Preventative Maintenance Standards Manual
Contents
1. uone uqn 10Nd 81 dois jou 7euu 01 3 100 eqni 2 eis 15 ssejureis 3q 01 8 Suid Q uajeainba 1u619AA 02 d p 1611 01 um Buuds X Siutod p SBuuds yore un SRM 8 Suid 6 01 Z 1901 un Page 23 Annual Inspections An Annual Safety Inspection is similar to an FDOT C level inspection An agency may use level inspection for a vehicle to serve the Annual Safety Inspection as long as the vehicle receives a C level inspection at least once annually An agency may make a copy of level inspection and write Annual Safety Inspection across the top of the page to identify it and place the inspection in the vehicle s history file or a separate filing area for all Annual Safety Inspections vehicle components for an Annual Safety Inspection must be checked at the same time or within 48 hours if the inspection is being performed by utilizing partial inspections for the inspection to be determined complete Chapter 14 90 requires that all agencies perform an Annual Safety Inspection on each public transit vehicle These inspections must be performed once a year using a certified mechanic and proper lift equipment Chapter 14 90 of th2. Pagel15 26 Apply the parking brake and shift vehicle into low gear slightly pulling against the brakes Vehicle should not move Accelerator Brake Pedal Check pedals for sticking binding or failure to return to normal position Check pedals for excessive pad wear The following components must be checked during a inspection in addition to the components that are checked during an A inspection 27 28 29 Brakes Remove wheels and inspect all brake pads linings for wear Check rotors drums for wear scoring and warping Check calipers cylinders and brake lines for signs of wear or leaks Check for any dirt or grease accumulation on the brake system Operational Check Check for smoothness of acceleration centering of steering wheel and the proper tracking of the vehicle smoothness of turns balance of tires and front end alignment Also check for looseness in steering wheel Check operation of speedometer Transmission Check operation and position of shift lever and indicator Check operation in each gear Check shift points through all gear ranges in drive position The following components must be checked during inspection in addition to the components that are checked during an A and B inspection 30 Wheel Bearings Driveshaft Remove and inspect front wheel bearings clean and lubricate or replace if necessary Check the driveshaft chock wheels if needed and pl
3. Florida Department of Transportation Preventative Maintenance Standards MANUAL Third Edition THE FLORIDA STATE UNIVERSITY COLLEGE OF BUSINESS the Marketing Institute Preventative Maintenance Standards Manual Sponsored by The Florida Department of Transportation Public Transit Office 850 414 4500 revised 11 01 11 Written by The Preventative Maintenance Planning Training and Technical Assistance Program The Marketing Institute College of Business Florida State University 850 644 2509 www prmpt or For questions regarding maintenance standards please contact Laurie Revell Program Coordinator 850 644 6956 cob fsu edu Julie Eck Maintenance Review Specialist 850 644 6954 jeck cob fsu edu Steve Stopiak Maintenance Technical Consultant 863 602 8515 sstopiak aol com Fleet Management Managing a fleet of vehicles that are funded by the Florida Department of Transportation requires following a set of minimum requirements established by Chapter 14 90 of the Florida Administrative Code These standards are created to ensure maximum vehicle life and passenger safety through regularly scheduled preventive maintenance The Preventive Maintenance Standards Manual is a description of the minimum requirements regarding preventive maintenance inspections and includes basic maintenance oversight practices Pre trip Post trip Daily Inspections Vehicles sh
4. Normal Operating Conditions o Everyday driving conditions Severe Operating Conditions o Making frequent short trips less than five miles o Making frequent short trips less than 10 miles when temperatures are below freezing o Driving in hot weather stop and go traffic o Extensive idling and or low speed driving for long periods of time taxi police door to door delivery etc o Driving at sustained high speeds during hot weather Towing a trailer o Driving in areas with heavy dust gravel roads construction zones etc Note Fluid change interval mileages can be different from the 6 000 mile Preventive Maintenance Inspections 19 Ball Joints Steering Drive Line Lubricate Inspect all ball joints according to manufacturer s recommendations Lubricate after inspection Due to the varying road conditions vehicle type age of vehicle and type of joint it is recommended to check the ball joints on every A inspection or if any of the symptoms listed below occur Front wheel shimmy at low speed Steering wander Clunking noises from the front suspension Camber wear on the tires Note Most original equipment ball joints today are designed to provide many miles of durability Many never make it that far for a variety of reasons One is wear The constant friction created by turning and driving creates friction between the ball stud and bearing The rougher the roads and the heavier the vehicle the f
5. e Extra invoicing e Opportunity cost Scheduling your repairs will put an end to these hidden administrative costs and give you valuable time to plan for purchasing the parts needed for such replacement repairs whereas when unscheduled repairs occur there is no time to plan for new parts Having this unique opportunity to plan major purchases will help you control your maintenance budget Also being able to plan for scheduled repairs gives your operations team time to make other service arrangements while the vehicle is temporarily out of service The amount of down time for the vehicle is reduced when the repairs are scheduled All of these advantages to preparing for scheduled repairs will help reduce your overall maintenance costs by improving fleet efficiency Take Advantage The last suggestion for optimizing your maintenance program is utilizing the tools and training opportunities that have been made available to you The Florida Department of Transportation has contracts in place to help agencies with technical assistance concerning maintenance These assistance programs are offered at no cost to your agency Each agency should also ensure that they are getting the most out of their state and federal financial assistance Agencies are encouraged to be proactive about their search for financial aid There may be financial opportunities available to you that you are unaware of If you have any questions about FDOT technical assistance prog
