01:02-04

Issue 6 en-GB

Gas engines

OSC9 G01 and OSC11 G03

Function and work description

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1 712 293 Scania CV AB 2015, Sweden
Contents

Contents
Function description General ..................................................................... 3
Overview of gas and ignition systems...................... 6
Gas equipment .......................................................... 8
Minimum load valve............................................... 13
Ignition system ....................................................... 13

Work description General ................................................................... 14

Lambda value, checking and adjusting .................. 15
Electric throttle linkage, adjustment....................... 25
Solenoid valves, checking for leaks ....................... 26
Charge air pressure switch, checking ..................... 26
Gas panel, complete renewal.................................. 27
Solenoid valve for high or low pressure
regulator, renewal ................................................... 28
Gas tanks, renewal.................................................. 29
Gas system, leak test............................................... 30
Ignition, checking and adjusting............................. 31
Ignition pulse sensor, renewal ................................ 36

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 Function description

Function description

General
Refer to the work description for each basic The lambda value, i.e. the ratio between air and
engine if engine work is not described in this gas, must be adjusted for the gas specification in
booklet. Basic engine specifications apply question. Attaining the correct power output and
unless otherwise stated. emission level is dependent on a correct setting.

Gas engines OSC9 G01 and OSC11 G03 are Gas engines can be adjusted to suit gas grades
both Otto engines with mechanical gas supply with a class H Wobbe index in accordance with
control. The engines operate according to the the European standard ISO/FDIS 15 403.
lean burn principle. Wobbe index = 46.1-56.5 MJ/m3 at a
temperature of 288.15 Kelvin and at a pressure
Basically, they are diesel engines (DSC9 11 and of 101.325 kPa. If the gas quality deviates from
DSC11 74) that have been fitted with new this specification, an adjustment must be made
cylinder heads and spark plugs, new valves and so that the engine provides the correct
new pistons. OSC11 G03 also has a different performance and emission level. An adjustment
camshaft in comparison to the diesel variant must also be made if the vehicle is refuelled
plus a water-cooled turbocharger. with gas of another grade than the one used for
The ignition system comprises a magnetic the latest setting. Natural gas must be processed
trigger disc, a control unit and separate ignition and cleaned.
coils for each spark plug.
The gas engines are equipped with a relief valve
that reduces the high charge air pressure that can
arise when the throttle valve closes rapidly. The
engine is also fitted with an electric throttle. The
function of the electric throttle is described in
booklet 14:02-55.

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Function description

Engines are factory-set to the following typical natural gas specifications.

These values apply at 288.15 Kelvin and 101.325 kPa.

Upper calorific value 41.0 MJ/m3

Effective calorific value 37.0 MJ/m3
Upper Wobbe index 52.0 MJ/m3
Relative density 0.62
Methane CH4 91.1 percent by volume
Ethane C2H6 4.7 percent by volume
Propane C3H8 1.7 percent by volume
Butane C4H10 1.4 percent by volume
Nitrogen N2 0.6 percent by volume
Carbon dioxide CO2 0.5 percent by volume

IMPORTANT!

The engine oil must be intended for use in heavy

duty engines with spark plugs. Engine oils
intended for use in petrol or diesel engines must
not be used.

The engine oil must comply with the following

specifications:
• Viscosity according to booklet 00:03-09,
Fuels, lubricants and fluids.
• Max. ash content 1.0 percent by weight.
• Max. sulphur content 0.4 percent by weight.
Gas engines are factory-filled with Mobil
Pegasus 1 15w-40.

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 Function description

Overview, left-hand side

Overview, right-hand side

The OSC11 GO3 is shown in the illustrations

1 Ignition coil 9 Magnetic trigger disc
2 Electric throttle 10 Wastegate valve
3 Throttle valve
4 Gas mixer
5 Gas inlet
6 Turbocharger
7 Relief valve
8 Ignition cable

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Function description

Overview of gas and ignition systems

OSC11 G03

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 Function description

OSC9 G01

1 Coolant line from engine

2 Coolant pipe to engine
3 High pressure regulators
4 Manometer
5 Manual shut-off valve
6 Solenoid valves
7 Low pressure regulators
8 Pressure switch
9 Reference pressure lines
10 Gas mixer
11 Idling speed adjusting screw
12 Ignition coils
13 Ignition system control unit
14 Magnetic trigger disc
15 Ignition pulse sensor, Hall sensor
16 Safety valve, high pressure section

