TC40102N

NOVA BUS

Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
04-05-95 3838 The left engine compartment hinge mount is cracked. Hinge mount crack welded/repaired. 1.5 1.5
04-25-95 4918 Both engine compartment door hinge mounts are broken. Both mounts welded/repaired. 2.0 2.0
05-19-95 5567 Numerous panel screws are missing from the panel behind the rear seats. Screws replaced. 0.5 0.5
06-23-95 9089 Ten screws are missing from the engine compartment cover. Ten screws replaced. 0.25 0.25
06-23-95 9089 Seven screws are missing from the front entrance panels. Seven screws replaced. 0.25 0.25
06-23-95 9089 Front access door; the hinge bolts are broken on the right upper hinge. Bolts replaced. 1.0 1.0
07-06-95 9851 Three panel screws are missing from the front door. Screws replaced. 0.25 0.25
07-06-95 9851 The rear doors will not close properly. Readjusted rear doors. 0.5 0.5
07-06-95 9851 The right side destination sign is falling down. Sign removed to eliminate further damage. 0.5 0.5
07-15-95 11052 The rear interior panel is missing ten fasteners. Replaced ten fasteners. 0.5 0.5
07-15-95 11052 The right front windshield is shifting. Manufacturer instructions; instlaled metal bracket/clips. 1.0 1.0
09-06-95 13443 The bracket for the hydraulic filter is broken. Bracket welded/repaired. 1.0 1.0
09-07-95 13660 The bearing is missing from the upper pin on the right front passenger door. Four washers temporarily installed in place of the bearing. 0.5 0.5
09-11-95 13873 Speedometer light bulb is burned out. Replaced light bulb. 0.5 0.5
02-16-95 697 Odometer is inoperative. Speedometer unit replaced. 0.5 0.5
02-20-95 826 Inspect for coolant loss. Trouble shoot electrical and hydraulic systems; radiator fan inoperative. Problem not located, manufacturer contacted. 3.0 3.0
02-20-95 826 The radiator fan is inoperative. Nova reps. replaced three hydraulic pumps and three suction lines. 48.0 7.5
02-27-95 963 Bus is disabled on the test track. All flange bolts on the drive shaft/transmission have come out. Drive shaft removed, but towed to garage. Drive shaft reinstalled with new bolts. 15.5 3.5
03-01-95 1164 Both cooling fans (coolant and charge air) are inoperative. Signal is not being received by the relays to power up the fans. Manufacturer requests hard wire for constant running of the fans. 3.0 3.0
03-02-95 1179 Inspect for hydraulic leak. The pressure line on the center hydraulic pump has separated from the fitting. Fittings removed and insalled in new line, line installed. 1.0 1.0
03-03-95 1317 Inspect for hydraulic leak. Found oil leaking from the valve3 body mounted on top of the fan drive. Removed valve body and inspect. Found damaged o-rings and gasket. Parts ordered. 1.0 1.0
03-06-95 1317 Valve body parts ordered 3/3/95 received. O-rings and gasket installed in valve body. 47.0 0.5
03-09-95 1723 Inspect for hydraulic leak in the engine compartment. Lower hydraulic line to the charge air cooling fan is broken. Remove broken line and replace with new. 2.5 2.5
03-14-95 2288 Inspect for hydraulic leak. The pump to valve body pressure line is broken. Pressure line replaced. 1.0 1.0
03-21-95 3044 The transmission side of the drive shaft is extremely hot and smoking. Replaced drive shaft. 2.0 2.0
03-28-95 3279 Both cooling fans (coolant and charge air) are inoperative. Both fans hard wired to run constant. 0.5 0.5
03-31-95 3499 Inspect for hydraulic leak at the cooling fan valve body. Replaced three o-rings on three valve body fittings. 1.0 1.0
04-05-95 3734 Bus has lost coolant and shut down. Broken coolant hose clamp replaced and coolant level topped off. 1.0 1.0
04-06-95 4039 Hydraulic leak at the radiator fan drive motor. Drive motor valve body gasket and o-rings replaced. 1.0 1.0
04-13-95 4617 Manufacturer requests the drive shaft be replaced. Replaced drive shaft. 1.0 1.0
04-14-95 4617 Air charge cooler bushings; the inside and outside bushing and one stud is broken. Bushings and stud replaced. 2.0 2.0
04-25-95 4918 Inspect for hydraulic leak. The radiator fan drive motor is leaking at the valve body. Replaced valve body o-rings and gasket. Upon start up a second leak occurred at the coupling. Replaced teflon wahser in the coupling. 2.0 2.0