6. or rusting Check mirrors for broken fading glass 16 Tires and Wheels Inspect all tires for signs of uneven wear due to imbalance or improper front end alignment check for exposed cord or steel belts inspect valve cores and check sidewalls for scrubbing or damage Determine tread depth using tread depth gauge Tread group pattern depth shall not be any less that 4 32 1 8 inch measured at any point on a major tread groove for tires on the steering axle and no less that 2 32 1 16 inch measured at any point on a major tread groove for all other tires Check air pressure in all tires including spare using tire air gauge Check condition of spare tire and mounting Check tires for cuts nails or other embedded foreign objects Check wheel lugs for proper torque Check all wheels including spare for any damage welds or improper bead seating of tire Check for missing balance weights Check hubcaps for secure mounting 17 Access Doors Inspect exterior access doors and lubricate hinges or spring latches as necessary Check fuel cap for proper fit and any signs of damage to fuel servicing piping hoses Check hood latch and lubricate Check hood retainer bar Service and Operation Inspection 18 Engine and Oil Filter Page 12 Change oil according to manufacturer s specifications either under the normal or severe duty operating conditions The information listed below defines which schedule you need to follow for each vehicle
7. providing written instructions on how your agency s maintenance department functions If your agency needs assistance developing a maintenance plan contact your FDOT District Representative to request this technical assistance Maintenance Oversight It should be the goal of every transportation provider to be running an optimal maintenance program one that is operating at the highest efficiency No matter the size of the agency or the amount of transportation the agency offers vehicle maintenance is the only area an agency can utilize to improve service and save money Whether your agency utilizes in house maintenance or outsourced maintenance it is imperative that vehicle maintenance is being monitored Your agency may have software designed to analyze vehicle inspection and repair data If not it is still possible to analyze this information manually A successful maintenance manager will be consistently looking for ways to improve their maintenance program The following are five ways to get the most out of your maintenance program Page 28 Be Proactive Maintenance activities must be scheduled to be considered preventive maintenance Scheduled maintenance includes repairs that are scheduled ahead of time and not as a result of failure or breakdown Agencies with optimum maintenance programs perform virtually all of their maintenance as scheduled maintenance Some agencies perform preventive maintenance inspections and change fluids an
8. the hi lo beam switches as well as the indicators on dash for proper function Check all emergency exit lights at emergency windows and rear exit door Exterior Lights Horn Outside assistance may be required when making this check Check parking low and hi beam headlights turn signal operation front and rear and hazard flashers Turn on all outside clearance lights and check operation At this time also check license plate lights back up lights and brake lights All lighting must comply with the minimum requirements set for the in Florida Statutes 316 220 316 221 316 224 316 225 316 226 316 234 and 316 235 Check horn The horn must be capable of emitting a sound audible under normal conditions from a distance of not less than 200 feet Warning system Page 10 10 11 12 13 14 Activate ignition switch and check all warning indicator lights oil battery engine etc for proper operation If the vehicle is equipped with gauges check proper readings after the engine has been started Check all switches levers and knobs for proper function Starter System Back up Alarm When starting engine listen for starter drag or grind belt squeal and any other unusual noises As engine warms monitor all gauges Check shift selector for smooth operation and can be shifted into all ranges While depressing the brakes shift the vehicle into reverse and check the audible back up alarm Check fast idle system for prope
9. 9 misfiring replaced Bus 101 4 23 2009 99 558 Jerking Ignition coil 269 57 replaced Several questions needed to be asked after the second identical repair was made Why did the coil have to be replaced a second time Did this fix the root of the problem or is it another temporary repair In slightly over 500 miles why was the part not covered under warranty Why is the cost of the part higher the second time There could be a logical explanation for this repeat repair If you are not monitoring your shop mistakes can be made and if the invoice is paid the agency is at a loss Page 30 Developing a good quality assurance program is all about staying informed By analyzing inspections and repairs you will be reassured that your maintenance inspections and repairs are being performed properly Preventive maintenance checklists should not always come back with all items marked That is a big clue that preventive maintenance inspections are not being performed thoroughly Repairs due to preventive maintenance inspections should be made fairly regularly It is your job to reinforce that the service your agency is paying for is expected to be completed correctly Start a Campaign Once your agency begins to track maintenance activities repair patterns will start to surface and maintenance becomes more predictable You do not have to be a maintenance expert to oversee a maintenance program The key to developing good preventive mai
10. IDES TORSION SPRINGS BOTH SIDES A HINGE d T LUBRICATE WITH PENETRATING OIL DETAIL B 2 LUBRICATE WITH DRY LUBRICANT GRAPHITE K Series Ricon Lift Lubrication Points Page 21 seueg 9015 preoqino ogeuioiny m seiejd epis jo eiqisi jou 1eujeg epis dwng Z suuy C epis 2 suuy 8015 iot 1ouuj lale 4 9Ield uonensnyp 9558 1 yn dung N ouo 77 juepuogd p 5 epis dung ejsoddo 467 e ois eiqeisn py 6 9 uoissexduio jsissy eiqipny siamo 2 seuoie1 2 ssepuyAd 2 Sway doy Page 22 seuegs uneJg 07 291128 07 2 5 en yn OT 1 uid ad weg 01 seixy 01 Suld
