BusRide Maintenance May 2016

MAY.2016

BUSRIDEMAINTENANCE.COM

THE EXCLUSIVE MAINTENANCE RESOURCE FOR THE TRANSIT AND MOTORCOACH INDUSTRY

All-electric = Less maintenance

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VLMs save time and money p4 | Advances in HVAC p6 | Heavy-duty lift PM p7

FROM THE EDITOR IN CHIEF

Move the ball forward

busridemaintenance.com VOL. 06 • NO. 4

In May, BUSRide Maintenance seeks to “move the ball forward” for maintenance techs – examining the different ways maintenance technicians can advance the technology in their garages to better increase efficiency and operational savings for their companies and agencies. This issue highlights topics such as all-electric vehicle maintenance; high-tech parts storage and management; the latest advances in climate control technology; and heavy-duty equipment certification.

Inside this issue: • On the cover: Ryne Shetterly of Complete Coach Works, makers of the revolutionary Zero-Emission Propulsion System (ZEPS), discusses the maintenance cost, time and efficiency savings that operators can yield by switching to all-electric vehicles

Richard Tackett Editor in Chief rtackett@busridemaintenance.com David Hubbard Associate Publisher dhubbard@busridemaintenance.com Steve Gamble Art Director sgamble@busridemaintenance.com Judi Victor CEO & Publisher Director of Sales jvfly@busridemaintenance.com Kevin Boorse Business Manager kboorse@busridemaintenance.com

• Steve Radomski and Jonathyn Reed of Maintenance Design Group explain the benefits of Vertical Lift Modules (VLM) – automated high-bay warehouse systems. VLMs provide space savings, controlled environments and faster retrieval times for parts managers.

Blair McCarty Sr. Sales and Marketing Coordinator bmccarty@busridemaintenance.com

• Steve Johnson of Thermo King details the latest advances in climate control technology for a new series – Focus On: HVAC.

BUS INDUSTRY SAFETY COUNCIL

• Sam Fielden of MAXIMA lists the critical areas of preventative maintenance for heavy-duty lifts, with a special emphasis on ALI certification and routine inspections.

Thank you for reading this issue of BUSRide Maintenance.

Richard Tackett Editor in Chief BUSRide Maintenance Magazine

A publication of:

CONTENTS MAY 2016

On the cover: Save on maintenance with electric propulsion

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Ryne Shetterly of CCW discusses the various cost, time and efficiency-related savings of all-electric vehicles Departments From the Editor in Chief Products and Services Maintenance Facility Design

By Steve Radomski and Jonathyn Reed

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BUSRIDE MAINTENANCE | MAY . 2016

Focus On: HVAC

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Focus On: Heavy-Duty Lifts

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By Steve Johnson

By Sam Fielden

BUSRide Maintenance Magazine 4742 North 24th Street, STE 340 Phoenix, Arizona 85016 Phone: (602) 265-7600 Fax: (602) 277-7588 busridemaintenance.com

BUSRide Maintenance™ Magazine is published 8 times each year by Power Trade Media, a division of The Producers, Inc., 4742 N. 24th Street, Ste. 340, Phoenix, AZ 85016. Subscription Rates: United States and Mexico $39 (USD) one year, Canada $42 (USD) one year (GST included), all other countries $75 one year, single issue United States $5 (USD), all other countries $6 (USD). All articles in BUSRide Maintenance™ Magazine are copyrighted and may not be reproduced in whole or in part without the express written permission of the publisher. For reprints of 100 or more, contact Judi Victor at (602) 265-7600 ext. 125.

Copyright 2016 by Power Trade Media. No advertisement or description or reference to a product or service will be deemed as an endorsement, and no warranty is made or implied by Power Trade Media Information is obtained from sources the editors believe reliable, accurate and timely, but no warranty is made or implied, and Power Trade Media is not responsible for errors or omissions.

busridemaintenance.com

PRODUCTS & SERVICES

Steri-Fab protects buses from bed bugs

American Seating unveils the Wayfarer

Perhaps no environment can hold the claim for being the hotbed of potential exposure for bedbugs. Bedbugs and a transient population are a perfect match due to both the breeding habits (bedbug eggs can remain dormant for over one year) and the ease with which passengers, and employees can unknowingly bring them onto a bus. Unlike insecticides that are residual, STERIFAB dries quickly, (15 – 20 minutes at room temperature), and is essentially inactive after it dries, allowing both employees and passengers to effectively inhabit the premises. This easy-to-use product contains no dyes or perfumes, and does not require dilution. It is registered for sale in all 50 states, and is distributed nationwide. Available in plastic pints, gallons, and 5-gallon containers.

