REFERENCE: Nova Bus ManualsSECTION: 09: Engine starting circuitRS NO: N/AEFFECTIVE IN PROD.: 2018OC

LEVEL DESCRIPTIONDIRECT CHARGES

TIMELABOUR MATERIAL

1 Replace the original oil-cooled generator (Delco) by an air-cooled generator (EMP). Nova Bus Nova Bus 8h

2 – – – –Materials will be available within 56 days. To order, please contact Prevost Parts by phone at 1-800-771-6682, by fax at 1-888-668-2555 or by email at prevostparts.commandes@volvo.com. Specify document number, quantity of parts required and shipping address.

SUBJECT: Generator replacement JUSTIFICATION: Improve the generator ground noise level.

REVISION HISTORYREV. DATE CHANGE DESCRIPTION WRITTEN BY

NR 2019JA11 Initial release André Pelletier

DISPOSAL OF PARTS

REMOVED PARTS ARE:DISCARDED * RETAINED * Dispose of the unused parts and the defective parts in

accordance with local environmental standards in effect.Yes –

APPROVED BY:

APPLICATION DEADLINE: 2020AL30CLAIM REFERENCE NUMBER: WB-4409

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MATERIALQTY PART NO REV. DESCRIPTION REPLACES PART N°

LEVEL 11 0444620 – Plug M-NPT-1/4 –1 0696471 – ELBOW –1 3099698 – Male Union –1 3678923 – Threaded Plug –1 3906696 – Rectangular Ring Seal –1 3964393 – Oil Drain Connection –1 12010996 – CONNECTOR –1 12015791 – CONNECTOR –1 12124580 – TERMINAL FEMALE WEATHER PACK –1 12124582 – TERMINAL MALE WEATHER PACK –2 15324981 – BLUE SEAL 10 AWG –

2.5 LF 8860102 A NYLON TUBING 1/4 BLACK –3.75 LF 8861140 – NYLON TUBING 3/8 GREEN –

7 G5007996 – CABLE TIE (0657558) –5 N12883 B CLAMP SPRING T-BOLT –1 N15278 – SPLICE –2 N16755 – BOLT M6X70 YP GR8.8 DIN931 –2 N17904 X WASHER LOCK EDG M6 YP DIN128A –

3 LF N18813 C GASKET RUBBER 0.625"WX0.500"T –2 N20779 X WASHER FLAT OVS M6 ZP DIN9021 –

1 LF N25831-25 – 16AWG-WHITE-GXL TC –1 N22781-07 – BREEZE CLAMP 4-1/4 TO 5-1/8 –1 N27280 – ELBOW 90° F-JIC-12 MJIC12 –2 N31593 – WASHER OVERSIZE M10 SS DIN9021 –4 N33228 B SCREW M10X30 H YZ TRIV 96H 8.8 –2 N36608 – SCREW HEX HD M10 X 30 SS –

50 N37749 B DUAL CLAMP TIE –6 N38593 – NUT FLANGED WITH INSERT –5 N40492 B SCREW M6X20 H YZ TRIV 96H 8.8 –4 N43233 A NUT HEX M8 FLANGED WITH INSERT –2 N43775 – BOLT M8X80 SS FLANGE –2 N44881-02 B SCREW M6X25 H YZ TRIV 96H 8.8 –2 N44884-01 C SCREW M6X20 FL SSA2 C70 D6921 –2 N44885-06 C SCREW M8X60 FL SSA2 C70 D6921 –

10 N44887 A NUT LOCKNYL M6 FL YP C8 D6926 –2 N44890 B NUT LOCKNYL M6 FL SSA2 C70 –4 N56816 A WASHER LOCK SPR 1/2" SS D127B –

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CLIENT ORDERROAD NUMBER VIN (2NVY/4RKY...)

