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Service Bulletin

Volvo Bus Corporation


Göteborg, Sweden Buses
Date Group No. Release Page
The bulletin supplements Service bulletin 4.43.119 5.02 43 136 01 1(7)
”Automatic gearbox ZF Ecomat 2 type
4/5HP502/592/602C”, Group 43 TSP136490
Gearbox, fault code table
ZF Ecomat 2

Automatic gearbox ZF Ecomat2


type 4/5HP 502/592/602 C

Fault code table


For a complete table of fault codes, see “Fault code table” page 2

TSP178867
ENG12109 English
Printed in Sweden
Page 2

Malfunction

Fault code table


Fault Sig- Connec- Reference Nominal FMI Fault description Miscella-
code nal/component tion, values value, mea- neous
J1587 ECU surement
against cable
harness
PID1 Clutch slip 0 Invalid data
PID1 Calibration re- 49 0.38- 0 Invalid data
sistance B16 4.200000V mm
retarder mo-
ment
PID 1 Gear-ID Internal fault in 14 Mismatch ECU-
the control unit gearbox
PID62 Signal reduc- Is activated by
tion, retarder value tempera-
setting ture sensor
sump, see
PID177
PID120 Temperature 3 max. 3519
/1819
NTC sensor

sensor, retarder 5.200000V at 80/100 C
PID 124 Oil level sensor 17.0-83.0% 14 Bad signal
PID155 Voltage supply 23, 68 24V mm 24V, fuse 17, 12
+30 30
PID155 Short circuit + 3 Short to voltage
unused digital
exit
850
at 20 C

PID161 Speed sensor 62 20- 2 Electrical fault
nT 5000Hz mm
PID161 Speed sensor 62 11 Abnormal fre-
nT quency
PID163 Gear selector 56, 42,
code fault 28, 50,
41, 21
PID 168 Working volt- 23 or 68 17.7- <32.3V 0
age (+30) 32.300000V mm
PID168 Working volt- 23 or 68 17.7- > 17.700000V 1 Insufficient voltage
age (+30) 32.300000V mm
1472
/1670


PID 177 Temperature 27-2 Below 105.0 C 14 Temperature too

sensor, gearbox at 80/100 C high
PID177 Temperature 27-2 1472
/1670
0 Temperature too

sensor, gearbox at 80/100 C high
PID177 Temperature 27-2 2.5- 1472
/1670
3 Short to voltage

sensor, gearbox 4.800000V mm at 80/100 C
PID177 Temperature 27-2 2.5- 1472
/1670
4 Short to earth

sensor, gearbox 4.800000V mm at 80/100 C
850
at 20 C

PID191 Rotation speed 16 20- 2 Electrical fault
sensor 5000Hz mm
850
at 20 C

PID191 Rotation speed 16 20- 11 Abnormal fre-
sensor 5000Hz mm quency
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 5.02 43 136 01 3(7)

Fault Sig- Connec- Reference Nominal FMI Fault description Miscella-


code nal/component tion, values value, mea- neous
J1587 ECU surement
against cable
harness
SID1 Solenoid valve 4 max. 67
/74
at 3 Short to voltage Activates

B (Y16) 1.500000A 20/80 C connection
B
SID1 Solenoid valve 4 max. 67
/74
at 4 Short to earth Activates

B (Y16) 1.500000A 20/80 C connection
B
SID1 Solenoid valve 4 max 1.5A 67
/74
at 5 Break

B (Y16) 20/80 C
SID2 Solenoid valve 5 60–80
67
/74
at 3 Short to voltage Activates

C (Y15) 20/80 C connection
C
SID2 Solenoid valve 5 max 1.5A 67
/74
at 4 Short to earth Activates

C (Y15) 20/80 C connection
C
SID2 Solenoid valve 5 max 1.5A 67
/74
at 5 Break Activates

C (Y15) 20/80 C connection
C
SID3 Solenoid valve 9 max 1.5A 67
/74
at 3 Short-circuit to Activates

D (Y14) 20/80 C voltage connection
D
SID3 Solenoid valve 9 max 1.5A 67
/74
at 4 Short to earth Activates

