RING TERM HD STUD 1/2 14-16AWG

–

4

N81450

–

SCREW HEX 1/2-13 X 1-1/4 ZPGR5

–

1

N84090-02

–

P-CLAMP ID 0.375"THK 0.030"M8

–

2

N84090-03

–

P-CLAMP ID 0.500"THK 0.030"M8

–

4

N84090-05

–

P-CLAMP ID 0.750"THK 0.030"M8

–

1

N84090-11

–

P-CLAMP ID 1.500"THK 0.030"M8

–

1

N90068

–

GENERATOR EMP 535A AIR COOLED

–

1

N91342

–

ELBOW RUBBER 4" AIR INTAKE ALT

–

1

N92986-01

–

CABLE ASSY C1075 4/0 AWG BK

–

1

N92987-01

–

CABLE ASSY C1076 4/0 AWG BK-RD

–

1

N92988-01

–

CABLE ASSY C1074 4/0 AWG BK-RD

–

1

N93001

–

BRACKET FUSE HOLDER ASSEMBLY

–

1

N93087

–

BRACKET SUPPORT ASSEMBLY

–

1

N93088

–

BRACKET STRAIN-RELIEF EMP ASSY

–

1

N93143

–

PIPE ASSEMBLY (55°) Generator EMP

–

1

N93144

–

SUPPORT AIR INTAKE Generator

–

1

N93157

–

SUPPORT FUEL FILTER L9N

–

1

N93158

–

SUPPORT ALT EMP PIPE

–

1

N93213

–

SUPPORT TENSIONER EMP ALT.

–

1

N93763

–

BOX ASSY AIR INTAKE Generator

–

1

N95060-199

B

HOSE SILICONE 4PLY 1" ID X21.5

–

1

N95703-46

–

HOSE ASM TEFLON

–

1

N95714-14

–

HOSE ASSEMBLY (TEFLON)

–

1

N95839-02

–

HOSE CNG ENG LOW PRESSURE 18.5

–

1

N95839-03

–

HOSE CNG ENG LOW PRESSURE 16

–

5ml

N37086

A

LOCTITE THREAD SEALANT WHITE

–

5ml

N10844

C

SIKA 205 AKTIVATOR

–

LEVEL 2

CLIENT

ORDER

ROAD NUMBER
FROM

TO

VIN (2NVY/4RKY...)
FROM

TO

QTY

Red Deer - Alberta

LB25

10074

10084

L82K5J9776525

L82K8J9776535

10

San Antonio Texas

LB26

692

710

L82KXJ9776536

L82K1J9776554

19

San Antonio Texas

LB26

712

735

L82K5J9776556

L82K6J9776579

24

PAGE 3 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

WARNING

FOLLOW YOUR INTERNAL SAFETY PROCEDURES.

PROCEDURE

Figure 1 - Original Oil Cooled Delco Generator (Some Parts Removed for Clarity)

PAGE 4 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

Figure 2 - New Air Cooled EMP Generator (Some Parts Removed for Clarity)

WARNING

Before starting any work on the vehicle, make sure the vehicle is completely and securely stationary.

PAGE 5 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

WARNING

Follow your internal safety procedures. CNG systems should be maintained and inspected, per the applicable
codes, by trained, qualified, and/or certified personnel.
As with all pressure vessels, CNG storage and fuel delivery systems are dangerous and should be treated
as such. Personnel involved in CNG fuel system maintenance, emergency response, servicing, testing or
inspecting must be properly trained, qualified, and/or certified as required by federal, state/provincial, and
municipal regulations.
1.1.

Make sure that the vehicle is turned off.

1.2.

Turn the manual shut off-valve on the FMM to the off position.

Figure 3 - Shut-off Valve on the FMM

1.3.

Start the engine from the engine compartment and run until it stops due to fuel starvation. Low pressure
gauge on the FMM should read zero.

PAGE 6 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN
1.4.

BS4409E

Disconnect the starting circuit on the control box at the rear of the vehicle and place the battery disconnect
switches in the off position.

CAUTION

For information on hoisting and towing of the vehicle, see section 18: hoisting and towing in the Nova Bus
maintenance manual. Use appropriate hoisting equipment for your protection and to prevent damage to
the vehicle.
1.5.

Raise the vehicle.

1.6.

Remove the dust pans.

1.7.

Remove and retain two bolts on the fan and fold it down to get a better access for the repair.

Figure 4 - Unbolt the Fan

PAGE 7 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

REMOVE GENERATOR OIL COOLING SYSTEM PARTS
1.8.

Disconnect the hoses coming from the generator at the engine and be careful to collect the oil that will drain
from them.

1.9.

Remove and discard the hoses once the oil has completely drained.

Figure 5 - Drain the Oil and Discard the Hoses

PAGE 8 OF 30
NQF772001 VERSION 3

BS4409E

SERVICE BULLETIN
1.10.

Remove and discard the port fittings on the engine that were used for the oil hoses. Put a plug 3678923 into
the port for the supply line. Replace the oil return connection port by the new 3964393 with a new ring seal
3906696, use the same bolts and torque to 40.5 lb-ft (55 N•m).

Install plug 3678923

Remove
Before

Install oil drain
connection with a new
ring seal and reconnect
the oil pipe
After

Figure 6 - Remove Oil Ports Fittings

NOTE

It is recommended to put a protective paint like Cummins Red Engine Paint over 3964393.

PAGE 9 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN
1.11.

BS4409E

Prior to install the new hose N95714-14, the fitting 3099698 and the 90° elbow N27280 shown in Figure 9,
drain the engine coolant. See your maintenance manual section 09: Engine cooling system. Then remove
the pipe on the engine block shown below to make up space for the new configuration installation.

Figure 7 - Remove the Pipe on Engine Block for a Better Access

PAGE 10 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

1.12.

Replace the 45° deg fitting on the engine by the 3099698, connect elbow N27280 to it and the new hose
N95714-14.

1.13.

Reinstall the pipe remove ont he engine block at step 1.11

1.14.

Discard hose N95709-41 and replace by N95703-46. Discard hose N95060-98 going to the bigger air cooler
pipe and replace by N95060-199.

Discard hose
N95060-98

Discard hose
and 45° fitting
Discard hose N95709-41

Figure 8 - Discard Hoses

Install new hose N95060-199

New fitting Cummins 3099698
New elbow N27280
New hose N95714-14

Keep fittings, install new hose N95703-46.
Secure with a swivel N56836 to the new
N95714-14.

Figure 9 - Install New Configuration Parts
PAGE 11 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN
1.15.

BS4409E

Remove the hose and the hardware for the breather hose.

Remove hose and hardware

Figure 10 - Remove Hose and Hardware

1.16.

Install a plug 0444620.

Figure 11 - Install Plug 0444620

PAGE 12 OF 30
NQF772001 VERSION 3

SERVICE BULLETIN

BS4409E

REMOVE GENERATOR CABLES
1.17.

Remove but keep the capacitor N92656-01 for later reinstallation.

1.18.

Remove and discard bracket N73956.

1.19.

Remove and discard cables N76630 and N82924 but keep the p-clamps for later reinstallation.

1.20.

Remove and discard bracket N83016.

Keep
Capacitor N93656-01
Discard
Bracket N73956

Discard
Cable N79630

Discard
Cable N82924

Discard
Bracket N83016

Keep
Bracket N10322

Figure 12 - Remove Cables, Bracket and Capacitor

PAGE 13 OF 30
NQF772001 VERSION 3