FT5404E Service Bulletin/Repair Instructions

FT5404
FAST TRACK

REFERENCE:
Nova Bus Manuals
SECTION:
09: Hydraulic system
RS NO:
MQR 7621-2642
APPLICATION DEADLINES:2024JL01

CLAIM REFERENCE NUMBER:WB5404
EFFECTIVE IN PROD.: LD64

SUBJECT:
Clamp on power steering hose
JUSTIFICATION:
There is a potential restriction of fluid due to an improperly placed clamp which could

cause the power steering system to not operate has intended.
LEVEL
DIRECT CHARGES
DESCRIPTION
LABOUR
MATERIAL
TIME
1
Verify that the clamp is installed properly.
Nova Bus
Nova Bus
10 min
2
If the clamp is crushing the hose (resticting the flow), the hose and

clamp needs to be replaced.
Nova Bus
Client*
1h10
* The cost of the material will be reimbursed when claiming for this service document.
MATERIAL REQUIRED PER VEHICLE

QTY
PART NO
REV.
DESCRIPTION
–
–
–
–
–
–
–
–
LEVEL 1
LEVEL 2 (only if required**)
1
N95797-02
–
Hose ASM (Engine & air brake)
2
N80726
–
Clamp Worm-Drive 16-27MM (# Prv 992082)
3.85 L
N30283
–
Castrol TRANSYND SYNTH ATF
Materials will be available within 107 days once your order has been placed.

To order, please contact novabus.parts@volvo.com

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.

**Material identified in Level 2 is to be ordered only for vehicles that meet the criteria defined in Level 1.
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
2023JN09
CHANGE DESCRIPTION
Initial release
Signature numérique

Irina

de Irina Negoescu

Date : 2023.07.07

NQF772004 VERSION 3 Negoescu 10:46:54 -04'00'
APPROVED BY:
WRITTEN BY
André Pelletier
PAGE 1 OF 7
FT5404
FAST TRACK

CLIENT
ORDER
ROAD NUMBER
VIN (2NVY/4RKY...)
QTY
FROM
TO
FROM
TO
L82L5L9777539
L82L5L9777539
1
University of Vermont
LC87
—
—
New York City Transit New York - NYCT
LC78
9620
9620
L82L4L9777581
L82L4L9777581
1
New York City Transit New York - NYCT Demo
LD23
9621
9622
L82LXL9777634
L82L5L9777668
3
New York City Transit New York - NYCT
LC79
9623
9703
L82L1M9777782
L82LXM9777862
81
New York City Transit New York - NYCT
LC79
9704
9784
L82L1M9777863
L82L4M9777954
81
New York City Transit New York - NYCT
LD64
9785
9798
L82L0M9777871
L82L8M9777973
14
New York City Transit New York - NYCT
LD64
9800
9885
L82L1M9777975
L82L0M9778115
86
New York City Transit New York - NYCT
LD64
9889
9901
L82L8M9778119
L82L0M9778146
13
New York City Transit New York - NYCT
LD64
9903
9908
L82L4M9778148
L82L8M9778153
6
New York City Transit New York - NYCT
LD64
9910
9910
L82L1M9778155
L82L1M9778155
1
Milwaukee Wisconsin - electric Bus - LFS-e+
LE16
1000
1000
L82M4N9778290
L82M4N9778290
1
San Francisco California SFMTA - LFS-e+
LE39
5010
5010
L82M2N9778305
L82M2N9778305
1
Houston - Texas
LE77
3000
3000
L82M3N9778605
L82M3N9778605
1
PAGE 2 OF 7

NQF772004 VERSION 3
SRT
Installation …
WARNING
70 min
FAST TRACK
FT5404
SPECIAL INSTRUCTION / IMPORTANTE NOTICE
No
Tools Needed:
2

3
¼ inch drive in lb. torque wrench

3/8 inch drive ft lb. torque wrench, ½ inch drive torque wrench
FOLLOW1YOUR

INTERNAL SAFETY PROCEDURES.

