bus body building guidelines for body builder - …dealer.vecv.net/dcs/pdf/annexure 08_eicher...

SECTION - 11

^mJ -11

BUS BODY BUILDING GUIDELINES FOR BODY BUILDER

11-1

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l Preface

The purpose of this docket is to provide

comprehensive informa�on on building

bus body on the drive away chassis

supplied by VE Commercial Vehicles Ltd.

This informa�on in the form of pictures

will facilitate in building bus of your

choice. The pictures in this docket are for

reference only.

The flow of this docket is as per the

following sub heads:

_ chassis 2 - 3

( Precautions )

_ Structure 4 - 13

( Cowl Integration )

_ Considerations 14 - 42

( service / maintenance )

_ Cladding / Body 43-43

( Steps / add-ons)

_ Miscellaneous 44-50

( Installations / Seating)

l àñVmdZm

Bg gmam±e (Do cket) H$m CÔoí` VE H$_{e©`b

do{hH$ëg {b{_Q>oS> Ûmam àXmZ {H$ò JE S´mBd Ado

Mo{gg na ~g ~°m‹S>r ~ZmZo hoVw {dñV¥V OmZH$mar

XoZm h¡& {MÌmo Ho$ én _| `h gyMZm AmnH$mo AnZr

ng§X >H$s ~g ~m°S>r ~ZmZo Ho$ {bò gw{dYm OZH$

hmoJr& Bg S>°mHo$Q> Ho$ {MÌ Ho$db g§X^© Ho$ {bò h¢& Bg

gmam§e H$m àdmh {ZåZ§m[H$V Cn erf©H$m| Ho$ AZwgma

h¢&

- Mo{gg 2-3

( gmdYm{Z`m± )

- T>m§Mm 4-13

(H$mCb B§Q>rJ«oeZ )

- H§$grS>aoeÝg 14-42

( godm / g§YmaU )

- Šb¡qS>J / ~m°S>r 43-43

( H X_/ Omo‹S>Zm h_|)

- {d{dY 44-50

( ñWmnZm / goqQ>½g )

BUS BODY BUILDING GUIDELINES ~g ~m°‹S>r {~pëS>¨J JmB©S> bmB©Ýg

11-2

BUS BODY BUILDING GUIDELINES FOR BODY BUILDER11

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l Chassis

The standard bus chassis comes along

with fitted cowl structure, steering

column, instrument cluster, driver seat

and spare tyre.

Following precautions to be taken of

various components of chassis during

body building to avoid any damage.

l Cowl

The chassis and cowl must not be cut for

bus body building. The steering column

and all the controls should not be

disturbed.

l Chassis Frame

No Holes to be drilled on the chassis and

welding is strictly prohibited.

The chassis frame, leaf springs and

radiator should be covered properly to

avoid any falling of weld splatters and also

to safe guard against any sudden impacts.

l Mo{gg

_mZH$ ~g Mo{gg {\$Q> {H$ò hþE H$mCb T>m§Mo ,

ñQ>r`[a¨J H$°mb_, BÝñQ®>_|Q> ŠbñQ>a MmbH$ grQ>

VWm A{V[aŠV Q>mà g{hV àXmZ {H$`m OmVm h¡ &

~°m‹S>r ~ZmVo g_` {d{dY H§$mnmoZ|Q²>g H$mo {H$gr àH$ma

H$s j{V Z hmo, Bgo Ü`mZ _| aIVo hþE {ZåZ

gmdYm{Z`m± ~aVZr hmoJr &

l H$mCb

~g H$s ~°m‹S>r ~ZmZo Ho$ {bò Mo{gg Am¡a H$mCb H$mo

H$mQ>Zm Zhr§ Mm{hò ñQ>r`[a¨J H$mCb Am¡a g^r

H§$Q´>moëg H$moo N>mo‹‹S>m Zhr OmZm Mm{h`|

l Mo{gg \«o$_

Mo{gg na H$moB© N>oX {S´>b Z {H$`m OmE Am¡a dopëS>¨J

H$s g»V _Zm hr h¡ , Mo{gg \«o$_ H$_mZr Ho$ nÅ>m|

(br\$ pñà¨½g ) VWm ao{S>EQ>a H$mo AÀN>o go T>m§H$ XoZm

Mm{hò, Vm{H$ dopëS>¨J H$aVo g_` C‹S>Zo dmbo N>rQ>o

(Spla�ers) CZ na Z {Jao Am¡a {H$gr Vah H$s

Q>ŠH$a Z hmo&

BUS BODY BUILDING GUIDELINES (Contd..)

