STURAA TEST 12 YEAR 500,000 MILE BUS. from ORION BUS INDUSTRIES, LTD. MODEL ORION II FEBRUARY 2000 PTI-BT-R P

Transcription

1 STURAA TEST 12 YEAR 500,000 MILE BUS from ORION BUS INDUSTRIES, LTD. MODEL ORION II FEBRUARY 2000 PTI-BT-R P The Pennsylvania Transportation Institute 201 Research Office Building (814) The Pennsylvania State University University Park, PA Bus Testing and Research Center

2 6th Avenue and 45th Street (814) Altoona, PA 16602

3 TABLE OF CONTENTS EXECUTIVE SUMMARY... 3 ABBREVIATIONS... 4 BUS CHECK-IN... 5 Page 2. RELIABILITY - DOCUMENTATION OF BREAKDOWN AND REPAIR TIMES DURING TESTING SAFETY - A DOUBLE-LANE CHANGE (OBSTACLE AVOIDANCE TEST) STRUCTURAL INTEGRITY 5.7 STRUCTURAL DURABILITY TEST *NOTE: Partial STURAA Testing was performed on this bus. Only those tests contracted by the manufacturer are included in this report. In order to remain consistent with the Time and Fee Schedule, the tests included in this report retain their original numbers and are not numbered sequentially.

4 EXECUTIVE SUMMARY Orion Bus Industries, Ltd. submitted a model Orion II, CNG powered 26-foot/23 seat bus, for partial STURAA testing in the 12 yr/ 500,000 mile category. The Federal Transit Administration determined that the following tests would be performed; 3. Safety and 5.7 structural Durability Test. The odometer reading at the time of delivery was miles. Testing started on December 15, 1998, and was completed on February 17, The Check-In section of the report provides a description of the bus and specifies its major components. The primary part of the test program is the Structural Durability Test, which also provides the information for the Maintainability and Reliability results. The Structural Durability Test was started on January 6, 1999 and was completed on February 10, The interior of the bus is configured with seating for 23 passengers including the driver. Additionally, free floor space will accommodate 13 standing passengers resulting in a potential load of 36 persons. At 150 lbs per person, this load results in a total vehicle weight of 24,070 lbs and exceeds the GAWR of both the front (12,000 lbs) and rear (11,000 lbs) axles. In order to avoid exceeding the rear axle weight rating, ballast simulating 9 standing passengers (1,350 lbs) was removed. Elimination of the 9 standing passenger positions resulted in an adjusted gross vehicle weight of 22,720 lbs. The SLW segment was performed at 22,150 lbs, and the final segment of the test was performed at a CW of 18,770 lbs. Durability driving resulted in several failures that required unscheduled maintenance. The Reliability Section compiles failures that occurred during Structural Durability Testing. Failures are classified according to subsystems. The data in this section are arranged so that those subsystems with more frequent problems are apparent. The problems also are listed by class as defined in Section 2. The Safety Test was safely performed in both right-hand and left-hand directions up to a maximum test speed of 45 mph. 4

5 ABBREVIATIONS ABTC - Altoona Bus Test Center A/C - air conditioner ADB - advance design bus ATA-MC - The Maintenance Council of the American Trucking Association CBD - central business district CW - curb weight (bus weight including maximum fuel, oil, and coolant; but without passengers or driver) db(a) - decibels with reference to microbar as measured on the "A" scale DIR - test director DR - bus driver EPA - Environmental Protection Agency FFS - free floor space (floor area available to standees, excluding ingress/egress areas, area under seats, area occupied by feet of seated passengers, and the vestibule area) GVL - gross vehicle load (150 lb for every designed passenger seating position, for the driver, and for each 1.5 sq ft of free floor space) GVW - gross vehicle weight (curb weight plus gross vehicle load) GVWR - gross vehicle weight rating MECH - bus mechanic mpg - miles per gallon mph - miles per hour PM - Preventive maintenance PSBRTF - Penn State Bus Research and Testing Facility PTI - Pennsylvania Transportation Institute rpm - revolutions per minute SAE - Society of Automotive Engineers SCH - test scheduler SEC - secretary SLW - seated load weight (curb weight plus 150 lb for every designed passenger seating position and for the driver) STURAA - Surface Transportation and Uniform Relocation Assistance Act TD - test driver TECH - test technician TM - track manager TP - test personnel 5

