Champion Bus CHALLENGER. Maintenance Manual

Congratulations on your new Champion Bus, Inc. bus. If this is your first, let me

extend a warm welcome to the Champion Bus family. If you are one of the many

Americans and Canadians for whom Champion Bus ownership has become a tradition,

we believe that your new Champion Bus will surpass your high expectations for a

motor coach. It’s no exaggeration to say that your new Champion Bus represents major

improvements in design and construction since the company began making buses.

Please take a few minutes to acquaint yourself with your new coach. In this manual,

along with the chassis, and other O.E.Ms., you will learn a great deal about your new

vehicle and any options it may have.

If you have additional questions, don’t hesitate to contact your National Bus Sales

Dealer or the Service Department on the following page.

Please count on us to deliver the unparalleled support you should expect as a

Champion Bus, Inc. bus owner.

Sincerely yours,

John Resnik

President, Champion Bus, Inc.

CONTENTS

About this manual…

This Maintenance Manual identifies service related issues for your Champion Bus Challenger.

These issues are the most common general maintence issues.

Information in this manual is listed in sections. These sections include; Chassis, Interior,

Seats, Doors, Windows, and More.

Use the Bookmark Tab to navigate through the manual or you can use the “Find” command

to search for a particular installation or part.

Service Instructions…

All inquiries must include: Customer, the Unit’s Number and Serial Number, Part Number

and description of problem. Address all correspondence to the following addresses of:

Mail:

Champion Bus, Inc.

331 Graham Road

Imlay city MI 48444

Phone:

800-776-1943 ext. 562

Fax:

810-724-6478

Note:

**This manual covers general maintence on the modified portion of the bus. The

chassis section is generic and specific service inquiries are to be directed to the original

manufacturer of the chassis.

**Specifications, descriptions and illustrations in this manual is as accurate as known at the time of publication.**

SECTION 1

General Information

General Coach America, Inc.

Serial Number

The GCA Serial Number is different from the Vehicle

Identification Number (VIN). The GCA Serial Number

is located on a plate in the engine compartment. It is

used by the manufacturer to identify the bus and it’s

options. When contacting the dealer for service or for

a warranty claim, be sure to provide the serial number

for identification. Refer to Fig. 2 for an example of a

serial number.

Fig. 1-1 Serial Number Plate

CAB AREA

The driver operates the bus from the cab area. To con-

trol the many electrical systems, wiring harnesses are

routed from the power distribution center (as shown in

Fig. 3), behind the cab’s interior trim panels to other

areas throughout the bus.

Fig. 1-2 Example of GCA Serial Number

WIRING HARNESS ARE LOCATED

BEHIND THE CAB’S INTERIOR TRIM

PANELS…NEVER PUNCTURE OR

ATTACH TO TRIM PANELS WITHOUT

FIRST CONSULTING YOUR DEALER.

SEVERE DAMAGE TO THE BUS’S

ELECTRICAL SYSTEM MAY RESULT.

Fig. 1-3 Power Distribution Center

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Champion Bus, Inc. Maintenance

SECTION 1

General Information

VEHICLE’S DASH PANEL

Details on Vehicle Dashboard instrumentation, steer-

ing, or other chassis controls are covered in the Ford

Owner’s manual included with your bus. Please read

the manual to become familiar with the Vehicle’s

Dashboad before operating the bus.

Fig. 1-4 Dash Panel

CONTROL CONSOLE

The Control Console (Fig. 5) allows the driver to

control some of the electrical components of the bus.

It also houses warning lights and buzzers that lets

the driver know if something is ajar, etc. The Control

Console is mounted to the dash board, within easy

reach and clear view of the driver. Controls and dis-

plays vary, depending on how the bus is equipped, but

all controls and switches are clearly labelled for easy

reference.

Fig. 1-5 Dash Mounted Control Console

CAB AREA HEATING & COOLING

Cab Area Heating and Cooling Controls are located

on the dashboard, within easy reach of the driver. Op-

erational and maintenance information on particular

system can be found in the chassis owner’s manual.

Fig. 1-6 Cab Heating & Cooling Controls

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Champion Bus, Inc. Maintenance

SECTION 1

General Information

POWER DISTRIBUTION CENTER

The Power Distribution Center (Fuse Panel) provides

power to different electrical systems within the bus.

They are located throughout the bus. These places

are: Within the Dash, inside the Underfloor Luggage,

Battery Box and the “Pro Heat Compartment”.

Fig. 1-7 Power Distribution Center

ELECTRICAL POWER IS

ALWAYS “LIVE” IN THE POWER

DISTRIBUTION CENTER. USE

CAUTION WHEN PERFORMING

REPAIRS OR WHEN THE ACCESS

DOOR IS “OPEN”. NEVER

OPERATE THE BUS WITH THE

ACCESS DOOR “OPEN”, A SHORT

CIRCUIT TO THE ELECTRICAL

SYSTEM COULD OCCUR

IN CASE OF AN EMERGENCY

Hazard Warning Lights

Activate the Hazard Warning Lights. Refer to the GCA/ABC Operator’s Manual for instructions.

DO NOT tow unbraked vehicles of the combined weight of both vehicles

is more than the sum of the gross axle weight ratings (GAWRs) of the

towing vehicle. Otherwise brake capacity of the towing vehicle will be

conpromised, which could result in personal injury or death.

Towing

When it is necessary to tow the vehicle, make sure the following instructions are used to prevent

damage to the vehicle. Front Tow Hookup

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SECTION 1

General Information

FRONT TOW HOOKUP

1. Disconnect battery ground cable.

2. If vehicle is to be lifted and towed, remove drive axle shaft.

Failure to remove the drive axle shaft when towing the vehicle with the

rear wheels on the ground could result in damage to the transmission

and other components.

3. Attach to towing device. Due to the many variables that exist in towing, positioning the lifting and towing

devices is the sole responsibility of the towing-vehicle operator, who must be familiar with the towing

industry safety standards.

4. Lift the bus and secure the safety towing chains. If additional clearance is needed, remove the front wheels.

Before releasing the parking brake, make sure the connection to the

towing vehicle is secured, or chock the disabled vehicle’s tires. Failure

to do so could result in hazardous conditions because the vehicle could

suddenly roll and injury could occur.

5. Connect clearance, tail, and signal lights to the towing vehicle’s wire harness. Connect any special towing

lights required by local regulations.

6. Release the parking brake.

Rear Towing Hookup

1. Place the front tires straight facing forward and secure the steering wheel into this position.

2. Disconnect the battery ground cable.

3. Attach to towing device. Due to the many variables that exist in towing, positioning the lifting and towing

devices is the sole responsibility of the towing-vehicle operator, who must be familiar with the towing

industry safety standards.

4. Lift the vehicle and secure the safety towing chains, if additional clearance is needed, remove the

bumper extension, if equipped.

5. Connect clearance, tail, and signal lights to the towing vehicle’s wire harness. Connect any special

towing lights required by local regulations.

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Champion Bus, Inc. Maintenance

SECTION 1

General Information

Vehicle batteries produce hydrogen gas and can create sparks, possibly

leading to anexplosion. DO NOT allow the vehicles to touch each other and

keep sparks, flames, cigarettes, etc. away from the batteries. DO NOT lean

over the batteries when making connections and keep all other persons

away from the batteries, otherwise severe personal injury could result from

explosion and or acid burns.

Make sure both starting systems have the same voltage outputs and avoid

making sparks. Otherwise the vehicle charging systems could be severely

damaged. Also DO NOT attempt to charge isolated, deep-cycled batteries with

jumper cables; follow the manufacturer’s `instructions when charging deep

cycle batteries.

Emergency Starting with Jumper Cables

When using jumper cables, use the following instructions:

1. Apply vehicle’s parking brake and turn “OFF” any exterior or

interior lights that may be “ON” and any other electrical loads.

2. Connect the (+) positive cable end of the booster battery to

the (+) positive terminal of the discharged battery.

3. Connect the (-) negative cable end of the booster battery to

the (-) negative terminal end (ground) at least 12 inches (300mm)

away from the discharged batteries. The vehicle frame usually

provides a good ground. DO NOT connect the cable to or near

the discharged batteries.

4. Start engine from the booster batteries and let engine run a

few minutes to charge the discharged batteries.

Fig. 1-8 Battery Cable Connection

5. Shut “OFF” the engine, then attempt to start engine . DO NOT

operate the starter longer than 30 seconds and wait at least two (2)

minutes between starting attempts to allow the starter to cool.

6. When the engine starts. Let it idle a few minutes.

Perform the next tasks exactly as instructed and DO NOT allow the

clamp of one cable to touch the clamp of the other cable, otherwise a

spark could occur near a battery, possibly resulting in severe personal

injury from explosion and acid burns.

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Champion Bus, Inc. Maintenance

SECTION 1

General Information

Emergency Starting with Jumper Cables (cont)

7. Disconnect ground (-) negative jumper cable from frame or other non-battery location, then disconnect

other end of (-) negative cable from booster battery.

8. Disconnect (+) positive jumper cable end from vehicle’s newly charged battery first; then disconnect other

cable end from booster battery.

Reflective Triangle Warning Kit

BEFORE LEAVING DISABLED

VEHICLE ALWAYS ACTIVATE THE

VEHICLE’S EMERGENCY FLASHERS

Divided Highway

Emergency Reflective Triangle

Warning Kit

On a straight highway Two (2) Lane:

1. On side of road, place one (1) Reflective Triangle

100 ft. in front of disabled vehicle (approx. 40 paces).

2. Then place another Reflective Triangle 100 ft.

from rear of disabled vehicle (approx. 40 paces).

On a divided highway:

Two-Lane Highway

1. Place two (2) Reflective Triangles on side of road

one at 100 ft. and the other at 200 ft. from rear of

disabled vehicle. (approx. 40 paces & 80 paces)

To assemble Triangle:

1. Raise two (2) arms of triangle and snap pin into

slot.

2. Turn base 90° to it’s “Stop” position.

Fig. 1-10 Emergency Reflective Triangle

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Champion Bus, Inc. Maintenance

SECTION 1

General Information

Running Out Of Fuel

Fuel is highly flammable. Whenever you approach a vehicle and a smell

of fuel is present, immediately shut off all engine and ignition sources.

Avoid causing sparks and stay away from arcing switches and equip-

ment. Extinguish any cigarettes, pilot lights, flames, or other

sources of ignition in the area. Immediately provide extra ventilation to

the area. DO NOT start the equipment or any other type of equipment

until the fuel leak is corrected and the area cleared of leaked fuel. Fail-

ure to perform these actions could lead to ignition of the fuel, which

could cause severe bodily harm and property damage and death.

If your vehicle runs out of fuel, stop the vehicle on a level surface away from traffic. The engine may be

restarted by adding at least two (2) gallons (8 liters) of fuel to the fuel tank. If the vehicle is not level, up to

six (6) gallons (22 liters) of fuel may be required. Prolonged engine cranking may be required to pump fuel

from the fuel tank to the engine before the engine will start. Diesel engines have “priming” pumps. See

your OEM Chassis Manual for this operation.

IMPORTANT

DO NOT crank the engine for more than 30 seconds at a time. Wait (2) two minutes after each try

to allow the starter time to cool. Failure to do so could result in starter damage.

If your vehicle will not start by cranking the engine, the fuel system may need to be primed. Contact your

service center for fuel system priming information.

Emergency Escape Exits

Roof Escape Hatch

To open the roof top emergency escape hatch from the

inside of the vehicle, follow the steps listed below:

1. Turn the handle clockwise to the “OPEN”

position.

2. Push up on the hatch to open.

To close the hatch, pull down on the hatch on turn the

handle to the “Latch” position to secure.

Note:

The roof escape hatch can also be used for ventilation, sim-

ply push up at the sides of the escape hatch and it will pop

Fig. 1-9 Escape Hatch

up for ventilation. Pull down and it will snap shut to close.

