LFS-TC4010 2N

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Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
11-20-96 1741 The right side lower body panel behind the front wheel is loose. Body panel cemented in place. 0.5 0.5
11-20-96 1741 The A/C roof cover is loose, latch needs repaired. Latch repaired. 0.5 0.5
11-21-96 1793 The hold down latches on the engine compartment are missing. Installed new latches. 0.5 0.5
12-06-96 3045 The top radiator access latch is broken. Latch repaired. 0.75 0.75
12-06-96 3045 The left back-up light is broken. Repaired back-up light. 0.5 0.5
01-23-97 5627 Bolt missing from the rear mount in the driver's seat. Air line to driver's seat is worn. Removed driver's seat and adjusted hole for mounting bolts. Replaced worn air line. 2.5 2.5
01-23-97 5627 Rear radiator access door; both top and bottom locking bolts are broken. Top and bottom locking bolts repaired. 2.0 2.0
02-18-97 6740 The driver's seat shock damper mount is broken. Moved the driver's seat shock damper from the left mounts to the right mounts. 1.5 1.5
02-28-97 8090 Two engine compartment door latches are broken. Latches replaced. 0.5 0.5
02-28-97 8090 The left brake light assembly is falling out. Replaced left brake light assembly. 0.5 0.5
04-21-97 11117 The front muffler mount is broken. Muffler mount repaired. 1.0 1.0
05-15-97 12824 The locks are missing from the right overhead electrical panel and the engine comprtment door. Installed new locks and adjusted. 0.5 0.5
05-20-97 13346 The hinge is broken on the rear engine door. Welded/repaired door hinge. 1.0 1.0
01-20-97 5509 The left rear maxi-brake chamber is broken. Replaced maxi-brake. 48.0 3.0
01-23-97 5647 The right rear slack adjuster bracket is broken. Slack adjuster bracket welded/repaired. 1.0 1.0
02-21-97 7100 The rear brakes require adjustment. Rear brakes adjusted. 0.5 0.5
03-07-97 8757 The left rear maxi brake chamber is damaged. Damage was caused by a previous failure. Replaced the left rear maxi brake chamber. 4.0 4.0
03-14-97 9389 The control arm on the right rear slack adjuster is broken. Both rear control arms replaced. 2.5 2.5
06-12-97 14971 The adjusting link is broken on the right rear slack adjuster. Replaced right rear slack adjuster. 1.5 1.5
11-12-96 915 The right rear turn signal lamp is burned out. Lamp replaced. 0.25 0.25
11-12-96 915 The left rear back-up lamp is burned out. Lamp replaced. 0.25 0.25
11-15-96 1375 Bus shut down will not crank. Trouble shooting found 20 amp circuit breaker tripped (wire 1-81 red). Trouble shooting driver's master switch circuit traced short to circuit 9R47A (1# right interior light). Circuit removed until short can be located. 2.5 2.5
11-20-96 1741 Further trouble shooting of shorted circuit reported on 11/15/96. Short in the #1 right interior light circut found and repaired. 1.0 1.0
12-18-96 4375 The right rear turn signal is burned out. Replaced lamp. 0.5 0.5
02-14-97 6572 Speedometer is not functioning. Trouble shooting found bad ground connection on the gauge. Ground repaired. 2.0 2.0
02-27-97 7866 Low voltage condition at the battery equalizer. Found fusible link at the ground terminal on the equalizer blown. The battery terminal adapters are dirty and loose. The positive terminals are smoking on start-up and the positive posts on both batteries are pitted. Replaced fusible link, cleaned and tightened battery terminals and replaced adapters. 2.0 2.0
03-11-97 9066 Low voltage condition at the battery equalizer. Found fusible link at the ground terminal on the equalizer blown. The battery terminal adapters are dirty and loose. Replaced fusible llink, cleaned and tightened battery terminals and replaced adapters. 1.5 1.5
05-01-97 12234 Trouble shoot charging system; 12 volt system is low (11.0 volts) and the 24 volt system is high (30 volts). One battery is boiling, replaced both batteries. 1.0 1.0
