Air Pressure Gauge Malfunction – 2021-2024 Blue Bird All American & 2021-2022 Vision School Buses

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-425 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Blue Bird Body Company Submission Date : JUN 13, 2023 NHTSA Recall No. : 23V-425 Manufacturer Recall No. : R23CH (School Bus) Manufacturer Information : Manufacturer Name : Blue Bird Body Company Address : P.O. Box 937 402 Blue Bird Boulevard Fort Valley GA 31030 Company phone : 478-822-2242 Population : Number of potentially involved : 1,424 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2022 Blue Bird Vision Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : HYBRID ELECTRIC Descriptive Information : Some T3 and CVEV units equipped with pneumatic brakes have been found to inconsistently not have functioning air pressure gauges, and visual/audible low air warnings on startup in ambient <=50°F (10°C) temps. Blue Bird Field Service started fielding reports of this failure in September of 2022. PHRED 562 was opened October 28, 2022 to track and 8D the problem. Replacing clusters with applicable service parts did not resolve the problem, however, installing Part Number 10068500 (nonvideo) would allow the system to work properly. All external influences of cluster internal were eliminated. Internal audit of cluster software/hardware found the copy of the ignition signal that the co-processor (only used with 7 gauge clusters) reads to start running was being loaded down by an internal pulldown in the co-processor (Magna-V) itself. It is loaded to a level that is marginal to be read as a valid high when cold. If the co-processor does not see ignition, it will not run and the air gauges + low air warnings will not be active. Production Dates : OCT 25, 2021 – DEC 19, 2022 VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-425 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Vehicle 2 : 2021-2024 Blue Bird All American Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : DIESEL Descriptive Information : Some T3 and CVEV units equipped with pneumatic brakes have been found to inconsistently not have functioning air pressure gauges, and visual/audible low air warnings on startup in ambient <=50°F (10°C) temps. Blue Bird Field Service started fielding reports of this failure in September of 2022. PHRED 562 was opened October 28, 2022 to track and 8D the problem. Replacing clusters with applicable service parts did not resolve the problem, however, installing Part Number 10068500 (nonvideo) would allow the system to work properly. All external influences of cluster internal were eliminated. Internal audit of cluster software/hardware found the copy of the ignition signal that the co-processor (only used with 7 gauge clusters) reads to start running was being loaded down by an internal pulldown in the co-processor (Magna-V) itself. It is loaded to a level that is marginal to be read as a valid high when cold. If the co-processor does not see ignition, it will not run and the air gauges + low air warnings will not be active. Production Dates : SEP 03, 2021 – JAN 13, 2023 VIN Range 1 : Begin : NR End : NR Not sequential Description of Noncompliance : Description of the Noncompliance : Some T3 and CVEV units equipped with pneumatic brakes have been found to inconsistently not have functioning air pressure gauges, and visual/audible low air warnings on startup in ambient <=50°F (10°C) temps. FMVSS 1 : 121 – Air brake systems FMVSS 2 : NR Description of the Safety Risk : In the absence of functioning air gauges and visual/audible warning, a driver would not have warning if brake air pressure was lost. Causing brake air pressure loss would result in non functioning brakes, therefore, increasing the chance of a crash. Description of the Cause : Some T3 and CVEV units equipped with pneumatic brakes have been found to inconsistently not have functioning air pressure gauges, and visual/audible low air warnings on startup in ambient <=50°F (10°C) temps. Identification of Any Warning that can Occur : A driver would be able to visually identify non functioning air gauges which is a pre-trip check requirement on air brake equipped buses. Involved Components : Part 573 Safety Recall Report 23V-425 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : Instrument Cluster Component Description : Instrument Cluster Component Part Number : 10069519 Component Name 2 : Instrument Cluster Component Description : Instrument Cluster Component Part Number : 10068500 Supplier Identification : Component Manufacturer Name : NR Address : NR NR Country : NR Chronology : 9/1/2022 – Blue Bird Field Service starting fielding reports of this failure. 10/28/2022 – 8D investigation was launched. 11/7/2022 – 8D investigation was closed determining a software malfunction. 11/18/2022 – Test software was installed & verified to correct the malfunction. 1/16/2023 – Instrument Clusters with updated software began to be used in Production. Description of Remedy : Description of Remedy Program : Cluster containing the updated software version began being used in production on January 18, 2023. If the modifications directed by this notification were performed on your bus prior to the receipt of this recall notification, provide a copy of the work order/invoice to [email protected] for Blue Bird warranty consideration. Blue Bird will reimburse the labor cost of the repair related to this recall at no cost to the Dealer or to the vehicle owner. Parts are not required; Ametek Software update. How Remedy Component Differs from Recalled Component : Software version identification; Ametek Software updated needed. Part 573 Safety Recall Report 23V-425 Page 4 The information contained in this report was submitted pursuant to 49 CFR §573 Identify How/When Recall Condition was Corrected in Production : Cluster containing the updated software version began being used in Production on January 16, 2023. Recall Schedule : Description of Recall Schedule : Dealer and Owner Notifications are to be issued on or before August 9, 2023. Parts are not required; Ametek Software update. Cluster containing the updated software version began being used in production on January 18, 2023. If the modifications directed by this notification were performed on your bus prior to the receipt of this recall notification, provide a copy of the work order/invoice to [email protected] for Blue Bird warranty consideration. Parts are not required; Ametek Software update. Planned Dealer Notification Date : AUG 09, 2023 – AUG 09, 2023 Planned Owner Notification Date : AUG 09, 2023 – AUG 09, 2023 * NR – Not Reported

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