BUSRide Maintenance March 2014

MARCH . 2014

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the exclusive maintenance resource for the transit and motorcoach industry

Brake products and training p4 Beads improve balancing p5 Low-tech diagnostics p6

From The EDITOR

Stay mindful of changes to FMCSA enforcement

Vol. 04 • No. 3

Operators and maintenance professionals will want to keep a watchful eye on further developments with the Federal Motor Carrier Safety Administration (FMCSA), as the research arms of Congress and the U.S. Department of Transportation (DOT) have released somewhat conflicting reports regarding the Compliance, Safety and Accountability (CSA) program.

While the DOT report paints a rosy picture, transportation advocates like the American Bus Association (ABA) have endorsed the more critical findings of Congress.

The report for DOT by the John A. Volpe National Transportation Systems Center, Cambridge, MA, found the FMCSA Safety Measurement System (SMS) to be more effective than the system it replaced. Researchers took two years of pre-SMS data for a subset of carriers it would have flagged by today’s standard and then tracked those companies’ crash records for 18 months, finding their future crash rate more than doubled the national average.

In contrast, the Government Accountability Office (GAO) reported that while CSA has been somewhat effective, SMS scoring needs work. GAO found two issues. First, most regulations used to calculate SMS scores are not violated often enough to strongly associate them with crash risk for individual carriers.

Secondly, most carriers lack sufficient safety performance data to ensure that FMCSA can reliably compare them with other carriers.

The GAO recommended that FMCSA ensure that any determination of a carrier’s fitness to operate properly accounts for limitations the report identified regarding safety performance information. As this issue goes to press, FMCSA has taken no action.

Such conflicting findings from separate branches of government suggest that the CSA program is by no means set in stone. Anyone not used to keeping tabs on legislative issues should try to make it a habit in 2014 as CSA enforcement is still a fluid issue with all of this back-and-forth. Where it finally stands will legitimately affect over-the-road business, so smart operators must be conscientious of changes as they develop.

Publisher / Editor in Chief Steve Kane steve@busride.com Group Publisher Sali T. Williams swilliams@busride.com Executive Editor David Hubbard david@busride.com Editor Richard Tackett rtackett@busride.com Art Director Stephen Gamble sgamble@theproducersinc.com Production Director Kevin Dixon kdixon@busride.com Accountant Fred Valdez fvaldez@powertrademedia.com

BUS industry SAFETY council

MARCH 2014

CONTENTS

Richard Tackett Editor BUSRide Magazine

Brake-ing news Beads conquer the balancing act

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OTR product continuously balances tires on moving vehicles

By David Hubbard

When only “low-tech” will do

A publication of:

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How a plastic cup confirmed coolant contamination and saved a sensor

By Christopher W. Ferrone

Auxiliary heater maintenance guarantees comfort It is never too late to inspect and repair

By Michael Zonca

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Rounding up the latest news from the world’s premier brake companies

BUSRIDE MAINTENANCE | MARCH.2014

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PRODUCTS & SERVICES

Rotary Lift introduces new lighting solutions for all vehicle lift users

ASA introduces a bigger monitor to the bus industry ASA Electronics debuted the new, larger JENSEN JE1569BVM 15” LCD bus monitor. ASA’s bigger monitor offers a user-friendly, simple “Hook & Latch” installation design providing for seamless integration aboard any bus. This 12 or 24-VCD power system features white LED illumination.

The Auto-On feature automatically detects when a video has been inserted into the appropriate player. Plus, the video input (RCA type) provides for a wider range of viewing options with this system. This system features injection molded housing and an LCD protective lens to guarantee it endures the hardships encountered over-the-road.

Gateway Safety’s Wheelz® Safety Goggles meet winter weather conditions Gateway Safety’s Wheelz® safety goggles offer several “cold-weather-friendly” features that make them a popular eye protection choice for outdoor workers in colder climates.

Wheelz goggles include a unique Whirlwind™ ventilation system, with 10 vents along the frame’s brow area and 10 additional vents on the frame’s underside, to circulate air through the inner frame area between the face and lens. The resultant strong “whirlwind” of air helps clear the fog and maintain unhindered vision at all times. For additional fog prevention, an anti-fog coating is also available.