05-13-97 12504 The coolant circulation pump is shutting off intermittently. Found corroded wire connection and repaired. 0.5 0.5
05-15-97 12824 Both batteries are cooking Replaced both batteries. 0.5 0.5
06-06-97 14943 The rear radiator bracket is broken. Replaced rear radiator bracket. 0.5 0.5
10-11-96 344 Oil pushing out of the filler cap and front cover. Cummins rep. reports the following: the engine is not using oil nor is there smoke at idle or under load. Removed rear belt guard to access engine. Installed a "blow-by" gauge to check oil pressure. Cleaned engine down with degreaser. Warmed up engine, found O.E.M. oil pressure gauge reads 85 psi at high rpm's when engine is cold and 63 psi when the engine is at operating temperature. Rep. stated the only problem with the oil pressure is a bad O.E.M. oil pressure gauge. During test drive there was 5.5" of "blow-by" when the engine was cold and 5.0" of "blow-by" at operating temperature. Found oil leaking out around filler cap. Rep. states that the oil drain from the alternator drains into the oil fill 3.0"below the fill cap. High pressure oil is shooting in against the fill tube, oil is flying everywhere inside the tube. (This can be seen by looking in the fill hole.) Also, the 2.0" drain hose is not oil compatible and one section seemed to be kinked. Removed intake piping off the turbo to check fins, fin OK. Rep. states the high blow by complaint is not high blow by it's an oil leak. Repair the leak and the problem will go away. 16.0 8.0
11-07-96 642 The battery tray is loose. Replaced left stripped out nut insert and tightened loose right nut insert. 0.5 0.5
11-08-96 903 The flex pipe from the exhaust to tail pipe is broken. Replaced flex pipe and rotated elbow 180 degrees so exhaust is directed to the gound instead of the roof. 1.0 1.0
11-12-96 915 The flexible elbow from the exhaust is broken. Flexible elbow replaced. 1.0 1.0
11-19-96 1677 Both hydraulic lines from the transmission to the oil cooler are leaking. Both hydraulic lines replaced. 1.5 1.5
11-21-96 1793 The right side battery case is cracked. Replaced battery. 0.5 0.5
11-21-96 1793 The water pump drive belt is cut and frayed. Safety cage, A/C belt and alternator belt removed to install new belt. 1.0 1.0
11-21-96 1793 The battery tray hold down bolts are missing. Installed new 1/4 x 20 nutserts and new bolts. 1.0 1.0
11-25-96 1976 Two 14 x 20 bolts are missing from the battery tray slide. Replaced 1/4 x 20 bolts. 0.5 0.5
12-06-96 3045 The bottom transmission hose is leaking. Transmission hose replaced. 0.5 0.5
12-06-96 3045 The two top radiator mounting bushings are worn and both mounts are broken. Both bushings replaced. Repaired front mount and replaced rear mount. 2.0 2.0
12-06-96 3045 The rear engine mount is worn. Replaced rear engine mount. 2.0 2.0
12-12-96 3567 The battery tray slide track is broken at the left rear brace. Fabricated a new brace and welded assembly. 4.0 4.0
12-18-96 4378 The battery tray hold down is broken. Repaired tray hold down and replaced battery cable end. 0.5 0.5
01-06-96 4940 The top front radiator mount is broken and the hardware holding the motor for the engine cooling fan is broken. New mount fabricated and hardware welded/repaired. 4.0 4.0
01-23-97 5627 Manufacturer requests cooling fan mounting bracket and all radiator mounting bushings be replaced. Replaced cooling fan mounting bracket and all radiator mounting bushings. 4.5 4.5
01-24-97 5743 Engine will not crank. Found rear battery cells dry. Filled battery, charged and started engine. 6.0 1.0
01-27-97 5773 Engine will not crank. Trouble shooting found charging OK. Found battery building excessive gas causing battery case to bulge. New batteries ordered. 24.0 2.5
01-27-97 5773 The flex exhaust pipe from the turbo to the muffler is broken. Flex exhaust pipe replace. 1.0 1.0
