SMB-179 – E – Stroke Troubleshooting – Disc Brakes – New Flyer Xcelsior

SEOCONTENT-START

SMB-179 1 of 5
SERVICE MANUAL BULLETIN
This Service Manual Bulletin is prepared by the Publications Department of New Flyer Industries
Canada ULC. Refer to details below.
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
ISSUE DATE: Apr 09 2019
SMB-179
APPLICABILITY
VEHICLE LENGTH  30ft.  35ft.  40ft.  60ft.  ALL
VEHICLE TYPE
 Xcelsior®  MiDi®  Invero®
 ALL
 Low Floor  High Floor
FUEL TYPE
 Diesel  Diesel/Electric  CNG  LNG
 ALL
 Fuel Cell  Trolley/Electric  Battery/Electric
SUBJECT E – Stroke Troubleshooting – Disc Brakes
SECTION TITLE 9 – Electrical System
DETAILS This bulletin provides revised OEM (MGM) information on the E-Stroke
troubleshooting charts.
The information supersedes any prior information on this subject already
provided in your New Flyer Service Manual.
Make this Service Bulletin available to service personnel to inform them
of changed information.
2 of 5 SMB-179
SERVICE MANUAL BULLETIN
SMB-179
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
1. E-Stroke Troubleshooting
E-STROKE TROUBLESHOOTING
FAULT TYPE FAULT SYMPTOM POSSIBLE CAUSE
RECOMMENDED
ACTIONS
Power Source System Warning Light
dose not illuminate.
Electrical 1, 3, 4
Power Source Warning Light stays on or
unable to access CCM
using diagnostic tool.
Electrical 1, 2, 3, 4
Dragging Brake CCM indicates dragging
brake: Left and Right of
same Axle.
Air Control 5, 6, 8
Dragging Brake CCM indicates dragging
brake on (1) wheel end
only.
Foundation Brake 6, 7, 10, 11, 12
Non-Functioning CCM indicates non-functioning
brakes on left and
right.
Air Control 8
Non-Functioning CCM indicates non-functioning
brake on a single
axle.
Foundation Brake 6, 7, 9, 10, 11, 12
CCM indicates Over
Stroke Condition
CCM indicates out of
adjustment condition.
Excess actuator stroke
with pressure between
12-50 psi.
Foundation Brake 6, 7
Non-Functioning and
Over-Stroke Fault
A combination of multiple
Non-Functioning, Over-
Stroke, and Drag faults
on one wheel end.
Foundation Brake See Low Caliper
Running Clearance
Low Caliper Running
Clearance
Low caliper running clearance
fault detected (Non-
Function/Over Stroke
faults may be recorded
for Wheel End as well).
Foundation Brake 7, 10, 11
Sensor Fault CCM indicates Active
Sensor Fault or Erratic
Fault Conditions on same
wheel.
Electrical 10, 11
SMB-179 3 of 5
SERVICE MANUAL BULLETIN
SMB-179
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
1.1. E-Stroke Troubleshooting
Actions
Pressure Transducer Pressure Transducer
Fault or Non-Functioning
Fault Reported for Multiple
Axles.
Electrical 11
E-STROKE TROUBLESHOOTING
FAULT TYPE FAULT SYMPTOM POSSIBLE CAUSE RECOMMENDED
ACTIONS
E-STROKE TROUBLESHOOTING ACTIONS
RECOMMENDED ACTION KEY RECOMMENDED ACTIONS
1. Verify System Input Power Verify Master Run Switch is in DAY-RUN or NIGHT-RUN
Verify Input Power is turned ON.
Verify System is NOT connected to Battery Power.
Verify e-STROKE CCM power source is properly functioning
Check CCM Power Cable for Electrical Shorts, Cut Wires, or
Damaged Connectors.
Test Vehicle System Voltage. e-STROKE System Input Voltage
must be between 10-30 Volts DC.
2. Verify J1939 Connection Check CCM J1939 connection.
Verify CCM is configured for J1939 data network speed
(250kbs vs 500 kbs).
Check for e-STROKE on network diagram in Vehicle Electrical
Schematics
3. Verify Warning Light Operation Check for faulty warning lamp by applying signal voltage to
test.
