Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
02-15-00 425 The right side wheel well, top front, (interior) has a 12" crack in the composite. Removed right front tire and inspected for exterior cracking. None found. Crack reported to manufacturer. No repair at this time. 2.0 2.0
02-29-00 1349 The first window by the netrance door is falling out. Window replaced with Machine Rite/Excel model 1.0 1.0
03-07-00 2153 Two mounting bolts on the right side cradle mount, bulkhead loaction are loose. both mounting bolts and nuts replaced and torqued. 0.5 0.5
03-20-00 3399 The fourth window right side is broken. Fourth window on right side replaced. 3.0 3.0
03-23-00 4048 The second window from the rear is falling out. New "Machine Rite/Excel" passenger windows installed by manufacturer's rep. 1.0 1.0
03-23-00 4048 The seats int he W/C area, left side are breaking away from the wall. Weight removed from seats and placed onthe floor. No repair to the seats at this time. 0.5 0.5
06-07-00 8206 The bond is broken on the composite seams on both sides of the rear door between the door and the windows. NABI reps performed repairs to bonded seams. 9.0 9.0
06-22-00 9290 The battery box is broken away from the composite. the bos shows signs of impact damage which may have contribuged to the failure. NABI reps. performed repairs to composite. 8.0 8.0
06-22-00 9290 The front cover for the CNG tanks has come off. Cover installed with nut-serts and rivets. 1.0 1.0
06-28-00 9585 Both front windshields and the rubber retaining gaskets are coming out at the bottom of the windshield opening. The windshields and gasket were reseated and retained with a strap for the duration of testing. 0.5 0.5
07-26-00 10929 The battery tray is broken. Tray reemoved, welded/repaired and replaced. 1.0 1.0
08-21-00 12944 Three latches have fallen apart for the fuel tank covers. Reassembled latches and fabricated new brackets. 1.0 1.0
08-21-00 12944 The front and rear fairings are loose on the fuel tank. Installed new screws and rivets as needed. 1.0 1.0
08-21-00 12944 The battery tray left track and left latch are broken. Battery tray replaced. 1.0 1.0
08-30-00 13803 The innner bolt is broken on the left side engine cradle to body mount. Broken bolt removed and new bolt installed. 1.5 1.5
03-27-00 4271 The low beam on the left side is burned out. Left side low beam lamp replaced. 0.25 0.25
06-29-00 9769 Engine shut down during durability driving. Engine will not crank resulting in no power to bus. Replaced broken battery terminal lug and cable. 1.0 1.0
07-24-00 10769 Bus will not start. Found rear battery at 6.3 volts. Battery replaced. 1.5 1.5
08-01-00 11426 The battery equalizer has shorted out internally. The equalizer and the rear battery have melted. Equalizer, battery and Amerex fuse replaced. 1.0 1.0
08-21-00 12994 The speedometer will not register itermittently. Installed new wire from the connector at the ZF module, to the connector at the speedometer. Installed bypass wire on pin #15 Deutshe connector on the Woodward pigtail (broken pin). Installed capacitor on wire J223 as per NABI rep. 4.0 4.0
09-01-00 14104 The rear battery is boiling. Battery replaced. 3.0 3.0
09-06-00 14523 The rear battery is boiling. Battery equalizer replaced. Adjusted voltage regulator to 26.9-27.0 volts. 1.0 1.0
03-20-00 3399 The bottom bearing/pivot roller on the righ tsection of the front door is worn. Bearing/pivot roller replaced. 1.0 1.0
02-17-00 504 Three front lower radiator bracket bolts are loose. Three bolts replaced and torqued to specs. 1.0 1.0
03-07-00 2153 Manufacturer requests six bolts on the rear most radiator-to-frame brace in the engine compartment. All six bolts replaced and torqued to specs. 0.5 0.5
03-16-00 3140 Bus is experiencing a loss of power. Loose charge air pipe clamps tightened. 0.5 0.5
03-20-00 3399 Both front shocks are worn. Both front shocks replaced. 1.0 1.0
03-20-00 3399 The wiper motor controller has failed. wiper motor controller replaced. 1.0 1.0
04-11-00 5438 Engine runs, no throttle. Troubleshooting; all electrical connections at doors, ramp switches, and relay at electrical panel. Troubleshoot Dinex system. Problem is intermittent. Throttle started operating. No problem found. 1.5 1.5