~g ~m°‹S>r {~pëS>¨J JmB©S> bmB©Ýg (H«$_e:)

11-3

11BUS BODY BUILDING GUIDELINES FOR BODY BUILDER

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l Tyres

Removable type proper covers should be

put on all the tyres to protect them from

falling of weld splatters and paint over

spays.

l Electrical Equipments

All the electrical equipments including

batteries should be isolated to protect

them from current surges due to welding

equipments.

l Piping and Wiring

While working on the bus body proper

covering of the cowl and chassis is to be

done to avoid any damage to all piping

and wirings. The suggested covering is

illustrated in the image below.

l Q>mà

g^r Q>màmo§ na hQ>mE Om gH$Zo dmbo H$dg© S>mb XoZm

Mm{hò Vm{H$ dopëS>¨J _| N>rQ>o VWm ñào H$m a§J CZ na

Z {Jao&

l {dÚwV gm_J«r (Equipments)

dopëS>¨J CnH$aUm| Ho$ H$maU Omo H$a|Q>© gO© hmoVm h¡ Cg

go ~Mmd hoVw gmar {dÚwV gm_m{J«`m| Am¡a ~¡Q>ar H$mo

AbJ H$a XoZm Mm{hò&

l nmBqnJ Am¡a dm`[a¨J

~g ~m°S>r na H$m_ H$aVo g_` H$mCb VWm Mo{gg H$mo

^br ^m§{V T>§H$ X| Vm{H$ g^r nmBnm| d dm`[a¨J H$mo

H$moB© j{V Z hmo ZrMo X{e©V N>{d _| H$da H$aZo H$m

VarH$m gwPm`m J`m h¡§&

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l Chassis

The chassis is fitted with following

standard equipments.

- Headlamp & Indicator lamp set

- Wiper arm assembly

- Rear combination lamp

Following general precautions to be taken

during the body building:

- The head lamp level and the distance

between them should not be changed.

- Chassis cross members should not be

dismantled as they are properly torque

at the Factory.

- The Cowl structure should not be

dismantled for bus body.

- The vehicle suspension is factory fitted

and it should not be dismantled or

modified.

l Mo{gg

Mo{gg _| {ZåZm§{H$V _mZH$ dñVwE± {\$Q> ahVr h¢&

- h¡S> b¢n Am¡a g§Ho$VH$ ~Îmr H$m goQ>

- dmBna Am_© Ago§å~br

- [a`a H$mpå~ZoeZ b¡ån

~°m‹S>r ~ZmVo g_` {ZåZ gmdYm{Z`m± ~aVr OmE±-

- h¡S> b¢n H$m bodb Am¡a CZHo$ ~rM Ho$ A§Va H$mo

~Xbm Z OmE&

- Mo{gg H«$mg _o§~g© H$mo Z Imobo§ Š`m§o{H$ CÝh|

H$maImZo _| hr AÀN>o go Q>mH©$ {H$`m OmVm h¡

- ~g ~m‹°‹S>s Ho$ {b`o H$mCb Ho$ T>§mMo H$mo Z Imob| &

- dmhZ H$m gñn|eZ H$maImZo _| {\$Q> {H$`m hþAm

hmoVm h¡ Am¡a Cgo Z Vmo Imobm OmE Am¡a Z Cg_|

H$moB© ~Xbmd {H$`m OmE &



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l Body Structure

Before commencing the body work on

the chassis, it is suggested to follow the

general guidelines in the various sub

heads mentioned below. The specific

guidelines for individual parts are

mentioned in the following pages of the

docket.

l Body Design

- The body design should be optimum for

the rated GVW and the desired payload

of the vehicle.

- The rated axle weight should never be

exceeded under any circumstances.

- The Shell structure design should

combine the strength and flexibility.

- It is suggested to distribute the overall

load evenly throughout the length and

width of chassis frame in order to

a c h i e v e t h e o p t i m u m w e i g h t

balancing.

l ~m°‹S>r H$m T>m§Mm (Structure)

Mo{gg na ~m°S>r H$m H$m`© Ama§^ H$aZo Ho$ nhbo, ZrMo

C n-erf©H$mo _| _o§ d{U©V gm_mÝ` {Xem{ZX}em| H$m

nmbZ H$aZo H$s gbmh Xr OmVr h¡, EH$b (AbJ-

AbJ) nwOm} Ho$ {bò {d{eï> {Xem{ZX}e S>m°Ho$Q> Ho$

{ZåZm§{H$V n¥ð>mo na {Xò JE h¡&

l ~m°‹S>r {S>µOmBZ (g§aMZm)

