Champion CTS FE (Front Engine)

Additional Info

GENERAL REQUIREMENTS AND DIMENSIONS FOR FREIGHTLINER M65 CHASSIS

CHASSIS

• The chassis shall have 5/16″ x 2.75″ x 9-1/8″ straight rail steel frame rated at 50,000 psi. 
• The chassis shall have a 60-gallon fuel tank, mounted between the frame rails.   The fuel filler cap shall be tethered to the bus.
• Service brakes shall be heavy-duty hydraulic disc brakes, with four-wheel anti-lock system.  
• Seven 19.5″ x 6.75″ white wheels, shall be provided.  The tires shall be steel belted Michelin XZE 245/70R 19.5 14-ply radials.   Mud flaps shall be provided at the front and rear tires.
• The engine shall be a 6.7L Cummins ISB-02 diesel engine rated at 185 bhp @ 2,500 rpm (420 ft-lbs. @ 1600 rpm). The cooling system shall be the highest capacity available for the specified chassis and shall include a 1,050 sq. in. side mounted radiator.  The air cleaner shall be a heavy-duty dry type with a replaceable element.  The oil filter shall be a full-flow, disposable type.
• The transmission shall be an Allison 2000 Series automatic with auxiliary transmission cooler.
• A TRW TAS-65 power steering gear shall be supplied.  A tilt/telescopic steering column and cruise control are required.
• The tail pipe shall exit at the rear of the bus.

ELECTRICAL

Chassis

• The Leece-Neville alternator shall be sized to meet the electrical load requirements and maintain a charged battery system.  There shall also be a driver controlled fast idle system.
• Two 12-volt batteries with a minimum rating of 750 CCA each shall be provided.
• An OEM electric horn shall be provided.

Body

• A fuse panel shall be conveniently accessible for service from inside the bus.  The door for access shall be a sliding panel.   A legend shall be posted inside the panel, which shall correspond with the components. 
• All wiring provided by the body manufacturer will be color-coded.  The wiring shall be bundled and clamped to protect the wires.
• Wires passing through metal shall be grommeted to protect the wiring.
• Switches installed by the body manufacturer shall be mounted in a separate panel, located to the left of the driver.

LIGHTING

Interior

• The passenger compartment lighting shall provide sufficient light for safety and security.  Incandescent lights are required.
• A separate switch from the chassis lights shall operate the passenger compartment interior lights.  Lights for each side of the passenger area will operate on their own switch.
• A dome light shall be provided in the operator’s area to provide sufficient light to read a map.

Exterior

• The headlights and turn signals provided by the manufacturer are acceptable and should not be replaced.
• Exterior lights added by the body manufacturer are to be incandescent type.  Except as noted in iii.
• LED lights, four inches in diameter, are to be mounted horizontally on the rear of the bus.  Red stop, turn and taillights are provided in LED.  The back-up lights are incandescent style four inches in diameter.
• Clearance and marker lights, amber front and red rear, are to be provided and mounted in compliance with FMVSS 108.

BODY

Structure

• The body shall have steel cage construction.   When the sidewalls, floor and roof are welded together, they shall form a continuous “hoop” structure, which is extremely strong and durable.
• The sidewalls shall be constructed of 1.5″ x 1.5 ” 16-gauge tubular steel studs and corner posts on maximum 48″ centers.  A 14-gauge, 1-1/2″ x 2″ tubular horizontal stringer shall be welded to the top of the studs.  A16-gauge Z-rail shall be welded to the studs at the bottom of the sidewall.   Seat track shall be welded to the sidewall studs.  
• The roof shall consist of 1.5″ x 1.5 16-gauge tubular steel rafters installed on maximum 48″ centers.  The roof rafters are welded into two 16-gauge steel “U” shaped sidewall caps.  The rafters, in conjunction with “C” Channel to form a “steel cage” type of construction.
• The backwall has a 1.5″ x 1.5″ 16 gauge tubular steel frame, reinforced with 16-gauge “C” channel.   A section of 16-gauge “Z” channel shall be welded to the bottom of the back wall.
• The floor frame shall be constructed of 11-gauge, 2-x 2.8 x 2 ” channel cross members, on a maximum 24″ center, with an outer 14-gauge angle steel impact rail. 11-gauge, 4″ wide flat steel shall be provided to support the floor track.  The floor frame shall be secured to the chassis frame in accordance with chassis manufacturer’s requirements.
• The floor shall be essentially a continuous flat plane, except at the stepwells, fuel fill cover and wheel housings.  
• The subfloor shall be mounted with Tek screws installed into the steel floor frame and shall be a minimum 5/8″ thick, CCX-PTS plywood.
• The rear wheel housings shall be constructed of minimum 14-gauge steel.  The wheel housings shall not protrude above the floor more than 6″.
• The step wells shall be constructed of 14-gauge steel.  All risers shall be of equal height, which shall not exceed 8.5″.

