CONTENDER TB-2242

CHAMPION MOTOR COACH, INC. Pdf Download PDF Report

Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
04-10-96 1322 Various front axle hold down bolts are loose. All front axle hold down bolts retorqued. 0.5 0.5
04-17-96 2079 The left rear axle u-bolts are shifting. U-bolts replaced and torqued. 1.0 1.0
04-17-96 2079 Front axle bolt torques checked. Front axle bolts retorqued. 0.5 0.5
04-22-96 2562 The left outside u-bolt on the rear axle is shifting. U-bolt positioned and torqued. 0.25 0.25
05-02-96 3014 The rear axle u-bolts are shifting. Retorqued rear axle u-bolts. 0.5 0.5
05-17-96 3763 The rear axle saddles are cracked, both rear spring hangers are worn, and manufacturer requests a new design rear upper shock brackets be installed. Rear axle saddles installed with added 3" x 3" x 1/8" shims. Both rear spring beam hangers replaced, and new design rear upper shock brackets installed. 5.5 5.5
06-14-96 4961 Front axle; the left rear axle-to-spring beam mounting bolt is broken. Bolt replaced. 0.5 0.5
03-06-96 205 The destination sign is loose. Sign removed to avoid damage. 1.0 1.0
03-06-96 205 The overhead panel above the front door is missing numerous fasteners. Fasteners replaced. 0.5 0.5
04-10-96 1322 Three body hold down clamps are loose. Body hold down clamps retorqued. 0.5 0.5
04-16-96 1892 The second interior light, right side, fell down. Light reinstalled and fasteners replaced. 0.5 0.5
05-06-96 3065 The rear modesty panel is loose. Fastener hole stripped out, panel removed. 0.25 0.025
05-06-96 3065 Forward most frame liners; the left front bolt is missing. Bolt replaced and remaining bolts, left and right, retorqued. 0.5 0.5
06-12-96 4895 The forward section of the rear door will not close completely. Lower pivot raised approximately 3/4" (door not fully seated in the upper pivot). Repaired damaged ground wire to air switch. 4.0 4.0
06-12-96 4895 Left rear spring beam hanger bolts are loose. All left rear spring beam hanger bolts torqued. 0.5 0.5
06-12-96 4895 Numerous rivets are missing from around the outside compartments and the rear stepwell. Replaced missing rivets around the outside compartments and rear stepwell. 1.0 1.0
06-12-96 4895 Numerous broken and missing fasteners around overhead panels above both doors and courtesy panels. Replaced missing and broken fasteners around overhead and courtesty panels. 1.0 1.0
06-13-96 4895 Three mounting bolts are missing from the upper frame bracket in the front door. New bolts installed. 2.0 2.0
06-17-96 5067 Front door; the lower pivot point of the forward section is broken. New lower pivot point fabricated and installed. 2.0 2.0
06-21-96 5956 Both engine compartment diagonal supports are broken. Threaded rod supports installed. 0.5 0.5
07-03-96 6544 The right rear compartment panel is missing three rivets. Rivets replaced. 0.25 0.25
07-03-96 6544 The right rear body support near the battery box is broken. Support welded/repaired. 0.5 0.5
07-12-96 6941 Battery box is loose, the support channel outside upper left corner is broken. New piece of channel welded in place. 1.5 1.5
07-12-96 6941 Right front air bag; the left rear axle-to-air bag pedestal bolt is broken. Bolt replaced. 0.5 0.5
07-16-96 7332 The forward section of the front door has fallen off, lower pivot has failed. New forward door section installed. 1.0 1.0
07-19-96 8035 Battery box is loose. 1/4" bolt installed in the slide track to secure box. 0.25 0.25
07-19-96 8035 Numerous body hold down bolts are loose. Hold down bolts retorqued. 0.5 0.5
07-24-96 8612 The rear half of the rear door fell off. Lower pivot adjusted and door installed. 1.0 1.0
07-25-96 8717 The forward section of the rear door is out of adjustment. Door repositioned and adjusted. 1.0 1.0