- ~m°‹S>r H$s {S>µOmBZ {Z{X©ï> GVW Ho$ Am¡a dmhZ Ho$

~m§{YV nobmoS> Ho$ {bò A{YH$V_ hmoZr Mm{hò&

- {H$gr ^r hmbV _| {Z{X©ï> Raled g\$b ^ma go

A{YH$ Zhr§ hmoZm Mm{hò&

- eob T>§mMo H$s {S>µOmBZ _| _a~yVr Am¡a Z_Zr`Vm

H$m g_Ýd` hmoZm Mm{hò &

- A{YH$V_ ̂ ma g§VwbZ àmßV H$aZo H$aZo Ho$ {bò

am` Xr OmVr h¡ {H$ Mo{gg _| nyar b§~mB© Am¡a

Mm¡‹S>mB© VH$ Hw$b (Overall) ̂ ma H$mo g_mZ én

go {dV[aV {H$`m OmZm Mm{hò&



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l Body Design

The typical ground clearances to be

maintained as indicated in the figure

below.

- Recommended Angle of Aperture (A) –

10 Deg.

- Recommended Angle of Departure (D)–

10 Deg.

- Recommended Ramp Over Angle (R) –

14 Deg.

l ~m°‹S>r {S>µOmBZ

{d{eï> (Typical) J«mCÝS> Šbr`a§og ZrMo Xr JB© AmH¥${V Ho$ AZwgma hmoZo Mm{h`o&

- AZwe§{gV E§Jb EnM©a (A) - 10 {S>J«r

- AZwe§{gV {S>nmM©a E§Jb (D) - 10 {S>J«r

- AZwe§{gV a¡ån Amoìha E§Jb (R) - 14 {S>J«r

Symbol Parameters Pro 3008H

Pro 3009

A

B

C

D

E

F

G

Wheel Base (WB), mm

Front Over Hang (FOH), mm

Rear Over Hang (ROH), mm

Over all width, mm

Over all height, mm

Departure angle, degree

Approach angle, degree

4320

1914

2527

2336

2257

11.6

10.2

4320

1914

2527

2336

2257

11.6

10.2



11-7


5260

LH

1914

3053

2336

2257

11.6

10.2

F

B A C

G

[MÝh noam_rQa Pro 3008H

Pro 3009

A

B

C

D

E

F

G

ìhrb ~og (WB) [_._r.

AJb m Amoda h¢J (FOH), [_._r.

{nN>bm Amoda h¢J (ROH), [ _ ._r.

g^r H$s Mm¡µS mB©, [_._r.

4320

1914

2527

2336

2257

11.6

10.2

4320

1914

2527

2336

2257

11.6

10.2

5260

LH

1914

3053

2336

2257

11.6

10.2

S>rnmM©a E|Jb, S>rJ«r

EnamoM E|Jb, S>rJ«r

g^r H$s b¨~mB©, [_._r.

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l Body Structure

- The maximum width of the bus allowed

is 2350mm.

- The rear overhang should not be more

than 60% of the wheelbase.

- Opening in Front grill for cooling system

is 0.3 sq. mt. (min) on the front of

Radiator and opening should align with

the radiator.

- The radiator and Intercooler should be

easily accessible for servicing.

- Front openable flap provision for

servicing of steering reservoir, clutch

reservoir, condenser tank, washer tank,

Radiator and Engine if placed in frontal

area.

l Safety & Legal

Body bui lder i s respons ib le for

adherence to statutory requirements

and regulations prevailing at the time of

body building.

l ~m°‹S>r T>§mMm (Structure)

- ~g H$s A[YH$V_ 2350mm Mm¡‹S>mB© H$s AZw_{V h¡

- {nN>bm Amoìha h¢J ìhrb ~og H$m 60% go A{YH$

Z hmo

- gm_Zo Ho$ {J«b _| erVb àUmbr hoVy AmonqZJ, AJbo

ao{S>EQ>a Ho$ gm_Zo 0.3 dJ© _rQ>a (Ý`yZV_ ) h¡ Am¡a

AmonqZJ, ao{S>EQ>a go AbmBÝS> hm|&

- ao{S>`Q>a Am¡a BÝQ>a Hy$ba VH$ g{d©qgJ Ho$ {bò

gabVm go nh±wM hmoZr Mm{hò&

- ñQ>r`[a§J [aµOadmà,ŠbM [aµOadmà,H$ÝS>|ga

Q>¢H$, dmea Q>¢H$, dmea Q>¢H$, ao{S>EQ>a Am¡a B§OZ,

AJa gm_Zo H$s Amoa go OmE Vmo, g{d©qgJ hoVw IwbZo

`mo½` \«§$Q> âb¡n H$m àmdYmZ hmoZm Mm{hò&

l gwajm Am¡a H$mZyZr

~m°‹S>r ~ZmVo g_` ~m°‹S>r {Z_m©Vm Ho$ {bò H$mZyZr

Amdí`H$VmAmo§ Am¡a {d{Z`_mo§ H$m nmbZ H$aZm

CgH$s {Oå_oXmar hmoJr&



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l Service & Maintenance

In general the body design should take

care of the service and maintenance

accessibility requirements of individual

u n i t s o f t h e c o w l c h a s s i s . D u e

considerations to be given for the

removal of the individual units and the

greasing point access requirements. In

the following pages of this docket,

individual units requirements are

mentioned.

