STURAA TEST
12 YEAR
500,000 MILE BUS
from
NEW FLYER of AMERICA
MODEL XDE 40
APRIL 2010
PTI-BT-R0913
The Thomas D. Larson
Pennsylvania Transportation Institute
201 Transportation Research Building (814) 865-1891
The Pennsylvania State University
University Park, PA 16802
Bus Testing and Research Center
2237 Old Route 220 N. (814) 695-3404
Duncansville, PA 16635
TABLE OF CONTENTS
Page
EXECUTIVE SUMMARY .......................................................................................................................... 3
ABBREVIATIONS .................................................................................................................................... 5
BUS CHECK-IN ....................................................................................................................................... 6
1. MAINTAINABILITY
1.1
ACCESSIBILITY OF COMPONENTS AND SUBSYSTEMS ....................................... 21
1.2
SERVICING, PREVENTATIVE MAINTENANCE, AND REPAIR AND
MAINTENANCE DURING TESTING ........................................................................... 24
1.3
REPLACEMENT AND/OR REPAIR OF SELECTED SUBSYSTEMS ......................... 29
2. RELIABILITY - DOCUMENTATION OF BREAKDOWN AND REPAIR
TIMES DURING TESTING ................................................................................................................ 33
3. SAFETY - A DOUBLE-LANE CHANGE (OBSTACLE AVOIDANCE TEST) .................................... 37
4. PERFORMANCE - AN ACCELERATION, GRADEABILITY, AND TOP
SPEED TEST ..................................................................................................................................... 40
5. STRUCTURAL INTEGRITY
5.1
STRUCTURAL STRENGTH AND DISTORTION TESTS - STRUCTURAL
SHAKEDOWN TEST ................................................................................................... 44
5.2
STRUCTURAL STRENGTH AND DISTORTION TESTS - STRUCTURAL
DISTORTION ............................................................................................................... 48
5.3
STRUCTURAL STRENGTH AND DISTORTION TESTS - STATIC
TOWING TEST ............................................................................................................ 60
5.4
STRUCTURAL STRENGTH AND DISTORTION TESTS - DYNAMIC
TOWING TEST ............................................................................................................ 64
5.5
STRUCTURAL STRENGTH AND DISTORTION TESTS
- JACKING TEST ......................................................................................................... 67
5.6
STRUCTURAL STRENGTH AND DISTORTION TESTS
- HOISTING TEST ........................................................................................................ 69
5.7
STRUCTURAL DURABILITY TEST ............................................................................ 71
6. FUEL ECONOMY TEST - A FUEL CONSUMPTION TEST USING AN
APPROPRIATE OPERATING CYCLE ............................................................................................ 88
7. NOISE
7.1
INTERIOR NOISE AND VIBRATION TESTS ......................................................... 103
7.2
EXTERIOR NOISE TESTS ...................................................................................... 109
3
EXECUTIVE SUMMARY
New Flyer of America submitted a Hybrid diesel/electric model XDE 40, diesel-
powered 42 seat (including the driver) 41-foot bus, for a 12 yr/500,000 mile STURAA
test. The odometer reading at the time of delivery was 1,938 miles. Testing started on
July 27, 2009 and was completed on April 6, 2010. The Check-In section of the report
provides a description of the bus and specifies its major components.
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 was started on August 24, 2009 and was completed on March 26, 2010.
The interior of the bus is configured with seating for 42 passengers including the
driver. Free floor space will accommodate 41 standing passengers resulting in a
potential load of 83 persons. At 150 lbs per person, this load results in a measured
gross vehicle weight of 40,720 lbs. The first segment of the Structural Durability Test
was performed with the bus loaded to a GVW of 40,720 lbs. The middle segment was
performed at a seated load weight of 34,760 lbs and the final segment was performed at
a curb weight of 28,580 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 are provided in the
Maintainability section of this report.
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.
The Reliability section compiles failures that occurred during Structural Durability
Testing. 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 also listed by class as defined in Section 2. The test bus encountered no
Class 1 or Class 2 failures. Of the twenty-three reported failures, 13 were Class 3 and
10 were Class 4.
The Safety Test, (a double-lane change, obstacle avoidance test) was safely
performed in both right-hand and left-hand directions up to a maximum test speed of 45
mph. The performance of the bus 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 37.96 seconds.
The Shakedown Test produced a maximum final loaded deflection of 0.344
inches with a permanent set ranging between -0.005 to 0.006 inches under a distributed
static load of 31,125 lbs. The Distortion Test was completed with all subsystems, doors
and escape mechanisms operating properly. Water leakage was observed during the
test at the side driver’s window, the left side of the windshield, and the window above
the left rear wheel well. All subsystems operated properly.
4
The Static Towing Test was performed using a target load (towing force) of
34,296 lbs. All four front pulls were completed to the full test load with no damage or
deformation observed. The Dynamic Towing Test was performed 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 rear, therefore, a rear test
was not performed. The Jacking and Hoisting Tests were also performed without
incident. The bus was found to be stable on the jack stands, and the minimum jacking
clearance observed with a tire deflated was 3.7 inches.
A Fuel Economy Test was run on simulated central business district, arterial, and
commuter courses. The results were 4.75 mpg, 4.81 mpg, and 7.57 mpg respectively;
with an overall average of 5.34 mpg.
A series of Interior and Exterior Noise Tests was performed. 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 New Flyer of America, Hybrid diesel/electric model XDE
40. The bus has a front door equipped with a New Flyer model 7:1 Slope hinged
handicap ramp forward of the front axle and a rear door forward of the rear axle. Power
is provided by a diesel-fueled, Cummins model ISL 280 engine coupled to an Allison
Transmission model EV40 transmission.
The measured curb weight is 8,860 lbs for the front axle and 19,720 lbs for the
rear axle. These combined weights provide a total measured curb weight of 28,580 lbs.
There are 42 seats including the driver and room for 41 standing passengers bringing
the total passenger capacity to 83. Gross load is 150 lb x 83 = 12,450 lbs. At full
capacity, the measured gross vehicle weight is 40,720 lbs.
7
VEHICLE DATA FORM
Bus Number: 0913
Arrival Date: 7-27-09
Bus Manufacturer: New Flyer of America
Vehicle Identification
Number (VIN): 2FYH8FV148D034335
Model Number: XDE 40
Date: 7-27-09
Personnel: T.S. & S.C.
WEIGHT:
Individual Wheel Reactions:
Weights
(lb)
Front Axle
Middle Axle
Rear Axle
Right
Left
Right
Left
Right
Left
CW
4,450
4,410
N/A
N/A
9,480
10,240
SLW
5,390
5,330
N/A
N/A
11,250
12,790
GVW
7,190
7,030
N/A
N/A
12,380
14,120
Total Weight Details:
Weight (lb)
CW
SLW
GVW
GAWR
Front Axle
8,860
10,720
14,220
14,780
Middle Axle
N/A
N/A
N/A
N/A
Rear Axle
19,720
24,040
26,500
27,760
Total
28,580
34,760
40,720
GVWR: 42,540
Dimensions:
Length (ft/in)
40 / 11.0
Width (in)
102.5
Height (in)
129.0
Front Overhang (in)
87.0
Rear Overhang (in)
120.0
Wheel Base (in)
284.0
Wheel Track (in)
Front: 85.7
Rear: 75.2
8
Bus Number: 0913
Date: 7-27-09
CLEARANCES:
Lowest Point Outside Front Axle
Location: Frame Clearance(in): 10.5
Lowest Point Outside Rear Axle
Location: Body Clearance(in): 10.7
Lowest Point between Axles
Location: Frame Clearance(in): 11.2
Ground Clearance at the center (in)
11.2
Front Approach Angle (deg)
8.4
Rear Approach Angle (deg)
7.8
Ramp Clearance Angle (deg)
4.5
Aisle Width (in)
23.4
Inside Standing Height at Center
Aisle (in)
Front: 95.5 Rear: 79.2
BODY DETAILS:
Body Structural Type
Monocoque
Frame Material
Steel
Body Material
Fiberglass
Floor Material
Plywood
Roof Material
Fiberglass
Windows Type
غ
Fixed
ع
Movable
Window Mfg./Model No.