08-07-96 9152 The bottom outer framework of the rear door is broken. Door frame welded/repaired. 2.5 2.5
08-07-96 9152 Two seats on the left and two seats on the right, above the wheel wells have broken brackets. Brackets welded/repaired. 1.5 1.5
08-07-96 9152 Weld broken in the overhead compartment above the rear door. Weld repaired. 0.5 0.5
08-07-96 9152 The crossmember located between the front axle and the fuel tank is broken at the lower left corner. Broken crossmember replaced. (Note: fuel tank must be removed for replacement of the crossmember). 5.0 5.0
08-15-96 9624 Rear door; the lower pivot point is broken on the forward section. Lower pivot point repaired and installed. 0.5 0.5
09-10-96 9880 Front crossmember; lower left bolt is broken. Replaced bolt. 1.0 1.0
09-16-96 10234 The rear trim work of the rear door is misisng five fasteners. Replaced five fasteners. 0.5 0.5
09-16-96 10234 The bottom corner of the rear window is missing two fasteners. Replaced two fasteners. 0.5 0.5
09-16-96 10234 The right windshield wiper is missing the attachment nut. Nut replaced. 0.25 0.25
09-16-96 10234 Two screws missing from the top of the rear window. Replaced missing screws 0.75 0.75
09-16-96 10234 Four rivets missing from the windshield washer reservoir bracket. Replaced rivets. 1.0 1.0
08-02-96 8984 Shim in the right rear brake retainer is broken. Replaced shim in the right rear brake retainer. 1.0 1.0
09-23-96 10567 Right rear brake; the slack adjuster has fallen off at the s-cam shaft. Reinstalled spacer, slack adjuster, washer and installed new snap-ring 1.5 1.5
09-25-96 10835 The right rear brake will not adjust. Found the spring retainers for the rollers bent. Installed new retainers. 1.0 1.0
04-17-96 2079 The 30 amp driver's heater blower fuse has blown and motor failed. Fuse and motor replaced. 1.0 1.0
05-10-96 3414 Engine will not crank, no electrical accessories functioning. Trouble shooting found numerous battery terminals loose. Terminals tightened. 1.0 1.0
06-12-96 4895 Batteries are loose in the battery tray. Batteries repositioned and tightened down. 0.5 0.5
06-24-96 6037 Brakes will not release, found rear door switch not engaging. Replaced broken rivets in switch bracket, replaced 15 amp fuse and repaired chaffed wire. 3.0 3.0
06-28-96 6292 The A/C condenser fan motor ground wire is broken. Ground wire repaired. 0.25 0.25
07-22-96 8124 Test bus is disabled on the durability track, engine will not crank. Trouble shooting found a short in the ignition circuit, short repaired. 1.0 1.0
08-07-96 9152 Speedometer failed. Replaced speedometer. 1.0 1.0
08-16-96 9880 Front heater blower motor failed. Replaced heater blower motor. 1.0 1.0
09-16-96 10234 15 amp fuse blown to the front heater blower motor. Trouble shooting found no cause. 15 amp fuse replaced. 0.25 0.25
09-18-96 10352 Speedometer is not functioning properly. Trouble shooting found moisture in the connector plug. Water flushed and dried. Test drive, speedometer functioning properly. 2.0 2.0
09-23-96 10567 Speedometer intermittently does not function properly. Trouble shooting; trouble shoot electrical, test drove test bus under various conditions (i.e. on durability track, smooth road, lights on, lights off) no problem found. Speed switch replaced. 2.0 2.0
09-25-96 10627 15 amp fuse blown to the front heater blower motor. Trouble shooting found no cause. 15 amp fuse replaced. 0.25 0.25
09-25-96 10627 Speedometer not functioning properly. Speedometer needle will drop to zero while odometer continues accurate opertation. Speedometer replaced with like speedometer from manufacturers other on sight test vehicle. Installation performed with manufacturers permission. 2.0 2.0
