Service Bulletin

Volvo Bus Corporation

Göteborg, Sweden Buses
Date Group No. Release Page
3.04 72 46 01 1(21)

Electronically controlled air suspension

Electronically controlled air suspension

Contents
“Electronically controlled air suspension” page 2
“Level sensor, air suspension, replace (one)” page 18
“ECS control unit, replace” page 21

20 010201
ENG13965 English
Printed in Sweden
Volvo Bus Corporation
Service Bulletin
Design and Function
Electronically controlled air suspension
System description
The electronically controlled air suspension (ECS)
regulates and sets bus height. The system is active
when the engine is running and where supply pressure is
sufficiently high.
Bus height is monitored continually by the level
sensors. The control unit compares sensor values with
programmed reference values to determine whether
any corner of the chassis requires raising or lowering to
maintain the bus at the correct height and level. Where
necessary, the control unit activates the solenoid valves to
supply air or release air from the air bellows. This permits
the bus to maintain a constant normal level.
Dependent on bus model, the driver can activate a
number of functions. Three function combinations are
available: only level raising, level raising and kneeling,
level raising and level lowering and kneeling. The control
unit registers the switch position and regulates the height
in accordance with the programmed reference values. By
opening and closing valves in the solenoid valve block,
the control unit can regulate the volume of air in each air
bellows and control bus height and slope. Kneeling, level
raising and level lowering are from bus normal level.
Level raising is normally only activated when a bus is
driven without passengers, for example when driving
onboard a ferry. A bus can be driven with raised level
irrespective of whether the passenger doors are open or
not. There is no speed limiter, but at speeds above 30
kph the symbol for level control flashes, see “Instruments
and controls” page 10.
The control unit’s reference values for level raising, level
lowering and kneeling can be reprogrammed by a PC with
a special diagnostic programme.
Date Group No. Release Page
3.04 72 46 01 2(21)
The electronically controlled air suspension consists of a
control unit, level sensor, solenoid valve block, air bellows
and components for compressed air supply.
Each level sensor signal is proportional to bellows
height. The control unit compares the input signals
with programmed reference values and, depending
on switch position and vehicle speed, the control unit
determines whether bellows height needs to be adjusted.
If contradictory control information is received by the
control unit, raising will be prioritised over lowering.
Dependent on version, micro switches or similar sensors
on the chassis can prevent level raising or kneeling in
some cases, for example when passengers are boarding
the bus.
The compressor supplies the primary tank with
compressed air. A pressure switch monitors supply
pressure after the primary tank. If the pressure falls below
9.0 bars, the yellow INFO-lamp comes on and the symbol
for low bellows pressure (charge pressure) is displayed
in the instrument. The solenoid valve block distributes
compressed air to the air bellows. Each block has three
air connections, one to the primary tank and two to the air
bellows. An evacuation valve on the block releases air
when emptying the air bellows.
Articulated buses have two identical control units but with
different data sets. The front control unit controls the front
axle and mid axle solenoid valve block and level sensors.
The rear control unit controls the trailer axle solenoid
valve block and level sensors. Some connections on the
control units are connected in parallel.
A 6x2 version bus has two air bellows on the trailing axle,
but no solenoid valve block and no level sensors on this
axle.
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 3(21)

The picture shows a simplified ECS-system for 4x2

and 6x2 version buses. For 6x2 version buses,
the components in the dashed box are in addition.
These are a trailing axle with a solenoid valve block
and two air bellows.

1 Control unit
2 Level sensors
3 Air bellows
4 Solenoid valve block
5 Primary tank
6 Overflow valve (dependent on
model)
7 Pressure monitor
8 Non-return valve for venting

T7009671
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 4(21)

The picture shows a simplified ECS-system for

articulated buses.

1 Control unit
2 Level sensors
3 Air bellows
4 Solenoid valve block
5 Primary tank
6 Overflow valve (dependent on
model)
7 Pressure monitor

T7009783
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 5(21)

Components
Control unit
The control unit is situated in the chassis front electrical
distribution unit.