Guardian / As-3 M55T3 DOT 22
Number of Doors
1 Front
1 Rear
Mfr. / Model No.
Vapor Bus International / Slide Glide
Dimension of Each Door (in)
Front: 36.6 x 77.7
Rear: 45.7 x 77.4
Passenger Seat Type
غ
Cantilever
ع
Pedestal
غ
Other
(explain)
Mfr. / Model No.
Ster / Prototype
Driver Seat Type
ع
Air
غ
Spring
غ
Other
(explain)
Mfr. / Model No.
USSC / Q90
Number of Seats (including Driver)
42
9
Bus Number: 0913
Date: 7-27-09
BODY DETAILS (Contd..)
Free Floor Space ( ft
2
)
66.5
Height of Each Step at Normal
Position (in)
Front 1. 13.6 2. N/A 3. N/A 4. N/A_
Middle 1. N/A 2. N/A 3. N/A 4. N/A_
Rear 1. 14.0 2. N/A 3. N/A 4. N/A_
Step Elevation Change - Kneeling
(in)
5.1
ENGINE
Type
ع
C.I.
غ
Alternate Fuel
غ
S.I.
غ
Other (explain)
Mfr. / Model No.
Cummins Motor / ISL 280
Location
غ
Front
ع
Rear
غ
Other
(explain)
Fuel Type
غ
Gasoline
غ
CNG
غ
Methanol
ع
Diesel
غ
LNG
غ
Other
(explain)
Fuel Tank Capacity (indicate units)
90 Gals
Fuel Induction Type
ع
Injected
غ
Carburetion
Fuel Injector Mfr. / Model No.
Cummins Motor / ISL 280
Carburetor Mfr. / Model No.
N/A
Fuel Pump Mfr. / Model No.
Cummins Motor / ISL 280
Alternator (Generator) Mfr. / Model
No.
EMP / P450
Maximum Rated Output
(Volts / Amps)
28 / 450
Air Compressor Mfr. / Model No.
WABCO / CP9575 (Single)
Maximum Capacity (ft
3
/ min)
18.7
Starter Type
ع
Electrical
غ
Pneumatic
غ
Other
(explain)
Starter Mfr. / Model No.
Allison Transmission / EV40
10
TRANSMISSION
Transmission Type
غ
Manual
ع
Automatic (Hybrid drive)
Mfr. / Model No.
Allison Transmission / EV40
Control Type
غ
Mechanical
ع
Electrical
غ
Other
Torque Converter Mfr. / Model No.
N/A
Integral Retarder Mfr. / Model No.
Allison Transmission / EV40
SUSPENSION
Number of Axles
2
Front Axle Type
غ
Independent
ع
Beam Axle
Mfr. / Model No.
MAN / VOK-07-F
Axle Ratio (if driven)
N/A
Suspension Type
ع
Air
غ
Spring
غ
Other
(explain)
No. of Shock Absorbers
2
Mfr. / Model No.
Koni / 4205 90 2517
Middle Axle Type
غ
Independent
غ
Beam Axle
Mfr. / Model No.
N/A
Axle Ratio (if driven)
N/A
Suspension Type
غ
Air
غ
Spring
غ
Other
(explain)
No. of Shock Absorbers
N/A
Mfr. / Model No.
N/A
Rear Axle Type
ع
Independent
غ
Beam Axle
Mfr. / Model No.
MAN / HY-1336B
Axle Ratio (if driven)
4.625 : 1
Suspension Type
ع
Air
غ
Spring
غ
Other
(explain)
No. of Shock Absorbers
4
Mfr. / Model No.
Koni / 2708 90 2518
Bus Number: 0913
Date: 7-27-09
11
Bus Number: 0913
Date: 7-27-09
WHEELS & TIRES
Front
Wheel Mfr./ Model No.
Alcoa / 22.5 x 8.25
Tire Mfr./ Model No.
Michelin XZU / 305/70R 22.5
Rear
Wheel Mfr./ Model No.
Alcoa / 22.5 x 8.25
Tire Mfr./ Model No.
Michelin XZU / 305/70R 22.5
BRAKES
Front Axle Brakes Type
غ
Cam
ع
Disc
غ
Other (explain)
Mfr. / Model No.
Knorr / SN7
Middle Axle Brakes Type
غ
Cam
غ
Disc
غ
Other (explain)
Mfr. / Model No.
N/A
Rear Axle Brakes Type
غ
Cam
ع
Disc
غ
Other (explain)
Mfr. / Model No.
Knorr / SN7
Retarder Type
Integrated Hybrid Drive
Mfr. / Model No.
Allison Transmission / EV40
HVAC
Heating System Type
غ
Air
ع
Water
غ
Other
Capacity (Btu/hr)
103,000 & 80,000
Mfr. / Model No.
Thermo King / MCC / Spheros / RLF1-M1 /
12-70206-SS FLR HTR & 12-70208-CS FLR HTR
Air Conditioner
ع
Yes
غ
No
Location
Exterior roof
Capacity (Btu/hr)
105,000
A/C Compressor Mfr. / Model No.
Thermo King Corp. / S39115
STEERING
Steering Gear Box Type
Hydraulic gear
Mfr. / Model No.
Shepherd / M110PMB31
Steering Wheel Diameter
22.0
Number of turns (lock to lock)
5.13
12
Bus Number: 0913
Date: 7-27-09
OTHERS
Wheel Chair Ramps
Location: Front door
Type: Hinged ramp
Wheel Chair Lifts
Location: N/A
Type: N/A
Mfr. / Model No.
New Flyer / 7:1 Slope
Emergency Exit
Location: Windows
Doors
Roof hatch
Number: 5
2
2
CAPACITIES
Fuel Tank Capacity (units)
90 gals
Engine Crankcase Capacity (gallons)
6.0
Transmission Capacity (gallons)
7.0
Differential Capacity (gallons)
3.96
Cooling System Capacity (gallons)
23.4
Power Steering Fluid Capacity
(gallons)
7.0
13
VEHICLE DATA FORM
Bus Number: 0913
Date: 7-27-09
List all spare parts, tools and manuals delivered with the bus.
Part Number
Description
Qty.
358649
Assy-engine strut LH ISL
1
358646
Assy-engine RH ISL
1
312485
Spring-air / bumper
4
203398
Shock absorber Frt Koni
2
240061
Bolt hex M18 x 2.0 x 115
24
344499
Rod radius lower Frt
4
354724
Washer M14
32
240064
Bolt hex M14 x 1.5 x 66
16
203269
Rod radius upper Frt
4
342508
Assy-Frt leveling valve
3
272217
Assy-link leveling
3
312485
Spring-air / bumper
10
204428
Shock Koni RR
6
313019
Rod upper rear radius 70mm
6
40N12000
Nut lock nylon ¾” 10 UNC
8
10B12104
Bolt hex ¾ “ UNC x 6.5
20
10B12064
Bolt hex ¾” 10 UNC x 4” LG
16
223196
Spacer Radius rod mtg
24
356808
Bolt M18 x 1.5 x 100 CL 10.9
16
10B06024
Bolt hex 3/8” 16 UNC x 1 ½” LG
16
30W06000
Washer lock 3/8” NOM
16
20W06000
Washer flat 3/8”
16
203772
Nut flange lock 3/8”-16
8
40N08000
Nut hex lock ½” NC
6
14
VEHICLE DATA FORM
Bus Number: 0913
Date: 7-27-09
List all spare parts, tools and manuals delivered with the bus.
