STURAA TEST
12 YEAR
500,000-MILE BUS
From
NABI
MODEL 60 LFW K-1
JUNE 2002
PTI-BT-R0217
The Pennsylvania Transportation Institute
201 Research Office Building
The Pennsylvania State University
University Park, PA 16802
(814) 865-1891
Bus Testing and Research Center
6th Avenue and 45th Street
Altoona, PA 16602
(814) 949-7944
TABLE OF CONTENTS
Page
EXECUTIVE SUMMARY .......................................................................................................................... 3
ABBREVIATIONS .................................................................................................................................... 6
BUS CHECK-IN 0217 .............................................................................................................................. 7
BUS CHECK-IN 0217A .......................................................................................................................... 81
1. MAINTAINABILITY
1.1
1.2
1.3
ACCESSIBILITY OF COMPONENTS AND SUBSYSTEMS ....................................... 19
SERVICING, PREVENTATIVE MAINTENANCE, AND REPAIR AND
MAINTENANCE DURING TESTING ........................................................................... 22
REPLACEMENT AND/OR REPAIR OF SELECTED SUBSYSTEMS ......................... 28
2. RELIABILITY - DOCUMENTATION OF BREAKDOWN AND REPAIR
TIMES DURING TESTING ................................................................................................................ 32
3. SAFETY - A DOUBLE-LANE CHANGE (OBSTACLE AVOIDANCE TEST) .................................... 90
4. PERFORMANCE - AN ACCELERATION, GRADEABILITY, AND TOP
SPEED TEST ..................................................................................................................................... 93
5. STRUCTURAL INTEGRITY
5.1
5.2
5.3
5.4
5.5
5.6
5.7
STRUCTURAL STRENGTH AND DISTORTION TESTS - STRUCTURAL
SHAKEDOWN TEST ...................................................................................................
STRUCTURAL STRENGTH AND DISTORTION TESTS - STRUCTURAL
DISTORTION ...............................................................................................................
STRUCTURAL STRENGTH AND DISTORTION TESTS - STATIC
TOWING TEST ............................................................................................................
STRUCTURAL STRENGTH AND DISTORTION TESTS - DYNAMIC
TOWING TEST ............................................................................................................
STRUCTURAL STRENGTH AND DISTORTION TESTS
- JACKING TEST .........................................................................................................
STRUCTURAL STRENGTH AND DISTORTION TESTS
- HOISTING TEST ........................................................................................................
STRUCTURAL DURABILITY TEST ............................................................................
6. FUEL ECONOMY TEST - A FUEL CONSUMPTION TEST USING AN
APPROPRIATE OPERATING CYCLE .........................................................................................
36
40
97
56
59
61
64
102
7. NOISE
7.1
7.2
INTERIOR NOISE AND VIBRATION TESTS .........................................................
EXTERIOR NOISE TESTS ......................................................................................
116
122
EXECUTIVE SUMMARY
North American Bus Industries, Inc. (NABI) submitted a model 60LFW K-1,
diesel-powered, 60-foot, articulated bus, for a 12 year/500,000 mile STURAA test. The
bus is equipped with 61 seats (including the driver and room for 62 standing
passengers. The bus initiated the test on November 17, 2002 with an odometer reading
of 3,113 miles. This bus will hereinafter be referred to as bus number 0217. The
following tests were performed: 1.1 Accessibility, 1.2 Servicing and Maintenance, 1.3
Replacement and/or Repair of Selected Subsystems, 2. Reliability, 5.1 Structural
Shakedown Test, 5.2 Structural Distortion Test, 5.4 Dynamic Towing Test, 5.5 Jacking
Test, 5.6 Hoisting Test and 5.7 Structural Durability Test. Near the completion of the
Structural durability test, it was discovered that the vehicle submitted for testing was not
representative of the production vehicle. The bus submitted for testing (0217) was
equipped with a rear axle ratio of 4.89:1 and a remanufactured engine with an ECU of
unknown age. The bus intended for production is equipped with a rear axle ratio of
5.38:1. It is reasonable to expect that this difference would affect certain test results,
therefore a second “production”, equipped with a new engine and production rear axle
was delivered by NABI for the remaining tests. The second bus, hereinafter referred to
as bus number 0217A, completed the remaining tests as follows: 3. Safety, 4.
Performance, 5.3 Static Towing Test, 6. Fuel Economy Test, 7.1 Interior Noise Test and
7.2 Exterior Noise Test.
With the exception of the axle ratio and new engine, NABI provides that the
replacement bus is the same model as the original. However, the replacement vehicle
is equipped with a different seating configuration that results in different vehicle weights.
In an attempt to identify the differences between the original bus and the replacement
bus, this report is divided into two parts. Each part contains a Check-In section that
provides specific vehicle data for each configuration and the resulting test data. In the
interest of providing test data representative of the production vehicle, the substitution of
test vehicles was approved by the Federal Transit Administration.
Testing on bus 0217 started on June 17, 2002 and was completed on May 6,
2003. The replacement bus (0217A) was delivered on May 21, 2003 and testing was
completed on June 9, 2003. The Check-In sections provided in both parts of this report
provide vehicle data and specifies major components for each bus.
The primary part of the test program is the Structural Durability Test, which also
provides the information for the Maintainability and Reliability results. The Structural
Durability Test performed on bus 0217 started on November 12, 2002 and was
completed on May 6, 2003.
The interior of bus 0217 is configured with seating for 61 passengers including
the driver. Free floor space will accommodate 62 standing passengers resulting in a
potential capacity of 123 persons. At 150 lbs per person, this load results in a
measured gross vehicle weight of 58,430 lbs. In order to avoid exceeding the GAWR
(26,000 lbs) of the rear axle, ballast for 9 standing passengers was eliminated. This
reduction from full capacity resulted in an adjusted measured gross vehicle weight of
3
56,910 lbs and was used for all dynamic testing. The middle segment was performed at
a SLW of 48,830 lbs and the final segment was performed at a CW of 37,920 lbs.
Durability driving resulted in unscheduled maintenance and failures that involved a
variety of subsystems. A description of failures, and a complete and detailed listing of
scheduled and unscheduled maintenance is provided in the Maintainability section of
this report.
The interior of bus 0217A is configured with seating for 62 passengers including
the driver. Free floor space will accommodate 52 standing passengers resulting in a
potential capacity of 114 persons. At 150 lbs per person, this load results in a
measured GVW of 58,500 lbs. SLW is 51,090 and CW is 42,150 lbs.
Accessibility performed on bus 0217, 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.
The Reliability section compiles failures that occurred during Structural Durability
Testing on bus 0217. Breakdowns are classified according to subsystems. The data in
this section are arranged so that those subsystems with more frequent problems are
apparent. The problems are listed by class as defined in Section 2. The test bus
encountered no Class 1 or Class 2 failures. Of the thirty-five reported failures, sixteen
were Class 3 and nineteen were Class 4.
The Safety Test, (a double-lane change, obstacle avoidance test) was safely
performed on bus 0217A in both right-hand and left-hand directions up to a maximum
test speed of 45 mph. The performance of bus 0217A is illustrated by a speed vs. time
plot. Acceleration and gradeability test data are provided in Section 4, Performance.
The average time to obtain 50 mph was 40.87 seconds.
The Shakedown Test performed on bus 0217 produced a maximum final loaded
deflection of 0.084 inches with a permanent set ranging between 0.000 to 0.006 inches
under a distributed static load of 46,125 lbs. The Distortion Test was completed on bus
0217 with all subsystems, doors and escape mechanisms operating properly. No water
leakage was observed throughout the test. All subsystems operated properly.
The Static Towing Test was performed on bus 0217A using a target load (towing
force) of 50,580 lbs. All four front pulls were completed to the full test load with no
damage or deformation observed during testing. Upon completion of the test,
examination of the manufacturer supplied towing brackets revealed deformation and
cracking of both the left and right brackets. Some deformation and cracking of the
receiver was also noted. The manufacturer does not recommend towing from the rear,
therefore, the rear test was not performed. The Dynamic Towing Test was performed
on bus 0217 by means of a front-lift tow. The towing interface was accomplished using
a hydraulic under-lift wrecker. The bus was towed without incident and no damage
resulted from the test. The manufacturer does not recommend towing the bus from the
4
rear, therefore, a rear test was not performed. The Jacking and Hoisting Tests were
also performed on bus 0217 without incident. The bus was found to be stable on the
jack stands, and the minimum jacking clearance observed with a tire deflated was 5.2
inches.
A Fuel Economy Test (bus 0217A) was run on simulated central business district,
arterial, and commuter courses. The results were 2.54 mpg, 3.03 mpg, and 5.38 mpg
respectively; with an overall average of 3.16 mpg.
A series of Interior and Exterior Noise Tests was performed on bus 0217A.
These data are listed in Section 7.1 and 7.2 respectively.
5
ABBREVIATIONS
ABTC
- Altoona Bus Test Center
A/C
- air conditioner
ADB
- advance design bus
ATA-MC - The Maintenance Council of the American Trucking Association
CBD
- central business district
CW
- curb weight (bus weight including maximum fuel, oil, and coolant; but
without passengers or driver)
dB(A)
- decibels with reference to 0.0002 microbar as measured on the "A" scale
DIR
- test director
DR
- bus driver
EPA
- Environmental Protection Agency
FFS
- free floor space (floor area available to standees, excluding ingress/egress areas,
area under seats, area occupied by feet of seated passengers, and the vestibule area)
GVL
- gross vehicle load (150 lb for every designed passenger seating
position, for the driver, and for each 1.5 sq ft of free floor space)
GVW
- gross vehicle weight (curb weight plus gross vehicle load)
GVWR
- gross vehicle weight rating
MECH
- bus mechanic
mpg
- miles per gallon
mph
- miles per hour
PM
- Preventive maintenance
PSBRTF - Penn State Bus Research and Testing Facility
PTI
- Pennsylvania Transportation Institute
rpm
- revolutions per minute
SAE
- Society of Automotive Engineers
SCH
- test scheduler
SEC
- secretary
SLW
- seated load weight (curb weight plus 150 lb for every designed passenger seating
position and for the driver)
STURAA - Surface Transportation and Uniform Relocation Assistance Act
TD
- test driver
TECH
- test technician
TM
- track manager
TP
- test personnel
6
TEST BUS CHECK-IN
I. OBJECTIVE
The objective of this task is to log in the test bus, assign a bus number, complete
the vehicle data form, and perform a safety check.
II. TEST DESCRIPTION
The test consists of assigning a bus test number to the bus, cleaning the bus,
completing the vehicle data form, obtaining any special information and tools from the
manufacturer, determining a testing schedule, performing an initial safety check, and
performing the manufacturer's recommended preventive maintenance. The bus
manufacturer must certify that the bus meets all Federal regulations.
III. DISCUSSION
The check-in procedure is used to identify in detail the major components and
configuration of the bus.
The test bus consists of a NABI, model 60LFW K-1. The bus has a front door
equipped with a T&T Transit Products model T7000-48SC handicap ramp, located
forward of the front axle, and a rear door centered between the axle and artic joint.
Power is provided by a diesel-fueled, Detroit Diesel model Series 50 Bus engine
coupled to a ZF model Ecomat 5HP 602C transmission.
The measured curb weight is 8,950 lbs for the front axle, 8,990 lbs for the middle
axle and 19,980 lbs for the rear axle. These combined weights provide a total
measured curb weight of 37,920 lbs. There are 61 seats including the driver and room
for 62 standing passengers bringing the total passenger capacity to 123. Gross load is
150 lb x 123 = 18,450 lbs. At full capacity, the measured gross vehicle weight is 58,430
lbs.
7
VEHICLE DATA FORM
Bus Number: 0217
Arrival Date: 6-17-02
Bus Manufacturer: NABI
Vehicle Identification
Number (VIN): 1N960LFW02A140005
Model Number: 60 LFW.001
Date: 6-17-02
Personnel: E.L. & D.L.
WEIGHT: *Values in parenthesis indicate the adjusted weights necessary to avoid exceeding the GAWR.
These values were used for all dynamic testing.
Individual Wheel Reactions:
Weights
(lb)
Front Axle
Middle Axle
Rear Axle
Right
Left
Right
Left
Right
Left
CW
4,760
4,190
4,160
4,830
10,170
9,810
SLW
5,680
4,910
5,970
7,110
12,270
12,890
GVW
7,200
(7,200)
6,090
(6,090)
8,030
(8,030)
9,380
(9,380)
13,950
13,210)
13,780
(13,000)
Total Weight Details:
Weight (lb)
CW
SLW
GVW
GAWR
Front Axle
8,950
10,590
13,290
(13,290)
14,600
Middle Axle
8,990
13,080
17,410
(17,410)
18,000
Rear Axle
19,980
25,160
27,730
(26,210)
26,000
Total
37,920
48,830
58,430
(56,910)
Dimensions:
Length (ft/in)
60 / 11
Width (in)
Front – 102.5
Height (in)
125.5
Front Overhang (in)
89.5
Rear Overhang (in)
124.0
Wheel Base (in)
Front – 239.0
Wheel Track (in)
Front: 86.3
Middle: 77.0
8
Rear – 104.0
Rear – 278.5
Rear: 78.0
GVWR: 58,600
Bus Number: 0217
Date: 6-17-02
CLEARANCES:
Lowest Point Outside Front Axle
Location: Skid plate
Clearance(in): 10.2
Lowest Point Outside Rear Axle
Location: Radiator bracket
Clearance(in): 10.7
Lowest Point between Axles
Location: Frame
Clearance(in): Front – 11.5
Rear – 10.0
Ground Clearance at the center (in)
10.0
Front Approach Angle (deg)
8.5
Rear Approach Angle (deg)
8.3
Ramp Clearance Angle (deg)
Front – 5.5
Aisle Width (in)
23.8
Inside Standing Height at Center
Aisle (in)
98.7
Rear – 4.1
BODY DETAILS:
Body Structural Type
Frame Material
Steel
Body Material
Aluminum
Floor Material
Plywood
Roof Material
Aluminum
Windows Type
Window Mfg./Model No.
