STREETCAR RTV

WRIGHT GROUP LTD. Pdf Download PDF Report

Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
05-05-09 44 The bus is overheating. Troubleshooting performed by manufacturer and ISE techs. Replaced blown fuse to cooling fans. 18.0 6.0
05-05-09 44 The bus is bottoming out on elements of the durability track. Manufacturer's rep raised the ride height by two inches. 1.0 1.0
05-07-09 401 The lower mounting nut, washers and bushing are missing from the right side, rear most shock at the middle axle. Replaced mounting hardward and bushing. Checked all other shock hardward for torque. 4.0 2.0
05-12-09 588 Middle axle: the left side sway bar clamp is broken, three attaching bolts are missing and one is broken. The right side mounting bracket is cracked at the radius. Repaired threads on the left side bracket. Welded/repaired crack on the right side bracket. Replaced brackets and sway bar with new hardward. As per manufacturer's request, added two 3:x5"x3/8" support plates to the right side bracket. 46.0 11.0
05-13-09 784 Rear axle: the right side sway bar clamp bolt is broken. Replaced broken bolt. 3.0 1.0
05-13-09 784 Check for coolant leak by the inverter and engine compartment. Replaced broken hose clamp at the inverter and tightened the quarter turn valve (engine compartment). 3.0 3.0
05-19-09 1,556 The left side sway bar bracket is broken on the rear axle. Repalced left sway bar bracket on the rear axle. 4.0 2.0
05-15-09 1,125 Rear axle: the right side sway bar clamp is broken. Replaced both sway bar clamps. 4.0 2.0
05-21-09 1,915 The lower attaching brackets for both front wheel covers are cracked at the mounting bolts. Welded/repaired attaching brackets. 3.0 3.5
05-21-09 1,915 The speedomter is inaccurate. Manufacturer's rep replaced speedometer. 4.0 3.0
05-26-09 2,173 The bus is overheating. The roof cooling fan is inoperative. Manufacturer's rep temporarily bypassed failed fan controller. 37.0 1.0
05-27-09 2,367 Bus shutting down on durability track. Troubleshooting performed by manufacturer's rep. No problem found. Restarted bus. 1.0 1.0
06-02-09 2,882 The battery case is cracked. Manufacturer's rep replaced original gel-cell batteries with acid batteries. The battery tray was widened by 1/2" to accommodate acid batteries. The right batter track was moved 1/2" to the right. 47.0 4.0
06-04-09 3,371 The left rear sway bar clamp is broken at the mounting bolt. Replaced the left rear sway bar clamp. 4.0 2.0
06-05-09 3,572 The mounting bracket for the left front wheel cover is broken. Manufacturer's rep removed wheel cover. 6.0 0.5
06-08-09 3,745 The right side, middle axle sway bar bracket is cracking at the radius. Removed drive shaft to access sway bar bracket. Removed bracket, welded/repaired. Reinstalled bracket and drive shaft. 6.0 5.0
06-09-09 3,946 The right side, rear axle sway bar bracket is broken. Replaced right side, rear axle sway bar bracket. 4.0 2.0
06-09-09 3,946 The fueld tank is leaking at a crack in the weld on the right rear corner. Sealed crack with fuel tank epoxy repair kit. 46.0 1.0
06-09-09 3,946 The fuel tank is leaking at a crack in the weld on the right rear corner. Sealed crack with fuel tank expoxy repair kit. 46.0 1.0
06-12-09 4,559 Gel cell batteries arrived. The temporary acid batteries that were installed on 6-2-09 were replaced with gel cell batteries. 1.0 1.0
06-12-09 4,559 The sensor location in the coolant tank is too low. Manufacturer's reps installed new coolant tank with higher sensor location. 2.0 2.0
06-22-09 5,912 The fuel tank venting unit at the filler neck has fallen apart. Replaced the filler neck housing with the one from the original tank. 28.0 3.0
06-25-09 6,121 The right front sway bar link anchor point bracket is broken. Welded/repaired anchor point bracket. Reinstalled link, bracket and sway bar. 46.0 7.5
06-30-09 6,675 The left side sway bar clamp, center axle is broken. REpalced left side, center axle sway bar clamp. 10.0 2.0
07-01-09 6,889 "Service Engine" light is on. Troubleshooting with Genisys diagnostic reader found code 101 "Engine Crankcase Pressure" fault. Replaced crankcase ventilation filter. 4.0 1.0
07-01-09 6,889 "System shut-down." Troubleshooting performed by ISE rep. No problem found. 3.0 3.0
07-06-09 7,331 The right side sway bar clamp is broken on the rear axle. Replaced right side sway bar clamp on the rear axle. 1.0 2.0
07-06-09 7,331 The left side sway bar clamp is broken on the center axle. Replaced the left side sway bar clamp on the center axle. 1.0 2.0
07-06-09 7,331 The left side sway bar clamp is broken on the center axle. Replaced the left side sway bar clamp on the center axle. 1.0 2.0
07-06-09 7,331 The cooling fans for the hybrid drive will not turn on. Wright Group rep. trouble shooting. No problem found. 2.0 2.0