6 TEST BUS CHECK-IN I. OBJECTIVE The objective of this task is to log in the NBM, assign a NBM number, complete the vehicle data form, and perform a safety check. II. TEST DESCRIPTION The test consists of assigning a NBM test number to the bus, cleaning the bus, completing the vehicle data form, obtaining any special information and tools from the manufacturer, determining a testing schedule, performing an initial safety check, and performing the manufacturer's recommended preventive maintenance. The bus manufacturer must certify that the bus meets all Federal regulations. III. DISCUSSION The check-in procedure is used to identify in detail the major components and configuration of the bus. The test bus has a front, curb-side door equipped with a handicap ramp, located behind the front axle. The engine is a CNG fueled, Cummins 5.9L. The transmission is an Allison AT 545. The measured curb weight is 10,600 lbs for the front axle and 8,170 lbs for the rear axle. These combined weights provide a total measured curb weight of 18,770 lbs. There are 23 seats including the driver and room for 13 standing passengers bringing the total passenger capacity to 36. Gross load is 150 lbs x 36 = 5,400 lbs. At full capacity, the measured gross vehicle weight is 24,070 lbs. This value was used for all static tests. In order to avoid exceeding the GAWR of the front axle (12,000 lbs) and the rear axle (11,000 lbs), the ballast for 9 standing passengers was eliminated. The reduction from full capacity resulted in an adjusted gross vehicle weight of 22,720 lbs and was used for all dynamic testing. 6

7 VEHICLE DATA FORM Bus Number: 9816 Arrival Date: Bus Manufacturer: Orion Bus Industries, Ltd. Vehicle Identification Number (VIN): 1VH249Y7W Model Number: Orion II Date: Personnel: B.L. & S.C. WEIGHT: *Values in parentheses indicate the adjusted weights necessary to avoid exceeding the GAWR. These values were used for all dynamic testing. Individual Wheel Reactions: Weights (lb) Front Axle Middle Axle Rear Axle Right Left Right Left Right Left CW 4,730 5,870 N/A N/A 4,150 4,020 SLW 5,310 6,250 N/A N/A 5,240 5,690 GVW 5,810 (5,530) 6,520 (6,200) N/A N/A 5,740 (5,300) 6,000 (5,690) Total Weight Details: Weight (lb) CW SLW GVW GAWR Front Axle 10,600 11,560 12,330 (11,730) 12,000 Middle Axle N/A N/A N/A N/A Rear Axle 8,170 10,590 11,740 (10,990) Total 18,770 22,150 24,070 (22,720) Dimensions: 11,000 GVWR: 28,800 Length (ft/in) 26 / 9.5 Width (in) 97.0 Height (in) Front Overhang (in) 45.0 Rear Overhang (in) 40.0 Wheel Base (in) Wheel Track (in) Front:

8 Rear: 80.5 Bus Number: 9816 Date: CLEARANCES: Lowest Point Outside Front Axle Lowest Point Outside Rear Axle Location: Tow eye Clearance(in): 10.8 Location: Frame below bumper Clearance(in): 9.2 Lowest Point between Axles Location: Motor mount Clearance(in): 7.1 Ground Clearance at the center (in) 9.0 Front Approach Angle (deg) 19.7 Rear Approach Angle (deg) 18.8 Ramp Clearance Angle (deg) 4.6 Aisle Width (in) 20.3 Inside Standing Height at Center Aisle (ft) 77.8 BODY DETAILS: Body Structural Type Frame Material Body Material Floor Material Roof Material Monocoque Stainless steel Fiberglass & Aluminum Plywood Fiberglass & Aluminum Windows Type Fixed Movable Window Mfg./Model No. Guardian / UU31496 Number of Doors 1 Front 0 Rear Mfr. / Model No. Bode /Single Plug Dimension of Each Door (in) Front x 75.5 Rear - N/A Passenger Seat Type Cantilever Pedestal Other (explain) 8

