EXCEL 102

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Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
10-11-02 4490 The evaporator on the front A/C unit is leaking. Evaporator replaced. 2.0 2.0
11-13-02 7664 The front A/C condenser is leaking. Evaporator removed and sent to Blue Bird. 1.0 1.0
03-11-03 13169 The axle mount bolt on the rear lateral bar is broken. Broken bolt replaced. 1.0 1.0
08-12-02 2531 The grill is broken out of the engine compartment on the left side. Grill reinstalled with epoxy, nuts and bolts. 0.5 0.5
11-06-02 6649 The outrigger at the rear PDU box is cracking. Removed PDU box and all wiring to it. Removed hydarulic reservoir. Outrigger replaced. PDU bow and wiring replaced. 5.0 5.0
01-16-03 11792 The battery hold-downs are loose and two cell caps are off leaking water in the battery compartment. Water level topped off, caps replaced, hold-downs tightened and compartment cleaned. 0.5 0.5
02-10-03 12537 The rear electrical panel broke loose at the top mount and the circulating fans broke loose on the left side. A/C unit removed, electrical panel remounted, circulating fans remounted, A/C unit reinstalled. 8.0 8.0
02-27-03 12970 Both upper horizontal posts on the rear A/C--heater unit are broken. A/C unit removed. Installed two pieces 1 1/2" x 1 1/2" x 61 1/2" tube steel. Hangers welded to tubes. 1" steel angle installed at the lower horizontal post area. A/C unit reinstalled. Six bolts replaced. 4.0 4.0
03-06-03 12970 The battery compartment door will not stay closed. Three loose rivets replaced, hinge reinstalled. Left door adjusted right door latch replaced (broken). Right door lock bracket replaced (missing). 1.0 1.0
03-18-03 13986 The upper A/C mounting bracket and tubing is cracked. Tubing and mounting bracket replaced. 5.0 5.0
03-20-03 14192 The front heater box is loose. Dash panel removed and missing fasteners replaced, dash reinstalled. 1.0 1.0
03-24-03 14200 The upper left and the rear mounting bolts on the A/C unit are loose. Two missing bolts replaced and others tightened. 1.0 1.0
07-17-02 537 Engine cranks but will not start. Trouble shooting found four relays and two circuit breakers have fallen out of the rear power distribution box. Relays and circuit breakers replaced. 1.0 1.0
07-17-02 537 The lights at the rear of the bus are inoperative. Trouble shooting found a wire harness disconnected at the front electrical panel. Wire harness connected. 0.5 0.5
08-08-02 2104 The front door is inoperative. Trouble shooting found the ground wire broken off at the three prong connector at the top door actuator. 1.0 1.0
08-12-02 2531 The air conditioniong is inoperative. Replaced blown fuse at F2, large circuit breaker and repaired loose connection at the right connector on the small circuit board. 1.0 1.0
08-26-02 2670 The air conditioning is inoperative. The F2 fuse in the A/C circuit board is blown. Monitored circuit for excessive load. (18 amps or higher after 2 minutes of operation). Circuit board inspected, nothing found. 2.0 2.0
09-10-02 3877 Engine cranks but will not start. Trouble shooting found broken wire at the Eng-Ign relay. Broken wire repaired. 4.0 4.0
10-11-02 4490 The engine will not start from the front. Engine will start from the rear. Trouble shooting found broken wire on fuse terminal #K4 (start/sig) at the front electrical center. Broken wire repaired. 7.0 7.0
10-11-02 4490 The tool port at the rear PDU is inoperative. Trouble shooting found 10 amp. fuse out of its socket at the PDU. Fuse replaced. 0.5 0.5
10-11-02 4490 The instrument panel is inoperative. Trouble shooting found 7.5 amp fuse out of its socket. Fuse replaced. 0.5 0.5
10-16-02 5049 The temperature control on the dash has failed. Temperature control panel replaced. 0.5 0.5
10-25-02 5861 The tail lights and the instrument panel lights are inoperative. Trouble shooting found shorted wire under the dash. Wire repaired. 1.5 1.5
11-06-02 6649 The rear A/C unit is inoperative. Trouble shooting found two shorted wires in the A/C board. Wires repaired. 1.0 1.0
12-04-02 9743 The hydraulic fan speed control line is leaking hydraulic fluid. Defective fitting replaced. 4.0 4.0
12-06-02 10033 The 7.5 amp fuse is blown and both ignition relays have failed in the rear electrical box. Both relays and fuse replaced. 4.0 4.0
12-09-02 10140 The front heater motor is inoperative. Replaced burned motor switch and wiring harness. 1.0 1.0
08-20-02 2637 Engine runs, no power, no throttle. Trouble shooting engine control system, wiring harnesses and connectors. John Deere requests "HEGO" sensor and ECM be replaced. 4.0 4.0
08-26-02 2670 Engine shuts down intermittently. "Eng-Bat" fuse is hot to touch. Blue Bird requests rewire of +24 v A/C alternator exciter wire, to engine alternator. 4.0 4.0
10-11-02 4490 The engine cooling fan cage is broken. Cage replaced. 3.0 3.0
11-27-02 8689 The engine cooling fan cage is broken. Cage replaced. 3.0 3.0
01-16-03 11792 The engine cooling fan cage is broken. Cage replaced. 2.5 2.5
01-27-03 12522 The front heater core is leaking coolant. Front heater core replaced. 2.0 2.0
03-06-03 12970 The hydraulic reservoir is leaking fluid at the weld of the center hose connection. Hydraulic reservoir replaced. 1.0 1.0
03-20-03 14192 The engine fan cage has three broken braces. Engine fan cage replaced. 2.5 2.5
08-06-02 1737 The bus is leaking fuel. Replaced a broken line fitting at the low pressure sensor located at the filling block. 1.0 1.0
09-04-02 3608 The stainless steel fuel line from the CNG fill manifold to the low pressure switch/indicator is broken. Broken fuel line replaced. 2.0 2.0
12-13-02 10912 The rear fuel tank mounting structure is cracked and the mounting plate or the fuel manifold is cracked. Fuel tank covers removed, cracked fuel tank mounting structure welded/repaired. Fuel manifold plate replaced. Covers reinstalled. 6.0 6.0
01-28-03 12522 Engine cranks but will not start. No fuel pressure into the metering block. Low pressure lock-off plunger removed. Engine started while troulbe shooting, no problem found. 3.0 3.0
11-13-02 7664 Five bolts are missing on the wheelchair lift mounting bracket. Realigned the wheelchair cassette and installed new bolts. 0.5 0.5
08-08-02 2104 The front right ride height is low. Ride height adjusted. 2.0 2.0
08-30-02 3307 The front, right rear air bag is leaking air. Front, right rear air bag replaced. 1.0 1.0
10-18-02 5225 Both track bar bushings (left and right) on the rear axle are worn. Bushings replaced. 3.0 3.0
11-04-02 6398 The right rear air bag supply line is leaking air. Right rear supply line replaced. 1.0 1.0
01-10-03 11480 Bus is disabled at the fueling station. The lateral bar is broken, axle has shifted and air lines are damaged. Bus towed to repair shop. Air lines repaired and lateral bar replaced. 3.5 3.5
02-13-03 12970 The lower shock bushings on the rear shocks are worn. Lower rear shock bushings replaced. 0.5 0.5
02-13-03 12970 The rear tires are worn. New tires installed on the front axle. Front tires rotated to the inside rear axle and new tires installed on the outside rear axle. 1.0 1.0