1. How Can We Make Fleets More Reliable
Lessons from Training Our Best Managers and Redesigning Buses

2. What Causes More Reliable Fleets
More Reliable Fleet from Better Bus Selections
More Reliable Fleet from Better Problem Solvers

3. Ford Engine Choices 2003
7.3
2 valve per cylinder, 275 HP, 525 Lb/Ft, Fixed Turbo
6.0
4 valve per cylinder, 325 HP, 560 Lb/Ft, VGT Turbo, EGR

4. Ford 6.0 Lessons in Design, Testing and Purchases
From 2003 to 2010, 6.0 in minibus E350, E450 (better EPA, power, noise)
Ford techs not prepared, most issues had more than one cause
IH had built 7.3 for years, switched to EGR (EPA), VGT turbo (power), these were tested components but transit applications (stop and go, low speeds)
Ten problems hurt reliability. EGR valve, cooler, head bolts, oil cooler, FICM, HEUI injectors, VGT turbo, HPOP (ICP,IPR), wire chafe, oil seals
TTY Head Bolts, Head Gasket Failures – out of service
EGR Cooler soot - low power roadcalls
EGR Valve sticks open - low power roadcall

5. Dissection of the Critical 6.0 Issues
Problems
Causes
EGR Cooler Fail
EGR Valve Fail
Oil Filter Capacity Exceeded by 3-5k miles, then goes to bypass mode. Hot, dirty oil destroys injectors
EGR Cooler flow restricted, then fails since gas is degrees, it slowly bakes, ruptures, oil-coolant mix
EGR valve can clog, stick open-lose engine power
Transit slow speeds not a fit for EGR valve clogging

6. Coincident Critical Issues
TTY Head Bolts
PCM, FICM, HPOP
MY used 10 bolts each head
Torque To Yield bolts best for load frequency and amplitude found in high torque diesel engine, but the OEM bolts were M14 (not strong enough), and the design clamping the heads and the valve rocker pivots to the block was flawed. The 6.4 used M16 studs and the head and block were direct mating, with wider and thicker washer.
Power Control Module and Fuel Injector Control Module had a variety of minor problems (vibration, chafing) caused hard start, rough run, stalling
HPOP critical to injectors, power. PSI is 3,000 at speed, 600 at idle; below 500 will not start
Injector Control Pressure and Injector Pressure Regulator sensors failed (chafing), oil O-rings common fail

7. How Did This Get So Bad How did the Ford 6.0 Implode?
What replaced the 6.0?
The 6.0 problems were each corrected, but often after misdiagnosis, repeats
But so many problems, and so many confused diagnostics led to owners suffering repeated failures after warranty.
Ford was reacting to new EPA regulations, and pushed International to improve exhaust (EGR was needed to reduce NOx). The EGR valve, EGR cooler were new.
International replaced the 6.0 with the 6.4 to cure most of the problems, but not for transit.
Introduced the DPF, compound turbos
Introduced the common-rail fuel injection, no more oil pressure-injector
But Ford had developed their own 6.7
Improved CGI block, 6 bolts/main bearing cap, 6 head bolts/cylinder, SCR, separate cooling for oil/coolant

8. How do we Redesign Buses
An Example

9. Zion NPS Eldorado National RE
August 2001 Bus Fire
Power Unit – Total Loss, Fire in Engine Compartment
Trailer Unit – Significant Damage
Evidence Found - Hydraulic leak, Cooling fan
Correction – Local maintenance team designed electric fan to replace and retrofit radiator
Hydraulic fluid 17 gallon down to 1.5 gallon
3,000 psi down to 1,500 psi, Alternator no change
Zion NPS Eldorado National RE

10. Conditions for Team to Solve Fan Problem
Safety Expert General Manager
Ingenious Maintenance Director, Team
Trusting Client
Steps Involved
Solve Fire Source
Source Electric Fan
Design Mounting
Test First Installation
Prove to Owner/Client; Agree on Fleet Retrofit
Conditions for Team to Solve Fan Problem
Most important element was being sure the causation was analyzed accurately

11. How do we Build the Best Team for Fleet Reliability
Part Training, Part Motivating, Part Scouting the Best Talent

12. Part Training ASE Certifications Mechanical systems
NTI Training Courses
Fundamentals of Management
ENO or other coursework
Leadership vs Management

13. Part Motivating
Each position needs evaluation of skills, compensation balance (including benefits)
Each position allows the incumbent to feel part of an important team
Each position must have basic process of recognizing outstanding performance
Each position becomes most valuable when the incumbent finds this career is his/her path to being all they can be

14. Part Scouting the Best Talent
Within the organization, we must objectively determine the greatest performances
Outside the organization it is important to assess who excels and why
For those that may be promoted from within, morale improves if the promotion seems earned
For those that must be found and brought into the organization, performance and morale improve if the new member is viewed as a star