9 Mfr. / Model No. American Seating / 6466 Driver Seat Type Air Spring Other (explain) Mfr. / Model No. Recaro / na Number of Seats (including Driver) 23 9

10 Bus Number: 9816 Date: BODY DETAILS (Contd..) Free Floor Space ( ft 2 ) 20.3 Height of Each Step at Normal Position (in) Front N/A 3. N/A 4. N/A Middle 2. N/A 3. N/A 4. N/A Rear 2. N/A 3. N/A 4. N/A 1. N/A 1. N/A Step Elevation Change - Kneeling (in) 13.0 ENGINE Type C.I. S.I. Alternate Fuel Other (explain) Mfr. / Model No. Cummins / B G Location Front Rear Other (explain) Fuel Type Gasoline CNG Methanol Diesel LNG Other (explain) Fuel Tank Capacity (indicate units) 8,920 3,600 psi Fuel Induction Type Injected Carburetion Fuel Injector Mfr. / Model No. Carburetor Mfr. / Model No. Fuel Pump Mfr. / Model No. Alternator (Generator) Mfr. / Model No. Maximum Rated Output (Volts / Amps) Air Compressor Mfr. / Model No. N/A Cummins / B G N/A North Power / / 175 Holset / QE296B Maximum Capacity (ft 3 / min) 15.0 Starter Type Electrical Pneumatic Other 10

11 (explain) Starter Mfr. / Model No. Delco Remy /

12 Bus Number: 9816 Date: TRANSMISSION Transmission Type Manual Automatic Mfr. / Model No. Allison / AT545 Control Type Mechanical Electrical Other (explain) Torque Convertor Mfr. / Model No. Integral Retarder Mfr. / Model No. Allison / AT545 N/A SUSPENSION Number of Axles 2 Front Axle Type Independent Beam Axle Mfr. / Model No. Dana / O1EH SD69 Axle Ratio (if driven) 4.52 Suspension Type Air Spring Other (explain) No. of Shock Absorbers 2 Mfr. / Model No. Gabriel / T41014BA Middle Axle Type Independent Beam Axle Mfr. / Model No. Axle Ratio (if driven) N/A N/A Suspension Type Air Spring Other (explain) No. of Shock Absorbers Mfr. / Model No. N/A N/A Rear Axle Type Independent Beam Axle Mfr. / Model No. Axle Ratio (if driven) GKN / TH8 N/A Suspension Type Air Spring Other (explain) No. of Shock Absorbers 2 12

13 Mfr. / Model No. Gabriel / na Bus Number: 9816 Date: WHEELS & TIRES Front Wheel Mfr./ Model No. Accuride 6720 lbs Max Tire Mfr./ Model No. Michelin XZU 275/70R 22.5 Rear Wheel Mfr./ Model No. Accuride 6720 lbs Max Tire Mfr./ Model No. Michelin XZU 275/70R 22.5 BRAKES Front Axle Brakes Type Cam Disc Other (explain) Mfr. / Model No. Spicer / na Middle Axle Brakes Type Cam Disc Other (explain) Mfr. / Model No. N/A Rear Axle Brakes Type Cam Disc Other (explain) Mfr. / Model No. Retarder Type Mfr. / Model No. Spicer / na N/A N/A HVAC Heating System Type Air Water Other Capacity (Btu/hr) 88,000 Mfr. / Model No. Thermo King / floor convectors Air Conditioner Yes No Location Roof Capacity (Btu/hr) 87,000 A/C Compressor Mfr. / Model No. Sanden / SD7H15 STEERING Steering Gear Box Type Ball & nut 13