3/8 drive 13mm socket, ¼ inch drive 10mm socket, 10mm open end wrench. ½ drive 1&1/8 crowfoot open end
Important notices
DESCRIPTION / WORK INSTRUCTION
Level 1 Inspected E-steering for potential restriction of fluid due to an improperly

placed clamp.

Step 1.
Inspection to verify the clamp is installed

properly and the black hydraulic hose is

routed properly and damage.
If the clamp is crushing the hose (restricting the flow), the hose and clamp needs to be replaced.
Service Instruction QJ#:

MQR 7621-2642
PAGE 3 OF 7

NQF772004 VERSION 3
FAST TRACK
FT5404
Important notices
DESCRIPTION / WORK INSTRUCTION
Level 2 Hose and clamp replacement if damage hose or if clamp is improperly

installed.
Step 1. Located in the battery box and Disconnect

the 24v power to the bus then Place a

lockout / tagout to the switch.
Step 2. Located on the street side front compartment

open the door and with square key and with

a 13mm wrench Loosen the 13mm bolt

swing bolt down and then with a square key

Turn the lock and Swing out the power

steering reservoir.
13mm bolt
Step 3. Remove the four-hose clamp bracket

hardware and bolts from the damage hose.

Do not discarded, will be used to secure

new hose..
Four-Hose

Clamp Bracket
Service Instruction QJ#:

MQR 7621-2642

PAGE 4 OF 7

NQF772004 VERSION 3
FAST TRACK
FT5404
Important notices
DESCRIPTION / WORK INSTRUCTION
Level 2 Hose and clamp replacement if damage hose or if clamp is improperly

installed.
Step 4. Place a drain pan under the damaged hose

located at the steering gear box and Remove

the hose from gear box, drain the oil from the

hose into the pan. Loosen clamp from the

other end of the hose and Remove hose.

Allow all oil to drain into pan. Discarded hose

and clamp.
Step 5. Install new hose (N95797-02) with new

clamp (N80726) on to the pump reservoir

piping ensuring the hose is past the raised

portion of the pipe. Place hose clamp 1mm

from the end of the hose and Torque clamp to

3.25 + 0.25 NM. or 27 to 31 lbs-in.
REF. AVT 0427

Service Instruction QJ#:

MQR 7621-2642

NQF772004 VERSION 3
PAGE 5 OF 7
FT5404
FAST TRACK

Important notices
DESCRIPTION / WORK INSTRUCTION
Level 2 Hose and clamp replacement if damage hose or if clamp is improperly

installed.
Step 6. Rout the hose through the four-hose clamp

brackets and hand tighten ensure the routing

is IAW Drawing 409347NB08E1. Secure

hose to the power steering gear box with

1&1/8 crowfoot. Torque hose ASM to gear

box to 48 lb-ft or 65 NM.
REF. Drawing 409347NB08E1
.
Step 7. Torque the four-hose clamp brackets to

10 + 1.5 NM or 84 to 102 lbs-in. Torque strip

nuts.
Step 8. Fill steering reservoir to max level mark

located on the reservoir with CASTROL

TRANSYND SYTH ATF N30283
Service Instruction QJ#:

MQR 7621-2642

NQF772004 VERSION 3
PAGE 6 OF 7
FAST TRACK
FT5404
Important notices
DESCRIPTION / WORK INSTRUCTION
Level 2 Hose and clamp replacement if damage hose or if clamp is improperly

installed.
Step 9. Place the main battery switch on and the

master run switch in the run position ( DO NOT

START ENGINE). Open the dash screen to

Test Sequence and then Power Steering Refill.

Fallow the instruction on the screen to refill the

power steering.

.
Step 9. Swing in the power steering reservoir carrier

and with a 13mm socket and torque wrench

Torque the bolt to 32 + 2 NM or 22 to 25

lbf- ft. Close and lock compartment door.
Service Instruction QJ#:

MQR 7621-2642

NQF772004 VERSION 3
PAGE 7 OF 7

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