TB-2242

CHAMPION MOTOR COACH, INC. Pdf Download PDF Report

Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
04-23-96 5613 A/C. inoperative. Trouble shooting found the left side A/C unit low pressure switch open, further trouble shooting found the condenser freon line broken. Manufacturer informed, no repair at this time. 0.5 0.5
04-19-96 5395 Driver's side folding seat is broken. Seat removed until repaired. 0.5 0.5
05-10-96 6986 The driver's seat will not maintain adjustment. Air leak repaired and mounting bolts tightened. 0.5 0.5
07-19-96 10416 The right windshield wiper arm is broken. Replaced the right windshield wiper. 0.5 0.5
07-19-96 10416 There are two cracks in the front left wheel well near the shock mount. Cracks welded/repaired. 1.0 1.0
03-11-96 1563 The right rear brake will not release. Trouble shooting found the maxi brake canister is not fully retracting when the brakes are released. Manufacturer notified. 2.0 2.0
03-28-96 3741 The right rear brake chamber air hose is worn. Air hose repalced. 1.5 1.5
07-10-96 9076 The right rear brake chamber housing is broken at the upper bolt mount area. Replaced the right rear brake chamber. 1.0 1.0
07-24-96 10918 Bus is disabled in route from the test track to the shop. The left rear brake will not release. Road call; replaced the left rear Maxi-brake. 2.5 2.5
02-13-96 271 Insufficient heat in the rear of the bus. Rear controls adjusted. 3.0 3.0
02-19-96 920 Wheelchair ramp, doors, and kneeling system will not function. Trouble shooting found a broken destination sign bracket; destination sign shifted causing wiring harness to chaff and short. Bracket and wires repaired. 8.0 8.0
02-19-96 920 Transmission reverse switch will not function. Reverse switch replaced. 0.5 0.5
02-19-96 920 Battery cable is chaffing on the bottom of the battery tray. Cable repaired and rerouted to prevent further damage. 1.0 1.0
02-19-96 920 The alternator to battery cable is resting on the exhaust pipe. Cable rerouted to prevent damage. 1.0 1.0
02-21-96 920 Speed switch has failed. Replaced speed switch 48.0 0.5
02-23-96 920 Front heater blower motor is not functioning. Switch and fuses replaced. Blower motor failed, blower motor replaced. 1.5 1.5
05-17-96 7032 The three speed heater switch has a broken terminal. Terminal soldered/repaired. New switch ordered. 1.0 1.0
05-17-96 7032 The Espar heater control pad is not functioning properly. Control pad disassembled and cleaned. 1.0 1.0
05-28-96 7852 Heater switch ordered on 5/17/96 arrived. Replaced heater switch. 0.25 0.25
06-13-96 8516 Handicap device stow switch has failed. Replaced stow switch. 0.5 0.5
06-25-96 8516 Both rear lower shock bushings are worn. Both rear lower shock bushings replaced. 0.5 0.5
06-25-96 8516 The front door switch will not function. Trouble shooting found the Dixon speed switch not providing power to the door circuit. New speed switch ordered. 2.0 2.0
07-08-96 8883 The back-up lights and warning alarm will not function. The connector at the switch is corroded and the terminals are breaking. Cleaned connector and repaired terminals. 0.5 0.5
07-08-96 8883 Engine shuts down when transmission is shifted to reverse. Neutral safety switch has failed. New switch ordered and switch temporarily by-passed. 0.5 0.5
07-08-96 8883 Dixon speed switch ordered on 6/25/96 arroved/ Installed Dixon speed switch. 0.5 0.5
07-11-96 9234 Engine shuts down when transmission is shifted to reverse. Note: the neutral safety switch is still by-passed. Trouble shooting found fuel solenoid is shutting off and electrical diagnoses found nothing. Currently the problem is intermittent and no cause found. 2.5 2.5