14 Mfr. / Model No. ZF / 8043 Steering Wheel Diameter 18.0 Number of turns (lock to lock) 4.25 Bus Number: 9816 Date: OTHERS Wheel Chair Ramps Location: Front Type: Motor driven Wheel Chair Lifts Location: N/A Type: N/A Mfr. / Model No. Emergency Exit Orion / na Location: Window Door Number: 5 1 CAPACITIES Fuel Tank Capacity (units) 8,820 3,600 psi Engine Crankcase Capacity (gallons) Transmission Capacity (gallons) 2.25 Differential Capacity (gallons) 1.50 Cooling System Capacity (gallons) 3.00 Power Steering Fluid Capacity (gallons)

15 VEHICLE DATA FORM Bus Number: 9816 Date: List all spare parts, tools and manuals delivered with the bus. Part Number Description Qty. N/A N/A N/A 15

16 COMPONENT/SUBSYSTEM INSPECTION FORM Bus Number: 9816 Date: Subsystem Checked Comments Air Conditioning Heating and Ventilation Body and Sheet Metal Frame Steering Suspension Interior/Seating Axles Brakes Tires/Wheels Exhaust Fuel System Removed SR5000 fuel fill nozzle and installed SR100. Power Plant Accessories Lift System Ramp hit door hinges when opening and closing. Interior Fasteners Batteries 16

17 CHECK - IN ORION BUS INDUSTRIES, LTD. MODEL ORION II 17

18 18

19 CHECK - IN CONT. ORION II EQUIPPED WITH AN ORION HANDICAP RAMP 19

20 20

21 2. RELIABILITY - DOCUMENTATION OF BREAKDOWN AND REPAIR TIMES DURING TESTING 2-I. TEST OBJECTIVE The objective of this test is to document unscheduled breakdowns, repairs, down time, and repair time that occur during testing. 2-II. TEST DESCRIPTION Using the driver log and unscheduled work order forms, all significant breakdowns, repairs, man-hours to repair, and hours out of service are recorded on the Reliability Data Form. CLASS OF FAILURES Classes of failures are described below: (a) Class 1: Physical Safety. A failure that could lead directly to passenger or driver injury and represents a severe crash situation. (b) Class 2: Road Call. A failure resulting in an enroute interruption of revenue service. Service is discontinued until the bus is replaced or repaired at the point of failure. (c) Class 3: Bus Change. A failure that requires removal of the bus from service during its assignments. The bus is operable to a rendezvous point with a replacement bus. (d) Class 4: Bad Order. A failure that does not require removal of the bus from service during its assignments but does degrade coach operation. The failure shall be reported by driver, inspector, or hostler. 2-III. DISCUSSION A listing of breakdowns and unscheduled repairs is accumulated during the Structural Durability Test. The following Reliability Data Form lists all unscheduled repairs under classes as defined above. These classifications are somewhat subjective as the test is performed on a test track with careful inspections every two hours. However, even on the road, there is considerable latitude on deciding how to handle many failures. The Unscheduled Repair List is also attached to provide a reference for the repairs that are included in the Reliability Data Forms. 21

22 The classification of repairs according to subsystem is intended to emphasize those systems which had persistent minor or more serious problems. There were no Class 1 or 2 failures. Of the forty Class 3 failures, nineteen were engine/transmission related, seventeen occurred in the suspension and four in the brake system. These, and the remaining two Class 4 failures are available for review in the Unscheduled Maintenance List, located in Section 5.7 Structural Durability. 22

23 (1 of 2) RELIABILITY DATA FORMS Bus Number: 9816 Date: Personnel: Bob Reifsteck Failure Type Subsystems Mileage Mileage Mileage Mileage Man Hours Down Time Engine/Transmission , , , , , , , , , , , , , , , , , ,