l Care during Body Building

- The chassis with the base structure

should be leveled on the shop floor with

maximum possible accuracy with the

help of supports in the front, middle and

rear. This way horizontal level for further

body building will be created.

l godm Am¡a g§YmaU (Service & Maintenance)

gm_mÝ` én go ~m°‹S>r H$s {S>µOmBZ Eogr hmoZr Mm{hò, {H$ Cg_| H$mCb Mo{gg H$s nhbr BH$mB`m| H$s godm VWm g§YmaU Ago§~br Oê$aVmo H$m Ü`mZ aIm Om gHo$. nhbr BH$mB`mo§ (Individual units) H$mo {ZH$mbZo Ed§ J«rqgJ ßdmB§Q²>g H$s Amdí`H$VmAm§o H$m CëboI {H$`m J`m h¡ .

l ~m°‹S>r ~ZmVo g_` ~aVr ~aVr OmZo dmbr gmdYm{Z`m±

- AmYma T>§mMo (Base Structure) g{hV Mo{gg H$mo emn âbmoa _§o grYm (leveled) A{YH$V_ g§^d Ìw{Q>a{hV pñW{V _| AmJ§o, ~rM _| Am¡a nrN>o ghmam| H$s _XX go aIm OmZm Mm{hò& Eogm H$aZo na AmJo H$s ~m°‹S>r ~ZmZo Ho$ {bò g_Vb ñWmZ CnbãY hmo gH$oJm&



Please refer AIS-052 for the bus body

regulation. Necessary assistance may be

sought from VE Commercial

Vehicles Ltd. for compliance of

regulations.

~°m‹S>r {d{Z`_m| Ho$ {bò H¥$n`m AlS-052 XoIo§&

Amdí`H$ ghm`Vm, {d{Z`_mo| Ho$ AZwnmbZ hoVw drB©

H$_{e©`b drhrH$ëg {b{_Q>oS go àmßV H$m Om

gH$Vr h¡

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- BZ ghmamo§ (Supports) H$mo eob T>§mMo H$r dopëS>¨J nyar hmoZo VH$ aIZm Mm{h`|

- Mo{gg na T>m§Mo H$s Ag|~br Ho$ g_` H¥$n`m gw{ZpíMV H$a| {H$ nm§BqnJ Ed§ dm`[a¨J ñQ´>ŠMab _|å~g© {nÝÀS> ̀ m j{VJ«ñV Z hmo OmE§&

- Xoa VH$ ~§X aIZo Ho$ níMmV B§OZ Mmby H$aZo Ho$ {b`o g{d©g _¡Ý`wAb XoI| &

- These supports to be kept till full welding

of shell structure is done.

- Please ensure during structure assembly

on the chassis that the chassis piping

and wiring are not pinched and damaged

by the structural members.

- Please refer service manual for starting

the engine after long halt.

l Cowl-body Integration

Cowl to be integrated with Bus body

Structure (Refer Given Image) The cowl

integration details are the general

guideline for the bodybuilder to follow.

l H$mCb-~m°‹S>r - B§Q>oJ«oeZ

H$mCb H$m ~g ~m°‹S>r T>mM| Ho$ gmW g_mH$bZ (Integra�on) hmoZm Mm{h`o (Xem©B© JB© N>{d (Image) H$mo XoI|) H$mCb g_mH$bZ H$m {ddaU ~m°‹S>r {Z_m©Vm Ûmam AZwnmbZmW© gm_mÝ` {Xem {ZX}e h¡&

Top view

40x40x2mm tk. tubular A-Pillar LH/RH

25x25x3mm tk. L angle connected base structure

75x25x3mm tk. L angle connected to RH structure

This member actsas a support for front step well



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l Cowl-body Integration

The integration of cowl with the front has

been explained in the image below.

