VOLVO TRUCKS (VECV) - Technical Failure Analysis Report

Purpose of TFAR
 Approval
Approval / feedback
 Warranty
Type of TFAR
 Truck Chassis
Subject/Complaint
Engine brake malfunction massage coming on driver display and engine brake not working.
Report Number 691230-1-2025-72633 Report Date 14-Oct-2025 Prepared By VSPCKORBA
Dealer ID 691230-1 Dealer Name VSPC-KORBA 1
Customer Name Kalinga commercial corporation Customer Contact Person Amit Sarkar
Workshop/Site-Location Dipka Customer Contact Number 09038616151
Chassis Model with Axle Configuration FM(4)-B 500 8X4 BS4 Body CuM & Application SAE 25.2 Cum Wider Rock Body
Chassis No 8-991390 Reg. Number DPV-1543 Date of Delivery 01-Oct-2024
Date of failure 14-Oct-2025 Repair Order No. 21921 Repair Date 14-Oct-2025
Failure Mileage kms 69100 Age in Months 13 Engine Hrs. 6575
Function Group 2533 Causal Part No. 21596649 Description control valve
Defect Code Group 4 ELECTRICAL FAULTS Defect Code 43-CONTACT FAULT
Spare parts warranty No Spare parts invoice details Spare parts fitment date 0000-00-00
Driveline Warranty Yes GDR No

Repair Estimate Summary

Material Cost 19803.60 Labor Cost 1412.46 Other Cost

Road Details

Type of road surface (Asphalt, Soil Gravel, Sharp stones etc. SOIL
Dust Condition (Heavy Slight, etc.,) SLIGHT
Approx. Gradient of the Road (required for engine and wheel Hub failures 1:16
Undulation on the Road( Heavy,Slight, Lot of pot holes, large Bumps, etc.) SLIGHT
Was the vehicle travelling Uphill or Downhill (required for engine and wheel hud failures NA

Load Details

Type of load carried OVER BURDEN Permitted Technical GCW 59 GCW during failure 57

Available information on the load types and GCW's handled by the vehicle earlier which could have caused the failure

NA

Aggregate details

Details of the concerned failed Aggregate ( Engine, Gearbox, Rear Axle, Diffeerential, Rear Axle, Diff. carrier, steering gear, Turbocharger, Superstructure Hydraulic parts etc.)
Aggregate NA Aggregate Part No. NA Aggregate Sr. No. NA

Interview with the Driver ( Applicable for all driveline related failures)

Driver Name RAHUL KUMAR Training details on the related variant Training at site on 17-10-22

Drivers description on the happening of the failure:

Engine brake malfunction massage coming on driver display and engine brake not working.

Technical Explination of complaint (Dealer comment):

After received complaint from driver we attained the vehicle and check the below points-

> At first, we collected data through driver interview.
> After that we conform the massage from driver display.
> Then we connect the VTT with the vehicle and found DTC in EMS P102113 as active, VCB control circuit, Circuit open.
> After that we start GD according to this DTC.
> We check the F44 fuse and found in good condition.
> Then we check the K27 relay and found in good condition.
> We checked all wiring and connectors, and all found in good condition.
> After that we removed the tappet cover from the engine and removed the VCB control valve.
> We checked the power supply and found ok.
> Then we checked the resistance of the control valve and found 0 Ohms.

> After that we checked the resistance of a new control valve and found in has 42 Ohms.


>> We suspected that the VCB control valve has internal contact fault which led to this failure.


EATS is not bypass in this vehicle since DOD.

Fault codes registered in vehicle (Including Active and Inactive Faults)

EMS P102113
Is the causal part a recently modified one NA

If Yes, kindly provide more details about the modification:

Parts Superseded from PN-21596649 to- PN-23509305
Is this a repeat failure No Is yes, provide relavant details
Relavant Argus No. If any Relavant DQR No. If any Relavant MQR No. If any
Relavant QJ No. If any

Affected Vehicle details

Chassis No Model Body No Date of Delivery Date of Failure Mileage Kms Engine hrs Parts Sl.no
-- -- -- -- -- -- -- --

Area(Photos Where required/Applicable)

Photo Area Description/Remarks
Affected vehicle- DPV-1543 Ch id- 8-991390
Vehicle data- KMR-69100 HMR-6575
Engine brake malfunction massage coming on driver display.
Active faults code.
GD Process.
GD Process.
GD Process.
GD Process.
GD Process.
GD Process.
GD Process.
GD Process.
GD Process.
GD Process.
GD Process.
GD Process.
GD Process.
GD Process.
GD Process.
GD Process.
Supply voltage found ok.
Supply voltage found ok.
VCB connector and pin found in good condition
Failed control valve resistance found 0 Oham.
Failed parts- PN-21596649 SL- 2416 0809
Causal parts in Impact.
Parts in VDA+.
Parts Superseded PN-21596649 to PN-23509305.
New parts- PN-23509305 SL- 2445 0343
New control valve resistance found 42 Oham.

