Caltrans

Creative Bus Sales

ELDorado National Factory Audit Pilot Vehicle Report

AEROELITE FORD 290 Class (E) Larger Cutaway Bus

Author: John Cano/Ralph Martinez

DGS Contract

No. 7-12-23-15-05

March 27, 2014

Table of Contents

Section-1. Introduction

Section-1.1 Post-Delivery Certification-DGS Contract# 7-12-23-15-05

Section-1.2 Pilot Vehicle Quote/Build Sheet/Purchase Order/Floor Plan

Section-1.3 Post-Delivery Completed Vehicle Inspection Report. (Tare Weight Analysis/Final Alignment Report/FMVSS Cert. Decal/Vehicle Incomplete Vin. Decal)

Section-2. Caltrans/Eldorado National Vehicle Initial Factory Audit/Pilot

Review Notes. (Salina, Kansas 03/27/2014 Pre-Award)

Section-3. Caltrans Post-Delivery Factory Pilot Vehicle Review Report

(Chino, California 05/22/2014 & 6/11/2014 First Article)

Section-4. Pre-Award Buy America Certificate and Parts Country of

Origin

Section-5. Post Award Buy America Certificate and Parts Country of Origin

Section-6. Federal Motor Vehicle Safety Standard Self Certification Cert

Section-7. Factory Pictures

Section-8. Supporting Documentation

A. Plant Flow

B. Quality Assurance Manual

C. Welding Testing and Certificates

D. Fastener Testing

E. Torque Wrench Calibration Log

F. Sample Drawings

G. Paint Adhesion And Thickness Testing

H. ISO 9001-08 Certification

I. ElDorado National AeroElite 290 Manufacturer Vehicle Warranty

Continued..

Page 2.

Table Of Contents:

J. Documentation/Proof Altoona Testing

K. Headlamp Adjustment Procedure

L. Suspension And Alignment Procedure

M. Altro Flooring Warranty Statement

N. Water Test Certification

O. Air Conditioning Charging And Recovery Procedure

P. ADA Lighting Test Certificate

Q. Floor Plan And Weight Analysis

R. Amperage Draw Test

Section 1– Introduction

On March 28 , 2014 the State Department of Transportation (Caltrans), Division of Mass Transportation

representatives conducted an on-site Factory Pre-Award and Post-Delivery Vehicle Inspection, aka First

Article Pilot Inspection on behalf of Federal Transit Administration (FTA) in accordance with Federal

Regulation Title 49 CFR Sub-Part 663, Pre-Award and Post-Delivery Audits of Rolling Stock Purchases.

A Post-Delivery review was started on May 22, 2014 and completed with acceptance of the First Article

on June 12, 2014 as specified in the Department of General Services (DGS) Contract# 7-12-23-15-05.

This report will serve as a historic record of proof confirming due diligence in meeting all contract

requirements by the Contractor Creative Bus Sales and the vehicle manufacturer ElDorado National

Corporation.

The First Article Pilot Inspection included a 2013 Ford F550 AEROELITE 290 Class (E) (VIN#

1FDGF5GY4DEA51978). Included in the Audit Report are documents confirming ELDORADO National

Corporation stated position of compliance with Title 49 CFR part 663.31, Post-Delivery Audit

Requirements. Caltrans Post-Delivery Review confirms this vehicle meets the requirements under 49

CFR Part 663.35, Post-Delivery Buy America Certification; 49 CFR Part 663.37, Post-Delivery Purchaser’s

Requirement Certification including meeting contract specification, vehicle construction and

roadworthiness; and 49 CFR Part 663.41, certification of compliance with Federal Motor Vehicle Safety

Standards.

In addition Caltrans also confirms this vehicle has met the applicable requirements of the California

Vehicle Safety Standard Code of Regulation Title 13; California Health and Safety Code; California Air

Resource Board and Environmental Agency Regulation; and the Society of Automotive Engineers and

International Standards.

All supporting documents detailed in this report were provided by the representatives of the respective

supplier companies with the intent to satisfy the requirements set forth by Federal and State Authority.

As required, Caltrans also confirms that final assembly of this vehicle took place in the United States.

Eldorado National Corporation is a second stage manufacturer situated at 1655 Wall Street, Salina,

Kansas, specializing in the manufacturing of accessible and mobility vehicles. The manufacturer has been

in existence respectively for 35 years.

-John Cano-

Caltrans Senior Vehicle Inspector

Section 1.1

Post Delivery Certification-DGS Contract#7-12-23-15-05

Section 1.2 Pilot Vehicle State Purchase Order/ Quote /Floor Plan/Build Sheet

Section-1.3

Post-Delivery Completed Vehicle Inspection Report

(Tare Weight Analysis/Final Alignment Report/FMVSS Vehicle Certification Decal)

Section 2.

Caltrans Pre-Award Factory Pilot Vehicle Review Notes & Report

Salina, Kansas 03/27/2014

Section 3.

