SERVICE MANUAL BULLETIN
This Service Manual Bulletin is prepared by the Publications Department of New Flyer Industries
Canada ULC. Refer to details below.

SMB-134
ISSUE DATE: Mar 07 2014

APPLICABILITY
VEHICLE LENGTH

 30ft.

 35ft.

 40ft.

 60ft.

 ALL

VEHICLE TYPE

 High Floor

 Low Floor

 Invero®

 Xcelsior®

 ALL

 Diesel

 Electric

 CNG

 LNG

 Diesel/Electric

 Gas/Electric

 Fuel Cell

FUEL TYPE

 ALL

SUBJECT

Front & Rear Disc Brake Chamber Reuse, Inspection & Installation

SECTION TITLE

PM - PREVENTIVE MAINTENANCE
1 - FRONT AXLE & SUSPENSION
2 - REAR AXLE & SUSPENSION

DETAILS

This bulletin provides recently revised OEM information to eliminate the
mandatory requirement for disc brake chamber replacement when
removed from the brake caliper during routine brake service. The brake
chamber is suitable for reinstallation providing it meets the inspection
criteria defined within this bulletin.
This information supersedes any prior information on this subject
already provided in your New Flyer Service Manuals. Make this Service
Bulletin available to service personnel to inform them of changed information.

SMB-134

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 © 2014 New Flyer Industries Canada ULC

1 of 4

SERVICE MANUAL BULLETIN
SMB-134
1.

Standard Brake Chamber

1.1.

Inspection

ble section of your New Flyer Service
Manual for torque specification.

☞NOTE:

When installing the front brake chamber,
ensure that the brake hose bracket is positioned between the lock nuts and the brake
caliper.
Disc brake chambers must be
inspected for seal condition and height
measurement before a used brake
chamber can be reinstalled.
If installing a used brake chamber, perform
the following inspection:
1. Inspect the condition of the seal. It must
not be torn, hardened, or show any other
signs of damage. Replace the brake chamber as an assembly if the seal is damaged.
2. Measure the height of the seal on the
brake chamber. The seal must protrude at
least 0.118” (3.0 mm) from the brake
chamber mounting surface. See “Fig. 1:
Brake Chamber Seal Measurement” on
page 2.
3. If the seal measures less than 0.118” (3.0
mm) then the brake chamber must be
replaced as an assembly.
1.1.1.

5. Ensure the front brake chamber rubber
vent tubes do not interfere with the brake
caliper. Rotate tubes as necessary, ensuring tubes face either downward or rearward for drainage.
6. Ensure the rear brake chamber balance
tube does not face directly toward road
surface.
7. Connect air line to brake chamber and
torque air line fitting to 25 to 30 ft-lbs. (34
to 40 Nm).
8. Start vehicle and charge air system to normal operating pressure.
9. Check for air leaks.
10.Actuate brakes several times and check for
proper operation.
.

Installation

Cover the brake chamber opening on
the brake caliper when cleaning the
mounting surfaces so as to prevent
entry of any contaminants.

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6($/

1. Clean the brake chamber and caliper
mounting surfaces. Ensure that any protective covers are removed from the brake
caliper.

´
PP

2. Apply Renolit Unitemp 2 grease to the
spherical cup located in the brake caliper
and to the end of the brake chamber push
rod. Do not apply an excessive amount of
grease.
3. Carefully install brake chamber on brake
caliper assembly.
4. Install new M16 lock nuts and torque to
specification. Refer to “Front Suspension
Torque Specifications” or “Rear Suspension Torque Specifications in the applica-

2 of 4

s134204a.svg

Fig. 1: Brake Chamber Seal Measurement

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 © 2014 New Flyer Industries Canada ULC

SMB-134

SERVICE MANUAL BULLETIN
SMB-134
2.

Brake Chamber with EStroke

2.0.1.

Inspection

.

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25,1*

ALWAYS maintain the brake chamber
and ESP Sensor Pack spacer as an
assembly. DO NOT install a brake chamber without the ESP Sensor Pack
installed.

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Disc brake chambers must be
inspected for seal condition and height
measurement before a used brake
chamber can be reinstalled.

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If installing a used brake chamber, perform
the following inspection:
1. Note the position of the ESP sensor pack
and carefully remove it from the brake
chamber. Retain the two O-rings. See “Fig.
2: Front Brake Chamber ESP Sensor
Pack” on page 3. and See “Fig. 3: Rear
Brake Chamber ESP Sensor Pack” on
page 3.
2. Inspect the condition of the seal. It must
not be torn, hardened, or show any other
signs of damage. Replace the brake chamber as an assembly if the seal is damaged

s134201a.svg

Fig. 2: Front Brake Chamber ESP Sensor Pack
.

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3. Measure the height of the seals on both
the ESP sensor pack and brake chamber.
The seal must protrude at least 0.118” (3.0
mm) from the ESP sensor pack and brake
chamber mounting surfaces. See “Fig. 4:
Brake Chamber & ESP Seal Measurement” on page 4.

25,1*

4. If either one of the seals measures less
than 0.118” (3.0 mm) then the brake chamber and ESP sensor pack must be
replaced as an assembly.

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5. Ensure the ESP sensor pack is correctly
positioned on the brake chamber and
retained with O-rings.
s134202a.svg

Fig. 3: Rear Brake Chamber ESP Sensor Pack

SMB-134

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 © 2014 New Flyer Industries Canada ULC

3 of 4

SERVICE MANUAL BULLETIN
SMB-134
2.0.2.

9. Ensure that the electrical harness is properly routed and clamped as follows:

Installation

a. Sufficient slack should be provided
between the ESP sensor pack and first
clamping location on the air line fitting.
Cover the brake chamber opening on
the brake caliper when cleaning the
mounting surfaces so as to prevent
entry of any contaminants.
1. Clean the brake chamber and caliper
mounting surfaces. Ensure that any protective covers are removed from the brake
caliper.
2. Apply Renolit Unitemp 2 grease to the
spherical cup located in the brake caliper
and to the end of the brake chamber push
rod. Do not apply an excessive amount of
grease.
3. Carefully install brake chamber on brake
caliper assembly being careful not to
scratch or otherwise damage the painted
surface or target material of the push rod.
4. Install new M16 lock nuts and torque to
specification. Refer to “Front Suspension
Torque Specifications” or “Rear Suspension Torque Specifications in the applicable section of your New Flyer Service
Manual for torque specification.

☞NOTE:

When installing the front brake chamber,
ensure that the brake hose bracket is positioned between the lock nuts and the brake
caliper.

b. Additional cable ties should be provided
every 6 to 12” along the length of the air
line.
c. Provide slack at the electrical connector
location for ease of future servicing.
d. Run a cable tie through the electrical
connector clip and secure connector
body to the air line.
10.Start vehicle and charge air system to normal operating pressure.
11.Check for air leaks.
12.Actuate brakes several times and check for
proper operation.
.

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25,1*

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PP

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386+52'

5. Ensure the front brake chamber rubber
vent tubes do not interfere with the brake
caliper. Rotate tubes as necessary, ensuring tubes face either downward or rearward for drainage.

´
PP

6. Ensure the rear brake chamber balance
tube does not face directly toward road
surface.
7. Connect air line to brake chamber and
torque air line fitting to 25 to 30 ft-lbs. (34
to 40 Nm).

s134203a.svg

Fig. 4: Brake Chamber & ESP Seal Measurement

8. Connect the electrical harness to the ESP
sensor pack.

4 of 4

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 © 2014 New Flyer Industries Canada ULC

SMB-134