06-12-96 4895 Coolant reservoir brackets are broken. Brackets repaired/welded. 0.5 0.5
03-06-96 205 The fuel tank filler neck is leaking fuel. Filler neck removed, teflon tape applied to threads and reinstalled. 1.0 1.0
03-25-96 822 The radiator is leaking coolant Failed radiator removed and replacement radiator ordered. 2.0 2.0
03-28-96 822 Radiator ordered 3/25/96 arrived. Brackets, framework and radiator installed. 72.0 4.0
04-10-96 1322 The spot weld at the bottom of the coolant surge tank mount is broken. Welded/repaired. 0.25 0.25
06-12-96 4895 The right front and both rear fuel tank brackets are broken. Fuel tank drained and removed, new brackets fabricated and installed. 3.0 3.0
06-12-96 4895 The radiator shroud is loose. New fasteners installed. 0.5 0.5
09-25-96 10627 The cooling system surge tank is leaking at the solder joint on the elbow. Manufacturer requests that like surge tank from another test bus the manufacturer has on sight be installed as replacement. Surge tank from other test vehicle installed. 2.5 2.5
09-26-96 10835 The elbow has pulled out of the coolant system surge tank. Replaced surge tank with used repaired tank. 1.0 1.0
04-17-96 2079 The pin in the handicap device guide arm fell out. Pin replaced. 0.25 0.25
04-17-98 2079 The alignment block, front side track of the handicap device fell out. Alignment block replaced. 0.25 0.25
05-06-96 3065 Handicap device is out of the stow postition. The left upper pivot is out of position and the right lower pivot bushing is out of position. Both repositioned. 1.0 1.0
05-30-96 4122 Handicap device control solenoid failed. Solenoid replaced. 0.5 0.5
06-03-96 4122 Handicap device will deploy but will not raise or stow. Lift control box replaced and roll stop micro switch adjusted. 3.0 3.0
06-12-96 4895 The handicap device control panel (at the right rear engine compartment) is loose. Mounting bolts and nuts replaced. 0.5 0.5
06-13-96 4895 The handicap device is inoperative. The control box mounting brackets are broken, all four relays have fallen out of their sockets, the barrier up switch out of adjustment and the pump solenoid is shorted. Manufacturer informed. (Trouble shooting). 2.0 2.0
07-03-96 6544 The hinge is broken on the manual handicap device lift control. Hinge repaired. 0.25 0.25
07-12-96 6941 The handicap device lift control box bracket is broken. Bracket welded/repaired. 0.5 0.5
03-06-96 205 The right side rear spring bolt is missing. Installed new bolt, nut, flat and lock washers. 2.0 2.0
03-08-96 460 The right front shock is broken. Right front shock replaced. 0.5 0.5
03-12-96 466 Replacement shocks ordered 3/8/96 arrived. Both front shocks replaced. 96.0 1.0
03-08-96 460 The spacers are missing from both rear spring beam eye bolts. Bolts removed and 3/4" flat washers installed. 2.5 2.5
03-08-96 466 Both front shocks are broken. Replacement shocks ordered. 0.0 0.0
03-18-96 518 Redesign, as per manufactuer, to correct broken front shock situation. Installed left and right frame liners for upper shock mount. Drilled four 1/2" and one 3/4" holes through the frame for each liner. Installed new lower shock mount brackets and shocks. Ride height adjusted to: front - 6 1/2" and rear -10 1/2". 6.0 6.0
03-22-96 750 Both front lower shock mount studs are broken. Both studs replaced. 1.0 1.0
04-01-96 856 The left front upper shock mount stud is broken. Replaced the left front upper shock mount stud. 2.0 2.0
04-01-96 856 The left front leveling valve was damaged due to broken left front stock mount stud. Leveling valve mounting bracket repaired and leveling valve replaced. 4.0 4.0
04-02-96 902 The left front upper shock mount stud is broken. Replaced the left front upper shock mount stud. 1.0 1.0