11. M 1NOMJ dd 1NVQN3d TOH1NOO 7 085 WHOA1V1d uvas eu 1 INOS alvidaodnia S3ONIH m _ 39VMNI1 ONIGIOS avaama _ wavy 318lanv WHY 1VOLLS3A HOLWO yano X90 MOLS 310949 wavy ii SWYY WOLLOS ANY 401 drove TVnNVI 73 GIOHSSYHL aividasva uvas Page 20 egular maintenance of the Ricon KlearVue K series Public Use wheelchair lift will optimize its performance and reduce the need for repairs This chapter contains lubrication and cleaning instructions a maintenance schedule troubleshooting section and maintenance diagrams _ CAUTION This Ricon product is highly specialized Maintenance and repairs must be per formed by an authorized Ricon service technician using Ricon replacement parts A LUBRICATION Do not lubricate motor or other electrical components Lubrication of electrical components may collect dirt and debris causing short circuits Lubrication should be performed at least every six months or sooner depending on usage Lubricate lift at points indicated with lubricants specified TORSION SPRINGS BOTH SIDES DETAIL A KNUCKLE LINKS 1 BOTH S
12. ace transmission in neutral Grasp either side of the u joint and rotate it back and forth while Page 16 31 32 33 34 35 36 watching feeling for any play between the cross and the yoke If the cross moves inside the yoke replacement of the u joint is warranted Check slip joint for play Lubricate all zirk fittings Shocks Springs Inspect shock absorber cylinders for signs of leakage Check bushings for signs of wear and the mounting brackets for secure mounting Inspect coil and or leaf springs for signs of damage or wear Check MOR ryde shear springs if equipped If equipped with air springs check for leaks cracks and dry rotting Rear Differential Inspect rear axles and axle housing for signs of stress wear and leaks Check differential level Note Change differential fluid every other C inspection Fuel Tank Check fuel tank for secure attachment to vehicle by inspecting for loose broken or missing mounting bolts or brackets some fuel tanks use springs or rubber bushings to permit movement Check fuel system for any visible leak at any point Engine Tune Up See vehicle service manual for details Cooling System Test coolant with pH test strips Change out coolant or add additive as necessary Change Transmission Fluid and Filter Remove transmission pan and drain fluid If the transmission torque converter is equipped with a drain plug drain fluid from it as well Inspect debri
13. aling devices j Handrails and stanchions Page 24 k Standee line and warning 1 Doors and brake interlock devices m Stepwells and flooring n Emergency exits o Tires and wheels p Suspension system q Steering system r Exhaust system s Seat belts t Safety equipment u Equipment for transporting wheelchairs v Working speedometer 4 A safety inspection report shall be prepared by the individual s performing the inspection and shall include the following a Identification of the individual s performing the inspection b Identification of the bus transit system operating the bus c The date of the inspection d Identification of the bus inspected e Identification of the equipment and devices inspected including the identification of equipment and devices found deficient or defective f Identification of corrective action s for any deficient or defective items found and date s of completion of corrective action s 5 Records of annual safety inspections and documentation of any required corrective actions shall be retained a minimum of four years by the bus transit system for compliance review Rulemaking Authority 334 044 2 341 041 3 341 061 2 a FS Law Implemented 341 061 2 FS History New 9 7 87 Amended 11 10 92 8 7 05 9 16 10 Page 25 Annual Safety Inspection Inspection Agency Inspector s Name Print Inspector s Signature Repairs Item Insp
14. aster the rate of wear will occur Wear can be further accelerated by contamination and or lack of lubrication With a greaseable joint lubing the chassis periodically is necessary to maintain a layer of grease within the joint Lubing the joint also helps flush out the old grease and contaminants which Page 13 20 21 extends the service life of the joint Most OEM ball joints today as well as some aftermarket replacement joints are sealed for life and have no grease fittings Load carrying ball joints do tend to wear at a faster rate than their unloaded counterparts because of the weight they carry That s why the lower ball joints on an SLA short long arm suspension typically wear out before the upper joints Check steering column for any absence or looseness of U bolts or positioning parts worn faulty or any welded universal joints Check steering wheel broken spokes or cracks and for securement Check steering box for any mounting bolts loose or missing any cracks in gear box or mounting brackets Check for any looseness of the pitman arm on the steering gear output shaft Check for leaks Check for any motion other than rotational between any linkage member and its attachment point Check for loose clamps or clamp bolt on tie rod or drag link Check for linkage components that are not secured with proper pins or devices Check for any looseness in any threaded joint Lubricate all steering zirk fittings Lubricate dri
15. ction to be considered complete The maintenance contractor must provide a completed inspection checklist for the items that were examined during the preventive maintenance inspection This checklist must be signed and dated by the contractor and filed in your vehicle history file Your agency will need to monitor the maintenance contractor just as you would with an in house Page 27 maintenance program or an outsourced maintenance facility These practices are listed in the section Maintenance Oversight Maintenance Plans The Federal Transit Administration requires all agencies with grant funded vehicles to develop and maintain a written maintenance plan A maintenance plan is a living document that describes an agency s maintenance procedures and practices in the following areas Maintenance Goals Fleet Inventory Preventive Maintenance Standards for Contractors Annual Safety Inspections Pre trip Post trip Inspections Road Calls Accidents Cleaning Warranty Parts Inventory if applicable On site Fueling if applicable Maintenance plans must be revised as maintenance procedures practices or fleet inventory changes Maintenance plans are used by FDOT representatives to evaluate your current maintenance department so it is important that these maintenance plans remain current and customized to your agency s specific maintenance procedures and practices Maintenance plans can also assist an agency with employee turnover by