Part Number
Description
Qty.
20W08000
Washer flat ½”
6
234815
Elbow 45 ½” OD x ¼” NPT
4
042440
Nut lock prevailing torque ¾”
12
5956376
Connector ½” OD x ¼” PT
2
5956114
Elbow 90 street ¼” MPT x ¼” FPT
2
347212
Assy LH leveling valve
3
247223
Clamp p .625 SS/H
3
335550
Bolt-U rear MAN axle
12
20W14000
Washer flat 7/8”
16
41N14000
Nut lock nylon 7/8” 14 UNF
16
289336
Assy link leveling LH
6
6358265
Element oil filter
3
6356784
Filter fuel
3
6362004
Filter assy secondary fuel
3
6331009
Filter corrosion resistor
3
P60866
Donaldson air filter
3
275163
Fltr-element hydr oil
3
6356984
Filter transmission
3
6356845
Control main filter, drive unit
3
8110071
Mount rubber
6
328612
Shaft upper steering drive
1
328613
Shaft lower steering drive
1
248498
Module VMM 1210
2
345258
Seal windshield
1
15
VEHICLE DATA FORM
Bus Number: 0913
Date: 7-27-09
List all spare parts, tools and manuals delivered with the bus.
Part Number
Description
Qty.
8112552
Blade wiper heavy duty
4
na
Rim alum
1
na
Assorted breakers
1
16
COMPONENT/SUBSYSTEM INSPECTION FORM
Bus Number: 0913
Date: 7-28-09
Subsystem
Checked
Comments
Air Conditioning Heating
and Ventilation
99
Body and Sheet Metal
9
Frame
9
Steering
9
Suspension
9
Interior/Seating
9
Axles
9
Brakes
9
Tires/Wheels
9
Exhaust
9
Fuel System
9
Power Plant
9
Accessories
9
Lift System
9
Interior Fasteners
9
Batteries
9
17
CHECK - IN
NEW FLYER of AMERICA
MODEL XDE 40
18
CHECK - IN CONT.
NEW FLYER of AMERICA
MODEL XDE 40 EQUIPPED WITH A NEW FLYER MODEL
7:1 SLOPE HANDICAP RAMP
19
CHECK - IN CONT.
OPERATOR’S AREA
20
CHEC
K - IN CONT.
INTERIOR
FRONT TO REAR
VIN TAG
21
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.
22
ACCESSIBILITY DATA FORM
Bus Number: 0913
Date: 4-5-10
Component
Checked
Comments
ENGINE :
Oil Dipstick
99
Oil Filler Hole
99
Oil Drain Plug
99
Oil Filter
99
Fuel Filter
99
Air Filter
99
Belts
99
Coolant Level
99
Coolant Filler Hole
99
Coolant Drain
99
Spark / Glow Plugs
99
Alternator
99
Diagnostic Interface Connector
99
TRANSMISSION :
Fluid Dip-Stick
99
Filler Hole
99
Fill through dip tube.
Drain Plug
99
SUSPENSION :
99
Bushings
99
Shock Absorbers
99
Air Springs
99
Leveling Valves
99
Grease Fittings
99
23
ACCESSIBILITY DATA FORM
Bus Number: 0913
Date: 4-5-10
Component
Checked
Comments
HVAC :
A/C Compressor
99
Filters
99
Fans
99
ELECTRICAL SYSTEM :
Fuses
99
Batteries
99
Voltage regulator
99
Internal regulator.
Voltage Converters
99
Lighting
99
MISCELLANEOUS :
Brakes
99
Handicap Lifts/Ramps
99
Instruments
99
Axles
99
Exhaust
99
Fuel System
99
OTHERS :
24
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
25
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.
26
27
28
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 &
#1935
Starplex II
Chassis grease
29
1.3 REPLACEMENT AND/OR REPAIR OF
SELECTED SUBSYSTEMS
1.3-I. TEST OBJECTIVE
The objective of this test is to establish the time required to replace and/or repair
selected subsystems.
1.3-II. TEST DESCRIPTION
The
test
will
involve
components
that
may
be
expected
to
fail
or
require
replacement during the service life of the bus. In addition, any component that fails
during the NBM testing is added to this list. Components to be included are:
1.
Transmission
2.
Alternator
3.
Starter
4.
Batteries
5.
Windshield wiper motor
1.3-III. DISCUSSION
During
the
test,
several
additional
components
were
removed
for
repair
or
replacement. Following is a list of components and total repair/replacement time.
MAN HOURS
Driver’s seat air line.
1.0
Left front air bag. 2.0
Upper radius rod. 2.0
Left front air bag hose. 2.0
Right front lower radius rod. 2.0
Transmission relay. 8.0
Rear H-beam. 12.0
Both outside rear view mirrors. 1.0
Right front air bag. 1.0
Belt guard. 4.0
A/C belt. 1.0
At the end of the test, the remaining items on the list were removed and replaced.
The transmission assembly took 18.0 man-hours (two men 9.0 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.
30
REPLACEMENT AND/OR REPAIR FORM
Subsystem
Replacement Time
Alternator
5.0 man hours
Transmission
18.0 man hours
Wiper Motor
0.5 man hours
Hybrid battery pack
1.0 man hours
Alternator
0.75 man hours
Batteries
0.5 man hours
31
1.3 REPLACEMENT AND/OR REPAIR OF
SELECTED SUBSYSTEMS
TRANSMISSION REMOVAL AND REPLACEMENT
(18.0 MAN HOURS)
WIPER MOTOR REMOVAL AND REPLACEMENT
(0.5 MAN HOURS)
32
1.3 REPLACEMENT AND/OR REPAIR OF
SELECTED SUBSYSTEMS CONT.
HYBRID BATTERY PACK REMOVAL AND REPLACEMENT
(1.0 MAN HOURS)
ALTERNATOR REMOVAL AND REPLACEMENT
(0.75 MAN HOURS)
33
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 en route 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.
34
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 thirteen Class 3 failures, 5 involved the suspension system,
4
occurred
with
the
brakes,
2
were
electrical
and
1
each
occurred
with
the
engine/transmission and frame. These, and the remaining ten Class 4 failures are
available for review in the Unscheduled Maintenance List, located in Section 5.7
Structural Durability.
