Champion Defender

Additional Info

General Requirements and Dimensions for Ford F550 Series Chassis

CHASSIS Ford F550 SERIES

• The chassis shall be a Ford F550 bus chassis with a GVWR of *. The wheelbase shall be *.    (*Insert appropriate information from above table).
• The single fuel tank shall have the maximum capacity available from the chassis manufacturer.  
• Service brakes shall be heavy-duty disc brakes, with four-wheel anti-lock system.  The parking brake shall be a transmission mounted drum type.
• Six 19.5″ x 6.75″ steel wheels, shall be provided.  The tires shall be all-season steel belted radials, 225/70SR19.5G.  Mud flaps shall be provided at the rear tires.
• The engine shall be a 6.7L diesel or 6.8L V-10 gasoline engine. The cooling system shall be the highest capacity available for the specified chassis.  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 a Ford 6-speed automatic with auxiliary transmission cooler.
• Power steering shall be supplied.  A tilt steering wheel and cruise control are required.
• The tail pipe shall exit at the rear of the bus.

ELECTRICAL

Chassis

• The alternator shall be sized to meet the electrical load requirements and maintain a charged battery system.
• A dual battery system is provided.
• An OEM electric horn shall be provided.

GENERAL REQUIREMENTS AND DIMENSIONS FOR INTERNATIONAL CHASSIS

CHASSIS INTERNATIONAL SERIES

• The chassis shall be a International bus chassis with a GVWR of *. The wheelbase shall be *.    (*Insert appropriate information from above table).
• The single fuel tank shall have the maximum capacity available from the chassis manufacturer.  
• Service brakes shall be heavy-duty disc brakes, with four-wheel anti-lock system.  The parking brake shall be a transmission mounted drum type.
• Six 19.5″ x 6.75″ steel wheels, shall be provided.  The tires shall be all-season steel belted radials, 245/70R19.5G.  Mud flaps shall be provided at the rear tires.
• The engine shall be a MaxxForce 7 EPA 10 diesel. The cooling system shall be the highest capacity available for the specified chassis.  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 automatic with auxiliary transmission cooler.
• Power steering shall be supplied.  A tilt steering wheel and cruise control are required.
• The tail pipe shall exit at the rear of the bus.

ELECTRICAL

Chassis

• The alternator shall be sized to meet the electrical load requirements and maintain a charged battery system.
• Two12-volt batteries with a minimum rating of 770 CCA shall be provided.  Both batteries are located in the OEM tray under driver’s seat.
• An OEM electric horn shall be provided.

GENERAL REQUIREMENTS AND DIMENSIONS FOR M2 FREIGHTLINER DEFENDER

CHASSIS

• The chassis shall be a Freightliner M2  bus chassis with a GVWR of *. The wheelbase shall be *.    (*Insert appropriate information from above table).
• The single fuel tank shall have the maximum capacity available from the chassis manufacturer.  
• Service brakes shall be heavy-duty disc brakes, with four-wheel anti-lock system.  The parking brake shall be a transmission mounted drum type.
• Six 19.5″ x 6.75″ steel wheels, shall be provided.  The tires shall be all-season steel belted radials, 245/70R19.5F.  Mud flaps shall be provided at the rear tires.
• The engine shall be a Cummins ISB10 diesel . The cooling system shall be the highest capacity available for the specified chassis.  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 automatic with auxiliary transmission cooler.
• Power steering shall be supplied.  A tilt steering wheel and cruise control are required.
• The tail pipe shall exit at the rear of the bus.

ELECTRICAL

Chassis

• The alternator shall be sized to meet the electrical load requirements and maintain a charged battery system.
• A 2200 CCA battery system is provided.
• An OEM electric horn shall be provided.

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.
• A dome light shall be provided in the operator’s area to provide sufficient light to read a map.
• A light shall be provided in the stepwell to illuminate the step area.

