FT5243

FT5243
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REFERENCE:
Nova Bus Manuals
SECTION:
09: Engine and Cooling
RS NO:
MQR 7621-1973
APPLICATION DEADLINE: 2024SE27
CLAIM REFERENCE NUMBER: WB-5243
EFFECTIVE IN PROD.: N/A
SUBJECT:
Radiator leaking coolant
JUSTIFICATION:
ECP radiator failures deemed to be due to overpressure events.
LEVEL
DIRECT CHARGES
DESCRIPTION
1
Installation of pressure relief valve on the radiator inlet vent
2
–
TIME
LABOUR
MATERIAL
Novabus
Novabus
1.5 h
–
–
–
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
2023FE08
APPROVED BY:
NQF772001 VERSION 3
CHANGE DESCRIPTION
Initial release
WRITTEN BY
Devanand
Digitally signed by Jean-Nicolas
Jean-Nicolas Fournier Fournier
Date: 2023.02.08 15:24:53 -05'00'
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FT5243
MATERIAL REQUIRED PER VEHICLE
QTY
PART NO
REV.
DESCRIPTION
1
501894
A
TEE F-NPT-1/4(2X),M-NPT-1/4
1
N32717
A
FITTING 45 1/4-18 NPT F37
1
501308
B
LONG ADAPTER F-NPT-4, M-NPT-4
1
N34500-05
–
BRACKET 90 DEG
1
N0271003
–
SCREW HEX 3/8X0.625 SS
12
G5007996
–
CABLE TIE (0657558)
1
N107280
–
VALVE RELIEF 22PSI
5
2494772
–
CLAMP MINIATURE WORTH
1
N95062-51
–
HOSE SAE 30R7 3/8"ID X 23" LG
1
N95062-46
–
HOSE SAE 30R7 5/16" ID X 20.5"
1
N17882
X
BOLT M6X25 SS GR.A2 DIN933
1
501337
A
TEE F-NPT-1/4 (3X) (0444120)
1
N17904
X
WASHER LCK CURV M6 YZ TRIV 96H
1
N11183
C
WASHER FLAT M6 YZ TRIV 96H
1
N44881-02
B
SCREW M6X25 H YZ TRIV 96H 8.8
1
N38593
A
NUT LOCKNYL FL M6 ZP
3
504751
A
SPACER DUAL SWIVEL SADDLE
1
N67059
B
MOUNT "H" SERIES 3/8"
2
N101746
–
HOSE BARB TO MALE PIPE 125HBL
1
642196
–
CONNECTOR HB-6, M-NPT-4 (N12850)
N95712-24
B
HOSE ASSEMBLY (TEFLON)
N70053
–
CAP SURGETANK 18 PSI
–
LOCTITE THREAD SEALANT WHITE
(cartridge of 50 ml)
LEVEL 1
LEVEL 2
1
LEVEL 3
1
LEVEL 1 SHOP SUPPLIES
10 ml
N37086
Materials will be available within 168 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.
Superseded Parts:
0444134 - 501894 TEE F-NPT-1/4(2X),M-NPT-1/4
N31302 - 501308 LONG ADAPTER F-NPT-4, M-NPT-4
0444120 - 501337 TEE F-NPT-1/4 (3X)
N56836 - 504751 SPACER DUAL SWIVEL SADDLE
N12850 - 642196 CONNECTOR HB-6, M-NPT-4
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NQF772001 VERSION 3
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CLIENT
ORDER
New York City Transit - New York
New York City Transit - New York
ROAD NUMBER
VIN (2NVY/4RKY...)
QTY
FROM
TO
FROM
TO
L958
5439
5442
S92J9G9775533
S92J9G9775631
4
L959
5443
5443
S92J0H9776118
S92J0H9776118
1
New York City Transit - New York
LB59
5444
5484
S92J7H9776195
S92J6H9776379
41
New York City Transit - New York
LA23
5485
5530
S92J5J9776380
S92J6J9776517
46
New York City Transit - New York
LA73
8504
8507
L82J8J9776445
L82J8J9776476
4
New York City Transit - New York
LB29
5531
5566
S92J9J9776687
S92J6J9776873
36
New York City Transit - New York
LA76
8508
8633
L82J9J9776924
L82J8K9777144
125
New York City Transit - New York
LB99
5567
5602
S92J2J9776935
S92J5K9777000
36
New York City Transit - New York
LB78
8526
8526
L82J3K9776984
L82J3K9776984
1
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NQF772001 VERSION 3
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STANDARD INSTALLATION INSTRUCTION FOR NPT FITTINGS
FITTING and ADAPTER NPT (National pipe threads)
The thread is tapered and the seal takes place by deformation of the threads.