Exterior Panels & Finishes

• The exterior skin shall be .020 (25-gauge) steel, two side galvanized.  The skin shall be laminated to 1/8″ lauan and shall be bonded to the structure using urethane foam insulation.  The construction methodology shall provide an exterior skin with no visible fasteners.
• The roof skin shall consist of a single sheet of composite material.  Rain gutters conceal the transition between the roof and the sidewalls and prevent water flowing from the roof onto the windows and sidewalls.
• The body shall have a prebaked enamel finish.  The basic body color shall be white with a single color stripe.   PPG products shall be used, if touch up paint is required.
• A rub rail, minimum 2″ high, shall be applied to each side of the exterior skin, at the floor line, below the window line, and at the seat level of the bus.
• The exterior mirrors shall be Lucerix model on the curbside and the driver’s side of the vehicle.
• Flexible black rubber fender skirts shall be provided at the rear wheel housing.  Wheels and tires shall be removable with the fender skirts in place.
• Rain gutters shall be provided over the passenger door.  Cross section of the gutter shall be adequate for proper operation.
• The front and rear bumpers shall be energy absorbing type designed and tested per FMVSS requirements.
• All underbody plywood and steel, with the exception of the drive shaft, catalytic converter, engine, transmission, exhaust system, etc. shall be undercoated to protect against corrosion.  The material shall be an abrasive free petroleum asphalt emulsion, formulated with corrosion inhibitors.

Interior Panels and Finishes

• Interior ceiling panels shall be constructed of London Smoke vinyl.  H-rail and screws along the seams retain the ceiling panels.  Trim molding covers the seams and fasteners.
• Interior sidewall panels are London Smoke vinyl.  The panel is held in place at the lower edge by J-rail and at the top edge by the window trim ring.  Pushpins secure the panel to the sidewall stud.
• Front bulkhead and transition panel cover shall be light gray padded vinyl.
• The passenger area floor covering shall be installed in accordance with the manufacturer’s recommendations.  Flooring shall be 3/16″ black ribbed rubber in the vestibule and aisle area with gray carpeting under the seats. Step treads and risers shall be covered with ribbed rubber, with a bright contrasting nosing at the forward edge.   
• Insulation – Minimum 1/2″ thick foam insulation shall be sprayed between the exterior skin and the interior panels.  Insulation shall be moisture proof and have excellent thermal and acoustic insulating characteristics.

HEATING/AIR CONDITIONING

Passenger compartment heating and air-conditioning are optional and should be specified based on the prevailing conditions in your operating area.

DOORS, WINDOWS

• Doors – shall be an outward opening, two-leaf type with an overlapping rubber seal at the meeting edges of the panels.  The door shall be attached to the body with two heavy-duty steel pivot pins with nylon bushings.  A heavy-duty bulb seal shall be installed at the top and hinged edge of the door and a brush type seal at the bottom edge.  Each door panel shall have an 11-gauge aluminum frame and shall be glazed with a full-height safety glass panel.   The door shall be driver-operated and electrically controlled.   The door clear opening shall be a minimum of 30″ wide by 89″ high. 
• Passenger Windows – The passenger windows shall be as large as possible and shall be of the full height slider type.  The windows shall be glazed with 23% LT tempered glass.  The window frame shall be black Flexnar coated.  Emergency escape provisions shall be in accordance with FMVSS 217.
• The front windshield and the driver’s left and right side windows will comply with FMVSS for tint and clarity requirements

ACCOMMODATIONS

Seating
Reference floorplans for seat configuration, layout and hip-to-knee room requirements.  The passenger seats shall be installed in seat track.  Integrated Child safety seats will be supplied two single restraint seats per vehicle (location to be determined prior to production).

Assists
An entrance grab rail shall be mounted to the aft side of the entry stepwell.  A stanchion and modesty panel shall be mounted in front of the first seat on the curbside of the bus.  A modesty panel with driver’s barrier shall be supplied.

Operators Area     
The operator’s work area shall be designed to minimize glare to the extent possible.  Objects within and adjacent to this area shall be dark gray in color wherever possible to reduce the reflection of light onto the windshield.

Visors
Adjustable sun visor(s) shall be provided for the side of the windshield and the operator’s side window.

Operator’s controls 
The chassis manufacturer’s standards switches, gauges and controls are acceptable.  All switches and controls added by the body manufacturer shall be conveniently located on a panel to the left of the operator and shall provide ease of operation.  The switches shall be of the backlit rocker type.   The air conditioning controls are exempt from this requirement. 

Driver’s seat 
The driver’s seat shall be a USSC 9002 mechanical seat.  The driver’s seat upholstery coordinated with the passenger seats.

Lift Door 
A single panel door, with a viewing window in the upper section, shall be provided.  The door panel shall consist of an 11-gauge aluminum frame with a composite skin. The lift door opening shall be in compliance with ADA regulations.  The door shall have an exterior lock and handle. A gas strut shall be provided to hold the door in the open position. 

Loading System 
All lifts shall be FMVSS 403/404 compliant  

Wheelchair Accommodations
Securement systems and their attachments to the vehicle shall be installed per manufacturers requirements and in accordance with SAE J2249.
The location of the lift and the securement systems are shown on the attached floor plan.