cover on the low pressure regulator is undamaged. If the
gas pressure is greater than the charge air pressure, check
whether the lever attached to the diaphragm is bent.
Otherwise, check the leaf spring at stage 1 in the low
pressure regulator (this is next to the gas inlet in the low
pressure regulator, and the entire regulator must be
dismantled).
F Fault in the low pressure Force the solenoid valve to open by connecting the
regulator electrical cables directly to the 24 V system or the battery.
You should not be able to hear a flow through the gas
regulators. If you can hear a hissing sound, check the
integrity of the valve for stage 1 in the low pressure
regulator. The rubber seal on the leaf spring may be
damaged, see 2 E. One likely cause is that the water
content in the gas is too high. Ask for analyses from the
gas supplier. Check that the diaphragm for stage 1 is not
damaged and that the sides enclosing the diaphragm at
stage 1 are flat.
56 ©
Troubleshooting

G Fault in the low pressure Check that there is no water or oil inside the cover on the
regulator low pressure regulator.
H Fault in the solenoid valve Check that the solenoid valve on the low pressure side is
working properly. The valve should click when a
voltage is applied.
I Fault in the gas mixer Check the integrity of the diaphragm on both sides in the
gas mixer, that it is not damaged and that there is no oil
or water inside the covers.
J Leakage in 1 inch gas hose Check that none of the hoses are damaged or kinked and
that the hose clamps are securely tightened.
K Fault codes in the Electric Rectify the fault according to the fault codes, clear the
throttle system fault codes and test drive again.
L Leakage between the gas Check for leaks (can be hard to find). Check that the
mixer and engine screws and hose clamps are securely tightened and that
the pressure switch has not come loose.
M Loose or damaged reference Check that all nipples on the reference pressure hoses
pressure hoses are securely tightened (both ends), that the hoses are not
damaged and that there is no water in the hoses.
01:01-07 ©
Troubleshooting
3. Checking
Symptom
The engine will not start.
A Fault in the gas system Check that gas is coming through the 1 inch gas hose.
Force open the solenoid valve and gently blow into the
reference pressure hose.
B Fault in the gas system Check the pressure differential between the charge air
pressure and gas pressure, see 2 E and 2 F.
C Fault in the ignition system Check that there is a spark on all plugs by shutting off
one cylinder at a time using the HD ECM tool. See 1 D.
D Fault in the ignition system Check the two sensors for ignition voltage. See Section
HD ECM.
F Fault in the solenoid valves Connect the solenoid valves directly to the battery and
listen for the valves clicking.
G No gas Check that there is gas in the tanks and that the gas tank
shut-off valves, the gas tank package main valve and the
high pressure shut-off valve are open.
58 ©
Troubleshooting
4. Checking
Symptom
4 The engine idling speed is too high
A Fault in the electric throttle Check whether the engine speed drops if the electric
or electric throttle linkage throttle linkage is disconnected and the idling stop is
screwed out as far as possible. Adjust the electric throttle
linkage and update the end position memory for the
electric throttle. See Electric throttle in the Scania
workshop manual.
B Fault in the minimum load If the engine speed is too high and the idling screw is
valve screwed out as far as possible, check that there is
approx. 1 mm clearance between the lever and the idling
stop. If the vehicle is new and the throttle valve is
completely closed, there may be a fault in the calibration
of the minimum load valve opening pressure (the
pressure must be at least 0.8 bar lower than atmospheric
pressure). If the vehicle is old the minimum load valve
may be leaking and must be renewed.
C Fault in the gas mixer Check that the valve on the inside of the diaphragm is
not damaged. If there are marks by the sealing surface it
may leak and must be renewed.
D Fault in the low pressure See 2 E and 2 F.
regulator
01:01-07 ©
Troubleshooting
5. Other checks
A Fault in the gas system Open the gas main valve and check what pressure the
manometer indicates. Close the valve. Crank the engine
using the starter motor and check whether the pressure
has dropped. If the pressure has not dropped, the engine
has not received any gas. Check whether the solenoid
valves open.
B Leakage downstream of the Open the gas main valve. Check what pressure the
main valve manometer indicates. Close the valve and wait for at
least 30 min. If the pressure has dropped there is a leak.
C Leakage Spray soapy water or leak detection spray onto all
threaded fittings if a leakage is suspected. A
hydrocarbon sniffer can be used to trace leaks.
D Fault in the ignition system Disconnect the ignition cable at the ignition coil. Hold
the electrical cable approx. 10 mm from the engine and
crank the engine using the starter motor. If there is no
visible spark the ignition system is inoperative.
Note: Hold the insulated section of the ignition cable
and do not touch the engine or vehicle. This check
should not be carried out in wet weather because of the
risk of electric shocks.
E Fault in the low pressure Connect a transparent hose with a water column between
regulator the reference pressure and gas pressure on the low
pressure regulator. The gas pressure should be
20-100 mm greater than the reference pressure. If the
gas pressure is greater there is probably a leak either at
the 1st or 2nd stage in the low pressure regulator.
F Fault in the low pressure See Section Work Description, Low pressure regulator,
regulator gas valve leak test.
60 ©
Troubleshooting
Fault codes
General
If a fault in the engine control system occurs
when the vehicle is being driven, the indicator
lamp on the instrument panel lights. At the same
time a fault code is stored in the control unit
memory. In the event of a minor fault or
temporary fault, extinguish the indicator lamp
by switching off the power using the starter key.
Diagnostics panel
1 Diagnostic switch
2 Indicator lamp, system
Fault codes from the engine control system are
displayed as a flash code by the indicator lamp
on the instrument panel and the system indicator
lamp for the system. The indicator lamps are
connected in parallel.
Note: The indicator lamp on the instrument

