FT5328

FT5328
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REFERENCE:
Nova Bus Manuals
SECTION:
08: Pneumatic System
RS NO:
MQR 7621-2506
APPLICATION DEADLINE: 2024FE28
CLAIM REFERENCE NUMBER: WB-5328
EFFECTIVE IN PROD.: N/A
SUBJECT:
Leveling valve out of Adjustment.
JUSTIFICATION:
Leveling valve N92260 found out of adjustment.
LEVEL
DIRECT CHARGES
DESCRIPTION
1
leveling valve re-adjustment.
2
–
TIME
LABOUR
MATERIAL
Novabus
Novabus
1h
–
–
–
MATERIAL REQUIRED PER VEHICLE
QTY
PART NO
REV.
DESCRIPTION
–
–
–
N30292
D
LEVEL 1
–
LEVEL 2
2
Suspension Linkage Kit
LEVEL 2 SPECIAL TOOLING
1
NT1090
NR
Suspension Air Bags Height Gage
1X NT1090 PER DEPOT
Materials will be available within 44 days once your order has been placed.
To order, please contact [email protected]
Or by phone for CANADA 1-800-771-6682, for USA 1-877-999-8808
Specify document number, quantity of parts required and shipping address.
DISPOSAL OF PARTS
REMOVED PARTS ARE:
DISCARDED *
RETAINED
Yes
–
* Dispose of the unused parts and the defective parts in
accordance with local environmental standards in effect.
REVISION HISTORY
REV.
DATE
NR
2022DE14
CHANGE DESCRIPTION
Initial release
Irina
Negoescu
NQF772001 VERSION 3
APPROVED BY:
Signature numérique de
Irina Negoescu
Date : 2022.12.14
11:23:13 -05'00'
WRITTEN BY
Devanand
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CLIENT
ORDER
New York City Transit New York - NYCT
New York City Transit New York - NYCT
ROAD NUMBER
VIN (2NVY/4RKY...)
QTY
FROM
TO
FROM
TO
LD08
8762
8763
L82J0M9778159
L82J7M9778160
2
LD08
8800
8800
L82J7M9778207
L82J7M9778207
1
New York City Transit New York - NYCT
LD08
8821
8821
L82J8M9778233
L82J8M9778233
1
New York City Transit New York - NYCT
LD08
8826
8826
L82J7M9778238
L82J7M9778238
1
New York City Transit New York - NYCT
LD08
8828
8850
L82J5M9778240
L82J3N9778268
23
New York City Transit New York - NYCT
LD08
8853
8858
L82J3N9778271
L82J6N9778278
6
New York City Transit New York - NYCT
LD08
8860
8860
L82J4N9778280
L82J4N9778280
1
New York City Transit New York - NYCT
LD08
8862
8867
L82J8N9778282
L82J7N9778306
6
New York City Transit New York - NYCT
LD08
8869
8871
L82J0N9778308
L82J9N9778310
3
New York City Transit New York - NYCT
LD08
8873
8874
L82JXN9778316
L82J1N9778317
2
New York City Transit New York - NYCT
LD08
8876
8877
L82J5N9778319
L82J1N9778320
2
New York City Transit New York - NYCT
LD08
8890
8891
L82J4N9778344
L82J2N9778357
2
New York City Transit New York - NYCT
LD23
—
9621
L82LXL9777634
L82L5L9777668
3
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NQF772001 VERSION 3
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FT5328
TOOLS REQUIRED:
•
•
•
•
•
•
•
Jig NT1090
Measuring Tape
Flathead screwdriver
10mm and 11mm socket wrench
Torque wrench
Torque seal
White sheet or cardboard
WARNING
Before proceeding with any adjustment, ensure that security stands are under the vehicle. Pressure in the
system must be a minimum of 120 psi (827 kPa).
NOTE
Make sure that the surface selected for the verification of the system is as level as possible.
1.1.
Run the bus.
1.2.