☞NOTE:
CCM will “Blink” a voltage signal from the Alarm Output
during start up.
Verify Multiplexing system is working
4 of 5 SMB-179
SERVICE MANUAL BULLETIN
SMB-179
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
4. Possible CCM Malfunction CCM Alarm output constant voltage, Warning Light remains
On after Start Up indicates CCM is not operating properly.
Lack of warning light bulb check after System Power (Recommended
Action 1) and Warning Light (Recommended
Action 3) are verified indicates CCM is not operating.
5. Possible Vehicle Operator Error Parking Brakes applied while vehicle is moving.
6. Inspect Foundation Brake and Caliper
for mechanical or operational
issue
Verify that caliper lever arm fully returns back to starting position
and does not remain applied.
Inspect Foundation Brake and Caliper for seized components
(i.e. caliper guide pins).
Inspect Caliper and Actuator Boots/Seals for damage or
tears.
Inspect Brake Pad Linings for irregularities or damage (i.e.
foreign material stuck in pads, excessive pad wear or part of
pad missing).
7. Inspect Caliper Running Clearance
Adjustment
Verify Caliper Adjustment refer to Section 1 or Section 2 of
this Manual for procedure
Verify caliper adjuster operation. Refer to Section 1 or 2 of
this manual for Adjuster Check Procedure.
Running Clearance below (0.030″) may reduce actuator
stroke resulting in Non-Function Faults reported.
☞NOTE:
Potential causes: 1) Caliper Adjuster Malfunctioning 2)
Incorrect clearance set at pad service 3) New lining
expansion during initial heat cycle.
8. Possible Service Brake Air Control
Issue
Check for Dirt, Moisture, or Ice in Air System (Air Line or
Valve blockage).
Confirm Proper Operation of Interlocks Function (Apply/
Release).
Confirm Proper QR Valve Operation (Apply/Release).
Confirm Valve Control Wiring. Refer to Vehicle System Drawings
9. Brake Actuator Inspection Check Brake Chamber for Service Diaphragm leak.
Check Parking Brake Spring Chamber for Leak (Diaphragm
or Piston)
☞NOTE:
Refer to the PM section of this Manual for Brake Chamber
Inspection procedures.
SMB-179 5 of 5
SERVICE MANUAL BULLETIN
SMB-179
The New Flyer vehicles described in this manual may be protected by one or more
patents and design applications or registrations in the United States and Canada,
and in other countries. Refer to “Vehicle Patent Information” in this manual.
Copyright © 2019 New Flyer Industries Canada ULC
10. Inspect Sensor Harness and Connectors
Check cable and wires for loss of connection, damage, cuts,
pinch’s, corrosion, shorts.
Check Exterior Wheel End.
Check CCM connectors for Damaged/Bent/Loose Terminals,
Corrosion. Ensure connector is fully installed into CCM.
Check Harness Connections at Artic Joint (if applicable).
Drag Fault could be from broken ground wire.
11. Verify Sensor Condition and Operation
Confirm correct Wheel End Location by unplugging Exterior
Sensor Connector (>60 sec) and confirm Sensor Fault at correct
wheel w/Diagnostic Tool (I.e. Front Left Wheel End
should show Sensor Fault on Axle 1 Left).
Inspect Sensor for damage or Signs of Corrosion.
Verify Sensor Voltage function. Check sensor voltage at
CCM connector with system power and wheels chocked.
Test green signal wire to black ground wire.
Brakes Released 0.1-1.99 VDC,
Brakes Applied >2.00 VDC.
Sensor Fault if <0.10 VDC after 60 Seconds.
Sensor Power: Red power wire to black ground wire. Voltage
should read >4.8 VDC.
Pressure Transducer: Inspect e-STROKE Pressure Transducer
and wiring. Use Diagnostic Tool to verify Pressure
Transducer read < 0.3 psi with NO brake application.
12. Inspect e-STROKE Brake Actuator
Piston Rod Reflective Target
Remove Brake Actuator and inspect Piston Rod Ball End
Reflective Target Material for Grease, Dirt or Damage.
Clean Grease from Piston Rod Reflective Targets with clean/
dry rag.
DO NOT use solvents.
☞NOTE:
Grease on the Black or Red targets can cause a Drag
Fault indication.