04-26-95 4936 The fan drive motor coupling is leaking hydraulic fluid. The teflon washer in the coupling was replaced three times. Each time the coupling leaked. Manufacturer informed. 5.0 5.0
04-27-95 4942 Manufacturer sent a newly designed teflon washer for the fan drive motor coupling. New design washer installed. 2.0 2.0
05-02-95 5250 The support bracket for the charge air cooler fan broke causing damage to the fan blades and the charge air cooler. Bypassed the fan and moved the bus to the garage. Removed the fan and charge air cooler. Ordered a new fan and sign glass for the hydraulic reservoir. Fabricated a new support bracket for the fan. Sent out the charge air cooler for repairs. 7.5 7.5
05-11-95 5250 Received parts ordered on 5/2/95. Installed repaired charge air cooler and new sight glass and fan. 216.0 4.5
05-12-95 5250 Manufacturer requests the hydraulic control valve body for the fans be replaced with a new design. Hydraulic control valve body replaced. (Note: six miles after installation, the fans would not longer function. Manufacturer informed.) 3.5 3.5
05-17-95 5263 Both the radiator and charge air cooler fans are inoperative. Troubleshoot electrical system, found no problems. Disassemble the hydraulic control valve body. Found valves stuck open due to aluminum shaving wedge in the valves. As per manufacturer's direction, the valves and valve body were cleaned and reinstalled in the open position and electrical wiring left disconnected for the fans to run constant. 120.0 1.5
05-19-95 5567 The battery hold down bolts are loose. Battery holddown bolts tightened. 0.25 0.25
05-22-95 5775 Continuous operating of cooling fans. Reconnected electrical wiring. Installed Pro-link and monitored. No problems found. Fans now operating properly. 1.0 1.0
05-23-95 6029 Both rear mounts for the air charge cooler are worn and the bolts are stripped. Replaced both rear mounts and bolts. 1.5 1.5
05-31-95 6731 Bus has an extreme loss of power. Turbo failed. Detroit Diesel rep. installed a new turbo. 144.0 8.0
06-01-95 6738 Hydraulic cooling fans are not functioning. Disassembled hydraulic valve body and found aluminum shavings throughout. Cleaned out all shavings, reassembled and reinstalled. 13.0 4.0
06-02-95 6797 Hydraulic cooling fans are not functioning. Disassembled hydraulic valve body and found aluminum shavings. Cleaned out all shavings, reassembled and reinstalled. 6.0 4.0
06-06-95 7114 Air charge cooler; the upper mounting bolt on the fan broke allowing the fan to drop causing contact with the air charge cooler. The fan and the air charge cooler are damaged. Ordered a new fan and sent air charge cooler out for repair. 14.0 4.0
06-07-95 7114 Received parts ordered on 6/6/95. Installed a new fan and repaired air charge cooler. 20.0 5.0
06-09-95 7481 The Wabasto heateris leaking coolant due to a crack in the tank. Tank bypassed with a 30" piece of heater hose. (no heat needed). 1.5 1.5
06-09-95 7481 Due to aluminum shavings found in the hydraulic system, the hydraulic fluid and filter was changed. Changed hydraulic filter and fluid. 1.0 1.0
06-14-95 8185 The air intake pipe bracket has a loose bolt. Belt guard removed to access bolt. Bolt tightened and guard replaced. 0.5 0.5
06-15-95 8236 The hydraulic line from the pump to the valve body has failed. Hydraulic line replaced. 12.0 3.0
06-15-95 8420 Water temperature is hight and coolant is pushing out of the radiator overflow. Cooling fan is not functioning. Troubleshooting found no problems. Wires disconnected in the J-box to allow fans to run continuously. 9.0 1.0
06-21-95 8652 The cooling fan drive motor is leaking hydraulic fluid. Replaced both the o-ring and gasket. 2.0 2.0
06-23-95 9089 The pipe clamp is broken on the charge air pipe. Clamp replaced. 1.0 1.0
06-23-95 9089 A bolt is broken on the charge air cooler fan support. Bolt replaced. 0.5 0.5
06-26-95 9296 Cooling fans are not functioning. Found air in the hydraulic line. Bleed air from hydraulic lines. 2.0 2.0
07-05-95 9764 Cooling fans are not functioning. Found air in the hydraulic line. Air bled from hydraulic lines. 1.0 1.0