QTYFROM TO FROM TO

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

MATERIALQTY PART NO REV. DESCRIPTION REPLACES PART N°

LEVEL 11 N56836 A SPACER DUAL SWIVEL SADDLE –2 N57040 B TIE CABLE MOUNT HI-HEAT –3 N71311 – WIRE CLAMPING CABLE TIE –

1.3 LF N75803 – HOSE DUCT AIR 4 in. –1.6 LF N75803 – HOSE DUCT AIR 4 in. –

1 N75806 A UNION 4 in. Generator –1 N81433-01 – 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 –

LEVEL 25ml N37086 A LOCTITE THREAD SEALANT WHITE –5ml N10844 C SIKA 205 AKTIVATOR –

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PROCEDURE

WARNING

FOLLOW YOUR INTERNAL SAFETY PROCEDURES.

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

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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.

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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.

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.

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.

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

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.

CAUTION

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

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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

REMOVE GENERATOR OIL COOLING SYSTEM PARTS

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Before After

Remove

Install plug 3678923

Install oil drain connection with a new ring seal and reconnect

the oil pipe

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).

Figure 6 - Remove Oil Ports Fittings

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

NOTE

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1.11. 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

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Figure 9 - Install New Configuration Parts

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

Install new hose N95060-199

New fitting Cummins 3099698New elbow N27280New hose N95714-14

Discard hose and 45° fitting

Discard hose N95709-41

Figure 8 - Discard Hoses

Discard hose N95060-98

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 1.111.14. 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.

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1.15. Remove the hose and the hardware for the breather hose.

1.16. Install a plug 0444620.

Remove hose and hardware

Figure 10 - Remove Hose and Hardware

Figure 11 - Install Plug 0444620

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DiscardBracket N73956

Keep Capacitor N93656-01

DiscardCable N82924Discard

Cable N79630

Figure 12 - Remove Cables, Bracket and Capacitor

DiscardBracket N83016

KeepBracket N10322

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.

REMOVE GENERATOR CABLES

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Discard Cable N73364

Discard:Bracket N34498Screw N4481-03Screw N80661 (x2)Locknut N44887Spacer N92297

Discard Bracket N82200

Keep Fuse assembly N47760for later

Discard:Bracket N10322 (2x)Screw N40492 (2x)Locknut N44887 (5x)

Figure 13 - Fan Cable Removal

1.21. Remove the fan cable supply. Keep the p-clamps N84090-05 for later reinstallation. Discard bracket N34498, screw N44881-03, screw N80661 (2x),locknut N44887 and spacer N92297.

1.22. Remove and discard the bracket N82200 under the engine box. Keep for later reinstallation the fuse assembly N47760 and discard brackets N10322 (2x) screw N40492 (2x) and locknut N44887 (5x).

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1.23. Lift up the retractor arm and pulley to remove the drive belt from the generator. Keep the belt for later reinstallation.

1.24. Remove and discard the belt tensioner bracket. 1.25. Remove the bolts attaching the generator to the engine mounting bracket. It might be easier to disconnect

the coil #1 for a better access to one of the bolts.1.26. Remove the four nuts and lock washers and lift the generator from its assembly rack.1.27. Install the new generator N90068. Due to his size, it might be easier to install the new generator from the

inside of the bus. Use the inside engine acess door from the seats located in the interior rear of the vehicle. Torque screws N81850 with washers N56816 to 69 ±4 lb-ft (94 ±6 N•m). Apply torque seal and reconnect the coil #1 if previously disconnected.

1.28. Install the new bracket n93213 for the tensioner with bolts N33228. Torque to 33 ±4 lb-ft (45 ±6 N•m). Apply torque seal.

1.29. Install the tensioner. Torque to 197 ±16 lb-ft (267 ±22 N•m).

Before unbolting the generator from its bracket, make sure it is held in place by a safety clip.

WARNING

Figure 14 - Torque Generator and Tensioner

69 ±4 lb-ft (94 ±6 N•m) (4x)

33 ±4 lb-ft (45 ±6 N•m) (4x)

GENERATOR REPLACEMENT

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1.30. Before installing the new bracket N93087, make sure that the bolt head for the clamp beside will be accessible (reposition it if required). Then install new bracket N93087 with screw N36608 (2x) and washer N31593 (2x). Torque to 33 lb-ft (45 N•m). Apply torque seal.