Make sure that there is sufficient air in the reservoirs (120 psi minimum at all times.) To do so, wait until
the pressure valve is released (engine running) or have continuous air supply.
1.3.
Park the vehicle on an even surface with the transmission on neutral.
1.4.
Apply the parking brake and set the master control switch to the stop position.
1.5.
Set the battery disconnect switch in the battery compartment to the off position
1.6.
Record the current height using the measuring tape at rear and front doors (See Figure 1).
Figure 1 - Measuring the Height of Front and Rear Doors
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1.7.
Raise the vehicle
NOTE
For more information on the raising and lowering of the vehicle, refer to section 18: HOISTING AND TOWING
of the Nova LFS maintenance manual. Respect your current internal safety procedures. Use the proper
hoisting equipment for your safety.
1.8.
If the wheels are not level between each other, adjust the lifts to allow the wheels to be level.
REAR LEVELING
1.9.
Locate the rear left air bag in front of the rear axle (See Figure 2).
Front of Bus
Figure 2 - Location of Rear Airbag
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1.10.
Using the jig NT1090, measure the distance from the air spring mounting plate and the bottom of the air
bag structure to which the air bag is attached (See Figure 3).
1.11.
Once the jig is in place, tighten the knob and remove the jig from the location.
NOTE
Make sure the jig is not touching the ridge of the frame and that the jig is flush. See picture of the incorrect
condition.
Figure 3 - Measurement of Air Springs - Rear
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1.12.
After removing the jig, measure the distance from the top of A to the bottom of B at the center of the jig using
a measuring tape (See Figure 4). Confirm that the plate x plate distance is within the specification shown
on table 1.
Center
A
Top of A
B
Bottom of B
Figure 4 - Measuring the Distance From Top A to Bottom B
Rear ride height Plate x Plate on lift specification
9 1/2" ± 1/4”
Minimum
9 ¼”
Maximum
9 ¾”
Table 1 - Plate Distance
1.13.
If the plate x plate measurement is not within specification, move on to the next step to adjust the rear plate
x plate height.
1.14.
Using a flathead screwdriver, loosen up the clamp attached to the top of the p-mount.
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1.15.
To increase the distance between the air spring mounting plates, slowly slide the p-mount downwards and
the rod upwards.
1.16.
To decrease the distance between the air spring mounting plates, slowly slide the p-mount upwards and the
rod downwards (See Figure 5).
NOTE
Let the pneumatic system settle roughly 5 minutes before taking measurements between the air spring
mounting plates.
Clamp
P-mount
Rod
Figure 5 - Location of Airspring Mounting Plates
NOTE
The p-mount arm must be even with the p-mount or protrude slightly. It should never be inside the p-mount.
Once the leveling is
complete, the p-mount
arm must be even with
or protrude slightly from
the p-mount
Figure 6 - View of P-mount arm
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1.17.
FT5328
Recheck the ride height on the airbag and once the height specification is achieved, tighten the clamp.
NOTE
Do not over-tighten to avoid damaging the p-mount.
NOTE
To get more adjustment, it’s possible to invert the position (flip) of the P-mount and tighten the clamps over
the knurled area.
(P-MOUNT inverted)
KNURLED AREA
P-MOUNT
(P-MOUNT not inverted)
KNURLED AREA
P-MOUNT
Figure 7 - Knurled Area of P-mount
1.18.
Repeat the steps 1.8 to 1.16 for the right rear side.
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FRONT LEVELING
1.19.
Locate the front left air bag (See Figure 8).
Front of Bus
Figure 8 - Location of Front Airbag
1.20.
Using the jig NT1090, measure the distance from the air spring mounting plate and the bottom of the air
bag structure to which the air bag is attached.
1.21.
Once the jig is in place, tighten the knob and remove the jig from the location (See Figure 9).
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Figure 9 - Measurement of Air Springs - Front
NOTE
Make sure the jig is not touching any plate hardware and confirm that the jig is flush. See picture of potential
hardware interference.
