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Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
06-22-98 8272 The A/C system has lost the refrigerant charge. Numerous leaks found in the area of the articulation joint. All leaks repaired and system recharged. 48.0 18.0
07-16-98 9047 The rear A/C evaporator has a cracked tube. Thermo King rep. replaced equalizer line and unit drier. System evacuated, recharged, codes cleared and parameters reset. 4.0 4.0
09-03-98 15000 The flexible A/C lines through the articulation joint are leaking. Flexible A/C lines replaced. 2.5 2.5
05-11-98 5600 The intermediate axle is cracked at both ends. Intermediate axle removed for installation of new. New axle ordered. Upon removal of the axle, found the weld cracked at the radius arm boss on the right side rear suspension arm and cracking on both rear suspension arm welds at the axle pads. 456.0 8.0
06-01-98 5600 Intermediate axle received. Installed new intermediate axle. 5.5 5.5
03-03-98 913 One bolt is broken in the artic joint cover plate. Broken bolt removed and new bolt installed. 0.5 0.5
03-09-98 1943 Both center pivot bolts for the vertical adjustment on the driver's seat are broken. Installed two metric bolts and bushings. OEM parts ordered from manufacturer. 1.5 1.5
04-27-98 4839 Two seats are broken on the artic platform. Repaired two seats on the artic platform. 2.0 2.0
06-22-98 8272 The driver's windshield wiper is loose. Threads repaired on the pivot bolt and nut replaced. 0.5 5.0
07-15-98 8954 Both front windshields are falling out. The left side windshield is cracked at the upper right corner. Repaired separated center post and installed windshields. 1.5 1.5
07-16-98 9047 The windshield center post is separating. Windshield removed and center post repaired with fiberglass. 3.0 3.0
07-30-98 10621 Both front windshields are falling out. Installed new windshields, both sides with new windshield gasket and pinch weld primer. Fabricated and installed 12 metal clips to hld the glass secure. 5.0 5.0
08-19-98 13989 The driver's side windshield is broken. Windshield and seal replaced. 3.5 3.5
08-19-98 13989 Three light panels are loose between the center door and the artic joint. Rivets replaced on the panel by the door and the other two panels removed. 1.5 1.5
03-16-98 2324 The A/C drive belt is worn. Removed the rear engine pulley guard and water pump belt. Installed new shims in the A/C idler pulley. Replaced belts and guard. 4.0 4.0
03-17-98 2548 "Hot Trans" light is on. Topped off transmission fluid. 0.5 0.5
03-20-98 2548 "Hot Trans" light continues to come on. Connected diagnostic equipment. Found active code 62-23 (retarder temp. sensor failed high) and inactive code 61-00 (retarder over temp). Trouble shoot the temp. sensor circuit. Checked the ground circuit and resistance. Checked all connectors and pins. The resistance value did not compare to the chart in the ATEC manual. Retarder temp. sensor ordered. Sensor installed upon arrival. 24.0 8.0
03-24-98 2643 The A/C and hydraulic pump belts were thrown off the pulleys. Both belts replaced. Found A/C belt hitting the engine mounting bracket. A/C belt temporarily removed. 2.0 2.0
04-01-98 3256 New A/C belt arrived. Installed new a/c belt. Belt will not stay on the pulleys at increased rpm's. The location of the idler pulley is making too great of an angle on the A/C pulley. Belt removed. 0.5 0.5
04-22-98 4839 The A/C compressor support is broken. Broken support removed. Two holes for mounting redrilled and tapped to 3/8." Realigned idler, replaced belt and installed new support. 4.0 4.0
06-16-98 7406 The test bus is experiencing intermittent loss of power and shutting off. Changed fuel, air, oil and oil filters. 1.5 1.5
06-25-98 8282 The A/C belt is worn. When replacing the A/C belt, the idler adjustment did not tighten the belt completely. 1/2" was removed from the idler adjustment hole. Belt tightened. 2.0 2.0
07-06-98 8344 The drive belt for the hydraulic pump is broken. Hydraulic pump drive belt replaced. 0.5 0.5
04-09-98 4782 Multiple cracks in articulation joint. Manufacturer instructed welder to stitch weld and plate all cracks. 96.0 5.0
04-07-98 4782 Inspection of the articulation joints found multiple cracks. Manufacturer will arrange for transportation to repair shop. 48.0 1.0
04-13-98 4839 Multiple cracks in articulation joint. Failed articulation joint removed. Manufacturer's rep. marked locations for holes for the locator pins. Joint removed and two holes drilled for locator pins. Reinstalled articulation joint. The six holes on the right side of the bulkhead did not line up. 240.0 12.0
04-23-98 4839 Correction for artic/bulkhead holes not lining up. Articulation joint removed, six holes on the right side of the bulkhead enlarged to 57/64". Installed articulation joint. Drilled and tapped two 1/4 - 20 holes in the turntable to attach the artic controller. 3.0 3.0
06-03-98 5678 Adjustment needed to articulation joint alignment. Manufacturer's rep. adjusted alignment for proper tracking. 0.5 0.5