panel is also lit if there is a fault in other control
systems. To see which systems are indicating
faults, the cover of the diagnostic switches must
be opened.
The fault codes can be read using the diagnostic

switch.
01:01-07 ©
Troubleshooting
The fault codes in the control unit memory are Reading fault codes
not cleared when the power is switched off
using the starter key. The fault codes in the control unit are displayed
with a three digit flash code by the indicator
Note: Fault codes that have been stored in the lamp on the instrument panel and the indicator
memory for 50 sequences (i.e. the engine being lamp by the diagnostic switch.
switched on and off), and not cleared manually,
The power must be switched on with the starter
are cleared automatically after 50 sequences.
key and the diagnostic switch must be pressed in
while the fault codes are read. The fault codes
The fault codes are cleared if the 24 V power are displayed for as long as the diagnostic
supply to the control unit is cut, by switch is pressed in or until the voltage is
disconnecting a battery terminal or switched off.
disconnecting the control unit for example.
The fault codes can also be read using the Note: The power supply must be switched on
GCP_Display software tool. for at least 20 s before they can be read.
62 ©
Troubleshooting
Flash sequence
1 Fault code 123 (Diagnostic function
activated) is displayed three times. Between
each time the indicator lamp is extinguished
for 1,200 ms.
• The hundreds are displayed as one flash,
after that the indicator lamp is
extinguished for 400 ms.
• The tens are displayed as two flashes in
succession, after that the indicator lamp
is extinguished for 400 ms.
• The units are displayed as three flashes
in succession, after that the indicator
lamp is extinguished for 400 ms.
2 The indicator lamp is extinguished for
3,000 ms.
3 The fault code is displayed three times.
Between each time the indicator lamp is
extinguished for 1,200 ms.
• The hundreds are displayed as a number
of flashes, after that the indicator lamp is
extinguished for 400 ms.
• The tens are displayed as a number of
flashes in succession, after that the
indicator lamp is extinguished for
400 ms.
• The units are displayed as a number of
flashes in succession, after that the
indicator lamp is extinguished for
400 ms.
The fault codes are displayed in succession
until all active fault codes have been
displayed. Between each fault code the
indicator lamp is extinguished for 3,000 ms.
4 The indicator lamp is extinguished for
3,000 ms.
5 Fault code 123 (Diagnostic function
activated) is displayed three times. Between
each time the indicator lamp is extinguished
for 1,200 ms.
01:01-07 ©
Troubleshooting
Fault code table

The fault codes apply to gas engines with the
engine control system from IMPCO-BERU and
EControls. A sequence means that the engine is
switched off and on again.
ECU (engine control unit) identification
1790824 Programmed ECU marking

1790820 Software number
Abbreviations
AL Adaptive Learn
BP Barometric Pressure
CAN Controller Area Network
CCP Calibration Protocol
CHT Cylinder Head Temperature
CL Closed Loop
CNG Compressed Natural Gas
DBW Drive-By-Wire
DM Diagnostic Message
DMM Digital Multi-Meter
DST Diagnostic Scan Tool
DTC Diagnostic Trouble Code
DVOM Digital Voltage and Ohm Meter
ECI EControls Inc.
ECIPP EControls Inc. Proprietary Protocol
ECM Engine Control Module
ECT Engine Coolant Temperature
ECU Engine Control Unit
EDIS EControls Display and Interface Software
ETB Electronic Throttle Body
ETC Electronic Throttle Control
FPP Foot Pedal Position
FMI Failure Mode Indicator
64 ©
Troubleshooting
GCP Global Control Platform

