r11sz: brake abs malfunction indicator light non-compliance
Contents
1. BLUE BIRD R11SZ ORIGINAL ISSUE DATE JUNE 23 2011 REVISION DATE AUGUST 10 2011 TO U S DEALERS SUBJECT RECALL R11SZ BRAKE ABS MALFUNCTION INDICATOR LIGHT NONCOMPLIANCE This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act Blue Bird Body Company has decided that certain 2007 through 2011 model year Vision conventional model school buses manufactured from October 23 2006 through December 09 2009 fail to conform to the requirements of Federal Motor Vehicle Safety Standard FMVSS 105 Hydraulic and Electric Brake Systems Section 5 3 lfor buses equipped with hydraulic brakes and FMVSS 121 Air Brake Systems Section 5 1 6 2 for buses equipped with air brakes On the subject buses the dash instrument panel ABS malfunction indicator light does not illuminate when the main ABS module is disconnected In the event the ABS circuit is disconnected from the main ABS module the bus operator would be unaware of the failure of the ABS braking system and the associated nonfunctioning ABS braking which could increase the risk of a crash in certain circumstances and could potentially result in property damage and or personal injury On buses manufactured with hydraulic brakes and equipped with the cab mounted behind the PDU cover D version of the Wabco hydraulic brake ABS module the main wiring circuit must be rewired Buses with Type D Wabco ABS mod2. bus Dealers may submit campaign claims in Blue Bird iWarranty Claims for buses with Type D Wabco ECUs will be filed under campaign R11SZ Type D in iWarranty If our records indicate affected buses were delivered in your service area a printout identifying affected buses is enclosed Dealers should verify correct owners and assure that complete mailing addresses are provided for each listed vehicle If you have in your possession or have sold a bus that was purchased from another dealer that may be affected by this recall please notify me at 478 822 2242 Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days Dealers are reminded of their responsibilities under section 154 of The National Traffic and Motor Vehicle Safety Act of 1991 Dealers are required to complete modifications on units in their inventory before delivering to the final owner Reference Blue Bird Body Company Distributor Memo No 42 92 Questions regarding this recall campaign should be directed to me at 478 822 2242 Thank you PL rae Bill Coleman Corporate Recall Administrator Blue Bird Corporation BLUE BIRD R11SZ June 23 2011 Dear Blue Bird Owner This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act Blue Bird Body Company has decided that certain 2007 through 2011 model year Vision mod
3. need to have the ABS module wiring circuit only modified according to the attached recall instructions These buses will not need to be reprogrammed You may contact your Blue Bird dealer to have this modification performed or you may perform this modification yourself You may also have this modification performed by a reputable local repair facility convenient to you A qualified technician must perform the wiring circuit modification Reimbursement for labor for performing the wiring modification on the Wabco Type D ECU may be obtained by completing the Completed Reply Labor Reimbursement sheet provided and returning it to Blue Bird in the enclosed pink postage prepaid envelope BLUE BIRD BODY COMPANY P O Box 937 402 Blue Bird Blvd Fort Valley Georgia 478 825 2021 Page 2 R11SZ If your bus is equipped with air brakes or equipped with hydraulic brakes and_not manufactured within the dates for buses equipped with Wabco Type D ECU s you will need to schedule an appointment with your dealer to have the dash instrument panel reprogrammed Your Blue Bird dealer must perform the software update The software needed to correct this condition on these buses is anticipated to be available to your Blue Bird dealer within the next 30 days Reprogramming the dash instrument panel will be performed by your Blue Bird dealer at no charge to you A qualified technician must perform the software update If the modifications directed b
4. GT ABS ACTIVE circuit use terminal 00005840 ABS GND ABS BATT MOD PUMP BATT circuit use terminal 0036508 ABS IGN circuit use terminal 00036507 Remove two C504 connectors C504 and splice each circuit to the ABS IGN OR SA gt ABS IGN 0R corresponding circuit ABS GND WH ABS GND WH ABS BAT RD ABS BAT RD MOD PMP BAT RD Bc MOD PMP BAT RD ABS LGI GN SE gt ABS LGI TN ABS ACTIVE GN SF gt ABS ACTIVE TN 6 Wiring update procedure is complete Page 7 of BLUE BIRD Stoneridge Instrument Cluster ABS Malfunction Indicator Noncompliance 1 Second System O K Blink Code 1 1 System OK Diagnostic Switch located in this panel 8 Blink code 1 1 indicates system OK and no fault codes Any other blink code indicates a fault code If any fault code exists please refer to maintenance manual 39 included in your Vision service manual 9 ABS wiring update procedure is complete PARTS PART NUMBER QUANTITY DESCRIPTION 00036507 Terminal Butt Conn 14 16 GA Sealed 1 00036508 3 Terminal Butt Conn 10 12 GA Sealed 00005840 2 Terminal Butt Conn 18 22 GA Sealed Page 3 of 3