Number of Doors
■ Fixed
■ Movable
Laird Transportation Products, Inc./ DOT 61 AS3 M8
1
Front
1 Rear
Mfr. / Model No.
NABI / O.E.M.
Dimension of Each Door (in)
Front:
Rear :
■ Cantilever
■ Pedestal
Passenger Seat Type
Mfr. / Model No.
Driver Seat Type
Mfr. / Model No.
Number of Seats (including Driver)
Q Other
(explain)
American Seating / 062819
■ Air
Q Spring
USSC / 86338
61
9
Q Other
(explain)
Bus Number: 0217
Date: 6-17-02
BODY DETAILS (Contd..)
Free Floor Space ( ft2 )
94.0
Height of Each Step at Normal
Position (in)
Front
Step Elevation Change - Kneeling
(in)
1. 17.0
2. N/A
3. N/A
4. N/A
Middle 1. N/A
2. N/A
3. N/A
4. N/A
Rear
2. N/A
3. N/A
4. N/A
1. 15.6
3.5
ENGINE
Type
■ C.I.
Q Alternate Fuel
Q S.I.
Q Other (explain)
Mfr. / Model No.
Detroit Diesel / Series 50
Location
Q Front
■ Rear
Q Other
(explain)
Fuel Type
Q Gasoline
Q CNG
Q Methanol
■ Diesel
Q LNG
Q Other
(explain)
Fuel Tank Capacity (indicate units)
120 gals
Fuel Induction Type
■ Injected
Q Carburetion
Fuel Injector Mfr. / Model No.
Diesel Technologies Corp./ NA
Carburetor Mfr. / Model No.
N/A
Fuel Pump Mfr. / Model No.
Detroit Diesel / Series 50
Alternator (Generator) Mfr. / Model
No.
C.E.Niehoff / C802
Maximum Rated Output
(Volts / Amps)
Air Compressor Mfr. / Model No.
Maximum Capacity (ft3 / min)
Starter Type
Starter Mfr. / Model No.
24 / 450
Bendix Tu-Flo / 750
16.5
■ Electrical
Q Pneumatic
Delco Remy / 1993 788
10
Q Other
(explain)
Bus Number: 0217
Date: 6-17-02
TRANSMISSION
Transmission Type
Mfr. / Model No.
Q Manual
■ Automatic
ZF Ecomat / 5HP 602C
■ Electrical
Control Type
Q Mechanical
Torque Converter Mfr. / Model No.
ZF Ecomat / 5HP 602C
Integral Retarder Mfr. / Model No.
ZF Ecomat / 5HP 602C
Q Other
SUSPENSION
Number of Axles
3
Front Axle Type
Q Independent
■ Beam Axle
Mfr. / Model No.
Meritor / FH 946RX 118
Axle Ratio (if driven)
N/A
Suspension Type
■ Air
No. of Shock Absorbers
Mfr. / Model No.
Middle Axle Type
Q Spring
2
Sachs / 481700124382
Q Independent
■ Beam Axle
Mfr. / Model No.
Meritor / RC26700NRRF4
Axle Ratio (if driven)
N/A
Suspension Type
■ Air
No. of Shock Absorbers
Mfr. / Model No.
Rear Axle Type
Q Spring
Sachs Boge / 481700 124 382
Q Independent
Meritor / 71163RX
Axle Ratio (if driven)
4.89
Suspension Type
■ Air
Mfr. / Model No.
Q Other
(explain)
4
Mfr. / Model No.
No. of Shock Absorbers
Q Other
(explain)
■ Beam Axle
Q Spring
4
Sachs / 481700 125 725
11
Q Other
(explain)
Bus Number: 0217
Date: 6-17-02
WHEELS & TIRES
Front
Rear
Wheel Mfr./ Model No.
Alcoa / 22.5 x 8.5
Tire Mfr./ Model No.
Firestone / 305/70R 22.5 16PR
Wheel Mfr./ Model No.
Alcoa / 22.5 x 8.5
Tire Mfr./ Model No.
Firestone / 305/70R 22.5 16PR
BRAKES
Front Axle Brakes Type
Mfr. / Model No.
Middle Axle Brakes Type
Mfr. / Model No.
Rear Axle Brakes Type
Mfr. / Model No.
Retarder Type
Mfr. / Model No.
■ Cam
Q Disc
Q Other (explain)
MGM / 24-73-01
■ Cam
Q Disc
Q Other (explain)
MGM / Type 24L
■ Cam
Q Disc
Q Other (explain)
MGM / Type 30-67-09
N/A
N/A
HVAC
Heating System Type
■ Water
Q Air
Capacity (Btu/hr)
180,000
Mfr. / Model No.
Thermo King / AT 10M12
Air Conditioner
■ Yes
Q No
Location
Rear
Capacity (Btu/hr)
130,000
A/C Compressor Mfr. / Model No.
Thermo King / X640
STEERING
Steering Gear Box Type
Mfr. / Model No.
Steering Wheel Diameter
Number of turns (lock to lock)
Hydraulic
RBL / 717113E14101 C700V
20.00
4.25
12
Q Other
Bus Number: 0217
Date: 6-17-02
OTHERS
Wheel Chair Ramps
Location: Front
Type: ????
Wheel Chair Lifts
Location: N/A
Type: N/A
Mfr. / Model No.
Emergency Exit
T & T Transit Products / T7000-48SC
Location: Windows
CAPACITIES
Fuel Tank Capacity (units)
120 gals
Engine Crankcase Capacity (gallons)
5.50
Transmission Capacity (gallons)
5.28
Differential Capacity (gallons)
3.50
Cooling System Capacity (gals)
25.00
Power Steering Fluid Capacity
(gallons)
8.50
13
Number: 9
VEHICLE DATA FORM
Bus Number: 0217
Date: 6-17-02
List all spare parts, tools and manuals delivered with the bus.
Part Number
Description
Qty.
41310.13004
Linkage, Leveling valve
41310.12468
Valve, Leveling, Knorr
6
60A.3740.111
Bracket, Leveling valve linkage
2
60A.3740.111T
Bracket, Leveling valve linkage
2
503.3740.014
Bracket, leveling valve
1
5029013
Air spring
10
101.3103.010 C
Torque rod
1
010.3103.020 C
Torque rod
1
101.3103.010 D
Torque rod
1
101.3103.010 E
Torque rod
1
5028303
Tire, Michelin 305 70R22.5 XZU2
2
5027540
Wheel, AL, PLT, Machine Finish, 335
2
722510.01.75
Bushing, torque rod
4
722510.02.75
Bushing, Torque rod
4
714469.02.75
Bushing, torque rod
7
714469.01.75
Bushing, torque rod
7
724764.01.75
Bushing, radius rod
2
6900765
Bushing, artic joint
2
5015811
Tube, Flex exhaust
1
416.06.1530.916
Clamp, T-bolt pipe
3
5026033
Isolator, mount, CB-1121-4
6
416.07.7444.900
Belt, A/C comp. 100” R5VX1000-2
2
5021080
Belt, Alternator 72” 12 GRV 20-8588
1
6303634
Filter, oil DDC #23518480
1
14
1 set
VEHICLE DATA FORM
Bus Number: 0217
Date: 6-17-02
List all spare parts, tools and manuals delivered with the bus.
Part Number
Description
Qty.
6900760
Filter, coolant DDC #23507189
1
5000460
Filter, fuel secondary
1
5000459
Filter, fuel primary
2
5011590
Element, air filter #P181015
1
70003.03798
Shocks (black)
6
70003.03787
Shocks (blue)
4
70003.79021
Gas spring, Riedex
2
31930.10520
Gas spring, Berva
2
5029395
Cable, 4/0 61” GND 3/8 & 3/8
1
70004.07256
Headlight, high beam, Hella
1
70004.07270
Turn signal, front
1
5023248
Equalizer, 100 amp, 52210
1
5026153
Module, DIO – 888, 115K
2
5028027
Module, MBC – 32, 115K
1
416.07.9402.900
Circuit breaker, 50 amp, MP
1
5000988
Circuit breaker, 30 amp, MP
1
416.07.9402.901
Circuit breaker, 20 amp, MP
1
5011904
Circuit breaker, 10 amp, MP
1
5011903
Circuit breaker, 5 amp, MP
1
416.00.9402.912
Relay, Bosch, 24V, 50 amp, lights
1
5022874
Relay, SPDT, resistor 12V, P&B
2
5022875
Relay, SPDT, Resistor 24V, P&B
2
5026517
Fuse, 20 amp, ATC
1
5015634
Fuse, 10 amp, ATC
1
15
VEHICLE DATA FORM
Bus Number: 0217
Date: 6-17-02
List all spare parts, tools and manuals delivered with the bus.
Part Number
Description
Qty.
5020897
Fuse, 5 amp, ATC
1
5020896
Fuse, 3 amp, ATC
1
5001671
Fuse, 10 amp, ATM
2
5001670
Fuse, 7.5 amp, ATM
2
5001669
Fuse, 5 amp, ATM
2
NA
Bulbs, Headlamp
2
NA
Fluid lines, artic joint
1 set
NA
Misc. door hardware
1 set
16
COMPONENT/SUBSYSTEM INSPECTION FORM
Bus Number: 0217
Subsystem
Date: 6-17-02
Checked
Air Conditioning Heating
and Ventilation
Τ
Body and Sheet Metal
Τ
Frame
Τ
Steering
Τ
Suspension
Τ
Interior/Seating
Τ
Axles
Τ
Brakes
Τ
Tires/Wheels
Τ
Exhaust
Τ
Fuel System
Τ
Power Plant
Τ
Accessories
Τ
Lift System
Τ
Interior Fasteners
Τ
Batteries
Τ
Comments
17
CHECK - IN
NABI’S MODEL 60LFW K-1
NABI’S MODEL 60LFW K-1 EQUIPPED WITH A
T & T TRANSIT PRODUCTS MODEL T7000-48SC
HANDICAP RAMP
18
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.
19
ACCESSIBILITY DATA FORM
Bus Number: 0217
Component
Date: 6-17-03
Checked
ENGINE :
Oil Dipstick
Τ
Oil Filler Hole
Τ
Oil Drain Plug
Τ
Oil Filter
Τ
Fuel Filter
Τ
Air Filter
Τ
Belts
Τ
Coolant Level
Τ
Coolant Filler Hole
Τ
Coolant Drain
Τ
Spark / Glow Plugs
Τ
Alternator
Τ
Diagnostic Interface Connector
Τ
TRANSMISSION :
Fluid Dip-Stick
Τ
Filler Hole
Τ
Drain Plug
Τ
SUSPENSION :
Bushings
Τ
Shock Absorbers
Τ
Air Springs
Τ
Leveling Valves
Τ
Grease Fittings
Τ
20
Comments
ACCESSIBILITY DATA FORM
Bus Number: 0217
Component
Date: 6-17-03
Checked
HVAC :
A/C Compressor
Τ
Filters
Τ
Fans
Τ
ELECTRICAL SYSTEM :
Fuses
Τ
Batteries
Τ
Voltage regulator
Τ
Voltage Converters
Τ
Lighting
Τ
MISCELLANEOUS :
Brakes
Τ
Handicap Lifts/Ramps
Τ
Instruments
Τ
Axles
Τ
Exhaust
Τ
Fuel System
Τ
OTHERS :
21
Comments
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 number
b. 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
22
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.
23
(Page 1 of 3)
SCHEDULED MAINTENANCE
NABI 0217
DATE
TEST
MILES
11-19-02
836
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
11-26-02
1,808
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
12-19-02
2,460
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
01-07-03
3,372
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
01-13-03
4,305
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
01-23-03
5,202
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
02-20-03
6,218
P.M. / Inspection
Fuel Economy Prep.
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
SERVICE
24
ACTIVITY
DOWN
TIME
HOURS
(Page 2 of 3)
SCHEDULED MAINTENANCE
NABI 0217
DATE
TEST
MILES
02-28-03
7,692
P.M. / Inspection
03-11-03
8,516
03-26-03
DOWN
TIME
HOURS
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
9,509
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
04-03-03
10,584
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
04-09-03
11,602
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
04-16-03
12,716
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
04-30-03
14,086
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
SERVICE
25
ACTIVITY
(Page 3 of 3)
SCHEDULED MAINTENANCE
NABI 0217
DATE
TEST
MILES
05-06-03
Complete
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed; all fluids checked.
4.00
4.00
05-30-03
Complete
P.M. / Inspection
Linkage, tie rods, universals/u-joints all
lubed. Oil, fuel, and air filters changed.
Transmission oil and filter changed.
8.00
8.00
SERVICE
26
ACTIVITY
DOWN
TIME
HOURS
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
27
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.
