INSTRUCTION TO SERVICE
ITS-61254

1/28/2025

SECTION:

246 – Air, Brake & Leveling System

SUBJECT:

VMAC Air Compressor GEN 1.1 Field Retrofit

ISSUE:

Supplier retrofit to incorporate recommended design updates to improve both
the function and reliability of the air compressor.

SUMMARY:

VMAC field instructions to upgrade compressors with GEN 1.1 retrofit kit.

ITS-61254
Ref. NHTSA Recall No.
Not Applicable

Ref. Transport Canada Recall No.
Not Applicable

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
ITS-61254

ITS-61254

Page 2 of 43

1/28/2025

INSTRUCTION TO SERVICE
ITS-61254

1.0 Table of Contents
1.
2.
3.
4.
5.

Table of Contents ........................................................................................ 3
IMPORTANT ................................................................................................ 4
Safety Messages ......................................................................................... 5
Safety Precautions ...................................................................................... 6
Gen 1.1 Retrofit (Kit# A710084) ................................................................. 8
5.1. Tools Required ......................................................................................... 8
5.2. Items for Rework and Disposal ............................................................. 12
5.3. Retrofit Procedure – Under the Bus ...................................................... 13
5.4. Retrofit Procedure – Inside the Bus ....................................................... 33
6.
IPL - Gen 1.1 Retrofit Pkg | A710084........................................................ 42

Rev

A

ITS-61254

Date

By

Document Revision History
VMAC 1901247
Eng Eng Notes / Summary of Changes

10DEC2024 MRR RRP NDB Initial release for retrofit service instructions

Page 3 of 43

1/28/2025

INSTRUCTION TO SERVICE
ITS-61254



NOTE: The instructions contained in this ITS document were created by VMAC. This field
retrofit is ONLY to be completed by VMAC personnel or properly trained field staff.

2. IMPORTANT
The designer, manufacturer, and seller of the bus’s (BUS OEM) service and maintenance instructions
take priority and supersede VMAC’s Global Technology Inc’s (VMAC) service instructions as long as
the minimum service intervals in this manual are performed by trained and authorized personnel. BUS
OEM’s lockout procedures, removal/installation, and maintenance instructions must be performed
before any service on VMAC’s compressor. Removal of any compressor access panels or of the unit
itself must be performed by qualified personnel as determined by the BUS OEM and the end user.
Service of the VMAC compressor may require following the BUS OEM’s instructions for the removal of
BUS panels or structural elements as defined by the BUS OEM and dependent on the level of repair or
maintenance. VMAC makes no service or warranty support for these bus parts beyond the control of
our design of the delivered compressor to the BUS OEM for factory installation.
The BUS OEM’s instructions for bus shutdown and lock out must be followed before servicing the
compressor. All service must be completed and the VMAC compressor restored to its operation ready
condition before proceeding with the bus’s startup procedure. VMAC’s compressor is application
approved in the BUS OEM factory configuration only. If the installation configuration is altered from its
factory configuration in anyway without VMAC and the BUS OEM’s written permission and acceptance,
then the bus should not be operated, and the BUS OEM service contacted directly.
Please contact VMAC in case of discrepancies or questions regarding the service of the compressor.
The information contained in this manual is based on sound engineering principles, research, extensive
field experience and technical information. Information is constantly changing with the addition of new
models, assemblies, service techniques and running OEM changes. If a discrepancy is found in this
manual, contact VMAC prior to initiating or proceeding with installation, service, or repair. Current
information may clarify the issue. Anyone with knowledge of such discrepancies, who proceeds to
perform service and repair, assumes all risks.
Only proven service procedures are recommended. Anyone who departs from the specific instructions
provided in this manual must first ensure that their safety and that of others is not being compromised,
and that there will be no adverse effects on the operational safety or performance of the equipment.
VMAC shall not be held responsible for any liability, consequential damages, injuries, loss, or damage
to individuals or to equipment caused by the failure of anyone to properly adhere to the procedures set
out in this manual, or standard safety practices. Safety must be the first consideration when performing
any service operations.

ITS-61254

Page 4 of 43

1/28/2025

INSTRUCTION TO SERVICE
ITS-61254

3. Safety Messages
This manual contains various warnings, cautions, and notices that must be observed to reduce the risk of
personal injury during installation, service or repair and the possibility that improper installation, service,
or repair may damage the equipment or render it unsafe.

This symbol is used to call attention to instructions concerning personal
safety. Watch for this symbol; it points out important safety precautions, it
means, “Attention, become alert! Your personal safety is involved”. Read
the message that follows and be aware of the possibility of personal injury
or death. As it is impossible to warn of every conceivable hazard, common
sense and industry standard safety practices must be observed.
This symbol is used to call attention to instructions on a specific procedure
that if not followed may damage or reduce the useful life of the compressor
or other equipment.
This symbol is used to call attention to additional instructions or special
emphasis on a specific procedure.