5. el conventional school and non school buses manufactured from October 23 2006 through December 09 2009 fail to conform to Federal Motor Vehicle Safety Standard FMVSS No 105 Hydraulic and Electric Brake Systems for buses equipped with hydraulic brakes and FMVSS No 121 Air Brake System for buses equipped with air brakes On the subject buses the dash instrument panel ABS malfunction indicator light does not illuminate when the ABS circuit is disconnected at the main ABS module In the event the ABS circuit is disconnected from the main ABS module the bus operator would be _ unaware of the failure of the ABS braking system and the associated nonfunctioning ABS braking which could increase the risk of a crash in certain circumstances and could potentially result in property damage and or personal injury Parts and labor required to complete Recall R11SZ will be provided at no cost to you Your Blue Bird bus es affected by this recall are identified by body serial number s on the enclosed cover sheet s The cover sheets will indicate the type of ABS module installed on the buses listed If you no longer own the subject bus es please complete the appropriate section of the cover sheet and return to Blue Bird in the enclosed pink postage prepaid envelope If your bus is equipped with hydraulic brakes and was manufactured between November 02 2006 and December 17 2008 and equipped with the Wabco Type D ABS module you will
6. ord 7658 8 MI Display Settings English aa a in a l Francais Espa ol Distance Em T Miles um F Krm Fuel consumption L400km MPG IMP gallona Talas a TimeDate Ock Format _ Date Format Contrast Night mode j iee i Change F Password Diag nostics A Engine ECU Fault Diagnostics Gearbox ECU Brake ECU Talltales test _ Cluster Self test Gauge test Speaker lest Pan Number AD Input Diag _Biigital Analog l F Configuration F Password Page 4 of BLUE BIRD Stoneridge Instrument Cluster ABS Malfunction Indicator Noncompliance Step 12 Using steering column stalk switch and instrument cluster configuration menu verify the ABS WL Source is set for J1939 Access to the configuration option is protected and requires the user to provide the access code via the Password option to enable it Enter the password 2290 first It is necessary to execute an ignition cycle OFF ON after revising desired parameters for EE parameter changes to take effect Display Settings Diagnostics Password 7655 8 ili Display Settings Francais Espanol Kore Leo0kmn MPG IMP gallons _ MPG US galons Fuel camsumptian Clock Format i Date Format _ Time Date Contrast Display Light _ f Backlight L Might mode Change LOF Password Diagnostics Faul Diagnostics Gearbox ECU Telltales test _ Cluster Self test Ga
7. tion ABS malfunction indicator may not based on instrumentation software version illuminate when required and ABS control module type Complete the appropriate corrective action procedure below SOFTWARE UPDATE PROCEDURE WARNING Always follow all Federal State Local and Shop safety standards and use proper safety equipment when performing these procedures NOTE Software update procedure is NOT applicable to buses with cab mounted D version ABS ECU s Step 1 Set the bus parking brake Step 2 Using steering column stalk switch and instrument cluster diagnostics menu verify current software version displayed under part number menu Display Settings Diagnostics Password Non Driving Mode 7658 8 Mi Display Settings Diagnostics Fault Diagnostics F Configuration Page l of 8 e BLUE BIRD Stoneridge Instrument Cluster ABS Malfunction Indicator Noncompliance Step 3 On units with version 1 4 or lower software installed flash the instrument cluster with version 4 11 software provided On units with version 1 5 or higher installed flash the instrument cluster with version 4 1 software provided Step 4 Connect Kvaser CAN interface cables supplied in kit 00114694 to the computers USB port and the Bus diagnostic connector located below the driver side dash area Connect to bus diagnostic connector Connect to a computer USB port Step 5 Once everything is connected t