2.
3.
4.
5.
Transmission
Alternator
Starter
Batteries
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
Artic joint bushings
5.00
R.R. turn signal lamp
0.50
Right front air bag
3.00
Turbo charger
4.00
Front heater fan motor
3.00
Left, rear, outside tire
1.00
Middle axle; right outside tire
1.00
All four drive axle tires
1.00
Right side fuel tank
1.50
28
Left front air bag
1.00
Front door, right side panel
1.00
Power steering pump
1.00
At the end of the test, the remaining items on the list were removed and replaced.
The transmission assembly took 16.00 man-hours (two men 8.00 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
16.00 man hours
Wiper Motor
1.00 man hours
Starter
1.00 man hours
Alternator
1.00 man hours
Batteries
0.50 man hours
29
1.3 REPLACEMENT AND/OR REPAIR OF
SELECTED SUBSYSTEMS
TRANSMISSION REMOVAL AND REPLACEMENT
(16.00 MAN HOURS)
WIPER MOTOR REMOVAL AND REPLACEMENT
(1.00 MAN HOUR)
30
1.3 REPLACEMENT AND/OR REPAIR OF
SELECTED SUBSYSTEMS CONT.
STARTER REMOVAL AND REPLACEMENT
(1.00 MAN HOUR)
ALTERNATOR REMOVAL AND REPLACEMENT
(1.00 MAN HOUR)
31
2. RELIABILITY - DOCUMENTATION OF BREAKDOWN
AND REPAIR TIMES DURING TESTING
2-I. TEST OBJECTIVE
The objective of this test is to document unscheduled breakdowns, repairs, down
time, and repair time that occur during testing.
2-II. TEST DESCRIPTION
Using the driver log and unscheduled work order forms, all significant breakdowns,
repairs, man-hours to repair, and hours out of service are recorded on the Reliability Data
Form.
CLASS OF FAILURES
Classes of failures are described below:
(a) Class 1: Physical Safety. A failure that could lead directly to
passenger or driver injury and represents a severe crash situation.
(b) Class 2: Road Call. A failure resulting in an enroute interruption
of revenue service. Service is discontinued until the bus is replaced
or repaired at the point of failure.
(c) Class 3: Bus Change. A failure that requires removal of the bus from
service during its assignments. The bus is operable to a rendezvous
point with a replacement bus.
(d) Class 4: Bad Order. A failure that does not require removal of
the bus from service during its assignments but does degrade coach
operation. The failure shall be reported by driver, inspector, or
hostler.
2-III. DISCUSSION
A listing of breakdowns and unscheduled repairs is accumulated during the
Structural Durability Test. The following Reliability Data Form lists all unscheduled repairs
under classes as defined above. These classifications are somewhat subjective as the
test is performed on a test track with careful inspections every two hours. However, even
on the road, there is considerable latitude on deciding how to handle many failures.
The Unscheduled Repair List is also attached to provide a reference for the repairs
that are included in the Reliability Data Forms.
32
The classification of repairs according to subsystem is intended to emphasize those
systems, which had persistent minor or more serious problems. There were no Class 1 or
2 failures. Of the 16 Class 3 failures, four involved the A/C and heating systems, three
occurred in the artic joint, two each to the engine/transmission and fuel system, and one
each with the seats/doors, suspension, wheels/tires, frame and steering. These, and the
remaining 19 Class 4 failures are available for review in the Unscheduled Maintenance
List, located in Section 5.7 Structural Durability.
33
RELIABILITY DATA FORMS
Bus Number: 0217
Date: 5-6-03
Personnel: Bob Reifsteck
Failure Type
Subsystems
Class 4
Bad
Order
Class 3
Bus
Change
Class 2
Road
Call
Class 1
Physical
Safety
Mileage
Mileage
Mileage
Mileage
Down
Time
4,307
5.00
5.00
5,344
17.50
17.50
6,218
0.50
0.50
6,500
1.00
1.00
7,692
1.00
1.00
9,275
3.00
3.00
10,289
1.00
1.00
13,099
1.50
1.50
6.00
6.00
1.00
1.00
2,460
4.00
4.00
5,344
1.50
1.50
11,602
1.00
1.00
1,637
1.00
1.00
2,460
1.00
1.00
3,372
1.00
1.00
5,344
2.00
2.00
1.00
1.00
0.50
0.50
Air Conditioning/Heat
Artic Joint
816
816
Seats/Doors
Man
Hours
12,554
3,372
34
RELIABILITY DATA FORMS
Bus Number: 0217
Date: 5-6-03
Personnel: Bob Reifsteck
Failure Type
Subsystems
Suspension
Class 4
Bad
Order
Class 3
Bus
Change
Class 2
Road
Call
Class 1
Physical
Safety
Mileage
Mileage
Mileage
Mileage
3.00
3.00
5,995
3.00
3.00
1.00
1.00
13,099
1.50
1.50
14,500
2.00
2.00
5,848
1.00
1.00
1.00
1.00
8,427
1.00
1.00
816
0.50
0.50
7,692
0.50
0.50
4,307
4.00
48.00
9,427
6.00
6.00
8,566
1.50
1.50
10,634
4.00
4.00
5,344
5.00
5.00
13,178
1.00
1.00
5,995
Electrical
Engine/Transmission
Fuel System
Frame
Steering
Down
Time
1,404
8,566
Wheels/Tires
Man
Hours
35
5. STRUCTURAL INTEGRITY
5.1 STRUCTURAL STRENGTH AND DISTORTION TESTS STRUCTURAL SHAKEDOWN TEST
5.1-I. DISCUSSION
The objective of this test is to determine certain static characteristics (e.g., bus floor
deflection, permanent structural deformation, etc.) under static loading conditions.
5.1-II. TEST DESCRIPTION
In this test, the bus will be isolated from the suspension by blocking the vehicle under
the suspension points. The bus will then be loaded and unloaded up to a maximum of
three times with a distributed load equal to 2.5 times gross load. Gross load is 150 lb for
every designed passenger seating position, for the driver, and for each 1.5 sq ft of free
floor space. For a distributed load equal to 2.5 times gross load, place a 375-lb load on
each seat and on every 1.5 sq ft of free floor space. The first loading and unloading
sequence will "settle" the structure. Bus deflection will be measured at several locations
during the loading sequences.
5.1-III. DISCUSSION
This test was performed based on a maximum passenger capacity of 123 people
including the driver. The resulting test load is (123 x 375 lb) = 46,125 lb. The load is
distributed evenly over the passenger space. Deflection data before and after each
loading and unloading sequence is provided on the Structural Shakedown Data Form.
The unloaded height after each test becomes the original height for the next test.
Some initial settling is expected due to undercoat compression, etc. After each loading
cycle, the deflection of each reference point is determined. The bus is then unloaded and
the residual (permanent) deflection is recorded. On the final test, the maximum loaded
deflection was 0.084 inches at reference point 11. The maximum permanent deflection
after the final loading sequence ranged from 0.000 inches at reference points 7 to 0. 006
inches at reference points 3, 6 and 12.
36
37
38
5.1 STRUCTURAL SHAKEDOWN TEST
BUS LOADED TO 2.5 TIMES GVL
(46,125 LBS)
39
5.2 STRUCTURAL STRENGTH AND DISTORTION
TESTS - STRUCTURAL DISTORTION
5.2-I. TEST OBJECTIVE
The objective of this test is to observe the operation of the bus subsystems when the
bus is placed in a longitudinal twist simulating operation over a curb or through a pothole.
5.2-II. TEST DESCRIPTION
With the bus loaded to GVWR, each wheel of the bus will be raised (one at a time)
to simulate operation over a curb and the following will be inspected:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Body
Windows
Doors
Roof vents
Special seating
Undercarriage
Engine
Service doors
Escape hatches
Steering mechanism
Each wheel will then be lowered (one at a time) to simulate operation through a pothole
and the same items inspected.
5.2-III. DISCUSSION
The test sequence was repeated fourteen times. The first and last test is with all
wheels level. The other eight tests are with each wheel 6 inches higher and 6 inches lower
than the other three wheels.
All doors, windows, escape mechanisms, engine, steering and handicapped devices
operated normally throughout the test. The undercarriage and body indicated no
deficiencies. No water leakage was observed during the test. The results of this test are
indicated on the following data forms.
40
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
: before
9 after
Left front
9 6 in higher
9 6 in lower
Right front
9 6 in higher
9 6 in lower
Right rear
9 6 in higher
9 6 in lower
Left rear
9 6 in higher
9 6 in lower
Right center
9 6 in higher
9 6 in lower
Left center
9 6 in higher
9 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies.
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
41
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
9 before
9 after
Left front
: 6 in higher
9 6 in lower
Right front
9 6 in higher
9 6 in lower
Right rear
9 6 in higher
9 6 in lower
Left rear
9 6 in higher
9 6 in lower
Right center
9 6 in higher
9 6 in lower
Left center
9 6 in higher
9 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies.
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
42
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
9 before
9 after
Left front
9 6 in higher
9 6 in lower
Right front
: 6 in higher
9 6 in lower
Right rear
9 6 in higher
9 6 in lower
Left rear
9 6 in higher
9 6 in lower
Right center
9 6 in higher
9 6 in lower
Left center
9 6 in higher
9 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies.
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
43
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
9 before
9 after
Left front
9 6 in higher
9 6 in lower
Right front
9 6 in higher
9 6 in lower
Right rear
: 6 in higher
9 6 in lower
Left rear
9 6 in higher
9 6 in lower
Right center
9 6 in higher
9 6 in lower
Left center
9 6 in higher
9 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies.
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
44
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
9 before
9 after
Left front
9 6 in higher
9 6 in lower
Right front
9 6 in higher
9 6 in lower
Right rear
9 6 in higher
9 6 in lower
Left rear
: 6 in higher
9 6 in lower
Right center
9 6 in higher
9 6 in lower
Left center
9 6 in higher
9 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies.
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
45
46
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
9 before
9 after
Left front
9 6 in higher
9 6 in lower
Right front
9 6 in higher
9 6 in lower
Right rear
9 6 in higher
9 6 in lower
Left rear
9 6 in higher
9 6 in lower
Right center
: 6 in higher
9 6 in lower
Left center
9 6 in higher
9 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies.
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
47
48
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
9 before
9 after
Left front
9 6 in higher
9 6 in lower
Right front
9 6 in higher
9 6 in lower
Right rear
9 6 in higher
9 6 in lower
Left rear
9 6 in higher
9 6 in lower
Right center
9 6 in higher
9 6 in lower
Left center
: 6 in higher
9 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies.
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
49
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
9 before
9 after
Left front
9 6 in higher
9 6 in lower
Right front
9 6 in higher
9 6 in lower
Right rear
9 6 in higher
9 6 in lower
Left rear
9 6 in higher
9 6 in lower
Right center
9 6 in higher
9 6 in lower
Left center
9 6 in higher
: 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies.
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
50
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
9 before
9 after
Left front
9 6 in higher
9 6 in lower
Right front
9 6 in higher
9 6 in lower
Right rear
9 6 in higher
9 6 in lower
Left rear
9 6 in higher
9 6 in lower
Right center
9 6 in higher
: 6 in lower
Left center
9 6 in higher
9 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies.
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
51
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
9 before
9 after
Left front
9 6 in higher
9 6 in lower
Right front
9 6 in higher
9 6 in lower
Right rear
9 6 in higher
9 6 in lower
Left rear
9 6 in higher
: 6 in lower
Right center
9 6 in higher
9 6 in lower
Left center
9 6 in higher
9 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies.
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
52
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
9 before
9 after
Left front
9 6 in higher
9 6 in lower
Right front
9 6 in higher
9 6 in lower
Right rear
9 6 in higher
: 6 in lower
Left rear
9 6 in higher
9 6 in lower
Right center
9 6 in higher
9 6 in lower
Left center
9 6 in higher
9 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies.
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
53
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
9 before
9 after
Left front
9 6 in higher
9 6 in lower
Right front
9 6 in higher
: 6 in lower
Right rear
9 6 in higher
9 6 in lower
Left rear
9 6 in higher
9 6 in lower
Right center
9 6 in higher
9 6 in lower
Left center
9 6 in higher
9 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies.
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
54
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
9 before
9 after
Left front
9 6 in higher
: 6 in lower
Right front
9 6 in higher
9 6 in lower
Right rear
9 6 in higher
9 6 in lower
Left rear
9 6 in higher
9 6 in lower
Right center
9 6 in higher
9 6 in lower
Left center
9 6 in higher
9 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies.
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
55
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0217
Date: 7-1-02
Personnel: E.D., T.S., M.H. & D.L.
Temperature(ΕF): 92
Wheel Position : (check one)
All wheels level
9 before
: after
Left front
9 6 in higher
9 6 in lower
Right front
9 6 in higher
9 6 in lower
Right rear
9 6 in higher
9 6 in lower
Left rear
9 6 in higher
9 6 in lower
Right center
9 6 in higher
9 6 in lower
Left center
9 6 in higher
9 6 in lower
Comments
: Windows
No deficiencies.
: Front Doors
No deficiencies.
: Rear Doors
No deficiencies.
: Escape Mechanisms/ Roof Vents
No deficiencies.
: Engine
No deficiencies.
: Handicapped Device/ Special
Seating
No deficiencies.
