Home

PREVENTIVE MAINTENANCE Manual

1. 53 TD 15 New Vechile Service Work Order aaa 54 18 Equipment Repair and Parts Order 56 TD 18 B Fuel and Lubricant Issue Ticket eese eere 57 TD 30 30 Day School Bus Inspection Work Sheet 58 June 5 1997 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Bus Driv r Sien aoo osa Da EE Ea eil Et 59 Extra Dus Schedule Assignment 60 Reported Bus Defect Eas a a a D MN res 61 Service E TT 62 14 SCHOOL BUS GARAGE SHOP EQUIPMENT 63 15 ADDITIONAL EQUIPMENT INSTALLATION sssccsssssssssesoseresnsersccresaceartoacencesecetseeceates 65 MANUAL COMMITTEE MEMBERS 66 June 5 1997 ii DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual A INTRODUCTION North Carolina school children deserve the safest transportation possible This is provided through the work and dedication of thousands of employees of local education agencies LEAs in cooperation with the Department of Public Instruction DPD T
2. Work Source V Vandalism Repair vandalism repairs to vehicles are to be indicated using work source V Any item damaged that is not normal wear shall be coded as vandalism Work Source W Warranty Repair repairs to vehicles that are a result of a defective product or product update and the replacements item is furnished at no charge by the vendor shall be coded as warranty repair Annual Goal Work Source Percentage Work Source A Road Calls Maximum 2 Work Source D Preventive Maintenance Minimum 35 Work Source K Miscellaneous Shop Time Maximum 590 paid hours are to be documented on a TD 18A Equipment Repair and Parts Order form for all garage personnel each workday Each county shall have 10096 accountability for all employee hours paid June 5 1997 17 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Please utilize the Monthly Garage Labor Report and the Monthly Garage Work Source Report These reports summarize monthly and year to date data on the utilization of the school bus garage staff and they provide the transportation director with usable management data Actual time to service or repair vehicles is to be recorded on the TD 18A Equipment Repair and Parts Order form and or the TD 8A amp B Preventive Maintenance Service sheets Do not indicate time for repairs not performed June 5 1997 18 DPI Transportation Services Preventive Maintenan
3. 7 Preventive Maintenance 48 000 Mile Service Repair Code 08 The 48 000 mile preventive maintenance service is a garage performed activity After completing the 24 000 mile procedure the following additional items shall be serviced every 48 000 miles Air Dryer Replace desiccant cartridge and inspect all connections fittings hoses etc Drain and Replace Brake Fluid Master cylinder clean flush reservoir and cylinder Refill reservoir Connect hydraulic brake pressure bleeder Bleed and flush the entire brake hydraulic system according to bleeding procedures outlined in manufacturer s service manual Before hydraulic brake pressure bleeder is activated pressurized remove the brake warning light switch and reinstall after the flush is completed This switch must also be removed during any brake bleeding operation and reinstalled after bleeding is completed Engine Valve Adjustment Diesel Engine valves adjustment not to exceed 48 000 miles or per manufacturer recommendations is required Valve adjustment frequency varies for each engine manufacturer Refer to the respective manufacturer for correct specifications and valve adjustment intervals Power Steering Filter and Fluid Change the power steering filter and fluid in reservoir Differential With differential at normal operating temperature drain lubricant and strain through a wire mesh screen to detect any metal particles which might be in lubricant If no repai
4. Preventive Maintenance and Vehicle Replacement Manual 13 Required Maintenance Record Documentation The following are maintenance record forms which are required to document the preventive maintenance program These forms are to be properly and thoroughly completed and filed in the appropriate assigned location The Transportation Services staff members will review periodically during the year Transportation Services will furnish upon request a copy of the following forms to the county school bus staff TD 8A Preventive Maintenance Oil Change Service Work Order TD 8B Preventive Maintenance 12 000 24 000 48 000 Mile Service Work Order TD 13 Discarded Equipment Supplies amp Material TD 15 New Vehicle Service Work Order TD 18A Equipment Repair and Parts Order 18 Fuel and Lubricant Issue Ticket TD 30 30 Day School Bus Inspection Work Sheet Note These forms are presented on the following pages The following required forms or files ARE NOT FURNISHED by Transportation Services Either the sample presented or a similar form which fills your county s particular needs is required to be used of the information requested on the samples presented must be included Sample Forms Bus Driver Sign In Sheet Extra Bus Schedule Assignment Reported Bus Defect Log Service Call Log Sample Files Discarded Equipment Supplies amp Materials File folder Extra Bu
5. 7 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual C PREVENTIVE MAINTENANCE The following program must be documented by proper completion of all the required preventive maintenance forms listed in this manual Documentation of maintenance is essential to conducting an effective safe and cost efficient maintenance program and in justifying budget needs and allocations The key operational factors upon which this PM program is based are vehicle mileage fuel consumption and elapsed time since the last recorded preventive maintenance service Therefore accurate speedometer operation and mileage recordings are essential as well as accurate record keeping of all routine daily records The performance of this maintenance program must be in accordance with all safety rules and regulations prescribed by the Occupational Safety and Health Administration the State Board of Education and the local education agency brake repairs shall be checked for operating safety and efficiency by using a Tapley Brake Meter or equivalent meter The percent of brake efficiency shall be recorded for future reference Each mechanic should be provided a copy of the Preventive Maintenance Manual Service manuals are required to be available at each school bus garage for each year model vehicle The manuals may be obtained from the bidding dealer June 5 1997 8 DPI Transportation Services Preventive Maintenance and V
6. DESC ADDITIONAL DESC 2 AMOUNT MECHANICS SIGNATURE GRAND SOURCE 1 5 N NON INV PARTS S SUBLET REPAIRS TOTAL Preventive Maintenance and Vehicle Replacement Manual TD 13 Rev 6 2000 DISCARDED EQUIPMENT SUPPLIES amp MATERIAL TO Surplus Property Agent Division of Purchase amp Contract Raleigh NC FROM County DATE We hereby recommend for sale surplus school transportation equipment materials and supplies as follows Bus Year Number Make Model Size Serial Number Price Miscellaneous The above is located and may be inspected at County School Bus Garage NC Persons or firms interested in purchasing same should see Mr for inspection of equipment Includes batteries tires scrap iron miscellaneous junk etc Area Transportation Consultant June 5 1997 53 DPI Transportation Services 1015 NEW VEHICLE SERVICE WORK ORDER Rev 7 97 CHASSIS Vehicle No Mileage Date Make Year Serial No Tire Size Ignition Key No BODY Make Body No Cap Date Mfg FRONT AXLE Adjust amp Refill wheel bearings Balance front tire and rim Brake lining thickness Left 32 Right 32 Torque backing plate spider mounting bolts Torque drum to hub bolts ft Ibs Torque spring u bolts ft Ibs Torque spring shackles amp eye bolts or spring pivot bolts Torque wheel bolts ft Ibs Drive in and torque king pin lock bolt nuts To
7. cccsssccessccesseceessecesseecesseeeessseesseeeesseeeeses 9 2 PREVENTIVE MAINTENANCE SCHEDULING aaa 13 3 30 DAY INSPECTION PROGRAM REPAIR CODE MI 19 4 PREVENTIVE MAINTENANCE 6 000 MILE SERVICE REPAIR CODE 05 26 5 PREVENTIVE MAINTENANCE 12 000 MILE SERVICE REPAIR CODE 06 28 6 PREVENTIVE MAINTENANCE 24 000 MILE SERVICE REPAIR CODE 07 34 7 PREVENTIVE MAINTENANCE 48 000 MILE SERVICE REPAIR CODE 08 36 8 PERSONNEL WTILIZA TION anu uhupi wiqi uka etal E RIED RS 38 9 SCHOOL BUS GARAGE PROCEDURES 20 2 2 2 2 10 2000010000000000000000000000000000 41 10 SERVICE VEHICLE MAINTENANCE AND 1 400000 0 000 00040 00000000002 45 11 VEHICLE BODY REPAIR AND REPAINTING PROCEDURES a 46 12 UTILIZATION OF SURPLUS EQUIPMENT cessere eene nnn 47 13 REQUIRED MAINTENANCE RECORD DOCUMENTATION 0 000000 000000000000 48 TD 8 Preventive Maintenance Oil Change Service 49 TD 8B Preventive Maintenance 12 000 24 000 48 000 mile service 50 TD 13 Discarded Equipment Supplies amp Material
8. components in a safe and acceptable manner Using a tire tread gauge that measures in 32nds of an inch measure the amount of brake lining above the rivet head at the thickest point of each brake shoe Record the measurement of the thickest shoe for each wheel in the appropriate space on the Preventive Maintenance 12 000 24 000 48 000 Work Order On air brake equipped buses which have cam ground or tapered lining the measurement should be made near the center of the brake shoe Compare these measurements with the measurements from the vehicle history to determine if the lining is still serviceable or needs to be replaced If brake lining thickness is acceptable inspect for possible lining cracks loose rivets defective brake shoe etc If brake lining thickness is unacceptable replace brake lining Replacement of Brake Lining Rebuild hydraulic brake wheel cylinders at any time brake lining is replaced if needed Brake drums shall be turned to a smooth surface each time brake lining is replaced if needed Inspect S cam bushings Replace if needed If applicable remove wheel bearings clean and inspect bearings and cups Repack wheel bearings with lubricant which meets vehicle manufacturer s specifications Install inner wheel bearing and seal in hub Install hub and drum assembly Replace with new drums if worn beyond OEM specifications Install outer wheel bearing washer and nut and adjust wheel bearings to specifications N
9. director at the time of the call The assignment of persons to demount repair and mount tires will be left to the foreman or director This will be done while also considering the assignment of personnel to maintenance work in the shop and at the schools tires and wheels to be repaired will be washed weather permitting before being taken to the tire shop All new tires and new recap tires should be balanced after mounting if proper equipment 15 available and before being placed on a vehicle or in the storage rack Used batteries shall be washed and cleaned properly prior to placing in the battery room or designated area for recharging or storage A ventilated location is required to recharge batteries As needed add antifreeze that meets OEM specifications to the cooling system of each bus Antifreeze protection should be approximately 15 degrees below lowest expected temperature Note Engine coolant DCA level test kits shall be used to determine if maintenance of the cooling system is needed Annually perform the motor vehicle inspection required by G S 20 183 3 a and attach the proper sticker to the assigned windshield location The following are maintenance record forms which are referred to in this section They are required to document the preventive maintenance program These forms are to be properly and thoroughly completed and filed in the appropriate assigned location Transportation Services staff members will revi
10. expected to fail before the next regularly scheduled monthly inspection This inspection shall include all the various parts of the vehicle When inspecting a vehicle which is to have preventive maintenance brake service the following shall be included as a part of the inspection check for wear and lost motion in the steering knuckle king bolts the upper and lower ball joints and the upper and lower control arms Any defects detected during this inspection will be listed on the TD 18A Equipment Repair and Parts Order form The inspecting mechanic shall sign the TD 18A Equipment Repair and Parts Order form and complete and sign the 30 Day School Bus Inspection Work Sheet if applicable He shall indicate on the 30 Day School Inspection Work Sheet those items which are acceptable with a check mark in the OK column and those items which need repair with an X in the Needs Repair column Vehicles that are scheduled for a 12 000 mile service shall have the engine washed after the 30 Day inspection is completed After a defective item is corrected the mechanic shall indicate this on the 30 Day School Bus Inspection Sheet by checking initialing and writing the date of repair in the column beside the repaired item When performing preventive maintenance on brakes and wheel bearings one man shall do both sides of an axle On all vehicles when the brakes are relined the brake drums shall be turned if needed and not to exceed manufacturers drum wear s
11. having set the brake meter on test The minimum score allowed is 6096 for an unloaded vehicle Any score less than 6090 requires additional testing and proper brake system repair to enable the vehicle to be returned to service You shall not operate any vehicle which does not pass the brake test The test results are to be recorded on the TD 8B Preventive Maintenance 12 000 24 000 48 000 Service Work Order Panic Stop While traveling in a safe area make a panic brake application without sliding wheels Observe braking action and after vehicle has come to a stop observe engine idle Acceleration While traveling at a speed that would allow heavy acceleration in high gear observe engine pings and knocks as well as engine performance Throttle Linkage Adjust for wide open throttle Rear Axle and Drive Line Noise Observe under varying operating conditions any abnormal noise in the drive train Governor Operation if equipped Record governor cut off high and cut in low speeds Also test for governor override allowing speed to increase beyond normal cut off variation between cut off and cut in speeds Transmission Automatic Observe operation of transmission and record the up and down shift points on the 12 000 mile service form Also note if gear changes are not normal After Road Test Park vehicle in a clean dry area and observe five minutes later for leaks from any component Emission Control Devices Are warranted to 50 00
12. is performed even if the vehicle has been previously inspected during the month The purpose of this preventive maintenance is to detect any defects in order that repairs can be made before returning the bus to service The engine compartment shall be inspected before the engine is washed in order that oil leaks may be more easily detected Refer to Section 13 for a sample copy of the Preventive Maintenance 12 000 24 000 48 000 Service Work Order Engine and battery compartments are to be washed at each 12 000 mile preventive maintenance service This will maintain relatively clean engine compartments and allow oil leaks to be detected more easily on regular 30 day inspections Also battery compartment service will be much easier if a regular cleaning procedure is used Although 12 000 miles has been established as a maximum interval at which to perform this preventive maintenance service you may want to use more frequent mileage intervals based upon factors such as terrain road conditions urban routes etc which may require more frequent servicing of your bus fleet Each mechanic is to record labor only for duties actually performed and the defect list work order file is to be reviewed for the vehicle being serviced prior to performing the preventive maintenance due Road Test During the road test the mechanic must be observant for proper operation of all components of the vehicle Any defect should be noted Also the results of the follow
