FT5243
Service Bulletin Details
Public Details for: FT5243
Ecp radiator failures deemed to be due to overpressure events.
Models from 2019
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2016 NOVA BUS LFS ARTIC |
FT5243 FAST TRACK 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' PAGE 1 OF 14 FAST TRACK 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 Superseded Parts: 0444134 - 501894 TEE F-NPT-1/4(2X),M-NPT-1/4 N31302 - 501308 LONG ADAPTER F-NPT-4, M-NPT-4 0444120 - 501337 TEE F-NPT-1/4 (3X) N56836 - 504751 SPACER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 PAGE 2 OF 14 NQF772001 VERSION 3 FT5243 FAST TRACK 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 PAGE 3 OF 14 NQF772001 VERSION 3 FAST TRACK FT5243 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. PAGE 4 OF 14 NQF772001 VERSION 3 FT5243 FAST TRACK 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 PAGE 5 OF 14 NQF772001 VERSION 3 FAST TRACK 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. PAGE 6 OF 14 NQF772001 VERSION 3 FT5243 FAST TRACK 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). PAGE 7 OF 14 NQF772001 VERSION 3 FAST TRACK FT5243 OVERVIEW OF MODIFICATION: Relief valve PAGE 8 OF 14 NQF772001 VERSION 3 FAST TRACK FT5243 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 PAGE 9 OF 14 NQF772001 VERSION 3 FT5243 FAST TRACK 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 PAGE 10 OF 14 NQF772001 VERSION 3 FAST TRACK 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. PAGE 11 OF 14 NQF772001 VERSION 3 FT5243 FAST TRACK 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 PAGE 12 OF 14 NQF772001 VERSION 3 FAST TRACK FT5243 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 PAGE 13 OF 14 NQF772001 VERSION 3 FAST TRACK FT5243 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. PAGE 14 OF 14 NQF772001 VERSION 3