01-29-97 5773 New batteries ordered 1/27/97 arrived. Installed new batteries and adjusted voltage regulator to 28.2 volts as per manufacturer. 3.0 3.0
02-11-97 6322 Hydraulic fluid is leaking from the hydraulic manifold located by the fan spider. Tightened fitting in hydraulic manifold. 1.0 1.0
02-12-97 6322 Hydraulic fluid is leaking from the hydraulic manifold located by the fan spider. Fitting replaced. 1.0 1.0
02-12-97 6322 Fitting is leaking hydraulic fluid at the control valve for the engine coolant fan motor. Fitting replaced. 1.0 1.0
02-21-97 7100 Bus down with hydraulic oil leak. An o-ring failed in the solenoid valve for the engine cooling fan motor. Valve replaced. 5.0 5.0
02-22-97 7201 The pivot bolt in the A/C compressor mounting bracket fell out. Pivot bolt replaced. 1.0 1.0
02-25-97 7394 Radiator; the right inner most mounting bolt and half the bushing are missing, the right outer bolt is loose and the mounting bolt to the spider is missing. Also the right upper radiator mounting bracket is broken and the brace on the charge air tubes is broken. Bracket and brace welded/repaired. Missing bolts and bushing replaced. 2.0 2.0
02-28-97 8090 The lower hydraulic line is leaking. Hydraulic line replaced. 1.0 1.0
03-11-97 9066 Both lower mounting bolts are missing from the radiator fan mounting spider and one bolt is missing from the right side of the radiator. The right upper mounting bracket is broken. New bolts installed and bracket welded/repaired. 1.0 1.0
03-18-97 9511 The spider mount for the radiator cooling fan broke causing the fan blade to contact the radiator. Radiator and fan blade, charge air cooler fan shroud and oil cooler damaged. Spider mount welded/repaired radiator, fan blade, charge air cooler, fan shroud and oil cooler replaced. 4.0 4.0
03-18-97 9511 The engine bell housing is broken in two placed at the left mount. Further inspection found the flywheel ring gear damaged (tooth broken) and starter gear damaged. New engine bell housing installed, flywheel ring gear replaced and starter repaired. Warranty work performed by Cummings rep. 228.0 23.0
03-19-97 9511 The throttle return spring is broken. Replaced throttle return spring. 0.5 0.5
04-01-97 10115 The engine bell housing is broken in two placed at the left mount. New bell housing installed by Cummins warranty rep. 240.0 32.0
04-09-97 10115 Transmission code #44-21. Trouble shooting found short curcuit in ground for "F" solenoid, ground repaired. 9.0 9.0
04-18-97 10786 The engine bell housing is cracked in two places at the left mount. Manufacturer requests the right side engine mount gusset be extended 7", washer welded over the front engine mount holes (holes are oblong), six shims added to the front engine mount (raised approximately 1"), and bracing mounted between the left and right engine mount to stabilize. New bell housing installed by Cummins warranty rep. 96.0 58.0
04-18-97 10786 The front blower motor for the stepwell area has broken loose from its mounts. Unit removed as per manufacturers rep. 1.0 1.0
04-21-97 11117 The coolant access door is missing numerous bolts. Bolts replaced. 1.0 1.0
04-23-97 11408 The hydraulic fitting is leaking at the power steering hose going into the pump. Fitting replaced 1.0 1.0
04-24-97 11594 Transmission will not shift properly. Trouble shooting found TPS connector plug loose and oil soaked. Plug cleaned and tightened. Transmission codes 45-21 and 22-14 still present. Internal wiring harness on order. 1.5 1.5
04-25-97 11594 The rear battery tray support is broken. Welded/repaired rear battery tray support. 1.5 1.5
04-25-97 11594 Warranty rep. (Allison) arrived with new internal transmission wiring harness. Wiring harness installed, codes clear. 48.0 4.0
04-29-97 11935 Trouble shoot transmission ATEC circuits for codes. Located and cleaned dirty ground wire connection under the left front of bus near the battery compartment. 2.0 2.0
