INSTRUCTION TO SERVICE
ITS: 59195

9-Mar-2021

SECTION:

241-Fuel System

WRITTEN BY:

Mike Pearson

SUBJECT:

Replace incorrect supplier installed LCV spring

ISSUE:

Supplier used an incorrect spring in the LCV valve

SUMMARY:

Supplier has sent replacement LCV springs and the customer will be installing
them, ITS is to document work and allow for billing of labor.

ITS59195

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
ITS59195

PROCEDURE:
1. Set park brake and chock wheels.
2. Turn the main battery disconnect switch to the “OFF” position.
3. Locate and open the fuel fill access door.

Fuel fill access
door location

Figure 1: Fuel Fill Access Door Location
4. If needed, remove and save the fuel fill snap adapter, gasket and mounting hardware (x4). Plug fuel neck with
a clean lint free rag to keep anything from accidently entering the fuel tank.

Plug fuel neck with
clean lint free rag

Remove and save the
fuel fill snap adapter

Figure 2: Fuel Snap Adapter Removal (Access Door Removed for Clarity)

ITS59195

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March 9, 2021

INSTRUCTION TO SERVICE
ITS59195
5. Remove and save the existing LCV valve, gasket and mounting hardware for reuse.
6. Cover the LCV boss with a clean lint free rag to keep anything from accidently entering the fuel tank.

Remove and save
existing LCV valve
mounting hardware (x4)

Remove and save
existing LCV valve
assembly

Remove and save
existing LCV
valve gasket

Figure 3: LCV Valve Assembly Removal



NOTE: Soft vice jaws will prevent any damage to the anodized LCV body.



NOTE: The retaining washer will be under light spring pressure and so care should be taken not to
lose the washer or circlip.

7. Place the LCV valve from Step 6 into a soft jawed vice as shown in Figure 4.
8. Remove and safe the securing circlip, see Figure 4.

Remove and safe
the securing circlip

Place the LCV
valve into a soft
jawed vice

Figure 4: LCV Valve Circlip Removal
ITS59195

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March 9, 2021

INSTRUCTION TO SERVICE
ITS59195
9. Remove the washer and existing spring, save the washer and discard the spring.

Remove the washer
and existing spring

Existing LCV
valve assembly

Figure 5: LCV Valve Washer and Spring Removal
10. Insert the replacement spring.
11. Place existing washer from Step 9 over the spring.
12. Re-install the circlip removed in Step 8.

Re-install the
circlip and
washer
Existing LCV
valve assembly

Figure 6: LCV Washer and Circlip Installation

ITS59195

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March 9, 2021

INSTRUCTION TO SERVICE
ITS59195
13. Verify for correct height of existing aluminum ball, light should be visible through the ball chamber vent hole,
at least 1/3rd of the hole should be clear, see Figure 7 for correct example.
At least 1/3rd of
the hole should
be clear

Existing LCV
valve aluminum
ball

Existing LCV valve
assembly

Figure 7: Example of Correct Aluminum Ball Height and Vent Hole Space
14. Remove clean cloth from the LCV valve mounting boss and clean the LCV mounting boss mating surface.
15. Install the existing gasket from Step 5.
16. Clean the mating surface of the reworked LCV valve from Step 13 and position the LCV on the boss in the
same position and orientation as was removed in Step 5.
17. Apply Loctite 222 p/n 030305 to the existing hardware from Step 5 and torque to 10-15 in*lbs.
18. If needed, remove the cloth used to protect the open fuel neck from contaminants. Reference Step 4.
19. Reinstall gasket, fuel fill adapter and hardware removed in Step 4. Position roll pin of adapter at left hand bottom
side. Position dust cap hinge at left hand side, see Figure 8. Torque hardware to 75-85 in*lbs.

Position dust
cap hinge at left
hand side
Reinstall gasket,
fuel fill adapter
and hardware if
needed.
Position roll pin of
adapter at left
hand bottom side

Figure 8: Fuel Snap Adapter Installation (Access Door Removed for Clarity)
ITS59195

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March 9, 2021

INSTRUCTION TO SERVICE
ITS59195
20. Remove all tools and debris and return the bus to service condition.
21. Close the fuel fill access door.
22. Turn the main battery disconnect switch to the “ON” position.

ALL Parts supplied by Gardner Denver

LABOUR ESTIMATE
Operation
1

Replace incorrect supplier installed LCV spring

Number of
Technician(s)
1

Hours
0.5

Labor Time
T X HR
0.5

PARTS REQUIRED
Item

Part Number

Description

1

Vpn 801143

Spring-LCV Valve

ITS59195

Qty.
per
Coach
1

Page 6 of 6

Units
EA

Notes
Supplied by Gardner
Denver

March 9, 2021