13. maintenance 5 Oil Change amp 30 Day Inspection 06 12 000 Mile Preventive Maintenance Service 6 12 000 Mile Preventive Maintenance Service amp 30 Day Inspection 07 24 000 Mile Preventive Maintenance Service 7 24 000 Mile Preventive Maintenance Service amp 30 Day Inspection 08 48 000 Mile Preventive Maintenance 8 48 000 PM Service plus 30 day numeric repair codes show the date of the last preventive maintenance service and the miles since the last preventive maintenance service on the screen The asterisk repair codes do not display the date of the last 30 day inspection June 5 1997 DPI Transportation Services 14 Preventive Maintenance and Vehicle Replacement Manual Preventive Maintenance Counter vehicles on the preventive maintenance program have a preventive maintenance counter on screen EQMI This counter monitors which preventive maintenance service is due next The following is a listing of all possible preventive maintenance counter indicators 08 0 1 mile MO DA YR new vehicle 08 1 6 000 mile MO DA YR Ist oil change after new vehicle service or 48 000 mile pm 06 0 12 000 mile MO DA YR 06 1 18 000 mile MO DA YR Ist oil change after 12 000 pm 07 0 24 000 mile MO DA YR 07 1 30 000 mile MO DA YR after 24 000 pm 06 0 36 000 mile MO DA YR 12 000 mile pm after 24 000 mile pm 06 1 42 000 mile MO DA Y
14. manual should be obtained from a bolt chart specifying torque Undercarriage Torque body to chassis mounting bolts to specifications Torque drive line u joints and center bearing support bracket bolts to specifications Tighten hose clamps and pipe fittings for all vacuum tubing air tubing tanks and air dryer Inspect the routing and mounting of all hoses tubing pipes battery cables and wiring Be observant for areas where any of the items may become worn by rubbing or damaged by vibration Make appropriate corrections or repairs Inspect air brake chamber push rod to slack adjuster angle to see that it is greater than 90 degrees has not passed over center at the specified amount of travel Angle should be approximately 93 94 degrees If interior angle is less that a right angle adjustment is needed Refer to OEM Service Manual June 5 1997 10 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Maximum Stroke at Which Brake Brake Chamber Type No Should be Adjusted inches 12 Less than 1 1 2 16 Less than 1 3 4 24 Less than 1 3 4 30 Less than 2 36 Less than 2 1 2 Body Inspect all lights for proper operation Inspect all seat belts and shoulder harnesses for proper mounting and operation Adjust entrance door air regulator Door control linkage should be adjusted for the rear leaf of entrance door to close just prior to front leaf Weather seals sh
15. of the following routine analyze and repair driver reported bus defects on the day he is at the school The mechanic shall visit his assigned schools to repair driver reported defects on the days designated by the shop foreman transportation director After repairing reported defects he will initiate his 30 day bus inspection which is the basic foundation of the preventive maintenance program Refer to the detailed explanation in the 30 day inspection section On the days the mechanic is at the garage he will be performing routine preventive maintenance or forced maintenance unscheduled repairs on vehicles assigned to him by the shop foreman or transportation director Note The mechanic should observe automatic transmission equipped buses for the use of chock blocks at a wheel when the bus is parked if required by the LEA Any time a mechanic is working on a bus chock blocks are to be used if needed Reporting of defect by drivers and repairing such defects bus drivers are required to sign in at each school where buses are terminated and indicate any defect detected on their bus on a Driver s Sign In Sheet A designated person shall call the bus garage upon arrival of all buses at the school giving a report on all defects reported by their drivers or e mail fax if available The assigned person at the garage shall record on a Reported Bus Defect Log the reported defects by school along with the time they were reported The assignment o
16. should not be intermixed Install inner wheel bearing seal in hub If brake lining thickness is unacceptable replace brake lining June 5 1997 32 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Replacement of Brake Lining Rebuild hydraulic brake wheel cylinders at any time brake lining is replaced if needed Brake drums shall be turned to a smooth surface each time brake lining is replaced if needed Torque brake backing plate or spider mounting bolts to manufacturer s specifications Reinstall wheel and drum assembly Install outer wheel bearing washer and nut if applicable Torque spindle nut to manufacturer s specifications Install and lock cotter pin Replace hub cover Inspect S cam bushings Replace as needed Road Test After all routine 12 000 mile service is completed road test vehicle as described earlier to insure proper operation of all serviced or repaired items After Road Test Park vehicle in clean dry area and observe five minutes later for leaks from any component The following are maintenance record forms which are referred to in this section They are required to document the preventive maintenance program These forms are to be properly and thoroughly completed and filed in the appropriate assigned location Transportation Services staff members will review these records periodically during the year TD 8B PREVENTIVE MAINTENANCE 12 000 24 000 48 000 MILE SERV
17. signal switch operation indicator lights cancellation Brakes pedal operation by pass booster test free travel pedal bushing pedal stop check low vacuum or air buzzer linkage and bushing Parking brake lever pawl ratchet spring operation adjustment check light and buzzer Air brakes check operation of low air pressure light or buzzer and air pressure gauges Mirror frame screws mounting bolts adjust for proper visibility Wheelchair mounts lift operation Interior lights Power test engine mounts Outside Body Reflectors 4 red and 2 amber 4 amber on 54 and 60 passenger Emergency door stop lock handle and nut lubricate June 5 1997 22 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Mirrors glass frames screws attaching bolts brackets crossview brackets vibration adjust for proper visibility Lights operation brightness lens license light Turn signal lens mounting bolts wiring grommets Gas door hinge lubricate filler pipe hose and clamps locking gas cap if equipped Walking arm operation and condition Stop arm operation condition of paint and lettering Sheet metal damage Chassis Body bolts and clamps tighten if needed Springs center bolts hangers shackle and eye bolts u bolts tighten if needed Brakes master cylinder booster hose lines leaks cracks abrasions kinks in hose atmospheric fil
18. the State inventory as long as the model year of a replacement bus is in excess of 8 years of the model year currently being replaced the bus can be considered for sale by the LEA No action A LEA may opt to retain a parked bus as a yellow school bus to be used as a spare vehicle It may be reinstated to status 2 subject to approval by Transportation Services to guarantee an appropriate operating condition and age If not reinstated the LEA permanently relinquishes the right to have that bus replaced in the future Each year each LEA will be asked to report statistics on its fleet usage by March 1 As part of this reporting LEAs will designate additional specific buses which have been designated as parked since the last reporting period B Service Vehicles Service vehicles pickups cargo vans fuel trucks and wrecker s chassis are replaced by the State much in the same manner as school buses The funds to purchase service vehicles come from three sources 1 sale of surplus buses and service vehicles 2 proceeds from the extra use of school buses such as field trips and 3 appropriation from General Assembly June 5 1997 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual DPI Transportation Services designates the service vehicles to be replaced using similar criteria as for buses i e mileage age and condition subject to the amount of funds available Once service vehicles have been repl
19. 0 miles as required by the federal government June 5 1997 29 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Tune Up Perform the following and replace defective items as required For all gasoline equipped vehicles refer to OEM service manual for specifications and requirements Vehicle Service Manuals May be obtained by ordering the desired manual from the dealer awarded the state bid for the respective vehicle model year Contact the parts department of the bidding dealer for additional information Battery and Compartment Clean compartment area and make any necessary repairs Paint brush inside of compartment and tray with corrosion resistant metal seal Lubricate tray slides Clean battery and cable terminals Install felt battery terminal protector rings and reconnect cables Felt protector rings will be more effective if soaked in EP 90 lubricant prior to installation If a battery terminal sealer is desired use high heat paint Do not use petroleum based lubricant Equipment required a battery terminal puller and battery terminal spreader Fuel System Test Air Filter Conduct air filter restriction test Fuel Filters If fuel filters have a replaceable element fuel water separator drain clean and install new element inspect flex hoses and tubing replace if necessary Note The installation date and mileage should be written on the fuel filters with a magic marker for futu
20. ICE 3 pages The mechanic shall complete this form at 12 000 mile intervals for the service life of the vehicle After entering all requested information and completing the 12 000 mile service the mechanic shall turn the form over to the shop foreman transportation director for review After keying the data into the computer the form shall be filed in the Individual Vehicle Maintenance History file for future reference A copy of this form is presented in Section 13 Note All labor performed as well as results shall be indicated on the Preventive Maintenance 12 000 24 000 48 000 Mile Service form Record actual time for each respective repair performed June 5 1997 33 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual 6 Preventive Maintenance 24 000 Mile Service Repair Code 07 The 24 000 mile preventive maintenance service is a garage performed activity After completing the 12 000 mile procedures the following additional items shall be serviced every 24 000 miles Rear Brakes If indicated by your operating conditions this service may need to be performed at the 12 000 mile preventive maintenance interval After rear of vehicle is raised from the floor and before the wheel and drum assemblies are removed Place safety stands under axle and remove both wheel and drum assemblies Inspect brake components for possible defects leaking wheel cylinders etc Clean brake drum shoes and other
21. IDENT K MISCELLANEOUS SHOP V VANDALISM W WARRANTY DATE DAY YR COMPLETE CHARGE ALL LABOR TO NEAREST TENTH HOUR RECEIVED TOTAL HOURS VMRS WA REPAIRS PERFORMED 5 5 TOTAL LABOR gt INVENTORY USED QNTY UNIT DOT VMRS MFG NO DESCRIPTION PRICE cD AMOUNT lt TOTAL QUANTITY TOTAL INVENTORY COSTS gt SUBLET REPAIRS QNTY VMRS WA ADDITIONAL DESC PRICE CD AMOUNT MECHANICS SIGNATURE GRAND SOURCE INV PARTS N NONINV PARTS 5 SUBLET REPAIRS TOTAL gt Preventive Maintenance and Vehicle Replacement Manual TD 18B FUEL AND LUBRICANT ISSUE TICKET School System Total Station Date Truck Page Type Oil Type Oil Fuel CR 6 4 Fuel HER VOLI Fuel Mileage LEA Oi Fuel Mileage No No Bulk Pump Reading Truck Meter Reading Ending Ending Beginning Beginning Gal Used Gal Used Charge fuel to nearest tenth of a gallon Mechanic No Mechanic Signature June 5 1997 57 DPI Transportation Services TD 30 30 DAY SCHOOL BUS INSPECTION WORK SHEET Rev 1 97 NOTE ALL ACTIVITY BUS INSPECTIONS REQUIRES USE OF WORK SOURCE 1 MILEAGE BUS NO MAKE MODEL SCHOOL DATE Needs Needs OK Items Inspected Repairs OK Items Inspected Repairs 1 Steering F
22. PREVENTIVE MAINTENANCE 12 000 24 000 48 000 MILE SERVICE DATE SHOP VEHICLE LICENSE wS MILEAGE MAKE MODEL AGENCY MO DAY YR D CHARGE ALL LABOR TO NEAREST TENTH HOUR All Mechanic Numbers 3 Digits Repair Order SECTION 1 06 12 000 MILE SERVICE Perform initial road test described in PM manual 1 REPAIRS PERFORMED RC ACT HRS MECH ACT HRS TRANS shift points 1 2 2 3 3 4 00 TRANS shift points down 4 2 2 1 00 GOV operation HIGH LOW VAR MG WASH ENG amp BAT Compartment area 04 CHG OIL amp OIL FILTERS 12000 24000 48 000 Select either 06 07 08 SERVICE lube fittings amp check all fluid levels 09 REP FUEL FILTERS 75 TEST amp SER AIR FILTER If needed 09 LUBE DOORS amp HOOD hinges amp latches 77 TOTAL HOURS PG 1 gt TOTAL LABOR COST gt Repair Order SECTION 2 06 12 000 MILE SERVICE 2 REPAIRS PERFORMED RC ACT HRS MECH ACT HRS MECH CRANKSHAFT END PLAY measured in thousands 14 CLEAN HEATER FILTER 84 ADJ GOV amp THROTTLE linkage check WOT 77 TEST COOLANT ADDITIVE DCA Level 81 REP COOLANT FILTER 09 PRESSURE TEST COOLING SYS 96 SER BATTERY cables amp compartment 21 INSPECT amp ADJ ENG BELTS 18 TOTAL HOURS PG 2 gt TOTAL LABOR COST gt Repair Order SECTION 3 06 12 000 MILE SERVICE 3 REPAIR
23. PREVENTIVE MAINTENANCE AND VEHICLE REPLACEMENT MANUAL NORTH CAROLINA DEPARTMENT OF PUBLIC INSTRUCTION SCHOOL SUPPORT DIVISION TRANSPORTATION SERVICES 919 715 1950 Preventive Maintenance and Vehicle Replacement Manual TABLE OF CONTENTS INTRODUCTION rc ICI H RR 1 B VEHICLE REPLACEMENT POLICIES 3 12 CAPITAL OUTLAY PURCHASES ere eee ee ovre una e CHER US 3 A SCHOOL BUS aee ete eee De 3 Bo SCPVICETIUCK CREER 3 ea ON ORO ASO AK SR ON SORA SLA AS LA AONE 3 Wreckers in akuy uY uu uya QQ Qa Ras as una uya aoaaa S 4 22 VEHICLE REPLACEMENT 2225 4 SCHOOL BUS CS tuy SEU sO sO ISN ASE SS ARO ROG I 4 1 School Bus Replacement td ns 2 Qe Parked BUSES os cere Mee estet e eni ee tee ere eee ME 5 B Service Vehicles e e RR ERE ERE ERE ey a ieee ees 6 25 SURPEUS VEHICLES eee ete 7 Al SCHOOL Bisous etse etse etse Coat te CAS cet DAC C 7 B Service TICK 21 11 4 EE BRE RARE Ahh bL eter 7 C PREVENTIVE MAINTENXAXNCCB 6 ccciecscccscccesccsctcccacddacesaccdeccdeoceeacseeccceacooddocedoadecosneodecaeeasesades 8 1 NEW VEHICLE SERVICE REPAIR CODE 08
24. R Ist oil change after 36 000 mile pm 08 0 48 000 mile MO DA YR The counter recycles for the life of each vehicle once the 48 000 mile service is completed of your vehicles should appear within the above range of counter indicators If your counter indicator s third digit exceeds one you may have a problem properly scheduling your vehicle until you correctly reset the preventive maintenance counter indicator Screen Display The EQS1 screen may be requested by keying any one of five options to view all the vehicles due preventive maintenance or a specific group of vehicles due preventive maintenance June 5 1997 15 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual The following is a sample of the EQS1 screen display If more information is needed refer to the cost clerk computer manual P N 6320 EQUIPMENT SHOP DUE PM IN PRIORITY 1 3 90 0939 Pagel DURHAM ESTPM EXPIRED ASSIGNED EQ JO LIC RC HRS S MO DA YR METER CD DEPT CO LAST NAME 63200264 72049R MI 12 04 30 96 2526 6320 00 GLENN 63202820 71345R 8 4 7 08 01 96 6030 6320 00 63200261 20090R 55 12 06 10 96 5806 6320 00 GLENN 63200313 33837R 05 1 2 09 27 96 5670 6320 00 JORDAN 63200257 20094R 7 3 4 08 21 96 5536 6320 00 WATTS 63200305 33826R 06 12 07 15 96 5032 6320 00 63200289 28554R 06 34 09 28 96 5526 6320 00 NEAL 63208032 92147P 05 2 08 30 96 2652 6320 00 LITTLE RIVER ue SS S sui W