05-07-97 12499 The engine bell housing is cracked at the left mount and the transmission housing is crakced on the left side at one of the bolt holes. O.E.M. aluminum bell housing replaced with cast steel bell housing and transmission housing replaced. 152.0 17.0
05-07-97 12499 Both upper radiator brackets are broken. Replaced both upper radiator brackets. 1.0 1.0
05-07-97 12499 The front heater case is broken. Heater case removed and reinforced 8" long steel strap. Case reinstalled. 2.5 2.5
05-09-97 12499 The left upper engine mount gusset has a 2" crack in the weld. Engine mount gusset welded/repaired and a new front engine mount installed. (Note: engine is not installed at this time due to bell housing failure). 1.5 1.5
05-09-97 12499 A fitting is leaking at the hydraulic pump power steering port. Threads are stripped in the pump housing, replaced pump. 1.0 1.0
05-09-97 12499 The transmission accumulator bracket is cracked in three places. Bracket welded/repaired. 0.5 0.5
05-09-97 12499 The air dryer bracket is cracked in four places. Bracket welded/repaired. 0.5 0.5
05-09-97 12499 The vertical post near the hydraulic reservoir has a 1.5" crack. Crack welded/repaired 0.5 0.5
05-20-97 13346 Two radiator braces are broken. Two new radiator braces fabricated and installed. 2.0 2.0
05-21-97 13525 A bolt is missing from the rear muffler bracket, the front bracket is broken and the flex pipe (elbow) is broken. Installed bolt in rear bracket, replaced flex pipe and welded/repaired front bracket. 4.0 2.0
05-22-97 13659 Both muffler brackets are broken. Replaced both muffler brackets. 1.0 1.0
05-23-97 13844 Both top radiator brackets are broken. Both brackets replaced. 1.0 1.0
05-28-97 14140 A loose hydraulic line at the pump is leaking fluid. Hydraulic line tightened and fliud topped off. 0.5 0.5
05-28-97 14140 The exhaust pipe between the turbo and muffler is broken at the flex end. Pipe replaced. 0.5 0.5
05-29-97 14202 Hydraulic fluid is leaking from the hydraulic pump. Worn 0-ring in hydraulic pump replaced and fluid topped off. 2.0 2.0
05-30-97 14290 Both front and rear muffler supports are broken. Both muffler supports replaced. 1.0 1.0
05-30-97 14290 The exhaust pipe at the turbo is cracked at the flex section and the pipe exiting the muffler is cracked at the flex section. Damaged sections on both pipes cut out and reinstalled. 1.5 1.5
05-30-97 14290 The front engine mount is worn. Replaced front engine mount. 1.5 1.5
05-31-97 14355 The top radiator mounting bracket is broken. Bracket replaced. 1.0 1.0
06-03-97 14479 Two blades on the engine cooling fan have broken and are hitting the lower right oil cooler mounting bolt causing damage to the radiator. Replaced radiator and cooling fan. 10.0 5.0
06-05-97 14857 Both top radiator brackets are broken. Replaced both top radiator brackets. 1.5 1.5
06-09-97 14943 The right engine mount is broken. Both left and right mounts ordered. New engine mounts installed. 96.0 5.0
03-19-97 9511 The vertical frame member by the driveshaft is cracked. Crack welded/repaired and 5" x 5" gusset added as per manufacturer. 1.0 1.0
05-09-97 12499 Two braces on the air cooler pipes in the engine compartment are broken. Braces welded/repaired. 0.5 0.5
05-22-97 13659 The vertical post at the hydraulic reservoir is cracked. Post welded/repaired. 0.5 0.5
05-27-97 14033 The vertical post at the hydraulic reservoir is cracked. Crack welded/repaired. Steel u-channel welded in place to reinforce the area. 2.5 2.5
10-07-96 0 Front air bags are leaking air and out of alignment Front air bags removed and different mounting plates installed for better alignment. 4.0 4.0
10-10-96 254 The left rear, rear air bag chaffed on the upper mounting plate bolt causing a leak. Replaced left rear, rear air bag. 2.5 2.5
10-14-96 348 The left rear, rear air bag is ruptured. Removed shock and electric water pump, installed new air bag. 4.0 4.0