07-16-98 9047 The articulation joint bushings are worn. Artic joint bushings replaced. 4.0 4.0
08-14-98 12838 The artic wrist joint bushings are worn and the rear axle, right rear lower radius rod, bushing on teh axle end is worn. Artic wrest joint and radius rod bushings replaced. 5.0 5.0
04-27-98 4839 Reference artic joint replacement. Reassemble the bellows around the articulation joint. The cover was left off as per manufacturer's request for the purpose of the strain gauging. 3.0 3.0
03-03-98 913 The 4 u-bolts anchoring the rear axle loosened causing the axle to shift. The shifting axle caused the lower rear axle cross member to crack, the rear axle suspension cross member to bend and crack, and bent the lower right side radius rod. Welded/repaired lower rear axle cross member. Straightened, and welded/repaired the rear suspension cross membere and replaced the right rear lower radius rod. All four rear axle anchor u-bolts replaced. 7.5 7.5
03-05-98 1033 The right side leveling arm link on the rear axle is bent. The rear suspension beams are out of alignment. Loosened rear suspension u-bolts and cross member assembly. Removed both struts on the suspension beams. Realigned suspension and installed new struts. Fabricated two new leveling valve link brackets and mounted them facing downward as per manufacturer's instructions. All fasteners retorqued. 4.0 4.0
03-05-98 1033 The rear leveling valve arms failed. Manufacturer's rep. replaced the rear leveling valve arms. 1.0 1.0
03-13-98 2310 Trouble shoot for noise under the artic joint. Replaced the right rear shock (broken) and the left front shock (leaking oil) on the intermediate axle. 1.0 1.0
03-13-98 2310 Bus ride height is low on the left side, rear axle. Replaced the broken leveling valve arm and link, left side, rear, and straightened bracket. 1.0 1.0
03-25-98 2821 The right lower radius rod, rear axle, is hitting the suspension. The worn bushings are causing the axle to shift. Replaced the lower right radius rod and retorqued the rear axle u-bolts. 1.5 1.5
03-30-98 3256 Rear axle; the upper right rear shock mount assembly is cracked. Replaced both upper shock mounts. 1.0 1.0
03-30-98 3256 The rear suspension cross tube assembly is broken at the mounting tab for the diagonal strut. The right rear lower radius rod is hitting the right suspension beam, and the front of the left suspension beam is hitting hte support channel of the rear wheel well. Manufacturer informed. Repairs pending instructions. 24.0 2.0
03-31-98 3256 Instructions received for repair of rear suspension failure on 3/31/98. Right front radius rod replaced. Installed three washers (as shims) between the right lower and upper radius rods and their mounting surfaces. Retapped the outboard mount on the right upper radius rod. Removed one of the shim wahsers at each position on the radius rods. Welded/repaired the strut mount tab on the cross tube assembly. Replaced the lock nuts on all rear axle u-bolts. 24.0 6.0
04-01-98 3256 Continued repairs to rear suspension failure on 3/31/98. Reinstalled the cross member tube assembly. Drilled new holes and replaced both struts on the suspension beam. Torqued all u-bolts and radius rod bolts. 16.0 4.0
05-05-98 5546 The right front mounting bolt on the left front air spring support is broken. Bolt replaced. 0.5 5.0
06-05-08 6060 The left rear leveling valve has failed. Manufacturer's rep. replaced the left rear leveling valve. 1.0 1.0
06-11-98 6972 The rear of the bus is not tracking properly. Mechanic found the rear suspension beams have shifted and the lower radius rod bushings (on the suspension end) are worn. Both rear lower radius rods removed and bushings replaced. Removed the cross tube (found cracks around the mounting holes), welded/repaired cracks. Filled the mounting holes with weld for the diagonal strut on the left suspension beam as per manufacturer's rep. Drilled new holes for the strut mount. Drilled holes in the new struts. Relaligned both suspension beams. Reassembled the rear suspension. 7.5 7.5
06-12-98 7023 Front axle; both lower shock mounts are cracked. Cracks welded/repaired. 3.0 3.0
07-29-98 9954 Both front shocks are leaking oil. Both front shocks replaced. 1.0 1.0
07-31-98 10621 Both right side shocks in the intermediate axle and the right rear shock on the rear axle are leaking oil. All three shocks replced. 1.5 1.5
08-18-98 13818 The left front bolt on the left side of the front axle-to-air spring support is broken. Broken bolt replaced and other retorqued. 0.5 5.0
08-24-98 15000 The right rear shock on the intermediate axle has failed. Shock replaced. 1.5 1.5
04-22-98 4839 The left side intermediate axle H-beam is cracked around the lower right rear radius rod. H-beam welded/repaired. 4.0 4.0
08-24-98 15000 The right rear leveling valve arm is broken. Arm welded/repaired. 1.0 1.0
03-04-98 1023 Hydraulic fluid is dripping from the ceiling above the artic joint. Loose power steering line fitting tightened. Two loose circulating pump clamps also tightened (not leaking). 1.0 1.0
06-26-98 8282 All tires are worn and need replaced. All tires replaced. 10.0 10.0