25. S PERFORMED RC ACT HRS MECH ACT HRS MECH TEST ALT AMPS 22 TEST REG VOLTS 22 SER AIR COMP filter amp moisture ejectors SA REP AUXILIARY FILTER automatic transmission 50 TEST STEER GEAR OPER 48 TORQUE SPRING U BOLTS hangers body clamps etc 44 SER WHEEL CHAIR LIFT MC FRONT END ALIGNMENT set toe in 40 TOTAL HOURS PG 3 gt TOTAL LABOR COST gt DATE SHOP VEHICLE LICENSE WS MILEAGE MAKE MODEL AGENCY MO DAY YR D CHARGE ALL LABOR TO NEAREST TENTH HOUR All Mechanics Numbers 3 Digits Repair Order SECTION 4 06 12 000 MILE SERVICE 4 REPAIRS PERFORMED RC ACT HRS MECH 4 ACT HRS MECH FRONT BRAKES RF 32 LF 32 Check or reline 3A TURN BRAKE DRUMS if needed 37 REPACK WHEEL BEARINGS all removed bearings 57 ADJ BRAKES 32 BUS TRAVEL Pickup amp delivery 99 BRAKE TEST 96 panic stop brake meter min 6096 37 ROAD TEST VEHICLE 00 TOTAL HOURS PG 4 gt SECTION 5 07 24 000 MILE SERVICE Repair Order TOTAL LABOR COST gt 5 REPAIRS PERFORMED RC ACT HRS MECH ACT HRS MECH SER AUTO TRANS replace fluid amp filters Adjust shift points if needed 50 REAR BRAKES RR 32 LR 32 check or reline 3B TURN BRAKE DRUMS if needed 37 REPACK ALL WHEEL BEAR All Removed Bearings 57 INSPECT S CAM BUSHINGS Replace if needed 37 CHECK TENSION BELT PULLEY 16 TUNE UP ENGINE 12 TEST STARTER draw AMPS
26. TED VEHICLES DIESEL AND GASOLINE Oil packed in sealed containers is highly recommended to reduce engine contamination and to maintain chassis manufacturers warranty requirements June 5 1997 26 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual TD 8A PREVENTIVE MAINTENANCE OIL CHANGE SERVICE 1 page This vehicle service is to be recorded on a TD 8A Preventive Maintenance Oil Change Service form by the mechanic performing the service This form is to be turned in daily to the appropriate person The TD 8A Preventive Maintenance Oil Change Service form is to be processed in the same manner as a TD 18A Equipment Repair and Parts Order A copy of the TD 8A Preventive Maintenance Oil Change Service form is presented in Section 13 June 5 1997 27 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual 5 Preventive Maintenance 12 000 Mile Service Repair Code 06 The 12 000 mile preventive maintenance service is a garage performed activity It is the first mileage based scheduled preventive maintenance after the lubrication oil and filter change The following procedures and instructions refer to the 12 000 mile service and the Preventive Maintenance 12 000 24 000 48 000 Service Work Order These service procedures are to be followed every 12 000 miles for the entire service life of all vehicles This service is similar to that described in the section on 30 day inspection and
27. The director shall permit only state funded school garage employees to operate service vehicles service vehicles are to be used only for official business Tort Claims insurance only covers vehicles operated by employees paid from the State Public School Fund on official business Note Follow vehicle manufacturer maintenance specifications for all items not listed June 5 1997 45 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual 11 Vehicle Body Repair and Repainting Procedures The appearance of each county s bus and service vehicle fleet has more effect on your public relations than any other maintenance factor While the appearance may or may not affect safety it does affect the manner in which the public views the mechanical condition of your bus and service vehicle fleet Driver attitudes and care of their assigned vehicles are influenced considerably by the appearance of those vehicles Pride in the operation of your transportation fleet is very much dependent upon the appearance and condition of the vehicles Vehicles shall be repaired and repainted as needed The following preparation procedures are to be followed These steps will greatly increase the durability and life expectancy of your paint jobs Wash and clean vehicle with a cleaning agent Wet sand vehicle All lettering must be sanded to a smooth surface Repair all exterior damage to vehicle Mask and paint with a good qu
28. VOLTS 24 TOTAL HOURS PG 5 gt Repair Order 8 SECTION 6 08 48 000 MILE SERVICE TOTAL LABOR COST gt 6 REPAIRS PERFORMED RC ACT HRS ACT HRS MECH SER POWER STEERING 48 SER AIR DRYER replace desiccant SA DRAIN amp REP BRAKE FLUID hydraulic system 33 SER DIFFERENTIAL drain amp replace non synthetic lube 56 RADIATOR DRAIN amp FLUSH replace with new antifreeze 81 ENGINE VALVE ADJUSTMENT 12 SERVICE OUTBOARD DRUM WHEEL BEARINGS 57 UNDER COAT BUS 44 Mechanic Signature TOTAL HOURS PG 6 gt TOTAL LABOR COST gt Revised 1 97 TD 8B IVEI DATA ENTRY INVENTORY USED DATE SHOP VEHICLE LICENSE WS MILEAGE MAKE MODEL AGENCY MO DAY YR 5 QNTY UNIT DOT NO MFG NO DESCRIPTION S PRICE CD AMOUNT 5900049 MOTOR OIL 8191600 CHASSIS GREASE 8191500 TRANS DEXRON II FLUID 8191601 80 90 EP 5500500 ANTI FREEZE OIL FILTER FUEL FILTER COOLANT FILTER AIR FILTER TRANS FILTER AIR COMPRESSOR FILTER 8191006 NALCOOL AUX TRANS FILTER FUEL FILTER TOTAL QUANTITY TOTAL INVENTORY COSTS INVENTORY USED QNTY UNIT DOT NO MFG NO DESCRIPTION S PRICE CD AMOUNT TOTAL QUANTITY TOTAL INVENTORY COSTS SUBLET REPAIRS QNTY RC STANDARD RC
29. aced a small number are retained for spare status These vehicles are available for transfer from one LEA to another in the event a service vehicle is destroyed by vandalism or accident 3 Surplus Vehicles The Transportation Services Section is charged with designating the old buses and service vehicles that are to be removed from active service and replaced with a new vehicle The number of vehicles removed and replaced annually depends on the annual appropriation from the General Assembly Funds realized from the disposal of old vehicles revert to the state vehicle replacement fund A School Bus Buses that have been replaced by the state are sold through State Surplus Property The bus lettering will be removed per instructions in the Preventive Maintenance Manual Proceeds from the sale of surplus buses are returned to the state vehicle replacement fund B Service Truck A local board may purchase service trucks that have been replaced by the state The local board agrees to pay the price that is set by DPI Transportation Services If the local board does not wish to purchase the truck it is sold at bid through State Surplus Property The local board is responsible for painting the truck a color other than yellow before delivering it to the surplus office DPI Transportation Services will determine which trucks are retained as spares Proceeds from the sale of surplus trucks are returned to the state vehicle replacement fund June 5 1997
30. ality unleaded polyurethane paint Make sure bus is dry Add a paint hardener catalyst into paint to increase paint life 1f recommended by paint manufacturer Use lettering screens or vinyl material to letter vehicles Use reflective material front and rear for background to letter school bus June 5 1997 46 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual 12 Utilization of Surplus Equipment With the approval of the regional area transportation consultant parts may be used from school buses which have been identified for salvage A number of complete buses may be identified for salvage or salvage parts may be removed and stored in a designated location To obtain a listing of salvage buses utilize screen EQSI Key in status Z type 6 and enter to view the salvage list Permission to use major components must be requested prior to installation on a regular bus Contact your regional area transportation consultant for the procedures and record keeping required on salvage equipment Equipment parts removed from vehicles without proper authorization shall be reinstalled on the original vehicle by the school bus garage staff If salvage parts are stored for future use items are to be tagged as salvage with the bus number and mileage noted Sale of Obsolete Vehicles Prior to being priced all buses shall have the lettering removed and the bus appearance altered in the following manner The
31. ansmission mounting bolts Check and adjust if needed brake chambers push rod to slack adjuster angle BODY Check all lights Adjust door controls a r regulator Adjust windshield wiper stroke and or arms Torque seat mounting bolts all seat belt mounting and operation Torque glass channel mounting screws Torque turn signal bolts and screws lens screws Adjust mirrors and tighten Check all electrical connections in body electrical panel Torque body to cowl bolts Check stop sign mounting screws align and tighten blade mounting bolts Modify battery box coat inside of box with metal seal Check and adjust brake pedal free travel Lubricate glass channels amp latches with silicone Lubricate drivers seat tracts Check for install if necessary a ground wire from body to the body electrical panel with warning light switch and solenoid Check wheelchair lift for ground wire INSTALL IF NECESSARY ELECTRICAL SYSTEM Test starter current draw Amps Volts ground secondary coil wire Starting circuit resistance test voltmeter from positive battery terminal to starter term volts Alternator output test regulated Amps Voltage regular test volts Charging system resistance test AT 20 AMPS use voltmeter Out put terminal of alternator to positive terminal of battery volts Frame of alternator to negative term of battery volts Diode stator test Residual current draw negative terminal of battery to negative cable Milliamperes ENGINE Check routing
32. are of a preventive nature Any item inspected serviced or repaired prior to that item breaking or malfunctioning is preventive maintenance AII fuel truck driver route time will be work source D and keyed in the same manner as administrative and clerical time to the Dummy Shop Vehicle Number using repair code 00 Work Source G Administrative amp Clerical Time transportation directors supervisors shop foremen and cost clerk s time not charged to a vehicle should be accounted for using work source G DO NOT USE THIS CODE TO RECORD ANY LEAVE TIME OR HOLIDAYS All work source G data is to be charged to the Dummy Shop Vehicle Number using repair code 00 Work Source 1 All County Vehicles type 7 amp type 8 ALL REPAIRS and all TD 18A Equipment Repair and Parts Order forms that involve working on county vehicles are to be work source D THERE ARE NO EXCEPTIONS All inventory charged to type 7 and type 8 vehicles on TD 18A Equipment Repair and Parts Order forms are to be keyed using work source I Work Source K Miscellaneous Shop Time All miscellaneous time such as shop equipment repair cleaning or repairing the garage staff meetings and or training sessions at the garage are to be indicated using work source K and charged to the Dummy Shop Vehicle Number using the appropriate repair code Work Source J Accident Repair All wreck or storm damage repair to vehicles is to be indicated using work source J
33. assigned days of the week The fuel truck driver will record mileage for each vehicle fueled The truck driver shall sign the form and turn it over to the cost clerk After keying the data into the computer the cost clerk shall file it in a designated file for future reference Note All added oil is to be recorded on the TD 18B Fuel and Lubricant Issue Ticket Do not record added oil on a TD 18A Equipment Repair and Parts Order form Only oil change quantities are to be recorded on a TD 18A Equipment Repair and Parts Order form Also all added oil is to be keyed into the computer using screen FISB Do not use screen IVEI to enter added oil into the computer of the above forms are presented in Section 13 June 5 1997 40 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual 9 School Bus Garage Procedures Proper garage operation is essential to a cost effective preventive maintenance program The maintenance program presented in this manual requires that the operation of the school bus garage be conducted in the manner described below The garage shall be kept in a clean workable safe condition at all times The following procedures should be utilized at the garage When a vehicle is brought to the garage the foreman or director if he sent after the vehicle shall write a TD 18A Equipment Repair and Parts Order form giving information regarding the items to be repaired Any defects detected by the me
34. cation Transportation Services staff members will review these records periodically during the year TD 30 30 DAY SCHOOL BUS INSPECTION WORK SHEET 1 page The mechanic shall use this form to inspect each school bus After completing the information on the top of the sheet the defects are to be noted by placing an X in the Needs Repair column by the respective item After repairs to each defective item have been completed the mechanic shall place a check mark in the OK column for that item If defects cannot be repaired the day of inspection the mechanic for his own use shall complete a Defect List The mechanic shall refer to the Defect List the next day he is at the school and repair these defective items if parts are available before inspecting another bus The mechanic shall record his inspection time on the form and turn in daily the 30 Day School Bus Inspection Work Sheet to the designated person The designated person shall file the 30 Day School Bus Inspection Work Sheet in the individual bus maintenance history file after keying inspection data and labor into the computer A copy of the 30 Day School Bus Inspection Work Sheet is presented in Section 13 TD 18A EQUIPMENT REPAIR AND PARTS ORDER 1 page The mechanic shall record his service truck subshop number on the Shop location the vehicle number work source code mileage make and model of the vehicle and the correct date A list of repairs completed shall be entered on th
35. ce filter maintenance oil fuel air etc is extremely critical to proper diesel engine servicing as well as gasoline engines Adverse weather and road conditions may warrant more frequent lubrication The 6 000 mile servicing frequency shall not be exceeded This is the first mileage based service for school buses For new buses only this service will require the following Drive in king pin bolt lock pins and torque lock nut see new vehicle king pin bolt instructions in Section 1 Retorque all body mounting bolts test wheel bearings Adjust tension on all engine accessory drive belts Use a magic marker to record oil change maximum quantity and computer oil filter numbers under the hood of each vehicle for future reference Every 6 000 miles or 12 months from date of last oil change all vehicles shall have the oil and filters changed as well as all grease fittings lubricated Engine should be at normal operating temperature when the oil is drained Also all doors and hood hinges and latches are to be lubricated The above lubrication oil and oil filter change frequency shall be required for the entire service life of all vehicles Factors that affect oil contamination are as follows Cold running engine use at least 185 degree thermostat Air cleaner Poor operating engine rich fuel mixture Weather conditions Road conditions OIL REQUIREMENTS 15W40 CD SH EOK 2 SHALL BE USED IN ALL STATE OPERA