The cowl integration details are the

general guideline for the bodybuilder to

follow.

l H$mCb - ~m°‹S>r B§Q>oJ«oeZ

ZrMo Xr JB© N>{d _| H$mC>b H$m ^mJ AJ« ^mJ go

g_mH$bZ Xem©`m J`m h¡

H$mCb g_mH$bZ H$m {ddaU ~m°‹S>r {Z_m©Vm Ûmam

AZwnmbZmW© gm_mÝ` {Xem-{ZX}e h¡ &

l Base Structure

Bus Body to Chassis connection by U B o l t

mounting Concept Guidelines.

- No part of Body structure or its fastening

should project below long member top

flange.

l AmYma T>§mMm

~g ~m°‹S>r go Mo{gg H$mo ̀ y ~moëQ> go Omo‹S>Zo Ho$ AdYmaU {Xem {ZX}e&

- ~m°‹S>r T>m§Mo `m CgHo$ CgZo (Fastening) H$m H$moB© ̂ r ^mJ bm§J _oå~a Q>mn âb¢O Ho$ ZrMo Zht hmoZm Mm{h`|&

Front view

60x20x3mm tk.L angle connector is connected to bodyA-pillars on RH

40x20x2mm tk.3 nos side connectorconnected bodyA-pillars on LH



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- Wheel Hump areas to be free from any

sharp edges, sharp corners and screws

to avoid any damage to tyres.

- Any modification relocation, cutting,

welding, drilling etc. in vehicle chassis

and its aggregates is strictly prohibited.

- U bolt to be fitted carefully to avoid any

rubbing or damaging to all other

aggregates.

- U Bolt to be placed at least 200 mm away

from Cross members.

- ìhrb hån joÌ H$mo {H$gr ^r àH$ma Ho$ VrIo {gam| Zw{H$bo {H$Zmamo Am¡a ñH«y$Amo§ go _wŠV hmoZm Mm{h`o, Vm{H$ Q>m`amo§ H$mo H$moB© j{V Z nhþ±Mo &

- dmhZ Ho$ Mo{gg Am¡a EJ«rJoQ²>g _| {H$gr ̂ r àH$ma H$m g§emoYZ, ~Xbmd, H$qQ>J, dopëS>¨J nyU©V d{O©V h¡&

- `y ~moëQ> H$mo AË`§V gmdYmZr go {\$Q> H$a| Vm{H$ dh AÝ` EJ«rJoQ²>g go aJ‹S> Z ImE `m CÝho j{V nhþ±MmE

- `y ~moëQ> H$mo H«$mg _oå~g© go H$_ go H$_ 200 mm Xÿa aIm OmE&

Cross member

Ny. lock nuts

Clamping angle

Canvas packing

Chassis member

Chassis stiffener

U-bolt

Packing piece

Use of wood to be strictly avoided in base structure

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l Front Structure

The front structure defines the overall

curves of the body structure. The front A

pillars of structure made using tubular

sections/hat sections should be secured

to the cowl front structure.

It is suggested to use YST – 240, 40x40x2.0

mm tk. G.I tubes for A-pillars and the rest

of the front structure.

The Anti-Sag member (Zoola) is to be

integrated in the cowl structure.

Preferably 60x40x2.5mm tk.

C-Section as shown in the adjacent image

connecting A-pillars & chassis long

members . The Ant i -Sag member

recommended to be bolted type for

engine removal.

l AJ« T>§mMm (Front Structure)

AJ« T>m§Mm, ~m°‹S>r T>mM| Ho$ g^r g_J« (Overall) _mo‹S>mo H$mo n[a_m{UV H$aVm h¡. T>mMo Ho$ AJboo A ñV§^ Q²>`w~wba goŠeZmo§ / h¡Q> goŠeZmo Ho$ Cn`moJ go ~ZmE OmE± Am¡a H$mCb AJ« T>m§Mo go Omo‹S>mo OmE±&

nam_e© h¡ {H$ A ñV§^mo Ho$ {bò VWm AJ« T>m§Mo Ho$ ghmao (Yes) Ho$ {bò YST-240�40�2.0 [_._r. Tk G.I Q²>`y~mo§ H$m à`moJ {H$`m OmE&

EÝQ>r g¡J _oå~a (Pybm) H$mo H$mCb T>m§Mo _| g_m{hV (Integrate) {H$`m OmE ~ohVa hmoJm {H$ gmY ^r N>{d _| Xem©E AZwgma 60�40�2.5 [_._r. Tk gr goŠeZ H$mo A ñV§^ Am¡a (Mo{gg bm§°J _ o ~ a m o § H o $ gmW Omo‹S>m OmE EÝQ>r g¢J _|~a Ho$ {bò ~moëQ>oS> Q>mBn H$s A§ewVm {Oggo B§OZ H$mo {ZH$mbZo H$s Ñ{ï> go ̂ r OmVr h¡&

