9201

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Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
07-23-92 2269 A/C high pressure switch broken off by leveling valve arm interferance. No repair at this time. New high pressure switch ordered. Repairs to be made when parts arrive. 0.0 0.0
08-07-92 4664 Top radiator mounts loose. Company rep retorqued top radiator mounts. 0.5 0.5
08-12-92 5313 High pressure switch reported on 7/23/92 arrived. Pressure switch installed and a/c system charged. 4.0 4.0
09-03-92 8301 Air conditioning high pressure switch broken off by leveling valve interferance. Freon leaked out. High pressure switch ordered. 0.0 0.0
09-08-92 9053 Received high pressure switch for air-conditioning reported on 9/3/92. Installed high pressure switch and charged air conditioning system with freon. 5.5 5.5
11-05-92 12228 Air-conditioning high pressure switch; wire broken off. Wire on high pressure switch repaired. 0.5 0.5
07-30-92 3441 3- 3/8" frame to body bolts broken. Bolts located at center of front wheels. 3-3/8" bolts replaced. 0.25 0.25
08-06-92 4490 Four 3/8" frame to body bolts broken. Bolts located at center of front wheels. Same as reported on 7/30/92. Company rep installed four shims approximately 1/32" to reduce shifting and replace bolts. 1.0 1.0
08-27-92 7601 Hand air valve for door release leaking air. Handle and packing nut tightened. 0.25 0.25
09-08-92 9053 One 3/8" bolt at frame to body interface at center of front wheels missing. 3/8" bolt replaced and shims re-aligned. 0.5 0.5
10-14-92 10863 Driver's side windshield leaking water at top middle. No repair at this time as per company rep. 0.0 0.0
10-16-92 11140 Front luggage rack loose right side. Company rep removed the front barrier panels and tightened luggage rack. Barriers replaced. 1.0 1.0
10-18-92 11266 Test driver heard a clicking noise under right front of bus. Driver and company rep found two 3/8" bolts loose that anchor wheel chair straps throught the floor. Two 3/8" bolts retorqued. 0.75 0.75
11-09-92 12854 Driver's sun visor fell off. Sun visor replaced fasteners tightened. 0.25 0.25
07-09-92 312 Bus would not start. Company rep jumped out the soleniod with two screw driver. Company rep tightened loose switch in fueling door. 0.5 0.5
07-17-92 1125 Horn not functioning. Circuit breaker reset. 0.25 0.25
07-24-92 2409 Horn not functioning. Circuit breaker reset. 0.25 0.25
08-10-92 4963 Low coolandt indicator bulb burned out. Company rep replaced bulb. 0.25 0.25
08-20-92 6758 12 volt alternator connector broken. Connector replaced. 0.25 0.25
08-26-92 7551 Oil gauge light burned out. Light bulb replaced. 0.25 0.25
08-26-92 7551 Two battery cables rubbing against an air line fitting. Battery cables wrapped with rubber to avoid wear. 0.25 0.25
09-08-92 9053 24 volt indicator guage not functioning. Loose wire on 24 indicator guage replaced. 1.0 1.0
09-23-92 9855 Engine hesitation, at 2070 rpm. Cummins and Co. rep. test drive to trouble shoot. Woodward controller replaced and calibrated. 24.0 6.0
10-19-92 11437 Rear access door inoperative. Found a broken wire to rear door. Company rep repaired broken power wire to rear door. 1.0 1.0
11-10-92 13032 Rear door inoperative. Broken wire. Company rep repaired broken wire. 0.75 0.75
11-11-92 13115 Brakes locked up. Rear door micro-switch interlock out of adjustment. Company rep adjusted micro-switch. 0.5 0.5
08-05-92 4469 Company rep feels oil consumption is too high ( 7-8 gallons per 3000 miles). Manufacturer called in Cummins Diesel Engines, Inc. personnel for analysis. Cummins Diesel rep performed the following: ran engine, checked out blow by: o.k. Drained lube oil and checked pan calibration: o.k.(7 gal. low/9 gal. high). Drained coolant, removed valve cover and after-cooler element. Gasket in tact, replaced cover. Intake ports damp only (normal). Checked turbo: o.k. Removed exhaust manifold, checked exhaust ports, all dry. Re-assembled engine, road tested 22 miles, checked oil level and found it to be higher than before road test (Expansion from heat). Engine does not appear to use any oil. Stack absolutely clear. See Cummins service report #22959. 16.0 8.0
09-03-92 8301 Engine hesitation and back firing. Cummins and company reps trouble shooting; all plugs replaced. Problems not corrected. 48.0 6.0