04-11-00 5438 The steering wheel came off. checked steering wheel for stripped threads and steering column for bad splines. Checked nut. No problem found. Reinstalled steering wheel. 1.0 1.0
05-01-00 5498 Engine is misfiring. Warranty work performed. Troubleshooting by technician found a bad #6 spark plug. Parts ordered and installed. 48.0 4.0
05-05-00 5656 The fire supression system has discharged. The cause of activation was not determined. The system was recharged and completed the test without further incident. 0.5 0.5
05-18-00 6920 The engine cradle is cracked on the left side. Crack welded/repaired. 1.5 1.5
05-24-00 7173 Manufacturer requests four gussets be added to the engine cradle at the cross member below the bell housing. Four 6' x 8" x 9 1/2" gussets installed as per manufacturer's request. 2.0 2.0
05-24-00 7173 A fitting is leaking on the coolant pipe from the engine to the circulating pump. Fitting replaced. 1.0 1.0
05-24-00 7173 Manufacturer requests newly designed lower radiator pipe be installed. New lower radiator pipe installed. 1.0 1.0
05-24-00 7173 The engine will not crank. Trouble shooting found the positive terminal on the battery broken. Terminal replaced. 0.5 0.5
06-07-00 8206 The engine cradle has a broken bolt in the top left bulkhead support. Engine support rod adjusted and new bolt installed. 1.5 1.5
06-07-00 8206 The bottom radiator hose is leaking. Hose clamp tightened. 0.5 0.5
06-15-00 8636 Ref. fire suppression system on 5/5/00. Installed new Amerex fire suppression bottle and actuator. 1.0 1.0
07-13-00 10073 Exhaust pipe from turbo is broken. wires, coolant level sensor, and A/C drain lubes are melted. Pipe, wires and drain tube repaird. Sensor replaced. 4.0 4.0
07-17-00 10146 Engine shut down. Cranks will not start. Fuel gauge shows no pressure. Found tripped 30 amp breaker for fuel solenoid. Reset breaker. No shorts founds. 3.0 3.0
08-07-00 12333 The strap for the charge air pipe is broken. Strap welded/repaired and reinstalled. 2.0 2.0
08-21-00 12944 The steering system is binding. Steering transfer gear box replaced. 0.5 0.5
02-23-00 883 The left front air bag is leaking. The bellows have broken away from the lower pedestal. Left front air bag replaced. 1.0 1.0
02-28-00 1232 The front suspension will not fill with air. The right front air bag is broken from the lower pedestal and the Skinner valve on the kneeling system will not close. Replaced the right front air bag remporarily bypassed the kneeling system. 1.5 1.5
03-07-00 2153 Both rear, lower radius rod nuts are loose. Nuts torqued to specs. 1.0 1.0
03-09-00 2474 The front suspension is bottoming out. Inspection found the bump stop broken in the air bag. Air bag was replaced. 1.0 1.0
03-13-00 2691 Three bolts are broken in the top mounting bracket on the right rear, forward shock. Three broken bolts removed, new bolts installed. 1.5 1.5
03-15-00 3063 The left front air bag has a hole in it. Left front air bag replaced. 2.5 2.5
03-31-00 4882 The left rear, forward, upper shock mount bracket bolts are broken and damaging the rear suspension air line. Broken bolts and upper bracket installed. Air line repaired. 1.5 1.5
04-04-00 5062 The rear, low radius rod bushings are worn on the suspension end. Both rear, lower radius rods replaced. 2.0 2.0
04-27-00 5498 The right front air bag has failed. Right front air bag replaced. 1.0 1.0
05-16-00 6855 The left rear, forward, upper shock mount bracket bolts broke damaging the rear suspension air line. Broken bolts removed and upper bracket reinstalled. Air line repaired. 1.5 1.5
06-12-00 8440 The bottom stud on the right front shock is broken. Right front shock replaced. 1.0 1.0
06-16-00 8724 The right front air bag has broken fromthe bottom pedestal. Right front air bag replaced. 1.0 1.0
07-25-00 10918 the left rear leveling valve L-bracket is broken. Repalced broken L-bracket. 1.0 1.0
07-28-00 11176 The left rear upper shock mount bolts are broken. Left rear upper shock mount bolts replaced. 1.5 1.5
08-11-00 12812 The right rear, lower radius rod is broken at the suspension end. Right rear lower radius rod replaced. 2.5 2.5
08-30-00 13803 The left front air bag is leaking. Left front air bag replaced. 1.0 1.0
08-11-00 12812 The left rear, forward shock is broken out of the upper mounting bolts. Upper mount repaired. 2.0 2.0