16. d filters at their regular inspection intervals without making other checks or adjustments and make repairs only when something fails Unfortunately these agencies are performing reactive maintenance Responding to failures instead of anticipating them limits the ability of the agency to plan and schedule their maintenance This creates a continual cycle of responding to chance failures and making emergency repairs to get vehicles back in service creating an unmanageable and costly situation Take control of your maintenance by actively searching for defects and failures to repair them before a breakdown occurs Below are some examples of how your agency will benefit from a proactive maintenance program Bus Type of Work Parts Total Cost Maintenance Performed Replaced Bus 1 Scheduled Rear Brake Job Pads only 253 40 Bus 2 Unscheduled Rear Brake Job Calipers Pads 1 358 88 including tow and Rotors service Bus Type of Work Parts Total Cost Maintenance Performed Replaced Bus 1 Scheduled Repack front Front Seals 150 00 wheel bearings Bus 2 Unscheduled Bus towed Spindle Brake 1 630 00 replace all front rotor pads end parts on caliper failed side bearings seals and new wheel Some managers succumb to reactive maintenance because they would prefer to limit the breaks in service due to vehicle downtime However this line of thinking is harmful to your maintenance program By schedu
17. e Florida Statutes states 14 90 009 Bus Safety Inspections 1 Each bus transit system shall require that all buses operated by such bus transit system and all buses operated by a private contract transit provider be inspected at least annually in accordance with bus inspection procedures set forth in this rule 2 It shall be the bus transit system s responsibility to ensure that each individual performing a bus safety inspection is qualified as follows a Understands the requirements set forth in this rule chapter and can identify defective components b Is knowledgeable of and has mastered the methods procedures tools and equipment used when performing an inspection c Has at least one year of training and or experience as a mechanic or inspector in a vehicle maintenance program and has sufficient general knowledge of buses owned and operated by the bus transit system to recognize deficiencies or mechanical defects 3 Each bus receiving a safety inspection shall be checked for compliance with the requirements for safety devices and equipment as referenced or specified herein Specific operable equipment and devices as required by this rule chapter include the following as applicable to Type I and II buses a Horn b Windshield wipers c Mirrors d Wiring and batteries e Service and parking brakes f Warning devices g Directional signals h Hazard warning signals 1 Lighting systems and sign
18. ealer and see if this is a known problem and if there is a fix for the premature failures Until the solution is found you should start a campaign on changing the belt at a predetermined mileage before it is noted to fail Page 31 Reduce Your Costs The task of beginning a preventive maintenance program with an existing fleet can be overwhelming at first and many may be confused about how to begin this process You should start with your next upcoming preventive maintenance inspections If these inspections have not been thorough in the past the amount of defects that are initially found will increase with the improved inspections along with the cost of your maintenance This is due to the extra labor hours and parts cost to repair mechanical problems that have escalated due to minimum maintenance performed in the past This increase will depend on the size of your fleet the age of your fleet and how many repairs need to be made But this increase in maintenance costs is temporary Once this period of adjustment is over the unscheduled repairs decline increasing efficiency which results in a better control of costs By implementing a thorough preventive maintenance program you will be avoiding several hidden costs that arise when dealing with unscheduled repairs These costs are often found in administrative duties such as e Contacting wrecker services to arrange towing Rescheduling trips to cover routes Notifying clients of the delay
19. ected OK Required Comments Windshield Wipers Mirrors 5 S e Ef Batteries and Wiring ooo o Service and Parking Brakes Jooo o ooo Waming Devices o o ef Directional Signals Hazard Warning Signals Lighting System and Sigang Deves T OO Handrails Stanchions IStandeeandWaming Doors and Interlock Devices Stepwell and Flooring o _ Emergency Exits TiresandWheels ____ __ Suspension System o Steering System ____ __ _ G Exhaust o o SeatBelts ____ __ Safety Equipment ______69 __1 ____ Speedometer ______ Note Attach any repair order invoice generated as a result of this inspection Chapter 14 90 009 Bus Safety Inspections Page 26 Standards for Contractors Preventive maintenance inspections can be performed using an in house maintenance program an outsourced maintenance facility or a combination of in house and outsourced maintenance If your agency wishes to use outsourced maintenance standards must be provided to the contractor to follow when conducting preventive maintenance inspections on your vehicles This can be accomplished by providing this handbook to the outsource facility or developing a service agreement that outlines expectations price and maintenance procedures that are agreed upon by both your agency and the outsource facility If your agency wishes to use an on site mobile maintenance cont
20. ents Manager s Signature Date Pagel5 Carefully inspect the entire vehicle exterior On the illustrations below locate and note any damage or problems using the following code Dent X Scratch as Indicate any other damage by circling the area and then describe the damage Description of damage 6 Scheduled Preventive Maintenance Inspections According to Chapter 14 90 of the Florida Statutes vehicles must be maintained using regular preventive maintenance inspections The Florida Department of Transportation recommends conducting progressive inspections that meet or exceed OEM manufacturer recommendations For a vehicle to remain under warranty its components must be inspected within the mileage projection noted in the vehicle s owners manual and these inspections must be documented in the vehicle history file FDOT recommends that preventive maintenance inspections be performed in ABC sequence Mileage projections can be determined by the agency but must not exceed 6 000 miles These mileage projections are determined by keeping several factors in mind the age of the vehicle the number of miles traveled by each vehicle and the road conditions that the vehicle regularly travels The following is an example of a preventive maintenance schedule with vehicle inspections performed at 6 000 mile intervals A 6 000 miles B 12 000 miles A 18 000 miles C 24 000 miles 30 000 mil