04-09-96 1088 The left rear spring beam is broken. Replaced left rear spring beam and u-bolts. 2.5 2.5
04-09-96 1107 The left fron upper shock mount stud is broken. Replaced the left front upper shock mount stud. 1.0 1.0
04-10-96 1272 The right front upper shock mount stud is broken. Replaced the right front upper shock mount stud. 1.0 1.0
04-10-96 1322 The four bolts in the left rear upper spring hanger are loose and worn. Bolts replaced and torqued. 1.0 1.0
04-10-96 1322 The four bolts in the right rear upper spring hanger are loose. Bolts retorqued. 0.25 0.25
04-10-96 1322 The weld is cracked at the bottom of the inside left rear spring hanger. Welded/repaired. 0.5 0.5
04-10-96 1322 Both front spring beam hanger bolts are loose. Retorqued all front spring beam hanger bolts. 0.5 0.5
04-11-96 1426 The right front upper shock mount stud is broken. Replaced the right front upper shock mount stud. 0.5 0.5
04-12-96 1564 Right front spring beam to axle hold down; the left rear bolt is broken. Bolt replaced. 0.5 0.5
04-12-96 1564 The left rear spring beam hanger mounting bolts are loose. Three nuts and bolts replaced and torqued. 0.5 0.5
04-12-96 1564 The rear axle lateral bar is loose at the axle housing. Nut retorqued. 1.0 1.0
04-12-96 1621 The right front lower shock mount stud is broken. Replaced the right front lower shock mount stud. 1.0 1.0
04-15-96 1674 Both rear leveling valve arms are worn. Replaced both rear leveling valve arms. 1.0 1.0
04-16-96 1753 The right front upper shock mount stud is broken. Replaced the right front upper shock mount stud. 1.0 1.0
04-16-96 1892 The right front lower shock mount stud is broken. Replaced the right front lower shock mount stud. 1.0 1.0
04-16-96 1906 The left front upper shock mount stud is broken. Replaced the left front upper shock mount stud. 1.0 1.0
04-17-96 2263 The left front upper shock mount stud is broken. Replaced the left front upper shock mount stud. 1.0 1.0
04-19-96 2407 The right front upper shock mount stud is broken. Replaced the right front upper shock mount stud. 1.0 1.0
04-22-96 2562 The right lower bolt is broken on the left rear spring hanger. All left rear spring hanger bolts replaced. 1.25 1.25
04-22-96 2562 The rear lateral bar mounting bolt (axle side) is loose. Retorqued the lateral bar mounting bolts. 0.25 0.25
04-29-96 2829 The right rear spring beam is broken 20" front the pivot end. Replaced the right rear spring beam. 2.0 2.0
05-01-96 2966 The right front upper shock mount stud is broken. Replaced the right front upper shock mount stud. 1.0 1.0
05-02-96 3014 Both left front shock mount studs are broken. Both left front shock mount studs replaced. 1.5 1.5
05-06-96 3065 Right front spring beam; the left front beam-to-axle mounting bolt is broken. All mounting bolts replaced. 0.5 0.5
05-06-96 3065 The right front spring beam bushings are worn. Replaced the right front spring beam bushing and spring beam. 1.5 1.5
05-06-96 3065 Bolt missing from the lateral bar mounting bracket Bolt replaced. 0.25 0.25
05-06-98 3065 Four body-to-frame hold down brackets are loose. Hold down brackets retorqued. 0.5 0.5
05-06-96 3065 Rear lateral bar; the axle side mounting bolt is loose. Bolt retorqued. 0.5 0.5
05-07-96 3228 The right front upper shock mount stud is broken. Replaced the right front upper shock mount stud. 1.0 1.0
05-08-96 3331 The rear track bar mounting bolt (axle side) broke allowing the rear axle to shift causing the left rear air bag to rupture. Repositioned rear axle, replaced broken track bar bolt and replaced left rear air bag. 2.0 2.0
05-09-96 3356 The right front upper shock mount stud is broken. Replaced the right front upper shock mount stud. 1.0 1.0
05-10-96 3420 The right front upper shock mount stud is broken. Replaced the right front upper shock mount stud. 1.0 1.0