IAC Idle Air Control
IAT Intake Air Temperature
IVS Idle Validation Switch
LED Light Emitting Diode
LPG Liquefied Propane Gas
MAP Manifold Air Pressure
mf Manufacture
MIL Malfunction Indicator Lamp
NG Natural Gas
OEM Original Equipment Manufacturer
PC Personal Computer
PCU Powertrain Control Unit
PWM Pulse Width Modulated
SAE Society of Automotive Engineers
SA Source Address
SPN Suspect Parameter Number
Tach Tachometer
TIP Throttle Inlet Pressure
TPS Throttle Position Sensor
UEGO Universal Exhaust Gas Oxygen sensor
VDC Voltage, Direct Current
Vsw Switched, Ignition Voltage
WPG Wastegate Pressure
01:01-07 ©
Troubleshooting
112
Fault code 112 UEGO open
Description Incorrect lambda signal
Detection The system detects faults in the lambda signal
Activated The UEGO sensor detects cold emissions for more than 40 s
Deactivated The UEGO sensor detects cold emissions for less than 40 s
Cause Electrical fault in the UEGO sensor connectors or cable harness.
Note
System response The indicator lamp lights. Adaptive learning for gas grade ceases
Action Possible fault in sensor, connector or cable harness.
Renew the sensor and check that the fault code indication stops
125
Fault code 125 CL high NG
Description The adaptive value for the closed loop (natural gas) has too high a
correction value
Detection The correction value needed to restore the correct catalytic conversion is
outside the limit value
Activated The adaptive correction value is above 20% and the engine speed
between 0-9,999 rpm and the vacuum in the intake between 0-99 psi
Deactivated The adaptive learning value is below 20%
Cause Gas grade too high, electrical fault in the UEGO sensor circuit or gas
leakage
Note -
System response The indicator lamp lights
Action No action if the engine is running well. Check whether the fault code
disappears after the next refuelling stop. Renew the UEGO sensor if the
fault code persists after refuelling
66 ©
Troubleshooting
126
Fault code 126 CL low NG
Description The adaptive value for the closed loop (natural gas) has too low a
correction value
Detection The correction value needed to restore the correct catalytic conversion is
outside the limit value
Activated The adaptive learning value is below -35%
Deactivated Adaptive learning value above -35%
Cause The gas grade is too low, there is an electrical fault in the lambda sensor
circuit or gas leakage
Note
145
Fault code 145 AL high NG
Description The adaptive value for adaptive learning (natural gas) has too high a
correction value
Detection The correction factor in the table needed to restore the correct catalytic
conversion is outside the limit value
Activated Adaptive learning value above 20%
Deactivated The adaptive learning value is below 20%
Cause The gas grade is too high or there is an electrical fault in the UEGO
sensor circuit
Note -
01:01-07 ©
Troubleshooting
146
Fault code 146 AL low NG
Description The adaptive value for adaptive learning (natural gas) has too low a
correction value
Detection The correction factor in the table needed to restore the correct catalytic
conversion is outside the limit value
Activated The adaptive learning value is below -35%
Deactivated Adaptive learning value above -35%
Cause Gas grade too low or electrical fault in the UEGO sensor circuit or gas
leakage
Note
153
Fault code 153 TIP high voltage
Description TIP sensor detects too high a voltage
Detection The system detects a fault in the pressure signal
Activated Signal above 4.8 V and MAP below 100 psi
Deactivated Signal below 4.8 V
Cause Electrical fault in the sensor or cable harness
Note Check whether fault code 231 is active.
Check that the sensor has the correct part number and is correctly
connected to the cable harness.
Action Renew the TIP sensor if fault code 231 is not active
Check the integrity of the hose and wastegate diaphragm if fault code 231
is active
68 ©
Troubleshooting
154
Fault code 154 TIP low voltage
Description TIP sensor detects too low a voltage
Activated Signal below 0.2 V
Deactivated Signal above 0.2 V
Note Check that the sensor has the correct part number and is correctly
connected to the cable harness
System response
Action Renew the sensor. Check the cable harness and connectors
155
Fault code 155 WGP high voltage
Description The wastegate pressure sensor detects too high a voltage
Activated Signal above 4.8 V
Note The indicator lamp lights
Action Renew the WGP sensor if fault code 231 is not active
Check the integrity of the hose and wastegate diaphragm if fault code 231
is active
01:01-07 ©
Troubleshooting
156
Fault code 156 WGP low voltage
Description The wastegate pressure sensor detects too low a voltage
161
Fault code 161 Low voltage
Description Battery voltage too low
Detection The system detects a low battery voltage
Activated Voltage below 18 V and engine speed above 1,000 rpm
Deactivated Voltage above 18 V or next sequence