21. es B 36 000 miles A 42 000 miles C 48 000 miles Page 7 PREVENTIVE MAINTENANCE INSPECTION REPORT Date Inspector s Signature Printed Name Employee Inspection B Inspection o C Inspection X was repaired or adjusted Followup c Not Ap cable Passenger Door amp amp Lif an Moun ng jnes amp Door Interlock Operation Check Operation of All Lights 71 ait Check Exhaust System for Standee Line amp Warning pg Fuel Cap and Door mag Mounting Leaks Restrictions Flooring Steps Alll Interior Panels DaorsiEn gine Cover 73 Underbody Mounts amp Frame Latch Operation Fuel Tank Mounting amp Fuel 74 Leaks Passenger Seat Belts Passenger Seat Condition Check Bumpers for Damage 25 Lift Manufacturer Tag Month Foldaway Seats Operation Mounting Rear Transition Panel amp Year Manufactured State of FL Certificate Check Wiring for Routing Motard ci B oy Chafing amp Loose Conn Check Lift for Damage uBE Inspect Lift Anchor Bolts Clean Batteries Terminal Ends Cycle Lift Check all Safety Emergency Window Operation i Check Electrolyte Level Systems Including Barriers Fire Extinguisher First Aid Kit Check Battery Hold Downs Check for Hydraulic Leaks 10 44 79 Emergency Triangles Cables Ground Straps Level Clean Lubricate amp Adjust Lift CRUS Check Belts Tensioners amp Hoses Inter
22. he near future Post trip Daily Inspections should also be conducted when a vehicle completes service for the day and should be performed similar to the Pre trip inspection Post trip inspections are important because the driver can note defects that were observed while driving the vehicle as well as other defects noted during the inspection process These checklists should be reviewed by a manager so adjustments to the fleet can be made in the case of a vehicle needing repair Page 3 Pre trip Post trip inspection checklists should be kept on file for a minimum of two weeks or up to one year depending on the preference of your FDOT District Representatives Pagel4 Pre trip Post trip Inspection Form Unit ID Date Exterior OK Defect Heights TaiBrake tiss Turn signals Clearance tins Windshield Wipers Fresh Body Damage ExautSytem mresWhees Jo annes oo Interior Gauges mtrumets interior tights Rear Vision Mirrors Windshield Wipers BlowerFans Brakes steering Hom Passenger Doos ains Safety Equipment Flares triangles fo o foo Fetmdkt Flashlight Back up Alarm Fire Extinguisher Accessibility Equipment W C Lift and Ramp I Belts amp Securement Devices Proper Number amp Condition Additional Items Driver s Name L Pre trip Inspection L Post trip Inspection Comm
23. hicle component was not properly inspected If your agency is not capable of performing these inspections quality assurance can also be accomplished by manually reviewing vehicle repair files This can be done in the same manner that was mentioned above A maintenance manager can review unscheduled repairs that have been made between preventive maintenance inspections to determine whether the unscheduled repair could have been avoided Unscheduled repairs can occur due to in service failures or defects noted on pre trip post trip inspections For each unscheduled repair the maintenance manager can review the previous preventive maintenance inspection and see whether the defective item was checked ok during the time of the inspection The maintenance manager should then attempt to make a determination about whether the defect could have been identified at the time of the preventive maintenance inspection A maintenance manager needs to be informed on all maintenance repairs scheduled or not If your agency outsources your maintenance you need to provide authorization on all repairs before they are made By doing so you can avoid a common error such as a repeat repair Below is an example of an agency that did not practice quality assurance and that used outsourced maintenance without requiring authorization for repairs Unit Date Miles Complaint Repairs Cost Bus 101 1 13 2009 99 029 Engine Ignition coil 254 0
24. ims for bends damage or welds Rims must not have any welding repairs Check valve stems for damage and for missing valve caps Check that the wheels and hubs are free of oil or grease Oil or grease present could indicate a leaking hub or axle seal Check that all lug nuts are present Check for signs of rust streaks or shiny threads that could indicate loose lug nuts 4 Steering e With the engine running turn the wheel back and forth Steering play should not exceed 2 inches on a 20 inch wheel until the front wheels barely move 5 Horn e Check that the horn works properly 6 Lighting devices e Turn on exterior lights Turn on 4 way Flashers Perform a complete walk around of the exterior of the vehicle and check all lights for proper operation and lens for cleanliness e Turn off 4 way flashers and turn on left turn signal and check left signal lights for operation e Turn on right turn signal and check right signal lights for operation e Turnon hi beam head lights and check for operation e Checking brake lights and back up lights may require assistance With someone in the driver s seat instruct them to step on the brake pedal while observing the operation of the brake lights At this time have the assistance place the vehicle in reverse Check back up light operation and back up alarm if equipped e Turn on all interior lights and check for operation 7 Windshield wipers e Check that the wipers operate
25. ior Uns EE Air Compressor Mounting B Brake Foundation vehicle Regitration Plates Manual ig E g Uining Rotors Drums EH 48 inspect for Leaks ______________ 22 Front Worn e ________ __ e RiFront Wom eal 50 Check Radiator Core Mounts 84 URear Wom see nee er ams SOS Rear Door Alarm amp No Start 51 Check Wiring for Routing Chafing amp RiRear Worn ee System Loose Connections E eres BEI NN UE 18 System Start Engine epics an 19 Check AllGauges Switches 20 Check Fast ide 5 54 Perform Leak Down Test Cores Lines for Check Steering Wheel for 23 Parking Brake Operation Brake Operation 58 Pressure Check Back Up Alarm amp Horn REN UNI PSI Torque Rods __________ 94 RIR Inside iis __ 61 check Ban Joints fos RR outside 28 Climate Control SystemFans 62 Steering GeariLinkage Ams 6 JUR Inside 29 Fare Collection System fes Steering Shaft amp Free Play E To ferec Engne em RD C 32 Condition of Al 67 Drain Refi Diferential ____ i00 _________ ss Ree Tames Fue 69 Check Front Wheel Bearings 5 So NN eS The following components must be checked during an A inspectio