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Function description

Gas equipment

The gas equipment comprises tanks, mechanical Principle drawing of gas panel
shut-off valves, electric solenoid valves,
manometer, high and low pressure regulators,
gas mixer and pressure switch.
The gas pressure from the tanks on the high
pressure side is reduced across the high pressure
regulators in the gas panel to approx. 10 bar.
The pressure is then further reduced in two steps
across the low pressure regulators to just above
the current charge air pressure from the
turbocharger. The low pressure regulators are
coupled to the gas mixer air intake via the
reference pressure lines.
The reference value is used to induce the
regulators to maintain the gas pressure at
approx. 2-12 mbar above the charge air
pressure. The gas then leaves the gas panel and
passes to the gas mixer, where it is mixed with
air.
1 Gas inlet 0-200 bar
All of the regulators are connected to the engine 2 Manual high pressure shut-off valve
cooling system. The gas is cooled drastically
3 High pressure manometer
when it expands and must therefore be heated by
the cooling system. 4 Coolant outlet
5 Safety valves, high pressure regulators
6 High pressure regulators
7 Solenoid valves
8 Low pressure regulators
9 Charge air reference pressure line
10 Gas outlet to gas mixer
11 Coolant inlet
12 Pressure switch
13 24V power supply

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The solenoid valves are used to open and close of gas to the engine will be stopped. The
the flow of gas when starting or stopping the connection will be made again once the pressure
engine or when the pressure in the intake has dropped.
manifold is too high. The high pressure side has
one manual valve after the tanks and one at the
inlet to the high pressure regulator. After the
high pressure regulators, there are solenoid
valves that open when the starter key is turned to
start position and the starter motor begins to
rotate. The solenoid valves are then kept open
by the voltage from the alternator output for
charge control.
If the pressure in the intake manifold is higher
than 1.5 bar, e.g. due to a defective wastegate
valve, the pressure switch will cut the electrical
connection to the solenoid valves and the flow

Gas mixer, component parts

1 Adjustable gas flow restriction valve 7 Variable gas passage
2 Diaphragm 8 Variable air passage
3 Support washer 9 Pressure connection to diaphragm chamber
4 Shim for idling mixture
5 Air/gas valve
6 Idling mixture screw

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Function description

Gas mixer, gas flow

1 Gas in
2 Air in
3 Gas/air mixture out

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Low pressure regulator

1 Gas inlet
2 Valve, stage 1
3 Diaphragm
4 Plug
5 Outer spring adjusting screw
6 Outer spring
7 Diaphragm
8 Spring
9 Reference value
10 Valve, stage 2
11 Gas outlet
12 Coolant line

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Function description

The gas package for buses comprises six A certificate from the manufacturer of the tank
composite tanks. Each tank holds 185 litres. The equipment must accompany the vehicle on
tank package has room for seven tanks. delivery.

The gas package for trucks is mounted in a

frame and comprises four 4,140-litre steel tanks
bound with composite material. 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.
The tanks have a shut-off cock at one end and a
blind plug at the other. The shut-off cock and
blind plug contain fusible links that will be
triggered at temperatures above 110°C. The
shut-off cock is a combined shut-off valve and
flow limiter. The flow limiter is activated in the
event of e.g. a break in a high pressure pipe and
limits the velocity of the leaking gas.

Tank package in truck

1 Tank shut-off cocks
2 Gas filling point
1 Gas tanks 3 Main tap
2 Gas panel

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 Function description

Minimum load valve Ignition system

There is a minimum load valve located on the The ignition system is of the capacitive
intake manifold by the throttle valve. It limits discharge type. A control unit receives data
the vacuum after the throttle valve in the intake concerning engine crankshaft position from a
manifold during engine braking to ensure magnetic trigger disc via a Hall sensor. Each
correct combustion. The minimum load valve spark plug has its own ignition coil.
also helps to reduce HCs (hydrocarbons), as too
high an HC content in relation to the air could The ignition system has integrated engine
destroy the catalytic converter. overspeed protection that cuts the power at
2,400 rpm. The overspeed protection also cuts
the supply of gas via the solenoid valves on the
gas low pressure side. The power and the gas are
restored once the engine speed drops below
2,200 rpm.
The control unit provides a basic supply of
approx. 350V to each ignition coil. The ignition
coils then provide an output of up to 40,000 V to
the spark plugs. The control unit is located
below the central electric unit inside the cab.