Cause Electrical fault in the alternator or battery
Note
Action Check the battery terminals. Check battery charging, recharge if the
voltage is too low. Check or renew the alternator
70 ©
Troubleshooting
162
Fault code 162 High voltage
Description Battery voltage too high
Detection The system detects a high battery voltage
Activated Voltage above 33 V
Deactivated Voltage below 33 V or next sequence
Cause Electrical fault in the alternator
Note
Action Disconnect the battery if it is connected. Check or renew the alternator
211
Fault code 211 IAT high voltage
Description The intake air temperature (IAT) sensor detects too high a voltage
Detection The system detects a fault in the temperature sensor signal
Note
01:01-07 ©
Troubleshooting
212
Fault code 212 IAT low voltage
Description The intake air temperature (IAT) sensor detects too low a voltage
Detection The system detects a fault in the temperature sensor signal
Note
213
Fault code 213 IAT greater than expected 1
Description The intake air temperature sensor detects too high a temperature
Detection The system detects too high a temperature reading
Activated Temperature above 99°C (210°F)
Deactivated Temperature below 99°C (210°F)
Cause Temperature too high or an electrical fault in the sensor or cable harness
Note
Action Check the function of the charge air cooler and fan.
Renew the sensor. Check the cable harness and connectors
72 ©
Troubleshooting
214
Fault code 214 IAT greater than expected 2
Description The intake air temperature (IAT) sensor detects too high a temperature
Activated Temperature above 104°C (220°F) and engine speed above 1,000 rpm
Cause Temperature too high or an electrical fault in the sensor or cable harness
Note Check whether fault code 213 is active
221
Fault code 221 ECT/CHT high voltage
Description The coolant temperature sensor ECT/CHT detects a high voltage.
Note: The cylinder head temperature is a calculated value based on the
engine coolant temperature
Detection The system detects too high a temperature signal
Note
01:01-07 ©
Troubleshooting
222
Fault code 222 ECT/CHT low voltage
Description The coolant temperature sensor ECT/CHT detects a low voltage.
Note: The cylinder head temperature is a calculated value based on the
engine coolant temperature
Detection The system detects too low a temperature signal
Note
223
Fault code 223 ECT greater than expected 1
Description The coolant temperature sensor detects a high temperature
Cause Coolant temperature too high or an electrical fault in the sensor or cable
harness
Note
Action Check the temperature gauge on the control panel. If the gauge indicates
a high temperature, check the coolant level, radiator and fan function.
74 ©
Troubleshooting
224
Fault code 224 ECT greater than expected 2
Description The coolant temperature sensor detects a high temperature.
Cause Coolant temperature too high or an electrical fault in the sensor or cable
harness
Note Check whether fault code 223 is active.
Action Check the temperature gauge on the control panel. If the gauge indicates a
high temperature, check the coolant level, radiator and fan function.
01:01-07 ©
Troubleshooting
231
Fault code 231 MAP high pressure
Description The MAP pressure sensor in the intake manifold detects a high pressure
Detection The system detects too high a pressure reading
Activated Pressure above 40 psi (1.7 bar above atmospheric pressure) and engine
speed above 0 rpm
Deactivated Pressure below 10 psi (0.3 bar below atmospheric pressure) or next
sequence
Cause Charge air control deactivated due to a fault in the proportional valve or
hose not connected to the wastegate actuator on the turbocharger or
leakage in the wastegate actuator. Electrical fault in the sensor or cable
harness.
Note Check whether fault code 153 is active. Check that the sensor has the
correct part number and is correctly connected to the cable harness.
System response The engine stops until the pressure drops below 10 psi. The indicator
lamp lights. The indicator lamp is lit until the voltage to the engine
control unit is cut by disconnecting a battery terminal or disconnecting
the connection between the terminal and the engine control unit.
Adaptive learning for gas grade ceases.
Action Increase the pressure on the wastegate actuator to approximately
0.7-1.0 bar and check that the turbocharger control moves. If not, check
the integrity of the wastegate hose and diaphragm and that the
turbocharger control moves without friction. Clear the fault codes by
disconnecting the connection to the engine control unit. Check all parts
between the nozzle on the aluminium pipe upstream of the gas mixer and
the wastegate on the turbocharger if the fault codes are displayed again
after the engine has been restarted.
76 ©
Troubleshooting
232
Fault code 232 MAP low voltage
Description The pressure sensor in the intake manifold detects low voltage