Exterior

• The headlights and turn signals provided by the OEM chassis manufacturer are acceptable and should not be replaced.
• Exterior lights added by the body manufacturer are to be incandescent type.
• Round lights, four inches in diameter are to be mounted horizontally on the rear of the bus.  Red stop, turn and taillights, and white backup lights, are provided.
• Clearance and marker lights, amber front and red rear, are to be provided and mounted in compliance with FMVSS 108. 

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.  A 16 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” Channels 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 2.88″ x 2″ channel cross members, on a maximum 34″ 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 the chassis manufacturer’s requirements.
•  The floor shall be essentially a continuous flat plane, except at the stepwells, fuel fill cover and wheel housings.  The sub-floor shall be mounted with Tek screws installed into the steel floor frame and shall be a minimum 5/8″ thick, CDX plywood. The rear wheel housings shall be constructed of minimum 16-gauge steel.  The wheel housings shall not protrude above the floor more than 6.5″.
• The stepwells shall be constructed of 14-gauge steel.  All risers shall be of equal height, which shall not exceed 9″.

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 shall conceal the transition between the roof and the sidewalls and prevent water flowing from the roof onto the windows and sidewall.
• The body shall have a pre-baked enamel finish.  The basic body color shall be white to match the chassis cab.  PPG products shall be used, if touch up paint is required.
• An aluminum trim rail, minimum 2″ high, shall be applied to each side of the exterior skin, at the floor line of the bus.
• The exterior mirrors shall be Rosco (Ford), Lucerix (GM610) and OEM (GMT 560 chassis).
• 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 bumper shall be the chassis OEM chrome bumper.  The rear bumper shall be constructed of 10-gauge steel, powder coated black.
• 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 covered luaun.  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 covered luaun.  The panels are held in place at the lower edge by J-rail and at the top edge by the window trim ring.  Pushpins secure the panels to the sidewall studs.
• Front bulkhead and transition panel cover shall be light gray ABS plastic.
• 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

Entrance Door
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 AS2 glass panel.  The door shall be driver-operated and manually controlled and shall incorporate a locking feature.  The door clear opening shall be a minimum of 28″ wide by 80″ high.

Driver’s Door
The original chassis door, with a roll-up window, shall be supplied.

Passenger Windows
The passenger windows shall be as large as possible and shall be of the top T-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.

PASSENGER ACCOMMODATIONS

Seating
The standard passenger seats are to be mid-high back type and shall be installed in seat track.  Reference attached floor plan for seat configuration(s), layout and hip-to-knee room requirements. Perfect for special event transportation use for churches, hotels or even school events!

Assists
An entrance grab rail shall be mounted to both sides of the entry stepwell.  A stanchion and modesty panel shall be mounted in front of the first seat on the curbside of the bus.

Operators Area
General – 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 pod directly in front of the operator and shall provide ease of operation.  The location of the pod shall not interfere with the operator’s viewing area.  The switches shall be of the backlit rocker type.  The air conditioning controls are exempt from this requirement.

Driver’s Seat
Ford – The seat shall be a Freedman FSC Ford seat that mounts directly to the OEM base and slides.  GM – The seat shall be the OEM driver’s seat.  The driver’s seat upholstery shall be identical to the passenger seats.

Interior Mirrors
The rearview mirror provided by the chassis manufacturer shall be left in place.

If an ADA compliant accessible vehicle is required, the following optional equipment must be specified:
Accessibility Provisions
The buses shall meet all requirements of 49 CFR, Part 38, Subpart B:  ADA Accessibility Specifications for Transportation Vehicles – Buses, Vans and Systems.  This includes the loading system, wheelchair accommodations, interior circulation, passenger information, lighting, doors, signs, etc.

Lift Door
A dual 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.

NOTE:    This specification reflects the base model vehicle.  Many options are available which will allow you to tailor this specification to reflect your unique requirements.  Please contact Champion Bus, Inc. or your nearest Champion Dealer for assistance in developing your custom specifications.