WARNING!

The spark plugs are supplied with 350 V.

Carelessness can cause lethal injuries.

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Work description

Work description

General
These instructions describe how to perform
repairs on the gas system and not who is
approved to carry them out.

IMPORTANT!

Before starting work: Read the safety

precautions for vehicle gas in 00:01-02, Safety
and fire protection in service workshops.

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 Work description

Lambda value, checking and adjusting

IMPORTANT!

If the vehicle is equipped with a catalytic

converter, the gas pressure must not be left so
low that it causes misfiring. Misfiring can
damage the catalytic converter.

Settings for gas/air mixture using

Scania-recommended tools

OSC9 G01 OSC11 G03

Sensor voltage at idling speed 1.6 V-1.9 V 1.6 V-1.9 V
Sensor voltage at 1,200 rpm and 50 bar tank pressure 2.81 V-2.99 V 2.81 V-2.99 V
Sensor voltage at 2,000 rpm and 50 bar tank pressure 2.92 V-3.17 V 2.92 V-3.17 V
Sensor voltage at 1,200 rpm and 150 bar tank pressure 2.75 V-2.91 V 2.75 V-2.91 V
Sensor voltage at 2,000 rpm and 150 bar tank pressure 2.88 V-3.1 V 2.88 V-3.1 V
Maximum charge air pressure at 1,200 rpm approx. 1.0 bar approx. 0.7 bar

The sensor voltage can be read using a

measuring instrument.

Special tools

Number Designation
588 460 Lambda sensor
588 462 Cable harness
588 461 Test control unit
588 094 Multimeter (included in kit 588 093)

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Work description

Fitting the test equipment

1 Screw the lambda sensor (1) into the outlet
on the exhaust system.

Note: Use heat-resistant lubricating grease,

Scania 561 205, when fitting the lambda sensor.

2 Connect the lambda sensor to the cable

harness.
3 Run the cable harness to the vehicle,
connect it to the test control unit and secure
the electrical cables so they are not damaged
during the test drive. Connect a power
supply via either a
12V socket or a voltage converter. The test
control unit will turn off if the supply
exceeds 28 V. During the warm-up phase,
the test control unit LED will flash for
4 X 2.5 seconds and subsequently for
10 seconds at a frequency of 10 Hz. The
LED will be lit constantly in normal test
mode.

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Connecting the test equipment

1 Lambda sensor 588 460
2 Cable harness 588 462
3 Test control unit 588 461
4 Switches
5 Light-emitting diode
6 Orange electrical cable, 12 V positive voltage input
7 Yellow electrical cable, negative voltage input, ground
8 Green electrical cable, positive voltage to multimeter
9 Black electrical cable, negative voltage to multimeter

Fault codes for test control unit 588 461

Number of flashes at 2.5-second Fault

intervals
1 Sensor not connected or incorrectly connected
2 Power supply too low, i.e. below 11 V
3 Power supply too high, i.e. above 28 V
4 Temperature in sensor element too low
5 Impaired sensor element or gas/air mixture too rich
6 Impaired sensor element or gas/air mixture too lean
7 Damaged sensor element

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Work description

Checking and adjusting when engine

under load

IMPORTANT!

All checks and adjustments must be carried out

with the engine at a temperature of at least 80°C.
Misfiring must not occur, as this will cause the
lambda sensor to give an incorrect reading.

1 Attach the test equipment as described in

Fitting the test equipment.
2 If the engine has not been adjusted before,
set the restriction valve to 1 on the gas
mixer inlet halfway between the L and R
marks.

3 Measuring
Vehicles with automatic gearbox
Measure with the drive mode selector in
position D and the vehicle brakes applied.
Press the accelerator pedal to the floor and
take a reading of the sensor voltage when
the engine speed is stable.