09-21-92 9822 Engine hesitation initially reported on 9/3/92. Engine hesitation at 2070 rpm. Cummins and company rep test drove and trouble shot problem. nothing found. 24.0 6.0
09-24-92 9855 Engine hesitation at 2070 rpm. Company rep trouble shooting electrical system. Rep. found alternator out-put too high. Alternator removed and sent to manufacturer for rebuild. 96.0 3.5
09-28-92 9855 Alternator returned to manufacturer. Alternator installed in bus. Engine hesitation remains. Cummins rep and company rep continue trouble-shooting. 24.0 8.0
09-29-92 9897 Engine hesitation at 2070 rpm, Company rep continues test driving and trouble shooting. 1.0 5.0
09-30-92 9900 Engine hesitation at 2070 rpm. Cummins and company rep trouble shooting problem. Woodward controller replaced and calibrated. Problem still exists. 24.0 8.0
10-01-92 9900 Engine hesitation at 2070 rpm. Cummins and Company reps trouble shooting engine hesitation. No solution. 24.0 8.0
10-02-92 9900 Engine hesitation at 2070 rpm. Cummins, Woodward and Company reps, trouble shooting engine hesitation. No solution. 24.0 8.0
10-05-92 9914 Engine hesitation at 2070 rpm. Cummins, Woodward and Company reps trouble shooting engine hesitation. All reps decided to change fuel actuator. 72.0 8.0
10-07-92 9973 Transmission cooler hose has a pin hole and is leaking. Hose replaced by company rep. 3.0 3.0
10-14-92 10863 Engine hesitation at 2070 rpm. Cummins, Woodward and Company reps trouble-shooting engine hesitation. 8.0 8.0
10-16-92 11098 Engine hesitation at 2070 rpm. Cummins and company reps replaced woodward controller and calibrated. 3.0 2.5
10-16-92 11167 Test driver experienced loss of throttle. Company rep trouble shooting; reset woodward controller. 4.0 2.0
10-19-92 11480 Upon return trip to test track, test driver experienced an excessive power surge. Driver pulled the bus off the road and called for assistance. Company rep determined the bus should not be run. Bus to be towed to the Altoona faciity. 9.25 3.0
10-20-92 11480 Engine malfunction. Bus towed to the Altoona facility (approximately 38 miles.) 12.0 3.0
10-20-92 11480 Touble shooing engine malfunction. Cummins, company rep and test mechanic disassembled engine, found #3 piston melted down. 12.0 3.0
10-21-92 11480 #3 piston melt down. Arrangement made with local Cummins dealer for repairs to engine. 24.0 1.0
10-22-92 11480 #3 piston melt down. Bus towed to Cummins dealer for engine repair. 24.0 5.0
10-22-92 11480 #3 piston melt down. Refer to Cummins dealer's work order. Invoice #207795. 192.0 72.0
10-31-92 11504 Transmission will not shift out of neutral. High speed idle linkage out of adjustment. High speed idle linkage adjusted properly. 8.0 1.0
11-20-92 14570 Engine surging. Refer to Cuymmins dealer's work order. #23696 1.5 1.5
08-08-92 4816 Exhaust pipe cracked at the turbo. Pipe ordered. Pipe received. Pipe cut, welded, and installed by Company rep. 13.25 12.5
11-14-92 13691 Exhaust flex pipe separated from muffler. Company rep reconnected flex pipe to muffler. Flex pipe had to be disconnected and stretched. 5.0 5.0
08-16-92 6065 Test driver heard a shrill noise from engine compartment. Company rep observed noise and said the noise was just the fuel regulator and to continue running. 3.0 3.0
09-05-92 8591 Test driver hears a high pitched noise coming from fuel tank area (fuel regulator). Company rep ok'd to run. No problem found by rep. 5.0 0.25
09-13-92 9486 High pitched noise from fuel regulator becoming worse; noise heard at all times. Company rep wated to continue operating. 0.0 0.0
09-15-92 9798 Primary fuel regulator has a high pitched noise. Primary fuel regulator replaced. 2.5 2.5
09-16-92 9807 Bus venting fuel. Primary fuel regulator checked out o.k. at 150 psi. Pop-off valve bench cheched at 125 psi (should be 180 psi). Pop-off reset to 180 psi and re-installed. 4.5 4.5
07-30-92 3441 Bolt missing from one side compartment latch. Bolt in latch replaced. 0.25 0.25
08-12-92 5313 Left front wheel house tie area has approximately 1/4 inch crack. Company rep recommends no repair at this time. Crack will be monitored. 0.0 0.0
07-09-92 420 Front lower shock bushings worn. Rep. replaced front lower shock bushings. 0.25 0.25
07-10-92 453 Master switch is loose. Company rep tightened switch. 0.25 0.25
07-01-92 537 All front shock bushings worn. Company rep replaced all front shock bushings. 0.75 0.75
