AN 440L


Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
09-30-94 3691 The top rear outside body panel; three of four mounting brackets are broken. Fabricated new brackets and installed. 1.5 1.5
01-10-95 6937 Rear panel; right side bracket is broken. Fabricated and install new bracket. 0.5 0.5
01-10-95 6937 Left side fuel tank compartment door fell off. Two broken screws replaced 0.5 0.5
01-19-95 7738 Rear roof panel, above the engine compartment; both mounting brackets are broken. Two new brackets fabricated and installed from 1" strap steel. 1.5 1.5
02-14-95 9093 Front door; upper rear control arm is broken. Control arm repaired. 0.5 0.5
03-02-95 11014 The handrail at the rear door is cracked at the floor attachment. Handrail welded/repaired. 0.25 0.25
07-18-94 482 Left rear turn signal will not function. Broken wire repaired. 0.5 0.5
07-18-94 482 Both rear light panels are loose. Fastener tightened on both rear light panels. 0.25 0.25
09-30-94 3691 Both front turn signals are burned out. Both front turn signal lamps replaced. 0.5 0.5
11-25-94 5174 Batteries are dead. Batteries charged. New batteries ordered. 1.0 1.0
11-30-94 5204 New batteries arrived. Batteries installed. 1.0 1.0
12-13-94 6023 Tail lights inoperative. Broken wires repaired and blown fuse replaced. 2.0 2.0
12-22-94 6558 Engine, electric, all systems shut down. Bus towed to the shop. Circulating pump wire shorted out. Wire repaired and 80 amp fuse replaced. 3.0 3.0
01-19-95 7738 High beams and clearance light will not function. Replaced 5 amp fuse in Dinex system. 0.5 0.5
01-19-95 7738 Right front turn signal will not function. Broken wire located on the front J-box and repaired. 1.0 1.0
02-01-95 8448 Test driver saw sparks from the inside compartment above the entrance door. All systems shut down. Electrical short in compartment found, wires repaired and the blown fuse in the battery compartment replaced. 10.0 2.5
02-16-95 9481 Rep. found the wiring harness above the front door chaffing. Rep. repaired damaged wires, tightened two loose terminals in the electrical panel, and two loose battery terminals. 2.5 2.5
02-20-95 9706 Transmission is coming out of gear. Rep. found the transmission relay loose, relay tightened. 1.5 1.5
01-18-95 7676 Check for erratic transmission shifting and engine shut down. Install DDEC reader and trouble shoot; no problems found. 2.5 2.5
02-20-95 9716 Rep. trouble shooting no lights on the right side of the bus. Chaffed wired found and repaired. 2.0 2.0
04-05-95 12469 Interior light panels, left side are all loose. Light panels removed and all mounting fasteners replaced. 4.0 4.0
04-06-95 12516 Dash lights are inoperative. Trouble shooting; two broken wires on the dimmer switch repaired. 1.5 1.5
04-13-95 13151 The entrance doors, speedometer, right rear interior lights and various clearance lights are inoperative. The overhead wiring harness, left side is chaffed. Repaired six wires, one wire terminal and replaced two blown dinex fuses. 10.0 10.0
04-19-95 13838 The wiring harness is loose, left front, overhead. Harness refastened. 1.0 1.0
04-21-95 14035 The condenser fan relay failed. Condenser fan relay replaced. 0.5 0.5
04-21-95 14035 The brake light fuse is blown. Replaced brake light fuse. 0.5 0.5
05-26-94 94 Radiator is leaking, bus disabled. Bus towed to maintenance shop. Radiator removed, repaired and replaced. 288.0 5.0
06-07-94 176 Lost throttle condition. Mechanic and Neoplan rep. trouble shooting, no problem found. 356.0 2.0
06-08-94 176 Lost throttle condition. Detroit Diesel Rep. called in. Trouble shooting found a 10 gauge wire chaffed through by a screw. Wire repaired. 4.0 4.0
07-18-94 482 Heater water pump is not stable. Second clamp installed to secure the pump. 0.5 0.5
08-15-94 2055 Right side fuel tank is leaking at the lower outside edge. Temporary repair of fuel tank. 6.0 3.0
08-15-94 2105 Bus to maintenance shop for replacement of fuel tanks. Both fuel tanks replaced. New tanks have no mounting tabs, mounting tabs welded on for installation 36.0 6.0