Anti-sag member

l Body Structure

The remaining body structure consisting

of side LH/RH, rear and roof can be made

u s i n g t u b u l a r S e c t i o n T h e b a s i c

nomenclature of the side structure is

shown in the adjacent sketch.

l ~m°‹S>r T>§mMm

eof ~m°‹S>r T>m§Mo _| LH/RH N>moa, n¥ð> Am¡a N>V Ho$ {bò Q²>`y~ H$a goŠeZ H$m Cn`moJ {H$`m Om gH$Vm h¡ gmBS> ñQ´>ŠMa H$s Zm_ nÕ{V H$mo ~mOy H$s aoImH¥${V _| Xem©`m J`m h¡&

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- It is suggested to use YST -240,

40x40x2.0mm tk. G.I tubes sections for

waist rail, window rail and vertical

pillars.

- B pillar will be YST 240,60X40X2.0mm

tk.G.I tubes.

- Rest of the members can be YST -240,

4 0 x 4 0 x 1 . 6 m m t k , 3 0 x 4 0 x 1 . 6 m m

tk,20x40x1.6mm tk, 20x20x1.2mm

tk.G.I tubes. Use strictly CO2 welding for

entire bus body.

- T h e e n t i r e s t r u c t u r e m u s t b e

adequately coated with anti corrosive

material.

- Extreme care must be taken to ensure

that the chassis units are not covered by

base structure mountings. Easy access

must be available to check the chassis

units.

- gbmh Xr OmVr h¡ {H$ {_ doñQ> aob,qdS>mo aob VWm I‹S>o (Ver�cal) ñV§_mo (Pillars) Ho$ {bò YST-240�40�2.0 [_._r. Tk G.I Q²>`y~ goŠeZmo§ H$m à`moJH$a|&

- ~r ñV§^ YST-240�40�2.0 [_._r. Tk G.I Q²>`y~m| H$m hmoJm&

- ~Mo hþE _|~g© YST-240�40�2.0 [_._r. Tk

30�40�1.6 [_._r. Tk 20�20�1.2 [_._r. Tk G.I Q²>`y~ hmo gH$Vo h¡& g§nyU© ~g ~m°‹S>r H$m dopëS>§J Ho$ {bò Ho$db C0 H$m hr Cn`moJ H$a|&2

- nyam T>m§Mm O§J amoYr gm_J«r go n`m©ßV ê$n go nmoVm OmE&

- `h gw{ZpíMV H$aZo Ho$ {bò {H$ Mo{gg `y{ZQ>, AmYma T>m§Mm _mCpÝQ>¨½g go H$dS>© Zhr h¡ nyar gVH©$Vm ~aVr OmE Mo{gg BH$mB`mo§ H$s Om°M hoVw gabVm go àdoe H$m Ü`mZ aIm OmZm Mm{hò ~m°‹S>r T>m°Mo _| bH$‹S>r Ho$ à`moJ go ~MZm Mm{hò&

Use of wood to be avoided in body structure



Cant railRoof arch member

Vertical pillars

‘A’ pillar ‘B’

pillarSkirt rail Cross

bearersWaist

rail

Body structure-Nomenclature

11-14


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R076



l Final Structure

The body structure is complete from the

point of view of paneling.

However various considerations needs to

be taken into account for fitment of

various assemblies.

These considerations are explained in the

following pages as a check list, prior to

external & internal paneling.

l A§{V_ T>m§Mm (Final Structure)

n¡ZoqbJ H$s Ð{ï> go ~m°‹S>r T>m§Mm A~ V¡`ma h¡

na§Vw, {d{_ÝZ Ag|~{b`m| H$mo {\$Q> H$aZo Ho$ {b`o

AZoH$ ~mVm| na {dMma {H$`m OmZm ~mH$s h¡

BZ gmoM {dMmam| go AmJo Ho$ n¥ð>m| _| ~mhar Am¡a A§Xa

H$r qbJ go nyd© Om±M gyMr Ho$ ê$n _| g_Pm`m J`m h¡ &

l Driver Area Considerations

The cowl has been designed considering

t h e s tat u to r y re q u i re m e nt s a n d

comfortable driving.

- Do not dismantle driver foot controls- In

case driver seat is replaced, please en

sure requirements of AIS-052 as

indicated in the following figures.