: Undercarriage
No deficiencies
: Service Doors
No deficiencies.
: Body
No deficiencies.
: Windows/ Body Leakage
No deficiencies.
: Steering Mechanism
No deficiencies.
56
5.2 STRUCTURAL DISTORTION TEST
RIGHT FRONT WHEEL SIX INCHES HIGHER
LEFT MIDDLE WHEEL SIX INCHES HIGHER
57
5.4 STRUCTURAL STRENGTH AND DISTORTION TESTS DYNAMIC TOWING TEST
5.4-I. TEST OBJECTIVE
The objective of this test is to verify the integrity of the towing fixtures and determine
the feasibility of towing the bus under manufacturer specified procedures.
5.4-II. TEST DESCRIPTION
This test requires the bus be towed at curb weight using the specified equipment
and instructions provided by the manufacturer and a heavy-duty wrecker. The bus will be
towed for 5 miles at a speed of 20 mph for each recommended towing configuration. After
releasing the bus from the wrecker, the bus will be visually inspected for any structural
damage or permanent deformation. All doors, windows and passenger escape
mechanisms will be inspected for proper operation.
5.4-III. DISCUSSION
The bus was towed using a heavy-duty wrecker. The towing interface was
accomplished by incorporating a hydraulic under lift. A front lift tow was performed. Rear
towing is not recommended. No problems, deformation, or damage was noted during
testing.
58
DYNAMIC TOWING TEST DATA FORM
Bus Number: 0217
Date: 4-14-03
Personnel: S.C.
Temperature (ΕF): 50
Humidity (%): 27
Wind Direction: SW
Wind Speed (mph): 6
Barometric Pressure (in.Hg): 30.65
Inspect tow equipment-bus interface.
Comments: A safe and adequate connection was made between the tow equipment
and the bus.
Inspect tow equipment-wrecker interface.
Comments: A safe and adequate connection was made between the tow equipment
and the wrecker.
Towing Comments: A front lift tow was performed incorporating a hydraulic under
lift wreaker. No problems with the towing interface were encountered.
Description and location of any structural damage: No damage or deformation
was observed.
General Comments: None
59
5.4 DYNAMIC TOWING TEST
TOWING INTERFACE
TEST BUS IN TOW
60
5.5 STRUCTURAL STRENGTH AND DISTORTION
TESTS – JACKING TEST
5.5-I. TEST OBJECTIVE
The objective of this test is to inspect for damage due to the deflated tire, and
determine the feasibility of jacking the bus with a portable hydraulic jack to a height
sufficient to replace a deflated tire.
5.5-II. TEST DESCRIPTION
With the bus at curb weight, the tire(s) at one corner of the bus are replaced with
deflated tire(s) of the appropriate type. A portable hydraulic floor jack is then positioned in
a manner and location specified by the manufacturer and used to raise the bus to a height
sufficient to provide 3-in clearance between the floor and an inflated tire. The deflated
tire(s) are replaced with the original tire(s) and the jack is lowered. Any structural damage
or permanent deformation is recorded on the test data sheet. This procedure is repeated
for each corner of the bus.
5.5-III. DISCUSSION
The jack used for this test has a minimum height of 8.75 inches. During the
deflated portion of the test, the jacking point clearances ranged from 5.2 inches to 20.3
inches. No deformation or damage was observed during testing. A complete listing of
jacking point clearances is provided in the Jacking Test Data Form.
JACKING CLEARANCE SUMMARY
Condition
Frame Point Clearance
Front axle – one tire flat
10.6”
Rear axle – one tire flat
20.1”
Rear axle – two tires flat
19.1”
61
JACKING TEST DATA FORM
Bus Number: 0217
Date: 6-20-02
Personnel: D.L. & M.H.
Temperature: 78
Record any permanent deformation or damage to bus as well as any difficulty
encountered during jacking procedure.
Jacking Pad
Clearance
Body/Frame
(in)
12.1“ I
10.6“ D
Jacking Pad
Clearance
Axle/Suspension
(in)
7.3“ I
5.3“ D
Left front
12.2“ I
10.6“ D
7.2“ I
5.2“ D
Right rear—outside
21.0“ I
20.3“ D
8.1“ I
7.5“ D
Right rear—both
21.0“ I
19.1“ D
8.1“ I
6.6“ D
Left rear—outside
20.9“ I
20.1“ D
8.0“ I
7.4“ D
Left rear—both
21.1“ I
19.1“ D
8.0“ I
7.3“ D
Right middle or
tag—outside
16.4” I
15.6” D
7.3” I
6.9” D
Right middle or
tag—both
16.4” I
14.5” D
7.3” I
5.6” D
Left middle or tag—
outside
16.2” I
15.8” D
7.3” I
7.0” D
Left middle or tag—
both
16.2” I
14.4” D
7.3” I
5.7” D
Deflated
Tire
Right front
Comments
Additional comments of any deformation or difficulty during jacking:
None
62
5.6 STRUCTURAL STRENGTH AND DISTORTION
TESTS - HOISTING TEST
5.6-I. TEST OBJECTIVE
The objective of this test is to determine possible damage or deformation caused by
the jack/stands.
5.6-II. TEST DESCRIPTION
With the bus at curb weight, the front end of the bus is raised to a height sufficient to
allow manufacturer-specified placement of jack stands under the axles or jacking pads
independent of the hoist system. The bus will be checked for stability on the jack stands
and for any damage to the jacking pads or bulkheads. The procedure is repeated for the
rear end of the bus. The procedure is then repeated for the front and rear simultaneously.
5.6-III. DISCUSSION
The test was conducted using four posts of a six-post electric lift and standard 19inch jack stands. The bus was hoisted from the front wheel, rear wheel, and then the front
and rear wheels simultaneously and placed on jack stands.
The bus easily accommodated the placement of the vehicle lifts and jack stands and
the procedure was performed without any instability noted.
63
HOISTING TEST DATA FORM
Bus Number: 0217
Date: 6-24-02
Personnel: T.S., E.L. & E.D.
Temperature (ΕF): 80
Comments of any structural damage to the jacking pads or axles while both
the front wheels are supported by the jack stands:
None noted.
Comments of any structural damage to the jacking pads or axles while both
the rear wheels are supported by the jack stands:
None noted.
Comments of any structural damage to the jacking pads or axles while both
the front and rear wheels are supported by the jack stands:
None noted.
64
5.6 HOISTING TEST
TEST BUS STABLE ON JACK STANDS
65
5.7 STRUCTURAL DURABILITY TEST
5.7-I. TEST OBJECTIVE
The objective of this test is to perform an accelerated durability test that
approximates up to 25 percent of the service life of the vehicle.
5.7-II. TEST DESCRIPTION
The test vehicle is driven a total of 15,000 miles; approximately 12,500 miles on the
PSBRTF Durability Test Track and approximately 2,500 miscellaneous other miles. The
test will be conducted with the bus operated under three different loading conditions. The
first segment will consist of approximately 6,250 miles with the bus operated at GVW. The
second segment will consist of approximately 2,500 miles with the bus operated at SLW.
The remainder of the test, approximately 6,250 miles, will be conducted with the bus
loaded to CW. If GVW exceeds the axle design weights, then the load will be adjusted to
the axle design weights and the change will be recorded. All subsystems are run during
these tests in their normal operating modes. All recommended manufacturers servicing is
to be followed and noted on the vehicle maintainability log. Servicing items accelerated by
the durability tests will be compressed by 10:1; all others will be done on a 1:1 mi/mi basis.
Unscheduled breakdowns and repairs are recorded on the same log as are any unusual
occurrences as noted by the driver. Once a week the test vehicle shall be washed down
and thoroughly inspected for any signs of failure.
5.7-III. DISCUSSION
The Structural Durability Test was started on November 12, 2002 and was
conducted until May 6, 2003. The first 6,250 miles were performed at a GVW of 56,910
lbs. The number of standing passengers was reduced from 62 to 53. The ballast for 9
standing passengers was eliminated. This reduction in passenger weight was necessary
to avoid exceeding the GAWR (26,000 lbs) of the rear axle. The GVW segment was
completed on February 20, 2003. The next 2,500-mile SLW segment was performed at
48,830 lbs. and completed on March 12, 2003. The final 6,250-mile segment was
performed at a CW of 37,920 lbs and completed on May 6, 2003.
The following mileage summary presents the accumulation of miles during the
Structural Durability Test. The driving schedule is included, showing the operating duty
cycle. A detailed plan view of the Test Track Facility and Durability Test Track are
attached for reference. Also, a durability element profile detail shows all the
measurements of the different conditions. Finally, photographs illustrating some of the
failures that were encountered during the Structural Durability Test are included.
66
NABI - TEST BUS # 0217
MILEAGE DRIVEN/RECORDED FROM DRIVERS= LOGS
DATE
TOTAL
DURABILITY
TRACK
TOTAL
OTHER
MILES
TOTAL
11/11/02 T0
11/17/02
630.00
82.00
712.00
11/18/02 TO
11/24/02
624.00
155.00
779.00
11/25/02 TO
12/01/02
302.00
15.00
317.00
12/02/02 TO
12/08/02
0.00
0.00
0.00
12/09/02 TO
12/15/02
25.00
264.00
289.00
12/16/02 TO
12/22/02
514.00
123.00
637.00
12/23/02 TO
12/29/02
0.00
0.00
0.00
12/30/03 TO
01/05/03
290.00
15.00
305.00
01/06/03 TO
01/12/03
1081.00
153.00
1234.00
01/13/03 TO
01/19/03
160.00
8.00
168.00
01/20/03 TO
01/26/03
811.00
92.00
903.00
01/27/03 TO
02/02/03
0.00
0.00
0.00
02/03/03 TO
02/09/03
0.00
0.00
0.00
02/10/03 TO
02/16/03
521.00
76.00
597.00
02/17/03 TO
02/23/03
524.00
126.00
650.00
02/24/03 TO
03/02/03
1102.00
152.00
1254.00
67
DATE
03/03/03 TO
03/09/03
TOTAL
DURABILITY
TRACK
592.00
TOTAL
OTHER
MILES
TOTAL
79.00
671.00
03/10/03 TO
03/16/03
265.00
264.00
529.00
03/17/03 TO
03/23/03
266.00
116.00
382.00
03/24/03 TO
03/30/03
340.00
120.00
460.00
03/31/03 TO
04/06/03
939.00
147.00
1086.00
04/07/03 TO
04/13/03
1109.00
154.00
1263.00
04/14/03 TO
04/20/03
804.00
138.00
942.00
04/21/03 TO
04/27/03
321.00
15.00
336.00
04/28/03 TO
05/04/03
1007.00
151.00
1158.00
05/05/03 TO
05/11/03
273.00
64.00
337.00
12500.00
2509.00
15009.00
TOTAL
68
69
70
71
(Page 1 of 5)
UNSCHEDULED MAINTENANCE
NABI 0217
DATE
TEST
MILES
11-19-02
816
The articulated joint bushings are worn.
Articulated joint bushings replaced.
6.00
6.00
11-19-02
816
The right side support arm on the articulated
joint curtain is broken at the welds.
Arm welded/repaired.
1.00
1.00
11-19-02
816
The right rear turn signal lamp is burned out.
Right rear turn signal lamp replaced.
0.50
0.50
11-22-02
1,404
The right front air bag is leaking air.
Right front air bag replaced.
3.00
3.00
11-25-02
1,637
The two right side seats, aft of the articulated
joint are broken from the mounts.
Bolts and mount are broken, seats removed.
1.00
1.00
12-18-02
2,460
The bushings are separating on the
articulated joint.
Articulated joint bushings (segmented style)
replaced, with solid rubber version
4.00
4.00
12-18-02
2,460
The fourth seat from the front, right side has
fallen free from its mount.
Seat extrusion reinstalled in the wall; seat
reinstalled.
1.00
1.00
01-07-03
3,372
Two seats, left rear, across from the door
have broken loose.
Seats removed.
1.00
1.00
01-07-03
3,372
The left side, outside rear view mirror is
loose.
Mirror fasteners tightened.
0.50
0.50
SERVICE
72
ACTIVITY
DOWN
TIME
HOURS
(Page 2 of 5)
UNSCHEDULED MAINTENANCE
NABI 0217
DATE
TEST
MILES
01-14-03
4,307
The turbo charger failed.
Warranty dealer replaced turbo charger.
48.00
4.00
01-14-03
4,307
The front heater motor failed.
Front heater motor replaced.
5.00
5.00
01-24-03
5,344
There are numerous ½ ” to 1 ½” long cracks
in the frame structure at the lower radius
rods of the rear, middle and front axle
locations.
The following repairs were made by NABI
reps; Two 2½“X2½“ tube gussets (one each
side) behind the front axle. Two 1½“X2
1/8”X37½“ tubes (one each side) at the lower
radius rod forward end, mid axle. Two
1½“X2 1/8“X30“ tubes (one each side) at the
lower radius rod, forward end, mid axle. Two
1½“X1½“X 13½“ tubes (one each side)
above the radius rod mounting plate, forward
end, mid axle. Eight web gussets 1/8” thick
(four each side) at the bulkhead of the artic
joint rear half of the bus. Two 1½“X2”X30”
tubes (one each side) at the lower radius rod,
forward end, rear axle, with a 2½“X2½“ tube
gusset at the rear of the tube. The following
were installed between the lower radius rods
at the drive axle; one 7/8” X 1½“X24” tube in
front of the air dryer. One 1½”X2½“X36”
tube behind the air dryer. Eight 5”X5”X1/8”
gussets (four each side) connected to the
tubes.