Rotary Lift is shedding some light on the vehicle repair process with Tech Lights, an innovative new line of LED shop lights.

The Rotary Lift Tech Lights series offers powerful lighting options that can be adapted to meet a variety of service bay needs.

Each light comes with mounting clips that are magnetic, so the lights can be set up in a variety of locations without drilling. Tech Lights shop lights are available in three kits.

The two-post lift kit (P/N FA5701) includes two 32-inch line light units, each embedded with 96 LEDs and fitted with two magnetic mounts.

Parker Hannifin adds complimentary products for SCR electrically-heated hose Parker Hannifin, the mobile leader in control technology, is pleased to announce new, complementary products for SCR systems and engines.

In addition to the custom heated hoses and the on-vehicle heated SCR hoses, Parker is working with DEF dispenser manufacturers to create a line of mobile dispensers suitable for the refilling of passenger vehicles to heavy equipment; at public fuel stations, service garages, equipment dealers and farms.

This system is designed for optimizing filling performance and vapor recovery. The complete system will be sold in permanent and mobile units. SCR products will be on display at the Parker Hannifin booth at IFPE 2014, booth S-80440 on March 4th – 8th, 2014, in Las Vegas, NV.

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Brake-ing News Rounding up the latest news from the world’s premier brake companies

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New Meritor mobile training boosts aftermarket customers’ product knowledge

will include an overview of the Federal Motor Vehicle Safety Standards (FMVSS 121) stopping distance requirements, reduced stopping distance regulations and the new compliance and safety accountability (CSA) structure.

Meritor Inc.’s aftermarket team unveiled mobile training with two new training trucks during Heavy Duty Aftermarket Week (HDAW) 2014 that will deliver onsite product and systems education to warehouse distributers, independent Meritor’s ELSA 195LE air disc brake is a weight-optimized version of the 225 and service garages and installs within a 19.5 inch wheel envelope. fleets in the United States and Canada.

Each of the Nissan high-roof NV3500 trucks, wrapped in unique Meritor trailer decals, will offer hands-on training to service managers, shop supervisors, service technicians, maintenance directors, drivers and dealer-fleet trainers for drivetrain and undercarriage aftermarket components. Meritor, Troy, MI, designed the training trucks to meet the immediate needs of North American customers for aftermarket products and systems.

“We’ve been hearing loud and clear that our customers — the warehouse distributors, OE dealers and fleets — want more product education,” said Rick Martin, senior manager, aftermarket training, Meritor. “During the first 12 months, training will focus on braking systems, which will help the industry manage through changes and new demands.”

The vehicle displayed in Meritor’s booth at HDAW 2014 will begin brief training sessions at customer locations after the show concludes. The second vehicle has already begun its scheduled visits to customers.

The training schedule was compiled after Martin and Meritor’s aftermarket regional directors Keith Evans, Paul Petrie and Rick Grimm studied customer input and the training requests.

Meritor expects its training efforts to play a key role in contributing to fleets’ safety records. The mobile training trucks will deliver instructor-led training on brakes and brake systems during 2014. A training schedule will be released in early February.

Training will cover regulations established by the Federal Motor Carrier Safety Administration (FMCSA). The curriculum

Bendix (Bendix Commercial Vehicle Systems and Bendix Spicer Foundation Brake), Elyria, OH, announced the 2014 schedule for its in-person Bendix Brake Training School, continuing its efforts to support and educate both new and experienced technicians. Bendix opens this year’s training school on Tuesday, March 25, in Owosso, MI. The schedule offers classes into November, with a total of 23 sessions in 13 U.S. states and Ontario.

Bendix trained more than 7,000 people through the program in 2013. Class participants recorded more than 30,000 training hours, learning from the venerable, 100 percent ASE-certified Bendix Service, Warranty, and Training (SWAT) team experts.

Together, the team members represent more than 195 years of comprehensive, practical commercial vehicle service and troubleshooting experience.

