R23-022 – Software Error May Cause Unintended Acceleration – 2022-2023 New Flyer XD35, XD40, XN35, XN40, & 2023 XD60, XE35, XE40, & XN60 Transit Buses

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-898
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
New Flyer of America, Inc. DEC 23, 2023 NHTSA Recall No. : 23V-898 Manufacturer Recall No. : R23-022 Manufacturer Information :
Manufacturer Name : New Flyer of America, Inc.
Address : 711 Kernaghan Avenue
Winnipeg, MB 00 R2C3T4 Company phone : 204-224-6706
Population :
Number of potentially involved : 211 Estimated percentage with defect : 100 %
Vehicle Information : Vehicle 1 : 2022-2023 New Flyer XD35, XD40, XE40, XN35, XN40 Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES Body Style : OTHER Power Train : NR
Descriptive Information : Recall population was based on buses with specific modules used.
Other buses with different modules are not affected. XD35: 2022-18, 2023-8
XD40: 2022-11; 2023-46
XD60: 2023-34
XE35: 2023-7
XE40: 2022-40
XN35: 2022-11, 2023-10
XN40: 2022-20, 2023-7
XN60: 2023-2
Production Dates : JUN 17, 2022 – DEC 15, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Vehicle 2 : 2023-2023 New Flyer XD60, XE35, XN60 Vehicle Type :
Body Style :
Power Train : NR
Descriptive Information : Recall population was based on buses with specific modules used. Other buses with different modules are not affected.
Production Dates : JUN 17, 2022 – DEC 15, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Part 573 Safety Recall Report 23V-898 Page 2 Description of Defect :
Description of the Defect : On buses with specific modules, if an address resistor fails, the module could allow an uncommanded throttle activation.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Uncommanded throttle activation increases the risk of a crash.
Description of the Cause : On buses equipped with specific modules, the programming of these modules allowed the module to continuously run an address detection subroutine. If an address resistor fails, the module would enter an error state, and would hold outputs to the last known state. Identification of Any Warning
that can Occur : When this happens, uncommanded throttle is possible. No warning likely precedes this condition. Involved Components : Component Name 1 : NR Component Description : NR Component Part Number : NR Supplier Identification : Component Manufacturer
Name : NR Address : NR
NR
Country : NR Chronology :
On December 5th, 2023, New Flyer received a Field Report of a bus that went into an engine high-rpm condition. The bus was stopped and towed back to the property. Over the next days, our Technical Support Specialist (TSS) worked with our technician and determined the module/node was continuously running an address subroutine. With this occurring, after a node is powered- up and the address is assigned, if there is any failure in the addressing resistor, the result will be that the node The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-898
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
in question will enter an “error state”. If this happens, all outputs will hold and remain in “last known state”.
A modified program was tested and confirmed on December 15th, 2023. This issue was presented to the Safety Committee for review on December 20, 2023, which resulted in concurrence a recall should be issued, culminating with this 573 report. There are no other known Field Reports or Warranty Claims for this issue, and no reported accidents/injuries.
Description of Remedy :
Description of Remedy Program : New Flyer will update bus programming to modify the address sub-
routine to only take place upon vehicle power-up, free of charge. How Remedy Component Differs from Recalled Component :
Identify How/When Recall Condition was Corrected in Production :
If customers prefer to install the software, New Flyer will provide the updated software and customers can submit for labor reimbursement through New Flyer warranty system.
The revision level of installed software. New Flyer started revising software version levels in affected production buses on December 18, 2023. Recall Schedule :
Description of Recall Schedule : Please note New Flyer does not utilize a dealer network. Dealer
notification dates are aligned with Owner Notification dates.
Planned Dealer Notification Date : FEB 14, 2024 – FEB 14, 2024
Planned Owner Notification Date : FEB 14, 2024 – FEB 14, 2024
* NR – Not Reported

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THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERRED TO FOR FUTURE MAINTENANCE UNTIL
THE NEW FLYER PARTS AND/OR SERVICE MANUAL IS UPDATED TO REFLECT WORK DONE AS A
RESULT OF THIS DOCUMENT. ENSURE THAT THIS DOCUMENT IS AVAILABLE FOR PARTS AND
MAINTENANCE STAFF GOING FORWARD.
This document and the contents discussed herein are the confidential and proprietary information of New Flyer Industries Canada
ULC and New Flyer of America Inc. and are disclosed by New Flyer in confidence. This document and the contents herein are not
to be disclosed by the intended recipient without the prior written authorization of New Flyer. Any unauthorized disclosure,
reproduction or other distribution of this document or information strictly prohibited and may result in action being taken against
the party making the unauthorized disclosure. This document and all copies hereof must be returned to New Flyer upon request.
INSTRUCTION TO SERVICE
ITS: 60895 December 21, 2023
SECTION:
284- Electrical Cntrol Panels
WRITTEN BY:
Troy Stutsky
SUBJECT:
Update Bus Programming for CM-3033 Modules
ISSUE:
CM-3033 module address detection was running continuously causing issues with bus operation.
SUMMARY:
Update bus programming to modify the address sub-routine to only take place upon vehicle power-up.
IT60895
Ref. NHTSA Recall No.
Ref. Transport Canada Recall No.
To be Determined
To be Determined
INSTRUCTION TO SERVICE
ITS60895
ITS60895 Page 2 of 3 December 21, 2023
PROCEDURE:
1. Contact your New Flyer Regional Product Support Manager and obtain updated programming for all the CM-3033 modules located inside the bus.
2. Follow standard procedure for updatating the programming for the CM-3033 modules. Programing obtained from your Regional Product Support Manager is SR specific and Node specific.
3. Once the updated programming has been loaded to each CM-3033 module, test the bus to ensure all systems are functioning as intended.
4. Clean up all tools and debris and return the bus to service condition.
INSTRUCTION TO SERVICE
ITS60895
ITS60895 Page 3 of 3 December 21, 2023
LABOUR ESTIMATE
Operation
Number of Technician(s)
Hours
Labor Time
T X HR
1
Update Bus Programming for CM-3033 Modules
1
0.25
0.25
PARTS REQUIRED
Item
Part Number
Description
Qty.
per Coach
Units
Notes
1
No Part Number
Obtain updated SR & Node specific CM-3033 module programming from your New Flyer RPSM

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