D (Y14) 20/80 C connection
D
SID3 Solenoid valve 9 max. 67
/74
at 5 Break Activates

D (Y14) 1.500000A 20/80 C connection
D
SID4 Solenoid valve 54 max. 67
/74
at 3 Short to voltage Activates

E (Y13) 1.500000A 20/80 C connection
E
SID4 Solenoid valve 54 max 1.5A 67
/74
at 4 Short to earth Activates

E (Y13) 20/80 C connection
E
SID4 Solenoid valve 54 max 1.5A 67
/74
at 5 Break Activates

E (Y13) 20/80 C connection
E
SID5 Solenoid valve 29 max 1.5A 67
/74
at 3 Short to voltage Activates

F (Y12) 20/80 C connection
F
SID5 Solenoid valve 29 max 1.5A 67
/74
at 4 Short to earth Activates

F (Y12) 20/80 C connection
F
SID5 Solenoid valve 29 max 1.5A 67
/74
at 5 Break Activates

F (Y12) 20/80 C connection
F
SID6 Solenoid valve 30 max. 67
/74
at 3 Short to voltage Activates
20/80 C67
/74


G (Y11) 1.500000A connection

at 20/80 C G
SID6 Solenoid valve 30 max 1.5A 67
/74
at 4 Short to earth Activates

G (Y11) 20/80 C connection
G
Page 4

Fault Sig- Connec- Reference Nominal FMI Fault description Miscella-


code nal/component tion, values value, mea- neous
J1587 ECU surement
against cable
harness
SID6 Solenoid valve 30 max 1.5A 67
/74
at 5 Break Activates

G (Y11) 20/80 C connection
G
SID7 Solenoid valve 11 max 1.5A 67
/74
at 3 Short to voltage Activates

WK (Y18) 20/80 C lock-up
(WK)
SID7 Solenoid valve 11 max 1.5A 67
/74
at 4 Short to earth Activates

WK (Y18) 20/80 C lock-up
(WK)
SID7 Solenoid valve 11 max. 67
/74
at 5 Break Activates

WK (Y18) 1.500000A 20/80 C lock-up
(WK)
SID8 Solenoid valve 10 max. 67
/74
at 3 Short to voltage Activates

A (Y17) 1.500000A 20/80 C connection
A
SID8 Solenoid valve 10 max 1.5A 67
/74
at 4 Short to earth Activates

A (Y17) 20/80 C connection
A
SID8 Solenoid valve 10 max. 67
/74
at 5 Break Activates

A (Y17) 1.500000A 20/80 C connection
A
SID10 Solenoid valve 51 max. 67
/74
at 3 Short to voltage MID222

(Y19) 1.500000A 20/80 C
SID10 Solenoid valve 51 max. 67
/74
at 4 Short to earth MID222

(Y19) 1.500000A 20/80 C
SID10 Solenoid valve 51 max. 67
/74
at 5 Break MID222

(Y19) 1.500000A 20/80 C
SID11 Current flow, 6 0.1–0.5A 25
/28
at 2 Resistance fault PWM con-

solenoid valve 20/80 C trolled 500
retarder Y1 Hz, 0-100%
(MID222)
SID11 Current flow, 6 0.1–0.5A 25
/28
at 3 Short to voltage PWM con-

solenoid valve 20/80 C trolled 500
retarder Y1 Hz, 0-100%
(MID222)
SID11 Current flow, 6 0.1–0.5A 25
/28
at 4 Short to earth PWM con-

solenoid valve 20/80 C trolled 500
retarder Y1 Hz, 0-100%
(MID222)
SID11 Current flow, 6 0.1–0.5A 25
/28
at 5 Break PWM con-

solenoid valve 20/80 C trolled 500
retarder Y1 Hz, 0-100%
(MID222)
≈60
at 20 C

SID12 Solenoid valve 8 0.1–0.5A 3 Short to voltage MID222
(Y2)
≈60
at 20 C

SID12 Solenoid valve 8 0.1–0.5A 4 Short to earth MID222
(Y2)
≈60
at 20 C

SID12 Solenoid valve 8 0.1–0.5A 5 Break MID222
(Y2)
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 5.02 43 136 01 5(7)