Detection The system detects too low a pressure reading
Activated Signal below 0.2 V and engine speed below 9,999 rpm
Deactivated Signal above 0.4 V or next sequence
System response The engine stops until the pressure drops below 20 psi. The indicator
lamp lights. Adaptive learning for gas grade ceases during the ongoing
sequence
234
Fault code 234 BP high pressure
Description The barometer pressure sensor detects a high pressure
Detection The system detects too high a pressure reading
Activated Pressure above 16 psi (1,103 mbar)
Deactivated Pressure below 16 psi (1,103 mbar) or next sequence
01:01-07 ©
Troubleshooting
235
Fault code 235 BP low pressure
Description The barometer pressure sensor detects a low pressure
Detection The system detects too low a pressure reading
Activated Pressure below 8.3 psi (572 mbar)
Deactivated Pressure above 8.3 psi (57 mbar) or next sequence
Action Renew the sensor. Check the cable harness and connectors.
242
Fault code 242 Interference in crankshaft synchronisation
Description Poor signal from the crankshaft position sensor
Detection The system detects interference in the signal
Activated More than one (1) incorrect activation signal within 800 ms
Deactivated No (0) incorrect activation signal within 800 ms
Cause Electrical fault in the crankshaft position sensor or cable harness
Note
78 ©
Troubleshooting
243
Fault code 243 No crankshaft synchronisation on start up
Description Poor signal from the camshaft or crankshaft position sensors
Detection The signal pattern from the camshaft and crankshaft position sensors
does not correspond
Deactivated No synchronisation signal within 4 sequences and engine speed above
90 rpm
Deactivated Synchronisation signal within 4 sequences
Cause Electrical fault in the camshaft or crankshaft position sensors or cable
harness
Note Check that the sensor is correctly connected to the cable harness
Action Renew the camshaft and crankshaft position sensors. Check the cable
harness and connectors.
244
Fault code 244 No camshaft signal
Description No signal from the camshaft position sensor
Detection The system does not detect a signal from the camshaft position sensor
Activated Signal absent within 2.5 cycles and the engine speed exceeds 1,000 rpm
Deactivated Signal within 2.5 cycles and the engine speed exceeds 1,000 rpm or the
engine speed is less than 1,000 rpm or next sequence
Cause Electrical fault in the camshaft position sensor or cable harness
Note Check that the sensor is correctly connected to the cable harness
Action Renew the camshaft position sensor. Check the cable harness and
connectors
01:01-07 ©
Troubleshooting
245
Fault code 245 Interference in the synchronisation of the camshaft position sensor
signal
Description Poor signal from the camshaft position sensor
Detection The system detects interference in the signal
Activated More than one (1) incorrect activation signal within 700 ms
Deactivated No (0) incorrect activation signal within 700 ms
Cause Electrical fault in the camshaft position sensor or cable harness
Note
253
Fault code 353 MegaJector delivery pressure greater than expected
Description The MegaJector detects a high pressure differential
Detection The system detects too high a pressure differential with the MegaJector
Activated If the actual MegaJector signal exceeds 4" (10 mbar)
Deactivated If the actual MegaJector signal is less than 4" (10 mbar)
Cause The gas grade is too low, there is an electrical fault in the lambda sensor
circuit or gas leakage
Note Check whether fault codes 125 or 145 are active
Action Check for gas leaks in the system. Check the UEGO sensor connectors
and cable harness. Renew the MegaJector. Renew the UEGO sensor.
80 ©
Troubleshooting
354
Fault code 354 MegaJector delivery pressure lower than expected
Description The MegaJector detects a low pressure differential
Detection The system detects too low a pressure differential with the MegaJector
Activated If the actual MegaJector signals are less than -2.99" (-7.6 mbar)
Deactivated If the actual MegaJector signals exceed -2.99" (-7.6 mbar)
Cause The gas grade is too high or there is an electrical fault in the UEGO
sensor circuit
Action Check the UEGO sensor connectors and cable harness. Renew the
MegaJector. Renew the UEGO sensor.
355
Fault code 355 MegaJector loss of communication
Description Loss of CAN communication with the MegaJector
Detection The system has no communication with the MegaJector
Activated The MegaJector transmits no CAN signals within 500 ms
Deactivated The MegaJector transmits CAN signals within 500 ms
Cause Electrical fault in the MegaJector or MegaJector circuit
Note
Action Check the connector and cable harness to the MegaJector. Renew the
MegaJector
01:01-07 ©
Troubleshooting
361
Fault code 361 MegaJector high voltage
Description The MegaJector detects high voltage
Detection The system detects too high a voltage in the power supply to the