07-06-09 7,331 The center hoop suspension wheel mount is broken. Temporary repair made until parts arrive. 1.5 3.0
07-07-09 7,480 The left side sway bar link bracket on the front axle is broken. Replaced the left side sway bar link bracket on the front axle. 7.0 2.0
07-16-09 7,854 Rear car; both upper structure, forward bellows frame assembly attaching brackets are broken at the floor mount area. Welded/repaired attaching brackets. 62.0 12.0
07-20-09 7,927 The right side sway bar clamp, middle axle is broken. Replaced the right side sway bar clamp at the middle axle. 1.0 2.0
07-20-09 7,927 Manufacturer's rep request all shocks be replaced. All shocks; front, middle and rear axles repalced. Note: to access the right front shock, the driver's seat must be removed to access the access panel for shock replacement. 164.0 8.0
07-21-09 7,927 The right front sway bar link bracket repair made on 6/25/09. Replaced the welded/repaired right front sway bar link bracket with new bracket. 1.0 2.0
07-21-09 7,927 Inspect for air leaks at rear of bus when brakes are applied. Numerous swivel fittings are worn and leaking air. Replaced four air brake lines at right rear and left rear axle and the right and left middle axle. 44.0 6.0
07-27-09 7,927 The bellows frame assembly brackets, rear car, forward; both left and right are cracked. The lower support on the right side is broken. Removed the lower support bracket. Cut out the right side frame assembly to the floor mount. Removed both floor mounts of the bellows frame. Repaired lower support bracket, repaired upper structure anchor points of the rear car, right side. Installed lower support bracket, installed right and left side brackets on the bellow frame assembly. 208.0 17.0
07-31-09 7,927 The inside battery on the 24 volt system is cracked at the top and side of the case. Replaced cracked battery with used batter. Replaced battery cable. 6.0 2.0
08-05-09 8,441 The fuel tank structure support outrigger is broken; rear car, right side. Removed fuel tank, welded/repaired outrigger aligned support. 32.0 5.0
08-05-09 8,441 The return fuel line is pinched above the fuel tank and leaking. Repaired leaking fuel line. 4.0 2.0
08-06-09 8,441 Test bus is shutting down on the Durability Test Track. Manufacturer's rep replaced possible failed VPM (voltage protection module). 4.0 4.0
08-06-09 8,441 The front and mid axle tires are worn. Replaced six front and mid axle tires. 1.5 3.0
08-07-09 8,653 The rear axle sway bar is broken at the right side radius. Replaced rear sway bar. 4.0 2.0
08-10-09 8,855 A broken P-clip has chafed through an I.S.E. cooling system line on the roof. I.S.E. 1.0 1.0
08-20-09 9,999 The rear axle, left side sway bar clamp bracket is broken. Replaced left side, rear axle sway bar bracket. 3.0 2.0
08-21-09 10,219 The left and right side, rear car bellows frame sub assemply brackets are cracking. Fabricated and installed (2) 6"x6"x12" L-shaped brackets from 3/8" steel. 6.0 5.5
08-21-09 10,219 The drive motor isolators are worn. Replaced drive motor isolators. 3.0 3.0
08-26-09 10,938 The left side, middle axle sway bar mount and the right side, rear axle sway bar mounts are broken. Replaced both sway bar mounts. 2.5 2.5
08-27-09 11,119 Bus will not start. Manufacturer's reps replaced the innermost battery. The positive post was damaged from arching. 6.0 2.0
09-01-09 11,811 Middle axle; the forward most air bag, right side is missing a mounting bolt. Replaced air bag and mounting hardward. 3.0 2.0
09-01-09 11,811 Both sway bar clamps on the middle axle are cracked. Replaced both middle axle sway bar clamps. 3.0 3.0
09-03-09 12,242 Middle axle: the right side sway bar clamp is cracked. Welded/repaired and reinstalled clamp. 4.0 6.0
09-08-09 12,613 Middle axle: the right side sway bar clamp bracket is broken. Replaced sway bar clamp. 36.0 4.0
09-10-09 13,110 Middle axle: the left side sway bar clamp bracket is broken. Replaced sway bar clamp. 4.0 2.0
09-14-09 13,395 The middle axle sway bar is broken at the left side radius. Replaced middle axle sway bar. 4.0 2.0
09-14-09 13,395 The left side sway bar clamp is broken on the rear axle and one bolt is broken on the right side clamp. Replaced left side, rear axle sway bar clamp and replaced broken bolt on the right side. 4.0 3.0
09-16-09 13,863 The right side sway bar link bracket is broken on the front sway bar. Replaced right side sway bar link bracket. 0.5 1.0
09-16-09 13,869 One attaching bolt is broken on the right side, rear axle sway bar clamp. Replaced broken bolt. 0.5 1.0
09-16-09 13,868 The left and right side, rear car bellows frame sub assembly brackets are cracking at the radius. Welded/reparied cracks and added tow gussets to the right side bracket. 3.0 3.0
09-17-09 14,094 Manufacturer's rep requests the crankcase ventilation filter be replaced. Replaced crankcase ventilation filter. 4.0 0.5