26. ling your maintenance you will be able to plan for a vehicle to be out of service and make other arrangements You do not receive this same opportunity when a vehicle is out of service due to failure or breakdown Be proactive in your preventive maintenance inspections and repairs This practice alone will save your agency money and valuable time Page 29 Cover Your Bases Quality assurance is key with developing an optimal maintenance program When a state purchased vehicle is involved in a serious accident FDOT may be called to perform an investigation Your agency is liable for the vehicles in service and it is the job of the maintenance manager or the person who oversees maintenance at your agency to ensure that maintenance inspections and repairs are thoroughly performed and that all inspection and repair documentation is accurate A successful maintenance manager will set up a quality assurance system that will monitor inspections and repairs by randomly inspecting vehicles that have just been inspected or repaired regardless of whether your agency uses in house maintenance or outsourced maintenance Performing a quality assurance check on a recently inspected vehicle can be as easy as performing an identical preventive maintenance inspection on that vehicle and comparing your findings to those that were marked on the inspection checklist For example if you found a defect that was marked OK on the checklist then you know that ve
27. n Interior Inspection 1 Fire Extinguisher s First Aid Kit Safety Triangles Inspect the above mentioned safety equipment to ensure it is in proper working order securely mounted and easily accessible Fire extinguisher must be fully charged with a dry chemical or carbon dioxide having at least a 1A BC rating and bearing the label Underwriters Laboratory Inc If equipped with fire suppression system check System OK LED is illuminated Check that system is properly charged and that all instruction labels are intact clean and legible Check maintenance tag for expiration date and condition of all components for damage or conditions that may prevent operation Nozzle outlets must be unobstructed and properly aimed 2 All Seats Seat Belts Seat covering for the driver and passenger seats should be inspected for rips tears gouges exposed springs and security of floor mounting Seat belts should be inspected for proper retraction mechanisms Arm rest s should be inspected for proper attachment to seat s Check folding seats for proper operation of adjustment controls Check the driver s seat for proper fore and aft movement and tracks should be lubricated as necessary 3 Doors Hinges Latches Emergency Exits Lubricate door hinges and latches check operation of windows doors and the condition of the glass Check condition of all exit signs to ensure location and operation decals are in place and legible Check emerge
28. ncy exits to insure all exits function properly and stay shut after opening 4 Interlock System Check to ensure interlock system is working properly Vehicle should not come out of park with either the front door or lift door open Page 19 If the rear emergency exit door is open or closed and locked the vehicle should not start Check for audible alarm and warning light if rear door is open with vehicle running Flooring Headliner Side Panels Grab Rails Inspect floor covering for tears rips or gouges Inspect headliner for damage sag or dirt Inspect the condition of side panels On vehicles designed to allow standees check the condition of the standee line and sign The line must be of contrasting color at least two inches wide and the sign prohibiting anyone from occupying a space forward of the line must be posted at or near the front of the vehicle Check steps for yellow edge or nosing to pronounce presence of steps Inspect condition of the grab rails and stanchions for the standee passengers Tighten grab rails as necessary Note if extensive repairs are necessary Mirrors Check inside rear view mirror s for proper mounting adjustment and condition of the glass Also check the right and left exterior mirrors for adequate field of vision Interior Lights Inspect the interior lights Check step well lights if applicable for proper function by opening door Check dome light switch rheostat Check turn signal and
29. ning devices are working properly Inspect tie down retractors for damaged webbing and proper locking Inspect floor tie down anchors Check lift padding and labels Check lift manual operation and instruction label Lubricate appropriate lube points see illustrations at the end of this section Refer to original owners manual for lift adjustments if necessary License Plates Registration Operators Manual Check condition and currency of license plate and registration and appropriate manuals Insure accident report forms and other appropriate documents are up to date and available in the vehicle Check for operating manual for the wheelchair lift Air Conditioning Systems Check Each spring prior to the season for constant air conditioning use the air conditioning system should be scheduled for a thorough operational check The system should be checked with the appropriate air conditioning service equipment and gauges Check the entire system for leaks Page 1 18 Note The Freon level should be checked and serviced as necessary If the system is to be serviced with the opening of a closed system the complete system should be evacuated the receiver dryer replaced and the system must be completely recharged including refrigerant oil Note All air conditioning work involving opening the system for repair and recharging must be performed by a licensed certified technician Page 19 9 y7 seues