08-17-94 2205 Both fuel tanks are leaking at various corners. Both fuel tanks welded/repaired. 6.0 6.0
08-17-94 2205 The rear transmission mount is broken. Transmission mount welded/repaired. 2.0 2.0
08-17-94 2205 The front transmission mount is loose. Transmission cooler removed to gain access to the front mount. Front transmission mount torqued. 1.0 1.0
08-19-94 2530 The right side fuel tank is leaking fuel. New tank ordered. New fuel tank arrived and installed. 444.0 4.0
09-19-94 2785 Fuel tank return line is leaking. Fuel line repaired. 1.0 1.0
09-20-94 2828 Strap rubber isolators have fallen out from fuel tank straps. Installed new rubber isolators. 0.5 350.0
09-23-94 3291 Cooling fan drive shaft is loose; the yoke on the PTO is loose causing the shaft to wear in the yoke. Yoke, universal joint, and woodruff replaced. 4.0 4.0
10-04-94 3691 The left front transmission mounting bolts are loose. Transmission oil cooler removed to gain access to the mounting bolts. Bolts torqued, oil cooler gasket and oil cooler replaced. 2.5 2.5
10-04-94 4003 Exhaust pipe clamp is broken. Rep. welded/repaired clamp. 1.0 1.0
11-22-94 5102 Transmission mounts are loose. Coolant drained and transmission cooler removed to gain access to mounts, mounts retorqued, cooler installed and coolant replaced. 2.0 2.0
11-28-94 5204 Cooling fan drive shaft fell off. Disassemble drive shaft, found set screw and shaft key missing. Parts ordered. 1.0 1.0
11-30-94 5204 Parts arrived for the cooling fan drive shaft. Parts installed. 48.0 150.0
12-12-94 6023 Engine coolant circulating pump mounting bracket is broken. Two rear air tanks removed to gain access to the bracket. Bracket welded/repaired with 0.75" strap iron. Air tanks replaced. 1.5 1.5
12-12-94 6023 Turbo line has too much movement. Rep. requested a bracket be added to secure line. A 0.75" strap iron bracket installed. 0.5 0.5
12-13-94 6023 Coolant line hangers in the engine compartment are broken. Hangers welded/repaired. 1.0 1.0
01-10-95 6937 Air cleaner clamp is missing a bolt. Bolt replaced, clamp repositioned. 1.0 1.0
01-10-95 6937 The right side fuel tank is leaking fuel. Loose fittings tightened through the floor panel. 13.5 1.5
01-10-95 6937 Engine oil dip tube is broken off in the oil pan. Broken piece removed and adapter fittings installed to the oil pan. 1.0 1.0
01-19-95 7738 Muffler bracket mounting studs are broken on both muffler brackets. Exhaust pipes and muffler removed to gain access to the brackets. Studs welded/repaired. Exhaust system reinstalled. 2.5 2.5
02-14-95 9093 Right side fuel tank; the rear strap is broken. Strap replaced. 0.5 0.5
02-23-95 10252 Air cleaner hold down strap is broken. Replaced broken strap with new one, 1.0 1.0
02-23-94 10252 The right side fuel tank is shifting causing the cross over pipe to rub against the frame. Tank straps loosened, rubber shims installed to prevent shifting, straps retorqued. 1.0 1.0
03-03-95 11030 Engine shutting down and transmission coming out of gear. Trouble shooting found engine hour meter hanging down in the engine compartment. Wires melted on the exhaust pipe. Wires repaired and hour meter fastened. 1.5 1.5
03-31-95 12098 The front radius beam mount at the main frame is cracked, and the frame section forward of the right fuel tank is cracked. Both cracks welded/repaired. 2.5 2.5
03-31-95 12098 The circulation pump mount is broken. New pump mount fabricated and installed. 1.0 1.0
04-13-95 13151 The engine belt idler pulley is loose Idler tightened. 0.25 0.025
04-13-95 13151 The rear lower transmission mounting bolts are loose. Mounting bolts retorqued. 0.25 0.25
04-14-95 13308 The circulating pump is leaking where the pipe threads into the pump. Leak repaired. 1.5 1.5
04-20-95 13998 The air conditioning compressor turnbuckle is broken. Temporarily repaired until ordered parts arrive. 1.5 1.5
04-20-95 13998 Braided line to the transmission accumulator is leaking. Temproarily repaired until ordered parts arrive. 0.5 0.5
04-21-95 14035 The air line from the air tank to the transmission oil heat exchange is leaking. Air line replaced. 0.5 0.5