07-06-95 9851 The upper bolt is broken on the charge air cooling fan motor support bracket. Bolt replaced. 0.25 0.25
07-06-95 9851 Coolant leak in the pipe fromthe circulating pump to the Webasto heater. Heater not needed. Shut off valves closed and heater disconnected. 1.0 1.0
07-13-95 10343 The upper bolt is broken on the charge air cooling fan motor bracket. New bolt installed. 1.0 1.0
07-14-95 10836 The radiator bushings are worn. Replaced radiator bushings. 6.5 1.5
07-14-95 10836 The radiator bracket is broken. Welded/repaired radiator bracket. 1.0 1.0
07-14-95 10836 The air charge cooler bracket is broken. Welded/repaired bracket. 0.5 0.5
07-19-95 11304 The left radiator bracket is broken. Bracket replaced. 2.0 2.0
07-20-95 11509 The upper mounting bolt is broken on the charge air cooling fan motor support. Upper mounting bolt replaced. 1.0 1.0
07-26-95 12014 The forward, left radiator mount is broken. Mount welded/repaired. 0.5 0.5
07-28-95 12420 Coolant leak. The hose is split on the front heater reutrn oline at the rear of the engine and a leak on the return line at the bulkhead. Leaking lines replaced. 72.0 4.5
08-01-95 12539 Inspect for a coolant leak. Leak located in the pipe from the circulating pump to the Wabasto heater. The pipe is chaffing against the bulkhead. Line temporarily closed off. 1.5 1.5
08-01-95 12539 The rear transmission support is broken. Transmission/engine removed and support repaired. Transmission/engine installed. 192.0 16.0
08-02-95 12539 The forward right radiator mount is cracked. Replaced mount and bushing. 0.5 0.5
08-09-95 12588 Bus down. Transmission will not function. Bus towed to garage. Rear transmission oil seal is leaking. Transmission removed and sent for warranty work. Warranty dealer found the P-3 planitary gear lock nut stripped off the shaft. Warranty dealer repaired threads, replaced lock nut, and replaced the rear seal. Dealer returned repaired transmission. Transmission installed in bus. 528.0 33.0
08-28-95 12653 The upper bolt is broken on the garage air cooler motor support bracket. Broken bolt drilled out, new bolt installed. 6.0 1.0
09-05-95 13376 Bus shut down, will crank but will not start. Trouble shooting with Pro-link found hard code, (cooling system low). Topper of cooling system. 1.0 1.0
09-07-95 13660 The fuel filter has a pin hole leak. Replaced fuel filter. 0.5 0.5
09-07-95 13660 The forward charge air cooler mount is broken. Mount welded/repaired. 1.0 1.0
09-11-95 13873 Engine overheated causing bus to shut down. Air bled from the hydraulic lines. 0.5 0.5
09-15-95 14540 Engine overheated causing bus to shut down. Air bled from the hydraulic lines. 1.5 1.5
05-22-95 5775 The front sway bar is broken. Front sway bar replaced. 1.0 1.0
05-23-95 6029 All shocks are worn. Replaced all shocks. 2.5 2.5
04-14-95 4617 The outlet pipe at the muffler is broken at the flange. Pipe welded/repaired. 1.5 1.5
06-21-95 8652 Two bolts on the bottom engine cradle cross member are sheared off. Replaced both bolts. 1.0 1.0
06-23-95 9089 Engine cradle; the lower rear support cross member is cracked on the right side. Welded/repaired. 1.5 1.5
07-14-95 10836 Engine cradle; the rear lower cross member isbroken. Welded/repaired cross member. 1.5 1.5
07-14-95 10836 Engine cradle; the rear lower cross member is broken. Welded/repaired cross member. 1.5 1.5
07-26-95 12014 Engine cradle; the rear lower cross member is broken. Welded/repaired cross member. 1.0 1.0
08-01-95 12539 While the transmission was removed during the previous failure, three cracks were found in the bulkhead. One 6" crack the transmission is located, one 8" crack on the left side of the bulkhead 34" above the cradle mount, and one 7" crack on the right side of the bulkhead 34" above the cradle mount. All cracks welded/repaired. 12.0 2.0
08-02-95 12539 Three bolts are loose on the left side of the engine cradle bulkhead above the transmission. New bolt, washers, and locknuts installed. 0.5 0.5
08-02-95 12539 Three bolts are loose on the left side of the engine cradle bulkhead above the transmission. New bolt, washers, and locknuts installed. 0.5 0.5