07-16-96 9732 Engine still shutting down when transmission is shifted to reverse. Note: the neutral safety switch is still by-passed. Trouble shooting found fuel solenoid is shutting off and electrical diagnoses found nothing. Note: wiring diagrams supplied by the manufacturer are not consistent with bus wiring. Problem is still intermittent and no cause found. 2.5 2.5
07-24-96 10949 Engine still shutting down when transmission is shifted to reverse. Trouble shooting found the master relay is defective, relay replaced. 1.5 1.5
07-30-96 1102 Numerous wires in the engine compartment have burned or melted. Found cause to be a shorted ground wire inside the rear electrical panel; shorted wire repaired also reaired damaged oil pressure gauge wire. Other wiring affected and repaired or replaced were the cable from the starter to relay, cable from relay to ground (near relay), cable from the starter to ground (left frame rail), and the cable from battery to ground (on starter bolt). Note: muffler removed to gain access to numerous wires. 10.0 10.0
07-30-96 11002 The front door will not operate. Repaired broken terminal on the Dixon speed switch. 0.5 0.5
05-10-96 6986 No heat in driver's or passenger's area. Reset the overheat switch. Note: timer control pad is not functioning properly. 0.5 0.5
02-19-96 920 Nut and bolt missing from the muffler clamp. Nut and bolt replaced. 0.25 0.25
02-28-96 1223 The exhaust pipe going into the muffler fell off. Pipe replaced. 1.0 1.0
04-04-96 4158 The air line from the air compressor to the air dryer is chaffing on the fuel filter bracket. Removed 4 1/2" of the air line, replaced fitting and rerouted air line. 4.0 4.0
04-09-96 4655 Coolant is dripping from the ceiling above the driver's area. Heating system surge tank is leaking at the pipe solder joint. Surge tank removed, leak repaired, tank reinstalled. Overheat switch reset. 3.0 3.0
04-23-96 5613 Fast idle is inoperative; fast idle cable fell out of its bracket. Fast idle cable reinstalled into bracket. 1.5 1.5
05-22-96 7546 Rubber fuel tank strap isolator has fallen out. Isolator replaced. 0.5 0.5
06-13-96 8516 The forward most fuel tank strap is broken. Welded/repaired fuel tank strap. 2.0 2.0
06-27-96 8666 The alternator mounting bolt is broken. Broken alternator mounting bolt replaced. 2.0 2.0
08-12-96 11283 The two bottom mounting brackets on the transmission cooler are broken. Welded/repaired broken brackets. 1.0 1.0
04-05-96 4308 Air line from air dryer to the junction was cut when Amerex tank bracket broke. Air line replaced and Amerex tank mounted under the rear seat bulkhead. 6.0 6.0
02-19-96 920 U-bolts and suspension mounting hardware on the rear axle are moving. U-bolts replaced and all fasteners torqued to 425 ft.lb. 1.0 1.0
02-21-96 920 The left rear shock is leaking oil. Left rear shock replaced. 2.0 2.0
02-27-96 1001 The right rear lower air bag pedestal is broken. Replaced the right rear air bag. 2.0 2.0
03-01-96 1422 The right rear spring beam is broken. Bus towed to the shop. Right rear spring beam replaced. 2.0 2.0
03-01-96 1422 As per the manufacturers request; the right rear upper clamp assembly and the right rear axle saddle was removed to inspect the axle housing for cracks. No cracks found. 1.0 1.0
03-01-96 1422 The right, rear axle locating pin is broken. Pin welded/repaired. 1.5 1.5
03-05-96 1422 The left front upper shock mounting stud has broken off. Stud welded/repaired and shock bushing replaced. 1.5 1.5
03-05-96 1422 The left rear air bag pedestal is cracked. Air bag pedestal replaced. 0.5 0.5
03-11-96 1563 The left front upper shock mounting stud is broken. Stud welded/repaired. 1.5 1.5
03-11-96 1563 The left front leveling valve was damaged from previous failure when the left front upper shock mounting stud broke. Leveling valve repalced. 1.0 1.0
03-26-96 3331 Left rear spring beam; the pivot bolt is broken and the bushing is worn. The spring beam has 1 1/2" crack located 10 1/2" from the eye of the beam. Left rear spring beam replaced. Note: the front beam mount is worn from the broken bolt. 3.0 3.0