24 (2 of 2) RELIABILITY DATA FORMS Bus Number: 9816 Date: Personnel: Bob Reifsteck Failure Type Subsystems Mileage Mileage Mileage Mileage Man Hours own ime D T Suspension 1, , , , , , , , , , , , , , , , , Brakes 2, , , ,

25 3. SAFETY - A DOUBLE-LANE CHANGE (OBSTACLE AVOIDANCE) 3-I. TEST OBJECTIVE The objective of this test is to determine handling and stability of the bus by measuring speed through a double lane change test. 3-II. TEST DESCRIPTION The Safety Test is a vehicle handling and stability test. The bus will be operated at SLW on a smooth and level test track. The bus will be driven through a double lane change course at increasing speed until the test is considered unsafe or a speed of 45 mph is reached. The lane change course will be set up using pylons to mark off two 12 foot center to center lanes with two 100 foot lane change areas 100 feet apart. The bus will begin in one lane, change to the other lane in a 100 foot span, travel 100 feet, and return to the original lane in another 100 foot span. This procedure will be repeated, starting first in the right-hand and then in the left-hand lane. 3-III. DISCUSSION The Safety Test was performed in both right-hand and left-hand directions. The bus was able to safely negotiate the test course in both the right-hand and left-hand directions up to the maximum test speed of 45 mph. Note: the air suspension was slow to recover in both directions during the 40 & 45 mph runs. 25

26 SAFETY DATA FORM Bus Number: 9816 Date: Personnel: B.L. S.C. & R.H. Temperature ( F): 46 Humidity (%): 42 Wind Direction: SW Wind Speed (mph): 8 Barometric Pressure (in.hg): SAFETY TEST: DOUBLE LANE CHANGE Maximum safe speed tested for double-lane change to left Maximum safe speed tested for double-lane change to right 45 mph 45 mph Comments of the position of the bus during the lane change: A safe profile was maintained through all portions of testing. Note: In both directions the air suspension was slow to recover during the 40 & 45 mph runs. Comments of the tire/ground contact patch: Tire/ground contact was maintained through all portions of testing. 26

27 3. SAFETY LEFT - HAND APPROACH 27

28 RIGHT - HAND APPROACH 28

29 5.7 STRUCTURAL DURABILITY TEST 5.7-I. TEST OBJECTIVE The objective of this test is to perform an accelerated durability test that approximates up to 25 percent of the service life of the vehicle. 5.7-II. TEST DESCRIPTION The test vehicle is driven a total of 15,000 miles; approximately 12,500 miles on the PSBRTF Durability Test Track and approximately 2,500 miscellaneous other miles. The test will be conducted with the bus operated under three different loading conditions. The first segment will consist of approximately 6,250 miles with the bus operated at GVW. The second segment will consist of approximately 2,500 miles with the bus operated at SLW. The remainder of the test, approximately 6,250 miles, will be conducted with the bus loaded to CW. If GVW exceeds the axle design weights, then the load will be adjusted to the axle design weights and the change will be recorded. All subsystems are run during these tests in their normal operating modes. All recommended manufacturers servicing is to be followed and noted on the vehicle maintainability log. Servicing items accelerated by the durability tests will be compressed by 10:1; all others will be done on a 1:1 mi/mi basis. Unscheduled breakdowns and repairs are recorded on the same log as are any unusual occurrences as noted by the driver. Once a week the test vehicle shall be washed down and thoroughly inspected for any signs of failure. 5.7-III. DISCUSSION The Structural Durability Test was started on January 6, 1999 and was conducted until February 10, The first 6,250 miles were performed at a GVW of 22,720 lb and was completed on September 30, The next 2,500 mile SLW segment was performed at 22,150 lb and completed on October 27, The final 6,250 mile segment was performed at a CW of 18,770 lb and completed on February 10, The following mileage summary presents the accumulation of miles during the Structural Durability Test. The driving schedule is included, showing the operating duty cycle. A detailed plan view of the Test Track Facility and Durability Test Track are attached for reference also, a durability element profile detail shows all the measurement of the different conditions. Finally, a list of scheduled and unscheduled maintenance. The scheduled maintenance lists the mileage, items serviced, the service interval, and amount of time required to perform the maintenance. The Unscheduled Maintenance List included describes the failures that were encountered along with related photographs during the Structural Durability Test. 29

