FIELD SERVICE BULLETIN

HC International
[ ] Safety Recall
[ ] Field Campaign
[X] Service Information
[ ] Product Improvement

Cab/Body Separation

FSB_2013-103
Revision: 0
Issue Date: 08/21/13
Manual Section: N/A
Author: Shawn Yopp
Approval: D. Hill
Form Rev. C 05/08/09

UNITS AFFECTED: Champion Bus and General Coach Golden Touch Units.
DESCRIPTION: Extreme conditions have caused separation of Cab and Body.
WARRANTY INFORMATION: CBI will compensate on a case-by-case basis
LABOR ALLOCATION: 1 Person – 2 Hours (a second person is needed for 15min)
CAMPAIGN EXPIRATION DATE: N/A
MATERIALS NEEDED:
Welder
Drill with screw bit
Socket/wrench
Supplied bracket, draw-plates and hardware

DISCLAIMER:
The procedures contained herein are not exclusive. General Coach America, Inc. cannot
possibly know, evaluate, or advise the transportation industry of all conceivable ways in which a
procedure may be undertaken or of the possible consequences of each such procedure. Other
procedures may be as good, or better, depending upon the particular circumstances involved.
Each carrier who uses the procedures herein must first satisfy itself thoroughly that neither the
safety of its employees or agents, nor the safety of any products, will be jeopardized by any
procedure selected.
PROCEDURE:

WARNING! Failure to follow Pre-welding instructions may void
warrantee of Electrical Systems. Refer to hybrid electrical disconnect
procedure supplement attached at the end of this Bulletin.

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1. Remove from front cab both extinguisher/bracket and flare/bracket from flooring just
forward of entry stairwell.

2. Remove staples and roll back front flooring mat, thus exposing cab floor.

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3. Place support bracket tight against stairwell structure (holes down) and align rectangular
cutout centered over cab support mount as shown.

4. Clamp bracket tightly to stair well in 2 places.

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5. Using drill and 3/8” steel bit, drill (7) holes through the cab floor using pre-drilled holes
in bracket as a guide.

6. Place supplied 3/8” x 1-1/2” grade-8 bolt & washer through drilled holes (7 places)

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7. From underside of bus, locate the newly protruded bolts and remove all foaming
materials around bolted area. Clear enough space to provide room for draw-plates.

8. Place first draw-plate (may require several attempts at orientation) and hold using
supplied washer and nylock grade-8 nuts.

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9. Tighten bolts to typical grade-8 bolt specifications.

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10. Disable PCM, Batteries and “kill switch” for hybrid systems per specifications of
disconnect procedures attached at the end of this bulletin.

11. Seal off compartment to prevent welding damage to interior of bus.

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12. Weld bracket on inside of bus to stair support structure, stitch-weld as shown using 1”
welds approximately 4” apart. Weld full length of bracket and (1) each side.

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13. Stitch-weld bracket to cab structure inside rectangular cutout as shown.

14. Replace matting, staples and emergency equipment removed.
15. Reconnect chassis electrical equipment.

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