Note: Max. stalling speed time with stable value

should not exceed 10 seconds per measurement.

Vehicles with manual gearbox

Measure at full acceleration in high gear
from approx. 1,200 rpm to 2,000 rpm and
take readings of the sensor voltage at
intervals of 200 rpm or so.

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 Work description

4 Make a copy of the chart and plot the

readings. The existing curves indicate the
permitted minimum and maximum values.

Sensor voltage with engine under load

The thin-line curves indicate limits at 150 bar gas pressure and the bold ones at 50 bar gas pressure.
The X axis shows the engine speed in rpm
The Y axis shows the sensor voltage in volts

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Work description

5 Adjust the gas pressure if the sensor voltage

is too high or too low across the whole
engine speed range.
6 Unscrew the plugs and adjust the gas
pressure with the adjusting screws on the
low pressure regulators. Adjust both
regulators the same amount. Turning
clockwise will increase the gas pressure and
lower the sensor voltage. Do not screw in
the adjusting screw more than 16 turns from
the fully unscrewed position.

Note: Screwing in the adjusting screw more

than 16 turns will cause the spring disc to come
loose from the screw.

IMPORTANT!

Refit the plugs in the low pressure regulators

before test driving. Leaks can affect the lambda
value.

7 Renew one of the regulator springs if the

adjustment range of the screw is
insufficient.

Location of springs in low pressure regulator

1 Outer regulator spring
2 Inner regulator spring
3 Outer regulator spring adjusting screw
4 Plug

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 Work description

The affect of the different regulator springs on

gas pressure:
Outer regulator spring
Gas pressure Part number Spring colour
Lowest 1 440 142 Unpainted metal
Higher 1 440 143 White
Highest 1 440 144 Brown

Spring 1 446 574 or 1 446 575 is located behind

the low pressure diaphragm lever. Remove it as
necessary to attain a higher gas pressure.
Inner regulator spring
Gas pressure Part number Spring colour
Higher 1 446 574 Orange
Lower 1 446 575 Blue

8 Change the setting of the restriction valve to

1 on the gas mixer inlet if the sensor voltage
is too high or too low across part of the
engine speed range, i.e. if the curve is
completely or partially outside the specified
limit values. The restriction valve acts most
at high engine speeds. For example, adjusting
towards R will give a richer gas mixture and
lower sensor voltage, mainly at high engine
speeds. Since a certain change in level also
takes place at low engine speeds, the gas
pressure must normally also be changed to
compensate.

9 The lambda value must also be checked at

idling speed if the gas pressure has been
changed. Changing only the mixer restriction
valve will not affect the lambda value at
idling speed.

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Work description

Checking and adjusting when engine is

idling

IMPORTANT!

All checks and adjustments must be carried out

at an engine temperature at least 80°C. Misfiring
must not occur, as this will cause the lambda
sensor to give an incorrect reading.

1 Run the engine until it reaches normal

operating temperature.
2 Check that the idling speed is approx.
550 rpm.
3 Adjust screw 1 when necessary so that it is
against the arm when the engine is warm.
Adjust the electric throttle if the engine
speed is not correct. See Electric throttle
linkage, adjustment.

4 Take a sensor voltage reading with the Sensor voltage at idling speed
multimeter. It should read between 1.6 V
and 1.9 V at 550 rpm.

The X axis shows the engine speed in rpm

The Y axis shows the sensor voltage in volts

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 Work description

5 Adjust the lambda value if necessary by

turning the mixture screw 1 on the gas
mixer. Turning clockwise will lower the
sensor voltage.

6 If the correct lambda value cannot be set,

take off the outer diaphragm of the gas
mixer and remove or add shims at the gas
valve.

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Work description

Adjusting with shims in the gas mixer

1 Note: Mark all the parts in the gas mixer so
that they can be refitted in the same
position.
Remove the outer blanking piece (1) from
the gas mixer.

2 Carefully remove the outer diaphragm unit

without damaging the diaphragm.
3 Remove the air/gas valve and the washer
from the diaphragm. The mark (2) must
point towards the square lug on the
diaphragm.

4 Add or remove shims (3) as necessary.

More shims will increase the sensor voltage
and less will reduce it.
5 Refit everything to its original position.
6 Repeat the check/adjustment according to
Checking and adjusting when engine is
idling.