- The cowl has been designed for the

required visibility towards bottom. In

no case the windshield bottom should

come above the cowl front top.

l MmbH$ joÌ gmoM {dMma

H$mCb H$s ~ZmdQ> H$mZyZr Amdí`H$VmAm| Am¡a Amam_Xoh MmbH$ na gmoM{dMma H$aHo$ V` H$r JB© h¡

- MmbH$ \y$Q> H§$Q´>mob H$mo Z Imob|&

- `{X MmbH$ ^r grQ> ~Xbr OmE Vmo H¥$n`m A{ZpíMV H$a| {H$ AIS-052 O¡gm {H$ ZrMo H$s AmH¥${V`mo§ _| ~Vbm`m J`m h¡ H$s Amdí`H$VmAm| H$m AZwnmbZ {H$`m J`m h¡&

- H$mCb H$r g§aMZm Bg àH$ma go ^r JB© h¡ {H$ ZrMo VH$ S>mH$ go {XIbmB© Xo {H$gr ̂ r _m_bo _| {dS>§erëS> ~mQ>_ H$mo H$mCb \«$Q> Q>mn Ho$ D$na Zhr AmZm M{h`|&

11-15


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R076



- The windshield top to be kept as per the

requirement in the sketch below. Please

refer AIS-032 for visibility requirements.

A Distance from Heel point to ‘H’ Point

---- --- 600-640 mm.

B Minimum Distance from Floor to ‘H .

---- --- 500 mm point with the driver seat

in the upper most position.

C Thigh Clearance ------- 200-260 mm.

D Minimum Distance from ‘H’ Point to

roof top ------- 1060 mm.

E Minimum distance from the lower end

of ------- 350 mm steering to the front

of driver seat back rest.

F Minimum distance for driver partition

from the rear ------- 25 mm of driver

seat with driver seat in the rear most

position.

- qdS>erëS> Q>mn H$mo ZrMo {Xò aoIm {MÌ H$mo Amdí`H$VmAm| Ho$ AZwê$n hmoZm Mm{hò H¥$n`m

ÐíQ>Vm Amdí`H$VmAmo| Ho$ {bò AIS 032 XoI|&

§ A hrb nmB§Q> go ‘H’ nmB§Q &>

B \$e© go ‘H’ nmB§Q> VH$ H$m A§Va O~ MmbH$ grQ> CÀMV_ pñW{V na hmo ...... 500 [_._r&

C O§Km A§Va ..... 200-260 [_._r&

D ‘H’ nmB§Q> go N>V VH$ H$m Ý`yZV_ A§Va ... 1060 [_._r.&

E ñQ>r`[a§J Ho$ {ZMbo go MmbH$ grQ> ~¡H$aoñQ> H$m Ý`yZV_ A§Va .... 350 [_._r.&

F MmbH$ grQ> Ho$ nrN>o go MmbH$ grQ> O~ EH$X_ nrN>o VH$ hmo H$o nmQ>ueZ H$m Ý`yZV_ A§Va .. 25 [_._r.&

11-16


Visibility zone

Locable Glove BoxLocation For First aid Box Accelerator heel Point (AHP)

SE

R076

l Front wheel hump and section require-

ments

The recommended size and clearances

for Front wheel Hump are indicated in

the adjacent sketch.

l AJbo n{h`o Ho$ Hy$~‹S> (hån) Am¡a goŠeZ Amdí`H$VmE±

AJbo n{h`o _| Hy$~‹S> (hump) H$m AZwe§{gV AmH$ma Am¡a \$mgbm gmW Ho$ aoIm {MÌ _| Xem©`m J`m h¡

Vehicle front Top LH tyre view, Section ofwheel hump at hegiht of

40 mm above frame

Front view LH tyre

180 max.

290 min. 290 min.

Chassis frame

80

225

100

40 min.

180 max.



11-17


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R076

l Rear wheel hump and Section

requirements

The recommended size and clearances

for Rear wheel Hump are indicated in the

adjacent sketch.

l {nN>bo n{h`o Ho$ Hy$~‹S> Am¡a goŠeZ H$s Amdí`H$VmE±

{nN>bo n{h`o Ho$ Hy$~‹S> Ho$ AZwe§{gV AmH$ma VWm A§Va

H$mo gmW _| aoIm {MÌ _| Xem©`m J`m h¡&

Vehicle front

Top LH tyre view, Section ofwheel hump at hegiht of

40 mm above frame

Front view rear LH tyre

60 max.

400 min. 400 min.

Chassis frame

80

225

100

40 min.

60 max.



11-18


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R076

l Air Filter

The Air filter placement is the integral

part of the Cowl considering ease in

serviceability.

The air filter opening should have

minimum 50mm clearance all around

from the Air filter for easy servicing.

As indicated in the side sketch, the air

filter access can be an open able panel.

Care should be taken that the air intake

through the Pre cleaner is not restricted.

In case a grill is provided in the panel then

the grill size should be 20% more than

the intake snorkel opening. Min opening

area for air intake is 0.02 sq. mt.