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Champion Bus, Inc. Maintenance

SECTION 2

Chassis

GENERAL INFORMATION

Champion Bus, Inc. buses are built on a variety of

chassis. This Model Bus is built on Ford E-350 or

E-450 model chassis.

For more specific chassis information, all persons

responsible for the operation and maintenance of the

vehicle should read and understand the guidelines

presented in the OEM Chassis Owner’s/Maintenance

Manuals that are included with your vehicle. All

questions regarding chassis operation or maintenance

should be directed to your bus dealer or a local chassis dealer.

LUBRICATION

The chassis manufacturer’s recommendations should be followed regarding chassis and engine lubrication

schedules and specifications. Note that special requirements may exist for severe driving conditions such

as heat, cold, dust, mud, or sustained high power output.

FILTERS

Filters should be changed on a regular basis, according to the manufacture’s specifications, using only

approved filters. Note that frequently driven buses may require more frequent filter changes to maintain

proper operating systems.

FUELS

Use only high quality low sulfur diesel fuel that meets or exceeds the minimum specifications of the engine

manufacturer. Failure to do so may result in damage to engine components.

FUELING THE VEHICLE

Use only fuels that meet or exceed the engine manufacturer’s specifications. Fuel should be free of water and

other contaminants. Avoid running the fuel tank near “Empty” as this can lead to condensation and fuel system

problems.

• Clean the exterior of the fuel cap and filler spouts before removing cap.

• Remove the fuel cap, place the fuel nozzle in the filler spout and proceed with fueling the vehicle.

• When full, remove fuel nozzle, replace fuel cap, and turn to tighten. Remove any spilled fuel from bus body

** Do NOT “top off” fuel tank.**

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Champion Bus, Inc. Maintenance

SECTION 2

Chassis

USE OF UNAUTHORIZED LUBRICANTS, FILTERS, FLUIDS, FUELS OR PARTS AND/OR

NEGLECT OF SCHEDULED MAINTENANCE MAY VOID THE WARRANTIES FOR YOUR

VEHICLE.

WHEELS & TIRES

Your bus is equipped with high-quality tires that meet the vehicle usage specifications. Tires are warranted by

the tire manufacturer as described in the documents provided with your vehicle.

• Inspect tires daily for evidence of damage such as cuts, scuffs, cracked sidewalls or any signs of rubber

separating from the tire. Also, inspect for abnormal wear and report any problems immediately.

• Check tire inflation pressure at least once per week while the tire is cold. If necessary, adjust the tire

pressure by adding or removing air until the designated pressure range for the tire is achieved. Always use

an accurate tire pressure gauge.

• Never attempt to check or adjust tire pressure while the tire is hot. Tire pressure increases with higher

temperature and subsequent readings will be faulty. Under-inflation may result from hot tire pressure check.

• Note that low tire pressure reduces the load carrying capacity and may lead to the overheating of tires and/

or potential tire failure. Similarly, excessive tire pressure affect vehicle handling and increases the risk of

tire failure.

• Tires should be rotated on a regular basis using a recommended rotation pattern. Rotating tires should result

in more uniform tread wear and may lengthen tire life. However, do not put a worn tire and a high-tread tire

on the same axle. Keep tire treads matched as closely as possible.

• If abnormal wear occurs, have the steering and wheel alignment checked by qualified service technicians.

Tire rotation will only temporarily disguise the problem if steering or alignment if off.

• With dual wheels, the outside tire will wear faster than the inner tire. To equalize wear, reverse the tire

positions on a regular mileage schedule. If one dual wheel must be replaced, always replace both duals to

keep wear equalized.

• Keep Lug Nuts tight. Loose lug nuts will quickly ruin a wheel and can result in loss of the wheel, thus

creating a dangerous situation for driver and passengers. If you suspect a loose wheel, pull off the road and

inspect the lug nuts immediately.

• Inspect lug nut at every chassis lubrication and inspection. If your bus is fitted with wheel covers, remove

them prior to inspection. Lug nuts should always be installed clean and dry. Never lubricate lug nuts. Hubs

should be clean dry, and free of rust and excess paint. Firm metal-to-metal contact is necessary to ensure

that wheels remain securely fastened.

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Champion Bus, Inc. Maintenance

SECTION 2

Chassis

WHEELS & TIRES (cont.)

• On new dual wheels, re-torque lug nuts at 100 miles and again at 500 miles.

• Replacement tires should equal or exceed load specifications of the original equipment. Do not mix tire

sizes and do not mix bias ply and radial tire construction. Dangerous vehicle handling conditions may

result.

• Wheels should be replaced if bent, badly rusted, or if loose lug nuts have caused excessive wear in the hub

area. Use only replacement wheels approved by the chassis manufacturer. Make sure the new wheels match

the original wheel size and load carrying capacity and that they are designed for the same size and type of

tires needed on your vehicle.

Tire Rotation

If tires are wearing irregularly, rotate them. If the front steering axle tires become irregularly worn, move them

to the drive axle. Have the front axle alignment checked to determine the cause of irregular tire wear. In a dual

assembly, if one tire wears faster than it’s mate, reverse the positions of the two tires.

For more information on tire specifications, refer to the Recreational Vehicle Tire and Care Guide provided with

your chassis manuals. OEM Manuals override all information provided by ABC and General Coach.

If a flat tire occurs while driving, gradually decrease vehicle speed.

Holding the steering wheel firmly, move to a safe place on the side of

the road.

Changing a Flat Tire (Refer to your OEM Chassis Manual for Jacking)

1. If possible, stop the vehicle on a level surface, away from traffic.

2. Apply the parking brake and turn “OFF” the ignition.

3. Turn “ON” the emergency flashers.

4. Remove spare tire, jack, handle, and lug wrench from storage, if equipped.

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Champion Bus, Inc. Maintenance

SECTION 2

Chassis

5. Block the diagonally opposite the wheel being changed.

Note:

The jacking point for the front and rear wheels is directly under the axle.

6. Place the jack on a solid surface. Insert the jack handle and pump the handle to slightly raise the

vehicle. DO NOT RAISE THE WHEEL OFF THE GROUND. Loosen the wheel lug nuts, but do not

remove them.

Note:

The dual rear wheels are attached using two-element lug nuts. The larger nut retains the outer dual. The

inner square stud retains the inner dual. Remove and install these nuts separately. The rear dual outer lug

nut must be loosened to check and retighten the inner nut.

7. Raise the vehicle until the wheel is off the ground. Remove the lug nuts and the wheel.

8. Install the spare wheel and lug nuts. Make sure the beveled sides of the nuts face inward.

9. In a “star” pattern, tighten the nuts evenly until snug.

10. Lower the vehicle until the wheel touches the ground. Tighten the lug nuts in the same pattern

126 to 170 ft/lbs. (170 to 230 N·m)

Failure to tighten the wheel nuts in a star pattern can result in

high brake disc runout, which will speed up the development brake

roughness, shudder and vibration.

11. Finish lowering the vehicle to the ground, then remove the jack.

12. Remove the block from the opposite tire of the repaired tire, then stow the jack, handle and lug wrench.

13. After operating the vehicle for 50 to 100 miles (80 to 160 km), retighten the nuts to 126 to 170 ft/lbs.

(170 to 230 N·m)

JACKING LOCATIONS

Lift vehicle at locations painted Yellow at either the front axle or rear axle. At Front Axle the Yellow painted

areas are located near the wheel assemblies. The Rear Axle Yellow painted locations are near the rear wheel

assemblies.

Raise the vehicle with an automotive type jack at the points painted “Yellow” by the manufacturer. Use these

lifting points to avoid any vehicle damage, serious injury, when components are being removed from the

vehicle.

Refer to your OEM Chassis Maintenance Manual provided with your bus for more information.

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Champion Bus, Inc. Maintenance

SECTION 3

Flooring & Interior

FLOORING

General Coach America, Inc. buses are constructed of ¾” exterior grade plywood, supported by steel cross-

members. This construction provides a lightweight, durable floor that insulates passengers from road noise and

the elements.

RUBBER FLOOR COVERING

The standard floor covering is transit-type and/or smooth rubber matting. Rubber flooring is durable and easy

to clean. With proper care, rubber flooring covering should last the life of the bus.

• Clean rubber flooring with a damp mop. A soap/water solution will clean most spills and stains. Tough

stains may require gentle scraping or use of a scrub brush.

• DO NOT clean bus floors by spraying water from a hose. Water may leak under the flooring seal and

cause floors to deteriorate.

• DO NOT use petroleum-based solvents on rubber flooring. They may present a fire hazard and will

damage the floor rubber.

INTERIOR WALLS & CEILING

• Interior Walls and Ceiling Panels should be cleaned every week with a mild soap/water solution. Foam type

cleaners and many plastic and vinyl cleaners also work well to remove any marks or stains from walls or

ceiling.

• Always follow the directions on cleaner labels and dry-off damp surfaces as soon as possible to

remove excess liquid.

Fig. 5.1 - Interior Walls & Ceiling

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SECTION 3

Flooring & Interior

MODESTY PANELS

Modesty Panels are provided for passengers’

privacy and protection. The standard modesty panels

are attached to the stanchions at the front of the

passenger area and are covered with material that

coordinates with the bus’s interior sidewall color and/

or Feature Panel pattern.

• Modesty Panels should be cleaned on a weekly basis

with a mild soap/water solution. Many plastic and vinyl

cleaners will work as well.

• Inspect Modesty Panels daily for secure attachment.

Screws at attachment points may work themselves

loose causing the panel to shake and/or fail. Loose

Fig. 5.2 Modesty Panels

screws should be tightened, as needed, to assure

safety.

INTERIOR TRIM

The driver operates the bus from the cab area.

To control its many systems, wire harnesses route from

the cab area to other areas throughout the bus. The

interior trim panels help to finish off the interior of the

cab but also cover and protect the wiring harnesses.

• Interior trim panels should be cleaned every week or

when needed. Interior Trim Panels may be cleaned

with a soap/water solution or a vinyl cleaner (follow

manufacturer’s directions).

• Avoid soaking Interior Trim Panels with

cleaning solutions as deterioration may result.

Fig. 5.3 - Interior Trim

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Champion Bus, Inc. Maintenance

SECTION 3

Flooring & Interior

WIRE HARNESS ROUTING

The busses Wire Harnesses are routed behind

the Interior Sidewalls, Ceiling and the flooring as

indicated in the photos, Most wiring can be accessed

by removing the trim panels. Your local dealer can

recommend the best removal procedures.

Because the gap between the interior trim panels and

wiring harnesses is minimal, DO NOT puncture the

panels or secure anything to the trim panels as the

electrical system may be easily damaged and severe

problems may result.

Some wiring harnesses and A/C lines run down along

the back corners of the bus. Interior Trim Panels can

Fig. 5.4 - Typical Ceiling Wiring

be removed to access the wiring and A/C lines, if

necessary.

Kick panels run along the floor to cover some wiring

and other wiring harnesses are routed behind the

ceiling panels. Wiring for speakers, interior lights and

other systems are routed inside the overhead parcel

racks.

BECAUSE WIRING HARNESS ARE

LOCATED BEHIND THE CAB AREA

INTERIOR TRIM PANELS AVOID

PUNCTURING THE TRIM PANELS OR

SECURING ANYTHING TO THE PANELS

WITHOUT FIRST CALLING YOUR DEALER

FOR ASSISTANCE. SEVERE DAMAGE TO

THE BUSES SYSTEMS MAY RESULT.

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Champion Bus, Inc. Maintenance

SECTION 4

Seats

GENERAL INFORMATION

General Coach America, Inc. offers a wide variety of high-quality standard and custom seating options. How-

ever, because of the number of seating alternatives, “standard” seating features are defined by the bus owner.

Regardless of seating styles, all seating meets or exceeds federally established safety standards. Seat frames

meet FMVSS #207 for crash protection and all seat coverings meet FMVSS #302 for burn resistance.

