6.501

ORION BUS INDUSTRIES Pdf Download PDF Report

Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
07-16-96 0 Numerous panels for the test bus arrived. Replaced overhead panels, side trim molding, weather strip, and overhead light at front, center and rear. 6.0 6.0
08-07-96 1033 Front door (rear panel): the bottom pivot is broken. Fabricate new pivot and installed. 2.0 2.0
08-07-96 1033 Front doors are out of adjustment. Kneeling system will not function. Door linkage in overhead panel adjusted, lower linkage adjusted. 2.0 2.0
08-15-96 1466 Front door, forward panel; bottom pivot is broken. Bottom pivot replaced. 0.5 0.5
12-10-96 7290 No power to the front center and rear access doors. Replaced wire off the interlock override switch and adjusted handicap micro switch. 1.5 1.5
02-28-97 13110 Batteries will not maintain charge. Batteries replaced. 0.5 0.5
08-13-96 1203 The front and rear brackets are broken on the left side of the hydraulic fluid reservoir. Fluid drained, cut off left engine compartment door stop, removed hydralic reservoir. All four reservoir brackets reinforced by welding 3/16" steel to existing brackets. Reinstalled reservoir and door stop. 3.5 3.5
08-15-96 1466 Engine cranks but will not start. Trouble shooting found no fuel system pressure due to failed fuel valve relay. Fuel valve relay ordered. 2.0 2.0
08-15-96 1466 Engine cranks but will not start. Trouble shooting found no fuel system pressure due to failed fuel valve relay. Fuel valve relay ordered. 2.0 2.0
08-19-96 1466 Relay ordered on 8/15/96 arrived. Installed fuel valve relay. 96.0 0.5
08-20-96 1475 Engine cranks but will not start. Trouble shooting found no fuel system pressure due to failed fuel valve relay. Fuel valve relay replaced. 1.0 1.0
08-26-96 1953 The fuel valve relay has failed. Replaced fuel valve relay. 0.25 0.25
08-27-96 2219 The right rear motor mount is loose. Retorqued right rear motor mount. 0.5 0.5
09-17-96 2544 Engine cranks but will not start. Replaced fuel valve relay. 1.0 1.0
09-19-96 2729 The upper radiator mount is broken. Mount welded/repaired, 6"X3"X3/16" plate added. 2.0 2.0
09-19-96 2729 Problem with fuel valve relays. Manufacturer rep. changed I.O. control as correction for relay failures. 1.0 1.0
09-23-96 3172 Engine problems; low power, runs rough, backfires and shuts off. Cummins Rep. comments and work; checked for oil in system - O.K., performed stall test to duplicate problem, engine misses and breaks up. Checked fuel P.S.I. found all readings in spec. Hooked up reader, critical faults found. Consulted with factory and found the engine needs numerous updates, i.e., factory update sent included the following, Engine Control Module (ECM), Governor Control Module (GCM), Throttle Actuator, Gas Flow Sensor, Oxygen Sensor and turbo exhaust clamp. Replaced all above parts, this prompted a GCM fault. Found cause of fault to be incorrect wiring to the new GCM. Wiring traced and corrected. (GCM J2 connector pins #13 & #15). This made fault inactive. Road test found all readings in spec. 72.0 24.0
11-05-96 5366 The upper radiator mount is broken. Welded/repaired. 2.0 2.0
11-13-96 5366 The lower bolt is missing from the left rear, rear air bag. Reposition air bag and install new bolt. 0.5 0.5
11-15-96 5448 The elbow at the hydraulic reservoir filter is cracked and leaking. Elbow replaced. 3.0 3.0
12-02-96 6699 Trouble shooting in engine compartment found failed bearing on the compressor side of the compressor drive shaft. Drive shaft removed for future repair, parts ordered. 1.0 1.0
12-17-96 8151 Road call: engine shut down, cranks but will not start. Trouble shooting found gasket blown on fuel filter. Fuel filter replaced. High pressure fuel regulator failed. New regulator ordered. 24.0 3.0
12-18-96 8173 High pressure fuel regulator ordered on 12/17/96 arrived. Installed new high pressure fuel regulator. 24.0 3.5
01-03-97 8383 The upper radiator mounting bracket is broken. Cut off broken radiator bracket and welded new bracket in place. 4.0 4.0