36. ce and Vehicle Replacement Manual 3 30 Day Inspection Program Repair Code MI The 30 day inspection is the backbone of our Preventive Maintenance Program If transportation personnel will thoroughly pursue the following description of a 30 day inspection the procedures in the remaining preventive maintenance sections of this manual will be easier to perform on the entire transportation fleet Refer to Section 13 for more information on the 30 Day School Bus Inspection Work Sheet GENERAL STATUTE 115 C248 a REQUIRES ALL SCHOOL AND ACTIVITY BUSES TO BE INSPECTED EACH 30 CALENDAR DAYS The purpose of this inspection is to identify mechanical defects or other defects which may affect the safe operation of the bus It is also recommended that all service pickups fuel trucks wreckers and tire trucks are inspected each 30 days in the same manner as school buses Each mechanic assigned to a specific group of buses shall inspect each assigned school bus and school activity bus once each thirty calendar days while buses are being operated This inspection is for the purpose of detecting any and all items which have failed or could be reasonably expected to fail before the next regularly scheduled monthly inspection The procedures for this inspection are as follows INSPECT BUSES AS THEY APPEAR ON THE 51 SCREEN DUE LIST On any assigned day of any month that buses are operated weather permitting a mechanic s designated by the
37. chanic who drove the vehicle to the garage will also be listed on the repair order If the vehicle is due preventive maintenance the proper form TD 8A or 8B is also required to be completed If the vehicle is not to be brought into the shop immediately it shall be parked on the designated incoming area leading to the school bus garage In such case the TD 18A Equipment Repair and Parts Order form will be placed in the proper folder in the Work Order file If the vehicle has not been inspected during the month a 30 Day School Bus Inspection Work Sheet will be included with the TD 18A Equipment Repair and Parts Order form Mechanics driving a vehicle at any time should consider this as a road test They should always be alert and observing for any defects Any defects detected shall be repaired immediately if practical If not repaired they shall be reported to the foreman or director Any time a spare bus is returned to the garage and the mechanic who drives it detects any mechanical defect to be repaired the bus shall be parked on the designated incoming area and the foreman or director notified of the defect The foreman or director shall then write a TD 18A Equipment Repair and Parts Order form and place it in the proper folder of the work order file It is required that a work order file be established to hold work orders until buses are brought into the garage for repair Note It is essential for broken speedometers be repaired immediatel
38. ctor any defects which could not be reasonably repaired at the school and would necessitate bringing the bus to the garage The mechanic shall make for his own use a Defect List of all defective items which he can repair at the school A defect list is simply a list made by the mechanic to remind him to repair those defective items on his next visit to that school Items which had been reported as defective but listed as not repaired on a previous day s 30 Day School Bus Inspection Work Sheet which are repaired during this day s work shall be reported on a Defect List and turned in with the following form There shall be a TD 18A Equipment Repair and Parts Order form completed for each bus with previously reported defects that were repaired during the day Any remaining defects on any bus would be handled in the same manner at the time they are repaired This procedure would insure that all defects are repaired Defect Lists for items completed that day along with the mechanic s 30 Day School Bus Inspection Work Sheets and the TD 18A Equipment Repair and Parts Order form shall be turned in at the parts department or other designated location daily At this time the mechanic shall secure from parts personnel parts to replace any items used from his service truck inventory during the day He shall also obtain from parts personnel any additional parts which are needed to make repairs to defective buses in his area This procedure of securing pa
39. d on the 30 Day School Bus Inspection Work Sheet and scheduled for repairs Axle studs and nuts Fuel tank and lines Hood hinges latches bumpers adjust hood 4 point contract lubricate Front End fenders skirts radiator support Fuel Visual inspection of linkage lines hose fuel pump injection pump Pump Throttle stops adjust Electrical Battery compartment condition and cleanliness terminals electrolyte level Starter ear test Road Test Travel angle Steering gear operation lock to lock lost motion shimmy Panic stop not sliding brake action engine idle Accelerate knocks pings performance Rear axle and drive line noise vibration Transmission automatic observe operation and shift points Governor operation MPH high low variation RECORD HIGH June 5 1997 24 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Instrument gauges observe all Test operation of hydraulic brake warning light Test operation of low air pressure buzzer and light The mechanic shall complete and sign the 30 Day School Bus Inspection Work Sheet and present completed forms to his supervisor daily The following are maintenance record forms which are referred to in this section They are required to document the preventive maintenance program These forms are to be properly and thoroughly completed and filed in the appropriate assigned lo
40. e Repairs Performed Section Labor shall be recorded to the nearest tenth of an hour for each type of repair Only one type of repair may be entered on a line The mechanic shall enter his mechanic number beside all labor time entered on each line of the repair order The mechanic or designated person shall record the remaining pertinent information needed inventory used DOT computer number manufacturer s number description and cost for all non inventory direct charge items and or sublet repairs When the job is completed the mechanic shall sign the form and turn it over to the designated person for review and for all data to be entered into the computer This form shall be filed in an individual vehicle cost record file by a designated person A copy of the TD 18A Equipment Repair and Parts Order is presented in Section 13 travel time from school to school or bus to bus etc is to be charged on the TD 18A Equipment Repair and Parts Order by using repair code 00 Charge actual time of repair for each specific repair performed to a vehicle June 5 1997 25 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual 4 Preventive Maintenance 6 000 Mile Service Repair Code 05 Proper servicing will increase vehicle life and help to deter high maintenance costs To achieve the extended life and high mileage we are currently obtaining school buses require consistent and thorough preventive maintenan
41. e a new bus The new bus will be added to the state replacement schedule upon delivery to the local board Under certain circumstances a LEA may purchase a used bus from another LEA for the purpose of capital outlay As long as the model year of the used bus is within 8 years of the current model year the used bus will be placed on the replacement schedule upon request The model years will coincide with fiscal years i e 1997 98 equates with 1998 model year B Service Truck These service vehicles are used by the garage mechanics to access the fleet for maintenance and service The buses are typically staged at schools or other parking facilities mid day and are available for routine inspections and minor servicing The service trucks are also used to respond to road calls in the event a bus becomes disabled A local board may add a service truck pickup cargo van to the state replacement schedule if the ratio of buses operated per service truck inventory exceeds 25 The general rule for service trucks is one truck per 20 to 25 buses The truck purchased must be new and comparable to the truck that is on state contract At such time that the truck purchased by the local board is replaced by the state the replacement will be of the same type trucks currently being offered by the DPI Four wheel drive may be added to a service truck but the local board must bear the cost of this option C Fuel Truck Fuel trucks are the primary source for distribut
42. e a safe transportation environment for the students in the Public Schools of North Carolina Therefore it is each LEAs responsibility to maintain their school buses as described in the PM Manual Because of the State s responsibility to replace school buses no school bus is to be altered in appearance color lettering or equipment unless authorized by the Department of Public Instruction Transportation Services Section Additional equipment may be added to school buses as described in Section 15 of this manual In order to provide the best information to all school districts regarding school bus equipment it is important that the installation of new equipment or alteration of appearance be coordinated through and approved by DPI Transportation Services This manual is used in conjunction with the State Vehicle Fleet Management System SVFMS The 5 5 is an online data system whereby all one hundred garages are connected to the State Computer Center The software was developed by the Department of Transportation and the bus June 5 1997 1 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual garages share the system with the DOT and Highway Patrol Data entered by the users is updated either real time or overnight in a batch format The principal areas addressed by the SVFMS are as follows E Preventive maintenance schedule and vehicle status a Inventory management for repair parts and tires a Vehicle main
43. e three geographical areas of the state June 5 1997 AREA 1 Eastern North Carolina Cato Devane Area Transportation Consultant NCDPI John Evans Transportation Director Johnston County Jeff Smith Transportation Director Onslow County Jerel Winslow Transportation Director Pasquotank County AREA 2 Central North Carolina Johnnie Hardee Area Transportation Consultant NCDPI Terry Smith Shop Foreman Guilford County Billy Smith Shop Foreman Randolph County Ronnie McDonald Shop Foreman Harnett County Ronnie Apple Shop Foreman Alamance County AREA 3 Western North Carolina David Sluder Area Transportation Consultant NCDPD Charles Ball Shop Foreman Forsyth County Alfred Schrum Shop Foreman Lincoln County Mike Ellis Shop Foreman Wilkes County DPI Transportation Services 66
44. ed for your operation QUANTITY TYPE OF EQUIPMENT 1 Headlight aligner complete set High pressure washer Ignition tester electronic Impact wrenches 1 2 and 3 4 or 1 Jack safety stands heavy duty Jacks hydraulic or air minimum 10 ton Key machine Kunrl machine valve guide repair Masking paper dispenser Metal cutting shears Metal lathe engine lathe Micrometers and calipers inside and outside complete set Milliampere meter 0 150 Paint gun 5 gallon pot with agitator Paint respirators OSHA approved Pin hole grinder Power hacksaw Press 40 ton Pressure gauges 1 air and 1 hydraulic Pressurized brake bleeder Radiator temperature gauge N e m m N e Go OO Dl Radio system two way 1 base station 1 radio station 1 radio on each service vehicle Rear axle nut sockets complete set Ridge reamer Rivet gun air operated Sander disc type heavy duty Sander orbital Socket set heavy duty metric and standard Steering wheel puller Tap and die set Timing light electronic Tire balancer Tire changers 1 truck and 1 car Tire inflation cage N m m m m Tire matching gauge June 5 1997 DPI Transportation Services 63 Preventive Maintenance and Vehicle Rep
45. ehicle Replacement Manual 1 New Vehicle Service Repair Code 08 The success of any preventive maintenance program is determined by a number of factors One of the initial factors and possibly one of the most important is the proper servicing of new vehicles prior to placing them into daily service Without proper new vehicle servicing the durability service and vehicle life will be adversely affected The following section is devoted to explaining what is required in the proper service of new vehicles and how to correctly accomplish this required new vehicle preventive maintenance program Refer to the New Vehicle Service Work Order in Section 13 PRE DELIVERY INSPECTION AND SERVICE FOR NEW BUSES Front Axle Balance front tire and rim assembly This balancing is done on a static truck tire balancer Using a tire tread gauge that measures in 32nds of an inch measure the amount of brake lining at the thickest point above the rivet head on each brake shoe Record on the New Vehicle Service Work Order this measurement for each axle Torque brake shoe backing plate or spider mounting bolts to specifications Torque brake drum to hub bolts to specifications Oil drain and refill with appropriate lube Install hub and drum assembly and adjust wheel bearings to specified torque Install tire and rim Align and torque wheel nuts Torque spring u bolts to specifications Torque spring shackles and eye bolts or spring pivot b
46. elines established for equipment replacement by Transportation Services A LEA may be allowed to adjust capacities depending on bus offerings in a given year For instance a LEA may be allowed trade in front engine school buses for rear engine buses based on a seating or cost exchange ratio that will be calculated each year LEAs may also be afforded the opportunity to upgrade by paying the difference in cost from a similar model 2 Parked Buses From time to time changes in a LEAs transportation pattern may enable that LEA to use fewer buses on a daily basis than its number of authorized Status 2 buses As this continues a LEA may have one or more buses which are retired from regular use but are a part of its authorized Status 2 inventory These buses will be designated as Status Parked buses These buses having been retired from regular service will not be part of the eligible pool of buses to be replaced by the state that pool consisting solely of Status 2 buses June 5 1997 5 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Upon designating a given vehicle as a Status OXX parked bus the LEA has several options available to it with regard to that vehicle a b c d Activity bus conversion Simply by notifying Transportation Services a LEA may convert a parked bus to an activity bus by making appropriate mechanical adjustments to the vehicle This includes pai