Tapered
Thread
O.D.
Male
Tapered
Thread
I.D.
Female
TABLE 1
NPT (National pipe threads)
1.1
Tapered pipe thread Fitting (NPT) Assembly Instructions
1.1.1
Inspect port and fitting to ensure that both are free of
contaminants and excessive burns and nicks.
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1.1.2
Apply a stripe of an anaerobic liqiud pipe sealant (360 º) around the male threads
leaving the first two threads uncovered.
Note: Always use proper thread sealants on tapered pipe threads. Do not confuse thread sealer
(white Teflon) with thread locker (blue, green or red.)
1.1.3
Screw in the adaptor or fitting by hand to ensure threads are correctly engaged 		
and tighten as much as possible by hand in to the port (Finger Tight).
1.1.4
Make a mark on hex portion of the part.
Using a wrench, tighten an additional 1-1/2 turn.
Note: Do not use yellow torque seal to make this mark
Note: Never back off an installed pipe fitting to achieve proper alignment.
Loosening installed pipe fittings will corrupt the seal and contribute
to leakage and failure.
Sealant
TABLE 2
NPT Thread Sealant
NovaBus
# p/n
Features
Loctite® 565
N37086
This product is designed for the locking and sealing of metal pipes and
fittings.
Loctite® 577
N74760
This product is designed for the locking and sealing of metal threaded
pipes and fittings. Particularly suitable for use on Stainless Steel.
N95505
This product is design for the sealing of threaded Plastic pipe fittings
and sensors.
Loctite® MR 5438
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FT5243
STANDARD INSTALLATION INSTRUCTION FOR JIC FITTINGS
JIC 37º & SAE 45° FLARE TYPE FITTINGS AND ADAPTORS
The JIC 37º & SAE 45º fitting seal with metal to metal contact between the flare nose
of the fitting and the flare tube face in the female connection.
Male
Female
TABLE 3
JIC 37º & SAE 45º Flare Fitting
Note: In a case where there are two fittings of different material use torque value of the material
with the lowest specification.
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2.1
Recommended JIC 37° SAE 45° Flare Fitting Assembly instructions
2.1.1
Inspect contact surface and threads for any damage or material flaw.
(Do not apply sealant on threads).
2.1.2
Use template NT9999-01 to determine the thread size of the fitting or adaptor.
NT9999-01
2.1.3
Screw in the adaptor or fitting by hand to ensure threads are correctly engaged
and tighten by hand as much as possible.
2.1.4
Use thread size to determine torque to be applied.
2.1.5
Screw in the adaptor or fitting by hand to ensure threads are correctly engaged
and tighten as much as possible by hand.
2.1.6
Using a wrench, complete tightening to the recommended torque.( see Table 5 )
6.1.7
Apply anti-tamper seal (“Torque Seal”) to indicate torque
has been applied (AVT-0203).
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FT5243
OVERVIEW OF MODIFICATION:
Relief valve
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TOOLS REQUIRED:
•
•
•
•
•
•
•
•
Square key
Ratchet
10 mm socket
16 mm wrench
18 mm wrench
15 mm wrench
¼” socket (hose clamps)
Airline blow gun
WARNING
FOLLOW YOUR INTERNAL SAFETY PROCEDURES.
PROCEDURE
1.1.
Park the vehicle on an even surface with the transmission in neutral.
1.2.
Set the master control switch in the stop position and apply the parking brake.
1.3.
Set the battery disconnect switch in the battery compartment to the off position.
1.4.
Drain approximately 5 gallons of coolant from the engine cooling circuit. Refer to section 09: Engine Cooling
of Nova Bus Maintenance Manual for draining of cooling system.
1.5.