5.00
5.00
01-28-03
5,344
The screws are broken on the seat wall
tracks at the left side rear and right side front
seats.
Broken screws replaced.
2.00
2.00
SERVICE
73
ACTIVITY
DOWN
TIME
HOURS
(Page 3 of 5)
UNSCHEDULED MAINTENANCE
NABI 0217
DATE
TEST
MILES
02-12-03
5,344
The linkage on the potentiometer in the artic
joint is disconnected and bent, and the
mounting bolts are broken.
Broken bolts replaced. Potentiometer arm
and bracket replaced.
1.50
1.50
02-12-03
5,344
The A/C cabinet (mounting frame) has
numerous cracks.
A/C unit removed. Added two pieces (one
each side) 40mm X 640mm to reinforce rails.
A/C unit reinstalled and charged.
17.50
17.50
02-14-03
5,848
The left rear outside tire is leaking air.
Installed two new tires on the front axle.
Installed right front tire at the left rear
outside.
1.00
1.00
02-19-03
5,995
The right front air bag is leaking air.
Right front air bag replaced.
3.00
3.00
02-19-03
5,995
The tire is flat on the right outside middle
axle.
Tire replaced.
1.00
1.00
02-20-03
6,218
The left side support mount for the A/C
condenser unit has three cracks.
Support mount replaced.
0.50
0.50
02-21-03
6,500
Refrigerant oil is leaking into the passenger
area, rear section, left corner by the artic
joint.
Leaking hose removed and ordered.
1.00
1.00
02-28-03
7,692
The front heater box is loose. The flange on
the right side is broken.
Added a 6” X 16” piece of flat aluminum to
the bottom of the box.
1.00
1.00
02-28-03
7,692
The windshield wipers are inoperative.
Tightened loose wiper switch in the dash.
0.50
0.50
SERVICE
74
ACTIVITY
DOWN
TIME
HOURS
(Page 4 of 5)
UNSCHEDULED MAINTENANCE
NABI 0217
DATE
TEST
MILES
DOWN
TIME
HOURS
03-05-03
8,427
The drive axle tires are worn.
All four tires replaced on the drive axle.
1.00
1.00
03-11-03
8,566
The right side fuel tank is leaking fuel.
Drained and removed fuel tank.
Welded/repaired cracks at the flange for the
crossover pipe and the crack in the bottom of
the tank. Left rear tank mount bracket on the
frame (cracked) welded/repaired.
1.50
1.50
03-12-03
8,566
The left front air bag has blown out.
Left front air bag replaced.
1.00
1.00
03-18-03
9,275
The A/C condenser unit-mounting frame is
cracking at the corners and mounting feet.
Manufacturer requests condenser unit be
removed and simulated weight mass be
installed for strain gauging.
3.00
3.00
03-20-03
9,427
Engine has no power, intermittent “Check
Engine” light comes on.
Connect Pro-Link, found SID 153 FM17
(VNT vanes not responding). The boost
pressure is 0-1 psi. Detroit Diesel (warranty
dealer) contacted. 3-21-03 Detroit Dealer
troubleshooting failed turbo. Turbo ordered.
3-24-03 new turbo installed by warranty
dealer.
6.00
6.00
04-01-03
10,289
The A/C unit framework is cracking.
Manufacturer requests A/C unit be removed
and simulated weight mass be installed so as
not to damage A/C unit.
1.00
1.00
04-03-03
10,634
The right side fuel tank is leaking.
New tank installed.
4.00
4.00
SERVICE
75
ACTIVITY
(Page 5 of 5)
UNSCHEDULED MAINTENANCE
NABI 0217
DATE
TEST
MILES
04-09-03
11,602
Several support mounts for plumbing and
wiring are broken in the artic joint area.
Support mounts repaired.
1.00
1.00
04-15-03
12,554
The right door panel of the front door is off
the bottom door pivot.
Door panel removed, lower knuckle
assembled threads cleaned, door reinstalled
and assembled.
1.00
1.00
04-18-03
13,099
The right front air bag is leaking air.
Right front air bag replaced.
1.50
1.50
04-18-03
13,099
The interior A/C roof grill is loose.
Worn fasteners replaced.
1.50
1.50
04-24-03
13,178
The power steering assist is inoperative.
Power steering pump replaced.
1.00
1.00
05-02-03
14,500
The bolts for the front top radius rods are
loose.
Bolts torqued.
2.00
2.00
SERVICE
76
ACTIVITY
DOWN
TIME
HOURS
UNSCHEDULED MAINTENANCE
FAILED ARTIC JOINT BUSHING
(816 TEST MILES)
LEAKING RIGHT FRONT AIR BAG
(1,404 TEST MILES)
77
UNSCHEDULED MAINTENANCE CONT.
BROKEN SEATS MOUNTS, RIGHT SIDE,
REAR OF ARTIC JOINT (1,637 TEST MILES)
LEFT SIDE REAR VIEW MIRROR
(3,372 TEST MILES)
78
UNSCHEDULED MAINTENANCE CONT.
FAILED TURBO CHARGER
(4,307 TEST MILES)
FAILED FRONT HEATER MOTOR
(4,307 TEST MILES)
79
UNSCHEDULED MAINTENANCE CONT.
NUMEROUS CRACKS IN THE FRAME STRUCTURE AT
THE LOWER RADIUS ROD AREAS
(5,344 TEST MILES)
80
UNSCHEDULED MAINTENANCE CONT.
NUMEROUS CRACKS IN THE A/C MOUNTING FRAME
(5,344 TEST MILES)
RIGHT SIDE FUEL TANKS IS LEAKING
(8,566 TEST MILES)
81
UNSCHEDULED MAINTENANCE CONT.
RIGHT SIDE FUEL TANK CRACK NEAR FLANGE
(8,566 TEST MILES)
RIGHT SIDE FUEL TANK LEAKING
(10,634 TEST MILES)
82
TEST BUS CHECK-IN
I. OBJECTIVE
The objective of this task is to log in the test bus, assign a bus number, complete the
vehicle data form, and perform a safety check.
II. TEST DESCRIPTION
The test consists of assigning a bus test number to the bus, cleaning the bus,
completing the vehicle data form, obtaining any special information and tools from the
manufacturer, determining a testing schedule, performing an initial safety check, and
performing the manufacturer's recommended preventive maintenance. The bus
manufacturer must certify that the bus meets all Federal regulations.
III. DISCUSSION
The check-in procedure is used to identify in detail the major components and
configuration of the bus.
The test bus consists of a NABI, model 60LFW K-1. The bus has a front door
equipped with an American TNT Transit Products model T 7000-SC-SS-48-handicap
ramp, located forward of the front axle, and a rear door centered between the rear axle
and the artic joint. Power is provided by a diesel-fueled, Detroit Diesel model Series 50
Bus engine coupled to a Friedrichshafen model Ecom AT2 5 HP 602C transmission.
The measured curb weight is 9,410 lbs for the front axle, 10,200 lbs for the middle
axle and 22,540 lbs for the rear axle. These combined weights provide a total measured
curb weight of 42,150 lbs. There are 62 seats including the driver and room for 52
standing passengers bringing the total passenger capacity to 114. Gross load is 150 lb x
114 = 17,100 lbs. At full capacity, the measured gross vehicle weight is 58,500 lbs.
83
VEHICLE DATA FORM
Bus Number: 0217A
Arrival Date: 5-21-03
Bus Manufacturer: NABI
Vehicle Identification
Number (VIN): 1N90600263A140231
Model Number: 60 LFW 02
Date: 5-22-03
Personnel: E.D. & E.L.
WEIGHT:
Individual Wheel Reactions:
Weights
(lb)
Front Axle
Middle Axle
Rear Axle
Right
Left
Right
Left
Right
Left
CW
4,750
4,660
4,800
5,400
11,380
11,160
SLW
5,510
5,390
6,780
7,500
12,810
13,100
GVW
6,710
6,550
8,290
9,100
13,750
14,100
Total Weight Details:
Weight (lb)
CW
SLW
GVW
GAWR
Front Axle
9,410
10,900
13,260
14,600
Middle Axle
10,200
14,280
17,390
18,000
Rear Axle
22,540
25,910
27,850
26,000
Total
42,150
51,090
58,500
Dimensions:
Length (ft/in)
60 / 10.75
Width (in)
102.0
Height (in)
126.0
Front Overhang (in)
88.5
Rear Overhang (in)
123.75
Wheel Base (in)
Front – 239.5
Wheel Track (in)
Front: 86.7
Rear: 78.4
84
Rear – 279.0
Middle – 76.2
GVWR: 58,600
Bus Number: 0217A
Date: 5-22-03
CLEARANCES:
Lowest Point Outside Front Axle
Location: Lower front radius rod
Clearance(in): 8.4
Lowest Point Outside Rear Axle
Location: Frame
Clearance(in): 8.4
Lowest Point between Axles
Location: Frame (Front)
Location: Frame (Rear)
Clearance(in): 11.7
Clearance(in): 9.8
Ground Clearance at the center (in)
Front – 11.7
Front Approach Angle (deg)
8.8
Rear Approach Angle (deg)
9.1
Ramp Clearance Angle (deg)
Front – 5.6
Aisle Width (in)
25.5
Inside Standing Height at Center
Aisle (in)
Front – 95.4
Rear – 7.8
Rear – 4.0
Rear – 80.2
BODY DETAILS:
Body Structural Type
Monocoque
Frame Material
Stainless steel
Body Material
Steel
Floor Material
Plywood
Roof Material
Fiberglass
Windows Type
Window Mfg./Model No.
Number of Doors
■ Movable
Q Fixed
Excel / AS3 M8 1/4G DOT 573
1
Front
1 Rear
Mfr. / Model No.
NABI / O.E. M.
Dimension of Each Door (in)
Front - 78.0 x 38.4
Rear – 78.0 x 46.0
■ Cantilever
■ Pedestal
Passenger Seat Type
Mfr. / Model No.
Driver Seat Type
Mfr. / Model No.
Number of Seats (including Driver)
Q Other
(explain)
American Seating / 6468
■ Air
Q Spring
Recaro Ergo Metro / #4F0 20 242
62
85
Q Other
(explain)
Bus Number: 0217A
Date: 5-22-03
BODY DETAILS (Contd..)
Free Floor Space ( ft2 )
78.7
Height of Each Step at Normal
Position (in)
Front
Step Elevation Change - Kneeling
(in)
1. 15.5
2. N/A
3. N/A
4. N/A
Middle 1. N/A
2. N/A
3. N/A
4. N/A
Rear
2. N/A
3. N/A
4. N/A
1. 15.0
3.0
ENGINE
Type
■ C.I.
Q Alternate Fuel
Q S.I.
Q Other (explain)
Mfr. / Model No.
Detroit Diesel / Series 50 Bus
Location
Q Front
■ Rear
Q Other
(explain)
Fuel Type
Q Gasoline
Q CNG
Q Methanol
■ Diesel
Q LNG
Q Other
(explain)
Fuel Tank Capacity (indicate units)
124.9 total
Fuel Induction Type
■ Injected
Q Carburetion
Fuel Injector Mfr. / Model No.
Detroit Diesel / Series 50 Bus
Carburetor Mfr. / Model No.
N/A
Fuel Pump Mfr. / Model No.
Detroit Diesel / Series 50 Bus
Alternator (Generator) Mfr. / Model
No.
C.E. Niehoff & Co. / C802
Maximum Rated Output
(Volts / Amps)
Air Compressor Mfr. / Model No.
Maximum Capacity (ft3 / min)
Starter Type
Starter Mfr. / Model No.
28 / 450
Bendix / 596
28.0
■ Electrical
Q Pneumatic
Delco-Remy / 1993788
86
Q Other
(explain)
Bus Number: 0217A
Date: 5-22-03
TRANSMISSION
Transmission Type
Mfr. / Model No.
Q Manual
■ Automatic
Friedrichshafen / Ecom AT2 5Hp 602C
■ Electrical
Control Type
Q Mechanical
Torque Converter Mfr. / Model No.
ZF / Ecom AT2 5Hp 602C
Integral Retarder Mfr. / Model No.
ZF / Ecom AT2 5Hp 602C
Q Other
SUSPENSION
Number of Axles
3
Front Axle Type
Q Independent
■ Beam Axle
Mfr. / Model No.
Meritor / FH946RX133
Axle Ratio (if driven)
N/A
Suspension Type
■ Air
No. of Shock Absorbers
Mfr. / Model No.
Middle Axle Type
Q Spring
4
Sachs / 481700124382
Q Independent
■ Beam Axle
Mfr. / Model No.
Meritor / RC26700NRRF4
Axle Ratio (if driven)
N/A
Suspension Type
■ Air
No. of Shock Absorbers
Mfr. / Model No.
Rear Axle Type
Q Spring
Sachs / 481700124382
Q Independent
Meritor / 71163RX
Axle Ratio (if driven)
5.38
Suspension Type
■ Air
Mfr. / Model No.
Q Other
(explain)
4
Mfr. / Model No.
No. of Shock Absorbers
Q Other
(explain)
■ Beam Axle
Q Spring
4
Sachs / 481700124382
87
Q Other
(explain)
Bus Number: 0217A
Date: 5-22-03
WHEELS & TIRES
Front
Middle
Rear
Wheel Mfr./ Model No.