Seat coverings are available in either vinyl, fabric or vinyl/fabric combinations and numerous colors and de-

signs. Seat cushions are made of dense, non-allergenic, air-blown urethane foam and offer a comfortable ride.

General information regarding seating options and maintenance is included in this section. Specific option

details also follow in this section, as provided by the seat manufacturer.

DRIVER’S SEATING

Many driver’s and co-pilot’s seating options are available with General Coach America, Inc. buses. Driver’s

seats may have a manual slide base or a two-way or six-way electric adjustable base and a fixed or swivel

base. A reclining bucket seat can also be chosen as another option.

Details regarding your particular driver’s seat, is provided by the seat manufacturer, by visiting their website.

Please refer to this information for operational and maintenance instructions.

PASSENGER SEATING

Passenger seating is available in bench, bucket, reclining bucket, folding, and perimeter styles. While most

passenger seating is modular in design and can be removed for repair, replacement, or reconfiguration of the

passenger seating area, seats are fastened securely in place for the safety and comfort of all passengers.

Details regarding passenger seating options for your bus follow this section. Please refer to this

information, provide by the seat manufacturer, for operation and maintenance instructions.

Figure 4.1 Seating Floor Plan

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SECTION 4

Seats

MAINTENANCE

• Inspect the seating area daily for tears, rips, or stains. Check seats for secure attachments. Tighten

any loose bolts to assure safety and prevent rattling.

• Vinyl seats should be wiped down one to two times per month with a soap and water solution of other

mild cleaning agent recommended for vinyl. Use of stronger solvents on vinyl seats is not

recommended as they reduce the strength of the vinyl and cause premature cracking.

• Vacuum fabric-covered seats one to two times per month to remove loose surface dirt as well as dirt

that has settled to the bottom of the fabric pile. A commercial grade or heavy duty vacuum is

recommended. Spot clean stains (as soon as possible) with a soap and water solution or mild cleaning

agent recommended for fabric.

• Steam-clean fabric cover seats every six months to restore the fabric pile and to remove stains and

odors. Spot clean stains, if necessary, before steam-cleaning.

Passenger Seating & Safety Requirements

Champion Bus, Inc. offers a wide variety of custom seating options. Regardless of your seating configuration,

seating meets or exceeds federally established Safety Standards. Weight Distribution and Payload Certifica-

tion. This vehicle, as manufactured, conforms to the weight distribution and payload requirements in Mid-Size

Bus Manufacturers Association (MSBMA) recommended practice 001.

It is the user’s responsibility not to load the vehicle above the number of designated seating positions and

luggage allowance.

Configuration A:

Manufacturer: General Coach America, Inc. Imlay City, Michigan

VIN/Body Serial #: _____________________________________

Number of designated seating positions: 40*

Number of designated Wheelchair positions: 0

Note: Number of designated seating positions is calculated using 150 lb. (68 KG) per designated seating

position, 20lb. (91KG) for wheelchair position, including driver. Luggage allowance is calculated using 5 lb.

(11.3KG) of luggage per designated seating position if vehicle is equipped with luggage compartment and 5 lb.

(2.3KG) if vehicle is equipped with an overhead shelf.

All seating exceeds all FMVSS standards. For identification of seating manufacturer, please see the manufac-

turer label located underneath each seat assembly.

*Number of Seating Positions May Vary depending on specific model of bus. Number is derived from Maxi-

mum amount of passengers Plus Driver.

SAFETY RESTRAINTS

FMVSS Compliance #209 specifies seat belt assembly characteristics in regards to adjustability, width,

colorfastness, breaking strength, elongation and resistance to abrasion, light and microorganisms.

Performance requirements to include ability of the complete assembly to withstand prescribed forces and to re-

sist excessive stretching. OEM meets these requirements. General Coach America, Inc. does not change OEM

seat belt assemblies, OEM seat belts are attached according to OEM specifications. Passenger seat belts have

met the testing requirements of FMVSS #207.

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SECTION 4

Seats

WHEELCHAIR TIEDOWNS

Install wheelchair restraints in accordance with OEM manufacturer’s Driver/Operator Instruction Guide

included with the vehicle.

Holdsworth Fabric Care

Holdsworth have established the following care and maintenance instructions for fabrics.

Considerable thought and development work has gone into the production of our fabrics to enable them to

withstand the rigorous use on public transport vehicles. We felt therefore, a few hints on the care and cleaning

would help you to obtain the best possible life from your fabric.

One of the main advantages of these fabrics is their construction which allows dirt to fall to the base of the pile.

This presents a relatively clean surface to your passenger which is obviously very important.

Routine Cleaning.

All that is required to remove the dirt is gentle beating with the hand or the back of a brush. This will bring the

dirt to the surface where it is easily removed by a vacuum cleaner or a soft brush. It is preferable to vacuum or

brush in the direction of the pile which can easily be recognized by running a hand lightly over the pile. Clean-

ing should be carried out as often as possible. If the fabric becomes excessively dirty, then particles of grit will

cause gradual wear to take place, thus reducing the life of the moquette.

Steam Cleaning.

Occasional steam cleaning will breathe new life into tired upholstery. Portable steam cleaners are readily avail-

able from hire shops to rent or buy, and we have many examples showing how a vacuum and steam clean

can rejuvenate a drab interior. (The need to follow safe operating procedures when steam cleaning is vital to

prevent risk of scalding.)

FABRIC MAINTENANCE

With proper care your upholstery will provide years of beautiful service. To help keep your upholstery looking

new, certain precautions and cleaning instructions should be followed. By giving your upholstery a little extra

attention, it will stay looking great for years!

According to the Environmental Protection Agency your upholstery serves as a magnet that collects a variety of

pollutants and contaminants from various sources. Internal sources include air conditioners, heaters, tobacco

smoke and food particles. Outdoor sources include pollen and spores from trees, plants and other vegetation

as well as exhaust fumes from cars, fireplaces and other form of pollution.

Satisfactory results are usually achieved by cleaning with a non-water-based foam cleaner, provided that

manufacturer’s directions are carefully adhered to. Any product or technique should always be tested on an

inconspicuous area before attempting overall cleaning.

CLEANING OF UPHOLSTERY

The seat cushion and back covering may be fabricated of different materials, consisting of both synthetic and

natural fabrics. Vinyl coated fabrics cannot be machine washed (laundered).

For cleaning of the seat upholstery in view of the above limitations, the following procedure is suggested:

Revised: October 2007

Page 26

Champion Bus, Inc. Maintenance

SECTION 4

Seats

Woven Fabrics

•

Frequent and thorough vacuum cleaning.

•

Occasional steam cleaning.

•

To the cover (not removed) apply a thick layer of soap (non-alkaline) or approved foam type

cleaner. Suds are to be scrubbed into fabric using a stiff bristle brush or a sponge.

•

After scrubbing sponge the suds from the fabric with a clean sponge or cloth dampened with

water. Rinse sponge or cloth frequently with clean water.

•

Do not water soak fabric, as this will cause shrinkage.

Method 1

Apply a non-inflammable solvent (trichlorethylene) with a clean, white, absorbent material, treating small areas

working from the outer edge towards the center of the stain. Blot frequently with a dry cloth to avoid rings.

*OPEN WINDOWS AND DOORS TO ALLOW FUMES TO DISPERSE.*

Method 2

Sponge the stain with a solution of household detergent and lukewarm water. DO NOT SOAK. Follow this by

rubbing with a damp cloth, rinsing cloth between each treatment.

Warning:

DO NOT USE SOAP, WASHING POWDER, AMMONIA, SODA,

BLEACH OR ANY PRODUCTS WHICH CONTAIN THEM.

Alcoholic Liquids

Sponge with water followed by Method 2

Battery Acid

Saturate with a solution of sodium bicarbonate, leave for several minutes before drying out. It is important for

the above treatment to be carried out immediately to avoid serious damage to the moquette.

Beverage Stains

Use Method 1. If stain persists, try methylated spirits.

Blood Stains

Use Method 2

Burns

Scrape blackened area with a knife and treat with Method 2. Extensive burns require expert attention.

Chewing Gum

Soften with cyclohexanone and scrape off carefully with a knife.

Cosmetics

Use Method 1, followed by Method 2.

Writing Ink

Use Method 2. If brown stain remains, treat as for rust.

Revised: October 2007

Page 27

Champion Bus, Inc. Maintenance

SECTION 4

Seats

Copying Ink

Treat with methylated spirits, blotting frequently to avoid ink spreading. Use cleaning Method 2 to complete the

treatment.

Ballpen Ink

Treat as copying ink.

Marking Ink (Felt-tipped pens)

Treat with Methyl Ethyl Ketone (M.E.K.), followed by Method 2.

Oil, Grease and Paint Marks

Remove surplus substance with a knife or spoon, then treat with Method 1, followed by Method 2. Should

stains reappear, repeat cleaning process.

Rust

Use Method 2, followed by a warm solution of oxalic acid. Complete treatment by sponging with water.

Tar

Soften with benzene and then treat with Method 1, followed by Method 2.

Urine

Use Method 2.

Vomit

Use Method 2.

NOTE: Prompt and correct cleaning will remove most stains. Wrong treatment will only increase the damage.

In cases where there is doubt, always seek expert advice. Information is to the best of our knowledge true and

accurate, but all recommendations or suggestions are made without guarantee since the conditions of use are

beyond our control.

We suggest that no matter the type or size of the stain, the cleaning process should go step

by step, You should start using the easy & simple to the complex solvents. In all cases, we

suggest to clean and brush in the pile direction.

Trim Maintenance

Cleaning of trim parts - Aisle End Panel & Rear Shell

Minor stains may be removed from trim parts with a good quality toilet soap. More severe cleaning problems

require the use of diverse cleaning agents and polishes. Most household cleaners, automotive waxes, and

polishes can be adapted to this job. Solvents and spray type household cleaners containing hydrocarbons, will

attack A.B.S. materials and should be used sparingly, if at all.

A cleaning solution should be applied sparingly with a clean, relatively dry cloth and wiped over the material

gently. It is recommended that the cleaning be accomplished by repeated applications of the cleaner rather

than one heavy application. All normal soaps and detergents may be considered safe for removing dirt and

grease from A.B.S. materials.

CAUTION:

Never soak panels in cleaning solution or allow them to remain

wet with solution for any length of time.

Do not use waxes which dry with a bloom as they are extremely

difficult to remove after application

Revised: October 2007

Page 28

Champion Bus, Inc. Maintenance

SECTION 4

Seats

The following material was supplied by

RECARO North America…

PREVENTATIVE MAINTENANCE SCHEDULE

ERGO METRO DRIVER’S SEAT

This maintenance schedule is instended to serve as a guide for inspection and service.

This schedule is not a complete list of all-possible inspections or services required. Action should be taken immediately

whenever a problem with the seat occurs.

The instervals of inspection or service that have been established should be considered maximum intervals, and shorter

intervals may be necessary depending on the enviroment or particular situation in which the vehicle is operated.

The M3035 is not equipped with a Recaro brand seat. However, the following information has value.

MILE S

6,00

12,000

24,00

48,000

ITE M

TYPE OF INSPECTION OR SERVICE

KM S

11,000

22,000

43,00

76,000

HOUR S

1200

2400

4800

9600

Section

Seat Belt Assembly

Check Anti-Cinch on Retractor

Check for Wear on Belt

Check for Proper Locking of Seat Belt Latch

Check Torque of Mounting Nuts

(37 FT-lbs)

Section

Tracks

Manually Check Fore and Aft Travel of Tracks

Visually Check for Dirty or Non-Lubricated Tracks

Lubricate with Grease

(Premium Moly-Lith Grease)

Check Bolts for Correct Torque

(16 FT-lbs.)

