INSTRUCTION TO SERVICE
ITS: 6236
SECTION:

246

WRITTEN BY:

Michael Rooney

SUBJECT:

Add PPV valve at the emergency tank.

Air, Brake & Levelling System.

ITS6236

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 IS 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.

PROCEDURE:
1. Turn the main battery disconnect switch to the “OFF” position.
2. Chock the wheels to prevent vehicle movement.
3. Drain the air from the air system following the procedure in the New Flyer Service Manual.

4. Remove the ad panels on the curb side forward of the rear door to gain access to the Emergency Air Tank.
5. Disconnect the 3/8” air-line labelled ERT- DCV 140665. Figure 1.
6. Remove and discard the check valve. Figure 1.

Air-Line ERT – DCV 140665

Check Valve

Figure 1: Emergency Air Tank

7. Install a reducer NF P/N 544613 in the bushing already in the port on the Emergency tank where the air-line
and check valve were previously attached. Use Loctite 567 NF P/N 8110442 on the threads, install the
reducer finger tight then apply two full turns past finger tight.
8. Install a valve NF P/N 622788 on the reducer using Loctite 567 thread sealant NF P/N 8110442. The port
marked “DEL” (Delivery) should be installed on the nipple. Orient the valve as seen in Figure 2.
9. Remove the existing connector on the air-line labelled ERT – DCV 140665 and install a new connector NF
P/N 5952460.
10. Install the 3/8” air-line labelled ERT – DCV 140665 in the other port marked “SUP” (Supply) on the new valve
using Loctite 567 thread sealant NF P/N 8110442. Install the connector finger tight in the valve then apply two
full turns past finger tight.

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Connect Air-Line
ERT-DCV to PPV
Here

PPV Valve
Emergency Tank

Figure 2: Valve Installed on Emergency Air Tank.

11. Turn the main battery disconnect switch to the “ON” position.
12. Start the bus and allow the air system to pressurize.
13. Check for air leaks at the emergency tank and repair as necessary.
14. Perform the Emergency/Parking Brake Test outlined in section 3.10.5 of the New Flyer Service Manual for
XD60 models and section 3.9.6 for XD40 models or refer to attached Appendix A for XD60s or Appendix B for
XD40s.
15. Replace the ad panels.
16. Remove all tools and debris to return the bus to service condition.

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APPENDIX A
Emergency/Parking Brake Test Procedure For XD60 model.

1. Park the vehicle on level ground and chock the wheels.
2. Start the engine and charge the air system to cut-out pressure. You will hear the emergency tank start to
fill once the service tanks reach 92 – 98 Psi.
3. Stop the engine.
4. Ensure the wheels of the bus are chocked and release the parking brake.
5. Drain the wet tank. The front, center and rear brake tanks should retain full pressure.
6. Drain the front axle brake tank. The low air warning lamp on the front brake tank gauge should illuminate
and the low air buzzer should sound. The center and rear brake tanks should retain full pressure.
7. With no air pressure in the front brake tank, make a service brake application. The center and rear axle
brakes should apply and release at least once and the rear brake lamps should illuminate.
8. Drain the rear axle brake tank. The center brake tank should retain full pressure.
9. Slowly drain the center axle brake tank. The parking brake control valve should pop to the applied position
when the center reservoir reaches approximately 45 psi.
NOTE:
DO NOT use the brake treadle to bleed down the center axle brake tank. Rapid pumping of the
brake treadle will cause pressure pulsations that can result in premature application of the spring
brakes, resulting in a false pressure reading.
10. Actuate the Emergency Brake Release control by pressing and holding the knob in the down position. The
park brakes at both center and rear axles should release and remain released as long as the control is held
in the down position. Release the control. The park brakes at both center and rear axles should reapply.
Repeat this cycle until the park brakes fail to release. Drain the emergency brake release tank. The park
brakes should remain in the applied position.
11. Close all tank drain valves, start the engine and recharge the air system to cutout pressure.
12. Stop the engine.
13. Drain the center axle brake tank. The low air warning lamp on the center brake tank gauge should
illuminate and the low air buzzer should sound. The front and rear brake tanks should retain full pressure.
14. With no air pressure in the center brake tank, make a service brake application. The front, center and rear
axle brakes should apply and release at least once and the rear brake lamps should illuminate.
15. If the parking brakes applied in the previous step, verify that the emergency brake release is capable of
releasing the park brakes and that the park brakes reapply when the control is released.
16. Verify that the park brakes at both center and rear axles release when the park brake control valve is in
the released position.