07-16-92 885 Arm broke on left rear leveling valve. Company rep replaced left rear leveling valve. 1.0 1.0
07-16-92 923 Right front shock leaking oil. Company rep replaced right front shock and shock bushings. 0.5 0.5
07-16-92 993 Front leveling valve not maintaining proper ride height. Company rep adjusted front leveling valve. 0.25 0.25
07-17-92 1125 Company rep requested all shocks be replaced. All four shocks and shock bushings replaced. 1.5 1.5
07-19-92 1523 Front of bus not maintaining proper ride height. Company rep adjusted front leveling valve to proper ride height. 0.75 0.75
07-20-92 1680 Left front shock leaking oil. Left front shock and shock bushings replaced. 1.0 1.0
07-20-92 1680 Left rear air bag rubbing against the frame. Left rear air bag replaced and adjusted. 2.5 2.5
07-21-92 1835 Air line to left rear air bag leaking due to rubbing against the leveling valve. 3/8" x 31" plastic air line to left rear air bag replaced. 7.0 2.0
07-21-92 1862 Left and right lower rear shock bushings worn. Company rep replaced left and right lower rear shock bushings. 0.5 0.5
07-22-92 2020 Left and right lower front shock bushings worn. Left and right lower front shock bushings replaced and all leveling valve adjustments verified. 1.5 1.5
07-22-92 2055 Right front shock leaking oil. Company rep replaced right front shock and shock bushings. 2.0 2.0
07-23-92 2269 Arm on left rear leveling valve broken. Company rep replaced leveling valve arm with an arm from a used leveling valve. 2.0 2.0
07-24-92 2409 Company rep requested all shocks be replaced. All four shocks and shock bushings replaced. 2.0 2.0
07-25-92 2582 Company rep requested all shock bushings be replaced. Company rep replaced all shock bushings. 1.0 1.0
07-25-92 2919 Arm broken on left rear leveling valve. Company rep replaced the left rear leveling valve. 1.0 1.0
07-27-92 2983 All lower shock bushings worn. All lower shock bushings replaced. 1.0 1.0
07-30-92 3363 Right front shock bushings worn and lower shock mounting bolt threads damaged. Right front shock bushings replaced and mounting bolt threads chased. 11.0 2.0
07-30-92 3441 Front right shock leaking oil. Company rep requested all four shocks be replaced. All four shocks and shock bushings replaced. 2.0 2.0
07-31-92 3542 Arm broken on left rear leveling valve. Company rep replaced left rear leveling valve. 0.5 0.5
08-02-92 3883 Both front lower shock bushings worn. Company rep replaced both front lower shock bushings. 0.5 0.5
08-03-92 4113 Bus not maintaining proper ride height. Bus leans to the right. Front and left rear leveling valves adjusted. 0.25 0.25
08-06-92 4490 Company rep requested all four shocks be replaced. All four shocks and shock bushings replaced. 2.0 2.0
08-06-92 4490 Bolt missing from right rear mud flap. Bolt replaced. 0.25 0.25
08-06-92 4490 Bolt missing from front leveling valve. Bolt replaced. 0.25 0.25
08-07-92 4637 Left rear leveling arm broken. Arm hitting a/c compressor. Company rep observed the problem. Rep determined that rod should be shortened by 4" and new 1/4" holes be drilled to accommodate linkage. 8.5 3.0
08-08-92 4720 Nut backed off front leveling valve linkage. Company rep observed the problem. Rep determined that the bolt should be lengthened to 2" and axle bracket bent to be parallel to valve. 2.5 2.5
08-10-92 4963 Left rear leveling valve arm broke. Company rep replaced the left rear leveling valve arm and adjusted the ride height. 1.25 1.25
08-11-92 5191 Right rear shock leaking oil. Right rear shock and shock bushings changed. 0.75 0.75
08-12-92 5313 Company rep requested front and left rear shocks be changed. Both front and left rear shocks and shock bushings changed. 1.0 1.0
08-17-92 6155 Test driver heard a clicking sound under the front of the bus when going over various elements. Company rep inspected bus and requested front shock bushings be replaced. All front shock bushings replaced. 1.0 1.0
08-18-92 6405 Left rear shock leaking oil. Left rear shock and shock bushings replaced. 0.75 0.75
08-19-92 6536 Left rear leveling valve arm broken. Arm rubbed against a/c wire harness. Left rear leveling valve arm replaced and wire harness taped. 0.75 0.75
08-19-92 6582 Company rep requested front shocks and right rear shock be changed. Both front shock and shock bushings and right rear shock and shock bushings replaced. 1.5 1.5
08-19-92 6582 Trunnion bushing on A-frame worn. Trunnion bushing replaced. 1.25 1.36