American Seating introduced the Wayfarer recliner to the motorcoach market in January 2015. Along with a world-class design, Wayfarer offers a FMVSS/CMVSS compliant threepoint belted option. The Wayfarer-TC will feature a contoured, adjustable headrest, enhancing the user experience; a slimline profile that allows passengers to stretch out and get comfortable; and a tapered back shape that provides a more open-coach feel.

The ergonomic design of the seat accompanied with a number of flexible features, make it the ideal choice for tour and charter operators and their customers.

Noble Pine Products Company Yonkers, NY

Antaira switches thrive in harsh environments

American Seating Company Grand Rapids, MI

MCI gives operators a Companion

Antaira Technologies is a global leading developer and manufacturer of industrial device networking and communication product solutions for harsh environments and is proud to announce its expansion in the industrial networking infrastructure family with the LMP-0800G series.

Antaira’s industrial gigabit managed Ethernet switch (LMP-0800G series) has been designed to fulfill industrial applications in harsh or outdoor environments. Some applications where the LMP-0800G switch works well includes: power/ utility, solar grids, windmills, mining infrastructures, factory/process control automation, ITS - roadway traffic control/monitoring, building facility outdoor infrastructures or security/surveillance and access control systems.

Motor Coach Industries (MCI) announced that MCI Service Parts, the aftermarket parts, service and support operation of MCI, is delivering cost savings and technology to motorcoach and bus operators. During the recent ABA (American Bus Association) Marketplace and UMA (United Motorcoach Association) Motorcoach EXPO, outlined its strategic moves. The new MCI Companion App gives coach operators fast access to support, mobile access to publications, drivers’ guides, routes to the nearest MCI location, parts promotions and one-touch MCI support calling for technical and ERSA assistance. The app is available through the iTunes App Store and Google Play. This is the result of feedback from MCI’s annual customer survey. For the past several years, MCI has issued independent surveys to gather input from MCI and Setra customers on all aspects of its products and services.

Antaira Technologies Anaheim, CA

Motor Coach Industries Des Plaines, IL

busridemaintenance.com | BUSRIDE MAINTENANCE

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VLMs prove their worth in maintenance facilities

by Steve Radomski and Jonathyn Reed

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From the first bus service in 1905, maintenance and repair efficiency have been critical to service quality and operational costs. A key component of that efficiency is parts availability and inventory control. It’s simple: the faster you can get parts to a bus, the faster you can get the bus back in service.

Parts were traditionally stored on shelving units; associated processes were manual. As bus transit agencies grew in size and diversity, parts space and staff grew as well. Over time, technology facilitated better parts inventory, tracking, and cost control. Drawer and shelving unit innovation followed. And efforts continued to reduce storage needs, retrieval times, and related staffing requirements.

One of the most recent and significant advancements in the quest for continual improvement is the Vertical Lift Module (VLM).

Proof in action UTA Lovendahl Light Rail Maintenance Facility, Midvale, UT Maintenance Design Group (MDG) first introduced VLMs to the transit industry in 2002 at the UTA Lovendahl Light Rail Maintenance Facility. The VLM increased productivity and inventory control. And the reduced area required for parts storage in this facility lowered construction costs, which more than offset the VLM cost. The idea quickly became a standard in most MDG facility designs, particularly when space is limited.

Vertical Lift Modules VLMs are automated high-bay warehouse systems. Each VLM stores the equivalent of about 200 shelving units in approximately 80 percent less floor space (75 square-feet vs. 1,500 square-feet).

The key is vertical storage. VLMs use a facility’s overhead space and drastically reduce the footprint needed to store a large amount of product. VLMs can vary in size and height to fit building design needs and hold up to 132,000 pounds, with each product tray typically accommodating up to 1,600 pounds.

VLMs can be designed for nearly any facility. They’re selfcontained, automated, and operated by computer console. The user enters a product number; inventory response comes back, along with a command to retrieve the tray on which the item is stored. The tray is presented and the item retrieved.