47. entive maintenance program The purpose of the 5 200 mile scheduling is to allow each county to perform preventive maintenance service before the maximum interval of 6 000 miles has been reached A second goal is to not exceed the 30 day limit on safety inspections on your fleet of vehicles 30 calendar days Vehicle Displayed Only active vehicles that are being used should appear on the EQS1 Screen If vehicles are no longer in service they should be removed from the screen permanently If you have spare vehicles or vehicles that are used only at rare intervals which have appeared EQS1 for preventive maintenance service based on the time factor since the last preventive maintenance service it is permissible to extend the time factor on screen EQMI If you need assistance in this area please call the Transportation Services Office in Raleigh at 919 715 1950 June 5 1997 13 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Repair Code Scheduling Vehicles will appear for preventive maintenance on screen EQSI by one of nine different repair codes RC MI 30 Day Inspection MO DA YR indicates date of last inspection Mileage indicated on the screen for MI is not relevant because this service is scheduled by time only days since last inspection 05 Oil Change MO DA YR indicates date of last preventive maintenance meter indicates mileage since last preventive
48. ew these records periodically during the year June 5 1997 43 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual INDIVIDUAL VEHICLE MAINTENANCE HISTORY FILE It is required that a separate folder be established to hold maintenance records for each vehicle in your fleet WORK ORDER FILE It is required that a folder be established to hold TD 18A Equipment Repair and Parts Order forms written in advance of vehicles coming to the garage for repairs EXTRA BUS SCHEDULE ASSIGNMENT This form is to be completed by a designated person to record when and where the spares are being operated Not only does this form assist in recording use of spare buses it also records down time of your regular buses This form is to be filed in an Extra Bus Schedule file for future reference A copy of the Extra Bus Schedule Assignment form is presented in Section 13 SCHOOL BUS ACCIDENT REPORT The transportation director shall record the county city unit number complete accident reports as needed and send one copy to the Attorney General s Office The county school superintendent for future reference should also retain one copy A copy of the School Bus Accident Report is available from the Attorney General s Office June 5 1997 44 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual 10 Service Vehicle Maintenance and Operation Maintaining your service vehicle fleet is essential in orde
49. f these defects to garage personnel will be as follows the assigned person shall contact by radio the fuel truck operators and mechanics who are already working in their respective areas and give them a list by bus number of all reported defects in their area If a mechanic assigned to an area not serviced by a fuel truck on that day is working in the garage the foreman and or transportation director shall give a list indicating the buses and their defects as reported by the drivers The mechanic shall then proceed into his area and make such repairs and return to his assigned duties The personnel to whom such defects are assigned shall inspect and repair these defects as far as they can provided they have the necessary parts with them to do so June 5 1997 38 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual personnel to whom a defect has been assigned who cannot repair said defect shall report that information along with any additional information that would be helpful in repairing the defect to the garage by radio The foreman or director will then decide the best course of action to take in the same manner he would with any other defective bus Personnel to whom defects have been assigned from the reported Driver Reported Bus Defect Log shall make a list of the defects by the bus number This list of defects for each bus with notations of corrections made shall be turned in at the parts departme
50. foreman or director will inspect all lights windshield wipers stop signs walking arms brake operation service and park steering components and rear door and window buzzers on all buses in the assigned area On all buses equipped with air brakes the travel of the air chamber push rods front and rear shall be checked at this time and adjusted if needed per manufacturer s specifications To complete the 30 day inspection the mechanic will on assigned days go to a school in his designated area and completely inspect and road test each bus due a 30 day inspection After inspecting a bus he will repair all defective items as far as he possibly can with parts available on his service truck before he starts inspecting another bus The mechanic is responsible for maintaining a repair parts inventory on his service truck The mechanic shall keep a copy of the inventory Parts shall be charged on a TD 18A Equipment Repair and Parts Order form when removed from the service truck The TD 18A Equipment Repair and Parts Order form and the mechanic s 30 Day School Bus Inspection Work Sheet shall be completed before beginning the inspection of the next bus Defective items for which the mechanic does not have the necessary parts to repair which do not constitute a hazard for operation or will not cause a greater mechanical problem will be left until the next day that the mechanic inspects in his territory On the next day that he inspects he
51. front and rear panel which formerly had School Bus indicated shall be painted from the flashing light on the left to the flashing light on the right a color other than school bus yellow Also the area of the body which formerly indicated NC Public Schools shall be painted a color other than school bus yellow The painted area is to be the full length of the bus Buses which are obsolete will be priced for sale or bid on a TD 13 Discarded Equipment Form by your regional area transportation consultant Buses shall not be sold unless priced in writing on the proper form prior to sale or verbal permission is given by phone by the area transportation consultant Service vehicles fuel trucks tire trucks and wreckers shall have all lettering removed and shall be painted inside and outside a color other than school bus yellow prior to being placed on bid unless sold to another school system Sale of Other Surplus Items Sale of all other surplus items is required to be placed on bid Proper procedures must be followed TD 13 DISCARDED EQUIPMENT SUPPLIES amp MATERIAL 1 page The area transportation consultant shall complete this form identifying vehicles or other items for sale or bid DISCARDED EQUIPMENT SUPPLIES amp MATERIALS FILE A file folder is required to hold authorizations of discarded equipment for future reference Keep in office until of no further administrative value June 5 1997 47 DPI Transportation Services
52. ge due to defects detected and road failures during the day The following are maintenance record forms which are referred to in this section They are required to document the preventive maintenance program These forms are to be properly and thoroughly completed and filed in the appropriate assigned location Transportation Services staff members will review these records periodically during the year BUS DRIVER SIGN IN SHEET This form is utilized at the school each day for the drivers to record the bus number and time of arrival Check the proper column if the bus is OK record the number of students transported note any bus defects or problems which the driver knows need to be checked by a mechanic and sign the report The designated person shall use this form as a record when notifying the school bus garage of driver reported bus defects A copy of this report shall be picked up by the gas truck driver or mechanic whoever is at the school that day and turned over to the designated person at the school bus garage After reviewing the form it shall be filed in a School Bus Drivers Sign In Sheet file DRIVER REPORTED BUS DEFECT LOG A designated person at the school bus garage shall record daily on this form the defects called in from each school The bus number school time of call mechanical problem and the assigned June 5 1997 39 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual mechanic shall be
53. hree 3 factors The number one factor is mileage M number two is fuel consumption F and number three is time T days since last PM Vehicles may appear for preventive maintenance service by any one of these three factors Screen Use The transportation director or his designated employee shall review the EQS1 Due PM screen each workday morning The daily work schedule should be adjusted accordingly dependant upon what vehicles are displayed One advantage of reviewing the screen daily is that it allows each county to service all vehicles before they exceed the preventive maintenance mileage maximum of 6 000 miles Early Display vehicles will appear for preventive maintenance 800 miles before they reach the maximum mileage allowed between preventive maintenance services Vehicles due 30 day inspections will appear seven 7 days before they exceed the maximum days allowed between inspections When school is in session each school bus and activity bus must be inspected each thirty calendar day period to meet state statues The one exception is when holiday periods are involved Example The computer will continue to count days over the Christmas and New Year holiday period When you return from this extended holiday period a large number of your fleet will be scheduled for 30 day inspections Preventive Maintenance Goals One of your goals is to not exceed the mileage maximum interval of 6 000 miles for any vehicle on the prev
54. ibed in the specifications The following list includes safety items that may be added to update older school bus specifications without specific written approval Reflective lettering Polyurethane paint Reflective stop sign material Air dryer Automatic slack adjusters Parking brake interlock Synthetic differential lube Driver fan Exhaust pipe extension turn down 11R22 5 radial tires Proform fire block seat material Strobe lights Rearview lens Double nickel mirrors Roof hatches Backup alarms Right side hand rails Other safety or cost efficiency items not included in the school bus specifications may be installed on your school buses However Transportation Services must receive a written request and approval granted prior to actual installation on a bus es Any item added would be considered a pilot test and must be reviewed by a Transportation Services staff member prior to the bus being put in service The following are some examples of test pilots that have been conducted crossover mirrors C ranspec roof hatches Strobe stop signs Rear mounted strobe lights adopted in 1996 School Bus Specifications Backup alarms adopted in 1996 School Bus Specifications June 5 1997 65 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual D PMMANUAL COMMITTEE MEMBERS The members of this committee were selected as representatives from th
55. ilizing a Fleetrite Coolant Test Kit or equivalent kit The coolant conditioner controls the buildup of scale with the cooling system of diesel engines OTHER REQUIRED TESTS Wheelchair Lift Inspect wheelchair lift for defects leaks and smoothness of operation Lubricate all lift wear points Also inspect the following items Observe electric motor pump performance Check the fluid level with the lift up Adjust as needed per OEM specifications Vented fluid cap will help reduce leakage Check the chains for looseness Lubricate all grease fittings Check complete lift hydraulic system for leaks Check all switch adjustments pressure release switches etc Check lift frame or cracks Check cam brackets for proper adjustment Check current draw on electric motor per EOM specifications Fluid pressure psi up position per OEM specifications By pass pressure if applicable per OEM specifications June 5 1997 31 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Crankshaft End Play Using a dial indicator placed against the flywheel on crankshaft harmonic balancer move crankshaft forward and backward to measure the amount of end play Compare with manufacturer s specifications Excessive crankshaft end play indicates worn thrust bearings and can destroy an engine block Crankshaft thrust bearing wear increases rapidly due to a defective torque converter Automatic Transmission Auxiliary Filter Replace A
56. ing fuel to the bus fleet With the buses typically staged away from the garage a remote system of fueling is essential A local board may request that June 5 1997 3 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual the DPI review the need for an additional fuel truck Several factors will be considered in granting the request including growth and current logistics for fueling the buses i e school locations and staging areas If the DPI agrees that the changing environment warrants an additional fuel truck the local board may proceed with purchase and the state will add the fuel truck to the replacement schedule D Wreckers Wreckers are used to tow disabled buses to the garage or another site for repairs If a county currently without at least one wrecker chooses to invest in a wrecker the DPI would place the vehicle on the replacement schedule and replace the wrecker chassis when appropriate The body which includes the wrecker boom could be transferred to the replacement chassis upon approval by Transportation Services or the local board would need to purchase a new body 2 Vehicle Replacement The Transportation Services Section is charged with allocating resources designated by the North Carolina General Assembly for school bus replacement among all local education agencies LEAs in the state in an equitable manner for the replacement of school buses and service vehicles Once vehicles are rep
57. ing items shall be noted on the work order Travel Angle Observation by using both side mirrors should indicate the bus travel angle in relation to the road or centerline A bus that appears to be running somewhat sideways rear axle not tracking on a straight line with the front axle could indicate either a misalignment of the axle to the springs or possibly a broken or bent spring center bolt Steering Gear Operation While traveling very slowly in the bus garage parking area or some similar safe place slowly turn the steering wheel to its extreme left back to its extreme right and then again to the straight ahead position Observe any roughness looseness or other defect June 5 1997 28 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual While driving along the road ease bus to the right until right wheel leaves the pavement then slowly to the left until bus returns to the pavement Observe if any shimmy or lost motion can be detected Load Test While traveling uphill or simply slowing down to a point allowing for acceleration while still in high gear accelerate the vehicle in a loaded condition and observe performance Brake Test Each vehicle is required to have its brakes tested by using a Tapley brake test meter or equivalent test meter This test is to be conducted on a dry paved road which is as level as possible for local terrain The test is made by making a panic stop at 20 mph after