The control unit consists of a voltage stabilizer, signal

convertor, processor, memory modules and current
amplifier.
The programme which controls the ECS-system, is
stored in the control unit’s memory with a parameter
set up. Some of these parameters can be programmed
by a stand-alone PC and are therefore called customer
parameters.

When the engine is started, the control unit carries out a

self-test. The kneeling lamp is on during self-testing. If no
faults are found, the lamp goes out after 2 seconds.
T7009726
A special diagnostic programme which is run on a
stand-alone PC can communicate with the control unit.
The programme allows fault tracing of the control unit and
the ECS-system to be carried out. The same program is
used, when necessary, to update data sets (parameter
set up), program customer parameters and calibrate
reference values from level sensors.
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 6(21)

Control unit connections

Pin Description
1
1 Power supply
3 Power supply cable valve 42 (VA), front solenoid valve block.
4 Power supply cable valve 41 (Z), front and rear solenoid valve block.
6 Input signal switch Kneeling (1102).
1
Pin 6 connected to earth when the switch is set in the reset position.
8 Input signal switch Level control (175) and Kneeling (1102). 1
Pin 8 is connected to earth when raising or kneeling is activated.
9 Power supply cable (-) level sensor left rear, pin 1.
10 Input signal level sensor left rear.
11 Input signal level sensor right rear.
12 Input signal level sensor left front.
13 Input signal level sensor right front.
14 Power supply cable (-) level sensor right front, pin 1.
1
15 Diagnostics link DIA-K
17 Multiplexed electrical system: Digital frequency modulated signal which activates the ECS-symbols (low
bellows pressure, level control, fault in ECS) in the driver display. 1
Conventional electrical system: 24 V to activate relay (3014A) for the level raising lamp.
18 Earth connection.
20 24 V when the vehicle kneels at least 80 %, speed is below 1 kph and the Kneeling switch is active.
21 Power supply cable valve 43 (HR), rear solenoid valve block.
22 Power supply cable valve 42 (HL), rear solenoid valve block.
24 Input signal switch Level control (175) and Kneeling (1102). 1
Pin 24 connected to earth when lowering or kneeling is activated.
25 Input signal pressure switch (7064). Connected to earth at pressures below 9.0 bars.
26 Power supply cable (-) level sensor right rear, pin 1.
27 Power supply cable (+) level sensor left rear, pin 2.
28 Power supply cable (+) level sensor right rear, pin 2.
29 Power supply cable (+) level sensor right front, pin 2.
30 Power supply cable (+) level sensor left front, pin 2.
31 Power supply cable (-) level sensor left front, pin 1.
1
32 Speed signal from the speedometer (C3) or the tachograph (B7).
1
33 Diagnostics link DIA-L
34 Power supply cable valve 43 (KN), front solenoid valve block.
35 Earth connection solenoid valves.
The remaining pins are not used.
1
For articulated buses connected in parallel with rear control units.
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 7(21)

Level sensors
The level sensors are fitted to brackets on the chassis.
They consist of an encased potentiometer which is
operated by a spindle. A link rod links the bus axle via a
lever to the sensor spindle. Each change in the distance
between the bus axle and the chassis, for example
when passengers board or disembark the bus, causes
the lever to move upwards or downwards and turns the
potentiometer so that the output signal to the control unit
is changed. The sensor is set so that the signal varies
around 2.50 V, which is equivalent to the bus’s normal
level.

T7009763

A sliding contact links two concentric circuits. The outer

circuit is connected to 5.00 V at one point and to 0 V
on the opposite side. A sensor signal, proportional to
the lever position, is transmitted to the control unit by
intermediary connections. The version and internal
resistance gives an output signal between 1.70 and 3.44
V with a resolution of around. 0.01 V/mm.