Open the rear radiator access panel and remove the lower grill (4 screws) (see figure 1). Retain the hardware.
Figure 1 - Location of Radiator Access Panel
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1.6.
Remove the radiator inlet vent hose on the radiator side only. Discard the elbow adaptor fitting. (see figure 2).
Discard
Retain
Remove radiator
side only
Figure 2 - Removal of Radiator Inlet Vent Hose
1.7.
Remove fan, if needed to place back up wrench onto radiator inlet vent fitting (see figure 3).
Raise fan cover
Remove fan
Remove fitting
Backup wrench
on this fitting
Below plate
Figure 3 - Removal of Fan
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1.8.
FT5243
Install the following parts on the radiator inlet vent line: Assembly order: 1-2, 3, 4 (see figure 4).
1. 501308 (Long Adapter F-NPT-4, M-NPT-4)
2. 501894 (Tee -NPT-1/4(2X),M-NPT-1/4)
3. N107280 (Valve Relief 22PSI)
4. N32717 (Fitting 45 1/4-18 NPT F37)
Or assemble all on a bench and install afterwards (if fan removed).
N32717
501894
N107280
501308
Figure 4 - Installation of Relief Valve
1.9.
Re-install removed hose between radiator and surge tank. If a new hose is required, see level 2 BOM
(N95712-24) (see figure 5).
N95712-24
Figure 5 - Installation of Vent Hose
1.10.
Remove the existing bolt, lock washer and washer from the power cable support mount.
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1.11.
Pre-install the mount N67059 and bolt N0271003 on bracket N34500-05 (see figure 6).
1.12.
Install bracket N34500-05 under the existing support mount and re-install with new hardware:
1. N11183 (Washer Flat M6)
2. N17904 (Washer Lock M6)
3. N17882 (Bolt M6X25)
1.13.
Secure existing hoses with tie-wraps G5007996 on either side of the new mount.
1.14.
Install the hose N95062-51 on the relief valve and route it into new mount.
N34500-05
N67059
N0271003
N17882
N17904
N11183
Figure 6 - Installation of New Support Mount
1.15.
Align the hose N95062-51 with existing bottom (black) vent hose and cut to size accordingly to install the
bottom T fitting 501337 with adaptors 642196 and 2x N101746. When securing the T-fitting to the hoses, the
hoses must be leveled at a downwards or straight pitch. Do not allow the hose to bend upwards. Left figure
not acceptable. Right figure is acceptable (see figure 7).
642196
N101746
N101746
501337
Figure 7 - Installation of T-Fitting Assembly
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1.16.
The routing of left side hose going to the T-fitting must be modified, use supplied hose N95062-46 and cut
to size accordingly (see figure 8).
1.17.
Relocate the plastic mount and secure with bolt N44881-02 (M6) and nut N38593 (M6).
NOTE
To ensure that the overflow line is not blocked. With the engine compartment door closed and using an
airline blow fitting, blow a small amount of compressed air in the vent line going to the bottom of the bus
to ensure that it is not blocked. A flow of air should be heard coming out of the catch tank overflow valve.
(Ensure that the engine compartment overflow tank is not full beforehand – the overflow tank should vent
to ambient air). If hose is blocked, it will have to be unblocked to ensure proper functioning.
2494772
N95062-51
N44882-02
N38593
N95062-46
Compressed air
2494772
By revolving TEE fitting toward front of bus,
We comfortably avoid contact between hoses.
Figure 8 - Installation of Relief Valve Hose
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1.18.
Secure all the hose connections with clamps 2494772 (see figure 8).
1.19.
Install spacer swivel mounts N56836 and tie wraps G5007996 to avoid direct contact between hoses as
required.
1.20.
Re-install fan (if removed).
1.21.
Re-fill the engine coolant to the appropriate (FULL COLD) level. Refer to section 09: Engine cooling of Nova
Bus Maintenance Manual for filling of cooling system.
1.22.
Perform a pressure test (20psi maximum) on the engine side surge tank pressure cap and replace if required
with N70053.
1.23.
Inspect installation for leaks
1.24.
Re-install the radiator grill and close the radiator access panel.
1.25.
The vehicle can return in service.
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NQF772001 VERSION 3