58. ion 18 authorized to own and operate a school bus fleet under Statute 115C 239 These fleets include school buses for basic to and from school transportation and the service vehicles required for bus maintenance and fuel delivery The local boards originally purchased these vehicles over a period of many years The state assumed the responsibility of replacing these vehicles in the 1930 s under Statute 115C 240 e f The rate at which vehicles are replaced depends on the age and mileage of the vehicles subject to appropriations from the General Assembly The State Board of Education has the responsibility of purchasing the vehicles and allocating those vehicles to the local boards fairly and equitably on an annual basis 1 Capital Outlay Purchases A LEA may purchase vehicles and increase the size of the fleet that provides school transportation The need for this action is generally the result of growth opening closing of schools or re districting A LEA is given this authority under Statute 115C 249 a and the request for such additions are reviewed by Transportation Services A School Bus When needs exceed resources a local board may request that a school bus be added to the state replacement schedule The state will pay for the operation of a temporary bus Status L loaner as long as the local board commits to the purchase of a new bus by submitting a letter requesting such use and drafting a purchase order within eighteen months to purchas
59. k day in which the inspections are made A record indicating the buses which have been inspected during the month will be maintained This record will indicate buses which have been inspected during the month whether the inspection and repairs are complete or if there are defects which have not been repaired For any bus which had been previously reported as inspected and not repaired a Defect Repair List must be turned in by the mechanic showing that he has completed any or all these defect repairs The foreman and or director shall indicate on the mechanic s 30 Day School Bus Inspection Work Sheet the defective item or items which have been corrected He will record the date of such corrections and file this information in the individual vehicle maintenance history file folder If a 30 Day School Bus Inspection Work Sheet indicates a defect making it necessary to bring a bus to the garage for repairs the foreman shall consider this in his planning of work for the coming day and in his discussion of the work schedule with the director If there are buses previously listed as inspected with defects not repaired and the mechanic assigned to the buses has moved on to inspecting and repairing other buses the foreman and or director shall discuss with that mechanic why those defective buses were not repaired prior to inspecting other buses THE FOLLOWING ITEMS ARE TO BE INCLUDED IN THE 30 DA Y INSPECTION Inside Body Tire chains check and wi
60. laced they remain titled to the LEAs however their authorized use is at the discretion of the state A School Buses In keeping with this charge school buses are classified in one of several categories as indicated below Status 2 a bus titled to the LEA authorized for use as a regular route bus subject to replacement by the state as the need arises and as funds are available Status S a bus titled to the LEA having already been replaced by the state with a new bus authorized for use as a spare bus when a regular route bus is not available due to mechanical failure or maintenance Status 4 a bus titled to the LEA having already been replaced by the state with a new bus not authorized for use as a regular or spare route bus Eventually most of these will be designated to be sold as surplus Proceeds from sale of this bus will be forwarded through State Surplus Property to the DPI vehicle replacement fund Status L a bus loaned to the LEA having already been replaced by the state with a new bus authorized for temporary operation from State funds as a regular route bus above current inventory levels due to LEAs additional transportation needs Authorization is contingent on a commitment by the LEA to purchase a capital outlay bus or eliminate the need for an additional bus route within one year June 5 1997 4 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Status a b
61. lacement Manual QUANTITY TYPE OF EQUIPMENT 3 Torque wrenches 3 8 drive 1 2 drive and 3 4 or 1 drive Transmission gear lube gun Transmission jack Transmission stand Tread depth gauge 1 for each man xi Tune up equipment complete set volt amp tester ohm meter timing light compression tester rpm gauge vacuum gauge combustion analyzer or preferably Engine analyzer Pro link 9 000 or equal electronic test unit ee Brake drum and rotor gauge Minimum 20 000 gallon fuel storage including 1 shop pump and 2 bulk pump with meter for each fuel type Each mechanic shall have a battery terminal puller and battery terminal spreader June 5 1997 DPI Transportation Services 64 Preventive Maintenance and Vehicle Replacement Manual 15 Additional Equipment Installation Because of the State s responsibility to replace school buses no school bus is to be altered in appearance color lettering or equipment unless authorized by the Department of Public Instruction Transportation Services Section It is permissible to update older model school buses to the current year school bus specifications Any safety item included in the most recent issue of the North Carolina School Bus Specifications may be added However the items must be of the same model and type of material as described in the specifications and also installed in the manner descr
62. luid Added 22 Clean Int Ext 2 Brake Foot Check amp Adjust peu 23 Fire Ext First Aid Kit 3 Clean Slacks w wire brush Body Fluid Kit 4 Drain Air Tanks Completely EN 24 Seats All covers foam pads frames seat cushions secure 5 Brake Fluid Added 25 Seat Belts 6 Brake Park Check amp Adjust 26 Exhaust System 7 Stop Sign amp Walking Arm 27 Cooling System Added BE 8 Batteries amp Cables 28 A Freeze Protection 9 Tires LF RF LRO LRI 29 Engine Oil Added Record Air Pressure RRO_ RR _ 10 Tires LF RF LRO LRI 30 Drain Fuel Water Separator p Record Tread Depth RRO RRI 31 Engine Belts Adjust All 11 Entrance Steps amp Handrails 2 Door Controls All 32 Transmission Fluid Added oor Controls 33 Drive Shaft 13 Warning Buzzers All 93 14 Bus Body Glass 34 Differential Lube Added us Body Glass 35 Springs and Hangers 15 Windshield Wipers Arm Travel 95 prng 9 2 Fluid Added 86 Lettering amp Paint Visor 17 B 37 Body amp Sheet Metal Damage orn 18 Lights All 38 Wheel Chair Mounts If equipped ights 19 Turn Signals amp Cancellation Mi All 40 Governor MPH maximum irrors 41 Check Travel Angle 21 Dash Instruments All 42 ROAD TEST COMPLETED Remarks Shop Work Source D Repair Code MI Labo
63. mile service for an explanation of a proper road test During the road rest the mechanic should be observant for proper operation of all components of the vehicle Any defect observed should be noted and repaired After Road Test Park vehicle in a clean dry area and observe five minutes later for leaks from any component Bar test rear wheels The following maintenance record form is referred to in this section It is required to document the preventive maintenance program This form is to be properly and thoroughly completed and filed in the appropriate assigned location Transportation Services staff members will review these records periodically during the year TD 8B PREVENTIVE MAINTENANCE 12 000 24 000 48 000 MILE SERVICE 3 pages The mechanic shall complete this form at 24 000 mile intervals for the service life of the vehicle After entering all requested information and completing the service the mechanic shall turn the form over to the shop foreman transportation director for review After all data is keyed into the computer the form shall be filed in the Individual Vehicle Maintenance History file for future reference copy of the Preventive Maintenance 12 000 24 000 48 000 Mile Service form is presented in Section 13 Note All labor performed as well as all test results are to be recorded on the form in the proper location June 5 1997 35 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual
64. nt and the removal of lettering referring to school bus and North Carolina Public Schools In this instance the LEA relinquishes its right for another bus in its place in the future as the parked bus is removed from the State inventory As long as the model year of a replacement bus is in excess of 8 years of the model year currently being replaced the bus can be considered for conversion Turn in to the state By mutual agreement the LEA would surrender the bus to the state for disposition DPI Transportation Services may opt to sell the vehicle or use it in another capacity in North Carolina In return Transportation Services would issue a credit to the LEA for a bus in the future should a need arise for additional vehicles Note that it would not necessarily entitle the LEA to a new vehicle immediately but it would guarantee a vehicle once a need is demonstrated Any bus requested to be returned to Status 2 must have operated 91 days or more in a given academic year No bus that has been designated as Status OXX for more than 7 years or is older than the current model year being replaced will be accepted by the State for credit purposes Sale of vehicle The vehicle may be sold outright and the proceeds would be returned to the LEA for use in any capacity just as with the sale of other surplus LEA property In this instance the LEA relinquishes its right for another bus in its place in the future as the parked bus is removed from
65. nt or designated location along with the TD 18A Equipment Repair and Parts Order forms by the person to whom they were assigned The foreman and or director shall check this Defect List against the reported Bus Defect Log daily Any defects not repaired shall be assigned to a mechanic for repair or the bus shall be scheduled to be brought to the garage for repairs The above procedures give specific guidelines for transportation personnel to pursue the field portion of the preventive maintenance program The shop foreman and or director shall plan a work schedule for the coming day In planning this schedule THE BUSES DUE PREVENTIVE MAINTENANCE SERVICE SHALL TAKE PRIORITY OVER OTHER REPAIRS The shop foreman transportation director shall consider any and all vehicles which are already at the garage awaiting repair any defective vehicles which are still operating but need repair both those which can be repaired at the school and those which will need to be brought to the garage any other vehicles in the fleet which need repair or preventive maintenance service and any other work tire repairs component parts etc which needs to be done Near the end of the workday the foreman shall plan the next day s work and discuss this plan and work schedule with the director The director shall make suggestions regarding the schedule Together they shall arrive at a final plan for a work schedule for the following day This schedule will be subject to chan
66. ntenance 12 000 24 000 48 000 Mile Service form is presented in Section 13 Note All labor performed as well as all test results are to be recorded on the form in the proper location June 5 1997 37 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual 8 Personnel Utilization An important factor in the effectiveness of a preventive maintenance program is the ability and willingness of all transportation personnel to work together with one goal in mind a cost efficient and safe preventive maintenance program The assignment of personnel to specific daily job duties is essential for the preventive maintenance program presented in this manual to be successful The following section describes typical job assignments for transportation personnel Personnel Assignments The fuel truck driver s daily service duties will consist of the following routine fuel vehicles fuel dispensed must be charged to the nearest tenth of a gallon on form TD 18B Fuel Issue Ticket and check oil water tires and under hood observation In addition to the above routine the fuel truck driver shall if assigned analyze and repair driver reported bus defects on the day he is at the school as well as assist with 30 day inspections Example minor repairs such as replacing fuses or light bulbs The fuel truck driver shall also obtain speedometer readings for each vehicle fueled The mechanic s daily service duties will consist
67. o the 12 000 mile service information for the following Engine electrical system and road test Brake test using brake test meter After road test bar test wheel bearings TD 15 NEW VEHICLE SERVICE WORK ORDER 2 pages The mechanic shall complete this form 2 pages during the new vehicle preventive maintenance service prior to the bus being placed in service The information requested for each item shall be completed After the inspection is finished the form shall be reviewed by the shop foreman transportation director and filed in the Individual Vehicle Maintenance History file and information transferred to a TD 8B 12 000 24 000 48 000 Service Sheet along with mechanic s signature and entered in the computer This will automatically set up the vehicle PM counter A copy of the New Vehicle Service Work Order is presented in Section 13 Note The mechanic is required to initial each service he performs as well as record all test results indicated on the new vehicle service work order After completion the new vehicle service work order shall be filed in the individual vehicle maintenance history file June 5 1997 12 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual 2 Preventive Maintenance Scheduling Preventive Maintenance Factors The preventive maintenance program is supported by an automated scheduling system The computer system schedules vehicles for preventive maintenance based on t
68. of heater hose install pipe and or support brackets tighten clamps Check oil pan valve cover and rocker arm cover bolts Torque manifold and exhaust pipe bolts and nuts Check all electrical connections Check throttle linkage and adjust on non electronic engine Adjust engine accessory drive belts Check modulator and governor linkage ROAD TEST Check travel angle Steering gear operation lock to lock lost motion shimmy Panic stop not sliding brake action engine idle Rear axle and drive line noise Transmission operation noise Automatic shift points up 1 2 2 3 3 4 WOT Automatic shift points down 4 2 2 1 Test for maximum mph top speed Break meter test 96 Brake meter min 6096 AFTER ROAD TEST Adjust lubricant level in transmission and differential Park vehicle in a clean dry area observe 5 min later for leaks Bar test wheel bearings Property complete a TD 8B Preventive Mileage Service Form REMARKS Mechanic Signature Revised 2 00 TD 18A EQUIPMENT REPAIR AND PARTS ORDER REPAIR ORDER NO SHOP VEHICLE LICENSE ws MILEAGE MAKE MODEL AGENCY WORK SOURCE A ROAD CALL B UNSCHEDULED REPAIRS C PAID TIME OFF D PREV MAINT ADM amp CLERICAL 1 COUNTY VEHICLES J ACC
69. olts With a hammer and a punch the same size as the king bolt lock bolt head front wheels still raised from the floor drive in king bolt lock pin and torque nut to specifications Torque steering gear mounting bolts and steering gear case bolts to specifications Torque steering pitman arm bolt and nut or sector nut to specifications Adjust steering gear lash and sector end play Inspect steering shaft u joints for free movement and trunion bearing snap rings for proper seating Torque steering shaft u joint yoke to shaft bolts and nuts to specifications June 5 1997 9 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Torque tie rod end nuts drag link end nuts third arm mounting nuts and tie rod arm nuts to specifications Check front end alignment and set toe in with the equipment available at the garage Rear Axle Measure and record on the New Vehicle Service Work Order the brake lining thickness in the same manner as on the front axle On air brake equipped buses having cam ground or tapered lining the measurement should be made near the center of the brake shoe Torque brake shoe backing plate or spider mounting bolts to specifications Pack and install wheel bearings and seal install hub and drum assembly and adjust wheel bearings to specifications Install and align wheels torque wheel nuts Note Torque values for any bolt not specified in the vehicle service