T7008468

Pressure monitor
A pressure switch (7064) monitors the supply pressure
after the primary tank. The pressure switch closes when
the pressure exceeds 9.7 bars and breaks if it falls below
9.0 bars. The closed pressure switch connects pin 25 on
the control unit to earth. The system attempts to control
vehicle height even where pressure is low. If the pressure
falls below 9.0 bars, the yellow INFO-lamp and the symbol
for low bellows pressure (charge pressure) comes on.

T7009764
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 8(21)

Solenoid valve block

The front solenoid valve block operates the front axle air
bellows. The electrical connectors are on the top of the
block and the air connections are on the block underside.

On right hand drive buses with kneeling type “front left”

or “left side”, the solenoid valve block air connections
(21, 22) and the control unit connectors to the front level
sensors are switched.

Compared with the rear solenoid valve block, the front

solenoid valve block has an extra valve (42a) connected
in parallel with valve (42). See “Circuit diagram” page 12.
This valve is controlled by air instead of electricity and
controls the airflow into and out of the bellows.

T7009653

Front solenoid valve block

The rear solenoid valve block controls the drive axle air
bellows. Electrical and air connections are similar to
those on the front solenoid valve block.

On right hand drive buses with kneeling type “left side”,

the solenoid valve block air connections (21, 22) and
the control unit connectors to the rear level sensors are
switched.

Articulated buses have three solenoid valve blocks,

one for each axle. The two rear blocks have identical
functions.

T7009654

Rear solenoid valve block

Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 9(21)

Air bellows
Air bellows are roller type. They consist of an outer
and an inner bearing of rubber containing two textile
bearings. The bellows therefore have even dilation and
compression. The type of rubber used can withstand a
wide temperature range and is not affected by oxygen
in the air.

The upper part of the air bellows seals against an upper

bellows plate and at the bottom seals against a roller
body. Sealing is as for a tubeless tyre. To achieve max.
air volume on the inside of the bellows, the roller body is
hollow, which means that the inside can also be used.
A large air volume is maintained which means good
suspension comfort.

When spring movement compresses the air bellows, the

bellows roll down over the roller body. When the bus is
raised, the bellows roll back and reveal a large part of the
outer surface of the roller body. This surface is specially
designed according to the roller radius, which extends T7008483
1 Compressed air supply from the solenoid valve
the air bellows lifetime.
block
Under some conditions, for example when driving in 2 Attachment screw
bends at high speed or when driving over a pronounced 3 Bump rubber cushion
bump, the air bellows can be pressed together until 4 Rubber cushion
the rubber cushion fitted on the underside of the upper 5 Air bellows
bellows plate is pressed downwards against the top of the 6 Air bellows roller body
roller body. This limits further suspension movement. The
rubber cushions also contribute to safety if air pressure in
the air suspension system suddenly falls.
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 10(21)

Instruments and controls

T7009647

Explanation of the picture:

• Symbol (A) with the yellow INFO-lamp under the

display indicates low bellows pressure (charge
pressure).

• Symbol (B) indicates level raising or lowering.

• Symbol (C) with the yellow INFO-lamp under the

display indicates a fault in the ECS-system.

• The kneeling lamp under the speedometer indicates

kneeling.
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 11(21)

When the upper part (raising) of the level switch (175)

is pressed in, pin 8 in the control unit is connected to
earth, and when the lower part is pressed in (lowering)
pin 24 is connected to earth. A symbol (B) in the display
indicates that the vehicle is being raised or lowered from
the normal level.

The control unit program ensures that kneeling or level

control cannot be started other than from the normal level.

T7009680

The bus may be fitted with level control that can only raise
the bus.

T7009681

When the lower part of the kneeling switch (1102) is

pressed in (kneeling), pin 8 and 24 in the control unit are
connected to earth, and when the upper part is pressed
in (resetting) pin 6 is connected to earth.