01-03-97 8383 Hydraulic fluid reservoir is cracked in the weld on the right bottom. Installed new reservoir, fittings and rubber bushings. 8.0 8.0
03-03-97 13110 Oil dipstick is broken. New dipstick was to long, cut new stick to proper length, marked appropriately and installed. 0.5 0.5
03-13-97 13110 Engine losing power. Cummins Rep. comments and work; hooked up computer, faults were as follows; codes 751IA, 545IA, 234IA, 466IA, & 752IA. Fault code 752 went active while running. Replaced O2 sensor. Found Wastegate Control Valve shorted to ground. New Wastegate Control installed. 120.0 16.0
03-20-97 13971 Engine shut down. Engine cranks but will not start. Manufacturer requests fuel filter be checked for oil. No oil found. Check Gas Mass Sensor for oil. No oil found. Spark plugs changed. 8.0 2.0
03-27-97 15000 The left motor mount is broken and one mounting bolt is broken. Replaced broken motor mount and broken bolt. 1.0 1.0
03-27-97 15000 The charge air cooler pipe (from the air cooler to the intake) is broken at the center support. Pipe welded/repaired. 1.5 1.5
11-13-96 5366 CNG fuel tank; back row, second tank from the right is leaking at a crack in the threads on the vent side. CNG fuel tank replaced. 144.0 0.5
08-13-96 1203 The left rear upper radius rod and the mounting plate at the left rear suspension beam are broken. Both left and right rear shocks damaged by broken radius rod. Bus prepared and towed to repair shop. Replaced left rear upper radius rod and the mounting plate at the left rear suspension beam. Replaced both left and right rear shocks. 120.0 7.0
08-20-96 1475 The left rear radius rod is disengaged at the cap bolt. Repositioned the rear suspension, reinstalled radius rod and cap bolt. (Note: limited access does not allow room for a torque wrench). 4.0 3.0
08-21-96 1687 The mounting plate, pivot point, for the right rear upper radius rod (on the suspension beam) is cracked at the base of the machined area. Mounting plate replaced. 3.0 3.0
08-28-96 2318 The left rear upper radius rod mounting plate is broken and the bus cranks but will not start. Fuel valve relay replaced and new design radius rod mounting plate installed. 29.5 5.5
09-05-96 2398 The left rear upper radius rod mounting plate is broken. Replaced left rear upper radius rod mounting plate. 10.0 4.0
09-06-96 2470 The right rear upper radius rod mounting plate is broken. Replaced right rear upper radius rod mounting plate. 13.5 3.5
09-16-96 2544 The left rear upper radius rod mounting plate is broken. Replaced left rear upper radius rod mounting plate with new design, (2nd design). 22.0 4.0
09-17-96 2544 Changed right rear upper radius rod and both rear lower radius rod for strain gauge testing. Replaced radius rod after testing and installed new design mounting plates, (3rd design). 4.0 4.0
10-29-96 3943 The right rear, rear air bag is leaking air. The left rear mud flap bracket broken and rubbed air bag. Air bag replaced and mud flap bracket repaired. 3.5 1.5
11-13-96 5366 Both rear, rear shocks are leaking oil. Replaced both rear, rear shocks. 1.0 1.0
11-27-96 6430 The front suspension lost air supply. Trouble shooting found relay R-14 failed. Relay R-14 replaced. 1.0 1.0
12-06-96 7118 The front ride height is too high. Leveling valve will not exhaust. Replaced leveling valve. 1.5 1.5
12-09-96 7282 The front ride height is too high. Leveling valve will not exhaust. Exhaust port plugged with rubber particles. Replaced leveling valve. 1.5 1.5
12-10-96 7290 The front ride height is too high. Leveling valve will not exhaust. Exhaust port plugged with rubber particles. Further trouble shooting found the front air bag rubber stops were breaking up and contaminating the air system with rubber particles. All four front air bags replaced and air system cleaned out. 3.0 3.0
02-28-97 13110 The right rear, rear shock failed. Shock replaced. 0.5 0.5
02-28-97 13110 Left rear, rear air bag mount; the bottom bolt at the gantry assembly is broken. Broken bolt drilled out, assembly aligned and installed. (Note: rear wheels need removed for access). 2.5 2.5