70. ork Source Codes Incorrect coding on the TD 18A Equipment Repair and Parts Order form can have an adverse effect on preventive maintenance scheduling The work source codes on the TD 18A Equipment Repair and Parts Order form are to be utilized in the following manner It is essential for these instructions to be strictly followed in order to generate accurate computer records and accurate monthly reports Work Source A Road Calls service calls and repairs to vehicles in route to school or in route home from school Work Source B Unscheduled Repairs unscheduled repairs to vehicles DO NOT INCLUDE ANY PREVENTIVE MAINTENANCE VANDALISM ACCIDENT OR WARRANTY REPAIRS Work Source C Paid Time Off leave time sick leave vacation holidays jury duty military leave etc shall be indicated using work source C This code shall not be used for any other purpose All leave time is to be charged to the Dummy Shop Vehicle example 6430 0000 and keyed in the same manner as work source G administrative amp clerical time The following repair codes are required to be used for leave time for ALL GARAGE PERSONNEL Type of Leave Repair Code Sick Gl Vacation G2 Holiday G3 Jury Duty or Military leave G4 June 5 1997 16 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Work Source D Preventive Maintenance repairs or services performed to vehicles that
71. ote Do not mix silicone brake fluid and non silicone brake fluid Alternator Check tension belt pulley June 5 1997 34 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Starter Motor and Solenoid Perform starter current draw test Repair if needed to meet manufacturer s specifications Tune Up Diesel Diesel engine shall be adjusted to meet manufacturer s specifications Replace items as necessary Automatic Transmission Filters and Fluid Replace filters internal amp external and fluid in automatic transmission Automatic transmission shift point test should be made with results recorded prior to removing fluid and filter This will allow for necessary valve body adjustments to be made when transmission pan is removed Fluid should be drained at normal operating temperature Remove transmission pan fluid and filters Fluid that is in transmission pan should be poured through a wire mesh screen in order to detect metal particles which might be in it Particles which are recovered should be analyzed to determine if additional repairs are needed After any needed adjustments or repairs are made install new filters and reinstall transmission pan Replace transmission fluid following instructions outlined in transmission service manual Note Automatic transmission fluid has a tendency to form an alga if used too long and condensation may build up in the transmission Road Test Refer to 12 000
72. ould lap against not butt against each other Lubricate emergency door handle Inspect for proper tightness all seat mounting bolts glass channel mounting screws glass frame screws turn signal lamp mounting bolts and screws Spray window track with silicone Adjust all mirrors for proper visibility and tighten adjusting nuts and screws Inspect all electrical connections in body electrical panel for proper assembly and tightness Inspect routing of wires to avoid wear due to abrasion Inspect ground wire from body electrical panel on which the warning light switch and body solenoid switches are mounted Inspect brake pedal for freeness of pedal movement and adjust pedal free travel to specifications Inspect alignment and mounting of accelerator pedal Inspect alignment and mounting of wheelchair mounts if equipped Check wheelchair ground wire If missing install Refer to 12 000 mile service instructions for wheelchair lift service Section 5 Stop Arm and Walking Arm Inspect mounting screws for tightness June 5 1997 11 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Align arm and tighten arm mounting bolts Check for proper operation Battery Compartment Remove battery and coat the battery tray and the inside of the compartment with a corrosive resistant metal seal Other Tests Check engine coolant DCA levels per manufacturer s specifications Refert
73. pecifications and the wheel cylinders rebuilt if needed All S cam shall be checked per OEM specifications The repairing mechanic shall record the brake lining thickness at the thickest point above the rivet head in the proper place on the TD 8B 12 000 24 000 48 000 Service Work Order A tread depth gauge measured in thirty seconds shall be used to measure rivet depth Rebuilding or repairing of transmission differentials cylinder heads and engines that are out of the chassis shall be conducted in a designated area of garage Cleaning and storing of tools and equipment used and the cleaning and sweeping of this area shall be on the same basis as a stall When the person who works in it finishes his job he shall clean and replace the tools and sweep the floor Scrubbing and hosing out of this area shall be on an as needed basis with assignment made by the foreman and or director Automatic transmissions engines and differentials replaced by stock units and left to be rebuilt later shall be stored in a designated area and tagged with the number of the bus from which removed and the apparent defects or symptoms Alternators governors starters starter solenoid switches brake cylinders carburetors etc replaced by stock units shall be turned in at the parts department or other designated area for storage and future rebuilding Those units will be rebuilt by the parts man or by that person designated by the June 5 1997 42 DPI Transpo
74. r Hours Mech Repair Code MI Labor Hours Mech Repair Code 32 Labor Hours Mech Mechanic s Signature Record labor to nearest tenth hour NOTE KEY LABOR BY DATE ON INSPECTION SHEET sa2iM2g 1 dd 1661 aunt 6S BUS DRIVER SIGN IN SHEET DATE SCHOOL PRINCIPAL BUS TIME IF BUS IS NO BUS DRIVER NO ARRIVED HERE TRANSPORTED REMARKS TO MECHANIC SIGN juourooe do IPMA pue ooutuojure A Preventive Maintenance and Vehicle Replacement Manual EXTRA BUS SCHEDULE ASSIGNMENT Date Extra Bus In Place of Bus Issued No No Date Extra Bus In Place of Bus Issued No No June 5 1997 60 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual REPORTED BUS DEFECT LOG DATE LIST SCHOOL AND TIME OF CALL FOR EACH GROUP BUS ASSIGNED NO TIME MECHANICAL PROBLEM SCHOOL MECHANIC June 5 1997 61 DPI Transportation Services 1661 aune sa2iM2g uoupj40dsupa 14 SERVICE CALL LOG BUS TIME PHONE NATURE OF ACTUAL MECHANIC LOCATION OF NO RECORDED CALLED FROM TROUBLE PROBLEM 10 24 VEHICLE ENUEN 3uaurooe dos IPA pue ooueuojure A Preventive Maintenance and Vehicle Replacement Manual 14 School Bus Garage Shop Equipment It is recommended that all school bus garages be equipped with the following minimum equipment Additional equipment may be requir
75. r to provide proper preventive maintenance service to your bus fleet The following procedures shall be followed for all service vehicles The 6 000 mile oil change service shall not be exceeded school garage service vehicles are to be maintained in good operating condition and in a safe state of repair Lubricate and change oil and filter every 6000 miles or 12 months from date of last oil change for all service vehicles Engine should be at normal operating temperature when oil is drained Service wheel bearings and inspect brake lining and components at 24 000 miles for all service vehicles Inspect each vehicle once each year in accordance with the Division of Motor Vehicles regulation G S 20 183 3 a Clean all service vehicles inside and out a minimum of once a month Body repair and repainting of service vehicles should be conducted as needed according to the repainting procedures section For information regarding tire replacement refer to the tire maintenance policy described in Section 9 service vehicles pickups fuel trucks wreckers and tire trucks are recommended to be inspected each 30 days in the same manner utilizing the same 30 day inspection form as school buses The transportation director is responsible for the supervision and assignment of care and maintenance of all school garage service vehicles This includes pickup trucks gasoline diesel fuel dispensing trucks tire trucks and wreckers etc
76. ransportation Services DPI services include providing both consultation on school bus transportation and the resources to facilitate school bus operations The State Board of Education is given statutory authority to fund public school transportation operations and the replacement of vehicles Specifically it is the responsibility of the State Board of Education to periodically adopt such rules and regulations with reference to the construction equipment color and maintenance of school buses No school bus shall be operated for the transportation of pupils unless such bus is constructed and maintained as presented in such regulations North Carolina General Statute 115C 240 c The statute assures that public school buses throughout the State are built to the same standards and are uniform in appearance DPI Transportation Services annually submits to the Department of Administration the North Carolina School Bus Specifications At any time the latest version of this document standardizes the construction and equipment to be included on North Carolina school buses This authority does not extend to private contractors that may provide bus transportation to a local LEA but school buses operated by private contractors should meet all requirements outlined in the federal regulations for school buses The Preventive Maintenance Program is a result of this public school law also It assures a uniform standard of maintenance necessary to provid
77. re check for original wire 2 loops if applicable secure chains Passenger seats frames covers seat foam pads seat cushions secured cushion clips mounting bolts wear Windows glass glazing rubber sash screws filler strips lock racks latches safety buzzer emergency window latches Sheet metal screws or rivets out marking modesty panel Emergency door lock operation hinge mounting bolts weather seal buzzer lubricate buzzer on lift door with or without lift June 5 1997 21 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Floor covering and metal strips Floor boards screws floor mats boots parking brake lever steering shaft boot Drivers seat covers mounting bolts slide rails rollers operation lubricate looseness check seat belt shoulder harness operation and condition Entrance doors step hinge mounting bolts weather seal safety latch control operation and adjustment lubricate if needed Sunvisor adjust Windshield wiper blades linkage arm travel and parking Stop sign valve operation lubricate adjust switch pilot lights Heater and defroster motors foot warmer operation heater remove lint from filter as needed Ground wire on electrical panel Gauges All oil temperature alternator vacuum brake warning light vacuum buzzer low air pressure buzzer and light high beam indicator Turn
78. re reference Electrical System Starting and charging system tests are performed with a volt amp tester connected at the battery With the engine cranking but not starting tester meter readings are observed for the number of amperes of current used and battery terminal voltage during starter operation This test provides performance serviceability information for starter motor and battery Alternator Test The alternator output test is performed with the engine running at a speed great enough to produce maximum output and the tester switch in output test position The battery load is increased by decreasing the resistance in the tester carbon pile rheostat until the maximum ampere rate of current is observed on the tester amp meter Voltage Regulator The voltage regulator test is performed with the engine running at the same speed and the tester switch in the voltage test position This places a resistor in series with the battery simulating a fully June 5 1997 30 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual charged battery The regulated voltage is obtained by observing the maximum voltage on the tester volt meter Diode Stator The diode stator test is performed with the engine running and the tester switch in the diode stator position If the test indicates a defect it will be necessary to disassemble the alternator to determine if the defect is a diode or the stator Follow instructions of
79. recorded for future reference This form shall be used to double check the Bus Drivers Sign In Sheet defects in order that no defects are overlooked After comparing the two forms this form shall be filed in a Reported Bus Defect Log file SERVICE CALL LOG A designated person shall complete this form daily The date weather condition bus number time of call phone number call received from nature of problem and location of vehicle shall be recorded at the time the service call 1s received The time the mechanic calls in that the bus is back in service and what the actual problem was will be recorded in the proper columns This form will be filed in a Bus Service Call Log file for future reference DEFECT LIST SHEET For each bus involved this sheet is to be turned in daily to the assigned person along with the TD 18A Equipment Repair and Parts Order form This form shall be reviewed by the designated person and compared with the Reported Bus Defect Log Note The defect list sheet may be a copy of the driver sign in sheet or a list of defects the mechanic has been assigned to repair TD 18B FUEL AND LUBRICANT ISSUE TICKET 1 page The fuel truck drivers shall complete the date truck number type fuel bulk pump readings both truck meter readings both and gallons used for each Also he will record the bus number quantity of gasoline diesel fuel to the nearest tenth of a gallon and total quarts of oil for each vehicle on the
80. rque steering gear mounting bolts and gear case bolts Torque pitman arm nut ft Ibs Adjust gear lash and sector end play Check steering shaft u joints for free movement and check trunion snap rings for seating Torque tie rod end nuts drag link end nuts and 3rd arm mounting nut Front End Alignment set toe in Adjustment Set Axle Stops for Wheels REAR AXLE Adjust amp Refill wheel bearings Torque drum to hub bolts ft Ibs Brake lining thickness Left 32 Right 32 Torque backing plate or spider mounting bolts Check brake shoe to backing plate clearance adjust key or lock adjusting bolts Torque Spring u bolts ft Ibs Torque spring shackles eye bolts or spring pivot bolts Torque differential to housing and inspection cover to housing bolts Torque wheel bolts ft Ibs OTHER MISCELLANEOUS TEST Pressure test cooling system visual inspection Crankshaft end play record in thousands Check adjust and torque tie rod end adjusting clamp bolts Lubricate check all fluid levels Adjust headlamps Install tire chains if needed NC Motor Vehicle Inspection Install Inspection sticker to windshield Test Engine DCA levels UNDER CARRIAGE Torque body mounting bolts Torque u joint nut and drive shaft center bearing bracket bolts Tighten hose clamps and pipe fittings for air lines air dryer and tanks Check routing and mounting of hose pipes battery cables and wiring Torque bolts in transmission case and tr