8. uge test Display test Speaker test Pant Number AID Input Diag Digital Analog F Configuration Q FT Password Step 13 Instrument cluster software update is complete Page 5 of BLUE BIRD Stoneridge Instrument Cluster ABS Malfunction Indicator Noncompliance WIRING UPDATE PROCEDURE WARNING Always follow all Federal State And Local and Shop safety standards and use proper safety equipment when performing these procedures Observe all safety precautions to secure the bus from rolling NOTE Wiring update procedure is ONLY applicable to buses with cab mounted D version ABS ECU s 1 Park the bus on a level surface apply parking brakes turn off engine and remove keys Chock wheels 2 Disconnect batteries Note When disconnecting the batteries remove the negative cable first 3 Remove chassis Power Distribution Unit PDU cover by unscrewing two thumb screws The thumb screws are located at the top of each side of the cover N V Re Thumb screws Cover is located lower center of dash Page 6 of BLUE BIRD Stoneridge Instrument Cluster ABS Malfunction Indicator Noncompliance WIRING UPDATE PROCEDURE 4 Locate connector C504 in PDU detail shown below Cut and remove connector C504 from the PDU and ABS harness 5 Splice each circuit from previous step to the corresponding circuit Use appropriate terminal as listed below ABS L
9. ules were manufactured from November 02 2006 through December 17 2008 See attached R11SZ instructions modification procedures for buses equipped with Type D ABS modules Note The instrument panel on buses equipped with Type D Wabco ABS modules will not be reprogrammed BLUE BIRD BODY COMPANY P O Box 937 402 Blue Bird Blvd Fort Valley Georgia 478 825 2021 Page 2 R11SZ All other buses subject to Recall R11SZ will require the Dealer to reprogram the Stoneridge instrument panel with the appropriate software as required The software for reprogramming the dash will be available on the Blue Bird Customer Service website within the next 30 days See attached R11SZ instructions for Stoneridge instrument panel reprogramming procedures Owners are being directed to contact their dealer to have Recall R11SZ performed We have included an updated owner list of units requiring reprogramming Labor time to rewire the type D ABS module on subject buses equipped with hydraulic brakes and manufactured from November 02 2006 through December 17 2008 is 0 2 hours per bus Labor time to rewire the air brake modules on subject buses equipped with air brakes and manufactured from October 23 2006 through February 23 2007 is 0 2 hours per bus Note Claims for this population of air brake buses are also to be filed under R11SZ Type D Labor time to install the appropriate software on all other buses is 0 2 hours per
10. urn ignition switch on Step 6 Run the Flash Tool application by double clicking the Flash Tool icon on your desktop F lt _ Icon on desktop Stoneridge s FlashTool Page 2 of BLUE BIRD Stoneridge Instrument Cluster ABS Malfunction Indicator Noncompliance Step 7 You will see the following screen main window Vition FlachTool v4_00 File Tools Help Blue Bird Hex File Motloaded TAWES Stabs of tee D1 1 1 34 PM Step 8 Click on Open Hex File button a Select the appropriate software version hex file supplied Step 9 Click on Flash button a A confirmation window will appear click on Flash button w Flash Unit Contirmation Make sure the unit is connected to the CAN bus and ignition is on WARNING Once the OK button Is pressed you will not be able to cancel the operation Page 3 of BLUE BIRD Stoneridge Instrument Cluster ABS Malfunction Indicator Noncompliance Step 10 Wait for the cluster unit to automatically restart Once the flash process has started there is no way to abort The status screen will display passed Operation successful when process is complete DO NOT switch ignition off while in process Step 11 Using steering column stalk switch and instrument cluster diagnostics menu verify software version displayed under part number menu is updated version level you installed Display Settings Diagnostics Passw
11. y this notification were performed on your bus prior to the receipt of this recall notification complete and sign the recall reply sheet and attached a copy of the work order invoice Mail the documents in the pink self addressed postage paid envelope included with the recall notification to Blue Bird for warranty consideration Reimbursements will be made in accordance with the requirements of the National Highway Transportation Safety Act Title 49 Code of Federal Regulations Parts 573 and 57I Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days If Blue Bird Body Company should fail to or is unable to remedy this condition without charge to you you may contact ADMINISTRATOR NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION 1200 NEW JERSEY AVENUE SE WASHINGTON D C 20590 Or you may call The National Highway Traffic Safety Administration toll free at 1 888 327 4236 TTY 1 800 424 9153 Or go to HTTP WWW SAFERCAR GOV Questions regarding this recall campaign should be directed to me at 478 822 2242 Thank you 6 Wy WM Bill Coleman Corporate Recall Administrator Blue Bird Corporation Stoneridge Instrument Cluster ABS BLUE BIRD Malfunction Indicator Noncompliance Models Affected 2007 2011 Model Year Vision Buses ISSUE CORRECTIVE ACTION Under certain conditions the anti lock brake Affected units will require corrective ac
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