35
RELIABILITY DATA FORMS
Bus Number: 0913
Date: 03-16-10
Personnel: Bob Reifsteck
Failure Type
Class 4
Bad
Order
Class 3
Bus
Change
Class 2
Road
Call
Class 1
Physical
Safety
Subsystems
Mileage
Mileage
Mileage
Mileage
Man
Hours
Down
Time
Suspension
1,591
2.00
2.00
2,327
2.00
1.00
2,375
5.00
120.00
4,273
2.00
1.00
4,815
2.00
1.00
7,751
1.00
0.50
7,751
1.00
6.00
13,516
2.00
3.00
Seats/Windows/Body
1,591
1.00
2.00
4,815
2.50
2.50
4,815
1.00
1.00
7,751
3.00
1.50
7,751
6.00
3.00
Brakes
512
0.50
6.00
2,327
1.00
8.00
2,375
2.00
1.00
4,273
1.00
1.00
36
RELIABILITY DATA FORMS
Bus Number: 0913
Date: 03-16-10
Personnel: Bob Reifsteck
Failure Type
Class 4
Bad
Order
Class 3
Bus
Change
Class 2
Road
Call
Class 1
Physical
Safety
Subsystems
Mileage
Mileage
Mileage
Mileage
Man
Hours
Down
Time
Engine/Transmission
4,396
8.00
72.00
7,751
4.00
24.00
7,751
1.00
0.50
Electrical
3,396
5.00
180.00
4,934
0.50
46.00
Frame
4,815
12.00
519.00
37
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 12
foot 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.
38
SAFETY DATA FORM
Bus Number: 0913
Date: 3-17-10
Personnel: B.S., T.S. & E.L.
Temperature (°F): 39
Humidity (%): 66
Wind Direction: Calm
Wind Speed (mph): Calm
Barometric Pressure (in.Hg): 30.10
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.
39
3. SAFETY
RIGHT - HAND APPROACH
LEFT - HAND APPROACH
40
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 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 37.96 seconds.
41
PERFORMANCE DATA FORM
Bus Number: 0913
Date: 3/17/10
Personnel: B.S., T.S. & E.L.
Temperature (°F): 39
Humidity (%): 66
Wind Direction: Calm
Wind Speed (mph): Calm
Barometric Pressure (in.Hg): 30.10
Air Conditioning compressor-OFF
99
Checked
Ventilation fans-ON HIGH
99
Checked
Heater pump motor-Off
99
Checked
Defroster-OFF
99
Checked
Exterior and interior lights-ON
99
Checked
Windows and doors-CLOSED
99
Checked
ACCELERATION, GRADEABILITY, TOP SPEED
Counter Clockwise Recorded Interval Times
Speed
Run 1
Run 2
Run 3
10 mph
5.04
5.01
4.82
20 mph
9.76
9.42
9.66
30 mph
16.32
16.29
16.48
40 mph
25.16
26.39
26.19
Top Test
Speed(mph) 50
38.12
38.50
38.71
Clockwise Recorded Interval Times
Speed
Run 1
Run 2
Run 3
10 mph
4.80
4.95
4.89
20 mph
9.70
9.45
9.29
30 mph
16.05
16.01
16.23
40 mph
25.45
24.95
25.04
Top Test
Speed(mph) 50
37.64
37.28
37.50
42
43
44
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 83 people
including the driver. The resulting test load is (83 x 375 lb) = 31,125 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 0.344 inches at reference point 3. The maximum permanent
deflection after the final loading sequence ranged from -0.005 inches at reference point
1 to 0.006 inches at reference points 5 and 9.
45
STRUCTURAL SHAKEDOWN DATA FORM
Bus Number: 0913
Date: 8-12-09
Personnel: T.S., E.D., E.L. & G.F.
Temperature (°F): 75
Loading Sequence:
ع
1
غ
2
غ
3 (check one)
Test Load (lbs): 31,125
Indicate Approximate Location of Each Reference Point
Right
Front
of
Bus
Left
Top View
Reference
Point No.
A (in)
Original
Height
B (in)
Loaded
Height
B-A (in)
Loaded
Deflection
C (in)
Unloaded
Height
C-A (in)
Permanent
Deflection
1
0
.047
.047
.019
.019
2
0
.129
.129
.000
.000
3
0
.247
.247
.019
.019
4
0
.383
.383
.021
.021
5
0
.374
.374
.023
.023
6
0
.007
.007
-.005
-.005
7
0
.004
.004
.000
.000
8
0
.362
.362
.018
.018
9
0
.323
.323
.029
.029
10
0
.257
.257
.018
.018
11
0
.156
.156
.011
.011
12
0
.026
.026
.016
.016
11 10 9 8
2 3 4 5
7
6
12
1
46
STRUCTURAL SHAKEDOWN DATA FORM
Bus Number: 0913
Date: 8-12-09
Personnel: T.S., E.D., E.L. & J.P.
Temperature (°F): 73
Loading Sequence:
غ
1
ع
2
غ
3 (check one)
Test Load (lbs): 31,125
Indicate Approximate Location of Each Reference Point
Right
Front
of
Bus
Left
Top View
Reference
Point No.
A (in)
Original
Height
B (in)
Loaded
Height
B-A (in)
Loaded
Deflection
C (in)
Unloaded
Height
C-A (in)
Permanent
Deflection
1
.019
.059
.040
.014
-.005
2
.000
.143
.143
.000
.000
3
.019
.363
.344
.024
.005
4
.021
.302
.281
.026
.005
5
.023
.395
.372
.029
.006
6
-.005
.008
.013
-.005
.000
7
.000
.000
.000
.001
.001
8
.018
.243
.225
.023
.005
9
.029
.301
.272
.035
.006
10
.018
.248
.230
.023
.005
11
.011
.253
.242
.016
.005
12
.016
.031
.015
.014
-.002
11 10 9 8
2 3 4 5
7
6
12
1
47
5.1 STRUCTURAL SHAKEDOWN TEST
DIAL INDICATORS IN POSITION
BUS LOADED TO 2.5 TIMES GVL
(31,125 LBS)
48
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. Body
2. Windows
3. Doors
4. Roof vents
5. Special seating
6. Undercarriage
7. Engine
8. Service doors
9. Escape hatches
10. 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 ten 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. Water leakage was observed during the test at the side driver’s
window, the left side of the windshield, and the window above the left rear wheel well.
The results of this test are indicated on the following data forms.
49
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0913
Date: 8-24-09
Personnel: E.D., E.L., J.P., G.F. & K.D.
Temperature(°F): 67
Wheel Position : (check one)
All wheels level
ع
before
غ
after
Left front
غ
6 in higher
غ
6 in lower
Right front
غ
6 in higher
غ
6 in lower
Right rear
غ
6 in higher
غ
6 in lower
Left rear
غ
6 in higher
غ
6 in lower
Comments
ع
Windows
Driver’s side window leaking.
ع
Front Doors
No deficiencies.
ع
Rear Doors
No deficiencies.
ع
Escape Mechanisms/ Roof Vents
No deficiencies.
ع
Engine
No deficiencies.
ع
Handicapped Device/ Special
Seating
No deficiencies.
ع
Undercarriage
No deficiencies.
ع
Service Doors
No deficiencies.
ع
Body
No deficiencies.
ع
Windows/ Body Leakage
No deficiencies.
ع
Steering Mechanism
No deficiencies.
50
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0913
Date: 8-24-09
Personnel: E.D., E.L., J.P., G.F. & K.D.
Temperature(°F): 67
Wheel Position : (check one)
All wheels level
غ
before
غ
after
Left front
ع
6 in higher
غ
6 in lower
Right front
غ
6 in higher
غ
6 in lower
Right rear
غ
6 in higher
غ
6 in lower
Left rear
غ
6 in higher
غ
6 in lower
Comments
ع
Windows
Driver’s side window leaking.
ع
Front Doors
No deficiencies.
ع
Rear Doors
No deficiencies.
ع
Escape Mechanisms/ Roof Vents
No deficiencies.
ع
Engine
No deficiencies.
ع
Handicapped Device/ Special
Seating
No deficiencies.