Probable Cause of Failure

We suspected that the VCB control valve has internal contact fault which led to this failure.

Corrective Action/Suggestions

Failed control valve need to be replaced.

Service and Repair History of the vehicle (Relevant to the failure)

S.No.
Job Card No.
Date
Mileage Kms
Engine Hrs.
 Job carried out Remarks
-- -- -- -- -- -- --

Repair Estimate

Material Cost

S.No. Part no Description Qty Unit Price Net Price GST % GST Amt. Net Price including GST Pay code Remarks
123509305CONTROL VALVE116782.7116,782.71183,020.8919,803.6009
Total 16,782.71 Total 19,803.60

Labour cost

S.No. Operation No Description Qty Unit Price Net Price GST % GST Amt. Net Price including GST Pay code Remarks
117010-2 Connect-disconnect of diagnostic tool 0.2855171.001830.78201.7809
225320-2 Control valve VEB, replace 1.28551,026.0018184.681,210.6809
Total 1,197.00 Total 1,412.46

Other cost

S.No. Description Qty Unit Price Net Price GST % GST Amt. Net Price including GST Pay code Remarks
Total 0.00 Total 0.00
Total cost of Repair( Material, Labor and Other cost) 21,216.06

Any Local solution or suggestion from the Field team for Prevention/ Quick resolution of Complaint

NA

ANNEXURES (Select the annexure attached)

17012-3 VCADS Pro Error Codes Test 1760433358_phv_(4).pdf Compulsory for all failures having fault codes
17034-3 Vehicle information test
28486-3 Sensor Values History Report Compulsory for all failures related with the engine
20007-3: Engine protection data
28407-3 Sensor Values, Monitoring
20005-3: Fuel consumption data
28108-8 Engine ECU, check Compulsary for all failures related with the engine ECU
PDF file of the Repair history of the vehicle in LDS– complete 1760433422_Service_History_1_2025101414462253687.pdf Optional
Scan or Fax copy of the Last BS or AS (as applicable) checksheet Compulsary
Completely filled checksheets and Protocols as given in Impact/FAG in YVD for the complaint Compulsary

Additional Attachments

S.No. Attatchemnt
11760434129_Driver_Training_KCC_Dipka_500.xlsx
2
3
4
5
6

Oil & Fuel Sample Test Reports (Compulsory for all major engine related failures):

Sample Date Sent to ELF Mumbai


Dispatch Details of Failed Parts( Mandatory for critical failures/failures related to safety/failures related to performance)

Docket No Dispatch Date Courier Name Transporter Veh No.

Present Status of the vehicle

Present Status Rectified & Running Reason Waiting for approval.


Comments

S.No. Remarks By Date & Time TFAR Status
1Dear Team,
Please find the VCB control valve failure case from KCC Dipka site, kindly approve this case under driveline warranty.

C1- Engine brake malfunction massage coming on driver display and engine brake not working.
C2- We suspected that the VCB control valve has internal contact fault which led to this failure.
C3- Failed control valve need to be replaced.

EATS is not bypass in this vehicle since DOD.

BR,
Raj.		VSPCKORBA2025-10-14 15:02:50TFAR RAISED
2Dear Sir,

Please find the VCB control valve failure case from KCCL Dipka site.

3Cs are as follows-

C1-Drive complaint of engine brake malfunction message popping up on the IC.

C2-On inspection found the DTC for EMS P102113 as active, VCB control circuit, Circuit open was active. On further measuring supply to control valve, found to be 25.06V and the connector pins were found in good condition. On measuring the coil resistance, found that the VCB control valve internal coil was in open loop.

C3-Need to replace the failed.

Seeking approval to support this case under driveline warranty.

Br,
Arihant
a.wankhede2025-10-15 16:00:15TFAR FORWARDED
3Approvedakthakur2025-10-15 04:12:35APPROVED