MegaJector
Activated
Deactivated
Note
MegaJector
362
Fault code 362 MegaJector low voltage
Description The MegaJector detects low voltage
Detection The system detects too low a voltage in the power supply to the
MegaJector
Activated
Deactivated
Note
MegaJector
82 ©
Troubleshooting
363
Fault code 363 MegaJector internal actuator fault
Description Actuator fault. The MegaJector detects an internal fault
Detection The system detects an internal fault in the MegaJector
Activated
Deactivated
Cause Electrical fault in the MegaJector
Note
Action Renew the MegaJector
364
Fault code 364 MegaJector internal circuit fault
Description Circuit fault. The MegaJector detects an internal fault
Activated
Deactivated
Note
01:01-07 ©
Troubleshooting
365
Fault code 365 MegaJector internal communication fault
Description Communication fault. The MegaJector detects an internal fault
Activated
Deactivated
Note
551
Fault code 551 Maximum engine speed for the regulator exceeded
Description Maximum engine speed for the regulator exceeded. The maximum engine
speed has a higher value for a regulator in the program.
Note: Contact Scania
Detection The maximum engine speed in the control unit is greater than 2,600 rpm
Activated Engine speed exceeds 2,600 rpm
Deactivated Engine speed is less than 2,600 rpm
Cause Electrical fault in the control unit or cable harness, or fault in the camshaft
or crankshaft position sensors
Action Renew the engine control unit
84 ©
Troubleshooting
552
Fault code 552 Fuel shut-off in the event of engine overspeed
Description The fuel supply is shut off in the event of a high engine speed
Detection The maximum engine speed is greater than 2,600 rpm
Action Check the cause of engine overspeed, e.g. poor gear changing or driving
downhill in too low a gear
553
Fault code 553 Ignition shut-off in the event of engine overspeed
Description The ignition is shut off in the event of high engine speed
Detection The maximum engine speed is greater than 2,600 rpm
Action Check the cause of engine overspeed, e.g. poor gear changing or driving
downhill in too low a gear
01:01-07 ©
Troubleshooting
611
Fault code 611 COP fault
Description Fault in the internal control unit
Detection The system detects an internal fault
Activated
Deactivated Next sequence
Cause Fault in the internal control unit
Note
System response The indicator lamp lights. The indicator lamp is lit until the voltage to the
engine control unit is cut by disconnecting a battery terminal or
disconnecting the connection between the terminal and the engine control
unit. Adaptive learning for gas grade ceases
Action Clear the fault codes by disconnecting the connection to the engine
control unit. Renew the engine control unit if the fault codes are
displayed again following a restart.
612
Fault code 612 Incorrect interruption
Activated
Note
disconnecting the connection between the terminal and the engine control
unit. Adaptive learning for gas grade ceases
control unit. Renew the control unit if the fault codes are displayed again
following a restart.
86 ©
Troubleshooting
613
Fault code 613 Loss of A/D
Activated
Note
disconnecting the connection between the control unit and the engine
control unit. Adaptive learning for gas grade ceases
control unit. Renew the control unit if the fault codes are displayed again
following a restart.
614
Fault code 614 Loss of RTI 1
Activated
Note
Action Clear the fault codes by disconnecting the connection to the control unit.
Renew the control unit if the fault codes are displayed again following a
restart.
01:01-07 ©
Troubleshooting
615
Fault code 615 Incorrect checksum
Activated
Note
disconnecting the connection between the control panel and the engine
restart.
616
Fault code 616 RAM fault
Activated
Note
restart.
88 ©
Troubleshooting
631
Fault code 631 5 V low voltage
Description Low voltage in the internal 5 V system for sensors
Detection The system detects too low a voltage in the 5 V system
Activated Voltage is less than 4.8 V
Deactivated Voltage exceeds 4.8 V
Cause Electrical fault in the sensor, control unit or cable harness
Note
Action Disconnect the connectors for all pressure and temperature sensors and
check that fault code 631 is not displayed. When the fault code is not
displayed, connect the sensors one by one until the fault code is displayed
and renew the faulty sensor. Otherwise check the cable harness. Renew
the control unit.
632
Fault code 632 5 V high voltage
Description High voltage in the internal 5 V system for sensors
Detection The system detects too high a voltage in the 5 V system
Activated Voltage exceeds 5.4 V
Deactivated Voltage less than 5.4 V
Cause Electrical fault in the control unit or cable harness
Note
Action Check the cable harness. Renew the control unit.
01:01-07 ©
Troubleshooting
655
Activated
Note
restart.
656
Activated
Note
restart.
90 ©
Troubleshooting
HD ECM for workshop