ع
Undercarriage
No deficiencies.
ع
Service Doors
No deficiencies.
ع
Body
No deficiencies.
ع
Windows/ Body Leakage
Windshield, left side, 6” from top.
ع
Steering Mechanism
No deficiencies.
51
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0913
Date: 8-24-09
Personnel: E.D., E.L., J.P., G.F. & K.D.
Temperature(°F): 67
Wheel Position : (check one)
All wheels level
غ
before
غ
after
Left front
غ
6 in higher
غ
6 in lower
Right front
ع
6 in higher
غ
6 in lower
Right rear
غ
6 in higher
غ
6 in lower
Left rear
غ
6 in higher
غ
6 in lower
Comments
ع
Windows
Driver’s side window leaking.
ع
Front Doors
No deficiencies.
ع
Rear Doors
No deficiencies.
ع
Escape Mechanisms/ Roof Vents
No deficiencies.
ع
Engine
No deficiencies.
ع
Handicapped Device/ Special
Seating
No deficiencies.
ع
Undercarriage
No deficiencies.
ع
Service Doors
No deficiencies.
ع
Body
No deficiencies.
ع
Windows/ Body Leakage
Windshield, left side, 6” from top.
ع
Steering Mechanism
No deficiencies.
52
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0913
Date: 8-24-09
Personnel: E.D., E.L., J.P., G.F. & K.D.
Temperature(°F): 67
Wheel Position : (check one)
All wheels level
غ
before
غ
after
Left front
غ
6 in higher
غ
6 in lower
Right front
غ
6 in higher
غ
6 in lower
Right rear
ع
6 in higher
غ
6 in lower
Left rear
غ
6 in higher
غ
6 in lower
Comments
ع
Windows
Driver’s side window leaking.
ع
Front Doors
No deficiencies.
ع
Rear Doors
No deficiencies.
ع
Escape Mechanisms/ Roof Vents
No deficiencies.
ع
Engine
No deficiencies.
ع
Handicapped Device/ Special
Seating
No deficiencies.
ع
Undercarriage
No deficiencies.
ع
Service Doors
No deficiencies.
ع
Body
No deficiencies.
ع
Windows/ Body Leakage
Windshield, left side, 6” from top.
ع
Steering Mechanism
No deficiencies.
53
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0913
Date: 8-24-09
Personnel: E.D., E.L., J.P., G.F. & K.D.
Temperature(°F): 67
Wheel Position : (check one)
All wheels level
غ
before
غ
after
Left front
غ
6 in higher
غ
6 in lower
Right front
غ
6 in higher
غ
6 in lower
Right rear
غ
6 in higher
غ
6 in lower
Left rear
ع
6 in higher
غ
6 in lower
Comments
ع
Windows
Driver’s side window leaking.
ع
Front Doors
No deficiencies.
ع
Rear Doors
No deficiencies.
ع
Escape Mechanisms/ Roof Vents
No deficiencies.
ع
Engine
No deficiencies.
ع
Handicapped Device/ Special
Seating
No deficiencies.
ع
Undercarriage
No deficiencies.
ع
Service Doors
No deficiencies.
ع
Body
No deficiencies.
ع
Windows/ Body Leakage
Windshield, left side, 6” from top.
ع
Steering Mechanism
No deficiencies.
54
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0913
Date: 8-24-09
Personnel: E.D., E.L., J.P., G.F. & K.D.
Temperature(°F): 67
Wheel Position : (check one)
All wheels level
غ
before
غ
after
Left front
غ
6 in higher
ع
6 in lower
Right front
غ
6 in higher
غ
6 in lower
Right rear
غ
6 in higher
غ
6 in lower
Left rear
غ
6 in higher
غ
6 in lower
Comments
ع
Windows
Driver’s side window leaking.
ع
Front Doors
No deficiencies.
ع
Rear Doors
No deficiencies.
ع
Escape Mechanisms/ Roof Vents
No deficiencies.
ع
Engine
No deficiencies.
ع
Handicapped Device/ Special
Seating
No deficiencies.
ع
Undercarriage
No deficiencies.
ع
Service Doors
No deficiencies.
ع
Body
No deficiencies.
ع
Windows/ Body Leakage
Windshield, left side, 6” from top.
ع
Steering Mechanism
No deficiencies.
55
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0913
Date: 8-24-09
Personnel: E.D., E.L., J.P., G.F. & K.D.
Temperature(°F): 67
Wheel Position : (check one)
All wheels level
غ
before
غ
after
Left front
غ
6 in higher
غ
6 in lower
Right front
غ
6 in higher
ع
6 in lower
Right rear
غ
6 in higher
غ
6 in lower
Left rear
غ
6 in higher
غ
6 in lower
Comments
ع
Windows
Driver’s side window leaking.
ع
Front Doors
No deficiencies.
ع
Rear Doors
No deficiencies.
ع
Escape Mechanisms/ Roof Vents
No deficiencies.
ع
Engine
No deficiencies.
ع
Handicapped Device/ Special
Seating
No deficiencies.
ع
Undercarriage
No deficiencies.
ع
Service Doors
No deficiencies.
ع
Body
No deficiencies.
ع
Windows/ Body Leakage
Windshield, left side, 6” from top.
ع
Steering Mechanism
No deficiencies.
56
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0913
Date: 8-24-09
Personnel: E.D., E.L., J.P., G.F. & K.D.
Temperature(°F): 67
Wheel Position : (check one)
All wheels level
غ
before
غ
after
Left front
غ
6 in higher
غ
6 in lower
Right front
غ
6 in higher
غ
6 in lower
Right rear
غ
6 in higher
ع
6 in lower
Left rear
غ
6 in higher
غ
6 in lower
Comments
ع
Windows
Driver’s side window leaking.
ع
Front Doors
No deficiencies.
ع
Rear Doors
No deficiencies.
ع
Escape Mechanisms/ Roof Vents
No deficiencies.
ع
Engine
No deficiencies.
ع
Handicapped Device/ Special
Seating
No deficiencies.
ع
Undercarriage
No deficiencies.
ع
Service Doors
No deficiencies.
ع
Body
No deficiencies.
ع
Windows/ Body Leakage
Windshield, left side, 6” from top. Window
above left rear wheel well is leaking.
ع
Steering Mechanism
No deficiencies.
57
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0913
Date: 8-24-09
Personnel: E.D., E.L., J.P., G.F. & K.D.
Temperature(°F): 67
Wheel Position : (check one)
All wheels level
غ
before
غ
after
Left front
غ
6 in higher
غ
6 in lower
Right front
غ
6 in higher
غ
6 in lower
Right rear
غ
6 in higher
غ
6 in lower
Left rear
غ
6 in higher
ع
6 in lower
Comments
ع
Windows
Driver’s side window leaking.
ع
Front Doors
No deficiencies.
ع
Rear Doors
No deficiencies.
ع
Escape Mechanisms/ Roof Vents
No deficiencies.
ع
Engine
No deficiencies.
ع
Handicapped Device/ Special
Seating
No deficiencies.
ع
Undercarriage
No deficiencies.
ع
Service Doors
No deficiencies.
ع
Body
No deficiencies.
ع
Windows/ Body Leakage
Windshield, left side, 6” from top. Window
above left rear wheel well is leaking.
ع
Steering Mechanism
No deficiencies.
58
DISTORTION TEST INSPECTION FORM
(Note: Ten copies of this data sheet are required)
Bus Number: 0913
Date: 8-24-09
Personnel: E.D., E.L., J.P., G.F. & K.D.