Hardware to clear
Figure 10 - Location of Hardware
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1.22.
After removing the jig, measure the distance from the top of A to the bottom of B at the center of the jig using
a measuring tape. Confirm that the plate x plate distance is within the specification shown on table 2.
Figure 11 - Measuring the Distance from Top A to Bottom B
NOTE
If the measurement is not within specification, document the measurement.
Front Ride Height Plate x Plate on lift specification
11 7/8" ± 1/8"
Minimum
11 ¾”
Maximum
12”
Table 2 - Plate Distance
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1.23.
Repeat steps 14-16 for the front right side.
1.24.
If the front left and the front right plate x plate measurements are not within specification, move on to the next
step to adjust both of the front plate x plate heights.
1.25.
Locate the center front leveling valve and remove the dust cover using a 10mm socket wrench (See Figure 12).
Figure 12 - Location of Center Front Leveling valve
1.26.
Confirm that the arm and bracket on the front leveling valve is 90deg and straight. If the arm and bracket are
not 90deg and straight (See Figure 13).
•
Loosen the M6 bolt using a 10mm socket wrench
•
Adjust the arm and bracket to be 90deg and straight
•
Tighten the bolt to 8.1 ± 0.75 lb ft (11 ± 1Nm) using a torque wrench and 10mm socket. Apply torque seal.
Torque 8.1± 0.75 lb-ft (11 ± 1Nm)
This Arm and
bracket must be
verified as straight
and at 90 degrees
M16 Bolt
Figure 13 - Angle between the Arm and Bracket
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1.27.
Using a 11mm socket wrench, loosen up the 2x bolts on the center leveling valve. While facing the streetside
of the bus, adjust the front right and left plate x plate height (See Figure 14).
•
Push the valve towards the front of the bus along the slot to increase/inflate the air springs.
•
Push the valve towards the rear of the bus along the slot to decrease/deflate the air springs.
2 x hardware to
loosen up
Front of Bus
Figure 14 - Loosening the bolts on the Center Leveling Valve
1.28.
Re-measure the front left and front right air spring plate x plate measurement using the jig to confirm if the
height is within specification.
NOTE
Let the pneumatic system settle roughly 5 minutes before taking measurements between the air spring
mounting plates.
1.29.
If the FRONT plate x plate heights were adjusted and cannot meet specification with the leveling valve adjusted
to max, adjust the REAR plate x plate measurement by returning to step 1.14 to1.18.
NOTE
The rear left and rear right measurements may become out of specification when the front left and
front right measurements become in specification. This is acceptable if the front measurements are within
specification.
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1.30.
Re-measure the front left and front right air bag heights using the jig. Once the front right and front left plate
x plate measurements are within specification, tighten the 2x bolts on the front leveling valve and torque to
3.7-4.4 lb ft (5-6 N●m) using a torque wrench and 11mm socket. Apply torque seal (See Figure 15).
Torque
ft lb lb-ft
(5-6 Nm)
Torque3.7-4.4
3.7-4.4
(5-6
N●m)
Figure 15 - Tightening the bolts
1.31.
Reinstall the dust cover over the front center leveling valve.
1.32.
Lower the vehicle.
APPENDIX – REFERENCE MEASUREMENTS
Refer to table 3 for reference vehicle front wheelchair ramp x ground height using a measuring tape.
NOTE
This height is only for reference purposes as the measurement is subjective based on the ground measuring
from the table.
Front ride height wheelchair ramp x ground
specification
15 1/4” ± 1/4”
Minimum
15”
Maximum
15 ½”
Table 3 - Ground Measuring
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APPENDIX - KNEELING SYSTEM
NOTE
Make sure that the surface selected for the verification of the kneeling system is as level as possible.
NOTE
The installation of batteries or the connection of electrical terminals to an external power source is required
for the following steps.
NOTE
The following tests are performed with an empty load (excluding the driver).
