Champion Crusader recalls

What is wrong

Champion Bus, Inc. (Champion) is recalling certain 2019 Challenger, Crusader, Defender and LF Transport and Goshen G-Force, Impulse and Pacer II shuttle buses equipped with Prolo roof emergency escape hatches. Due to a manufacturing issue, the roof hatch external handle may unexpectedly break under reasonable use.

Risk

If the roof hatch external handle breaks, in the event of an emergency, the hatch cannot be easily opened from outside the vehicle, increasing the risk of injury.

Remedy

Champion will notify owners, and dealers will replace the handle, free of charge. The recall began September 16, 2019. Owners may contact Champion customer service 1‑810‑724‑1753, extension 415.

Recall number 19V554000 · Recall details

What is wrong

Champion Bus (Champion) is recalling certain 2012-2018 Champion American Coach, American Crusader, American S2, Challenger, Crusader, Defender, and Impulse vehicles, equipped with certain S-Series and K-Series Titanium Wheelchair Lifts, models K200, K201, K550, K551, S200, S2201, S550 and S551. The wheelchair lift positioning input cam may fail while the lift is in use, allowing the platform to travel higher than the vehicle's floor height.

Risk

If the wheelchair lift platform stops above the vehicle floor, the wheelchair user can tip inwards toward the vehicle when exiting the lift, increasing their risk of injury.

Remedy

Dealers will replace the injection molded cam with an aluminum machined cam, free of charge. The recall began November 1, 2018. Owners may contact Champion customer service 1‑810‑724‑1753 extension 415 or Ricon customer service at 1‑800‑322‑2884 or by emailing Ricon at [email protected].

Recall number 18V573000 · Recall details

What is wrong

Champion Bus, Inc. (Champion) is recalling certain model year 2009-2015 Crusader, Stacked Rail, and CTS RE vehicles manufactured April 5, 2010, to October 14, 2015, equipped with Recaro Ergo-M Commercial Bus Driver Seats. The affected seats have J-Brackets that may be missing welds which could allow the seat belt anchorage assembly to separate from the J-Bracket.

Risk

If the seatbelt anchorage assembly separates from the J-Bracket, the bus driver may not be properly restrained in the event of a crash increasing their risk of injury.

Remedy

Champion will notify owners, and dealers will inspect the seats to determine if welds are missing. Any J-Bracket that is missing welds will be removed and replaced, free of charge. The recall began on February 25, 2016. Owners may contact Champion customer service at 1‑810‑724‑6474, or Johnson Controls (manufacturer of Recaro seats) customer service at 1‑248‑484‑3203.

Recall number 16V010000 · Recall details

What is wrong

Champion Bus, Inc. (Champion) is recalling certain model year 2006-2015 Challenger, Defender, Crusader, American, American Coach, American Crusader, Corporal, CTS-FE, CTS-RE, HC American, Platinum Shuttle, and Stacked Rail transit buses manufactured January 1, 2006, to August 25, 2015, equipped with certain model S2005, S2010, S5005, S5010, S5505, and S5510 wheelchair lifts. The affected lifts are equipped with folding link arms that may have pivot holes that are too big, allowing the bearings to move out of position.

Risk

If the bearings move out of position, the stowed platform may have excessive movement resulting in failure of the platform mounting. This failure could cause the wheel chair lift platform to fall out of the vehicle when the doors are opened, increasing the risk of injury for the lift operator.

Remedy

Champion will notify owners, and Ricon will inspect the link arms for damage or for displaced bearings. The platform will be inspected for cracks. Any damaged parts will be replaced, free of charge. The recall began on December 21, 2015. Owners may contact Champion customer service at 1‑810‑724‑1753 extension 415, or Ricon customer service at 1‑800‑322‑2884. Champion's number for this recall is 15E-068. Note: These buses and wheelchair lifts were subject to a similar recall in 2014. All vehicles that received that recall remedy are still affected by this recall as well.

Recall number 15V757000 · Recall details

What is wrong

Champion Bus, Inc. (Champion) is recalling certain model year 2013-2015 American Crusader, American Coach, Challenger, Crusader, CTS-FE, CTS-RE, Defender, EZ Trans, HCAC, HC, DFUC, LF Transport, Premier, and Spirit transit buses manufactured March 1, 2013, to June 12, 2015. In the affected vehicles, the passenger seat belts may rub against the metal seat frame and fray. As a result, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 209, "Seat Belt Assemblies."

Risk

A frayed seat belt fray may fail to properly restrain the seat occupant in the event of a crash, increasing the risk of injury.