An acoustic signal is activated if the bus is driven at

the same time as the kneeling function is selected. At
a speed of 5 kph, the control unit starts regulating to
normal level. The acoustic signal ceases when 80% of
the normal level is achieved.
T7009689
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 12(21)

Functional description
Circuit diagram

T7009673

Simplified diagram of the control unit, solenoid

valves and airflow.

The table below specifies how the valves are designated

in the wiring diagram. Valve “42a” on the front block is
compressed air operated and is therefore not in the wiring
diagram.

6035F 6035R
43 42 41 41 42 43
KN VA Z Z HL HR
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 13(21)

Level raising, function

Read the description with the circuit diagram in section
“Circuit diagram” page 12.

Front solenoid valve block

Control Level raising Level raising, stop Level raising return Level raising, stop at
at the high position the normal level
ECS control unit The level switch (175) The level sensor The level switch (175) The level sensor
(9002) connects pin 8 to signals reach the connects pin 8 to signals reach the
earth. programmed value for earth. programmed value for
The program sends normal level. The program normal level
“+” to pin 3 and 4, The program connects pin 4 and 34 The program connects
and connects pin connects pin 3 and 4 to earth, and sends pin 3 to earth, and
34 to earth. Pin to earth, and sends “+” to pin 3. sends “+” to pin (4)
35 is continuously “+” to pin 34. and pin (34).
connected to earth
when the control unit
is working.
Solenoid valve (41) Activated by “+” from Activated by “-” from Activated by “-” from Activated by “+” from
pin 1. Outlet (3) pin 1. Change to pin 1. Remains pin 1. Outlet (3)
closed, inlet (1) open. outlet (3), ready for connected to outlet closed, inlet (1) open.
level raising return. (3).
Solenoid valve (42) Activated by “+” from Activated by “-” from Activated by “+” from Activated by “-” from
pin 2. Valve open. pin 2. Valve closed. pin 2. Valve open. pin 2. Valve closed.
Valve (42a) Opened by air from Closed by no air Opened by air from Closed by no air being
solenoid valve (42). being supplied from solenoid valve (42). supplied from solenoid
solenoid valve (42). valve (42).
Solenoid valve (43) Activated by “-” from Activated by “+” from Activated by “-” from Activated by “+” from
pin 3. Valve open. pin 3. Valve closed. pin 3. Valve open. pin 3. Valve closed.
Results The air bellows on The air bellows on The air bellows The air bellows on
both sides receive air both sides are closed on both sides are both sides are closed
supply from (21) and at (21) and (22). connected with outlet at (21) and (22).
(22). Front part of the bus (3) through (21) and Front part of the bus
Front part of the bus remains at the high (22). remains at the normal
is raised. level. Front part of the bus level.
is lowered.
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 14(21)

Rear solenoid valve block

Control Level raising Level raising, stop Level raising return Level raising, stop at
at the high position the normal level
ECS control unit The level switch (175) The level sensor The level switch (175) The level sensor
(9002) connects pin 8 to signals reach the connects pin 8 to signals reach the
earth. programmed value for earth. programmed value for
The program sends normal level The program normal level
“+” to pin 21, 22 and The program connects pin 4 to The program connects
4. connects pin 21, earth, and sends “+” pin 21 and 22 to earth,
22 and 4 to earth. to pin 21 and pin 22. and sends “+” to pin 4.
Solenoid valve (41) Activated by “+” from Activated by “-” from Activated by “-” from Activated by “+” from
pin 1. Outlet (3) pin 1. Change to pin 1. Remains pin 1. Outlet (3)
closed, inlet (1) open. outlet (3), ready for connected to outlet closed, inlet (1) open.
level raising return. (3).
Solenoid valve (42) Activated by “+” from Activated by “-” from Activated by “+” from Activated by “-” from
pin 2. Valve open. pin 2. Valve closed. pin 2. Valve open. pin 2. Valve closed.
Solenoid valve (43) Activated by “+” from Activated by “-” from Activated by “+” from Activated by “-” from
pin 3. Valve open. pin 3. Valve closed. pin 3. Valve open. pin 3. Valve closed.
Results The air bellows on The air bellows on The air bellows The air bellows on
both sides receive a both sides are closed on both sides are both sides are closed
supply of air from (21) at (21) and (22). connected with outlet at (21) and (22).
and (22). Rear part of the bus (3) through (21) and Rear part of the bus
Rear part of the bus remains at the high (22). remains at the normal
is raised. level. Rear part of the bus level.
is lowered.
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 15(21)

Kneeling, function
Read the description with the circuit diagram in section
“Circuit diagram” page 12.