The three-day Bendix Brake Training School curriculum takes a comprehensive approach to teach maintenance professionals the description, operation, and service of the entire range of foundation and air brake system components. As the only authorized training in Bendix products and services, the program also offers in-depth coverage of safety solutions such as Bendix brand air disc brakes, antilock braking systems (ABS), SmarTire Tire Pressure Monitoring System (TPMS) by Bendix CVS, stability technologies like Bendix ESP Electronic Stability Program full-stability system, and Bendix Wingman Advanced™ – A Collision Mitigation Technology.

In addition to classroom lectures and product cutaways, visual aids are incorporated to demonstrate the components and related systems in each training class. All locations feature operational demonstration boards.

The program also covers the commercial vehicle regulatory landscape, including federal Reduced Stopping Distance (RSD) regulations and Compliance, Safety, Accountability (CSA).

BUSRIDE MAINTENANCE | MARCH.2014

Bendix announces 2014 brake training school schedule

busridemaintenance.com

Beads conquer the balancing act OTR product continuously balances tires on moving vehicles

By David Hubbard

While wheel weights have been around for years, a better solution for heavy-duty commercial vehicles might be the use of balancing beads. Inserted into the tires and easily installed, these over-the-road (OTR) products continuously balance the tires as the vehicle is moving.

Innovative Balancing, Rochester, NY, markets its high-density ceramic beads as Dyna Beads, which are placed directly into the tire where they move freely and automatically balance the complete wheel assembly.

Dyna Beads are essentially free-moving weights that react to the centrifugal force in the rotating tire to counterweight a tire imbalance from a point farthest from the axis of rotation.

Innovative Balancing says the amount of material will distribute itself in weight and position dependent on the balance requirements of the individual tire. If the axle were hard fixed in a bearing with no chance of movement, the bearing would be forced to handle the imbalance and the beads would do nothing significant. However, vehicles come with a suspension system and the axle moves as required.

According to Innovative Balancing, as the vehicle speeds up, the force of the tire imbalance increases as the tire seeks to rotate around its own center of rotating mass, which may not be at the center of the axle. The center of mass is on the heavy side of the wheel with respect to the center of the axle. This is precisely where the beads will roll. The company says the result is a smooth, vibration-free ride, derived from continuous repositioning of the beads as the tire wears, ridding wheel vibration and tire cupping problems.

Innovative Balance says its reusable balancing beads are less expensive than bolt-on balancers and will not break down in tires or damage the inner liner such as with powders and granules. The product also is safe for shop personnel and kind to the environment.

Three ways to install Applicator Method — The applicator method is the standard installation for tires already mounted. Simply remove the valve core, install the customer Applicator and allow the beads to flow into the tire.

Pour In — For tires not yet mounted on the rims, simply mount the first tire bead over the rim, then cut the bag and pour in the contents. Mount the last tire bead and inflate.

EZ Open Bags® — The preferred installation for volume users of large heavy-duty commercial vehicles.

The Applicator cannot be used on valve stems with TPMS unit attached. In that case, the Pour In method must be used.

Properly balanced tires run cooler, place less stress on suspension components, and can even increase fuel mileage.

Innovative Balancing provides this explanation:

When the tire is at rest, all the beads are on the bottom.

As the tire begins to roll, the beads distribute equally around the inner circumference of the tire.

Every time the heavy spot in the tire goes up slightly and quickly, the beads resist this motion and are forced downward.

As the oscillations get smaller, the beads move more slowly to a point of final precise counterbalance. All this happens within a few seconds with no transitional vibration.

The tire is vibration-free and the beads stay fixed in their position due to centripetal force.

busridemaintenance.com | BUSRIDE MAINTENANCE

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A simple diagnostic procedure can be performed with a two-liter plastic beverage bottle.

When only “low-tech” will do How a plastic cup confirmed coolant contamination and saved a sensor

By Christopher W. Ferrone For the gear heads out there who truly appreciate and respect a “low-tech” solution to a perplexing problem, I offer this rather simple diagnostic step we were able to devise recently on one of our American Sightseeing coaches.

Still on the subject of sensors (see BUSRide Maintenance, February 2014, Sharpen your ESP; save the bus), we were having issues with low-water sensors. When these sensors detect any sort of problem, they automatically shut down the engine.

Faced with this situation with one of our coaches out on the road in early January, we were able to bring the vehicle back to Chicago only after we were able to confirm the actual water level and then disconnect the low-water sensor plug.

