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 13
NQF772001 VERSION 3

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FT5244

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 13
NQF772001 VERSION 3

FT5244

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 13
NQF772001 VERSION 3

FAST TRACK

FT5244

OVERVIEW OF MODIFICATION:

Relief valve

PAGE 8 OF 13
NQF772001 VERSION 3

FAST TRACK

FT5244

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 13
NQF772001 VERSION 3

FT5244

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 13
NQF772001 VERSION 3

FAST TRACK
1.8.

FT5244

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

PAGE 11 OF 13
NQF772001 VERSION 3

FT5244

FAST TRACK
1.10.

Loosen the two nuts holding the power cable split block.

1.11.

Install (slide-in) bracket N106372 (see figure 6).

1.12.

Re-tighten split-block nuts.

N106372

Loosen

Figure 6 - Installation of New Support Mount

1.13.

Install the hose N95062-51 on the relief valve and route it into new mount N93464-13, secure with bolt
N16826 and nut N44887 (see figure 7).

1.14.

Align the hose N95062-51 with existing bottom (black) vent hose and cut all 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 13
NQF772001 VERSION 3

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1.15.

FT5244

Secure all the hose connections with clamps 2494772 (see figure 8).

N95062-51

2494772

N93464-13
N16826
N44887

Compressed air

2494772

Figure 8 - Installation of Relief Valve Hose
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.
1.16.

Install spacer swivel mounts N56836 and tie wraps G5007996 to avoid direct contact between hoses as
required.

1.17.

Re-install fan (if removed).

1.18.

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.

1.19.

Perform a pressure test (20psi maximum) on the engine side surge tank pressure cap and replace if required
with N70053.

1.20.

Inspect installation for leaks

1.21.

Re-install the radiator grill and close the radiator access panel.

1.22.

The vehicle can return in service.

PAGE 13 OF 13
NQF772001 VERSION 3