West Ox Bus Operations and Maintenance Facility, Fairfax County, VA One of the few facilities shared by two transit agencies in North America, the West Ox facility accommodates two users – Washington Metropolitan Area Transit Authority (WMATA) and Fairfax County’s “Fairfax Connector” system. Both agencies agreed to share maintenance bays during the project’s first phase but required separate parts control and security, so an individual VLM was installed for each agency. During the phase II expansion, WMATA maintenance operations will move to a separate wing, with a new WMATA parts storage area and VLM added. Meanwhile, Fairfax Connector will take over both existing parts areas and VLMs by removing the wire mesh dividing them. At West Ox, VLMs not only save space, but also provide security, separation, and future flexibility.

Benefits of VLMs Agencies reap benefits beyond space savings. VLMs provide controlled environments that prevent facility dust and debris from damaging parts. Retrieval time decreases as users stand an average of 10 feet from VLM inventory versus walking up to 80 feet for each shelved part. And automation increases efficiency and productivity.

Users benefit too. VLMs are 99 percent accurate. They’re also safer as users retrieve parts at an ergonomically correct height and without the risks associated with a typical warehouse environment.

Equipment Maintenance and Transit Operations Center, Montgomery County, MD Montgomery County replaced its maintenance and operations center to make room for new transit-oriented development (TOD) next to the WMATA Shady Grove Metro Transit Station.

The campus accommodates maintenance operations for 1,200 bus, highway, and heavy vehicles. Building concepts incorporated high-density planning approaches for the county’s diverse fleet.

Two VLMs were installed in the new facility; a future third can accommodate growth and increased fleet diversity. With VLMs, Montgomery County can maintain operations while supporting community-critical TOD.

VLMs Increase

VLMs Decrease

Storage density Efficiency and productivity Safety Security and accountability Operational cost savings

Building footprint Parts damage Retrieval time

BUSRIDE MAINTENANCE | MAY . 2016

Self-contained, automated, and operated by computer console, VLMs can be designed for nearly any facility.

Steve Radomski, AIA, LEED AP and eastern region manager, and Jonathyn Reed, facility designer, at Maintenance Design Group have collectively worked on more than 80 operations and maintenance facilities across the U.S. For more valuable insights on facility design, please visit www.maintenancedesigngroup.com.

busridemaintenance.com

Save on maintenance with electric propulsion BUSRide recently spoke again with Ryne Shetterly, ZEPS sales manager at Complete Coach Works (CCW). CCW manufactures Zero-Emission Propulsion System (ZEPS), a remanufactured transit bus, saving agencies hundreds of thousands of dollars on fuel and maintenance.

In this chapter, Shetterly discusses the various cost, time and efficiency-related savings that operators can gain from all-electric vehicles – specifically, in the maintenance garage.

CCW takes a previously-used transit bus powered by a diesel engine and remanufactures it into like-new condition with an all-electric powered drivetrain system. The process of remanufacturing improves the service life of the bus and avoids material waste. The ZEPS bus relies on this reuse-reduce-recycle philosophy.

How do all-electric vehicles save time in a maintenance garage setting?

By switching to all-electric vehicles, operators will immediately reduce time spent working on the engine compartment. Time savings will be quantified differently from agency to agency, but a reduction of at least 25 percent is normal.

Annual maintenance cost savings are estimated by using several published reports by transit authorities. The cost of maintenance of a ZEPS bus, for example, will be almost one-fifth of the diesel-powered bus. An all-electric bus will significantly improve vehicle reliability, helping transit agencies to minimize downtime between failures and improve service to communities.

How much can operators save in fuel costs?

Apart from the reduction in greenhouse gas emissions, an all-electric transit bus will also significantly reduce fuel costs.

Using the EPA’s MPG equivalent formula for electric vehicles, it is estimated that a ZEPS bus will provide MPG equivalent

of 21.2, which is four times more efficient than conventional diesel buses. More efficient buses will result in lower fuel and maintenance costs. Overall lifecycle cost calculations show that the ZEPS bus will save more than $340,000 in comparison to a diesel bus.

Do electric vehicles reduce garage waste?

As the ZEPS bus does not require engine oil, transmission fluid, diesel particulate filters, urea injection, emission control equipment, oil filters, fuel filters and transmission filters, the cost of procuring such components – around $44,000 over 12 years – and the environmental damage caused by disposal is eliminated.