30 30

31 31

32 32

33 33

34 34

35 35

36 36

37 37

38 38

39 (Page 1 of 2) SCHEDULED MAINTENANCE Orion 9816 DATE TEST MILES SERVICE ACTIVITY DOWN TIME HOURS P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked ,679 P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked ,377 P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked ,154 P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked ,195 P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked ,080 P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked ,983 P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked. 39

40 (Page 2 of 2) SCHEDULED MAINTENANCE Orion 9816 DATE TEST MILES SERVICE ACTIVITY DOWN TIME HOURS ,152 P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked ,066 P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked ,954 P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked ,023 P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked ,636 P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked ,071 P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked ,079 P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked Complete P.M. / Inspection Linkage, tie rods, universals/u-joints all lubed; all fluids checked. (Page 1 of 6) 40

41 DATE UNSCHEDULED MAINTENANCE Orion 9816 TEST MILES SERVICE ACTIVITY DOWN TIME HOURS The fuel system pressure gauge has failed. Fuel system pressure gauge replaced The new fuel pressure gauge is not registering pressure. Pressure gauge replaced Lack of engine power and engine miss. Installed heat wrap around the fuel pressure regulator on the roof Lack of engine power and engine miss. Changed spark plugs and fuel filter. 1, ,463 Engine shutting down. Manufacturer requests high pressure regulator be replaced. High pressure regulator replaced ,520 Engine misfiring, loss of power and transmission will not shift. Found driver s seat chaffing through the engine access panel and coil packs. Trouble shooting. Seat plate raised 1½ to clear engine access panel. Coil packs replaced. (Cummins service performed repairs) ,982 The test bus is bottoming out on the durability track. Front ride height raised. Leveling valve link raised one hole

42 (Page 2 of 6) UNSCHEDULED MAINTENANCE Orion 9816 DATE TEST MILES SERVICE ACTIVITY ,073 Engine will not accelerate above idle. As per manufacturer, foot throttle actuator removed and sent to King Controls for repair. DOWN TIME HOURS ,073 Repaired throttle actuator returned with ECM attached. Installed actuator and mounted ECM to the engine side of the engine compartment door ,073 The cage on the engine coolant fan is broken. New fan unit installed ,397 Air leak by the left front wheel when the brakes are applied. Broken tee fitting found mounted on the frame replaced. (Difficult access) ,397 The air conditioning is inoperative. Thermo King rep trouble shooting; found no power to the clutch, reconnected wires 514 and ,397 The right front air bag is chaffing on the axle. Air bag replaced ,723 The upper radiator support strut is broken. Upper radiator support strut replaced (Page 3 of 6) UNSCHEDULED MAINTENANCE 42

43 DATE Orion 9816 TEST MILES SERVICE ACTIVITY DOWN TIME HOURS ,916 The right front air bag chaffed through. Right front air bag replaced ,916 The left front leveling valve linkage is bent. Linkage straightened ,663 Test bus is disabled on the test track; engine shut off and will not crank. Reset 15 amp. Circuit breaker, trouble shooting cause found nothing ,840 Test bus is disabled on the test track; engine shut off and will not crank. Reset 15 amp. circuit breaker, trouble shooting cause found nothing ,421 Air leak by the left front wheel when the brakes are applied. Split air hose and fitting replaced ,421 Air conditioning compressor failed. Thermo King rep replaced failed A/C compressor and replaced failed diode on A/C mode switch ,421 Engine shut down, will not crank. Reset 15 amp. circuit breaker, trouble shooting cause found nothing ,421 Burned smell coming from the engine compartment. Found A/C clutch coils fed with 24 volts. A/C clutch coils rewired with 12 volts ,421 New A/C compressors will not engage when set to the cool position. Found diode between terminals 2 and 4 installed backwards. Reinstalled diode properly (Page 4 of 6) UNSCHEDULED MAINTENANCE