ITS-61254

Page 5 of 43

1/28/2025

INSTRUCTION TO SERVICE
ITS-61254

4. Safety Precautions
Burn Hazard
• The compressor system gets very hot during operation, contact with
the components or the oil can cause serious injury. Allow sufficient time
for the system to cool prior to performing service.
• Avoid contact with the engine or compressor components until the
system has cooled sufficiently.
Personal Safety
• Do not breathe the compressor air as vaporized oil is a respiratory
hazard.
• Always use the appropriate personal protective equipment when
servicing the compressor.
Fire and Explosion Hazard
• Vaporized oil propelled by high pressure air is an explosive mixture.
• Fire in the compressor can cause an explosion and flame projection.
Should this occur, there is potential for serious injury or death.
• Ensure the compressor air intake is located in a well-ventilated area
that is free of flammable vapors, dust, or other combustible materials
• Never place objects against or on top of the compressor.
• Never expose the system to extreme heat.
Skin Contact Hazard
• Wear nitrile gloves or similar protective equipment when servicing the
compressor to protect against grease, compressor oil, and coolant.
Compressor Air and Oil Hazard
• The compressor system is under sufficient pressure that a leak could
force the air/oil mixture through the skin directly into your
bloodstream. This could cause serious injury or death.
• Ensure the system is completely depressurized before attempting
maintenance or repair.
• Do not use compressed air to clean off clothing or skin, compressed air
and/or entrained particles can penetrate the skin causing serious injury
or death.
• Do not service the system while it is pressurized or operating.
• Components and hoses under pressure could separate suddenly and
cause serious injury or death. The air supply system and piping must be
drained prior to servicing the system.
• Never adjust or attempt to make any repairs to the system while the
compressor is running. Components and hoses under pressure could fail
and cause serious injury or death.

ITS-61254

Page 6 of 43

1/28/2025

INSTRUCTION TO SERVICE
ITS-61254

Electrical Shock/High Voltage Hazard
The voltage supplying the compressor is potentially deadly! Any time
the compressor is operating, the compressor is drawing nominal 600
Vdc. Prior to disconnecting the compressor, ensure the motor is deenergized and appropriate lockout procedures are utilized.
Burst Hazard
This system is designed to generate air pressure up to the Original
Equipment Manufacturers (OEM) specification during normal operation.
• Serious injury or death may result from an air tank explosion.
• Never exceed manufacturer’s maximum air pressure rating.
• Do not repair components, only replace with approved parts.
• Do not tamper with or disable factory safety equipment.
Moving Parts Hazard
• Prior to performing service, ensure the motor is de-energized and
appropriate lockout procedures are utilized.
General Warnings
• Prior to attempting any repair or service, ensure the compressor and
compressor motor are de-energized and appropriate lockout procedures
are utilized.
• Be attentive for unexplained changes in operation parameters and
record any changes.
• Ensure scheduled service intervals are adhered to.
• Use only approved oils, hoses, and replacement parts.
• Keep hoses and wiring away from hot, sharp, or moving
components.
• Do not modify the equipment.
• Do not operate this system unless this manual has been read in its
entirety.
• Do not operate this system when fatigued or under the influence of
alcohol or drugs.
• Never bypass or disable any of the safety equipment.
• Never adjust, or attempt to make any repairs to this system while the
compressor system under pressure or energized.
• Components and hoses that are under pressure could fail and cause
serious injury or death, take precautions!

ITS-61254

Page 7 of 43

1/28/2025

INSTRUCTION TO SERVICE
ITS-61254

5. Gen 1.1 Retrofit (Kit# A710084)
5.1 Tools Required
5.1.1 Under bus tool kit
12

14
9

8

3

15

10

17

11

1
7

13
16

5

18

6
4

2

19

24 5

21
23

22

20

2.2

2.1
1. Laptop with pre-loaded software installation zip-file and 2 available USB-A ports. Operating system must be
either Windows or Linux, Apple Mac is incompatible with Kvaser drivers.
2. VMAC low voltage bypass harness with attached:
2.1. Kvaser leaf CAN interface device
2.2. USB 12V Power booster for updating the software on the motor
3. Hose/tube cutter for cutting the blowdown tube
4. 3/8” drive Battery powered ratchet tool for removing panels (low clearance)
5. M10 socket (3/8” drive) for removing panels
6. M13 socket (3/8” drive) for removing bolt on bottom plate
7. 2” long 3/8” socket extension
8. Washer installation tool for holding star washers

ITS-61254

Page 8 of 43

1/28/2025

INSTRUCTION TO SERVICE
ITS-61254

9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

Small magnetic battery powered flood light
Torque paint (Markal security check paint marker Red, or similar) for marking motor bolt and MPCV bolt
Shop towel for cleaning torque paint
VMAC MPCV calibration tool for calibrating MPCV
VMAC MPCV socket tool for removing and installing MPCV
3/8” drive torque wrench
10mm open box end wrench for calibrating MPCV
3mm hex bit socket (3/8” drive) for calibrating MPCV
1” Adjustable wrench for calibrating MPCV
Long needle nose pliers with 45° angle tips for removing MPCV piston
3/8” socket wrench with omni-directional head for installing and removing MPCV
4” diam magnetic tray for holding fasteners and bits
Snipping tool for snipping zip ties
Zip ties for replacing cut zip ties
VMAC calibrated ¼” drive torque wrench for installing panels
1/4" female to 3/8” male socket drive adaptor for installing panels

5.1.2 Optional under bus accessories:

A

F

B
C

E

D
A.
B.
C.
D.
E.
F.

Magnetic retrieval tool
Spare oil pen
XL sharpie for marking boxes
Spare needle nose pliers
Spare magnetic light source
Spare tube cutter

ITS-61254

Page 9 of 43

1/28/2025

INSTRUCTION TO SERVICE
ITS-61254

5.1.3 Inside the bus tool kit:
1

37

3

2

4

5

A

7

6

C

8

9

10

25
20

22
28

19

21
23

24

27

26

32 33

29
31

11
15

30
12
34

B

35 36 37 38

D
16
18

13
14

17
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Impact driver for removing bolts
Wire cutters for cutting for removing zip ties
Needle nose pliers for setting inlet adaptor bolts in place
Long needle nose pliers with 45° angle tips for setting inlet adaptor bolts in place
T-handle 8mm square drive for operating hatch latches and service panel latches (E100110A)
Hose/tube cutter for adjusting Teflon blowdown tube