08-19-92 6582 Front radius rod mounting bracket has approximately 3/8" crack. Front radius mounting bracket replaced. 0.5 0.5
08-19-92 6758 Bus not setting at proper ride height. All leveling valves set to proper height. Front leveling valve bracket was bent as per company rep's instructions to acquire proper adjustments. 0.75 0.75
08-21-92 6983 Company rep requested front lower shock bushings be replaced. Front lower shock bushings replaced. 0.25 0.25
08-23-92 7015 Front leveling valve not maintaining proper fide height. Company rep replaced front leveling valve and adjusted front and rear ride height. 53.0 3.5
08-24-92 7103 Right rear leveling valve not maintaining proper ride height. Replaced missing nut on right rear leveling valve linkage. 0.75 0.75
08-25-92 7374 Company rep requested both front lower shock bushings be replaced. Both front lower shock bushings replaced. 0.75 0.75
08-26-92 7551 Company rep requests all shocks be replaced. All shocks and shock bushings replaced. 1.5 1.5
08-31-92 7946 Left rear ride height low. Adjusted left rear leveling valve to proper ride height. 0.25 0.25
09-01-92 8094 Company rep requested both front shock and shock bushings be replaced. Company rep replaced front lower shock bushings and left rear shock and shock bushings. 1.5 1.5
09-02-92 8204 Left rear leveling valve arm broke. Company rep replaced left rear leveling valve arm. 6.0 0.75
09-03-92 8301 Company rep requested both front and right rear shocks be replaced. Both front and right rear shock and shock bushings replaced. 1.5 1.5
09-04-92 8427 Left rear leveling valve bracket anchored to bottom of air bag support broken off (1" channel). 1" channel bracket removed. New bracket fabricated and welded to air bag support. Leveling valve installed and ride height adjusted. 15.0 9.5
09-05-92 8591 Leveling valve arm nut backed off. (left rear). Company rep replaced nut on leveling valve arm. (left rear) 5.5 0.25
09-08-92 9053 Left rear shock leaking oil. Company rep requested all shocks be replaced. All shocks and shock bushings replaced. 2.0 2.0
09-14-92 9675 Left rear shock leaking oil. Left rear shock and shock bushings replaced. 4.0 1.0
09-15-92 9798 Company rep requested front lower shock bushings be replaced. Front lower shock bushings replaced. 0.25 0.25
10-12-92 10601 Company rep requested all shocks be replaced. All shocks and shock bushings replaced. 2.0 2.0
10-19-92 11437 Both front lower and right rear lower shock bushings worn. Both front lower and right rear lower shock bushings replaced. 0.5 0.5
11-05-92 12228 Company rep requsted all shocks be replaced. All shocks and shock bushings replaced. 2.0 2.0
11-09-92 12854 Air leak found in front suspension. Company rep requested to continue running bus. 0.0 0.0
11-10-92 13028 Front lower shock bushings worn. Front lower shock bushings replaced. 0.5 0.5
11-12-92 13317 Front right shock leaking oil. Both front shocks and shock bushings replaced. 3.5 1.0
11-17-92 14102 Company rep requested all shocks be changed. Company rep replaced all shocks and shock bushings. 2.0 2.0
11-17-92 14102 Trunnion bushing on A-frame worn. Trunnion bushing replaced. 1.5 1.5
07-10-92 453 Steering box leaking power steering fluid. Added one quart of fluid. O ring ordered. Company rep said to run the bus until parts arrived. 0.0 0.0
07-30-92 3363 Right side tie rod end loose. Tie rod end retorqued. 1.0 1.0
08-21-92 6983 Noise reported on 8/17/92; steering hydraulic line found to be hitting on floor when going over various elements. Company rep re-routed hydraulic line to avoid line from hitting the floor. 0.75 0.75
08-15-92 5821 Lug nut loose on front left wheel. Nut retorqued. All lug nuts on all wheels checked. 0.5 0.5
08-19-92 6582 Right front hub leaking oil. Gasket replaced in right front hub. 1.0 1.0
09-09-92 9486 Left front wheel has a broken wheel stud. All lug nut torques on all wheels checked. Wheel stud ordered. 0.25 0.25
09-21-92 9822 Left front wheel stud reported on 9/13/92 arrived. Left front wheel stud replaced. 1.0 1.0
10-12-92 10601 Test drivers feel shimmy in steering. Company rep requested front wheels be balanced. Front wheels balanced. 1.0 1.0
11-21-92 14768 Left rear wheel lug nuts found loose. Left rear lug nuts retorqued and all others checked. 0.25 0.25
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