30. ntenance is being able to analyze failure trends and use this information to predict future failures Some examples are Alternators You find that the alternators on a particular order of buses are failing at 65 000 miles With each failure there was a road call involved resulting in a tow charge the bus was down until parts were shipped and the emergency repair could be made To avoid the unscheduled repair and added costs the alternators can be scheduled to be replaced at 60 000 miles Brakes Say your buses run an average of 20 000 miles until the rear brakes are re lined At close to this mileage you should expect the brakes to be re lined at an upcoming inspection Notify your shop of the anticipated brake lining replacement and ask for an estimated mileage of the life of the pads if they are not changed As discussed earlier the price of total failure can lead to over 1 000 in unnecessary costs Transmissions This is another component that has predictable failure patterns Pay close attention to the failure mileages on transmissions to avoid tow charges unscheduled down time and possibly higher shipping charges for the emergency repair There are instances when new vehicles are placed into service and unforeseen problems occur that you may not have experienced on your existing fleet Example you notice that you have a belt on the engine that seems to fail twice the rate than you can remember This is when you need to notify the d
31. ould be inspected each day before they enter into service Chapter 14 90 states that the following components must be checked during this inspection 1 Service Brakes From the driver s seat pump the brake pedal three or four times and then hold constant downward pressure on pedal for at least five seconds The brake pedal should hold firm and not drift down If equipped with a hydraulic brake reserve system with the key off depress the brake pedal and listen for the sound of the reserve system electric motor If equipped with hydro boost system or vacuum assist system with the key off pump the brake at least five times and depress the brake pedal It should feel firm Remain holding the pedal and start the engine The pedal should move slightly to the floor and then rise Check that the warning buzzer or light is off 2 Parking Brakes Apply the parking brake and shift vehicle into low gear slightly pulling against the brakes Vehicle should not move 3 Tires and Wheels The minimum tire tread depth on steering axle is 4 32 inch in every major groove No re caps are allowed on the steering axle The minimum tread depth on all other tires is 2 32 inch in every major groove Check all tires for uneven tread wear and cuts or damage to tread and sidewalls Check for tire inflation by hitting the tires with a mallet or similar device to check for flats To check for exact tire inflation a tire air gauge must be used Check r
32. r level and check for any unusual noises or abnormal operation Check all warning lights and audible signals for proper operation Due to varying lift configurations refer to your lifts Owner s Manual for a list of warning lights and audible alarms to ensure all of these safety warning devices are working properly e Stow lift e With lift door in the open position check shift interlock by trying to shift vehicle into gear Bus should not shift out of park e Inspect retractors for damaged webbing and proper locking e Inspect shoulder belts e Inspect foldaway seats for operation e Inspect floor anchors 12 Safety security and emergency equipment e Inspect for three red reflective triangles e Check for properly charged and rated fire extinguisher e Check two way communication equipment 13 Additional items e Your agency may require additional items to be checked during the pre trip post trip inspection such as fluid checks engine hoses and belts under the hood Check additional items as necessary using procedures set forth by your agency A Pre trip Post trip Inspection checklist should be completed with each component either marked Ok or with a defect noted These checklists should be reviewed by a manager prior to the vehicle entering service for the day Vehicles with defects that pose a Safety risk should be repaired immediately before the vehicle returns to service Other defects can be scheduled for repair in t
33. r operation Air System Check Build air system to maximum air pressure and observe governor cut out 100 125 psi Shut off engine and chock wheels if necessary Release emergency brake and make a full brake application and hold for one minute Check air gauge to see if pressure drops more than three pounds in one minute Next rapidly pump the foot brake Buzzer should activate before air pressure drops below 60 psi Continue to pump brakes until emergency brake pops up This should occur at approximately 40 psi Drain all air tanks and check operation of system drier Windshield Windshield Wipers Washers Blades Inspect windshield for cracks scratches and any visible damage Operate windshield wipers through all ranges on wet glass Inspect condition of windshield wiper blades and arms Replace if needed Check washer fluid level Windows Inspect side and rear windows for cracks scratches and proper function of opening mechanisms Comfort System Operate and check heater and air conditioning controls through all selector ranges and check varying fan speed for proper function Check rear unit output as applicable Page 11 Exterior Inspection 15 Exterior Body and Components Inspect exterior of vehicle for signs of body damage missing trim decals paint condition and any signs of developing rust Inspect the outside of all windows for cracks blemishes or other damage Inspect mirror brackets for secure mounting
34. ractor to perform preventive maintenance inspections on your vehicles the following requirements must be met by the contractor If the contractor is performing preventive maintenance inspections based on time projections rather than mileage projections all vehicle components must be inspected within the mileage projections stated in the OEM recommendations for your vehicle while the vehicle is under warranty When the vehicle is no longer under warranty vehicle components must be inspected at least every 6 000 miles using the ABC inspection procedures previously mentioned For example all items listed for the inspection must be inspected by the contractor before 6 000 miles all of the items listed for the inspection must be inspected by the contractor within 12 000 miles etc The contractor must use proper equipment when performing preventive maintenance inspections on your vehicles The following vehicle components must be inspected while your vehicle is suspended on a lift e Ball joints e A frames bushings e Physical check of suspension parts e Steering e U joints e Front wheel bearings e Rear wheel bearings If a preventive maintenance inspection is going to be performed using a combination of an on site inspection and maintenance garage inspection for components needing specialized vehicle equipment both partial inspections should be performed within 48 hours of each other for the preventive maintenance inspe