44 DATE Orion 9816 TEST MILES SERVICE ACTIVITY DOWN TIME HOURS ,614 Air leak by the left front wheel when the brakes are applied. Split air hose and fitting replaced ,614 The rubber bushing is missing from the left front leveling valve link. Leveling valve link replaced ,614 The upper A/C compressor will not engage. Replaced clutch coil relay, coil, pulley and clutch ,614 The front trailing arm bushings are worn. Front trailing arm bushings replaced ,670 Front ride height needs adjusted. Adjusted front ride height ,998 Alternator failed. Replaced alternator ,998 The left front air bag is chaffing on the lateral bar. Air bag and replaced brass Tee fitting on front brakes replaced ,230 The left rear trailing arm is broken at the web behind the spindle. Removed the left arm, hub, and brake assembly. Installed new trailing arm, four trailing arm pivot bushings (left and right side), and replaced rear shocks ,954 The inner and outer bracket bushings are worn on both rear axle trailing arms. Four bushings replaced (Page 5 of 6) UNSCHEDULED MAINTENANCE

45 DATE Orion 9816 TEST MILES SERVICE ACTIVITY DOWN TIME HOURS ,470 Hose clamp on the radiator hose is loose. Clamp tightened and coolant topped off ,353 The right front air bag has chaffed on the lateral bar and is leaking air. Air bag replaced ,424 The bushings are worn on both rear trailing arms. New trailing arms installed ,424 The left upper radiator support bracket is broken. Replaced broken support ,984 The brake air supply line to the right front brakes has chaffed on the lateral bar. Air line replaced ,930 All four bushings on the front suspension beams are worn. All four bushings replaced ,930 All four bushings on the rear axle assembly are worn and the right outside bushing plate is cracked. All four bushings replaced. Crack welded/repaired ,549 The left rear air bag is leaking air. Air bag replaced (Page 6 of 6) UNSCHEDULED MAINTENANCE

46 DATE Orion 9816 TEST MILES SERVICE ACTIVITY DOWN TIME HOURS ,042 The right front air bag is leaking air. Air bag replaced ,059 Both rear shocks are leaking oil. Rear shocks replaced ,059 The radiator fan is hitting a fitting on the hydraulic fan motor causing a leak. Fitting repaired and interference corrected

47 UNSCHEDULED MAINTENANCE RIGHT FRONT AIR BAG CHAFFING ON THE AXLE (2,397 TEST MILES) 47

48 RIGHT FRONT AIR BAG CHAFFED ON THE AXLE (2916 TEST MILES) 48

49 UNSCHEDULED MAINTENANCE CONT. FAILED A/C COMPRESSOR (4,421 TEST MILES) FAILED A/C COMPRESSOR CLUTCH (4,614 TEST MILES) 49

50 UNSCHEDULED MAINTENANCE CONT. FAILED ALTERNATOR (4,998 TEST MILES) 50

51 CRACKED LEFT REAR TRAILING ARM (6,230 TEST MILES) 51

52 UNSCHEDULED MAINTENANCE CONT. WORN REAR AXLE TRAILING ARM BRACKET BUSHING (8,954 TEST MILES) 52

53 RIGHT FRONT AIR BAG CHAFFED ON THE LATERAL BAR (10,353 TEST MILES) UNSCHEDULED MAINTENANCE CONT. 53

54 RADIATOR FAN HITTING RADIATOR (14,059 TEST MILES) 54