Connect the HD ECM diagnostic tool
equipment to the diagnostic socket in order to
display and change the engine management
system settings or for troubleshooting.
The control system receives and stores
information. This information is processed and
transmitted in the form of signals to various
units in the engine management system to
control the amount of fuel, 15-supply at spark
plug, charge air pressure and combustion etc.
Information in Affects Signal to

Lambda value, engine speed, Gas/air ratio MegaJector (differential
charge air pressure, water and pressure)
air temperature
Camshaft angle, crankshaft Firing angle Ignition coil
angle, charge air pressure and
engine speed
Charge air pressure upstream Proportional valve (PWM
of the throttle (TIP) and signal)
pressure to the wastegate valve
(WGP)
Active and historical fault codes are stored in

the control unit.
01:01-07 ©
Troubleshooting
Program
• Start the program.
Login
1 Enter the password.

• G0GF-WTPX-JVNV-U3VG to display
all pages and make diagrams.
• VUWL-M1AN-FS1G-YDKM to shut
off one cylinder at a time.
2 Mark the check box to remember the
password next time the program is started.
• Click OK to log in.
92 ©
Troubleshooting
General functions
1 Click on the arrows to navigate the pages in

the program.
2 Current page.
3 ECM communication. Green shows that
communication is working.
4 Variable. Right click to select a variable and
create a log file or a plot. See Plot.
Note: The variables vary between pages.
5 MIL. The indicator lamp is lit when the

engine is stationary or if there are active
fault codes.
Note: Their location varies between pages.
01:01-07 ©
Troubleshooting
Start
1 The variables in the column show the

progress of the start sequence, for example
if the signals from the flywheel and
camshaft are synchronised.
94 ©
Troubleshooting
Charge air pressure
1 Intake pressure.
2 Pressure upstream of the throttle, TIP.
3 Reference value for charge air pressure.
Note: The values for intake pressure, pressure

upstream of the throttle and charge air pressure
reference value should be equal at full load.
01:01-07 ©
Troubleshooting
MegaJector
1 Reference value for MegaJector pressure.

2 Current value for MegaJector pressure.
Note: The reference values and the current

values for the MegaJector pressure are equal
when gas is being delivered to the engine and
the MegaJector is working properly.
96 ©
Troubleshooting
PhiNG
1 Indicate an adaptive value for complete

lambda compensation.
2 Adaptive value for lambda. The basic value
is specified in the adaptation table for
natural gas on the CLCal NG page. The
value is adjusted automatically towards a
correct value. The longer the distance driven
the more correct the value.
Note: Adaptation is reset when renewing the

control unit or when the supply voltage to the
control unit is disconnected.
01:01-07 ©
Troubleshooting
CLCalNG
1 Value for idling speed.
Note: At low engine speeds and low loads the

idling speed adjusting screw on the gas mixer
can be adjusted to get the value close to 0.
2 Adaptive value for lambda. Min. -35/

Max. 20.
98 ©
Troubleshooting
Faults
1 Historical fault codes.

2 Active fault codes.
01:01-07 ©
Troubleshooting
Test
1 Click on the arrow to select from the list. Note: The cylinders in the list are numbered in
Normal to select normal cylinder function, firing order i.e.:
or desired cylinder in order to shut off one
cylinder at a time.
• 1 = cylinder 1.
• 2 = cylinder 5.
• 3 = cylinder 3.
• 4 = cylinder 6.
• 5 = cylinder 2.
• 6 = cylinder 4.
100 ©
Troubleshooting
Plot
• Select Plot/Log in the main menu.
• Select one of the alternatives: Clear tags,
Plot tags, Load plot setup, Log tags.
• Select the variables (tags) for the plot/log by
selecting a variable and right clicking.
Note: To create a log file or a plot at least one

variable must be selected. Max. 10 variables.
The plot settings are made in the plot function.