Reposition clamp if required

Install bracket N93087

Figure 15 - Install Bracket N93087

INSTALL THE NEW GENERATOR CABLES

Use a product like Maxi-coat (N35450) to inhibit the corrosion on electrical connections. Whenever torque seal is applied, it must be done after the torque is applied AND after the application of the anticorrosion product.

NOTE

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1.31. Install new cables N92987 and N92986. Use the white tapes for the proper position. Install original p-clamps and new dual clamp ties N37749. Torque the cables on their junction block to 31 N•m.

1.32. Install transmission dipstick on the bracket.

Figure 16 - Install Cables N92987, N92986 and Dipstick

Cable N92987

Cable N92986

Dual clamp ties

Dual clamp tie

Dipstick

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1.33. Install the bracket N93088 on the generator with bolt N16755 (2x), washer N20779 (2x) and lock washer N17904 (2x). Torque to 6.5 ±0.5 lb-ft (9 ±1 N•m).

Figure 17 - Install Bracket N93088

1.34. Install tie mount N57040 (2x) with screw N44881-02 (2x) and locknut N44887 (2x). Fix the connectors (2x) to the tie mounts with cable ties G5007996 (2x).

1.35. Install cable N82294 to the negative post of the generator and cable N92987 to the positive. Do not tighten yet. Attach them with a p-clamp N84090-05 and a locknut N44887.

Figure 18 - Install Tie Mounts on Generator Bracket

Tie mount

Tie mount

Capacitor

P-clamps N84090-05

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1.36. Install the original capacitor N92656-01 by fixing the capacitor on the positive cable N92987 with a dual clamp tie N37749. Attach the wires with three wire clamping cable ties N71311.

1.37. Install a new terminal ring N81433-01 on the black wire of the capacitor and install it on the negative post. Torque the nut to 32 ±2 lb-ft (44 ±3 N•m).

1.38. Install the cable N92987, the fan cable N92988 and the red wire of the capacitor on the positive post. Torque the nut on the positive post to 32 ±2 lb-ft (44 ±3 N•m). See the next two Figures.

Attach capacitor wire with N71311

Attach capacitor with dual clamp N37749

Torque to 32 ±2 lb-ft (44 ±3 N•m)

Figure 19 - Connect Cables and Capacitor

Fan cable N92988with p-clamp N84090-05 and locknut N38593

Figure 20 - Install Fan Cable

Install a swivel N56836 between hose and cable

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1.39. Install bracket N93001 under the engine box.1.40. Install the original fuse assembly N47760 with two new locknuts N44887.1.41. Install cable N92988 with original p-clamps and new locknuts N44887.1.42. Install the original cable on the new bracket and to the fuse holder.

Attach the original cable to the bracket.

New cable N92988 with original p-clamps

Original fuse holder N47760

New bracket N93001

Figure 21 - Install Fan Cable and Fuse Holder Bracket

NEW FAN CABLE INSTALLATION

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1.43. Cut the ring terminals on the wires going to the generator.1.44. Install splice N152758 and wire N25831-25 on the 64-2096 circuit.1.45. Install the terminals, seals and connectors as per the Figure below.

WIRE MARKER AWG COLOR TERMINAL SEAL CONNECTOR64-1546 14 RD 12124582 15324981 1201099664-2096 16 WH 12124580 15324981 12015791

WIRE MARKER AWG COLOR TERMINAL SEAL CONNECTOR64-2096 16 WH 12124580 15324981 12015791

Figure 22 - Install New Connectors

MODIFICATIONS ON GENERATOR CONNECTORS

WIRE MARKER AWG COLOR TERMINAL SEAL CONNECTOR

64-2096 16 WH 12124580 15324981 1201591

WIRE MARKER AWG COLOR TERMINAL SEAL CONNECTOR

64-1546 14 RD 12124582 15324981 12010996

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1.46. Route and secure harness 64 as shown below with cable ties G5007996, spacer N56836 and p-clamp N84090-02.