Fault Sig- Connec- Reference Nominal FMI Fault description Miscella-


code nal/component tion, values value, mea- neous
J1587 ECU surement
against cable
harness
SID40 Gear signal 1 55 Under 19V 3 Short to voltage
SID40 Gear signal 1 55 Over 7.5V 4 Short to earth
SID40 Gear signal 1 55 Over 4.5V 5 Break
SID45 Speed signal 1 32 Under 19V 3 Short to voltage
SID45 Speed signal 1 32 Over 7.5V 4 Short to earth
SID45 Speed signal 1 32 Over 4.5V 5 Break
SID55 Proportional 57-46 max. 2 Resistance fault
solenoid valve 1.100000A
SID55 Proportional 57-46 max. 3 Short to voltage
solenoid valve 1.100000A
SID55 Proportional 57-46 max. 4 Short to earth
solenoid valve 1.100000A
SID55 Proportional 57-46 max. 5 Break
solenoid valve 1.100000A
SID225 Status lamp on 4.500000V mm 3 Short to voltage
gear selector
SID225 Status lamp on 4.500000V mm 4 Short to earth
gear selector
SID225 Status lamp on 4.500000V mm 5 Break
gear selector
SID231 J1939 bus, fault 25-26 50–140
2 Loss of data MID222,
value MID223
SID250 J1708, fault 7-9V mm 2 Loss of data MID222,
MID223
SID250 J1708, fault 7-9V mm 5 Break
SID250 J1708, fault 7-9V mm 9 Loss of data MID222,
warning MID223
SID253 Faulty mem- Error in check 11
ory/check sum sum
SID253 Error memory Error in check 12
sum
SID253 Faulty mem- Internal fault in 13 Error in check sum
ory/check sum the control unit
SID253 Work time, Internal fault in 14 Work time in hours,
memory the control unit counter reset
SID254 System fault, Unidentifiable 11
ECU fault
Page 6

Fault Sig- Connec- Reference Nominal FMI Fault description Miscella-


code nal/component tion, values value, mea- neous
J1587 ECU surement
against cable
harness
PSID40 Slippage time, 0 The fault
fault with code is set
changing up 1- when the
2 slippage
time takes
longer than
the time de-
fined in a
parameter
in the con-
trol unit.
PSID41 Slippage time, 0 The fault code is
fault with set when the slip-
changing up 2- page time takes
3 longer than the
time defined in a
parameter in the
control unit.
PSID42 Slippage time, 0 The fault
fault with code is set
changing up 3- when the
4 slippage
time takes
longer than
the time de-
fined in a
parameter
in the con-
trol unit.
PSID43 Slippage time, 0 The fault
fault with code is set
changing up 4- when the
5 slippage
time takes
longer than
the time de-
fined in a
parameter
in the con-
trol unit.
PSID44 Slippage time, 0 The fault
fault with code is set
changing up 5- when the
6 slippage
time takes
longer than
the time de-
fined in a
parameter
in the con-
trol unit.
PSID70 Gear selector, 56 Under 19V 3 Short to voltage
output voltage
PSID70 Gear selector, 56 Over 7.5V 4 Short to earth
output voltage
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 5.02 43 136 01 7(7)

Fault Sig- Connec- Reference Nominal FMI Fault description Miscella-


code nal/component tion, values value, mea- neous
J1587 ECU surement
against cable
harness
PSID70 Gear selector, 56 Over 4.5V 5 Break
output voltage
PSID71 Brake light, out- 51 Under 19V 3 Short to voltage
put K10/Y19
PSID71 Brake light, out- 51 Over 7.5V 4 Short to earth
put K10/Y19
PSID71 Brake light, out- 51 Over 4.5V 5 Interruption
put K10/Y19
PID120 Temperature 24-3 0.4- 0 Temperature too MID222
sensor, retarder 4.800000V mm high
PID120 Temperature 24-3 0.4- 3 Short to voltage MID222
sensor, retarder 4.800000V mm
PID120 Temperature 24-3 0.4- 4 Short to earth MID222
sensor, retarder 4.800000V mm
PID120 Temperature 24-3 0.4- 14 Temperature too MID222
sensor, retarder 4.800000V mm high