Caltrans First Article & Post-Delivery Vehicle Review Report

Chino, California 05/22/2014 & 06/11/2014

2014 Pre-Award/First Article Vehicle Inspection Report

El Dorado National Kansas

Grant 61 RFP#11-03

AEROELITE FORD 290Class E Larger

VIN#1FDG5GY4DEA51978 EBC#EFTGN291ME04A5617

Pilot Vehicle:

1) Relocate Drivers Modesty Panel To Front to comply with ADA Hip/Knee Envelope. Task completed and

verified 31” Hip/Knee clearance 05/22/2014

2) Overhead Yellow Grab Elbow Rails need to be fitted properly. Task completed and verified 05/22/2014

3) Street side Interior Second Row Seat Base needs to be secured. Task completed and verified 05/22/2014

4) Rosco Mirror Controller Panel Requires relocation to provide a Visual. Task completed and verified

05/22/2014

5) Continuous Weld on exhaust pipe Joints. (do not weld Tail Pipe) Task completed and verified 05/22/2014

6) Exhaust hanger are not to be welded. Task completed and verified05/22/2014

7) Install Decal to identify Air Conditioning Service ports. Task completed and verified 05/21/2014

8) Install Coolant Capacity Decal. Pending re-inspection. Task Completed 06/11/2014-John

9) Decals to be placed on Under Hood Deck. Pending re-inspection. Task completed 06/11/2014

10) Install Lighting on Interior Wheel Chair Door Area. Task completed and verified 05/21/2014

11) Exterior Wheel Chair Door Not Operational. Task completed and verified 05/21/2014

12) Caltrans Accepted Screws on End caps to be mounted with metal screws to be secured into floor

metal. Task Completed and verified 05/21/2014

13) Install Armrest on Rear Wall Mount flip seat. Task completed and verified 05/21/2014

14) Install Exterior Wheel Chair Ground light. Task completed and verified 05/21/2014

15) Interior/Exterior Stairwell lighting should not operate with interior passenger area lighting while

vehicle is in motion. Task completed and verified 05/21/2014

Continued..

Requested Documentation:

1) Weld Testing And Employee Certifications. Task completed 04/21/2014-John Cano

2) Provide Extended Warranty Statement On Flooring. Task completed 04/16/2014-John Cano

3) Operating Manual on Headlight Aiming Procedure. Task completed and verified 05/22/20140-John Cano

4) Provide Supporting Documents on Suspension Alignment Process and Procedure. Need confirmation on Toe Specifications being set at second stage manufacturer prior to shipment. Ford QVM process calls for this procedure .

5) Provide Supporting Documents on Amperage Draw Calculation Exclusive to AeroElite 290. Task com-pleted and verified 04/19/2014 –John Cano

6) Buy America Cost Break Down (Post Delivery). Task completed and verified 04/19/2014-John Cano

7) Buy America Certificate of Origin. (Pilot Post Delivery). Task completed and verified 04/19/2014-John Cano

8) Vehicle Warranty Information (Second Stage). Task completed and verified 05/22/2014. Manufacturer provided thumb

drive.-John Cano

9) Vehicle As Built Owners Manual. Task Completed and verified 05/22/2014. Manufacturer provided thumb drive.-John Cano

10) Air Conditioning System Installation And Charging Procedure. Need to get confirmation that dealer will check all unit ‘s as part of PDI process. Don White needs to confirm this action will take place. 06/11/2014 Don White confirmed A/C charge levels will be

done as a PDI on every vehicle moving forward. –John Cano

Notes: First Article Pilot Inspection 05/22/2014 and 06/11/2014

1) Overhead Grab Rails (Curb Side) Needs to be replaced and adjusted to match Street side and be

at equal height of 2 1/2” front top of rail and ceiling. Task completed and verified 06/12/2014-John Cano

2) Auxiliary Battery Decal needs to be installed under Hood Lid to identify one exist. Dealer has

agreed to provide. Manufacturer did not include on pilot. Task completed and verified 06/12/2014-John Cano

3) Decal must be installed that identifies secondary air conditioner service port locations. Dealer

has agreed to provide. Manufacturer did not include on pilot. Task Completed and verified 06/12/2014-John Cano

4) Second L-Track (From Front) lacking a hold down screw. Dealer corrected deficiency

05/22/2014. Task completed and verified 06/11/2014—John Cano

5) Radiator Fan Shroud will need to be replaced discovered 05/22/2014 to be ruined as a result of

change to A/C compressor. Dealer has agreed to correct and replace 05/22/2014. Task completed and verified 06/12/2014-John

6) A/C Compressor will require re-designed Bracket/Support. Dealer replaced bracket and

corrected 05/22/2014. Need to confirm with dealer that this shall be expectation. Dealer confirmed (Don White) With ElDorado that New A/C Bracket will be Installed on all vehicle’s.-John 06/12/2014

7) Flooring (at front) behind modesty panel will require welding to seal floor. Task completed and verified 06/12/2014-John

8) All Braun Wheel Chair lifts shall be equipped with Safety Belts at no charge. Don White Confirmed with

Braun. This Belts will be provided and installed by dealer at no extra charge. 06/11/2014-john

Section 4.

Pre-Award Buy America Certificate And Country of Origin

Section 5.

Post Award Buy America Certificate and Parts Country of Origin

Section 6.

Federal Motor Vehicle Safety Standard Self Certification Certificate

Section 7.

Factory Pictures

Section 8.

Supporting Documentation

A.Plant Flow

B. Quality Assurance Manual

C. Welding Testing And Certificates

D. Fastener Testing Certificates

E. Meter and Torque Wrench Calibration and Certification

F. Sample Drawings

G. Paint Adhesion And Thickness Testing

H. ISO 9001-08 Certification

I. AeroElite 290 Manufacturer Warranty

J. Altoona Testing Documentation

K. Headlamp Adjustment Procedure

L. Suspension And Alignment Procedure

M. Altro Flooring Adhesive Warranty Statement

N. Water Test Certification

O. Air Conditioning Charging And Recovery Procedure

P. ADA Lighting Test Certification

Q. Floor Plan And Weight Analysis

R. Amperage Draw Test