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 Work description

Electric throttle linkage, adjustment

For other work descriptions concerning the electric throttle, see 14:02-56.

1 Run the engine until it reaches normal

operating temperature.
2 Disconnect the throttle linkage.
3 Set the idling speed to 550 rpm using the
idling screw.
4 Switch off the power with the starter key.
5 Start the engine and keep the accelerator
pedal depressed for at least 2 seconds.
Note: The throttle linkage must be
disconnected.
6 Stop the engine by shutting off the supply of
gas. Leave the power on.
7 Adjust the length of the linkage so that it fits
onto the ball when the lever is in the idling
position.
8 Depress the accelerator pedal all the way
and adjust the linkage so that it travels
2-4 mm further than the full throttle position
on the throttle lever. If necessary, move the
upper ball pin in the slot on the electric
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 Delete any fault codes.

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Work description

Solenoid valves, checking for leaks

The solenoid valves are located between the

high and low pressure regulators on the gas
panel.
1 Allow the engine to idle. Unplug the contact
housings for both solenoid valves. The
engine should stop immediately when the
current to the last valve is cut.
2 Connect the first valve again and repeat the
test with only this valve.

Charge air pressure switch, checking

Special tools

99 405 Bleeding tool

The pressure switch detects the charge air

pressure via the reference pressure line at one of
the low pressure regulators.
1 Remove the pressure switch (1) from the
low pressure regulator.
2 Attach the hose from tool 99 405.
3 Start the engine and run it at idling.
4 Slowly increase the pressure from zero. The
engine should stop when the pressure is
between 1.1 and 1.5 bar.

1 Pressure switch

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 Work description

Gas panel, complete renewal

Removal

1 Empty the gas system by turning off all the

taps to the tanks and leaving the engine idling
until it stops.
2 Make sure that all the taps are closed.
3 Clamp the coolant hoses so that they can be
removed without leaking coolant.
4 Remove the coolant hoses from the gas
panel.
5 Unplug all the contact housings.
6 Remove the reference pressure line between
the low pressure regulators.
7 Undo the connection for the gas inlet.
8 Undo the connection for the gas outlet.
9 Remove all the fastening bolts and take away
the gas panel as one unit.
Fitting
Fit in reverse order and perform a leak test.

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Work description

Solenoid valve for high or low pressure regulator,

renewal

1 Remove the gas hose between the regulators.

2 Unscrew the relevant regulator section from
the upper manifold pipe and renew the
solenoid valve.
Fitting
Fit in reverse order and perform a leak test.

IMPORTANT!

All unions have tapered threads. The regulator

housing can crack if tightened too hard. Seal all
threads with thread sealing compound.

1 Manifold pipe
Thread sealing compound Loctite 577 2 High pressure regulator
3 Solenoid valve
4 Low pressure regulator

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 Work description

Gas tanks, renewal

Tightening torque Tap side Plug side

Nuts 22 Nm 10 Nm

WARNING!

It is highly dangerous to work on the tanks as

the pressure in them is very high.
When the tanks have been lifted off, it is
important to follow the instructions in the
booklet before doing anything with the tanks.

Removal
1 Empty the gas system by turning off all the
shut-off cocks to the tanks and leaving the
engine idling until it stops.
2 Make sure that all the shut-off cocks are
closed.
3 Remove all pipes and pipe unions on the tap Tank mounting
side as one unit. 1 Lock nut
4 Remove the caps holding the tanks in place. 2 Nut
3 Cap
5 Lift off the tanks.
Fitting
1 Lift the tanks into position.
2 Position them and attach the pipe
connections.

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Work description

3 Tighten the pipe unions. Gas system, leak test

First stage of tightening new union
Check for leaks in the gas system after each
1. Insert the pipe until it bottoms. repair or adjustment during which a part of the
gas system has been dismantled.
2. Tighten the union nut by hand as hard as
possible. Make sure that all the taps are open. Check for
leaks using Scania leak detection spray
3. Tighten the union nut another 1 1/4 turns 584 018 or soapy water. Any leaks will appear
with a spanner. as bubbles.
Refitting an old union
1. Insert the pipe until it bottoms.
2. Tighten the union nut by hand as hard as
possible.
3. Tighten the union nut another 1/4 turn
with a spanner.
4 Fit the caps securing the tanks in place and
torque tighten the nuts as specified in the
table.