Recycling of the bus chassis also conserves valuable metal resources.

Using a liquid-cooled motor enables CCW to A single ZEPS bus will eliminate the need for a transmission. Direct drive conserve more than significantly improves the reliability and reduces 10,000 pounds of ferrous the maintenance cost of the system. Overall metals. The activities lifecycle cost is reduced by elimination of engine and transmission rebuild costs. related to mining, extraction and shipping of metals adds significant quantity of greenhouse gas emissions.

What other maintenance-related savings can agencies expect from all-electric remanufacturing?

Savings extend to components, as well. Regenerative braking, and thus longer brake pad life, means that brake replacement on an electric vehicle costs around $12,000 over 12 years, versus $25,000 over the same period with a diesel-powered bus.

Transmission rebuilds, which can cost up to $12,000, are nonfactors in an electric vehicle.

Agencies will see significant savings in training, and parts inventories don’t have to change. If an agency is running a fleet of Gillig buses, they can still use Gillig parts to service their vehicles after all-electric manufacturing.

Ryne Shetterly has over five years of experience in the transportation industry. He is currently working with other industry leaders in order to create the zero-emission bus standard, helping shape the future of transportation.

Visit www.zepsdrive.com for more information.

busridemaintenance.com | BUSRIDE MAINTENANCE

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FOCUS ON:

HvAC

The latest advances in climate control technology

By Steve D. Johnson, Sr. What are the latest advances in climate control technology? It sounds like a relatively easy question to answer, right? When the question was asked of me recently, however, my thoughts went immediately to “what’s trending in the transit bus industry?”

Ask any transit professional today and most will mention “energy efficiency and sustainability” in one context or another. So what does that mean and how is it related to HVAC technology?

Consider this statement: “I want to become more environmentally conscious by reducing my carbon footprint and I am looking for new technologies that help me achieve this, including but not limited to: components and systems that reduce engine emissions and improve MPG, alternative fuels, and electrification of buses and all accessories. I want the per mile cost to operate the bus to go from $0.98 cents to less than $0.30 cents. ” Here are some recent advances in climate control technologies that support “energy efficiency and sustainability”.

• Controls: Mechanical controls are now microprocessor based with J1939 communications capability. Advanced microprocessor technology can be used for energy management and conservation.

• Motors: Permanent magnet and field wound are now ECDC brushless with variable speed control for energy conservation.

• Heating Controls: On/Off solenoids are now motorized valves with PWM control providing energy conservation during the reheat mode.

• Capacity Control: Mechanical EPR valves are now unloading compressors and electronic capacity control. The energy used by parasitic loads is reduced.

• Unit Weight: Units weigh 200 to 300 pounds less. Weight matters. An empty bus gets better fuel mileage than a loaded bus.

• Compressors: More efficient piston type and high efficiency screw compressors provide faster pull down capability.

Make no mistake about it, everything on this list contributed to improvements in efficiency. But is it enough? Given the fact that the HVAC system is the single largest load on the bus, and a better understanding of what’s trending, it’s clear that current and future climate control technologies are driven by the need for greater efficiency. The trend with the greatest impact is electrification.

The trend towards HVAC electrification has been around for some time but has taken on new momentum recently as users realize the value proposition through field trials and testing. Did you know that you can have an all-electric HVAC system on a conventional diesel or CNG powered bus? This technology is available from transit HVAC suppliers and can be considered as one of the latest advancements.

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BUSRIDE MAINTENANCE | MAY . 2016

The one-piece all-electric Athenia AMII E-800 from Thermo King is a hermetically sealed rooftop unit for hybrid bus, trolley bus and alternator-powered applications.

Here are the benefits of all-electric HVAC that will help drive down your cost of operation.

• Saves fuel by eliminating the effect of variable engine RPM on bus load and cooling demand • Constant A/C unit capacity at all bus speeds including idle.

Capacity is not dependent on engine speed.

• Dramatically improved reliability because the units are hermetically sealed and tested at the factory. No field plumbing, evacuation and charging in the field is necessary.

• Hermetically sealed, integrated electric compressors with variable speed control to eliminate belt-driven parasitic loads • A reduced number of maintenance items and components that can fail • No tubing or hoses needed in engine compartment to connect the HVAC unit and compressor. Potential leak points are eliminated.

