INSTRUCTION TO SERVICE
ITS: 59109
SECTION:

246

Air, Brake & Levelling System.

WRITTEN BY:

Michael Rooney

SUBJECT:

Retrofit updated Smart Rider PCU (40’ Buses)

ITS59109
THIS ITS DOCUMENT SHOULD BE RETAINED AND REFERED 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 UNAUTHOIZED 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. On XE40 & XE60 Electric Buses.
a.

Disconnect, lockout and apply a lockout tag to the High Voltage Interlock Switch.

3. Chock the wheels and drain the air system.
4. If necessary, raise coach in accordance with the New Flyer Service Manual.

Front PCU Replacement.
5. Open the access panel on the bottom of the bus under the driver’s area.
6. Locate the front Smart Rider PCU (Pneumatic Control Unit).

BVA/E6 Valve

PCU Unit

Figure 1: Front PCU Location.
7. Disconnect the two ½” Blue air lines and the 5/8” Blue air line attached to the PCU noting their locations for
reassembly later.
8. Unlatch and disconnect the electrical connector on the right side of the PCU unit.
9. Loosen and then remove the three bolts and lock nuts that secure the PCU unit to the mounting bracket then
remove the PCU from the vehicle. Set hardware aside for reuse later.

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½” Blue Air Line
FTRH - FTPCUP2
1/2 “ Blue Air Line
FTLH - FTPCUP1

Electrical Connector
Location

5/8” Blue Air Line
KNLTK - FTPCUSPLY

Figure 2: PCU Mounting Bolts, Air Lines & Electrical Connector.
10. On the work bench, remove the air line fittings noting their installation locations and set them aside for reuse
later.
11. Remove the muffler assembly and set it aside for reuse later.
12. Set the old PCU assembly aside for return to Supplier.
13. On a new PCU unit NF P/N 860463, Re-install the air line connectors removed from the old PCU unit.
a.

Re-install the two 45 deg elbows in ports one and two using Loctite 567 thread sealant NF P/N 8110442
on the threads. Take care not to block the openings with thread sealant and leave the first two threads
free of sealant. Install the fittings finger tight, then apply 1 – 1.5 turns past finger tight and align in the
orientation seen in Figure 3.

b.

Re-install the straight air line fitting using Loctite 567 thread sealant NF P/N 8110442 on the threads.
Take care not to block the openings with thread sealant and leave the first two threads free of sealant.
Install the fittings finger tight, then apply 2 turns past finger tight.

c.

Re-install the muffler using Loctite 567 thread sealant NF P/N 8110442 on the threads. Take care not to
block the openings with thread sealant and leave the first two threads free of sealant. Install the fittings
finger tight, then apply 2 turns past finger tight.

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PCU Unit
Straight Air Line Fitting

45 Deg Elbows

Muffler

Figure 3: PCU Unit Assembly.
14. Re-install the PCU unit assembly in the bus using the original nuts and bolts.
15. Re-attach the ½” Blue air lines in their original locations (Figure #2). Screw the nut down finger tight and then
apply 4 turns past finger tight.
16. Re-attach the 5/8” Blue air supply line. Screw the nut down finger tight and then apply 3 ½ turns past finger
tight.
17. Re-attach the electrical connector to the PCU. Take care to ensure that the connector is fully seated and
properly latched.
18. Close and secure the access door on the bottom of the bus.

Rear PCU Replacement.
19. Locate the rear PCU Smart Rider PCU (Pneumatic Control Unit) on the mounting plate containing the air
brake valves ahead of the rear suspension.

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PCU Unit

Figure 4: Rear PCU Unit Location.
20. Disconnect the two ½” Blue air lines and the 5/8” Blue air line attached to the PCU noting their locations for
reassembly later.
21. Unlatch and disconnect the electrical connector on the right side of the PCU unit.
22. Loosen and then remove the three bolts and lock nuts that secure the PCU unit to the mounting bracket then
remove the PCU from the vehicle. Set hardware aside for reuse later.

½” Blue Air Line
RRPCUP2 - JUNC
PCU Unit
½” Blue Air Line
RRPCUP1 - JUNC

Electrical Connector

Muffler

5/8” Blue Air Line
KNLTK-RRPCUSPLY

Figure 5: Rear PCU Mounting Bolts, Air Lines & Electrical Connector.

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23. On the work bench, remove the air line fittings noting their installation locations and set them aside for reuse
later.
24. Remove the muffler assembly and set it aside for reuse later.
25. Set the old PCU assembly aside for return to Supplier.
26. On a new PCU unit NF P/N 860463, Re-install the air line connectors removed from the old PCU unit.
a.

Re-install the two 90 deg elbows in ports one and two using Loctite 567 thread sealant NF P/N 8110442
on the threads. Take care not to block the openings with thread sealant and leave the first two threads
free of sealant. Install the fittings finger tight, then apply 1 – 1.5 turns past finger tight and align in the
orientation seen in Figure 6.

b.

Re-install the 45 deg elbow air line fitting using Loctite 567 thread sealant NF P/N 8110442 on the
threads. Take care not to block the openings with thread sealant and leave the first two threads free of
sealant. Install the fittings finger tight, then apply 2 turns past finger tight.

c.

Re-install the muffler using Loctite 567 thread sealant NF P/N 8110442 on the threads. Take care not to
block the openings with thread sealant and leave the first two threads free of sealant. Install the fittings
finger tight, then apply 2 turns past finger tight.
90 Deg Elbow Fittings

PCU Unit

45 Deg Elbow Fitting

Muffler

Figure 6: PCU Unit Assembly.
27. Re-install the PCU unit assembly in the bus using the original nuts and bolts.
28. Re-attach the ½” Blue air lines in their original locations (Figure #5). Screw the nut down finger tight and then
apply 4 turns past finger tight.

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29. Re-attach the 5/8” Blue air supply line. Screw the nut down finger tight and then apply 3 ½ turns past finger
tight.
30. Re-attach the electrical connector to the PCU. Take care to ensure that the connector is fully seated and
properly latched.
31. Lower coach in accordance with the New Flyer Service Manual.
32. On XE40 & XE60 Electric Buses.
a.

Remove the lock, lock out tag and switch the Hight Voltage Interlock Switch on.

33. Turn the main battery disconnect switch to the “ON” position.
34. Start the bus and allow the air system to charge.
35. Check the Smart Rider functions such as kneeling to ensure that the system is functioning correctly. Repair as
necessary.
36. Remove all tools and debris and return the bus to service condition.

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LABOUR ESTIMATE
Operation
1

Remove and replace front & rear suspension PCUs

People

Hours

Labor Time

1

2.0

2.0

PARTS REQUIRED
Item

Part Number

Description

1

860463

VALVE – PNEUMATIC SUSPEN

2

8110442

LOCTITE 567 THREAD SEALANT

Qty.
per
Coach
2

Units

0.01

EA

Notes

EA

SPECIAL TOOLS REQUIRED
Item

Part Number

Description

Qty.
per
Coach

Units

Notes

NO SPECIAL TOOLS REQUIRED

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