Alcoa / 22.5 x 8.25
Tire Mfr./ Model No.
Firestone City Transport Radial / 305/70R22.5 16PP
Wheel Mfr./ Model No.
Alcoa / 22.5 x 8.25
Tire Mfr./ Model No.
Firestone City Transport Radial / 305/70R22.5 16PP
Wheel Mfr./ Model No.
Alcoa / 22.5 x 8.25
Tire Mfr./ Model No.
Firestone City Transport Radial / 305/70R22.5 16PP
BRAKES
Front Axle Brakes Type
Mfr. / Model No.
Middle Axle Brakes Type
Mfr. / Model No.
Rear Axle Brakes Type
Mfr. / Model No.
Retarder Type
Mfr. / Model No.
■ Cam
Q Disc
Q Other (explain)
Meritor Metro / R301 / R602, 16-1/2” x 6”
■ Cam
Q Disc
Q Other (explain)
Meritor Metro / SOR 610, 1601/2” x 8-5/8”
■ Cam
Q Disc
Q Other (explain)
Meritor Metro / SOR 610, 16-1/2” x 8-5/8”
Hydraulic integral transmission
ZF / Ecom AT2 5Hp 602C
HVAC
Heating System Type
■ Water
Q Air
Capacity (Btu/hr)
180,000
Mfr. / Model No.
Thermo King / R5E
Air Conditioner
■ Yes
Q No
Location
Rear
Capacity (Btu/hr)
130,000
A/C Compressor Mfr. / Model No.
Thermo King / X640
STEERING
Steering Gear Box Type
Mfr. / Model No.
Steering Wheel Diameter
Number of turns (lock to lock)
Hydraulic mechanical
RBL / 717 113 B 42 2 87
20.0
5.0
88
Q Other
Bus Number: 0217A
Date: 5-22-03
OTHERS
Wheel Chair Ramps
Location: Front
Type: ramp
Wheel Chair Lifts
Location: N/A
Type: N/A
Mfr. / Model No.
Emergency Exit
American TNT Transit Products / T 7000-SC-SS 48
Location: Windows
Doors
CAPACITIES
Fuel Tank Capacity (units)
124.9 total
Engine Crankcase Capacity (gallons)
5.50
Transmission Capacity (gallons)
5.28
Differential Capacity (gallons)
3.50
Cooling System Capacity (quarts)
25.0
Power Steering Fluid Capacity
(gallons)
8.50
89
Number: 15
2
VEHICLE DATA FORM
Bus Number: 0217A
Date: 5-22-03
List all spare parts, tools and manuals delivered with the bus.
Part Number
Description
90
Qty.
COMPONENT/SUBSYSTEM INSPECTION FORM
Bus Number: 0217A
Subsystem
Date: 5-22-03
Checked
Air Conditioning Heating
and Ventilation
Τ
Body and Sheet Metal
Τ
Frame
Τ
Steering
Τ
Suspension
Τ
Interior/Seating
Τ
Axles
Τ
Brakes
Τ
Tires/Wheels
Τ
Exhaust
Τ
Fuel System
Τ
Power Plant
Τ
Accessories
Τ
Lift System
Τ
Interior Fasteners
Τ
Batteries
Τ
Comments
91
3. SAFETY - A DOUBLE-LANE CHANGE
(OBSTACLE AVOIDANCE)
3-I. TEST OBJECTIVE
The objective of this test is to determine handling and stability of the bus by
measuring speed through a double lane change test.
3-II. TEST DESCRIPTION
The Safety Test is a vehicle handling and stability test. The bus will be operated at
SLW on a smooth and level test track. The bus will be driven through a double lane
change course at increasing speed until the test is considered unsafe or a speed of 45
mph is reached. The lane change course will be set up using pylons to mark off two 12foot center-to-center lanes with two 100-foot lane change areas 100 feet apart. The bus
will begin in one lane, change to the other lane in a 100-foot span, travel 100 feet, and
return to the original lane in another 100-foot span. This procedure will be repeated,
starting first in the right-hand and then in the left-hand lane.
3-III. DISCUSSION
The double-lane change was performed in both right-hand and left-hand directions.
The bus was able to safely negotiate the test course in both the right-hand and left-hand
directions up to the maximum test speed of 45 mph.
92
SAFETY DATA FORM
Bus Number: 0217A
Date: 6-2-03
Personnel: B.S., M.H. & S.C.
Temperature (ΕF): 52
Humidity (%): 58
Wind Direction: Calm
Wind Speed (mph): Calm
Barometric Pressure (in.Hg): 30.03
SAFETY TEST: DOUBLE LANE CHANGE
Maximum safe speed tested for double-lane change to left
45 mph
Maximum safe speed tested for double-lane change to right
45 mph
Comments of the position of the bus during the lane change: A safe profile was
maintained through all portions of testing.
Comments of the tire/ground contact patch: Tire/ground contact was maintained
through all portions of testing.
93
3. SAFETY
LEFT HAND APPROACH
RIGHT HAND APPROACH
94
4. PERFORMANCE - AN ACCELERATION, GRADEABILITY,
AND TOP SPEED TEST
4-I. TEST OBJECTIVE
The objective of this test is to determine the acceleration, gradeability, and top speed
capabilities of the bus.
4-II. TEST DESCRIPTION
In this test, the bus will be operated at SLW on the skid pad at the PSBRTF. The
bus will be accelerated at full throttle from a standstill to a maximum "geared" or "safe"
speed as determined by the test driver. The vehicle speed is measured using a Correvit
non-contacting speed sensor. The times to reach speed between the ten mile per hour
increments are measured and recorded using a stopwatch with a lap timer. The time to
speed data will be recorded on the Performance Data Form and later used to generate a
speed vs time plot and gradeability calculations.
4-III. DISCUSSION
This test consists of three runs in both the clockwise and counterclockwise directions
on the Test Track. Velocity versus time data is obtained for each run and results are
averaged together to minimize any test variability which might be introduced by wind or
other external factors. The test was performed up to a maximum speed of 50 mph. The
fitted curve of velocity vs time is attached, followed by the calculated gradeability results.
The average time to obtain 50 mph was 40.87 seconds.
95
PERFORMANCE DATA FORM
Bus Number: 0217A
Date: 6-2-03
Personnel: B.S., M.H. & S.C.
Temperature (ΕF): 52
Humidity (%): 58
Wind Direction: Calm
Wind Speed (mph): Calm
Barometric Pressure (in.Hg): 30.03
Air Conditioning compressor-OFF
Τ Checked
Ventilation fans-ON HIGH
Τ Checked
Heater pump motor-Off
Τ Checked
Defroster-OFF
Τ Checked
Exterior and interior lights-ON
Τ Checked
Windows and doors-CLOSED
Τ Checked
ACCELERATION, GRADEABILITY, TOP SPEED
Counter Clockwise Recorded Interval Times
Speed
Run 1
Run 2
Run 3
10 mph
5.06
5.55
5.39
20 mph
9.43
9.99
9.58
30 mph
14.15
14.96
14.74
40 mph
22.90
23.43
23.46
Top Test
Speed(mph) 50
42.25
43.97
42.09
Clockwise Recorded Interval Times
Speed
Run 1
Run 2
Run 3
10 mph
5.65
5.68
5.62
20 mph
9.84
9.86
9.93
30 mph
15.09
15.21
15.02
40 mph
23.84
23.80
23.58
Top Test
Speed(mph) 50
38.43
39.46
39.03
96
97
98
5.3 STRUCTURAL STRENGTH AND DISTORTION
TESTS - STATIC TOWING TEST
5.3-I. TEST OBJECTIVE
The objective of this test is to determine the characteristics of the bus towing
mechanisms under static loading conditions.
5.3-II. TEST DESCRIPTION
Utilizing a load-distributing yoke, a hydraulic cylinder is used to apply a static tension
load equal to 1.2 times the bus curb weight. The load will be applied to both the front and
rear, if applicable, towing fixtures at an angle of 20 degrees with the longitudinal axis of the
bus, first to one side then the other in the horizontal plane, and then upward and
downward in the vertical plane. Any permanent deformation or damage to the tow eyes or
adjoining structure will be recorded.
5.3-III. DISCUSSION
The load-distributing yoke was incorporated as the interface between the Static Tow
apparatus and the manufacturer supplied towing brackets. The test was performed to the
full target test weight of 50,580 lbs (1.2 x 42,150 lbs CW). No damage or deformation was
observed during all four front pulls of the test. Upon completion of the test, examination of
the manufacturer supplied towing brackets revealed deformation and cracking of both the
left and right brackets. Some deformation and cracking of the receiver was also noted.
The manufacturer does not recommend towing from the rear, therefore, the rear test was
not performed.
99
STATIC TOWING TEST DATA FORM
Bus Number: 0217A
Date: 6-6-03
Personnel: S.C., M.H., D.L., E.L. & E.D.
Temperature (ΕF): 64
Inspect right front tow eye and adjoining structure.
Comments: No damage or deformation to the test vehicle observed.
Check the torque of all bolts attaching tow eye and surrounding structure.
Comments: No damage or deformation to the test vehicle observed.
Inspect left tow eye and adjoining structure.
Comments: No damage or deformation to the test vehicle observed.
Check the torque of all bolts attaching tow eye and surrounding structure.
Comments: No damage or deformation to the test vehicle observed.
Inspect right rear tow eye and adjoining structure.
Comments: N/A
Check the torque of all bolts attaching tow eye and surrounding structure.
Comments: N/A
Inspect left rear tow eye and adjoining structure.
Comments: N/A
Check the torque of all bolts attaching tow eye and surrounding structure.
Comments: N/A
General comments of any other structure deformation or failure:
Towing brackets supplied by manufacturer were inserted into frame receiver. The
full test load of 50,580 lbs (1.2 x 42,150 lbs CW) was reached with no damage or
deformation to the test vehicle observed. Towing from the rear is not recommended.
Upon completion of the test, examination of the manufacturer supplied towing
brackets revealed deformation and cracking of both the left and right brackets.
Some deformation and cracking of the receiver was also noted. See following
pictures.
100
5.3 STATIC TOWING TEST
20º UP PULL
20º DOWN PULL
101
5.3 STATIC TOWING TEST
20º-LEFT PULL
20º RIGHT PULL
102
5.3 STATIC TOWING TEST
TOWING BRACKETS DEFORMED DURING STATIC
TOWING TEST
103
6. FUEL ECONOMY TEST - A FUEL CONSUMPTION
TEST USING AN APPROPRIATE OPERATING CYCLE
6-I. TEST OBJECTIVE
The objective of this test is to provide accurate comparable fuel consumption data on
transit buses produced by different manufacturers. This fuel economy test bears no
relation to the calculations done by the Environmental Protection Agency (EPA) to
determine levels for the Corporate Average Fuel Economy Program. EPA's calculations
are based on tests conducted under laboratory conditions intended to simulate city and
highway driving. This fuel economy test, as designated here, is a measurement of the fuel
expended by a vehicle traveling a specified test loop under specified operating conditions.
The results of this test will not represent actual mileage but will provide data that can be
used by recipients to compare buses tested by this procedure.
6-II. TEST DESCRIPTION
This test requires operation of the bus over a course based on the Transit Coach
Operating Duty Cycle (ADB Cycle) at seated load weight using a procedure based on the
Fuel Economy Measurement Test (Engineering Type) For Trucks and Buses: SAE 1376
July 82. The procedure has been modified by elimination of the control vehicle and by
modifications as described below. The inherent uncertainty and expense of utilizing a
control vehicle over the operating life of the facility is impractical.
The fuel economy test will be performed as soon as possible (weather permitting)
after the completion of the GVW portion of the structural durability test. It will be
conducted on the bus test lane at the Penn State Test Facility. Signs are erected at
carefully measured points, which delineate the test course. A test run will comprise 3 CBD
phases, 2 Arterial phases, and 1 Commuter phase. An electronic fuel measuring system
will indicate the amount of fuel consumed during each phase of the test. The test runs will
be repeated until there are at least two runs in both the clockwise and counterclockwise
directions in which the fuel consumed for each run is within ∀ 4 percent of the average
total fuel used over the 4 runs. A 20-minute idle consumption test is performed just prior to
and immediately after the driven portion of the fuel economy test. The amount of fuel
consumed while operating at normal/low idle is recorded on the Fuel Economy Data Form.
This set of four valid runs along with idle consumption data comprise a valid test.
104
The test procedure is the ADB cycle with the following four modifications:
1.
The ADB cycle is structured as a set number of miles in a fixed time in the
following order: CBD, Arterial, CBD, Arterial, CBD, Commuter. A separate idle
fuel consumption measurement is performed at the beginning and end of the
fuel economy test. This phase sequence permits the reporting of fuel
consumption for each of these phases separately, making the data more useful
to bus manufacturers and transit properties.
2.
The operating profile for testing purposes shall consist of simulated transit type
service at seated load weight. The three test phases (figure 6-1) are: a central
business district (CBD) phase of 2 miles with 7 stops per mile and a top speed of
20 mph; an arterial phase of 2 miles with 2 stops per mile and a top speed of 40
mph; and a commuter phase of 4 miles with 1 stop and a maximum speed of 40
mph. At each designated stop the bus will remain stationary for seven seconds.
During this time, the passenger doors shall be opened and closed.