35. rams or financial assistance please contact your local FDOT District Representative to discuss these items further Page 32 Work Order Invoice Unit ID Repair Facility Make Model Address VIN Odometer Reading Date Vehicle In Description of Problem Road Call Y N Description of Repair Repair Category me e ransmission suspension Materials Parts Used Total Price Mechanic Print Name Sign Name Date Page 33 Road Call Information Sheet Dispatch Informtion 1 Date 2 Vehicle Number 3 Time of Call __ 4 Operator _ 5 ____ E 6 Received By Location of Vehicle Street Address City etc Reported Problem Technicians Report 1 Time of Call _ 2 Time Arrived at Vehicle 3 Circle One In Service Repair Vehicle Exchanged Towed 4 Problem Found Action Taken 5 Time of Road Call Completion Fleet Managers Signature Date Page 34
36. s in the bottom of pan for signs of internal transmission damage Check the color of fluid for signs of overheating Remove and replace filter screen Note any abnormalities on the check off sheet Page 17 Note A ways check manufacturers recommended transmission change interval as some vehicles come from the factory equipped with synthetic oil and have an extended mileage change interval Accessories 37 38 39 Wheel Chair Lift and Accessories Cycle lift from stow position to floor level and check outboard roll stop barrier for proper latching Continue to lower lift to ground level and check for any leaking damaged missing parts and for smooth operation Raise lift from ground level With platform slightly off ground make certain the outboard roll stop barrier raises and it is latched securely This must be performed by visually inspecting the latching mechanism to ensure it is in the correct locked position and by physically attempting to pull push barrier down with an adequate amount of force to make certain the barrier is secured Continue to raise lift to floor level and check for any unusual noises or abnormal operation Stand on lift platform or place at least 50 pounds of weight on platform and attempt to stow lift Lift should not fold in Remove weight and stow lift Due to varying lift configurations refer to your lifts Owner s Manual for a list of warning lights and audible alarms to ensure all of these safety war
37. smoothly and the arms and blades are secure e Check that the windshield washer works correctly e Windshield should be clean with no obstructions or damage to glass 8 Rear vision mirrors e Mirrors should be secure with no mirror bracket damage Check for proper adjustment Check mirror glass for cleanliness or fading 9 Passenger doors e Check doors for damage and that they operate smoothly Hinges should be secure with seals intact e Check door entry area for debris and any loose or extensively worn flooring 10 Exhaust system e Check tailpipe for placement and secure mounting e Start engine and listen for exhaust leaks and check for exhaust fumes in areas other than the tailpipe end 11 Equipment for transporting wheelchairs Check wheelchair lift doors for operation and damage e Cycle lift from stow position to floor level and check outboard roll stop barrier for proper latching Page 2 e Cycle lift to ground level and check for any leaking damaged missing parts and for smooth operation Raise lift from ground level With platform slightly off ground make sure outboard roll stop barrier raises and it is latched securely This must be performed by visually inspecting the latching mechanism to ensure it is in the correct locked position and by physically attempting to pull push barrier down with an adequate amount of force to make certain the barrier is securely latched e Continue to raise lift to floo
38. uel lines for leaks or damage Belts Hoses Wiring Inspect all belts for signs of wear fraying cracks glazing and proper tension Inspect heater hoses and connections Inspect wiring for signs of chafing corrosion loss of insulation and crimping Ensure wiring does not come in contact with moving parts or heated surfaces Under Hood Exhaust System Check transmission fluid level with the fluid warm and the engine running Check color of fluid for any signs of overheating Visually inspect the transmission pan front and rear seal speedometer drive and dipstick tube for signs of leakage Visually check the transmission oil cooler lines and connections for signs of a leak Check the exhaust system for mounting routing leaks and restrictions Service and Parking Brakes From the driver s seat pump the brake pedal three or four times and then hold constant downward pressure on pedal for at least five seconds The brake pedal should hold firm and not drift down If equipped with a hydraulic brake reserve system with the key off depress the brake pedal and listen for the sound of the reserve system electric motor If equipped with hydro boost system or vacuum assist system with the key off pump the brake at least five times and depress the brake pedal It should feel firm Remain holding the pedal and start the engine The pedal should move slightly to the floor and then rise Check that the warning buzzer or light is off
39. veline u joints and slip yoke Battery Check battery mounting tray condition corrosion and wear and battery hold down Check battery case for cracking or damage Check post and fasteners for corrosion clean and cover with protectant Check cables for fraying or signs of deterioration If applicable check and service water levels If it is maintenance free battery check green indicator Record output voltage Cooling System Visually check cooling system for leaks Check the overflow tank for adequate coolant and inspect the cleanliness and condition of the coolant Inspect the condition of the upper and lower radiator hoses and check the security of the fasteners Check butterfly drain for snugness Inspect water pump and engine intake at the thermostat housing for signs of leaks Inspect radiator cap for signs of leaks or pressure loss Before removing the cap allow the engine to cool down Relieve any built up pressure in the system 14 22 23 24 25 Remove and inspect the radiator cap At this time the radiator cores and the interior of the radiator housing may be visually inspected for corrosion or clogging Also if circulation problems are suspected operation of the water pump and circulation of the coolant may be verified with the engine running Air Cleaner Filters Remove air filter and inspect Inspect air intake hoses and clamps Visually inspect all vacuum hoses and connections Inspect f
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