Front solenoid valve block

Control Kneeling Kneeling stopped Kneeling return Kneeling return
downwards (only at the kneeling (only when the stopped at normal
when the whole side position whole side is level
is lowered) lowered)
ECS control unit The kneeling switch The level sensor The kneeling switch The level sensor
(9002) (1102) connects pin 8 signals reach the (1102) connects pin 6 signals reach the
and 24 to earth. programmed value for to earth. programmed value for
The program sends kneeling level. The program sends normal level.
“+” to pin 3 and The program “+” to pin 3, 4 and 34. The program connects
34, and connects connects pin 3 and 4 pin 3 and 4 to earth,
pin 4 to earth. Pin to earth, and sends and sends “+” to pin
35 is continuously “+” to pin 34. 34.
connected to earth
when the control unit
is working.
Solenoid valve (41) Activated by “-” from Activated by “-” from Activated by “+” from Activated by “-” from
pin 1. Change to pin 1. Remains pin 1. Outlet (3) pin 1. Reset to outlet
outlet (3). connected to outlet closed, inlet (1) open. (3), ready for kneeling.
(3).
Solenoid valve (42) Activated by “+” from Activated by “-” from Activated by “+” from Activated by “-” from
pin 2. Valve open. pin 2. Valve closed. pin 2. Valve open. pin 2. Valve closed.
Valve (42a) Opened by air from Closed by no air Opened by air from Closed by no air being
solenoid valve (42). being supplied from solenoid valve (42). supplied from solenoid
solenoid valve (42). valve (42).
Solenoid valve (43) Activated by “+” from Activated by “+” from Activated by “+” from Activated by “+” from
pin 3. Valve closed. pin 3. Valve closed. pin 3. Valve closed. pin 3. Valve closed.
Results Air from the kneeling Outlet passage (21) The kneeling side The air bellows on
side front air bellows is closed, lowering is bellows are supplied both sides are closed
is released through stopped. air by (21), the at (21) and (22).
(21). The opposite The opposite side opposite side’s Front part of the bus
side air bellows close air bellows are still bellows are closed remains at the normal
at (22). closed at (22). at (22). level.
The bus’s front corner The bus is raised on
is lowered. the kneeling side.
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 16(21)

Rear solenoid valve block

Control Kneeling Kneeling stopped Kneeling return Kneeling return
downwards (only at the kneeling (only when the stopped at normal
when the whole side position whole side is level
is lowered) lowered)
ECS control unit The kneeling switch The level sensor The kneeling switch The level sensor
(9002) (1102) connects pin 8 signals reach the (1102) connects pin 6 signals reach the
and 24 to earth. programmed value for to earth. programmed value for
The program sends kneeling level. The program normal level.
“+” to pin 21 and The program connects pin 22 to The program connects
connects pin 4 and 22 connects pin 4, 21 earth, and sends “+” pin 4, 21 and 22 to
to earth. and 22 to earth. to pin 4 and pin 21. earth.
Solenoid valve (41) Activated by “-” from Activated by “-” from Activated by “+” from Activated by “-” from
pin 1. Change to pin 1. Remains pin 1. Outlet (3) pin 1. Reset to outlet
outlet (3). connected to outlet closed, inlet (1) open. (3), ready for kneeling.
(3).
Solenoid valve (42) Activated by “-” from Activated by “-” from Activated by “-” from Activated by “-” from
pin 2. Valve closed. pin 2. Valve closed. pin 2. Valve closed. pin 2. Valve closed.
Solenoid valve (43) Activated by “+” from Activated by “-” from Activated by “+” from Activated by “-” from
pin 3. Valve open. pin 3. Valve closed. pin 3. Valve open. pin 3. Valve closed.
Results Air is released from Outlet passage (22) The kneeling side The air bellows on
the rear air bellows on is closed, lowering is bellows is supplied both sides are closed
the right side through stopped. with air through (22). at (21) and (22).
(22). The air bellows The opposite side The opposite side Rear part of the bus
on the left side are air bellows are still bellows are closed at remains at the normal
blocked at (21). closed at (21). (21). level.
The bus’s rear, right The bus is raised on
corner is lowered. the kneeling side.
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 17(21)