05-10-96 3451 The right front upper shock mount stud is broken. Replaced the right front upper shock mount stud. 1.0 1.0
05-13-96 3630 The right front upper shock mount stud is broken. Replaced the right front upper shock mount stud. 1.0 1.0
05-17-96 3763 Both rear spring beams; all bushings are worn. Replaced all rear spring beam bushings, both sides. 3.0 3.0
05-17-96 3763 As per manufacturers request; new design front shock mount brackets installed. Front shock mount brackets (upper and lower) removed, existing mounting hole (upper) plug welded as needed, new design brackets installed. 4.5 4.5
05-30-96 4122 Front lateral bar; right side mounting bolt is broken. Bolt repalced. 2.0 2.0
06-06-96 4497 The left side mounting bolt in the front sway bar is broken. Bolt replaced. 1.0 1.0
06-06-96 4523 The right side mounting bolt on the rear lateral bar is broken. Bolt replaced. 1.5 1.5
06-12-96 4895 The shock bushings are worn on the left front and both rear shocks. Bushings replaced. 2.0 2.0
06-13-96 4959 Frame rail bolt missing from the left side near the fuel tank. Bolt replaced. 0.5 0.5
06-21-96 5956 Rear suspension u-bolts and hanger bolts are loose. U-bolts and hanger bolts retorqued. 0.5 0.5
06-28-96 6292 The right rear spring beam has a 1 3/4" crack approximately 8 inches from the eye. Right rear spring beam and u-bolts replaced. 1.5 1.5
06-28-96 6292 Manufacturer requests rear Koni shocks be replaced with Gabriel shocks. Rear shock replaced. (Koni to Gabriel) 1.0 1.0
06-28-96 6292 The crossmember located between the front axle and the fuel tank is broken at the lower left corner. Broken crossmember replaced. (Note: fuel tank must be removed for replacement of the crossmember). 8.0 8.0
07-11-96 6800 The lower left mounting bolt on the left rear spring beam hanger is broken. Broken bolt replaced. Torque verified on all other hanger bolts. 0.5 0.5
07-12-96 6941 Bolt broken in the frame-to-body mount, right side, forward of the fuel tank. Also, frame-to-body mount left side, behind the rear axle is loose. Broken bolt replaced and loose bolt retorqued. 0.5 0.5
07-17-96 7564 The rear suspension bolts are loose. The rear suspension bolts retorqued. 0.5 0.5
07-24-96 8633 The right front shock is leaking oil. Right front shock replaced. 0.5 0.5
07-25-96 8717 Rear spring beam hangers, bolts are loose on both sides. Retorqued all bolts on both rear spring beam hangers 1.0 1.0
08-01-96 8803 The right rear spring beam is broken approximately 16" from the eye. Right rear spring beam replaced. 2.0 2.0
08-01-96 8803 Both left and right rear spring beam hanger bolts are loose. Bolts retorqued. 0.5 0.5
08-02-96 8984 The right rear spring beam u-bolts are loose. U-bolts retorqued. 0.5 0.5
08-02-96 8984 Bolt broken in the right rear speing hanger. Bolt replaced. 1.5 1.5
08-13-96 9152 The right front spring beam is cracked approximately 10" from the eye. Replaced right front spring beam and u-bolts. 120.0 2.0
08-15-96 9624 Left rear spring hanger; lower left bolt is broken. Bolt replaced. 0.5 0.5
09-10-96 9880 Right rear spring hanger bolts are loose and the front left bolts are loose. Verify and torque all suspension bolts. 2.5 2.5
09-12-96 10004 The right rear spring beam is broken. Replaced the right rear spring beam and u-bolts. 3.0 3.0
09-16-96 10234 Bushing sleeves in both front shocks are broken. Replaced both front shocks. 1.5 1.5
09-25-96 10657 The left rear spring beam hanger has one loose and one broken bolt. Replaced broken bolt and retorqued all rear spring beam hanger bolts, both sides. 1.0 1.0
09-16-96 10234 Miter box on the steering assembly is failing (grinding). Replaced miter box in the steering assembly. 1.5 1.5