NOTE
Before performing these tests, make sure that all objects in the way are removed (e.g. safety supports).
NOTE
120 psi minimum in the reservoirs at all times and make sure that the doors have air.
1.33.
Place the master control switch in the RUN position and front start the engine.
1.34.
Place the kneeling and ramp master switch in the ON position (See Figure 16).
NOTE
Make sure that the ramp is retracted and that the doors are closed.
1.35.
Activate the kneeling switch to begin kneeling (See Figure 16).
NOTE
Make sure that the underbody does not rest on the axle. No contact is allowed.
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Figure 16 - Kneeling Switch
1.36.
The alarm must sound during kneeling and the exterior yellow indicator lights must blink.
1.37.
Check that the yellow dashboard tell-tale lights up and remains lit until the command to raise is given.
1.38.
Allow the bus to settle.
1.39.
Measure the kneeling height with a measuring tape in accordance to table 5 from the top of the wheelchair
ramp floor to ground.
NOTE
This height is only for reference purposes as the measurement is subjective based on the ground measuring
from the table.
Front kneeling height wheelchair ramp x ground specification
11 1/8” -0” / +1/2”
Minimum
11 1/8”
Maximum
11 5/8”
Table 4 - Ground Measuring
1.40.
Activate the kneeling switch to start rising.
NOTE
The cycle ends when the brake interlock releases.
1.41.
Turn off the master run switch.
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LEVELING VALVE KIT
BOM FOR LEVELING VALVE KIT
•
N30292 Linkage Kit 2 per bus if needed
•
Kits includes items below
•
Link x1
•
Grommet x1
•
1/4" Stud x2
•
Hose clamp x1
•
P-mount x1
•
Lock Washer 1/4 x4
•
Hex Bolt 1/4 -20NC x4
Linkage Kit being used with the leveling valve
The Kit includes:
Link (P/N 22025-3)
1x
Grommet (P/N 26424)
1x
1/4" Stud
2x
Hose clamp (P/N 25921-6)
1x
P-Mount (P/N 26425-1)
1x
Lock Washer 1/4"
4x
Hex Bolt 1/4-20NC
4x
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NOTE
For more information on the raising and lowering of the vehicle, refer to section 18: HOISTING AND TOWING
of the Nova LFS maintenance manual. Respect your current internal safety procedures. Use the proper
hoisting equipment for your safety.
1.42.
Raise the vehicle to locate rear leveling valves, one on each side (See Figure 17).
Figure 17 - Location of Rear Leveling Valve
1.43.
Loosen top and bottom nut (See Figure 18).
Top
Bottom
Figure 18 - Loosening the Nuts
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1.44.
FT5328
Leveling valve with top and bottom nut loosened (See Figure 19).
Top
Bottom
Figure 19 - Leveling the Valve
1.45.
Leveling valve removed from the bus (See Figure 20).
Figure 20 - Removal of Leveling Valve
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1.46.
Pre-assemble new valve, adjustment will be done after installation (See Figure 21).
Figure 21 - Installation of New Valve
1.47.
Install the support rod and hardware for top and bottom (See Figure 22).
Top
Nut
Nut
Flat washer
Lock washer
Bottom
Figure 22 - Installation of Support Rod and Hardware
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1.48.
FT5328
Secure top and bottom hardware and torque the nuts to 8.1 ± 0.75 lb ft (11 ± 1N●m) (See Figure 23).
Torque 8.1 ± 0.75 lb ft (11 ± 1N●m)
Hardware
Figure 23 - Tightening the hardware
1.49.
Slide the adjustment rods (See Figure 24).
1.50.
Adjust leveling valve as per ride height instructions.
Top
Bottom
Figure 24 - Adjusting the Leveling valve
1.51.
Lower the vehicle.
1.52.
Set the battery disconnect switch in the battery compartment to ON position.
1.53.
Set the Master control switch in the ON position.
1.54.
The vehicle can return in service.
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NQF772001 VERSION 3