Altoona Report: Maintainability

1. MAINTAINABILITY

1.1 ACCESSIBILITY OF COMPONENTS AND SUBSYSTEMS

1.1-I. TEST OBJECTIVE

The objective of this test is to check the accessibility of components and subsystems.

1.1-II. TEST DESCRIPTION

Accessibility of components and subsystems is checked, and where accessibility is restricted the subsystem is noted along with the reason for the restriction.

1.1-III. DISCUSSION

Accessibility, in general, was adequate. Components covered in Section 1.3 (repair and/or replacement of selected subsystems), along with all other components encountered during testing, were found to be readily accessible and no restrictions were noted. Note: the upper alternator (add-on) must be removed to gain access to the lower (OEM) alternator.

ACCESSIBILITY DATA FORM

Bus Number: 0706

Date: 9-5-07

Component	Checked	Comments
ENGINE :
Oil Dipstick	X
Oil Filler Hole	X
Oil Drain Plug	X
Oil Filter	X
Fuel Filter	X
Air Filter	X
Belts	X
Coolant Level	X
Coolant Filler Hole	X
Coolant Drain	X
Spark / Glow Plugs	N/A
Alternator	X	Two alternators – upper is very accessible, the upper alternator must be removed to gain access to the lower.
Diagnostic Interface Connector	X
TRANSMISSION :
Fluid Dip-Stick	X
Filler Hole	X
Drain Plug	X
SUSPENSION :
Bushings	X
Shock Absorbers	X
Air Springs	X
Leveling Valves	X
Grease Fittings	X

ACCESSIBILITY DATA FORM

Bus Number: 0706

Date: 9-5-07

Component	Checked	Comments
HVAC :
A/C Compressor	X
Filters	X
Fans	X
ELECTRICAL SYSTEM :
Fuses	X
Batteries	X
Voltage regulator	X
Voltage Converters	X
Lighting	X
MISCELLANEOUS :
Brakes	X
Handicap Lifts/Ramps	X
Instruments	X
Axles	X
Exhaust	X
Fuel System	X
OTHERS :

1.2 SERVICING, PREVENTIVE MAINTENANCE, AND REPAIR AND MAINTENANCE DURING TESTING

1.2-I. TEST OBJECTIVE

The objective of this test is to collect maintenance data about the servicing, preventive maintenance, and repair.

1.2.-II. TEST DESCRIPTION

The test will be conducted by operating the NBM and collecting the following data on work order forms and a driver log.

1. Unscheduled Maintenance
a. Bus numberb. Date

c. Mileage

d. Description of malfunction

e. Location of malfunction (e.g., in service or undergoing inspection)

f. Repair action and parts used

g. Man-hours required

2. Scheduled Maintenance

a. Bus number

b. Date

c. Mileage

d. Engine running time (if available)

e. Results of scheduled inspections

f. Description of malfunction (if any)

g. Repair action and parts used (if any)

h. Man-hours required

The buses will be operated in accelerated durability service. While typical items are given below, the specific service schedule will be that specified by the manufacturer.

A. Service
1. Fueling

2. Consumable checks

3. Interior cleaning

B. Preventive Maintenance
4. Brake adjustments

5. Lubrication

6. 3,000 mi (or equivalent) inspection
7. Oil and filter change inspection

8. Major inspection

9. Tune-up

C. Periodic Repairs
1. Brake reline

2. Transmission change

3. Engine change

4. Windshield wiper motor change

5. Stoplight bulb change

6. Towing operations

7. Hoisting operations

1.2-III. DISCUSSION

Servicing and preventive maintenance were performed at manufacturer-specified intervals. The following Scheduled Maintenance Form lists the mileage, items serviced, the service interval, and amount of time required to perform the maintenance. Table 1 is a list of the lubricating products used in servicing. Finally, the Unscheduled Maintenance List along with Unscheduled Maintenance-related photographs is included in Section 5.7, Structural Durability. This list supplies information related to failures that occurred during the durability portion of testing. The Unscheduled Maintenance List includes the date and mileage at which the malfunction occurred, a description of the malfunction and repair, and the time required to perform the repair.

0706schedmaint2

Table 1. STANDARD LUBRICANTS

The following is a list of Texaco lubricant products used in bus testing conducted by the Penn State University Altoona Bus Testing Center:

ITEM	PRODUCT CODE	TEXACO DESCRIPTION
Engine oil	#2112	URSA Super Plus SAE 30
Transmission oil	#1866	Automatic Trans Fluid Mercon/Dexron II Multipurpose
Gear oil	#2316	Multigear Lubricant EP SAE 80W90
Wheel bearing & Chassis grease	#1935	Starplex II

1.3 REPLACEMENT AND/OR REPAIR OF SELECTED SUBSYSTEMS

1.3-I. TEST OBJECTIVE

The objective of this test is to establish the time required to replace and/or repair selected subsystems.

1.3-II. TEST DESCRIPTION

The test will involve components that may be expected to fail or require replacement during the service life of the bus. In addition, any component that fails during the NBM testing is added to this list. Components to be included are:
1. Transmission

2. Alternator

3. Starter

4. Batteries

5. Windshield wiper motor

1.3-III. DISCUSSION

During the test, several additional components were removed for repair or replacement. Following is a list of components and total repair/replacement time.

MAN HOURS

Both suspension travel limit cables - 1.00
All tires - 2.00

At the end of the test, the remaining items on the list were removed and replaced. The transmission assembly took 8.5 man-hours (two men 4.25 hrs) to remove and replace. The time required for repair/replacement of the four remaining components is given on the following Repair and/or Replacement Form.

REPLACEMENT AND/OR REPAIR FORM

Subsystem	Replacement Time
Transmission	8.50 man hours
Wiper Motor	0.50 man hours
Starter	0.25 man hours
Alternator	1.00 man hours
Batteries	0.25 man hours