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17. With the park brakes released, make another service brake application and verify that the front, center
and rear brakes apply at least one more time.
18. Close all tank drain valves, start the engine and recharge the air system to cut-out pressure.
19. Stop the engine.
20. Drain the rear axle brake tank. The low air warning lamp on the rear brake tank gauge should illuminate
and the low air buzzer should sound. The front and center brake tanks should retain full pressure.
21. With no air pressure in the rear brake tank, make a service brake application. The front, center and rear
axle brakes should apply and release once and the rear brake lamps should illuminate.
22. Close all tank drain valves, start the engine and recharge the air system to cut-out pressure.
23. Stop the engine.
24. Open the emergency tank drain. Watch the gauges for the front and center service tanks, service tanks
should drain down to approximately 80 psi at which point the Pressure Protection Valve on the emergency
tank will close and pressure in the front and center service tanks will stabilize. Watch the gauge for the rear
service tank as well, the pressure in the rear tank should not drop as the emergency tank is drained. The
emergency tank will continue to drain until empty.
25. Test is complete. Close all reservoir drain valves, start the engine and recharge the air system to cut-out
pressure.

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APPENDIX B
Emergency/Parking Brake Test Procedure For XD40 model.
1. Park the vehicle on level ground and chock the wheels.
2. Start the engine and charge the air system to cut-out pressure. You will hear the emergency tank start to
fill once the service tanks reach 92 - 98 Psi.
3. Stop the engine.
4. Ensure the wheels of the bus are chocked and release the parking brake.
5. Drain the wet tank. The front and rear brake tanks should retain full pressure.
6. Drain the front axle brake tank. The low air warning lamp on the front brake tank gauge should illuminate
and the low air buzzer should sound. The rear brake tanks should retain full pressure.
7. With no air pressure in the front brake tank, make a service brake application. The rear axle brakes should
apply and release at least once and the rear brake lamps should illuminate.
8. Slowly drain the rear axle brake tank. The parking brake control valve should pop to the applied position
when the center reservoir reaches approximately 45 psi.
NOTE:
DO NOT use the brake treadle to bleed down the rear axle brake tank. Rapid pumping of the brake
treadle will cause pressure pulsations that can result in premature application of the spring brakes,
resulting in a false pressure reading.
9.

Actuate the Emergency Brake Release control by pressing and holding the knob in the down position. The
park brakes at the rear axle should release and remain released as long as the control is held in the down
position. Release the control. The park brakes at the rear axle should reapply. Repeat this cycle until the
park brakes fail to release. Drain the emergency brake release tank. The park brakes should remain in the
applied position.

10. Close all tank drain valves, start the engine and recharge the air system to cutout pressure.
11. Stop the engine.
12. Drain the rear axle brake tank. The low air warning lamp on the rear brake tank gauge should illuminate
and the low air buzzer should sound. The front brake tank should retain full pressure.
13. With no air pressure in the rear brake tank, make a service brake application. The front and rear axle
brakes should apply and release at least once and the rear brake lamps should illuminate.
14. If the parking brakes applied in the previous step, verify that the emergency brake release is capable of
releasing the park brakes and that they reapply when the control is released.

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15. Verify that the park brakes at the rear axle release when the park brake control valve is in the released
position.
16. With the park brakes released, make another service brake application and verify that the front and rear
brakes apply at least one more time.
17. Close all tank drain valves, start the engine and recharge the air system to cut-out pressure.
18. Stop the engine.
19. Open the emergency tank drain. Watch the gauges for the front and rear service tanks, service tanks
should drain down to approximately 80 psi at which point the Pressure Protection Valve on the emergency
tank will close and pressure in the front and rear service tanks will stabilize. The emergency tank will
continue to drain until empty.
20. Test is complete. Close all reservoir drain valves, start the engine and recharge the air system to cut-out
pressure.

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LABOUR ESTIMATE
Operation
1

Add PPV at the emergency tank.

Men

Hours

1

0.75

Labour Time
M X HR
0.75

PARTS REQUIRED
Description

Qty.
per
Coach
0.01

Units

Item

Part Number

1

8110442

LOCTITE 567 – THREAD SEALANT

2

5952460

CONNECTOR-1/4MPT X 3/8SYN

1

EA

3

544613

ADAPTER-1/4 X 1/2 NPT EXT BRASS

1

EA

4

622788

VALVE – RSVR CTRL (PR-3)

1

EA

Notes

EA

SPECIAL TOOLS REQUIRED
Item
1

Part Number

Description

Qty.
per
Coach

Notes
Units

No Special Tools Required.

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