Note: Fit a gasket between the cap and the tank

on the tap side.

5 Tighten the lock nuts without disturbing

the nuts.
6 Test for leaks.

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 Work description

Ignition, checking and adjusting

IMPORTANT!

Close the main tap before all engine repairs and

empty the gas system by leaving the engine
idling until it stops.

IMPORTANT!

The positive terminals on the ignition coils are

connected to the chassis ground via ignition
coils 1 and 6.

Spark plugs and spark plug gaps

OSC9 G01 and OSC11 G03

Type Champion RN 79G (spark gap 0.38 mm, 0.015")
Spark plug gap 0.35-0.5 mm
Tightening torque 35-40 Nm
Distance between magnetic trigger disc and igni- 0.8-1.0 mm (0.5-0.7 turns back from contact)
tion pulse sensor

Other tools

Number Designation
588 463 Ignition timing tool
Stroboscope lamp

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Work description

Ignition timing diagram

The X axis shows the engine speed in rpm

The Y axis shows the ignition timing in degrees
BTDC (before top dead centre).

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Adjusting using the ignition timing tool 588 463

OSC9 G01 OSC11 G03

Engine speed 0 rpm 0 rpm
Ignition timing, BTDC 24° 22°

The ignition timing tool indicates the angle of

the crankshaft when the ignition pulse sensor
gives a signal. The control unit changes the
ignition timing to the engine speed by displacing
the ignition pulse in varying amounts. A certain
distance must therefore be present between the
sensor signal and the earliest ignition. The
distance for the Altronic control unit is 7 engine
degrees.
Example:
Since the most advanced ignition timing for the
OSC11 G03 is 15° BTDC (before top dead
centre), the sensor signal must arrive at
15° + 7° = 22° BTDC. This applies to the piston
position in cylinder 1 in compression and the
corresponding magnet in the magnetic trigger
disc.

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Work description

Setting
1 Fit the tool at the ignition system control
unit under the central electric unit. Put the
toggle switch in the Input position.
2 Rotate the engine until piston 1 is in
ignition position according to the flywheel
graduation in its compression stroke. See
table.

1 Ignition pulse sensor, Hall sensor

2 Magnet for cylinder 1, marked X
3 Index for magnetic trigger disc position
4 Direction of rotation
5 Magnetic trigger disc

3 Undo the clamp bolt (2) for the magnetic

trigger disc.
4 Carefully tap the magnetic trigger disc (1)
in its direction of rotation until the magnet
for cylinder 1 turns on the indicator lamp
in the instrument.
5 Tighten the clamp bolt (2) for the magnetic
trigger disc.
6 Check the setting by rotating the engine in
the opposite direction and then slowly
rotating it in its direction of rotation until
the lamp just starts to come on. Check the
graduation on the flywheel and compare it
with the table.

1 Magnetic trigger disc

2 Clamp screw

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 Work description

Adjusting using a stroboscope lamp

OSC9 G01 OSC11 G03

Engine speed/angle 550 rpm/5° BTDC 550 rpm/3° BTDC
Engine speed/angle 2,000 rpm/17° BTDC 2,000 rpm/15° BTDC

1 Connect the stroboscope lamp to the

ignition cable for cylinder 1.
2 Start the engine and run it at idling speed.
3 Read off the current ignition timing on the
flywheel.
4 Switch off the engine.
5 Undo the clamp bolt (2) for the magnetic
trigger disc.
6 Rotate the magnetic trigger disc to the
correct timing.
7 Check the ignition timing again after
adjusting the magnetic trigger disc and
readjust if it is still not correct.

1 Magnetic trigger disc

2 Clamp screw

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Work description

Ignition pulse sensor, renewal

Distance between magnetic trigger disc and ignition pulse sensor 0.8-1.0 mm

Remove the old ignition pulse sensor. Fit the

new one and adjust it to the correct distance
from the magnetic trigger disc.

1 Ignition pulse sensor

2 Magnetic trigger disc

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