Remedy

Champion will notify owners, and dealers will install a plastic sleeve over the metal seat frame, and replace any seat belts that show evidence of fraying, free of charge. The recall began on September 16, 2015. Owners may contact Champion customer service at 1‑810‑724‑1753 extension 562.

Recall number 15V391000 · Recall details

What is wrong

Champion Bus, Inc. (Champion) is recalling certain model year 2012-2014 American Crusader, Challenger, Crusader, CTS-FE, CTS-RE, Defender, EZ-Street, HC American, HCAC, LF Transport, M1235, Platinum Shuttle, Stacked Rail, and Federal Coach Premier, and Spirit transit buses manufactured January 1, 2012, to October 1, 2014, equipped with certain triangle warning signs manufactured by Imperial Supplies, LLC. Test reports indicate that the triangle warning signs, labeled C&J, may reflect an inadequate amount of light. As such, these triangle warning kits fail to comply with Federal Motor Vehicle Safety Standard No. 125, "Warning devices."

Risk

Warning triangles that do not properly reflect light may fail to warn others that a vehicle is parked, increasing the risk of a crash.

Remedy

Champion will notify owners to inspect their triangles for production dates between April 2011, to April 2014, and the affected triangles will be replaced, free of charge. The recall began on January 6, 2015. Owners may contact Champion customer service at 1‑810‑724‑6474.

Recall number 14V821000 · Recall details

What is wrong

Champion Bus, Inc. (Champion) is recalling certain model year 2014-2015 LF Transport, HCAC, Defender, Crusader, and Challenger transit buses manufactured September 2, 2014, to October 14, 2014. The spring nuts used to secure the passenger seats failed durability testing.

Risk

Spring nuts that fail to secure the seat and allow seat movement could increase the risk of personal injury in the event of a vehicle crash.

Remedy

Champion will notify owners, and dealers will replace the defective seat nuts, free of charge. The recall began in December 2014. Owners may contact Champion at 1‑810‑724‑6474.

Recall number 14V748000 · Recall details

What is wrong

Champion Bus, Inc. (Champion Bus) is recalling certain model year 2006-2014 American Coach, American Crusader, Challenger, Corporal, Crusader, CTS-FE, CTS-RE, Defender, HCAC, HC American, Platinum Shuttle, and Stacked Rail transit buses manufactured January 1, 2006, to July 31, 2014, equipped with certain model S2005, S2010, S5005, S5010, S5505, and S5510 wheelchair lifts manufactured by Ricon Corporation. The platform side plate of the affected wheelchair lifts may crack.

Risk

If the platform side plates crack, the lift platform can separate from the lift and come to rest against the vehicle's lift door. When the doors are opened, the platform may fall out, increasing the risk of injury to the lift operator.

Remedy

Champion Bus will notify owners to take buses to a Ricon dealer or service center who will install supplemental platform support bumpers. Any platform that has already started cracking will be replaced, free of charge. The recall began in November 2014. Owners may contact Champion Bus customer service at 1‑810‑724‑6474. Owners may contact Ricon customer service at 1‑800‑322‑2884.

Recall number 14V742000 · Recall details

What is wrong

Champion Bus is recalling certain model year 2010 American Crusader, American Coach, CTS-FE, CTS-RE, and IC Low Floor buses; and 2009-2010 Challenger and Crusader buses; and 2009-2011 Defender and EZ Trans buses; and 2010-2011 IC High Floor buses. The buses are manufactured from August 1, 2009, through May 19, 2011, and equipped with A&M Systems door headers containing model 3230 circuit boards. Voltage spikes may damage electrical components and electrical circuits, causing the circuit board to develop high resistance.

Risk

High resistance may cause the board to overheat, increasing the risk of a fire.

Remedy

Champion Bus will notify owners, and dealers will inspect the door header and replace any defective circuit board, free of charge. The recall began on October 22, 2013. Owners may contact Champion at 1‑810‑724‑6474.

Recall number 13V422000 · Recall details

What is wrong

Champion Bus is recalling certain model year 2006, and certain model year 2008-2013 buses, models: American Crusader, Challenger, Crusader, and Defender; manufactured September 30, 2006, through November 16, 2012. The buses are equipped with a Ricon manufactured wheelchair lift which has an optional armored pendant cable. The cable may have been installed such that it doesn't clear the wheelchair lift and without a protective cover, or a misinstalled protective cover.

Risk

The cable may contact the power lug at the base of the wheel chair lift causing a short circuit that could result in a fire.

Remedy

Champion Bus is working with Ricon to notify owners. Ricon will provide a supplemental cover kit with instructions, free of charge. Owners may contact Champion Bus at 1‑819‑724‑6474 or Ricon at 1‑818‑267‑3000.