For the all-electric battery bus, which is gaining popularity, it is a given that you must have an all-electric HVAC system. While the same benefits are available, the all-electric bus is driving further improvements in climate control technology such as smaller and even more efficient HVAC systems. Here, efficiency is related to the range of the bus before the batteries have to be recharged. Naturally, the focus is on the HVAC system which happens to be the largest load on the battery. You can expect continuous improvement.

I will close with this final thought: In its pursuit of improved efficiency, the industry must not forget the original intent of HVAC – passenger comfort. Our goal must be to provide the most efficient HVAC system possible without compromising passenger comfort.

Steve D. Johnson, Sr. serves as product marketing manager, Bus HVAC, at Thermo King, Minneapolis, MN. Thermo King is a world leader in transport temperature control systems for buses. Thermo King also manufactures auxiliary power units, which dramatically reduce engine idling. All Thermo King products are backed by a nationwide dealer network. Visit www.thermoking.com for more information.

busridemaintenance.com

FOCUS ON:

Heavy-Duty Lifts

The 4 Safety “Must Dos” in Preventive Maintenance

By Sam Fielden Heavy-duty lifts are one of the most productive tools in a bus maintenance facility. Not only do they make the technician’s job easier by lifting a 30,000-40,000 pound bus, but they can also increase a shop’s performance, revenue and safety.

To make sure your heavy-duty lift is operating safely, at full capacity, preventive maintenance is highly important. #1: Purchasing a lift – Not all heavy-duty lifts are equal. One of the most important components when purchasing a lift is to make sure that it is an Automotive Lift Institute (ALI) certified lift – you can find this certification on the lift.

The ANSI (American National Standards Institute) is the testing standard that all ALI-validated lifts must meet. In fact, the newly revised IBC (International Building Code) now requires that ALL vehicle lifts meet the American National Safety Standard ANSI/ ALI ALCTV (current edition) Safety Standards for the Construction, Testing and Validation of Automotive Lifts.

All ALI-certified lifts are provided with an owner’s installation, operation and maintenance manual. The manual details operation safety standards, inspection and maintenance schedule for that specific lift. Information about operator training, as well as guidelines for hiring lift repairmen, including the qualifications that repairman should meet is also included with each lift.

With the variety of lifts available – from parallelograms to four-posts, in-grounds, mobile columns and more – installation, maintenance and operation can vary from lift to lift, so it is imperative to read the operators’ manual carefully.

The “Lift Safety Tips,” is another important visual aid that is included with all ALI-certified lifts. It details the “do’s” and “don’ts” of safe-lift operation.

Keep in mind that the owner of the lift is responsible for ensuring that the lift meets current safety standards and that it is maintained properly. #2: Daily inspections – Daily inspections are critical.

Daily inspections should include (but are not limited to): * Checking for oil leaks. * Checking hoses, wires and cables to ensure they are not frayed, broken or leaking.

With the variety of lifts available – from parallelograms to four-posts, in-grounds, mobile columns and more – it is imperative to read the operators’ manual carefully.

* Checking the lift and the surrounding area to make sure it is clean and free of debris. #3: Lift operations – The operators’ manual and ANSI safety requirements booklet each contain operator training logs. The “Lifting It Right Guide,” also published by the ALI, provides detailed information on everything from how to position vehicles on the lifts to vehicle weight limits; proper lifting techniques; using the correct lifting points; and more. #4: Lift yearly inspections and repairs – The national safety standards require annual inspections, which are extremely detailed and can take up to an hour per lift.

It is also important that annual inspections are conducted by a certified lift inspector. For information regarding certified lift inspectors in your area, visit www.autolift.org or contact your lift manufacturer.

Should repairs be required, it is critical to only use OEM parts on ALI-certified lifts. Buying non-certified lift parts means that those parts have not been tested or validated. If an operator elects to use non-OEM parts on a lift, the lift’s ALI certification is null and void.

Please remember • A vehicle lift is a safety device that should be inspected daily.

• Preventive maintenance begins when you first purchase your lift- by making sure it is ALI Certified.

• I f you see a problem with your lift, report it immediately to a supervisor.

MAXIMA manufactures ALI validated lifts with many different lifting capabilities and configurations and are proud to be an Automotive Lift Institute member.

Sam Fielden is vice president of MIT Automobile Inc. Visit them online at www.maximaproducts.com or call 626-774-5700 to reach Sam Fielden directly.

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