3.
The individual ADB phases remain unaltered with the exception that 1 mile has
been changed to 1 lap on the Penn State Test Track. One lap is equal to 5,042
feet. This change is accommodated by adjusting the cruise distance and time.
4. The acceleration profile, for practical purposes and to achieve better
repeatability, has been changed to "full throttle acceleration to cruise
speed".
Several changes were made to the Fuel Economy Measurement Test (Engineering
Type) For Trucks and Buses: SAE 1376 July 82:
1. Sections 1.1, and 1.2 only apply to diesel, gasoline, methanol, and any other fuel
in the liquid state (excluding cryogenic fuels).
1.1
SAE 1376 July 82 requires the use of at least a 16-gal fuel tank. Such a
fuel tank when full would weigh approximately 160 lb. It is judged that a 12-gal tank
weighing approximately 120 lb will be sufficient for this test and much easier for the
technician and test personnel to handle.
105
1.2
SAE 1376 July 82 mentions the use of a mechanical scale or a flowmeter
system. This test procedure uses a load cell readout combination that provides an
accuracy of 0.5 percent in weight and permits on-board weighing of the gravimetric tanks
at the end of each phase. This modification permits the determination of a fuel economy
value for each phase as well as the overall cycle.
2. Section 2.1 applies to compressed natural gas (CNG), liquefied natural gas
(LNG), cryogenic fuels, and other fuels in the vapor state.
2.1
A laminar type flowmeter will be used to determine the fuel consumption.
The pressure and temperature across the flow element will be monitored by the flow
computer. The flow computer will use this data to calculate the gas flow rate. The flow
computer will also display the flow rate (scfm) as well as the total fuel used (scf). The total
fuel used (scf) for each phase will be recorded on the Fuel Economy Data Form.
3. Use both Sections 1 and 2 for dual fuel systems.
FUEL ECONOMY CALCULATION PROCEDURE
A. For diesel, gasoline, methanol and fuels in the liquid state.
The reported fuel economy is based on the following: measured test quantities-distance traveled (miles) and fuel consumed (pounds); standard reference values--density
of water at 60ΕF (8.3373 lbs/gal) and volumetric heating value of standard fuel; and test
fuel specific gravity (unitless) and volumetric heating value (BTU/gal). These combine to
give a fuel economy in miles per gallon (mpg), which is corrected to a standard gallon of
fuel, referenced to water at 60ΕF. This eliminates fluctuations in fuel economy due to
fluctuations in fuel quality. This calculation has been programmed into a computer and the
data processing is performed automatically.
The fuel economy correction consists of three steps:
1.)
Divide the number of miles of the phase by the number of pounds of fuel
consumed
total miles
phase
miles per phase
per run
CBD
1.9097
5.7291
ART
1.9097
3.8193
COM
3.8193
3.8193
FEomi/lb = Observed fuel economy =
106
miles
lb of fuel
2.)
Convert the observed fuel economy to miles per gallon [mpg] by multiplying by
the specific gravity of the test fuel Gs (referred to water) at 60ΕF and multiply
by the density of water at 60ΕF
FEompg = FEcmi/lb x Gs x Gw
where
3.)
Gs = Specific gravity of test fuel at 60ΕF (referred to water)
Gw = 8.3373 lb/gal
Correct to a standard gallon of fuel by dividing by the volumetric heating value
of the test fuel (H) and multiplying by the volumetric heating value of standard
reference fuel (Q). Both heating values must have the same units.
FEc = FEompg x Q
H
where
H = Volumetric heating value of test fuel [BTU/gal]
Q = Volumetric heating value of standard reference fuel
Combining steps 1-3 yields
==> FEc = miles x (Gs x Gw) x Q
lbs
H
4.)
Covert the fuel economy from mpg to an energy equivalent of miles per BTU.
Since the number would be extremely small in magnitude, the energy
equivalent will be represented as miles/BTUx106.
Eq = Energy equivalent of converting mpg to mile/BTUx106.
Eq = ((mpg)/(H))x106
B. CNG, LNG, cryogenic and other fuels in the vapor state.
107
The reported fuel economy is based on the following: measured test quantities-distance traveled (miles) and fuel consumed (scf); density of test fuel, and volumetric
heating value (BTU/lb) of test fuel at standard conditions (P=14.73 psi and T=60 ΕF).
These combine to give a fuel economy in miles per lb. The energy equivalent
(mile/BTUx106) will also be provided so that the results can be compared to buses that
use other fuels.
1.)
Divide the number of miles of the phase by the number of standard cubic
feet (scf) of fuel consumed.
total miles
phase
miles per phase
per run
CBD
1.9097
5.7291
ART
1.9097
3.8193
COM
3.8193
3.8193
FEomi/scf = Observed fuel economy =
2.)
miles
scf of fuel
Convert the observed fuel economy to miles per lb by dividing FEo by the
density of the test fuel at standard conditions (Lb/ft3).
Note: The density of test fuel must be determined at standard
conditions as described above. If the density is not defined at the
above standard conditions, then a correction will be needed before the
fuel economy can be calculated.
FEomi/lb = FEo / Gm
where Gm = Density of test fuel at standard conditions
3.)
Convert the observed fuel economy (FEomi/lb) to an energy equivalent of
(miles/BTUx106) by dividing the observed fuel economy (FEomi/lb) by the
heating value of the test fuel at standard conditions.
Eq = ((FEomi/lb)/H)x106
where
Eq = Energy equivalent of miles/lb to mile/BTUx106
H = Volumetric heating value of test fuel at standard conditions
108
6-III. DISCUSSION
This is a comparative test of fuel economy using # 1 diesel fuel with a heating value
of 20,214.0 btu/lb. The driving cycle consists of Central Business District (CBD),
Arterial (ART), and Commuter (COM) phases as described in 6-II. The fuel
consumption for each driving cycle and for idle is measured separately. The results are
corrected to a reference fuel with a volumetric heating value of 127,700.0 btu/gal.
An extensive pretest maintenance check is made including the replacement of all
lubrication fluids. The details of the pretest maintenance are given in the first three
Pretest Maintenance Forms. The fourth sheet shows the Pretest Inspection. The next
sheet shows the correction calculation for the test fuel. The next four Fuel Economy
Forms provide the data from the four test runs. Finally, the summary sheet provides the
average fuel consumption. The overall average is based on total fuel and total mileage
for each phase. The overall average fuel consumption values were; CBD – 2.54 mpg,
ART – 3.03 mpg, and COM – 5.38 mpg. Average fuel consumption at idle was 5.40
lb/hr (0.86 gph).
109
FUEL ECONOMY PRE-TEST MAINTENANCE FORM
Bus Number: 0217A
Date: 5-27-03
SLW (lbs): 51,090
Personnel: E.D., E.L. & S.C.
FUEL SYSTEM
OK
Date
Initials
Install fuel measurement system
Τ
5-27-03
E.D.
Replace fuel filter
Τ
5-27-03
E.D.
Check for fuel leaks
Τ
5-27-03
E.D.
Specify fuel type (refer to fuel analysis)
#1 diesel
Remarks: None
BRAKES/TIRES
OK
Date
Initials
Inspect hoses
Τ
5-27-03
E.L.
Inspect brakes
Τ
5-27-03
E.L.
Relube wheel bearings
Τ
5-27-03
E.L.
Check tire inflation pressures (mfg. specs.)
Τ
5-27-03
E.L.
OK
Date
Initials
Check hoses and connections
Τ
5-27-03
S.C.
Check system for coolant leaks
Τ
5-27-03
S.C.
Remarks: None
COOLING SYSTEM
Remarks: None
110
FUEL ECONOMY PRE-TEST MAINTENANCE FORM (page 2)
Bus Number: 0217A
Date: 5-27-03
Personnel: E.D. & E.L.
ELECTRICAL SYSTEMS
OK
Date
Initials
Check battery
Τ
5-27-03
E.D.
Inspect wiring
Τ
5-27-03
E.D.
Inspect terminals
Τ
5-27-03
E.D.
Check lighting
Τ
5-27-03
E.D.
OK
Date
Initials
Drain transmission fluid
Τ
5-27-03
E.L.
Replace filter/gasket
Τ
5-27-03
E.L.
Check hoses and connections
Τ
5-27-03
E.L.
Replace transmission fluid
Τ
5-27-03
E.L.
Check for fluid leaks
Τ
5-27-03
E.L.
OK
Date
Initials
Drain crankcase oil
Τ
5-27-03
E.L.
Replace filters
Τ
5-27-03
E.L.
Replace crankcase oil
Τ
5-27-03
E.L.
Check for oil leaks
Τ
5-27-03
E.L.
Check oil level
Τ
5-27-03
E.L.
Lube all chassis grease fittings
Τ
5-27-03
E.L.
Lube universal joints
Τ
5-27-03
E.L.
Replace differential lube including axles
Τ
5-27-03
E.L.
Remarks: None
DRIVE SYSTEM
Remarks: None
LUBRICATION
Remarks: None
111
112
FUEL ECONOMY PRE-TEST MAINTENANCE FORM (page 3)
Bus Number: 0217A
Date: 5-27-03
Personnel: E.D. & E.L.
EXHAUST/EMISSION SYSTEM
OK
Date
Initials
Τ
5-27-03
E.D.
OK
Date
Initials
Replace air filter
Τ
5-27-03
E.L.
Inspect air compressor and air system
Τ
5-27-03
E.L.
Inspect vacuum system, if applicable
Τ
5-27-03
E.L.
Check and adjust all drive belts
Τ
5-27-03
E.L.
Check cold start assist, if applicable
Τ
5-27-03
E.L.
OK
Date
Initials
Check power steering hoses and connectors
Τ
5-27-03
E.L.
Service fluid level
Τ
5-27-03
E.L.
Check power steering operation
Τ
5-27-03
E.L.
OK
Date
Initials
Τ
5-27-03
S.C.
OK
Date
Initials
Check brake operation
Τ
5-27-03
E.D.
Check transmission operation
Τ
5-27-03
E.D.
Check for exhaust leaks
Remarks: None
ENGINE
Remarks: None
STEERING SYSTEM
Remarks: None
Ballast bus to seated load weight
TEST DRIVE
Remarks: None
113
114
FUEL ECONOMY PRE-TEST INSPECTION FORM
Bus Number: 0217A
Date: 5-30-03
Personnel: E.D. & D.W.
PRE WARM-UP
If OK, Initial
Fuel Economy Pre-Test Maintenance Form is complete
E.D.
Cold tire pressure (psi): Front 120 Middle 120 Rear 120
E.D.
Tire wear:
E.D.
Engine oil level
E.D.
Engine coolant level
E.D.
Interior and exterior lights on, evaporator fan on
E.D.
Fuel economy instrumentation installed and working properly.
E.D.
Fuel line -- no leaks or kinks
E.D.
Speed measuring system installed on bus. Speed indicator
installed in front of bus and accessible to TECH and Driver.
E.D.
Bus is loaded to SLW
E.D.
WARM-UP
If OK, Initial
Bus driven for at least one hour warm-up
E.D.
No extensive or black smoke from exhaust
E.D.
POST WARM-UP
If OK, Initial
Warm tire pressure (psi): Front 122 Middle 124 Rear 125
E.D.
Environmental conditions
Average wind speed <12 mph and maximum gusts <15 mph
Ambient temperature between 30Ε(-1Ε) and 90ΕF(32ΕC)
Track surface is dry
Track is free of extraneous material and clear of
interfering traffic
E.D.
115
FUEL ECONOMY DATA FORM (Liquid Fuels)
Bus Number: 0217A
Manufacturer: NABI
Run Number: 1
Personnel: E.D., T.S. & B.S.
Test Direction: 9CW or ■CCW
Temperature (ΕF): 70
Humidity (%): 76
SLW (lbs): 51,090
Wind Speed (mph) & Direction: Calm
Barometric Pressure (in.
Time (min:sec)
Cycle Time
(min:sec)
Cycle
Type
Start
Finish
CBD #1
0
9:17
ART #1
0
CBD #2
Date: 5-29-03
Fuel
Temperature
(ΕC)
Load Cell Reading (lb)
Start
Start
Finish
9:17
25.2
113.60
108.90
4:18
4:18
26.7
108.90
104.95
0
9:27
9:27
28.6
104.95
100.20
ART #2
0
4:17
4:17
32.7
100.20
96.20
CBD #3
0
9:25
9:25
34.1
96.20
91.50
COMMUTER
0
6:11
6:11
35.5
91.50
87.20
Total F
20 minute idle : Total Fuel Used = 1.80 lbs
Heating Value = 20,214.0 BTU/LB
Comments: None
116
FUEL ECONOMY DATA FORM (Liquid Fuels)
Bus Number: 0217A
Manufacturer: NABI
Run Number: 2
Personnel: E.D., T.B. & B.S.
Test Direction: ■CW or 9CCW
Temperature (ΕF): 70
Humidity (%): 76
SLW (lbs): 51,090
Wind Speed (mph) & Direction: Calm
Barometric Pressure (in.