Recall number 12V593000 · Recall details

What is wrong

Champion bus is recalling certain model year 2008 through 2011 transit buses equipped with braun century-2 and/or vista-2 wheelchair lifts. Over time and with frequent use, the roll stop latches on the outer barrier may become bent or misaligned.

Risk

A wheelchair occupant may defeat or ride over the insufficiently latched roll stop. If this occurs when the lift platform is in an elevated position, the wheelchair’s occupant could fall and sustain injury.

Remedy

Champion bus will notify owners, and the repairs will be performed by authorized braun dealers free of charge. The safety recall began on august 17, 2012. Owners may contact champion bus at 1‑810‑724‑6474.

Recall number 12V275000 · Recall details

What is wrong

Champion bus is recalling certain vehicles equipped with carrier genv em-1 evaporator units. Due to time, temperature, and/or vibration, the fuse may loosen in the fuse holder resulting in high resistance and arcing.

Risk

If sufficient arcing occurs, the fuse holder may melt, and may be accompanied by flame, smoke and potential fire.

Remedy

Champion bus will notify owners and provide information on how to obtain the retrofit kit from carrier along with repair instructions. This service will be performed free of charge. The safety recall began on march 8, 2011. Owner may contact carrier at 1‑800‑793‑4741 or champion bus at 1‑810‑724‑6474.

Recall number 11V141000 · Recall details

What is wrong

Champion bus has notified the federal safety agency about a defect in certain model year 2008-2010 buses manufactured between september 2007 and february 2010, equipped with certain ricon s series and k series l-model wheelchair lifts, due to a problem in the software that controls the lift's "up" function. If the "up" switch is released before the floor level limit switch is activated, the lift may continue its upward travel for approximately 1 second before stopping. The continued upward travel may overrun the floor level cut off point.

Risk

When the platform overruns the vehicle floor level and stops at an angle from 15-20 degrees, it is possible for a person in a wheelchair to tip over and for someone standing on the platform to fall, possibly resulting in injuries.

Remedy

Champion bus will notify owners and the repairs will be performed by authorized ricon dealers please see ricon's defect report 09e-061. Ricon will provide owners with a bulletin outlining proper wheelchair lift operation and will ship owners a dvd-based training aid to promote proper lift operation. The safety recall is expected to begin during may 2010. Owners may contact ricon customer service at 800- 322-2884, emailing at [email protected].

Recall number 10V131000 · Recall details

What is wrong

Champion bus has notified the federal safety agency of a defect in certain model year 2007-2010 buses fitted with ricon public use lifts. The restraint belt on these lifts was designed to prevent the lift from moving, unless the tongue of the belt is fully engaged and latched in the buckle. Ricon has discovered, however, that it is possible for the operator to insert the belt tongue into the buckle without fully engaging the latching mechanism. In this case, the restraint belt would appear to be latched, and the operator could run the lift. If the restraint belt tongue is not fully engaged into the restraint belt buckle, and latched, the lift may operate with an occupant on the platform.

Risk

The user of the lift could be injured should the lift move without the restraint belt properly buckled.

Remedy

Champion bus is working with ricon and ricon will be handling the remedy for this campaign. Please see ricon's defect report 09e-060. Ricon will provide customers with a warning decal and a dvd-based training aid. The safety recall began on may 5, 2010. Owners may contact ricon customer service at 800‑322‑2884, emailing at [email protected].

Recall number 10V129000 · Recall details

What is wrong

Champion bus is recalling certain model year 2009 and 2010 transit buses equipped with carrier k410 rooftop condensers. Inadequate overcurrent protection of one or more of the fans in the k410 condenser may cause overheating of the fan's wires.

Risk

Overheating of the condenser unit wires could result in a fire causing property damage, personal injury or death.

Remedy

Champion bus will notify owners to contact an authorized carrier dealer to obtain the remedy free of charge. Please also see carrier's defect report 09e-055. The safety recall began on november 30, 2009. Owners may contact carrier at 1‑800‑673‑2431 or champion bus at 1‑810‑724‑6474.

Recall number 09V426000 · Recall details

What is wrong

Champion bus is recalling 503 my 2005-2007 challenger, crusader, defender, my 2005-2006 corporal, my 2006 cts-re, and my 2007 cts-fe and ic defender transit buses equipped with a ricon platform style wheelchair lift. This lift fails to comply with the requirements of federal motor vehicle safety standard no. 403, "platform lift systems for motor vehicles." the anti-stow interlock may not detect the presence of a wheelchair or mobility aid user. The pressure sensing switch that detects the presence of weight on the platform was not adjusted to the necessary sensitivity level. The lift could stow even though someone or something is still on the lift.