03-28-96 3741 Both left and right rear spring beam bushings are worn. Dropped the rear suspension, replaced spring beam bushings. Replaced worn left side pivot bolt, nut and washer. 6.5 6.5
04-09-96 4655 Both left and right rear spring beam bushings are worn. Dropped the rear suspension, replaced spring beam bushings. Replaced worn left side pivot bolt, nut and washer. 6.0 6.0
04-15-96 4821 The rear nylon lateral bar guide is worn. Replaced rear nylon lateral bar guide. 1.0 1.0
04-23-96 5613 Both rear spring beam pivot bushings are worn. Replaced both rear spring beam pivot bushings. 4.0 4.0
04-25-96 5830 The left rear nylon lateral bar guide block and mounting bolts have broken. Replaced left rear nylon lateral bar guide and bolts. 0.75 0.75
04-26-96 6071 Both front shocks are worn. Replaced both front shocks. 1.0 1.0
05-07-96 6744 Both rear spring beam mounts are cracked, left mount cracked in three places, right mount cracked in one place. All four cracks welded/repaired. 1.5 1.5
05-07-96 6744 Both rear spring beam bushings are worn. Both rear spring bushings replaced. 5.0 5.0
05-10-96 6986 Trouble shoot for noise in the right front. Found the right front upper ball joint worn, parts ordered, bus sent to shop. Manufacturer informed and parts ordered. 168.0 0.5
05-17-96 7032 Right front upper ball joint parts ordered 5/10/96 arrived. Replaced the right front upper ball joint. 8.0 8.0
05-24-96 7802 The left rear spring beam eye bolt is broken. Replaced left rear spring beam eye bolt. 2.0 2.0
05-28-96 7852 Both left and right rear spring beam bushings are worn. Replaced both left and right rear spring beam bushings. 8.0 8.0
06-05-96 8031 The rear spring beam bolts are loose. Rear spring beam bolts retorqued. 0.5 0.5
06-13-96 8516 The positive terminals on both batteries are loose. Terminals will not retorque. Terminals replaced. 0.5 0.5
06-13-96 8516 The rear spring beam bushings are worn. Both lower axle saddles are cracked. Both rear spring beam pivot bushings are worn. Disassembled rear suspension, installed new spring beam bushings. Cut off both axle saddles and installed new. Replaced pivot bushings. 288.0 8.0
06-27-96 8666 The right front leveling valve is broken. Replaced the right front leveling valve. 2.0 2.0
07-03-96 8745 The right rear nylon lateral bar guide block is worn. Replaced the right rear nylon lateral bar guide. 2.0 2.0
07-09-96 9076 The right rear spring beam is broken, bus disabled on the test track. Rear axle secured and bus moved to shop. Upon removal of spring beam, the right rear axle near block was found to be broken and the mounting holes in the upper clamp are worn. Upper mounting holes welded shut and redrilled. New spring beam and u-bolts ordered. 3.0 3.0
07-10-96 9076 Received right rear spring beam and u-bolts. Installed new spring beam and u-bolts. 24.0 2.0
07-15-96 9574 No air in the rear air bags. The rear leveling valve arm has flipped 180 degrees. Adjust leveling valve and inspect air bags for damage. No damage found. 0.5 0.5
07-19-96 10416 Both front shocks are leaking oil. Both front shocks replaced. 2.0 2.0
07-23-96 10736 The left rear spring beam is broken. Replaced the left rear spring beam. 2.5 2.5
07-24-96 10949 The left rear, rear spring beam hanger is cracked at the outside weld. Crack welded/repaired. 1.0 1.0
04-25-96 5830 The left side steering arm is loose. Steering arm castle nut tightened. 0.25 0.25
05-07-96 6744 Both ends of the center steering link are loose. Nuts retorqued and new cotter pins installed. 0.5 0.5
07-19-96 10416 The front steering arm bolt is loose. Front steering arm bolt retorqued. 0.25 0.025
07-23-96 10735 The left rear inside tire is flat. Replaced the left rear inside tire. 0.5 0.5