04-21-95 14035 The exhaust pipe clamp and the lower exhaust pipe flange is broken. Clamp replaced and flange welded/repaired. 2.5 2.5
05-05-95 15000 The top center bolt on the engine cooling fan shroud is loose. Bolt tightened. 0.25 0.25
05-16-95 15000 The brackets on the right side of the surge tank are broken. Surge tank removed and brackets repaired. 1.5 1.5
05-23-95 15000 Three cracks found in the engine cradle. Cracks welded/repaired. 1.5 1.5
02-14-95 9093 The engine compartment framing, top right and lower right is cracked. Cracks welded/repaired. 1.0 1.0
08-09-94 1656 The frame is broken through on the right rear at the interface with the engine cradle. Bus towed to the maintenance shop. Frame welded/repaired, 0.25" plate installed for reinforcement 48.0 4.0
10-04-94 3691 The left rear crossmember forward of the engine cradle is cracked. Crack welded/repaired 1.5 1.5
10-04-94 3691 The rear upper engine cradle suport is cracked. Support welded/repaired. 1.5 1.5
10-10-94 4091 Engine compartment framing is cracked in the upper left rear corner. Crack plated, welded/repaired. 2.0 2.0
12-13-94 6023 Engine cradle frame has six cracks. All cracks welded/repaired. 12.0 12.0
12-15-94 6024 The left rear upper engine support is cracked approximately 1.5" Crack welded/repaired. 1.0 1.0
12-19-94 6299 Front leveling valve linkage is broken. Rep. repalced the front leveling valve linkage and adjusted the ride height. 1.5 1.5
01-19-95 7738 The following cracks were located; support tubing above the engine by the coolant surge tank, engine cradle front to rear (six locations), and the front axle lateral bar mount (frame side.) All cracks welded/repaired. (Note: An additional beam from the front lateral bar mount to frame side was added). 79.0 8.0
01-30-95 8104 Right rear upper corner of the engine cradle is cracked and the outlet of the air charge cooler is cracked. Outlet crack welded/repaired, and engine cradle crack plated and welded/repaired. 3.0 3.0
02-23-95 10252 Lower left rear engine cross member is cracked. Crack plated and welded/repaired. 2.0 2.0
03-02-94 11014 Both upper rear corners of the engine cradle frame work are cracked. Two gussets added to both upper corners, cracks welded/repaired. 6.0 6.0
03-02-95 11014 Frame is cracked at the lower left by the radius beam mount. Frame crack welded/repaired. 1.0 1.0
04-05-95 12469 Inspection found the following cracks; both rear engine cradle verticle supports, both uprights forward of the rear axle by the shocks, and the gussets on the forward radiator mounts. Radiator gussets and uprights welded/repaired. Gussets added to the engine cradle verticle supports and the supports welded/repaired.. 3.5 3.5
04-13-95 13151 The right rear upper engine cradle frame member is cracked. Crack welded/repaired. 0.5 0.5
04-14-95 13308 The engine cradle frame is cracked on the right by the engine mount. Crack welded/repaired. 2.0 2.0
04-19-95 13838 Cracks located in the upper right rear engine compartment, two cracks by the right verticle engine cradle support, one crack at the longitudinal engine cradle support, and the left and right lateral supports. All cracks welded/repaired. 1.5 1.5
04-21-95 14035 Both the left and right rear, engine cradle vertical supports are cracked. Cracks welded/repaired. 0.5 0.5
04-26-95 14245 Both the left and right rear, engine cradle vertical suports are cracked on three sides. Supports plated, welded/repaired. 2.5 2.5
05-03-95 15000 The upper engine cradle support is cracked at the right side. Crack welded/repaired. 5.0 5.0
05-06-94 94 The right front air bag is leaking air. Right front air bag replaced. 0.5 0.5
06-23-94 289 The bus will not recover from the kneeling position. The ruptured left front air bag was replaced. 5.0 1.0
06-27-94 387 The right front leveling valve linkage has come apart. Manufacturer rep. reconnected the linkage. 0.5 0.5
06-28-94 387 The right front air bag is leaking. Replaced the right front air bag. 4.0 1.0
