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Unscheduled Maintenance

Date Test Miles Service Activity Downtime Hours
06-14-11 16 The bus will not maintain proper ride height. Manufacturer's representatives disabled all four height sensors and set the ride height with shop air until new leveling valves arrive. 10.0 4.0
06-23-11 197 The rear, upper radius rod mounts are broken. Area prep and welded/repaired rear, upper radius rod mounts. 164.0 9.0
06-29-11 377 Three transmission mounting bolts are loose. Manufacturer's representative tightened two bolts and drilled out/replaced one with a through bolt. 48.0 4.0
07-08-11 836 The transmission is leaking transmission fluid. Troubleshooting performed by manufacturer's representatives for transmission fluid leak. Drain fluid being sent for analysis. Transmission topped with fluid. 8.0 8.0
08-29-11 2007 Right side, first battery pack; five stainless steel nutsert spot welds have broken from the battery box. Removed batteries. Rewelded/repaired nutserts. Reinstalled batteries. 16.0 2.0
09-01-11 2167 The rear transmission mount is cracked and the mounting bolt is broken. Removed broken bolt and cracked mount. Replaced new left side bolt and both left and right side mounts. 144.0 4.0
09-07-11 2167 Manufacturer requests the transmission isolators be replaced. Replaced transmission isolators. 16.0 2.0
09-09-11 2219 Manufacturer troubleshooting "loss of throttle" condition. Found damaged and broken wires on the transmission clutch speed sensor. 14.0 1.0
09-09-11 2219 The windshield wipers are inoperative. Wiper motor failed. Found damaged and broken wires on the transmission clutch speed sensor. Replaced transmission clutch speed sensor. 14.0 1.0
09-12-11 2258 Two pins on the Deutsch connector for the DC to DC convertor are damaged. Manufacturer repaired/replaced two pins. 22.0 1.0
09-19-11 3141 The brass air fitting is broken from the top plate of the right front air bag. Replaced brass fitting. 5.0 2.0
09-19-12 3141 The heads of three transmission case bolts are broken off. Manufacturer representative replaced three transmission case bolts. 5.0 2.0
09-20-11 3407 Received the replacement wiper motor that was ordered on 9/9/11. Replaced wiper motor. 2.0 2.0
09-26-11 3644 The electrical system is showing erratic voltage readings. Manufacturer removed the right side battery pack and replaced the battery module. Battery pack reinstalled. 4.0 1.0
09-27-11 3644 The left front transmission cross member bushing has failed. Manufacturer representative replaced the left front transmission cross member bushing. 48.0 3.0
10-05-11 3989 The adhesive failed between the glass and the aluminum frame of the 5th passenger window, left side. Reinstalled window. 1.5 3.0
10-06-11 4135 Manufacturer requests rear transmission single mount be replaced with duel mount. Removed transmission/power train cradle. Removed single mount. Installed duel mount. Reinstalled transmission/power train. 16.0 15.0
10-06-11 4135 The left front tire is worn. Replaced left front tire. 1.0 3.0
10-12-11 4916 The left front tire is flat Replaced left front tire. 1.0 2.0
10-13-11 5064 The windshield wiper motor failed. Manufacturer representative replaced the windshield wiper motor. 1.0 1.0
10-14-11 5071 Manufacturer is finding false fault codes in transmission ECU. Manufacturer representative added a Gateway module to the rear interior fuse panel for the transmission ECU. 1.0 1.0
10-17-11 5071 The bottom right transmission mounting bolt is broken. Manufacturer representative replaced mounting bolt. 2.0 2.0
10-26-11 5824 The front tires continue to wear excessively. Manufacturer representative requests shims to be added to the front suspension. Replaced front shocks. 8.0 8.0
10-28-11 6019 Bus experiencing loss and power and loss of throttle. Replaced failed traction motor resistor. 6.0 2.0
11-01-11 6202 Manufacturer requests new design transmission cradle be installed. Manufacturer representative removed transmission cradle and installed new design cradle. 48.0 6.0
11-02-11 6202 Two body-to-frame mounting brackets are cracked/broken. One right side forward of front axle the other left side behind the front axle. Repaired/welded both body to frame mounts. 2.0 4.0
11-08-11 6669 The safety latch on the 6th passenger window, left side is broken. Replaced 6th passenger window, left side. 2.0 2.0
01-03-12 9284 The transmission is leaking transmission fluid at the input seal. The case bolts are stripped. There is no hydraulic pressure and the speed switch is malfunctioning. Manufacturer representative replaced the transmission. 288.0 18.0
01-12-12 10554 The steering column support is broken at the weld on the right side diagonal support. Installed angle steel to support. 4.0 1.0
01-13-12 10765 The right rear, lower radius rod inboard bolt on the axle is broken. The outboard bolt is stripped and the threads are damaged in the axle. Removed broken bolt. Drilled out outboard hole and tapped to 3/4-10. Installed new bolts. 6.0 6.0
01-24-12 12018 Troubleshooting for intermittent loss of power steering and all electrical power. Manufacturer representative found multiple wires damaged/shorted at the ZR/MUX station at the left front wheel well. Repaired all damaged wires. Manufacturere also installed a fluid temperature sensor in the transmission. 8.0 8.0
02-01-12 12910 The transmission oil pump is inoperative. Located and repaired broken wire in the transmission connector. 2.0 2.0
02-06-12 13604 The left sie forward battery pack is not accepting charge. Manufacturer representative removed battery pack. Found moisture build up on circuit board. Circuit board dried. One battery module replaced due to corrosion. Battery pack installed. 6.0 6.0
02-08-12 13855 Test bus experieinceing intermittent loss of acceleration. Manufacturer representative trouble shooting communication between drive train and acceleration pedal. No diagnosis at this time. 23.0 18.0
02-10-12 13977 The output shaft in the transmission is broken. Removed transmission and seperated drive motor. 4.0 12.0
02-13-12 13977 Replacement transmission arrived. Manufacturer representative installed new drive motor/transmission assembly. 72.0 28.5
02-23-12 15000 Loss of throttle and "Hot Transmission" warning light is on. The electric drive motor failed. Manufacturer replaced the electric drive motor. 24.0 6.0