Temperature(°F): 67
Wheel Position : (check one)
All wheels level
غ
before
ع
after
Left front
غ
6 in higher
غ
6 in lower
Right front
غ
6 in higher
غ
6 in lower
Right rear
غ
6 in higher
غ
6 in lower
Left rear
غ
6 in higher
غ
6 in lower
Comments
ع
Windows
Driver’s side window leaking.
ع
Front Doors
No deficiencies.
ع
Rear Doors
No deficiencies.
ع
Escape Mechanisms/ Roof Vents
No deficiencies.
ع
Engine
No deficiencies.
ع
Handicapped Device/ Special
Seating
No deficiencies.
ع
Undercarriage
No deficiencies
ع
Service Doors
No deficiencies.
ع
Body
No deficiencies.
ع
Windows/ Body Leakage
Windshield, left side, 6” from top.
ع
Steering Mechanism
No deficiencies.
59
5.2 STRUCTURAL DISTORTION TEST
LEFT FRONT WHEEL SIX INCHES HIGHER
LEFT FRONT WHEEL SIX INCHES LOWER
60
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 test bus tow hook/eyes. All four front pulls were performed to
the full target test weight of 34,296 lbs (1.2 x 28,580 lbs CW). No damage or
deformation was observed during all four front pulls of the test. The test bus was not
equipped with any type of tow eyes or tow hooks therefore a rear test was not
performed.
61
STATIC TOWING TEST DATA FORM
Bus Number: 0913
Date: 3-24-10
Personnel: B.L., E.D., E.L., S.C. & G.C.
Temperature (°F):
Inspect right front tow eye and adjoining structure.
Comments: No damage or deformation observed.
Check the torque of all bolts attaching tow eye and surrounding structure.
Comments: Welds inspected and verified.
Inspect left tow eye and adjoining structure.
Comments: No damage or deformation observed.
Check the torque of all bolts attaching tow eye and surrounding structure.
Comments: Welds inspected and verified.
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: All four front
pulls were completed to the full target test load of 34,296 lbs (1.2 x 28,580 CW). No
damage or deformation was observed. The rear is not equipped with any type of tow
eyes or tow hooks therefore a rear test was not performed.
62
5.3 STATIC TOWING TEST
FRONT 20° UPWARD PULL
FRONT 20° DOWNWARD PULL
63
5.3 STATIC TOWING TEST CONT.
FRONT 20° LEFT PULL
FRONT 20° RIGHT PULL
64
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.
65
DYNAMIC TOWING TEST DATA FORM
Bus Number: 0913
Date: 3-22-10
Personnel: B.L. & T.S.
Temperature (°F): 60
Humidity (%): 83
Wind Direction: ESE
Wind Speed (mph): 10
Barometric Pressure (in.Hg): 29.75
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 wrecker.
Description and location of any structural damage: No damage or deformation
was observed.
General Comments: No problems with the tow or towing interface were
encountered during the test.
66
5.4 DYNAMIC TOWING TEST
TOWING INTERFACE
TEST BUS IN TOW
67
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 hack 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 3.7 inches to 9.8
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
7.9”
Rear axle – one tire flat
9.8”
Rear axle – two tires flat
7.5”
68
JACKING TEST DATA FORM
Bus Number: 0913
Date: 7-29-09
Personnel: T.S. & E.D.
Temperature (°F): 66
Record any permanent deformation or damage to bus as well as any difficulty
encountered during jacking procedure.
Deflated
Tire
Jacking Pad
Clearance
Body/Frame
(in)
Jacking Pad
Clearance
Axle/Suspension
(in)
Comments
Right front
10.6 “ I
8.9 “ D
6.5 “ I
3.9 “ D
Left front
11.0 “ I
7.9 “ D
6.7 “ I
3.7 “ D
Right rear—outside
11.0 “ I
9.8 “ D
7.5 “ I
6.9 “ D
Right rear—both
11.0 “ I
7.6 “ D
7.5 “ I
5.5 “ D
Left rear—outside
11.0 “ I
9.8 “ D
7.3 “ I
6.8 “ D
Left rear—both
11.0 “ I
7.5 “ D
7.3 “ I
5.4 “ D
Additional comments of any deformation or difficulty during jacking:
69
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 19
inch 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.
70
HOISTING TEST DATA FORM
Bus Number: 0913
Date: 7-29-09
Personnel: T.S. & S.C.
Temperature (°F): 66
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.
71
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 August 24, 2009 and was conducted
until March 26, 2010. The first 6,250 miles were performed at a GVW of 40,720 lbs. and
completed on December 23, 2009. The next 2,500 mile SLW segment was performed at
34,760 lbs and completed on January 20, 2010, and the final 6,250 mile segment was
performed at a CW of 28,580 lbs and completed on March 26, 2010.
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.
72
73
74
75
76
77
78
79
80
81
82
83
UNSCHEDULED MAINTENANCE
LEAKING LEFT FRONT AIR BAG
(1,591 TEST MILES)
WORN BUSHING: RIGHT SIDE, UPPER RADIUS ROD
(2,327 TEST MILES)
84
UNSCHEDULED MAINTENANCE CONT.
BROKEN ABS VALVE BRACKET
(2,327 TEST MILES)
BROKEN “F1” WIRE IN THE ALTERNATOR
(3,396 TEST MILES)
85
UNSCHEDULED MAINTENANCE CONT.
WORN BUSHING; RIGHT FRONT LOWER RADIUS ROD
(4,273 TEST MILES)
BLOWN OUT LEFT FRONT AIR BAG
(4,815 TEST MILES)
86
UNSCHEDULED MAINTENANCE CONT.
BROKEN REAR VIEW MIRROR MOUNTING BLOCK
(4,815 TEST MILES)
FAILED SEAT BRACKET
(7,751 TEST MILES)
87
UNSCHEDULED MAINTENANCE CONT.
BOTTOM STUD BROKEN ON LEFT FRONT AIR BAG
(13,516 TEST MILES)
88
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.
89
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, and 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.
90
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 60 F (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 60 F. 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
FEo
mi/lb
= Observed fuel economy = miles
lb of fuel
91
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 60
°
F and
multiply by the density of water at 60
°
F
FEo
mpg
= FEc
mi/lb
x Gs x Gw
where
Gs = Specific gravity of test fuel at 60
°
F
(referred to water)
Gw = 8.3373 lb/gal
3.)
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 = FEo
mpg
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/BTUx10
6
.
Eq = Energy equivalent of converting mpg to mile/BTUx10
6
.
Eq = ((mpg)/(H))x10
6
B. CNG, LNG, cryogenic and other fuels in the vapor state.
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 psia and T=60
°
F).
These combine to give a fuel economy in miles per lb. The energy equivalent
92
(mile/BTUx10
6
) 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
FEo
mi/scf
= Observed fuel economy = miles
scf of fuel
2.)
Convert the observed fuel economy to miles per lb by dividing FEo by the
density of the test fuel at standard conditions (Lb/ft
3
).
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.
FEo
mi/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/BTUx10
6
) by dividing the observed fuel economy (FEomi/lb) by the
heating value of the test fuel at standard conditions.
Eq = ((FEomi/lb)/H)x10
6
where
Eq = Energy equivalent of miles/lb to mile/BTUx10
6
H = Volumetric heating value of test fuel at standard conditions
93
6-III. DISCUSSION
This is a comparative test of fuel economy using diesel fuel with a heating value of
19,631.0 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 – 4.75 mpg,
ART – 4.81 mpg, and COM – 7.57 mpg. Average fuel consumption at idle was 0.67
gph.