Program functions
Time delay Control time monitoring
The control unit program contains a number of time The system continuously controls vehicle height in
delays: accordance with the selected function (normal level,
raising, lowering, kneeling) so that the sensor values
• If the bus is stationary, the control unit waits 1 second
are close to the programmed values for the different
after it receives a signal to change bus height before
functions. If the system after 4 minutes cannot achieve
sending the necessary signals to the solenoid valves.
the programmed value, the fault code“Regulation time
monitoring” is set and level control is disengaged.
• If the bus starts moving while it is in the kneeling
position, it is automatically raised to the normal level
when a speed of 5 kph is reached.

• If the bus drives faster than 1 kph, after being

stationary, the system waits for 15 seconds before
sending signals to raise the level of the suspension
system.

• If the bus drives faster than 3 kph, and brakes, the

system waits for 15 seconds before sending signals to
raise the level of the suspension system.

• At speeds above 10 kph and if two contradictory

signals are received from level sensors on the same
axle, these will be interpreted as driving in a bend and
level control is disengaged for 25 seconds.
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 18(21)

Service Procedures
72513-2
Level sensor, air suspension, replace (one)

WARNING
Take care when working on the ECS. The vehicle can
be unintentionally lowered. Crush risk!
Set the vehicle on axle stands if work under the
vehicle is to be carried out.
ECS always returns the vehicle to normal height when
the engine is started.

1
Main switch off.

2
Apply the parking brake, or ensure using other methods
that the vehicle cannot begin to roll.

3
Release the link rod lower ball joint.

T7009642

4
Remove the lever from the level sensor.

T7009676
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 19(21)

5
Remove both the level sensor attachment screws.

T7009677

6
Remove the contact piece from the level sensor.

T7009678

7
Fit the contact piece to the new level sensor.

8
Fit the new level sensor and tighten to 25 ± 6 Nm.

25 ± 6 Nm

9
Fit the lever on the level sensor and tighten to a torque of
12 ± 2 Nm.

12 ± 2 Nm

T7009676
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 20(21)

10
Connect the link rod ball joint.

11
Main switch On.

12
Check bellows heights.
See service information: Group 72.
IMPACT: Group 720, Repair, “Bellows height, check
measurement”.
Volvo Bus Corporation Date Group No. Release Page
Service Bulletin 3.04 72 46 01 21(21)

72858-2
ECS control unit, replace
1
Check the control unit.
See service information: Group 72.
IMPACT: Group 728, Repair, “ECS control unit, check
before replacing”.

2
Main switch off.

3
Remove the connector from the control unit.

4
Remove the attachment screws and remove the control
unit.

5
Fit the new control unit and fit the screws.

6
Connect the connector

7
Program the control unit with a data set.
See service information: Group 72.
IMPACT: Group 728, Repair, “ECS control unit,
programming”.

8
Where necessary, program customer parameters.
See service information: Group 72.
IMPACT: Group 728, Repair, “ECS customer parameters,
setting”.

9
Check bellows heights.
See service information: Group 72.
IMPACT: Group 720, Repair, “Bellows height, check
measurement”.