Time (min:sec)
Cycle Time
(min:sec)
Cycle
Type
Start
Finish
CBD #1
0
9:22
ART #1
0
CBD #2
Date: 5-29-03
Fuel
Temperature
(ΕC)
Load Cell Reading (lb)
Start
Start
Finish
9:22
35.9
87.20
82.55
4:25
4:25
37.3
82.55
78.65
0
9:27
9:27
38.0
78.65
74.15
ART #2
0
4:30
4:30
38.9
74.15
70.40
CBD #3
0
9:15
9:15
39.4
70.40
65.65
COMMUTER
0
6:04
6:04
41.0
65.65
61.15
Total F
20 minute idle : Total Fuel Used = N/A lbs
Heating Value = 20,214.0 BTU/LB
Comments: None
117
FUEL ECONOMY DATA FORM (Liquid Fuels)
Bus Number: 0217A
Manufacturer: NABI
Run Number: 3
Personnel: E.D., T.S. & D.W.
Test Direction: 9CW or ■CCW
Temperature (ΕF): 57
Humidity (%): 77
SLW (lbs): 51,090
Wind Speed (mph) & Direction: 3/WSW
Barometric Pressure (in.
Time (min:sec)
Cycle Time
(min:sec)
Cycle
Type
Start
Finish
CBD #1
0
9:06
ART #1
0
CBD #2
Date: 5-30-03
Fuel
Temperature
(ΕC)
Load Cell Reading (lb)
Start
Start
Finish
9:06
26.9
114.0
109.25
4:17
4:17
24.5
109.25
105.15
0
9:38
9:38
22.6
105.15
100.30
ART #2
0
4:21
4:21
21.7
100.30
96.15
CBD #3
0
9:36
9:36
21.1
93.15
91.45
COMMUTER
0
6:02
6:02
20.9
91.45
86.95
Total F
20 minute idle : Total Fuel Used = N/A lbs
Heating Value = 20,214.0 BTU/LB
Comments: None
118
FUEL ECONOMY DATA FORM (Liquid Fuels)
Bus Number: 0217A
Manufacturer: NABI
Run Number: 4
Personnel: E.D., T.S. & D.W.
Test Direction: ■CW or 9CCW
Temperature (ΕF): 6;0
Humidity (%): 77
SLW (lbs): 51,090
Wind Speed (mph) & Direction: 3/WSW
Barometric Pressure (in.
Time (min:sec)
Cycle Time
(min:sec)
Cycle
Type
Start
Finish
CBD #1
0
9:41
ART #1
0
CBD #2
Date: 5-30-03
Fuel
Temperature
(ΕC)
Load Cell Reading (lb)
Start
Start
Finish
9:41
28.6
87.00
82.35
4:24
4:24
29.8
82.35
78.45
0
9:24
9:24
32.0
78.45
73.70
ART #2
0
4:22
4:22
32.8
73.70
69.80
CBD #3
0
9:22
9:22
33.7
69.80
64.95
COMMUTER
0
6:04
6:04
35.8
64.95
60.45
Total F
20 minute idle : Total Fuel Used = 1.80 lbs
Heating Value = 20,214.0 BTU/LB
Comments: None
119
120
7.1 INTERIOR NOISE AND VIBRATION TESTS
7.1-I. TEST OBJECTIVE
The objective of these tests is to measure and record interior noise levels and check for
audible vibration under various operating conditions.
7.1-II. TEST DESCRIPTION
During this series of tests, the interior noise level will be measured at several locations
with the bus operating under the following three conditions:
1.
With the bus stationary, a white noise generating system shall provide a uniform sound
pressure level equal to 80 dB(A) on the left, exterior side of the bus. The engine and
all accessories will be switched off and all openings including doors and windows will
be closed. This test will be performed at the ABTC.
2.
The bus accelerating at full throttle from a standing start to 35 mph on a level
pavement. All openings will be closed and all accessories will be operating during the
test. This test will be performed on the track at the Test Track Facility.
3.
The bus will be operated at various speeds from 0 to 55 mph with and without the air
conditioning and accessories on. Any audible vibration or rattles will be noted. This
test will be performed on the test segment between the Test Track and the Bus Testing
Center.
All tests will be performed in an area free from extraneous sound-making sources or
reflecting surfaces. The ambient sound level as well as the surrounding weather conditions
will be recorded in the test data.
7.1-III. DISCUSSION
This test is performed in three parts. The first part exposes the exterior of the vehicle to
80.0 dB(A) on the left side of the bus and the noise transmitted to the interior is measured.
The overall average of the six measurements was 55.8 dB(A); ranging from 52.3 dB(A) at
the driver=s seat to 60.0 dB(A) in line with the middle speaker. The interior ambient noise
level for this test was 38.6 dB(A).
The second test measures interior noise during acceleration from 0 to 35 mph. This
noise level ranged from 70.3 dB(A) at the driver=s seat to 75.7 dB(A) at the rear passenger
seats. The overall average was 72.4 dB(A). The interior ambient noise level for this test
was 34.0 dB(A).
121
The third part of the test is to listen for resonant vibrations, rattles, and other noise
sources while operating over the road. No vibrations or rattles were noted.
122
INTERIOR NOISE TEST DATA FORM
Test Condition 1: 80 dB(A) Stationary White Noise
Bus Number: 0217A
Date: 6-4-03
Personnel: M.H. & S.C.
Temperature (ΕF): 56
Humidity (%): 95
Wind Speed (mph): Calm
Wind Direction: Calm
Barometric Pressure (in.Hg): 30.00
Initial Sound Level Meter Calibration: : checked by: S.C.
Interior Ambient
Noise Level dB(A): 38.6
Exterior Ambient
Noise Level dB(A): 51.8
Microphone Height During Testing (in): 48.0
Measurement Location
Measured Sound Level dB(A)
Driver's Seat
52.3
Front Passenger Seats
54.3
In Line with Front Speaker
57.9
In Line with Middle Speaker
60.0
In Line with Rear Speaker
55.8
Rear Passenger Seats
54.6
Final Sound Level Meter Calibration: : checked by: S.C.
Comments: All readings taken in the center aisle.
123
INTERIOR NOISE TEST DATA FORM
Test Condition 2: 0 to 35 mph Acceleration Test
Bus Number: 0217A
Date: 6-2-03
Personnel: B.S., M.H. & S.C.
Temperature (ΕF): 61
Humidity (%): 44
Wind Speed (mph): 7
Wind Direction: W
Barometric Pressure (in.Hg): 30.03
Initial Sound Level Meter Calibration: : checked by: S.C.
Interior Ambient
Noise Level dB(A): 34.0
Exterior Ambient
Noise Level dB(A): 41.4
Microphone Height During Testing (in): 48.0
Measurement Location
Measured Sound Level dB(A)
Driver's Seat
70.3
Front Passenger Seats
70.4
Middle Passenger Seats
73.0
Rear Passenger Seats
75.7
Final Sound Level Meter Calibration: : checked by: S.C.
Comments: All readings taken in the center aisle.
124
INTERIOR NOISE TEST DATA FORM
Test Condition 3: Audible Vibration Test
Bus Number: 0217A
Date: 6-2-03
Personnel: B.S., M.H. & S.C.
Temperature (ΕF): 61
Humidity (%): 44
Wind Speed (mph): 7
Wind Direction: W
Barometric Pressure (in.Hg): 30.03
Describe the following possible sources of noise and give the relative location on the bus.
Source of Noise
Location
Engine and Accessories
None noted.
Windows and Doors
None noted.
Seats and Wheel Chair lifts
None noted.
Comment on any other vibration or noise source which may have occurred
that is not described above:
None noted.
125
7.1 INTERIOR NOISE TEST
TEST BUS SET UP FOR CONDITION #1 (80 dB(A) )
INTERIOR NOISE TEST
126
7.2 EXTERIOR NOISE TESTS
7.2-I. TEST OBJECTIVE
The objective of this test is to record exterior noise levels when a bus is operated
under various conditions.
7.2-II. TEST DESCRIPTION
In the exterior noise tests, the bus will be operated at a SLW in three different
conditions using a smooth, straight and level roadway:
1.
2.
3.
Accelerating at full throttle from a constant speed at or below 35 mph and just
prior to transmission upshift.
Accelerating at full throttle from standstill.
Stationary, with the engine at low idle, high idle, and wide open throttle.
In addition, the buses will be tested with and without the air conditioning and all
accessories operating. The exterior noise levels will be recorded.
The test site is at the PSBRTF and the test procedures will be in accordance with SAE
Standards SAE J366b, Exterior Sound Level for Heavy Trucks and Buses. The test site is
an open space free of large reflecting surfaces. A noise meter placed at a specified location
outside the bus will measure the noise level.
During the test, special attention should be paid to:
1.
2.
3.
The test site characteristics regarding parked vehicles, signboards, buildings, or
other sound-reflecting surfaces
Proper usage of all test equipment including set-up and calibration
The ambient sound level
7.2-III. DISCUSSION
The Exterior Noise Test determines the noise level generated by the vehicle under
different driving conditions and at stationary low and high idle, with and without air
conditioning and accessories operating. The test site is a large, level, bituminous paved
area with no reflecting surfaces nearby.
With an outside ambient noise level of 44.2 dB(A), the average test result obtained while
accelerating from a constant speed was 75.0 dB(A) on the right side and 74.7 dB(A) on the
left side.
127
When accelerating from a standstill with an exterior ambient noise level of 44.8 dB(A),
the average of the results obtained were 75.0 dB(A) on the right side and 74.5 dB(A) on the
left side.
With the vehicle stationary and the engine, accessories, and air conditioning on, the
measurements averaged 65.5 dB(A) at low idle, 68.4 dB(A) at high idle, and 74.6 dB(A) at
wide open throttle. With the accessories and air conditioning off, the readings averaged 0.2
dB(A) higher at low idle, 0.9 dB(A) higher at high idle, and 0.3 dB(A) lower at wide open
throttle. The exterior ambient noise level measured during this test was 42.7 dB(A).
128
EXTERIOR NOISE TEST DATA FORM
Accelerating from Constant Speed
Bus Number: 0217A
Date: 6-2-03
Personnel: B.S., M.H. & S.C.
Temperature (ΕF): 61
Humidity (%): 44
Wind Speed (mph): 7
Wind Direction: W
Barometric Pressure (in.Hg): 30.03
Verify that microphone height is 4 feet, wind speed is less than 12 mph and ambient
temperature is between 30ΕF and 90ΕF: : checked by: S.C.
Initial Sound Level Meter Calibration: : checked by: S.C.
Exterior Ambient Noise Level dB(A): 44.2
Accelerating from Constant Speed
Curb (Right) Side
Accelerating from Constant Speed
Street (Left) Side
Run #
Measured Noise
Level dB(A)
Run #
Measured Noise Level
dB(A)
1
73.7
1
74.0
2
74.8
2
73.7
3
74.9
3
74.6
4
75.0
4
74.8
5
74.9
5
74.3
Average of two highest actual
noise levels = 75.0 dB(A)
Average of two highest actual
noise levels = 74.7 dB(A)
Final Sound Level Meter Calibration Check: : checked by: S.C.
Comments: None
129
EXTERIOR NOISE TEST DATA FORM
Accelerating from Standstill
Bus Number: 0217A
Date: 6-2-03
Personnel: B.S., M.H. & S.C.
Temperature (ΕF): 61
Humidity (%): 44
Wind Speed (mph): 7
Wind Direction: W
Barometric Pressure (in.Hg): 30.03
Verify that microphone height is 4 feet, wind speed is less than 12 mph and ambient
temperature is between 30ΕF and 90ΕF: : checked by: S.C.
Initial Sound Level Meter Calibration: : checked by: S.C.
Exterior Ambient Noise Level dB(A): 44.8
Accelerating from Standstill
Curb (Right) Side
Accelerating from Standstill
Street (Left) Side
Run #
Measured Noise
Level dB(A)
Run #
Measured
Noise Level
dB(A)
1
74.8
1
74.3
2
75.2
2
74.2
3
74.8
3
74.5
4
74.6
4
74.2
5
74.8
5
74.4
Average of two highest actual noise
levels = 75.0 dB(A)
Average of two highest actual noise
levels = 74.5 dB(A)
Final Sound Level Meter Calibration Check: : checked by: S.C.
Comments: None
130
EXTERIOR NOISE TEST DATA FORM
Stationary
Bus Number: 0217A
Date: 6-2-03
Personnel: B.S., M.H. & S.C.
Temperature (ΕF): 61
Humidity (%): 44
Wind Speed (mph): 7
Wind Direction: W
Barometric Pressure (in.Hg): 30.03
Verify that microphone height is 4 feet, wind speed is less than 12 mph and ambient
temperature is between 30ΕF and 90ΕF: : checked by: S.C.
Initial Sound Level Meter Calibration: : checked by: S.C.
Exterior Ambient Noise Level dB(A): 42.7
Accessories and Air Conditioning ON
Throttle Position
Engine RPM
Curb (Right) Side
dB(A)
Street (Left) Side
db(A)
Measured
Measured
Low Idle
750
65.4
65.5
High Idle
998
67.8
69.0
2,225
74.8
74.3
Wide Open Throttle
Accessories and Air Conditioning OFF
Throttle Position
Engine RPM
Curb (Right) Side
dB(A)
Street (Left) Side
db(A)
Measured
Measured
Low Idle
786
65.2
66.1
High Idle
1,003
70.0
68.5
Wide Open Throttle
2,226
74.8
73.7
Final Sound Level Meter Calibration Check: : checked by: S.C.
Comments: None
131
7.2 EXTERIOR NOISE TEST
TEST BUS UNDERGOING EXTERIOR NOISE TESTING
132