Risk

A lift occupant can be injured should the lift begin to stow unintentionally.

Remedy

Champion bus is working with ricon to correct the wheelchair lift free of charge (please see 07e097). Owners may contact ricon at 1‑818‑267‑3000 or champion bus at 1‑800‑331‑5761.

Recall number 08V490000 · Recall details

What is wrong

Champion bus is recalling 31 my 2007-2008 defender, challenger and my 2008 crusader buses built on general motors 560 chassis and equipped with intermotive gateway 401 module interlock harness. These buses have been found to exhibit extreme voltage spikes during engine cranking. These extreme spikes can damage the diode in the harness near the shift lock solenoid connector. If the diode fails in the shorted condition, the gateway 401 module can be damaged.

Risk

If this occurs, the shift lock solenoid may not engage. If this lock does not engage, the vehicle will have the ability to move while the wheelchair lift is deployed which may result in personal injury.

Remedy

Intermotive is handling the remedy for this campaign (please see 08e004). Intermotive will replace the defective harness free of charge. Owners may contact intermotive at 1‑800‑969‑6080 or champion bus at 1‑810‑724‑6474.

Recall number 08V225000 · Recall details

What is wrong

Champion bus is recalling 503 my 2005-2008 defender, challenger, cts-re, cts-fe and crusader buses equipped with ricon platform style wheelchair lifts. These buses fail to comply with the requirements of federal motor vehicle safety standard no. 404, "platform lift installations in motor vehicles." the threshold warning system may not detect the presence of a wheelchair or mobility aid user in a certain spot within the defined threshold area.

Risk

The user of the lift could be injured should the lift move unintentionally.

Remedy

Champion bus is working with ricon to correct the wheelchair lifts free of charge (please see 07e095). Owners may contact ricon at 1‑818‑267‑3000 or champion bus at 1‑937‑596‑6849.

Recall number 08V182000 · Recall details

What is wrong

Certain buses equipped with ricon platform style wheelchair lifts fail to comply with the requirements of federal motor vehicle safety standard no. 403, 'platform lift systems for motor vehicles.' the inner barrier interlock switch system in the lift baseplate may not detect the presence of a passenger (either wheelchair or standee) on the barrier and can allow the platform to move down more than one inch below floor level when occupied.

Risk

In the event this condition occurs during passenger operations, it may be possible for the wheelchair to tip backwards onto the platform if the user is backing onto the lift from inside the vehicle and has the small front wheels fully or partially on the inner barrier when the platform was lowered. A person standing could lose his or her balance if they were positioned fully or partly on the inner barrier when the platform was lowered. Either condition could cause personal injury.

Remedy

Champion bus is working with ricon to repair these wheelchair lifts (please see 06e101). Owners can contact ricon at 1‑800‑322‑2884 or champion bus at 1‑800‑331‑5761.

Recall number 07V061000 · Recall details

What is wrong

On certain diesel buses built on ford e-series chassis and equipped with carrier vacuum pump brackets, the brackets could break.

Risk

When the bracket breaks, the vacuum pump that provides the power to the power brakes becomes inoperative, increasing the risk of a crash. Also, the power steering could be affected if the belt gets caught in the other belts.

Remedy

Carrier is conducting the owner notification and remedy for this campaign. Owners may contact carrier service department at 1‑800‑450‑2211.

Recall number 05V174000 · Recall details

What is wrong

On certain buses equipped with sure-lok wheelchair securement systems, the sprocket teeth of the retractor assembly is out of alignment.

Risk

In the event of a vehicle crash, the wheelchair may not be adequately secured possibly resulting in injuries to a wheelchair occupant.

Remedy

Sure-lok is conducting the owner notification and remedy for this campaign. Dealers will inspect and replace the wheelchair securement retractors as necessary. Owners should contact sure-lock at 1‑908‑231‑1804 or champion at 810‑724‑6474.

Recall number 04V521000 · Recall details

What is wrong

On certain buses equipped with cp traveling retractor lap (type 1) seat belts, the plastic cover housing the reserve end of the seat belt web can break. If the two halves of the cover completely separate, the connector portion of the belt will detach from the cover. Once detached, the connector rivet can separate from the connector frame causing the frame to become unusable.

Risk

This condition cannot occur during use, however, the belt will be unsuable and may result in an occupant seating position without a seat belt. In the event of a vehicle crash, an unbelted individual could be seriously injured or killed.

Remedy

Amsafe will notify its customers and provide a plastic outer cover that snaps over the existing cover on units in the field and will replace broken seat belts free of charge. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact amsafe at 574‑266‑8330 or champion at 810‑724‑6474.

Recall number 02V160006 · Recall details