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44 CHAPTER 6 SAMPLE MAINTENANCE PRACTICES Seven maintenance practices were developed from apply- ing the guidance offered in this Guidebook. Topics were selected to appeal to a wide range of agencies operating small, âcutawayâ-type automotive vans to full-size transit buses. The practices illustrate how the guidance is applied and offers agencies seven actual practices that they can use as is or modify to suit their particular needs and local oper- ating conditions. Four members of the research team, each with varying degrees of computer and writing skills, devel- oped the practices. Although the sample practices were proofread for grammar and accuracy, each reflects the writ- ing style and approach of the individual author. The sample practices were all developed in cooperation with transit agencies based on their local conditions. Lessons learned from developing these practices were then used to fine-tune Guidebook material. In some cases, the finished practice builds upon an existing agency practice and enhances it with additional detail offered by the Guide- book, such as the use of photos, additional safety infor- mation, and more descriptive step-by-step work proce- dures. In other cases, the practices were developed to fill a void in the agencyâs existing library of practices. For example, the Potomac and Rappahannock Transportation Commission (PRTC) recently took delivery of Gillig buses with an AC system new to their operation. The AC PMI practice was developed specifically for their new AC/bus combination. Each practice follows the format presented in Chapter 4 of the Guidebook. Some were developed using the MS Word template, while others were created without the template. Practice titles are based on the classification system used to post practices on the Web Board as defined in Chapter 5. Table 6-1 summarizes the seven sample practices included in this chapter. Practice Title Purpose Cooperating Agency and Reference Material Notes #1 - Bus PMI; 1990 GMC/RTS/NOVA, 40-foot high floor Provides instructions for conducting a PMI on a full-size bus - MTA New York City Transit (MTA NYCT) - GMC/RTS/NOVA - Guidebook format was used to create an introduction to the PMI checklist - Checklist format is based on MTA NYCT inspection sheet, which is extremely thorough - Includes body diagram for noting defects #2 - Bus PMI; 2003 STARTRANS Senator, 20-Ft.; Ford E-350 Chassis Provides instructions for conducting a PMI on an automotive-based "cutaway"- style bus - RADAR, Unified Human Services Transportation Inc., Roanoke, VA - Supreme - Ford Motor Company - Haynes - Word template format was used to create an introduction to the PMI checklist - Practice is of particular interest to smaller agencies operating this popular Ford chassis #3 - Component PMI; Thermo King Model T11-M85 AC with IntelligAIRE II; 2004, Gillig, 30- foot low floor Provides instructions for conducting an air conditioning system PMI on a full-size bus - Potomac and Rappahannock Transportation Commission (PRTC) - Thermo King Corporation - Applicable to large buses with a similar AC system - Serves as a framework for developing HVAC PMI on other buses - Section added that lists additional AC reference material available to technicians if needed #4 - Electrical; Repair; All buses Provides an introduction to electrical circuit failures, meter usage, and repair - PRTC - Thermo King Corporation - TMC RP 129 - Applicable to all buses - Includes general electrical troubleshooting, wire repairs, and use of multi-meters - Prohibits use of jumpers and test lamps TABLE 6-1 Summary of sample practices
45 Practice Title Purpose Cooperating Agency and Reference Material Notes #5 - Brakes; Remove and Replace Front Brakes; 2003 STARTRANS Senator, 20-Ft.; Ford E-350 Chassis Provides instructions for the proper removal and replacement of front brake pads on a cutaway-style bus - RADAR, Unified Human Services Transportation Inc., Roanoke, VA - Supreme - Ford Motor Company - Haynes - Word template format was used to create the entire practice - Practice is of particular interest to smaller agencies operating this popular Ford chassis #6 - Body; Door Adjustment; Vapor/NFIL Slide Glide Door; 2002 New Flyer, 40LF Provides instructions for the proper adjustment of front or rear slide glide style doors on a full-size bus - SEPTA - New Flyer Industries, Ltd. - Applies to front and rear door adjustments - Can be adapted to other buses with similar door style - Includes adjustment of door operating speeds #7 â Service; Service Line Functions Defines the duties for daily service line operations, including fueling, cleaning, and critical mechanical checks - Lynx, Orlando, FL - Can be applied to any service line operation - Includes daily servicing and cleaning functions - Also includes detailed cleaning functions TABLE 6-1 (Continued) Summary of sample practices
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49 PREVENTIVE MAINTENANCE INSPECTION - SHEET 1 INSPECTION TYPE A B C Signature Employee No. Bus Number Garage Inspector Hub Mileage Date Helper Supervisor Beginning Checks Action Items: Hook up manometer to check air-intake vacuum restriction. Clear work area in rear of bus to check speedometer and parking brake. Turn master switch to âRunâ. Listen for ABS valve bursts. Start engine. Reverse bus. Move forward, check speedometer. Align bus in work area for lifting. Confirm exhaust hose is in place. Performance Checks: Check Criteria: OK NG 1. ABS/Traction Control Valves Total of four air bursts should be heard 2. Back-Up Alarm Must be audible from driverâs seating area 3. Speedometer Operation Must register vehicle speed 4. Parking Brake Operation Bus does not move OR bus stops upon application Engine Diagnostics/Miscellaneous Action Items: Hook-Up Engine Diagnostics. Print out fault codes. Attach to inspection sheet. Clear all inactive codes. Take following engine performance readings: Performance Checks: Check Criteria: OK NG 5. Engine Oil Pressure (psi) IDLE: ______ (25-45) TOP RPM: ______ (40-64) 6. Engine Speed (rpm) IDLE: ____ (800+/-50) FAST: _____(1000+/-50) TOP RPM: _____(2150+/-50) 7. Air Intake Restriction (in H2O) Must be less than 7â H2O at top RPM 8. Fuel Pressure IDLE: 25 TO 30 psi: TOP RPM 70 TO 90 psi 9. Transmission Fluid Level Level OK for Cold & Hot running conditions (Non-Sealed Sticks) 10. Hydraulic Filtration Pressure (psi) Must be less than 25 psi (or within green zone in dial) 11. Anti-Freeze Protection Level Should be in range of -340 +/- 100 F Drivability Function Checks (Engine Running) Action Items: Release Parking Brake. Deplete Air System until Parking Brake Button Pops Up Performance Checks: Check Criteria: OK NG 12. Low Air Alarm Trigger Audible and visual low air indicator below 70 psi 13. Parking Brake Safety Pop-Up Engages at 30 to 40 psi, if applicable 14. Air System Re-Charge Time Must be less than 4 minutes 15. Air Governor Cut-In Pressure Cut-in pressure: about 90 psi 16. Air Governor Cut-Out Pressure Cut-out pressure: about 120 psi 17. Air Dryer Purge Cycle Operation Cycles when governor cuts-out 18. Starter Interlock Starter must not engage when engine running 19. Front Door & Dome Lights Must open and close as intended; lights illuminate 20. Kneeling System and Interlock Kneeler horn & lights activate; interlock engages; kneels and retracts 21. Electric Side Mirror Adjustment Must be operational 22. Windshield Wipers/Wash Must operate as intended 23. Dash Lights/Dimmer Switch Gauges must Illuminate 24. Dash Tell-Tale Lamps All squares should illuminate in test mode 25. Voltage Guage Readings 12V: 13/8+/- 0.3V 24V: 27.6+/- 0.3V 26. Speak-Easy Operation Voice recording must be clearly audible w/door operation 27. Horn/Steering Wheel Adjustment Horn must be audible in all S/W positions
50 PREVENTIVE MAINTENANCE INSPECTION - SHEET 2 INSPECTION TYPE A B C Bus Number Date: Drivability Function Checks (Engine Running) - Contâd Performance Checks: Check Criteria: OK NG 28. Steering Wheel Adjustment S/W must be fully adjustable; all hardware & controls intact 29. Seatbelt/Seat Adjustment Must be fully adjustable; all hardware & controls intact 30. Sun Visor & Vehicle Registration Operable and present 31. Fire Suppression System Manual actuator pull-pin and/or guard in place; system âOKâ Light is on; pressing âtestâ triggers audible and visual alarm 32. Operatorâs Light Must be operational Drivability Function Checks (Engine âOffâ) Action Items: Turn Engine âOffâ Turn âOnâ Interior Lights Activate Rear Door Performance Checks: Check Criteria: OK NG 33. Accelerator/Brake Pedals Roller, plunger and pedal pin all secure and intact 34. Handheld Fire Extinguisher Present, secure and charged in green zone 35. Interior Mirrors Present and secure 36. Operatorâs Stanchion Present and secure 37. Forward Roof Hatch Secure, opens and closes 38. Stanchions & Related Hardware Secure and free of damage 39. Passenger Seats Secure and clean (free of rips, tears, graffiti, gum, etc.) 40. Interior Decals Secure, clean and legible 41. Passenger Stop Requests All touch tapes and pushbuttons are properly indicated 42. Windows None broken/cracked & are secure, slide and locks 43. Emergency Window Hatches Open and latch shut as intended 44. Rear Roof Hatch Opens and closes as intended 45. Interior Lighting All lights operational. Light panels in place & secure Rear Door Checks Action Items: Turn Engine âOnâ Performance Checks: Check Criteria: OK NG 46. Rear Door âOpenâ Lights All green lights illuminate 47. Rear Door Touch Tapes Left and right door touch tapes activate door opening 48. Door Gap & Push-Pull Test Gap< 3â. Minimal play. Door hinges & seals intact 49. Door Open Interlock Function Brake is applied & accelerator is disabled when doors are held open following a âClose Doorâ command Bus movement disabled upon a âforcedâ unauthorized door opening 50. Door Closed Interlock Function Stepwell voice recording and/or buzzer is audible 51. Door Cycle Test Door opens & closes as intended after above steps Bus Exterior Checks Action Items: Turn Master Switch to âOffâ then to âLightsâ position. (Engine Not Running) Set Destination Sign to Test Pattern. Turn âOnâ all Exterior Lights Performance Checks: Check Criteria: 52. Wipers/Wiper Blades Secure. Blade edges not worn & free of damage 53. Front Route Sign Sign illumination operational. 54. Curbside Minor Secure & undamaged OK NG Conduct Walk-Around Inspection. Note Body Damage on Bus Diagram Sheet.
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66 5. Inspect liquid line indicator in AC compartment for moisture content. Record color below. Green (dry) _____ Yellow (wet) _______ 6. Inspect compressor clutch for evidence of wear, overheating, and broken friction plate or springs. Inspect for leaks at front compressor seal. Mark as acceptable or defective. Elaborate on any defects on attached Defects Record Sheet. Clutch Condition: Acceptable_____ Defective_________ Clutch
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71 a) To initiate the Relay Test, press either the up or down arrow key when (RT) appears in the display. When initiated, the Relay Test turns on the first relay. b) To scroll through the relay tests, press either the up or down arrow key. The output on the digital display is turned on and all other outputs are turned off. Consult the unit schematic diagram to determine what component(s) are controlled by each output. Note: The controller has time limits for outputs that can cause damage if left on too long. c) To exit the Relay Test at any time, press the Display Select key. Ensure that the main and sidewall water valves are opening and closing when the unit cycles on/off (lines should be warm when operating) and check coolant booster pump seal for evidence of leaks. Mark as acceptable or defective. Elaborate on any defects on the attached Defects Record Sheet. Acceptable: _____ Defective: ______
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