Secure connector

Secure harness

Secure connector

Install p-clamp N84090-02 and locknut N44887

Install a spacer N56836 with two cable ties and fix it to cable N92988

Figure 23 - Secure Harness

HARNESS 64 ROUTING

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1.47. Remove and discard fuel filter hoses.1.48. Remove the three bolts holding the fuel filter to the bracket.

CAUTION

The qualified personnel should take the necessary precautions to avoid any risk of personal injury or damage to the equipment. Adjacent surfaces should be suitably protected (by using proper fire blocker blankets, etc.) to prevent damage.

Figure 24 - Unbolt the Fuel Filter (Some Parts Removed For Clarity)

1.49. Cut and remove the fuel filter bracket completely from the square tube. Grind and clean the surfaces as needed.

Figure 25 - Cut the Fuel Filter Bracket

FUEL FILTER REPOSITIONING

Front Rear

Discard hoses

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1.50. Using the bracket N93157 as a jig, mark the holes required to install the bracket.1.51. Drill the two holes (3/8 in.) and install the fuel filter bracket N93157 and the pipe bracket N93158 with bolts

N44885-6 and nuts N43233.

1.52. Install the fuel filter on the new bracket.1.53. Install the new fuel filter hoses N95839-02 then N95839-03 then reorient the fittings as required.

Figure 26 - New Fuel Filter Configuration

Front Rear

N93157

N93158

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INSTALLATION OF THE AIR COOLING PIPE

Air intake box N93763

Hose N75803 with clamps N12883

Elbow (90°) N91342 withclamp N12883

Elbow (55°) N93143

Figure 27 - EMP Air Cooling Installation

Air intake box bracket N93144

Union N75806

Clamp N22781-07

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1.54. Using the bracket as a jig and the distance shown below to mark the first hole, drill the two 3/8 in. holes in the structure. Install the air intake box bracket N93144 with bolts N43775 and nuts N43233. Torque to 24.4 ±1.5 ft-lb (33 ±2 N•m).

3 1/8 in.

Air intake box bracket N93144

1.55. Install the air intake box N93763 onto the bracket N93144 with two bolts N40492 and nuts N44890. Torque to 8 ±0.7 lb-ft (11 ±1 N•m).

1.56. Cut and install gasket N18813 on the air intake box.

Air intake box gasket N18813

Figure 28 - Drill the Two Holes for the Air Intake Bracket

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1.57. Install elbow N93143 on the bracket N93158 with bolts N40492 and nuts N38593. Torque to 8 ±0.7 lb-ft (11 ±1 N•m).

Elbow N93143

Bracket N93158, bolts N40492 and nuts N38593

P-clamp N84090-11, bolts N40492 and nuts N38593

Figure 29 - Install Elbow N93143 (Some Parts Removed for Clarity)

1.58. Install the elbow N91342, the union N75806, the hoses N93763 and the p-clamps as per Figure 24. Torque the p-clamp to (6 ±1 N•m).

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DRAIN HOSE INSTALLATION1.59. Drill two 3/8 in. holes to fix the p-clamps N84090-03 for the drain tube 8860102. See the Figure below.1.60. Install the fitting 0696471 on the elbow N93143, then install the drain hose to the fitting and the p-clamps.

Figure 30 - Drain Hose Installation

6 5/8 in.3.5 in.

1.5 in.3 3/8 in.

P-clamps N84090-03 Drain tube

8860102

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1.61. Install the engine belt as per your manual section 09: AltErnAtor And voltAgE rEgulAtor.1.62. Route the hoses for the air dryer as per Figure below. Replace the shortest one with a new tubing 8861140

and adjust the length accordingly. Secure with cable ties.

FINALIZATION OF THE INSTALLATION

Figure 31 - Route the Air Dryer Hoses

Before After

1.63. Route and secure the hoses out of the way of the air cooling pipe.

Figure 32 - Route and Secure Hoses

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1.64. Fill with engine coolant as per the manual section 09: EnginE cooling systEm and make sure to remove the air in the system.

1.65. The vehicle can be put back into service.

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