10-21-96 385 Manufacturer reps. request front and rear upper air bag mounting plates be replaced with new design, (recessed holes for mounting bolts). Assist manufacturer reps. replace front and rear upper air bag mounting plates. 8.0 8.0
10-31-96 400 The right front forward air bag is leaking air. Right front forward air bag replaced 1.5 1.5
11-21-96 1793 Manufacturer requests front air suspension system be redesigned from a four bag to a two bag system. Assisted manufacturer rep in converting the front air suspension system from a four to a two bag system. 8.0 8.0
12-06-96 3045 The left front shock is missing the bottom nut. Nut replaced. 0.25 0.25
12-11-96 3436 The right rear, bottom, center radius rod is broken at the forward bushing mount. Replaced radius rod. 4.0 4.0
12-13-96 3687 The right rear, bottom, center radius rod is broken at the forward bushing mount. Replaced radius rod. 1.5 1.5
01-10-97 5457 The rear axle is out of alignment. Found the left rear upper radius rod broken at the forward mount. Broken rod also caused damage to the left rear brake canister. Parts ordered. Broken radius rod and damaged brake canister replaced. 384.0 6.0
01-20-97 5509 The two front bolts, upper radius rod arm are broken. Replaced bolts. 5.0 5.0
01-23-97 5627 Manufacturer requests that all radius rod mounting bolts and spacers be replaced. Replaced all radius rod mounting bolts and spacers. 1.5 1.5
01-31-97 5869 The right front shock is leaking oil. Replaced right front shock. 1.0 1.0
02-05-97 6080 The lower, right rear radius rod mounting tab is broken. Replaced the lower, right rear radius rod. 4.0 4.0
02-12-97 6322 Manufacturer requests both front air bags be changed out to be tested. Air bags replaced. 3.0 3.0
02-12-97 6322 Manufacturer requests the rear axle left and right upper and lower radius rod grade 8.8 bolts be replaced with grade 10.9 bolts. Bolts replaced. 4.0 4.0
02-17-97 6666 The rear axle has shifted to the right, found the left rear lower radius rod broken at the forward inner mount. Replaced radius rod. 4.0 2.0
02-21-97 7100 Both front shocks are worn. Both front shocks replaced. 1.5 1.5
03-04-97 8384 The right rear, upper radius rod is broken at the forward inside mount. Right rear upper radius rod replaced. 2.5 2.5
03-06-97 8669 The lower left rear radius rod is broken at the forward mount. Lower left rear radius rod replaced. 1.5 1.5
03-14-97 9389 Manufacturer requests both upper and both lower radius rods be replaced with new rods with new designed bushings. New radius rods installed. 3.0 3.0
04-09-97 10115 The forward right rear shock is broken at the bottom eye. Replaced forward right rear shock. 0.5 0.5
04-22-97 11259 The right front shock is broken at the top mount. Right front shock replaced. 1.0 1.0
04-30-97 12029 The lower right front radius rod is broken. Replaced lower front radius rod. 5.0 5.0
05-02-98 12273 The left front air bag ruptured. Replaced left front air bag. 1.5 1.5
05-12-97 12499 The right front air bag is leaking air. Replaced right front air bag. 1.5 1.5
05-12-97 12499 Manufacturer requests the following front radius arms be replaced with a new bushing design; front left, front right and front left center. Above radius arms replaced with new bushing design. 2.5 2.5
05-15-97 12824 The right front shock is broken at the lower mounting eye. Right front shock replaced. 0.5 0.5
05-20-97 13346 The left front shock failed. Left front shock replaced. 1.0 1.0
05-29-97 14165 Both forward bolts are broken on the left rear center radius rod. Repositioned the rear suspension and installed new bolts, washers, and locks. 1.5 1.5
06-30-97 14479 The upper mount is broken on the right rear forward shock. Right rear forward shock replaced. 0.5 0.5
06-04-97 14654 The right front shock is worn. Right front shock replaced. 0.75 0.75