Check Tracks

Check Auto Actuator Switch

Section

Control Panel

Check for Dirt in Air Switches

Check Tightness of Control Panel Attachment Screw s

Check Air Lines into Panel for Wear or Cracks

Revised: October 2007

Page 30

Champion Bus, Inc. Maintenance

SECTION 4

Seats

MILE S

6,000

12,000

24,000

48,000

ITE M

TYPE OF INSPECTION OR SER VICE

KMS

11,000

22,000

43,000

76,000

HOUR S

1200

2400

4800

9600

Section

Suspension

Check “UP” and “DOWN” Travel of Suspension

Check Airlines

Check

Check Rake Adjustment

Check Bellows

Check Air Springs

Inspect Shocks

Check Shock Mounts

Check all Bushings

Lubricate All Bushings

Section

Seat Back

Check Lumbar Bags

Check Torque of Mounting Bolts on Each Side

(37

FT-lbs.)

Check Proper Function of Recline

Section

Covers & Foam

Check Covers

Check Foam

Section

Headrest

Check Fore & Aft Tilt

Check “UP” & “DOWN” Travel

Check

Revised: October 2007

Page 31

Champion Bus, Inc. Maintenance

SECTION 5

Exterior

EXTERIOR BODY PANELS

Exterior Body Panels (Roadside, Curbside, and Roof) are made up of a painted steel material and are

attached to the body frame structure with a ManusBond Adhesive.

The inside of the Exterior Body Panels (Roadside, Curbside, and Roof) are sprayed with an expandable foam

material to form a sound deadening barrier and provide some strength. Once the foam has cured luan

substrates are installed over the inner walls of the frame structure.

ManusBond is used to seal the exterior seams between body panels and to seal exterior skirt and fender

flare seams.

FRONT FIBERGLASS CAPS

The Front Cap and the Rear Corners are made up of fiberglass. A gel coating over the outer layer of the

fiberglass gives the exterior a smooth, glossy surface that is corrosion resistant. With regular cleaning, these

fiberglass panels should retain their bright appearance for years.

ManusBond or equivalent is also used to seal the seams between the fiberglass caps and the metal exterior body

panels (Sidewalls & Roof). Repairs to windows that have been removed from the bus body can be resealed on

the exterior by reapplying a bead of Sikaflex® or equivalent to the seam. This material forms a flexible, water-

resistant barrier to eliminate leakage between seams.

CLEANING THE EXTERIOR

• Wash the exterior body panels, windows, doors, and wheels on a regular basis with warm, soapy water

and a soft cloth or sponge. A power-wash wand may also be used to clean the exterior. Avoid using brushes

as they collect dirt that may scratch exterior surfaces. Any standard body wax may also be used to achieve

a high gloss finish.

• Heavy film or smudges on the gel coated front or rear fiberglass caps may be removed using a light liquid

abrasive. Avoid harsh abrasives that will dull the gel coat finish.

• Wash the undercarriage of the bus often by spraying with warm soapy water. Dirt accelerates the corrosion

of frame, suspension, and exhaust components, as well as brake and fuel lines and fasteners. If salt is used

to melt snow and ice during winter months, it is especially important to wash the undercarriage frequently

and thoroughly.

• If your bus is equipped with a skirt-mounted condenser, inspect for road-dirt buildup on the condenser fins.

Leaves and debris that reduce cooling efficiency can usually be removed with jet of water or high-pressure

air. Before cleaning, ensure that the engine is “OFF” and the NO electrical power is being supplied to the

condenser unit.

• Check that window and door water drain holes are clean and clear of debris so that water entering the

window and door tracks drain properly. A thin, pointed object can be placed gently into the drain holes to

dislodge any objects blocking proper drainage.

• Windows should be cleaned daily to assure visibility. Exterior door glass and window surfaces should be

cleaned using a household ammonia solution or other glass cleaner and a soft, nonabrasive cloth, sponge,

or chamois to remove dirt or film.

Revised: October 2007

Page 34

Champion Bus, Inc. Maintenance

SECTION 5

Exterior

MINOR FIBERGLASS DAMAGE REPAIR

1. Remove loose dirt and broken fragments from the damaged area. Use a grinder or power sander with medium

grade sandpaper to prep area for body filler.

2. Apply filler as directed by the manufacturer’s recommendations, smoothing it out as you fill.

3. After filler has hardened, power sand area with a fine grade sandpaper and repaint or gel coat.

MAJOR FIBERGLASS REPAIR

It is recommended that repair of wide cracks or areas where the fiberglass has separated from the frame struc-

ture be completed by an GCA dealer or authorized body shop. Complete front and rear caps are available for

purchase through your local GCA dealer.

REPAIR OF STRESS CRACKS

Thin stress cracks (“spider webs”), caused by minor impacts, may only require repair of the gel coat without

repair to the fiberglass substrate.

Repair by rough sanding and cleaning the damaged area, then reapplying the gel coat. Allow gel coat to cure,

then finish sand until area is smooth to the touch. Buff to a gloss finish.

REFINISHING THE REPAIRED AREA

When repairs are complete, it is necessary to refinish the repaired area to color match the original finish.

Consult with your local GCA dealer for appropriate finish instructions and materials. When refinishing is

complete, use a rubbing compound to blend the repair area to the existing finish.

Revised: October 2007

Page 35

Champion Bus, Inc. Maintenance

SECTION 6

Doors

GENERAL INFORMATION

GCA installs bus Doors, except for the driver’s door,

according to options specific to how the bus was

ordered. Passenger Entry Doors, Cargo Doors, and

Emergency Exit Doors are available for various ap-

plications throughout the bus. Regardless of the Door

Type, regular inspections and routine maintenance

will help keep Bus Doors operating properly and look-

ing good.

STANDARD DOORS

CHASSIS CAB DOORS

Fig. 2.1 - Cab Doors

The Chassis Cab Doors are a typical automotive style

door with a standard release handle, window crank,

and door locking mechanism. GCA does not modify

the Chassis Cab Door in any way. For additional in-

formation regarding the operation and maintenance of

these doors, consult the chassis owner’s manual.

PASSENGER ENTRY DOOR

The Passenger Entry Door is located on the curb-

sideof the bus and can be opened by an electric

motor. The steel door frame and stepwell are fixture-

welded to form a single unit which offers strength and

durability. Door panels open outward and are mount-

ed in the door fram with pivot pins at both the top and

bottom. Opening, closing, and locking procedures, as

well as door adjustment instructions and maintenance

schedules for your Passenger Entry Door can be

found with the door information specific to your bus

Fig. 2.2 - Passenger Entry Door

that follows in this section.

DOOR ACTUATOR TRIM PANEL

The Door Actuator Trim Panel is located above

thepassenger entry door. This Trim Panel protects the

door linkage, actuator, and door motor (Electric Doors

Only) for manual, pneumatic, and electric doors. To

access the door mechanism, turn knobs, lift slightly

and remove.

Fig. 2.3 - Door Actuator Trim Panel

Revised: October 2007

Page 38

Champion Bus, Inc. Maintenance

SECTION 6

Doors

GENERAL MAINTENANCE

• DOOR SEALS - Inspect door seals every week for

material quality and tight fit. Repair or replace

damaged seals, as necessary. Spray door seal sur-

faces with a light coating of silicone every 12,000

miles or 3 months to keep seals soft and supple. If

doors seals do not close tight and they do not show

excessive wear, adjust the closing mechanism ac-

cording to the diagrams in this manual.

• HINGE & CLOSING MECHANISMS - Lubricate

hinges and closing mechanisms monthly with one

Fig. 2.4 - Door Seals

(1) or two (2) drops of light machine oil. This helps

prolong the life of hinge pins and closing mechanisms,

prevents corrosion, binding, and squeaks. SAE 5

weight non-detergent motor oil and/or WD-40™ spray

work well for these lube applications. White lithium

grease is also recommended to lubricate the closing

mechanism linkage. For all applications, avoid overlu-

brication as excess oil or grease tend to collect

dirt and soil clothing.

• DOOR ALIGNMENT - Check door alignment

weekly. Over time, worn door pins and loose

fasteners may allow door hinges to shift. Tighten

loose nuts, replace worn parts, and/or realign door

Fig. 2.5 - Door Alignment Check

panels as necessary. Door diagrams, indication points

of adjustment for your door, follow in this section.

• KEY LOCKS & SWITCHES - Lubricate key locks

with a lubricant that is recommended for door locks.

DO NOT use lightweight or detergent-type lubricants

as they may wash the original graphite lubricants out

of the lock tumblers, harming the function of the key

locks.

• WINDOWS - Windows on bus doors should be

cleaned on a regular basis to assure visibility and

passenger safety. Interior and exterior door glass

surfaces should be cleaned daily using a household

Fig. 2.6 - Outside Door Switch

ammonia solution or other glass cleaner and a soft

nonabrasive cloth, sponge, or chamois to remove any

dirt or film.

Revised: October 2007

Page 39

Champion Bus, Inc. Maintenance

SECTION 6

Doors

ENTRY DOOR LEAF ADJUSTMENTS.

1. Optimum Door Leaf Operation:

a. Open Door’s Rear Leaf so that it “Opens”

90° to the door header.

b. When you “OPEN” the Door’s Rear Leaf

the Door’s Front Leaf will open

somewhere between 5° to 10° past 90°.

Fig. 2.7 - Door Alignment Check

ADJUST

1. Adjust Door’s Control Rod’s Length:

a. Remove Cotter Pin and Clevis Pin from

Control Rod’s “Still” end.

b. To Adjust Control Rod’s length…loosen

Yoke’s Locknut and turn Yoke“Clockwise” to

shorten or “Counterclockwise” to lengthen

the Rod.

c. It is recommended that you only turn the

Yoke 2-complete revolutions and check

the door operation each time you make

and adjustment.

Fig. 2.8 - Door Adjustment Rod

d. After you achieved Door Leaf Optimal

Operation as mentioned in step 1b, tighten

locknut to secure adjustment.

2. Check for Proper Adjustment:

a. Close Door’s Rear Leaf until it bottoms

out at the door header, the Door’s Front

Leaf Edge Seal should be 4” away from

the Rear Leaf’s Edge Seal (Rubber).

b. If everything falls within these specs.

Fig. 2.9 - Proper Adjustment

Then Mechanical Adjustment has been

achieved.

Revised: October 2007

Page 40

Champion Bus, Inc. Maintenance

SECTION 6

Doors

PARATRANSIT DOOR

The Bi-Fold Paratransit Door consists of two panels

fastened to the bus with upper and lower pivots. Each

door panel has its own handle that rotates locking

rods, away from the door jamb allowing the door to

open “outward”. Typically, two bi-fold door leaf assem-

blies are used in a door portal, one each opening to

the right and left sides, respectively. (Refer to Fig. 10)

The Bi-Fold Door panels may also have Gas Struts or

“dampeners” installed to restrict the free movement of

the door leafs after opening.

Fig. 2.10 - Paratransit Door

ELECTRIC PASSENGER ENTRY DOOR

The electric passenger entry door consists of two door

panels that are opened by an electric switch mounted

on the drivers control console. The rack and pinion

drive mechanism, located at the top of the door, al-

lows both door panels to be moved when the switch is

activated.

To operate the Electric Entry Door, the vehicle must

be in “PARK”. The door can then be opened and

closed by using the toggle or rocker switch (depend-

ing on the option) located driver’s control panel.

Fig. 2.11 - Electric Door Assembly

To “OPEN” the entry door, hold the toggle or rocker

switch in the “OPEN” position until the door panels

open to a full travel.

To “CLOSE”, hold the toggle or rocker switch in the

“CLOSED” position until the door panels close tightly.

For passenger safety, ensure that exiting passengers

have moved away from the bus and/or all boarding

passengers are seated before closing the entry door

and taking the bus out of “PARK”.