The scales of the x and y-axes can be changed
while a plot is being drawn. Press stop, change
the scale and press start again.
The printout can be saved, as an EXCEL file for

example. A previously saved printout can be
retrieved and displayed.
01:01-07 ©
Troubleshooting
Parameters
Parameter Description Unit Min. Max.
value value
time Time sec.
rpm Engine speed rpm 0 2,500
MAP Intake pressure downstream of the psi 0 38
throttle
TIP Intake pressure upstream of the throttle psi 0 38
bst_TIPd Target value for maximum pressure psi 0 38
upstream of the throttle
Phi_cmd Phi (fuel/air ratio), ref. value 0 1
Phi_UEGO Phi (fuel/air ratio), current value 0 1
CL_BM1 Feedback adaptation (saved offset) % -20 20
A_BM1 Feedback adaptation (desired offset) % -20 20
MJ_P_cmd MegaJector pressure, ref. value "H2O -5 5
MJ_P_act MegaJector pressure, current value "H2O -5 5
WGP_gage Wastegate pressure % 0 100
bst_WGAcmd Wastegate area, ref. value % 0 100
MILout_mirror Flash code lamp 0 1
spk_adv Firing angle °BTDC -6 35
ECT Coolant temperature °F -40 220
MAT Intake manifold, air temperature °F -40 220
IAT Turbocharger, air temperature °F -40 220
MJ_A_CT MegaJector opening area, current in²
MJ_A_cmd MegaJector opening area, current in²
102 ©
Troubleshooting
Field information
Bypass valve Rotational speed sensor for
engine control unit
Part number/Description
1 348 320/Bypass valve
1 420 305/Rotational speed sensor
The bypass valve has a small sealing surface and
can cause leakage on the pressure side or create 271 360/Incorrect shim
a whistle when air is vented. The valve is to be
fitted upright and not horizontally; this is so that 271 670/Correct shim
the diaphragm and air work in the same
direction when air is vented. This makes the The rotational speed sensor for the engine
opening of the valve smooth and means that the control unit should be fitted using a shim, for the
diaphragm holds the valve closed for as long as correct voltage. Without a shim the voltage can
the pressure is greater in the inlet pipe. be above 100 V at maximum rpm and with more
than one shim the voltage may be too low. Too
high a voltage on repeated occasions will create
fault codes from the engine control unit.
Gas pressure sensor

1 747 313/Faulty sensor
1 774 112/Correct sensor
The gas tank pressure sensor has an operating
range of between 0.5-4.5 V which means that
the fuel level in the measuring instrument
swings between half tank and empty tank. This
pressure sensor must be replaced with a pressure
sensor with an operating range between
0.5-3.5 V. See Scania workshop manual
01:02-04.
01:01-07 ©

Gas Engine OC9 G02 Function and Work Description: en-GB

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Function and work description

Work description ................................................................................ 37

Specification and limits

Gas specification Combustion

Engine and ignition system

The OC9 G02 is a 6-cylinder, 9 litre Otto engine

Combustion generates exhaust gases that are

Overview engine, right-hand side

1 Minimum load valve

Overview engine, from behind

Gas control system

Overview, gas control system

1 Throttle valve 8 Pressure pipe to air intake

Overview, gas control system

1 Sensor, wastegate valve (charge air

Principle drawing of gas panel

1 Gas intake 200 bar

Engine and ignition

The spark plugs are supplied with 25,000 V.

The purpose of the ignition coils is to raise the

Type: NGK IRIFR7U4D

Ignition pulse sensor

Note: The firing position cannot be changed in

The engine exhaust gases are expelled from the

Minimum load valve 1 2 3 4 5 6

1 Throttle valve housing 7

Gas control system

Gas panel overview

1 Sensor, gas pressure 6 Test connection

Low pressure regulator

Pressure reduction in the low pressure regulator

High pressure regulator

Shut-off valve, high pressure

Engine management system

1 Differential pressure sensor

1 Accelerator pedal 6 Low pressure valve

Lambda sensor Wastegate valve (pressure sensor)

MAP sensor (Manifold Air Pressure) T605. The

TIP sensor (Throttle Inlet Pressure) T1019. The Diagnostic socket

Note: The sensor is not operational and if

1 Gas flow adjusting screw (factory set)

Note: The adjusting screw, 1, is factory set to

Note: The idling speed adjusting screw, 6, is

Gas mixer, gas flow

C. Pressure connection to the diaphragm

Chassis and gas system

1 Gas tank package

Gas tank package

Main valve, gas tank package

Shut-off valve, gas tank

1. Gas tank S1. Lambda sensor

Communication electrical cable

X. Scania connection (view from behind)

Part numbers for electrical cables:

Note: Use only ECE R110 approved

Action prior to repair

MAP sensor, renewal

8 Disconnect the sensor connector and

11 (Split the bracket, 9 at the marking.)

TIP sensor, renewal

1 Disconnect the sensor cable.

Atmospheric pressure sensor, renewal