06-29-94 482 Right rear upper radius rod mount has three broken bolts. Bus towed to the maintenance shop. Rear suspension removed for inspection. Futher inspection found the left rear forward upper shock mount was broken and the left rear transmission mount was broken. Both the shock mount and transmssion mount were welded/repaired. Rear suspension installed. 316.0 11.0
07-19-94 583 Left front air bag ruptured. Left front air bag replaced and the air bag pedestal flange was ground down to reduce chaffing of the air bag. 3.0 3.0
07-28-94 917 Left rear, forward upper shock mount is broken. Shock mount welded/repaired. 160.0 4.0
07-28-94 917 The right front air bag is chaffing on the air bag pedestal flange. Air bag removed, flange ground off, and new air bag installed. 1.5 1.5
07-29-94 1063 The left front air bag ruptured. Left front air bag replaced. 4.0 2.0
08-01-94 1217 The left front air bag ruptured. Leveling valve linkage is bent. Left front air bag replace, air bag pedestal repositioned, and the leveling valve linkage straightened. 6.5 2.5
08-02-94 1421 The left rear forward shock is leaking oil. Left rear forward shock replaced. 1.0 1.0
08-11-94 1816 Air line to the rear suspension has worn through due to contact with the drive line. Air line repaired. 1.5 1.5
08-11-94 1865 The left rear forward upper shock mount is broken. Left rear forward upper shock mount welded/repaired. 48.0 2.0
10-04-94 3691 Front lateral bar frame mount is cracked. Front lateral bar frame mount welded/repaired. 1.5 1.5
10-19-94 4943 Left front lateral bar mounting bracket is cracked. Cracks welded, area plated. Replaced bolts in lateral bar and radius beam. 6.0 6.0
11-22-94 5102 Right front torque arm is broken. Parts ordered. Bus towed to repair shop. New torque arm arrived and installed. 552.0 2.0
12-08-94 5907 Front ride height will not maintain proper height. Left front air bag has a small hole. Air bag replaced. 2.0 2.0
01-10-95 6937 The left rear, forward upper, shock mount is broken. Shock mount welded/repaired. 5.0 5.0
01-17-95 7620 The left front air bag ruptured. Left front air bag replaced. 2.0 2.0
02-07-95 8453 The right rear foward and left rear forward shocks are leaking oil. Alll six shocks replaced at rep's request. 3.0 3.0
02-07-95 8453 Front lateral bar mount, frame side; the bolts pulled through the box beam. Bolt hole area plated, new bolt holes drilled out, and lateral bar reinstalled. 120.0 8.0
02-08-95 8453 The right front air bag is chaffing on the inside of the frame. Rep. requests air bag be replaced. Air bag replaced. 1.0 1.0
02-08-95 8453 The front leveling valve linkage is cracking. Front leveling valve linkage replaced. 0.75 0.75
02-08-95 8453 The left front air bag is leaking at the fitting and at the upper inteface with the mounting plate. Air bag and fitting replaced. 0.75 0.75
03-03-95 11014 The right rear lower air bag mount is cracked. Crack welded/repaired. 1.0 1.0
03-02-95 11014 The lateral support by both rear, forward shocks are cracked. Gussets added to both sides, cracks welded/repaired. 2.0 2.0
03-06-95 11148 The left front air bag is leaking air. Replaced the left front air bag. 1.0 1.0
03-07-95 11372 Left front radius beam; the pivot bushing is worn and the pivot pin is broken. Part not available from manufacturer. New pin fabricated and installed with a new bushing. 408.0 5.0
04-05-95 12469 The right rear, rear shock is leaking oil. Replaced the right rear, rear shocks. 0.5 0.5
04-11-95 12987 The left front air bag pedestal mounting bolts are loose. Bolts retorqued. 1.0 1.0
04-21-95 14035 The left front air bag is leaking due to chaffing against the inner fender well. Left front air baf replaced. 1.0 1.0
04-26-95 14245 The left rear, rear shock is leaking oil. Replaced the left rear, rear shock. 0.5 0.5
05-05-95 15000 The rear upper radius rod bushings are worn. Replaced rear upper radius rod. 0.5 0.5
05-05-95 15000 Right rear, rear shock is leaking oil. Replaced right rear, rear shock. 0.5 0.5
05-16-95 15000 The left rear, forward shock is broken. Both left rear shocks replaced. 1.5 1.5