With the bus safely back in the garage, we simply installed a new low water sensor and with the new part the bus ran fine — but only for four days. When the problem returned we began troubleshooting.

To confirm that we were working with a functioning circuit for the low-water sensor, we jumped the plug with a cotter pin, which turned off the CHECK ENGINE and LOW WATER dash lights, confirming the circuit was in working order.

So, why did the new low-water sensor go bad after only four days? Could it be that the coolant was contaminated?

Any sort of contaminant in the coolant typically creates a coating on the sensor probe surface. With the probe insulated 6

BUSRIDE MAINTENANCE | MARCH.2014

from the coolant, the sensor then falsely indicates there is no coolant in the surge tank.

To confirm the coolant was contaminated, we removed the sensor from the surge tank and (with it still plugged into the circuit) totally submerged it in fresh water.

Allowing the engine to run continuously without shutting off, we were able to confirm that the coolant was coating the sensor probe and insulating the tip.

Go low-tech Here’s the cool “low-tech” aspect of this method: The best way to conduct this procedure is to use a two-liter plastic beverage bottle.

• Cut the bottle in half and fill with water.

• Submerge the sensor while still plugged into the circuit.

• Place the container on top of the CAC radiator. It’s safer than having a technician hold the container.

• Start the engine. With fresh, clean coolant, the engine should now run continuously.

For the last step, we flushed the contaminated coolant, refilled the tank with a clean batch and put the coach back into service.

Christopher W. Ferrone operates American Sightseeing and is president of Americoach Systems Inc., both located in Chicago, IL, specializing in transport technology, safety, management and logistics.

busridemaintenance.com

Auxiliary heater maintenance guarantees comfort It is never too late to inspect and repair

By Michael Zonca March is not too late to address preventive maintenance on the auxiliary fuel-fired coolant heater to achieve maximum comfort and reliability throughout the winter months. Spheros North America Inc., a global manufacturer of auxiliary heaters, offers these tips on seasonal maintenance for many types and makes of auxiliary heaters.

It is best to inspect auxiliary heaters, coolant pumps and related systems for proper functioning before winter sets in, all which could possibly use a tune up or basic preventive maintenance.

An early thorough visual inspection of the heater mounting hardware, coolant lines, fuel lines and electrical wiring allows plenty of time to make any necessary adjustments and repairs before the weather turns cold. Replace any fuel filters or air filters at least once a year. Most large capacity heaters will require some internal maintenance, such as cleaning the combustion tubes and inside surface of the heat exchanger to remove accumulated carbon deposits. Some heaters will also require annual replacement of the fuel atomizing nozzle.

Check the area around the heater for accumulated debris.

Also take a good look at the exhaust tubing for damage or blockage. If the heater is equipped with air intake tubing, it will need to be inspected as well. Take note of any uncovered issues and set a course of action for repair.

Keep those vehicle batteries in top condition. Your heater will not perform at its optimum level if it cannot get the power it needs. Clean the battery terminals and surfaces of contamination and keep connections protected with an application of a dielectric compound to ward off corrosion.

After completing all visual inspections and making any needed repairs, run the auxiliary heater to further diagnose its present operating condition. Various heater manufacturers offer diagnostic tools to aid in the detection of problems. The

Spheros Thermo Test tool and software for the Thermo Series heaters connects to a laptop computer and allows the technician to view and test all internal systems.

Auxiliary heaters should be run periodically throughout the year. To keep the moving parts lubricated and fresh fuel in the fuel system, our recommendation is to run the heaters for a minimum of 20 minutes at least once monthly during the offseason.

Technical documentation for Spheros products is available for free download at www.spheros.eu/Service/TechnicalDocuments.html. Many auxiliary heater manufacturers support their products with technical manuals and related documentation. Most are available at their respective web sites.

If at any time the instructions appear unclear or if there are questions about the documentation for the auxiliary heater, or about the equipment, contact the manufacturer’s authorized trained specialists for professional advice and assistance.

Michael Zonca serves as product application engineer for Spheros North America Inc., a developer and manufacturer of heating systems, air conditioners and roof hatches. Contact him at michael.zonca@spheros.us. busridemaintenance.com | BUSRIDE MAINTENANCE

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