09-06-95 13443 All three left side tail lights are broken off. Mounts repaired, tail light reinstalled. 1.0 1.0
09-06-95 13443 The right side rear view mirror has two broken bolts. Bolts replaced. 1.0 1.0
09-14-95 14486 The skid plate on the wheelchair lift is hanging down. Numerous tabs are broken off. Skid plate removed due to close completion of tests. 0.5 5.0
02-15-95 428 The right front sway bar link is rubbing against the fuel tank. Installed a 6" piece of rubber hose around the l ink to reduce rubbing. 0.5 0.5
02-17-95 763 Front axle; the left side suspension support has two broken support studs. Removed broken studs and welded new 3/4" x 5" studs. 12.5 2.5
02-17-95 763 The right front sway bar link is rubbing against the fuel tank. Front sway bar repositioned and retorqued. 1.0 1.0
03-21-95 3044 Bushings are worn on both front lower radius rods. Bushings replaced. 1.5 1.5
03-21-95 3044 The rear sway bar is broken on the left side. Replaced the rear sway bar. 1.0 1.0
03-31-95 3499 Two mounting bolts are loose on the front axle radius rod/lateral rod mount. One lock nut replaced and all bolts retorqued. 0.5 0.5
04-05-95 3838 The front sway bar is broken on the left side. Front sway bar replaced. 1.5 1.5
04-13-95 4617 The left front axle beam mounting studs are broken. New mounting studs welded in place. 2.5 2.5
04-14-95 4617 The rear sway bar is broken on the left side and both sway bar links are worn. Sway bar and sway bar links replaced. 1.5 1.5
05-19-95 5567 The rear sway bar is broken on the left side. Rear sway bar replaced. 0.75 0.75
05-19-95 5567 Both front sway bar links are worn. Replaced both front sway bar links. 1.5 1.5
06-05-95 7011 The front upper radius rod has a broken mounting bracket bolt. Bolt replaced. 2.0 0.5
06-09-95 7481 The rear sway bar is cracked on the left side of the bend. Replaced the rear sway bar. 1.0 1.0
06-14-95 8185 The front lower radius rod bushings and the rear radius rod bushings are all worn. All four radius rods replaced. 4.0 4.0
06-14-95 8185 The left rear sway bar link and both front sway bar links are worn. Both front and both rear sway bar links replaced. 1.5 1.5
06-23-95 9089 The bolts on the right front radius rod tower-to-bulk are loose. Bolts replaced and torqued. 0.5 0.5
06-23-95 9089 The front lateral bar mounting bracket is cracked. Bracket welded/repairded. 1.0 1.0
07-05-95 9764 Front axle; the u-bolt is broken on the lateral bar to axle mount. U-bolt replaced. 0.5 0.5
07-06-05 9851 The rear sway bar is broken on the right side. Rear sway bar replaced. 1.0 1.0
07-06-95 9851 Both front shocks are leaking oil. Replaced both front shocks. 1.0 1.0
07-06-95 9851 Three bolts are loose on the upper left front support tower, forward of the front axle. Bolts torqued. 0.5 0.5
07-26-95 12014 Both rear sway bar links are worn. Both rear sway bar links replaced. 1.0 1.0
08-01-95 12539 The u-bolt on the front axle lateral bar is broken. U-bolt replaced. 0.5 0.5
09-07-95 13660 The lower left bolt is missing from the rear lower engine cradle cross member. Bolt replaced. 0.25 0.25
09-14-95 14501 The front lateral bar mount-tow-axle u-bolt is broken. U-bolt replaced. 0.5 0.5
03-21-95 3044 The right side steering box u-bolt is broken. Replaced broken u-bolt. 0.5 0.5
05-17-95 5275 Hydraulic leak and loss of power steering. Replaced blown power steering line. 2.0 2.0
05-19-95 5567 Steering box; the right side u-bolt is broken. U-bolt replaced. 0.5 0.5
06-08-95 7320 The left side steering box u-bolt is broken. Replaced both steering box u-bolts. 1.0 1.0
07-05-95 9764 The right side steering box u-bolt is cracked. U-bolt replaced. 0.5 0.5
07-10-95 10137 The control valve for the engine cooling fan is leaking oil. Replaced u-bolt. 0.5 0.5
07-11-95 10343 The left u-bolt on the steering box is broken. Replaced u-bolt. 0.5 0.5
07-18-95 11105 The right -bolt is broken on the steering box. U-bolt replaced. 0.5 0.5
09-07-95 13660 The right side steering box u-bolt is broken. Feed line is leaking fluid. U-bolt replaced. Feed line tightened. 0.5 0.5
09-14-95 14501 The left side steering box u-bolt is broken. U-bolt replaced. 0.5 0.5
09-07-95 13660 The left front tire is worn. Both front tires replaced. 0.5 0.5