Revised: October 2007

Page 41

Champion Bus, Inc. Maintenance

SECTION 7

Windows

GENERAL INFORMATION & MAINTENANCE

Safety glass is used for all windows in this bus. Windows in the passenger area also have tint to reduce sun

glare and heat. When windows are installed in the passenger area of the bus, the window frames are sealed

to the bus body by a compressed, adhesive-backed rubber seal. This seal forms a water and air tight seal

between the inside of the bus to the outside of the bus.

• Windows should be cleaned and maintained on a regular basis to assure visibility and passenger

safety. Interior and exterior glass surfaces should be cleaned daily using a household ammonia

solution or other glass cleaner and a soft, nonabrasive cloth, sponge or chamois to remove any dirt or

film.

• Latches and seals around sliding or hinged panels should be checked and windows should be

opened and closed daily as the windows are cleaned. Special attention should be given to egress

(emergency exit) windows to assure that release handles are in the fully locked position. Apply silicone

lubricant to release handles on egress windows as needed. If release handles become difficult to

operate, consult your GCA Dealer for recommended service.

• If leaks occur, apply ManusBond window weld, or a silicone-based sealant around window frames

and/or glass. For best results, clean surfaces thoroughly before application.

• Replacement windows and other window parts may be obtained through your GCA Dealer.

EGRESS (EMERGENCY EXIT) WINDOWS

GCA Buses are equipped with egress, or emergency

exit,windows in the passenger area. Egress windows are

easily identified by window decals and/or option red lights

above the windows and two-release handles

either along the sides or at the bottom of the window

frame.

To operate these windows, rotate the red release

handles away from the window frame and push out on

the window. The frame has a fixed hinge at the top that

allows the egress window to swing out for emergency

exit and swing back to close. Operating instruction are

provided on window decals.

• Egress window release handles should be

checked daily to assure they are in the fully

locked position.

Figure 7.1 - Egress Handle

Apply silicone lubricant to the release handles if

they become difficult to operate.

DO NOT OPEN EGRESS WINDOWS WHILE THE BUS IS IN MOTION!

PERSONAL INJURY OR BUS DAMAGE MAY RESULT.

Revised: October 2007

Page 44

Champion Bus, Inc. Maintenance

SECTION 7

Windows

SLIDING WINDOWS

Most passenger windows can be “OPENED” for

ventilation. This sliding window will be located either

at the top or bottom of the window frame.

To “OPEN”, push “DOWN” on the lock release latch

(located at the center of the sliding window frame) and

pull the sliding window pane to the side. “CLOSE” the

window gently - by pushing the sliding window pane

to the side until closed and lock into position by push

“UP” on the lock release.

• Clean and apply silicone lubricate to the

window groove every two (2) months, or as

Fig. 7.2 - “OPEN” Slider Window

needed, to help keep sliding window’s action

smooth.

PLUG WINDOW

The Plug Window is located in front of the Entry Door

on the curbside of the bus, Plug Windows allow the

driver, while seated in the driver’s seat, to observe the

curb and passengers who may be standing in front of

the entry door.

Plug Windows are installed using an adhesive sealant

that holds the window in place and forms a water-

resistant and air resistant barrier around the window.

Fig. 7.3 - “LOCK” Slider Window

A rubber trim panels around the window helps seal

the window to the bus body.

• Plug windows should be cleaned every day,

as dirt and grime from daily driving may collect

on the window and block visibility.

Fig. 7.4 - Plug Window

Revised: October 2007

Page 45

Champion Bus, Inc. Maintenance

SECTION 8

Electrical & Lighting

GENERAL INFORMATION

This section contains information on portions of the electrical system and lighting that are unique to the GCA

bus. All bus circuits are connected to the chassis 12-Volt Negative Ground Electrical System. The ignition switch

activates most of the bus circuits.

Information on the chassis circuits and wiring, including headlights, turn signals, dashboard lighting, and fuse

panel may be found in the manuals provided by the chassis manufacturer. In addition, the chassis owner’s

manual includes a listing of bulbs and fuses used for chassis related components. Chassis service literature,

including wiring diagrams and electrical troubleshooting manuals, are available from your local Ford or Chevy

dealer or by using the order forms in the chassis owner’s manual.

Bus Reversing Aid (if applicable)

1. USE CAUTION WHEN TESTING. A trained driver with assistance in a secured area is recommended.

2. Engage reverse gear. The Bus Reversing Aid will activate automatically.

3. Drive backward slowly until voice distance indicator is heard.

4. Keep sensors clean of dirt and other debris.

POWER DISTRIBUTION CENTER (FUSE PANEL)

The Power Distribution Center (Fuse Panel) provides

power to different electrical systems within the bus.

Wiring diagrams or schematics of the Power Distribution

Center (Fuse Panel) clearly identify the circuits and

are shipped with of your vehicles. All wiring for the

body conversion (except wires less than 12 inches in

length) is color-coded and stamped every 12 inches

with circuit numbers and abbreviated codes, making

circuit tracing easier. Most wiring is bundled into “wiring

harnesses” that are routed from the Power Distribution

Center (Fuse Panel) into the parcel racks. The wires

usually are routed the shortest distance to the area

where power is being supplied. Removable interior

trim panels protect and allow access to the wiring that

is routed throughout the bus.

AUTOMATIC-RESET CIRCUIT BREAKERS

Automatic-reset Circuit Breakers, located in the Power Distribution Center (Fuse Panel), are an optional feature

that protect heavy power demand circuits. A power draw overload will cause a brief interruption in electrical

power before the circuit breaker automatically resets itself.

• If a breaker is frequently interrupted or if the circuit breaker “cycles”, look for a “short” or other problem

before returning the bus to service.

Revised: October 2007

Page 48

Champion Bus, Inc. Maintenance

SECTION 8

Electrical & Lighting

ELECTRICAL SYSTEM REPAIR

Electrical system troubleshooting should begin with the Fuse Panel. Wiring diagrams included with the bus

indicate wiring colors, the stamped circuit numbers, and the circuit schematics.

• Wiring repairs should only be performed by a qualified technicians.

• Consult your local GCA dealer before performing any electrical, or other repairs. Unauthorized repairs may

void bus warranties.

• Use replacement fuses of the specified type and amperage rating only. Using other fuses may cause damage

to electrical systems and increase the risk of electrical fires.

• When repairing circuits, be sure that wiring is protected from damage.

• Use ring terminals, spade connectors, or butt connectors as a last resort. Solder all connections and heatshrink

to insulate whenever possible.

• Place repaired wire back into loom and secure with plastic wire-ties. Avoid routing wire harness close to major

heat sources or sharp edges.

• The cigarette lighter receptacle may be used as a power source for accessories.

ELECTRICAL POWER IS ALWAYS “LIVE” IN THE POWER DISTRIBUTION CENTER (FUSE

PANEL). USE CAUTION WHEN PERFORMING REPAIRS. DO NOT OPERATE THE VEHICLE

WITH THE ACCESS DOOR OPENED. DOING SO MAY ENDANGER PASSENGERS AND

COULD SHORT CIRCUIT THE VEHICLE’S ELECTRICAL SYSTEM.

EXTERIOR LIGHTING

LED Exterior Lighting is designed to assure the visibility of the bus to other drivers and pedestrians. Exterior

lighting consists of front and rear clearance lights, rear tail, brake, backup, and stop lights, license plate light,

side marker lights, and headlights.

Wiring Harnesses for exterior lighting originate in the Power Distribution Center (Fuse Panel) and are routed

throughout the bus. Most wiring can be accessed by removing the interior trim panels.

Revised: October 2007

Page 49

Champion Bus, Inc. Maintenance

SECTION 8

Electrical & Lighting

HEADLIGHTS

The vehicle’s Headlight Control Knob is located on the dash. Headlights should be turned “ON” when

driving at night, or whenever weather or safety conditions require that headlights be “ON”.

LED MARKER LIGHTS

The incandescent Marker Light consists of a circular red lens on a circular base. One light is located on either

side of the rear of the bus. The incandescent Marker Lights indicate the exterior side wall of the bus and provide

noticeability at night and in less than desirable driving conditions.

Standard Front Marker Lights are a component of the body lighting system. These amber colored lights

are located at he front corners of the bus and are activated when the headlights are turned “ON”. These lights

are combined with the parking lights and also flash “ON/OFF” when turn signals are activated.

• Marker Lights should be inspected daily for proper

operation.

• To replace burned-out Marker Lights, pry out from

rubber grommet.

• Disconnect wire harness connector from Marker Light

and discard light.

• Connect new Marker Light to wire harness

connector.

• Apply a bead of silicone around perimeter of Marker

Light, align holes in light to holes in bus body. Push in

until secure.

INTERIOR LIGHTING

Interior Lighting consists of Incandescent Lights that

are attached to the ceiling. There are also LED Lights

attached to the parcel racks. These lights provide an

even cabin illumination for passenger and driver

safety.

• Interior Lighting should be inspected daily for

proper operation.

Revised: October 2007

Page 50

Champion Bus, Inc. Maintenance

Wire Stamping and Coding

STAMPING CODES

Air Conditioner

Chime

Field

Low

Power

Tail

Ajar

Circuit Breaker

Fluorescent

Light

Public Address

Throttle

Alarm

Cigarette

Front

Laminator

Pressure

Timer

Accessory

Defrost

Fuel

Lavatory

Pump

Toilet

Actuator

Docking

Ground

LTR

Lighter

Rear

Transmission

Air

Dome

Gauge

Micro

Radio

Turn

Auxiliary

Dash

Generator

Medium

Reading

Tap

Auto

Destination

Guard

Marker

Remote

Television

ALT

Alternator

Door

Head

Mirror

Relay

Tag

Amber

Disconnect

High

Master

Request

Tag Axel

Brake

Driver

Hold

Mid Turn

Reset

Temperature

Back-up

Deceleration

Heat

Memory

Right

Telma

Box

Energize

Hood

Meter

Regulator

Valve

Buzzer

Entry

Hour

Main

Safety

Vortec

Braun

Exit

Idle

Motor

Signal

Videocassette Rec.