81. rs are needed replace lubricant with proper type as specified by chassis manufacturer Lubricant should have EP extreme pressure qualities Synthetic lube draining not required Coolant System Drain and flush the coolant system Refill system with a proper mixture of water and glycol based antifreeze solution and install the proper amount of coolant conditioner Do not use a soluble oil based cooling system additive After refilling the coolant system test the coolant for the proper level of conditioner If conditioner is needed use an ethylene glycol based or OEM recommended conditioner For more information on conditioner testing refer to Section 5 page 28 Wheel Bearings If equipped with out board drums remove all wheel bearings clean repack and bar test wheel bearing Undercoat Bus Clean and re apply undercoat to areas needed June 5 1997 36 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual TD 8B PREVENTIVE MAINTENANCE 12 000 24 000 48 000 MILE SERVICE 3 pages The mechanic shall complete this form at 48 000 mile intervals for the service life of the vehicle After entering all requested information and completing the service the mechanic shall turn the form over to the shop foreman transportation director for review After all data is keyed into the computer the form shall be filed in the Individual Vehicle Maintenance History file for future reference A copy of the Preventive Mai
82. rtation Services Preventive Maintenance and Vehicle Replacement Manual foreman and or director Before being turned in those items shall be tagged with the number of the bus from which they were removed and the apparent defects or symptoms indicated Note Rebuild all major components and sub assemblies to the manufacturers recommended specifications The responsibility for maintaining safe tires on school buses regular and spare will be assigned by the foreman and or supervisor This does not relieve other employees of responsibility Any employee who detects an unsafe tire just as any other defect on any vehicle maintained by the school bus garage becomes responsible for changing the tire or repairing that defect or informing the foreman or director that such action is needed The determining factor of when to change a tire will be when it has worn to the point where the thinnest tread has only 4 32 on steering axle and 2 32 on rear axle of tread depth remaining radial tires Proper front end alignment is essential to cost effective tire life When installing tires on vehicles new tires are required to be installed on the front axle Rear duel tires shall be matched for size to within a maximum of 1 4 diameter of each other if possible New tires are required on the front axle of all school buses The determination of who will make a service call to change a flat tire on a vehicle stopped along the road will be made by the foreman or
83. rts on the afternoon of the day the bus was inspected will allow time to procure parts not in stock and have them ready for the mechanic on his next regularly scheduled day out Any defective item on a vehicle which cannot be repaired at the school and which would not be expected to cause a greater mechanical problem or will not be considered as hazardous if the vehicle is continued in operation will be noted as such on the 30 Day School Bus Inspection Work Sheet For such items the foreman and or director will complete a TD 18A Equipment Repair and Parts Order form On this form he will give the vehicle number make and model the date reported and description of the defect and also the name of the reporting mechanic The TD 18A Equipment June 5 1997 20 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Repair and Parts Order form will be placed in the proper folder of the work order file in order that these repairs may be made when the vehicle is in the shop or when such affected component part 18 removed from the vehicle Examples of such repairs are Transmission bearing noisy repair when transmission is out Flywheel ring gear bad replace when transmission is out Body damage repair when bus is at the garage The foreman and or director will check the mechanic s 30 Day School Bus Inspection Work Sheets Defect List and TD 18A Equipment Repair and Parts Order forms daily near the end of the wor
84. s Schedule Assignment File folder Individual Vehicle Cost Record File folder Individual Vehicle Maintenance History File folder Work Order File folder All of the forms and file folders listed in this section are essential for proper documentation of your preventive maintenance program An explanation of each form listed above is presented in the appropriate section of this manual June 5 1997 48 DPI Transportation Services Revised 7 91 PREVENTIVE MAINTENANCE OIL CHANGE SERVICE TD 8A REPAIR ORDER NO SHOP VEHICLE LICENSE ws MILEAGE MAKE MODEL AGENCY D DATE DAY YR COMPLETE RECEIVED CHARGE ALL LABOR TO NEAREST TENTH HOUR TOTAL HOURS LUBE DOOR amp HOOD HINGES amp LATCHES REPAIRS PERFORMED RC ACT HRS MECH ACT HRS MECH CHANGE OIL amp OIL FILTER 05 LUBE GREASE FITTINGS AND CHECK ALL FLUIDS 09 77 TOTAL LABOR gt SOURCE 1 5 N NON INV PARTS S SUBLET REPAIRS INVENTORY USED QNTY UNIT DOTNO MFG NO DESCRIPTION PRICE CD AMOUNT 5900049 OIL OIL FILTER 8191600 GREASE TOTAL QUANTITY TOTAL INVENTORY COSTS SUBLET REPAIRS QNTY R C STANDARD R C DESC ADDITIONAL DESC PRICE CD AMOUNT MECHANICS SIGNATURE GRAND TOTAL gt Revised 1 97 TD 8B
85. tenance and repair costs histories The program presented in this manual represents the minimum requirements for all school buses and service vehicles in the Public Schools of North Carolina However MORE FREQUENT SERVICE may be warranted in your county The purpose of this maintenance program is to promote repair consistency and cost efficiency and assure that school buses and service vehicles are in safe operating condition Although this document provides a thorough explanation of the required preventive maintenance program supplements will be forthcoming from the Division of School Support Transportation Services Technical training and workshops will be conducted to support local efforts to pursue this maintenance program Success of this maintenance program will be assured through the cooperation of all local transportation staffs Assignment of personnel to the prescribed duties listed in this manual is essential in order for the preventive maintenance program to function properly and to be cost efficient The prescribed school bus garage operational procedures are to be followed as closely as possible depending upon staff facilities and available shop equipment Questions regarding the contents of this manual should be directed to DPI Transportation Services 919 715 1950 June 5 1997 2 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual B VEHICLE REPLACEMENT POLICIES Each local board of educat
86. ter and hose check brake fluid level adjust brakes Air Brakes check air chamber and rod travel equal rod travel on both sides of an axle front and rear are required adjust air brakes adjust treadle valve bleed air tanks completely Oil seal and fluid leaks at compressor front and rear wheels Shock absorbers mounting brackets links insulators Exhaust system pipes muffler hangers tail pipe extended beyond rear bumper Drive line u bolts center bearings cushion supports yokes and nuts alignment of drive line sections pinion flange transmission flange Engine mounts and brackets Engine belts Check all belts for proper adjustment cracks wear etc Wiring loose frayed clips Oil leaks at engine transmission differential check oil fluid and lube levels Antifreeze check protection level and record degree as needed June 5 1997 23 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual Steering gear box mounting sector seal tie rod ends drag link third arm idler arm shaft and bushing shaft couplings joints snap rings mast jacket bearings upper and lower check fluid level Cross members cracked loose bolts or rivets Tires wear pattern condition check for proper inflation and record pressure readings minimum 90 16 maximum 110 Ibs pressure for radial tires Jf excessive tire wear indicates improper front end alignment it is to be note
87. us titled to the LEA and was once authorized for use as a regular route bus but because of current demands is not being utilized on a daily basis At such time that the fleet is reviewed for bus replacements these status 0 parked buses will not be included in the replacement pool 1 School Bus Replacement Criteria DPI Transportation Services will consider all of the following in determining which buses in the statewide fleet are to be replaced in a given year Age of the bus Mileage of the bus of bus engine e g gasoline or diesel Condition of the bus Availability of funds Unique circumstances about a given bus Number of Status 2 buses operated by each LEA Buses destroyed by accident or vandalism total loss A bus must have been operated by a LEA as authorized under General Statute 115C 242 to be considered for replacement Any use of a replacement bus by an LEA or other entity for purposes other than to and from school shall require reimbursement to the State for depreciation of capital equipment In general a LEA will receive a bus of similar construction and size to the one being replaced If a bus to be replaced has a capacity greater than is being currently offered as replacement the State will use the largest capacity bus currently offered on contract as the replacement If a LEA is not replacing a wheelchair lift bus but desires a lift the LEA must purchase the lift according to guid
88. uxiliary filter only Air Compressor Filter Replace air compressor filter Front Brakes After front of vehicle is raised from the floor and before the wheel and drum assemblies are removed the steering knuckle king bolts or upper and lower ball joints shall be inspected for lost motion or other defects which might necessitate repairs being made while servicing front brakes and wheel bearings Place safety stands under axle and remove both wheel and drum assemblies Inspect brake components for possible defects leaking wheel cylinders etc Clean brake drum shoes and other components in a safe and acceptable manner Using a tire tread gauge that measures in 32nds of an inch measure the amount of brake lining above the rivet head at the thickest point of each brake shoe Record the measurement of the shoe for each wheel in the appropriate space on the Preventive Maintenance 12 000 24000 48 000 Work Order Compare these measurements with the measurements from the vehicle history to determine if the lining is still serviceable or needs to be replaced If brake lining thickness is acceptable inspect for possible lining cracks loose rivets defective brake shoe etc Remove wheel bearing clean and inspect bearings and cups Repack wheel bearing with manufacturer s specified lubricant Outboard drum equipped vehicles bar test wheel bearing adjustment Note Sodium base lubricant is not compatible with lithium base lubricant and
89. will start by completing the repairs on any buses on which the defects were not repaired on his previous day s June 5 1997 19 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual inspection After unfinished minor repairs on previously inspected buses have been repaired he will move on to any remaining buses at the school which have not been inspected When all buses at this school have been completed as far as possible with the parts available on his service truck that day he will move on to the next school in his area and start the same inspection process at that school This is repeated until all buses in the area have been inspected and repaired during the month Items found to be defective by the mechanic during the inspecting of buses which may create a safety hazard or a greater mechanical problem shall be repaired prior to operating the bus or a spare bus will be put in service in place of the defective bus until proper repairs can be made The decision shall be made by the foreman or director while considering the availability of parts and personnel as well as the amount of time necessary to make the needed repairs At the end of each day the mechanic shall turn in the inspection sheets for all buses which he has inspected during the day Any items which are not repaired shall be shown as such on the mechanic s 30 Day School Bus Inspection Work Sheet The mechanic shall report to the shop foreman or dire
90. y whenever they are detected as malfunctioning Correct vehicle mileage is essential for the proper scheduling of the preventive maintenance program by the computer If no defects are detected by the mechanic the spare bus shall be fueled the water and oil checked the interior of the bus swept if necessary and then it shall be parked in the area designated for parking spare buses available for use The foreman or the supervisor shall maintain the information on the location of a spare bus when he sends for a bus to be brought to the garage A means of detailing where spare buses are in use as replacements for regular vehicles is required When a vehicle is brought into the garage the mechanic who is assigned to the vehicle will get the TD 18A Equipment Repair and Parts Order form along with the 30 Day School Bus Inspection Work Sheet if applicable and any Defect List for the vehicle from the Work Order file or from the June 5 1997 41 DPI Transportation Services Preventive Maintenance and Vehicle Replacement Manual foreman or supervisor Unless it is impracticable due to some mechanical failure that must be repaired beforehand the vehicle shall be inspected before any work is performed Except for the checking of lights steering charging and cranking systems the remainder of the inspection shall be performed by one person This inspection is for the purpose of detecting any and all items which have failed or could reasonably be
91. your test equipment Residual Current Draw Test With the engine and all electrical components turned off and the negative battery cable disconnected place a milliampere meter in series with the circuit and observe meter reading Observing polarity connect one lead to the negative battery terminal and the other to the negative cable A meter reading greater than 100 milliamperes indicates current leakage through some component of the electrical system The proper component is located by the process of elimination dirty or wet battery will allow current to travel along the case to ground through the battery tray Alternators with integrated internal voltage regulators will have a residual current draw of approximately 50 millamperes Engine Accessory Drive Belts Inspect for condition and proper adjustment of belt tension Cooling System Test Using a pump type pressure tester installed on radiator filler pipe pressurize system and observe for leaks Using the same tester test operation of radiator pressure cap Visually inspect radiator hoses water pump and other components coolant recovery tank for defects Inspect radiator support and support mounting bolts and insulators Conditioner Test TEST THE COOLANT SYSTEM DCA LEVEL WITH AN ENGINE COOLANT SYSTEM TEST KIT If conditioner is needed use a conditioner per OEM specifications This test is extremely critical for proper diesel engine maintenance The test shall be conducted ut

PREVENTIVE MAINTENANCE Manual

Contents

Download Pdf Manuals

Related Search

Related Contents