94
FUEL ECONOMY PRE-TEST MAINTENANCE FORM
Bus Number: 0913
Date: 3-9-10
SLW (lbs): 34,760
Personnel: B.L., T.S. & S.C.
FUEL SYSTEM
OK
Date
Initials
Install fuel measurement system
99
3/9/10
S.C.
Replace fuel filter
99
3/9/10
S.C.
Check for fuel leaks
99
3/9/10
S.C.
Specify fuel type (refer to fuel analysis)
Diesel
Remarks: None noted.
BRAKES/TIRES
OK
Date
Initials
Inspect hoses
99
3/9/10
S.C.
Inspect brakes
99
3/9/10
S.C.
Relube wheel bearings
99
3/9/10
S.C.
Check tire inflation pressures (mfg. specs.)
99
3/9/10
S.C.
Remarks: None noted.
COOLING SYSTEM
OK
Date
Initials
Check hoses and connections
99
3/9/10
S.C.
Check system for coolant leaks
99
3/9/10
S.C.
Remarks: None noted.
95
FUEL ECONOMY PRE-TEST MAINTENANCE FORM (page 2)
Bus Number: 0913
Date: 3-9-10
Personnel: B.L., T.S. & S.C.
ELECTRICAL SYSTEMS
OK
Date
Initials
Check battery
99
3/9/10
S.C.
Inspect wiring
99
3/9/10
S.C.
Inspect terminals
99
3/9/10
S.C.
Check lighting
99
3/9/10
S.C.
Remarks: None noted.
DRIVE SYSTEM
OK
Date
Initials
Drain transmission fluid
99
3/9/10
B.L.
Replace filter/gasket
99
3/9/10
B.L.
Check hoses and connections
99
3/9/10
B.L.
Replace transmission fluid
99
3/9/10
B.L.
Check for fluid leaks
99
3/9/10
B.L.
Remarks: None noted.
LUBRICATION
OK
Date
Initials
Drain crankcase oil
99
3/9/10
B.L.
Replace filters
99
3/9/10
B.L.
Replace crankcase oil
99
3/9/10
B.L.
Check for oil leaks
99
3/9/10
B.L.
Check oil level
99
3/9/10
B.L.
Lube all chassis grease fittings
99
3/9/10
B.L.
Lube universal joints
99
3/9/10
B.L.
Replace differential lube including axles
99
3/9/10
B.L.
Remarks: None noted.
96
FUEL ECONOMY PRE-TEST MAINTENANCE FORM (page 3)
Bus Number: 0913
Date: 3-9-10
Personnel: B.L., T.S. & S.C.
EXHAUST/EMISSION SYSTEM
OK
Date
Initials
Check for exhaust leaks
99
3/9/10
S.C.
Remarks: None noted.
ENGINE
OK
Date
Initials
Replace air filter
99
3/9/10
B.L.
Inspect air compressor and air system
99
3/9/10
S.C.
Inspect vacuum system, if applicable
N/A
3/9/10
S.C.
Check and adjust all drive belts
99
3/9/10
S.C.
Check cold start assist, if applicable
99
3/9/10
S.C.
Remarks: None noted.
STEERING SYSTEM
OK
Date
Initials
Check power steering hoses and connectors
99
3/9/10
S.C.
Service fluid level
99
3/9/10
S.C.
Check power steering operation
99
3/9/10
S.C.
Remarks: None noted.
OK
Date
Initials
Ballast bus to seated load weight
99
3/9/10
S.C.
TEST DRIVE
OK
Date
Initials
Check brake operation
99
3/9/10
S.C.
Check transmission operation
99
3/9/10
S.C.
Remarks: None noted.
97
FUEL ECONOMY PRE-TEST INSPECTION FORM
Bus Number: 0913
Date: 3-9-10
Personnel: S.C., T.S. & E.D.
PRE WARM-UP
If OK, Initial
Fuel Economy Pre-Test Maintenance Form is complete
S.C.
Cold tire pressure (psi): Front 120 Middle N/A Rear 120
T.S.
Tire wear:
T.S.
Engine oil level
T.S.
Engine coolant level
T.S.
Interior and exterior lights on, evaporator fan on
T.S.
Fuel economy instrumentation installed and working properly.
T.S.
Fuel line -- no leaks or kinks
T.S.
Speed measuring system installed on bus. Speed indicator
installed in front of bus and accessible to TECH and Driver.
T.S.
Bus is loaded to SLW
T.S.
WARM-UP
If OK, Initial
Bus driven for at least one hour warm-up
T.S.
No extensive or black smoke from exhaust
T.S.
POST WARM-UP
If OK, Initial
Warm tire pressure (psi): Front 120 Middle N/A Rear 120
T.S.
Environmental conditions
Average wind speed <12 mph and maximum gusts <15 mph
Ambient temperature between 30°F(-1C°) and 90°F(32°C)
Track surface is dry
Track is free of extraneous material and clear of
interfering traffic
T.S.
98
99
100
101
102
FUEL ECONOMY SUMMARY SHEET
BUS MANUFACTURER :New Flyer BUS NUMBER :0913
BUS MODEL :XDE 40 TEST DATE :03/16/10
FUEL TYPE : DIESEL
SP. GRAVITY : .8400
HEATING VALUE : 19631.00 BTU/Lb
FUEL TEMPERATURE : 60.00 deg F
Standard Conditions : 60 deg F and 14.7 psi
Density of Water : 8.3373 lb/gallon at 60 deg F
---------------------------------------------------------------
CYCLE TOTAL FUEL TOTAL MILES FUEL ECONOMY FUEL ECONOMY
USED(GAL) MPG(Measured) MPG (Corrected)
---------------------------------------------------------------
Run # :1, CCW
CBD 1.100 5.73 5.209 4.80
ART .739 3.82 5.169 4.76
COM .469 3.82 8.145 7.51
TOTAL 2.308 13.37 5.793 5.34
Run # :2, CW
CBD 1.125 5.73 5.093 4.69
ART .752 3.82 5.080 4.68
COM .441 3.82 8.662 7.98
TOTAL 2.318 13.37 5.768 5.32
Run # :3, CCW
CBD 1.104 5.73 5.190 4.78
ART .725 3.82 5.269 4.86
COM .482 3.82 7.925 7.30
TOTAL 2.311 13.37 5.785 5.33
Run # :4, CW
CBD 1.115 5.73 5.139 4.74
ART .715 3.82 5.343 4.92
COM .469 3.82 8.145 7.51
TOTAL 2.299 13.37 5.816 5.36
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IDLE CONSUMPTION (MEASURED)
----------------
First 20 Minutes Data : .21GAL Last 20 Minutes Data : .20GAL
Average Idle Consumption : .62GAL/Hr
RUN CONSISTENCY: % Difference from overall average of total fuel used
---------------
Run 1 : .0 Run 2 : -.4 Run 3 : -.1 Run 4 : .4
SUMMARY (CORRECTED VALUES)
-------
Average Idle Consumption : .67 G/Hr
Average CBD Phase Consumption : 4.75 MPG
Average Arterial Phase Consumption : 4.81 MPG
Average Commuter Phase Consumption : 7.57 MPG
Overall Average Fuel Consumption : 5.34 MPG
Overall Average Fuel Consumption : 38.81 Miles/ Million BTU
103
7. NOISE
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 51.7 dB(A); ranging
from 49.3 dB(A) at the rear passenger seats to 55.5 dB(A) at the driver’s seat. The
interior ambient noise level for this test was < 34.0 dB(A).