Battery

ENG

Engine

Ignition

Neutral

Solenoid

Volt

Cord

Edge

Interlock

Off

Sign

Vacuum

Cargo

Fare

Interlock

Overhead

Spare

Wheelchair

Control

Fresh

Illumination

Open

Sensor

Window

Full

Isolation

Oil

Starter

Wiper

Circuit

Fan

Interrupt

Override

Switch

Water

Constant

Frost

Kneeler

Plug

Shot

Warning

Clutch

Fast

Left

Park

Stop

Well

Courtesy

Fire

Luggage

Pull

step

Cut out

Flasher

Lift

Panel

Sensitive

Compressor

Fog

Limit

Passenger

STA

Stator

Wire Stamping and Coding

WHITE

PINK

BLACK

DRIVER FAN LOW

DOOR MOTOR

SINGLE CONDENSER

DRIVER FAN HIGH

RIGHT READING LIGHT

HOOD LIGHT

DUAL CONDENSOR

EXIT LIGHT

IN GEAR

MOTOR GROUND

WHEELCHAIR SWITCH

DOME LIGHT

OIL

08A

WHEELCHAIR SWITCH

STOP REQUEST

12V STARTER

ENTRY DOOR

09A

STOP REQUEST

TEMP

WHEELCHAIR ALARM

TAG AXLE VACUUM

DOOR CLOSE

BRAUN INTERLOCK SL

RAMP STOW

STOP REQUEST

ALTERNATOR IGNITION

DEFROST POWER

DRIVER LIGHT

PULL CORD

BUZZER ALARM

23A

PULL CORD

AIR CONDITIONER

WINDOW AJAR

ENGINE KILL

BLUE

ENGINE KILL

GRAY

COMPRESSION AMPLIFIER

BROWN

DASH LIGHT

SINGLE COMPRESSO

DOOR MOTOR

LUGGAGE DOOR AJAR

READING LIGHT

LOW AIR

WHEELCHAIR DOOR SL

COURTESY LIGHT

MAP LIGHT

DESTINATION SIGN

BRAKE LIGHT

MARKER LIGHT

14A

HOOD LIGHT

WHEELCHAIR DOOR

12V RUN

LUGGAGE LIGHT

STOP REQUEST

FARE BOX

DOCKING LIGHT

TRANSMISSION HOLD

Wire Stamping and Coding

RED

YELLOW

ORANGE

PURPLE

DOME LIGHT POWER

12V BATTERY

HEATER #2 HIGH

AUXILIARY POWER

HEATER #2 POWER

HEATER #2 MEDIUM

HEATER VALVE

DUAL COMPRESSOR

LEFT READING LIGHT

SIGH MOTOR

TAG AXLE POWER

HEATER #2 LOW

VOLT METER

HEATER #1 MEDIUM

HEATER #1 HIGH

PUBLIC ADDRESS POWER

HEATER #1 POWER

DOOR OPEN

TM SWITCH

HEATER #1 LOW

RIGHT READING LIGHT

OEM COURTESY LIGHT

STEP LIGHT

IGNITION SIGNAL

DOOR POWER

LEFT TURN SIGNAL

WHEELCHAIR DOOR

IGNITION INTERLOCK POWER

AUXILIARY DOOR POWER

7" LIGHT

10A

AJAR LIGHT

PASSENGER SIGNAL

RADIO IGNITION

19A

FRONT 7" LIGHT

PULL CORD

DRIVER DOME LIGHT

RADIO BATTERY

FRONT FO

12A

PULL CORD

PARK BRAKE

DESTINATION SIGN

MEDIUM FO

WHEELCHAIR POWER

7" LIGHT

TM SOLENOID POWER

REAR FO

VORTEC SL SIGNAL

IGNITION SIGNAL

RIGHT TURN SIGNAL

WINDOW AJAR

7" LIGHT

IGNITION SIGNAL

PASSENGER PULL CORD

WINDOW AJAR

18A

REAR 7" LIGHT

DRIVER FAN

23A

PASSENGER PULL CORD

BUZZER GROUND

IGNITION LOW

DRIVER FAN

WINDOW AJAR

IGNITION LOW

TEMPERATURE ALARM

WHEELCHAIR PULL CORD

IGNITION LOW

OIL ALARM

25A

WHEELCHAIR PULL CORD

STARTER DISABLE

RAMP DEPLOY

STARTER DISABLE

Wire Stamping and Coding

TAN

Green

LUGGAGE LIGHT

No Stamping Required.

LUGGAGE LIGHT SWITCH

May be coded with the letter "G“ and a

RUN ACCESSORIES

suffix of manufacturers specifications.

PASSENGER SIGNAL

LIFT LIGHT

TM ENTRY

IL ALARM SIGNAL

SPEAKERS (TAGS)

TELMA

RT REAR SPEAKER

STRIPED

P/K

RT REAR SPEAKER

W/B

DRIVER THERMOSTAT

LEFT REAR SPEAKER

K/W

AC DEM THERMOSTAT

G/K

LEFT REAR SPEAKER

E/W

DUAL AC OEM THERMOSTAT

RIGHT FRONT SPEAKER

O/W

A/C FAN HI SPEED

E/K

RIGHT FRONT SPEAKER

R/W

A/C FAN LOW SPEED

LEFT FRONT SPEAKER

W/B

A/C FAN POWER

W/K

LEFT FRONT SPEAKER

Y/W

A/C FAN MEDIUM SPEED

SPK5C

EXTERNAL SPEAKER

BRAUN INTERLOCK SL

SPK5T

EXTERNAL SPEAKER

ALTERNATOR IGNITION

SPK6C

RE PUBLIC ADDRESS SPEAKER

PULL CORD

SPK6T

RE PUBLIC ADDRESS SPEAKER

23A

PULL CORD

SPK7C

FT PUBLIC ADDRESS SPEAKER

WINDOW AJAR

SPK7T

FT PUBLIC ADDRESS SPEAKER

Connector Locations

Connector

Function

Harness

Location

C 100

Console

Front Floor

Right side of the engine access cover

C 100A

Console

Front Floor

Right side of the engine access cover

C 100B

Console

Front Floor

Right side of the engine access cover

C 100C

Console

Front Floor

Right side of the engine access cover

C 101

Entry Feed

Front Floor

Behind electrical center panel

C 102

Front Cap

Front Floor

Behind electrical center panel

C 103

RH O/H

Front Floor

Behind electrical center panel

C 104

RH O/H

Front Floor

Behind electrical center panel

C 105

LH Dome Lights

Left Overhead

Above entry door behind cover

C 106

Rear Cap

RH O/H

Passenger side rear corner

C 107

Heater 1

RH O/H

Behind electrical center panel

C 108

Heater 2

Front Floor

Behind electrical center panel

C 109

LH Interior Lights

RH O/H

Above entry door behind cover

C 110

RH Interior Lights

RH O/H

Above entry door behind cover

C 111

Rear Cap

RH O/H

Passenger side rear corner

C 112

Tag Axle

Rear Cap

Driver side rear corner

C 113

Electric Door Motor

Entry Door

Above entry door behind cover

114

Floor Courtesy Lights

RH O/H

Above entry door behind cover

115

Restroom

Rear Cap

Driver side rear corner

116

Rmt. Entry Door

Entry Feed

Above entry door behind cover

117

RH/LH Reading Lights

Int. Lt.

Above entry door behind cover

118

RH/LH Dome Lights

Int. Lt.

Above entry door behind cover

119

I/P

Rear Evap AE

Behind driver switch panel

120

Engine Alarm

Front Floor & I/P AE

Behind driver switch panel

121

Top Relay Row

Front Cap

On main electrical panel

Connector Locations

Connector

Function

Harness

Location

C 122

Entry Door

Front Floor AEN

Above entry door behind cover

C 123

I/P to RH O/H

I/P AE

Behind driver switch panel

C 124

Left Front Speaker

Front Cap

Driver side wing panel

C125

Trans Interlock

Front Floor (Not AT/AL)

not used

C126

Trans Interlock

Front Floor

not used

C127

Fuse Block

Front Cap

above driver wing pad

C128

Fuse Block

Front Cap

above driver wing pad

C129

Right Front Speaker

Front Cap

right side top of front cap

C130

Sensitive Edge

Entry Door

above entry door behind cover

C131

Park Brake/Low Air

Front Floor / I/P AE

center dash behind radio

C132

Rear Door Ajar

Front Floor

center rear of rear cap

C133

Window Ajar

Front Floor / I/P AE

behind electrical center panel

C134

Pass Pull Cord

Front Floor / I/P AE

behind electrical center panel

C135

WC Pull Cord

Front Floor / I/P AE

behind electrical center panel

C136

EN DR AR VL

not used

C137

Radio

Front Floor

center dash behind radio

C138

LH Exit Lights

Left Overhead

driver side rear corner

C139

Ramp

Entry Feed - AA

behind electrical center panel

C140

RH Brake & Tail

Rear Cap

passenger side rear middle

C141

RH Mid Turn/Marker

Rear Cap

passenger side rear middle

C142

RH Turn

Rear Cap

passenger side rear middle

C143

RH Brake & Tail

Rear Cap

passenger side rear middle

C144

RH Back-up

Rear Cap

passenger side rear middle

C145

CTR Brake

Rear Cap

top center rear

C146

LH Brake & Tail

Rear Cap

passenger side left middle

Connector Locations

Connector

Function

Harness

Location

C147

LH Mid Turn/Marker

Rear Cap

passenger side left middle

C148

LH Turn

Rear Cap

passenger side left middle

C149

LH Brake & Tail

Rear Cap

passenger side left middle

C150

LH Back-up

Rear Cap

passenger side left middle

C151

RH Pwr.

Rear Cap

not used

C152

LH Pwr.

Rear Cap

not used

C153

Tag Light

Rear Cap

driver side bottom rear corner

C154

RH Dome Lights

Front Cap

above entry door behind cover

C155

Rear Brake

Front Floor

behind electrical center panel

C156

Engine & STR Kill

Front Floor

behind electrical center panel

C157

RH Exit Lights

Front Cap

above entry door behind cover

C158

Right Rear Speaker

Rear Cap

passenger side rear corner

C159

Left Rear Speaker

Rear Cap

driver side rear corner

C160

Tow Plug

Rear Cap

driver side bottom rear corner

C161

Ford Connector

Rear Cap

driver side bottom rear corner

C162

Entry Door

Entry Feed

above entry door behind cover

C163

Lift Door

Entry Feed

above entry door behind cover

C164

I/P

Entry Feed AE

behind driver switch panel

C165

Step Well Light

Entry Feed

below entry door sides

C166

Tag Light

Rear Cap

driver side bottom rear corner

C167

Engine & STR Kill

Front Floor

behind electrical center panel

C168

Farebox

Front Floor

behind electrical center panel

C169

Reverse Alarm

Rear Cap

driver side bottom rear corner

C170

Rear Door Switch

Rear Cap

Center top of rear cap

C171

Grounds

Rear Cap

driver side bottom rear corner

Connector Locations

Connector

Function

Harness

Location

C172

RH Rear 7" Light

Rear Cap

passenger side top rear corner

C173

LH Rear 7" Light

Rear Cap

driver side top rear corner

C174

Grounds

Front Cap

above entry door behind cover

C175

RH Pass Pull Cord

Rear Cap

passenger side rear corner

C176

LH Pass Pull Cord

Rear Cap

driver side rear corner

C178

PA/Radio

Front Floor

behind electrical center panel

C180

RH WC Pull Cord

Rear Cap

passenger side rear corner

C181

LH WC Pull Cord

Rear Cap

driver side rear corner

C188

Ign. Sol

Front Floor

behind electrical center panel

C189

Rear WDO Exit Light

Rear Cap

Center top of rear cap

C190

Marker Light

Front & Rear Caps

top of rear cap

C191

RH Front 7" Light

Front Cap

passenger side top front corner

C192

LH Front 7" Light

Front Cap

driver side top front corner

C194

Dest. Sign

Front Cap

driver side top front corner

C195

Stop Reg. Sign

Front Cap

driver side top front corner

C196

RH Window Ajar

Rear Cap

passenger side rear corner

C197

I/P

Front Cap AE

behind electrical center panel

C198

LH Window Ajar

Rear Cap

driver side rear corner

C199

Rear Window Ajar

Rear Cap

Center top of rear cap

C200

Rear Luggage Light

Rear Cap

Center top of rear cap

4450M

1/6

NAVISTAR HOUSING:

2/6

PN # 2039312C91

C215-CP

3/6

NAVISTAR TERMINAL:

1/6

PN # 2033912C1

4/6

09 N

2/6

18 W

5/6

18 W

3/6

18 Y

6/6

4/6

09 N

5/6

18 R

4460M

6/6

1/3

09 B

18 Y

NAVISTAR HOUSING:

2/3

18 R

PN # 3553961C1

3/3

NAVISTAR TERMINAL:

09 B

PN # 2033912C1

NOTES:

1. HARNESS IS TO BE LOOMED.

2. HARNESS IS 15' IN LENGTH.

3. ALL WIRES ARE 14 AWG.

TITLE:

PRECISIONWORKS

MANUFACTURING

CHASSIS TIE IN HARNESS

120 9TH AVE E-4

LONGMONT, CO 80501

REVISIONS

ADDITIONAL INFO:

THIS DRAWING IS THE PROPERTY OF

REV.

DATE

DESCRIPTION

RELEASE #

PRECISIONWORKS MANUFACTURING AND IS

NOT TO BE DUPLICATED OR USED IN ANY

NAVISTAR

WAY DETRIMENTAL TO THEIR BEST INTEREST.

SIZE:

RELEASE NO.

DWG NO.