The second test measures interior noise during acceleration from 0 to 35 mph.
This noise level ranged from 71.9 dB(A) at the front passenger seats to 76.1 dB(A) at
the driver’s seat. The overall average was 73.3 dB(A). The interior ambient noise level
for this test was < 34.0 dB(A).
104
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.
105
INTERIOR NOISE TEST DATA FORM
Test Condition 1: 80 dB(A) Stationary White Noise
Bus Number: 0913
Date: 7-27-09
Personnel: S.C. & P.S.
Temperature (°F): 77
Humidity (%): 61
Wind Speed (mph): 8
Wind Direction: SSW
Barometric Pressure (in.Hg): 30.00
Initial Sound Level Meter Calibration:
ع
checked by: S.C.
Interior Ambient
Noise Level dB(A): < 34.0
Exterior Ambient
Noise Level dB(A): 48.5
Microphone Height During Testing (in): 48.0
Measurement Location
Measured Sound Level dB(A)
Driver's Seat
55.5
Front Passenger Seats
52.9
In Line with Front Speaker
52.0
In Line with Middle Speaker
50.8
In Line with Rear Speaker
49.6
Rear Passenger Seats
49.3
Final Sound Level Meter Calibration:
ع
checked by: S.C.
Comments: All readings taken in the center aisle.
106
INTERIOR NOISE TEST DATA FORM
Test Condition 2: 0 to 35 mph Acceleration Test
Bus Number: 0913
Date: 3-17-10
Personnel: B.S., T.S. & E.L.
Temperature (°F): 39
Humidity (%): 66
Wind Speed (mph): Calm
Wind Direction: Calm
Barometric Pressure (in.Hg): 30.10
Initial Sound Level Meter Calibration:
ع
checked by: T.S.
Interior Ambient
Noise Level dB(A): < 34.0
Exterior Ambient
Noise Level dB(A): 35.0
Microphone Height During Testing (in): 48
Measurement Location
Measured Sound Level dB(A)
Driver's Seat
76.1
Front Passenger Seats
71.9
Middle Passenger Seats
72.2
Rear Passenger Seats
73.1
Final Sound Level Meter Calibration:
ع
checked by: T.S.
Comments: All readings taken in the center aisle.
107
INTERIOR NOISE TEST DATA FORM
Test Condition 3: Audible Vibration Test
Bus Number: 0913
Date: 3-17-10
Personnel: B.S., T.S. & E.L.
Temperature (°F): 39
Humidity (%): 66
Wind Speed (mph): Calm
Wind Direction: Calm
Barometric Pressure (in.Hg): 30.10
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.
108
7.1 INTERIOR NOISE TEST
TEST BUS SET-UP FOR 80 dB(A)
INTERIOR NOISE TEST
109
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.
Accelerating at full throttle from a constant speed at or below 35 mph and just
prior to transmission up shift.
2.
Accelerating at full throttle from standstill.
3.
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.
The test site characteristics regarding parked vehicles, signboards,
buildings, or other sound-reflecting surfaces
2.
Proper usage of all test equipment including set-up and calibration
3.
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 exterior ambient noise level of 35.0 dB(A), the average test result obtained
while accelerating from a constant speed was 67.9 dB(A) on the right side and 67.7
dB(A) on the left side.
110
When accelerating from a standstill with an exterior ambient noise level of 35.1
dB(A), the average of the results obtained were 66.3 dB(A) on the right side and 66.6
dB(A) on the left side.
With the vehicle stationary and the engine, accessories, and air conditioning on,
the measurements averaged 61.1 dB(A) at low idle, 63.3 dB(A) at high idle, and 70.7
dB(A) at wide open throttle. With the accessories and air conditioning off, the readings
averaged 1.4 dB(A) lower at low idle, 1.0 dB(A) lower at high idle, and 0.1 dB(A) higher
at wide open throttle. The exterior ambient noise level measured during this test was
35.0 dB(A).
111
EXTERIOR NOISE TEST DATA FORM
Accelerating from Constant Speed
Bus Number: 0913
Date: 3-17-10
Personnel: B.S., T.S. & E.L.
Temperature (°F): 39
Humidity (%): 66
Wind Speed (mph): Calm
Wind Direction: Calm
Barometric Pressure (in.Hg): 30.10
Verify that microphone height is 4 feet, wind speed is less than 12 mph and ambient
temperature is between 30°F and 90°F:
ع
checked by: T.S.
Initial Sound Level Meter Calibration:
ع
checked by: T.S.
Exterior Ambient Noise Level dB(A): 35.0
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
67.1
1
67.5
2
67.4
2
67.6
3
67.6
3
67.5
4
68.1
4
67.5
5
67.1
5
67.8
Average of two highest actual
noise levels = 67.9 dB(A)
Average of two highest actual
noise levels = 67.7 dB(A)
Final Sound Level Meter Calibration Check:
ع
checked by: T.S.
Comments: None noted.
112
EXTERIOR NOISE TEST DATA FORM
Accelerating from Standstill
Bus Number: 0913
Date: 3-17-10
Personnel: B.S., T.S. & E.L.
Temperature (°F): 39
Humidity (%): 66
Wind Speed (mph): Calm
Wind Direction: Calm
Barometric Pressure (in.Hg): 30.10
Verify that microphone height is 4 feet, wind speed is less than 12 mph and ambient
temperature is between 30°F and 90°F:
ع
checked by: T.S.
Initial Sound Level Meter Calibration:
ع
checked by: T.S.
Exterior Ambient Noise Level dB(A): 35.1
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
65.6
1
65.5
2
65.6
2
65.9
3
66.6
3
67.0
4
65.9
4
66.1
5
65.6
5
66.0
Average of two highest actual noise
levels = 66.3 dB(A)
Average of two highest actual noise
levels = 66.6 dB(A)
Final Sound Level Meter Calibration Check:
ع
checked by: T.S.
Comments: None noted.
113
EXTERIOR NOISE TEST DATA FORM
Stationary
Bus Number: 0913
Date: 3-17-10
Personnel: B.S., T.S. & E.L.
Temperature (°F): 39
Humidity (%): 66
Wind Speed (mph): Calm
Wind Direction: Calm
Barometric Pressure (in.Hg): 30.10
Verify that microphone height is 4 feet, wind speed is less than 12 mph and ambient
temperature is between 30°F and 90°F:
ع
checked by: T.S.
Initial Sound Level Meter Calibration:
ع
checked by: T.S.
Exterior Ambient Noise Level dB(A): 35.0
Accessories and Air Conditioning ON
Throttle Position
Engine RPM
Curb (Right) Side
dB(A)
Street (Left) Side
db(A)
Measured
Measured
Low Idle
749
60.3
61.9
High Idle
999
62.7
63.9
Wide Open Throttle
2,001
70.2
71.2
Accessories and Air Conditioning OFF
Throttle Position
Engine RPM
Curb (Right) Side
dB(A)
Street (Left) Side
db(A)
Measured
Measured
Low Idle
781
58.8
60.5
High Idle
1,001
61.6
62.9
Wide Open Throttle
1,999
69.8
71.8
Final Sound Level Meter Calibration Check:
ع
checked by: T.S.
Comments: None noted.
114
7.2 EXTERIOR NOISE TESTS
TEST BUS UNDERGOING
EXTERIOR NOISE TESTING
| File Type | application/pdf |
| Author | Sondra Hoover |
| File Modified | 2019-10-09 |
| File Created | 2019-10-09 |