MATERIAL SPEC:

0032192-120

MODEL:

SCALE

DATE

SHEET

NTS

Champion

C103-Y-P

C106-R-P

1/15

28 G

2/15

28 P

3/15

GND

4/15

28 G/K

5/15

28 P/K

6/15

18 R

7/15

03 T

8/15

GND

9/15

09 B

10/15

23 Y

11/15

18 Y

12/15

07 I

13/15

23 I

14/15

"DIM A"

14/15

18 O

15/15

03 E

C104-G-P

C111-G-P

1/6

02 P

2/6

07 O

ELDORADO PN

DIM A

UNIT SIZE

3/6

07 P

0032192-122

214"

190/200/210/220

4/6

0032192-125

239"

240/250

12 O

5/6

0032192-129

268"

270/290

18 W

0032192-130

276"

300

6/6

09 N

0032192-132

300"

320

0032192-135

336"

350

NOTE:

TITLE:

PRECISIONWORKS

1) SEE 0032192 FOR SCHEMATIC.

MANUFACTURING

2) ALL DIMENSIONS ARE SHOWN IN INCHES.

LEFT OVERHEAD HARNESS (LENGTH) EP3

120 9TH AVE E-4

LONGMONT, CO 80501

REVISIONS

ADDITIONAL INFO:

THIS DRAWING IS THE PROPERTY OF

REV.

DATE

DESCRIPTION

RELEASE #

PRECISIONWORKS MANUFACTURING AND IS

NOT TO BE DUPLICATED OR USED IN ANY

WAY DETRIMENTAL TO THEIR BEST INTEREST.

SIZE:

RELEASE NO.

DWG NO.

MATERIAL SPEC:

00000

0032192-LENGTH

MODEL:

SCALE

DATE

SHEET

NTS

12/4/07

Champion

WIRING INFORMATION:

08HAB: Connectors are located inside the driver's side frame rail at the BOC.

08HAE: Connectors are located inside the driver's side frame rail at the EOF.

7-Way Connector Information

Wire

Cavity Gauge Color Description

Fuse

Available

Number

Rating

Current

(Amps)

N68BB

Brown Tail Light

N56BB

Yellow Left Turn

Light

N57BB

Light

Right Turn

Green Light

N54BB

Brown Marker

Light

N71BB

Light

Back-up

Blue

Light

N12BB

Light

Accessory

Blue

Feed

N11-GD

White GND

More 7-Way Connector Information

Description

Chassis Harness Body Builder Harness

(4450) 7-Way Connector

2039311C91

2039312C91

Lock

2039342C1

12 Gauge Seals

589390C1

14 Gauge Seals

589391C1

16 Gauge Seals

1652325C1

12 Gauge Terminals

2039344C1

1687848C1

14 Gauge Terminals

3535486C1

2033912C1

16 Gauge Terminals

2039343C1

2033911C1

3-Way Connector Information

SECTION 9

HVAC & Plumbing

AIR CONDITIONING — “IN-DASH” DRIVER AIR

The front HVAC unit supplies fresh outside air or recirculated inside air, heated or cooled, to the driver, to the

front part of the vehicle and to the windshield for defrosting.

The front HVAC unit is located below the dash panel, at the curbside of the vehicle.

Air from the exterior or interior of the coach is forced through the evaporator, the heater core, and the ducts to

the windshield, the driver’s feet, driver’s upper body, and to the front of the vehicle.

The driver may adjust the air outlets to the desired position.

A 3-position switch (OFF/LOW/HIGH) controls the blower speed. The blower motor cannot be rebuilt. When

blower is faulty, noisy or when there is excessive play on motor shaft, replace complete motor and blower wheel

assembly.

The rear evaporator on some buses is ducted to divert some of the A/C output to adjustable aircraft-style vents

located above the windows at each side of the bus. This offers passengers a degree of individual control, but,

overall the main A/C output is directed down the center aisle through louvers in the evaporator. So keep pas-

senger comfort high on your list of priorities and check the “climate” frequently — especially in extremely hot

weather.

All buses equipped with an optional air conditioning system have a single belt-driven compressor. Condensers

are located in the engine compartment and/or skirt mounted. Passenger -system evaporators are located over-

head at the rear of the passenger seating compartment.

AIR CONDITIONING UNIT - PASSENGER AREA

Buses equipped with passenger air conditioning have an evaporator assembly mounted on the ceiling at the rear

of the bus, with separate thermostat and fan-speed controls on the Driver’s Control Console.

For maximum cooling when the bus is first placed into service on a hot day, turn the thermostat and fan-speed

controls to their highest settings. The driver should be sure to monitor passenger comfort and adjust the controls

accordingly. This is especially important in busses that have both passenger and in-dash air conditioning. These

“dual” systems allow the driver to set the temperature and fan controls mounted on the dashboard to cool the cab

area. Always keep in mind that the temperature in the passenger compartment is regulated by the two Control

Consoles and influenced by passenger proximity to entry doors, large windows and the rear evaporator. Become

familiar with the settings that maintain a comfortable and well-balanced climate for all on-board the bus. Refer

to included Carrier’s website or your nearest Carrier dealer for more details.

NOTE: The Control Console’s thermostat control activates the compressor and

must be turned “ON” for either the passenger or driver’s in-dash air conditioning

to operate.

Revised: October 2007

Page 62

Champion Bus, Inc. Maintenance

SECTION 9

HVAC & Plumbing

ROUTINE PREVENTATIVE MAINTENANCE

Maintenance on these three basic A/C components can be divided into three areas. You’ll need to check under

the hood for the compressor and “In-Dash” A/C components, under the bus for the skirt-mounted condenser,

and underneath the Overhead Cover on the ceiling mounted Evaporator Unit.

UNDER-THE-HOOD INSPECTION

Whether your bus has passenger air, in-dash air, or both you’ll need to periodically inspect components under

the hood. With the engine “OFF”, check to see that all A/C fitting, hose clamps, and mounting hardware are

properly tightened. Signs of oil or dirt buildup at a fitting could indicate a leak in the system. Inspect hoses for

signs of wear. Make sure they are not exposed to exhaust heat or routed so they are not rubbing against rough

metal edges.

Check the compressor belt for wear, alignment, and proper tension. Loose or improperly aligned pulleys will

cause belts to vibrate and “dance”. If the belt is correctly tensioned (with engine “OFF”), it should deflect no more

that ½” when pulled “UP” or pushed “DOWN” with a firm hand. Finally, check the sight glass on the condenser

for proper charge. To do this, run the engine at fast idle and engage the compressor clutch by turning the A/C

on high. Let the A/C unit run for several minutes and observe the refrigerant flow through the glass. If it appears

“milky” or “cloudy”, you may need to recharge the system.

UNDER-THE-BUS INSPECTION

This step is necessary if you have one of the larger passenger compartment air conditioners. These units have

a skirt mounted condenser. With the engine “OFF” and no electrical power supplied to the unit, check for built-up

road dirt on the condenser fins. Leaves and other debris that reduce cooling efficiency can usually be removed

with a jet stream of water or high pressure air.

Use a water hose to clean fins by spraying water through the fins from the fan motor side, opposing the airflow

pattern. Turn fans by hand to make sure they rotate freely. Have any damage to fan blades or guards repaired by

your dealer. Check hoses and wiring for signs of wear or improper routing. Keep hoses as far as possible from

exhaust heat. Check hose clamps, electrical connections, and fittings for tightness. Also check fitting for telltale

dirt and oil that could indicate leakage.

Next, start your engine and run at fast idle. Turn the A/C on high and let the unit run for several minutes before

checking the condenser sight glass. Persistent cloudiness indicates low Freon™ charge. Your A/C condenser

has safety cutoffs to protect the unit from overheating, but that can be small consolation on a hot day. So have

your dealer or qualified service technician add refrigerant as soon as possible whenever it is needed.

While the unit is operating, note the air flow across the condenser fins. If hot air is being recirculated, have your

dealer investigate the problem. Carefully touch the hose fitting on the discharge hose (hot gas in). If everything

is functioning correctly, it should be hot. Then touch the hose fitting on the liquid line (liquid out). It should run at

air ambient temperature and may be slightly warm to the touch.

Revised: October 2007

Page 63

Champion Bus, Inc. Maintenance

SECTION 9

HVAC & Plumbing

EVAPORATOR INSPECTION

When the bus is hot, routinely turn “UP” the fan speed control to be sure that the evaporator blower operates

at all three settings. This assures that it can handle a variety of warm weather demands. Note that an

automatic thermal control switch cuts out the highest fan speed when the air temperature inside the bus drops

to moderately cool level.

Check the temperature differential between the air entering and leaving the evaporator. When all major A/C

system components are operating properly, the temperature drop between air “IN” and “OUT” will be between

15° to 20° F.

For a thorough inspection, the evaporator housing must be removed. It is secured with screws. You may want

to refer to the A/C manual supplied by the manufacturer for specific details on removing the housing and

inspecting the evaporator. With the housing removed, make sure the drain lines are secured in place and run

downhill for proper drainage.

Also check the drain pan; it should slope down toward the rear of the bus. If the slope needs adjustment,

loosen the drain pan screws, pull “down” on the rear edge of the pan, and retighten the screws.

Make sure hose clamps and expansion valve fittings are tight. Check hoses for signs of wear and improper

routing (rubbing against metal) and fittings for signs of oil or dirt buildup that might indicate a leak. Removable

interior trim panels along the roadside of the bus provide access to the hoses routing from the condenser to

the evaporator.

With the engine at fast idle and the A/C running, check the sight-glass on the liquid line at the expansion

valve. If needed, have a qualified technician add refrigerant, following manufacturer’s recharging procedures.

While you have the A/C running check the strainer-drier by alternately touching the inlet and outlet sides of

the drier. If both sides feel about the same temperature, the drier is okay. If there is an extreme temperature

change, warm “IN” and cold “OUT”, the drier may be clogged. If so, it should be replaced. Replace the evapora-

tor housing when your inspection is complete. A screwdriver is the only tool needed.

For more information visit: www.transportaircon.carrier.com.

PASSENGER HEATING

Concern for passenger comfort should apply in cold weather as well as hot. Your bus may be outfitted with one

or more low-profile, floor mounted heaters located underneath passenger seating. The heat source for these op-

tional heaters is the same hot engine “coolant” that circulates through the chassis heater core in the driver’s area.

A switch located on the Driver’s Control Console operates a variable-speed fan that draws inside air across the

heating coils of the floor mounted heater. The driver’s in-dash temperature control must be switched to the warm

or hot air range to assure proper coolant flow to the passenger area heater. Drivers should be mindful that the

ambient temperature in the cab may differ considerably from that in the passenger area. They should experiment

with adjustments of the in-dash and floor heater settings until both give suitable comfort levels.

Be sure to check heater fan, hoses, and connections whenever your chassis maintenance schedule recommends

inspecting or servicing the engine coolant system. Hoses are normally routed at the underbody. Make sure

that the hoses are correctly routed and do not rub against metal edges — and that all hose clamps are tight.

Revised: October 2007

Page 64

Champion Bus, Inc. Maintenance

SECTION 10

Optional Equipment

OVERVIEW

There are many options available to your Champion Bus. The following is maintence information for the

options ordered on this bus.

Telma Brake Retarder

The TELMA is a very low maintenance device. However, there are several general maintenance procedures

that can improve the life and performance of your TELMA.

Routine Maintenance Checklist

It is recommended that the TELMA maintenance checklist be incorporated into the regular vehicle

maintenance schedule. The maintenance intervals may vary depending upon the severity of operation and

the annual mileage of the vehicle. The following maintenance schedule is recommended:

Note:

IMPORTANT! In the case of any abnormalities, consult Champion Bus, Inc.

or the factory as soon as possible for assistance in the maintenance of your vehicle.

Revised: October 2007

Page 67

Champion Bus, Inc. Maintenance

SECTION 10

Optional Equipment

Braun Lift

The Following information has been provided by the Braun Corporation.

NHTSA Operations Checklist

•

Vehicle movement is prevented unless the platform is fully stowed.

•

Lift operation shall be prevented unless the vehicle is stopped and vehicle movement is prevented.

•

The platform will not fold/stow when at least 50 pounds is on the platform.

•

The inner rollstop will not raise if occupied by at least 25 pounds.

•

The outer barrier will not raise if occupied by at least 25 pounds.

•

Verify platform lighting* when lift is deployed and pendant illumination when lift is powered.

•

An audio warning (and visual warning for public lifts) will activate if at least 25 pounds is on the

threshold area when the platform is at least one inch below floor level.

•

Lowering the platform beyond the inner rollstop locking position is allowed only when the inner

rollstop is locked in position.

•

Raising the platform more than 3” off of the ground is prevented unless the outer barrier is raised.

Note:

Public use vehicle manufacturers are responsible for complying with the lift lighting requirements in Federal

Motor Vehicle Safety Standard No. 404, Platform Lift Installations in Motor Vehicles (49 CFR 571.404).

Maintenance and Lubrication

Proper maintenance is necessary to ensure safe, troublefree

operation. Inspecting the lift for any wear, damage or other

abnormal conditions should be a part of all transit agencies’s

daily service program. Simple inspections can detect potential

problems. The maintenance and lubrication procedures specified

in the following schedule must be performed by a Braun

authorized service representative at the scheduled intervals

according to the number of cycles.

NCL Series lifts are equipped with hardened pins and self-

lubricating bushings to decrease wear, provide smooth operation

and extend the service life of the lift. When servicing the lift at the

recommended intervals, inspection and lubrication procedures

specified in the previous sections should be repeated.

Clean the components and the surrounding area before

applying lubricants. LPS2 General Purpose Penetrating Oil is

recommended where Light Oil is called out. Use of improper

lubricants can attract dirt or other contaminants which could result

in wear or damage to the components. Platform components

exposed to contaminants when lowered to the ground may require extra attention. Lift components requiring

grease are lubricated during assembly procedures. When these components are replaced, grease must be

applied during installation procedures. Specified lubricants are available from The Braun Corporation.

Revised: October 2007

Page 68

Champion Bus, Inc. Maintenance

SECTION 10

Optional Equipment

**Maintenance and lubrication procedures must be performed as specified by an authorized service technician.

Failure to do so may result in serious bodily injury and/or property damage.

All listed inspection, lubrication and maintenance procedures should be repeated at “750 cycle” intervals

following the scheduled “4500 Cycles” maintenance. These intervals are a general guideline for scheduling

maintenance procedures and will vary according to lift use and conditions. Lifts exposed to severe conditions

(weather, environment, contamination, heavy usage, etc.) may require inspection and maintenance procedures

to be performed more often than specified.

Discontinue lift use immediately if maintenance and lubrication procedures are not properly performed, or if

there is any sign of wear, damage or improper operation. Contact your sales representative or call The Braun

Corporation at 1-800-THE LIFT. One of our national Product Support representatives will direct you to an

authorized service technician who will inspect your lift.

Revised: October 2007

Page 69

Champion Bus, Inc. Maintenance

SECTION 11

Maintenance Checklists

BUS MAINTENANCE

The following pages contain checklists that show when certain maintenance procedures should be completed to help

maintain a properly operating bus. These checklists are intended as supplements — not substitutes — for the maintenance

schedules provided by the manufacturers of the vehicle’s chassis or other major components.

These checklists focus on bus maintenance rather than chassis maintenance. The lists are not comprehensive and do not

cover many critical areas such as engine or chassis lubrication. As such, it is the bus owner’s responsibility to consult

the materials assembled in the General Coach America, Inc. Operation, Service, and Parts Manuals for more complete

information on keeping your bus in top condition.

Furthermore, technicians responsible for chassis maintenance should follow the recommendations on service intervals,

maintenance procedures, lubrication specifications, and approved service replacement parts that are provided either in the

chassis Parts, Service or Maintenance manuals. Failure to do so may void the chassis manufacturers’ warranties.

The following checklists are organized into Daily, Weekly, Monthly, Semi-Annual, Annual and Cyclical (dependant on

cycles, mileage or hours) tables so that the lists can be copied and kept in the bus for convenient up-to-date records.

Please note that some items on the checklists may not be applicable to your vehicle and that copies and alterations

can be made as needed for each unit being maintained.

DRIVER’S RESPONSIBILITIES

Regardless of who is responsible for bus maintenance, it is the driver’s responsibility to report —in writing—any problems

they encounter while operating the vehicle. Anything that might affect the safe operation of the bus should be reported

promptly. System malfunctions or unusual conditions including, but not limited to, the following should be reported

immediately:

• Steering

• Brakes

• Lights

• Windshield Washer & Wipers

• Tires

• Power Train (Engine, Transmission)

• Suspension

• Doors

• Windows

• Wheelchair Lifts & Restraints

• Seat Belts

• Unusual Noises

• Unusual Vibrations

• Unusual Exhaust Noise or Fumes

• Unusual Odors (for example; Hot Rubber or Burning Insulation)

Revised: October 2007

Page 75

Champion Bus, Inc. Maintenance

SECTION 11

Maintenance Checklists

CYCLICAL MAINTENANCE CHECKLIST

ACCEPTED

ITEM

SUGGESTED

FREQUENCY

REJECTED

PASSENGER ENTRY DOO R

INSPECT FOR DAMAGE, LUBRICATE LOWER HINGE PINS

2000 CYCLES

INSPECT FOR DAMAGE & LOOSE BOLTS. LUBRICATE

PASSENGER ENTRY DOO R

6000 CYCLES

UPPER HINGE PINS.

SKIRT MOUNTED

INSPECT, CLEAN COIL & FINS WITH JET OF WATER.

100 HOUR S

CONDENSER

STRAIGHTEN BENT FINS WHEN NECESSARY.

AIR CONDITIONIN G

CHECK COMPRESSOR DRIVE BELT CONDITION &

100 HOUR S

COMPRESSO R

TENSIO N

AIR CONDITIONIN G

CHECK COMPRESSOR CYLINDER UNDER LOAD

100 HOUR S

COMPRESSO R

CONDITIONS. ADJSUT IF NECESSARY.

AIR CONDITIONIN G

COMPRESSOR CLUTCH

CHECK FOR SIGNS OF OVERHEATING OR SLIPPAGE.

100 HOURS

ASSEMBLY

AIR CONDITIONIN G

INSPECT HOSES, HOSE CLAMPS, FAN, FAN GUARD .

300 HOUR S

SYSTEM

INSPECT BELTS & FITTINGS FOR TIGHTNESS.

CHECK REFRIGERENT LEVEL AT RECEIVING TANK

AIR CONDITIONIN G

SIGHT GLASS. CHECK FOR REFRIGERENT OIL LEAKS.

600 HOUR S

REFRIGERENT LEVEL

CHECK A/C CHARGE.

INSPECT FAN BLADES FOR DAMAGE & PROPER

CONDENSER FAN DRIVE

CLEARANCE TO SHROUD. INSPECT BRUSHES FO R

600 HOUR S

MOTOR S

WEAR.

CHECK AIR TEMPERATURE AT “IN” &

“

EVAPORATO R

600 HOUR S

TEMPERATURE SHOULD SHOULD BE 15°F TO 20°F.

EVAPORATOR FIN S

CLEAN COIL & STRAIGHTEN BENT FINS

600 HOURS

REFRIGERENT SYSTEM

CHECK HOSES & TUBING FOR LEAKS

600 HOURS

AIR CONDITIONIN G

CHECK COMPRESSOR & PLATFORM MOUNTING BOLTS

600 HOUR S

COMPRESSO R

FOR TIGHTNESS

AIR CONDITIONIN G

CHECK WIRING HARNESS

600 HOURS

COMPRESSOR CLUTCH

REFRIGERENT PRESSUR E

CHECK WITH MANIFOLD GAUGE

1000 HOURS

100 MILES

DUAL WHEEL LUG NUTS

CHECK TORQUE. TIGHTEN AS NEEDED.

500 MILES

6000 MILES

Revised: October 2007

Page 82

Champion Bus, Inc. Maintenance

SECTION 11

Maintenance Checklists

SEMI-ANNUAL MAINTENANCE CHECKLIST

ACCEPTED

ITEM

SUGGESTED

FREQUENCY

REJECTED

500 MILES

WHEEL LUG NUTS

CHECK TORQUE. TIGHTEN AS NEEDED

6000 MILES

1000 MILES

CHECK TORQUE ON NUTS, BOLTS & FITTINGS. TIGHTEN

AIR RIDE SUSPENSIO N

3000 MILES

OR REPLACE AS NEEDED .

12,000 MILES

REFER TO OEM

BRAKE RETARDER

INSPECT & PERFORM MECHANICAL MAINTENANCE

MANUAL

DRIVER'S SEAT

CHECK SEAT MOUNTING BOLTS FOR TIGHTNESS

6000 MILES

BATTERY, LO W

INSPECT. ADD ELECTROLYTES AS NEEDED .

6000 MILES

MAINTENCE TYPE

PASSENGER SEATS

INSPECT SEAT MOUNTING BOLTS AND BRACKETS.

12,000 MILES

INSPECT WELDS AT FRAME & OUTRIGGERS,

UNDERBOD Y

12,000 MILES

BULKHEADS & BODY FRAME .

BATTER Y

CLEAN & INSPECT

12,000 MILES

TIRES

ROTATE TIRES

12,000 MILES

WHEEL MOUNTING STUD S

INSPECT FOR DAMAGED THREADS.

12,000 MILES

INSPECT FOR DAMAGE OR WEAR. REPLACE

AIR RIDE SPRING &

NECESSARY. CORRECT ANY CONDITION CAUSIN G

12,000 MILES

SHOCK ABSORBER S

ABRASION OF AIR BAGS.

TAG AXLE & FRONT PIVO T

CHECK FOR LOOSNESS. RE-TORQUE OR REPLAC E

12,000 MILES

CONNECTION S

PARTS AS NEEDED .

INSPECT FOR FRAYED, LOOSE, CORRODED OR

BATTERY CABLES

24,000 MILES

DAMAGED CABLES.

INSPECT HEADLIGHT ALIGNMENT. ADJUST

HEADLIGHTS

24,000 MILES

NECESSARY.

CHECK HARNESSES & CABLES HAVE ENOUGH T

WIRIN G

CLEARANCE FROM SHARP OBJECTS, HEAT SOURCES,

24,000 MILES

AND MOVING PARTS.

HEATER COR E

CLEAN & STRAIGHTEN BENT FINS.

24,000 MILES

CHECK WITH AUTHORIZED SERVICE DEPARTMENT TO

BRAKE RETARDER

30,000 MILES

INSURE PROPER OPERATION .

Revised: October 2007

Page 83

Champion Bus, Inc. Maintenance

INDEX

Flooring, Rubber Covering

Air Conditioning

Fueling the Vehicle

Factory

Fuels

Inspection

62-63

Maintenance

Guide, Bolt Torque

Passenger

Hatch, Escape

Heating

Brake Retarder

Cab

Breakers

Passenger

Cab Area

Lift

67-71

Ceiling, Interior

Lights

Console, Control

Exterior

Cooling, Cab

Hazard

Headlights

Interior

Marker

Warning

Dash Panel

Lubrication

Doors

Actuator Trim Panel

Adjustments

Chassis

Electric

Maintenance Schedules

75-85

Entry, Passenger

Maintenance

Paratransit

Panels, Modesty

Power Distribution Center

4,47

Emergency

Roof Escape Hatch

Running out of Fuel

Starting

6-7

Repair

Warning Kit

Electrical System

Major Fiberglass

Minor Fiberglass

Refinishing Fiberglass

Stress Cracks

Fiberglass

Reversing Aid

Cap

Cleaning

Repair

Filters