Air intake to be take care to avoid dust

entry during Bus body Air intake turbo

charger mouth to be closed (During

body building) Do not reroute air intake

position.

Position of air filter should not be

altered.

l Eà {\$bQ>a

godm (Service) _| AmgmZr Ho$ _ÔoZµOa Eà

{\$ëQ>a ßbog_|Q> H$mCb H$m A{dpÀN>ÝZ ̂ mJ h¡&

g\$bVm go g{d©qgJ hoVy Eà {\$ëQ>a Ho$ g~ Amoa

H$_ go H$_ 50 mm H$m A§Va Eà {\$ëQ>a

AmonqZJ hmoZm Amdí`H$ h&

O¡go {H$ ~mOy _| aoIm {MÌ _| ~Vm`m J`m h¡, Eà

{\$ëQ>a nhþ±M (access) Imobm Om gm_Zo `mo½`

n¡Zb hmo gH$Vm h¡ Bg ~mV H$m Ü`mZ aIm OmZm

Mm{hò {H$ àrZbrOa Ho$ O[aò BZQ>oH$ ~m{YV Z hmo

`{X n¡Zb _| {J«b {X`m Om ahm hmo , Vmo {J«b H$m

AmH$ma BZQ>|H$ ñZmH}$b AmonqZJ go 20% A{YH$

hmo Ý`yZV_ joÌ hdm gr Mbo (Air intake) H|$ {bò

0.02 dJ© _rQ>a h¡&

Eà BZQ>oH$, ~g ~m°‹S>r _| Yyb Ho$ àdoe go ~MmVm h¡

~m°‹S>r ~ZmVo g_` Eà BZQ>oH$ Q>~m}MmO©a H$m _w±h ~§X

hmoZm Mm{hò, hdm Ho$ A§Xa AmZo H$s pñW{V H$mo Z

~Xb|, Eà {\$ëQ>a H$s pñW{V H$mo ~XbZm Zhr

Mm{h`|&



11-19


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R076

l Battery

The battery needs to be mounted on the cradle in the separate compartment as shown in the images on this page.

The battery compartment should not be used for storage of any other goods as this may lead to short circuiting of the battery terminals.

Battery to be disconnected at a time of electrical welding and Bus body building.

l Battery MTG

Battery location on Body to be on Left side of vehicle. The front face of battery should not be placed more than 1720 mm from front axle center location on the bus body (as shown in image below) . Sufficient length of cable is provided in chassis and any extension /modification is strictly prohibited in battery cables, cut off switch cable , maxi fuse cable etc.

l ~¡Q>ar

~¡Q>ar H$mo AbJ H§$nmQ>© _|Q> _| Pybo na ñWm{nV {H$`m OmZm Oê$ar h¡, O¡go{H$ Bg n¥ð> na N>{d`m| _| Xem©`m J`m h¡&

~¡Q>ar H§$nmQ>© _|Q> H$mo {H$Ýhr AÝ` dñVwAm| H$mo aIZo Ho$ {bò à`wŠV Zht H$aZm Mm{h`|, Eogm H$aZo go ~¡Q>ar Q>{_©Zbm| H$s emQ>© g{H©$qQ>J hmo gH$Vr h¡&

{~Obr Ûmam dopëS>§J Am¡a ~g ~m°‹S>r ~ZmVo g_` ~¡Q>ar H$mo {S>gH$ZoŠQ> (~mob XoZm) H$m XoZm Mm{h`|&

l ~¡Q>ar MTG

~m°‹S>r _| ~¡Q>ar H$m ñWmZ dmhZ Ho$ ~mB© Amoa h¡ ~¡Q>ar H$m AJ«_wI, ~g ~m°‹S>r na \«$Q> EŠgb g|Q>a ñWmZ go 1720 [_._r. go Á`mXm D$na Z hmo (O¡go {H$ ZrMo N>{d _| ~Vbm`m J`m h¡) Mo{gg _| n`m©ßV b§~r Ho$~b Xr JB© h¡, Am¡a H$Q> Am\$ pñdM Ho$db, _¡Šgr â`yO Ho$~b Am{X _| {H$gr ^r àH$ma H$m {dñVma / g§emoYZ nyU©V: d{O©V h¡&



Air Filter Service Openingl

Opening for Air Filter Service required to

have min size of min. 350x 380 mm on RH

side.

l Eà {\$ëQ>a g{d©g AmonqZJ

Eà {\$ëQ>a H$r g{d©g Ho$ {bò AmonqZJ H$m Ý`yZV_

AmH$ma 350� 380 mm Xm{hZr Amoa hmoZm M{hò&

11-20


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R076

- ~¡Q>ar H§$nmQ>©_|Q> Ho$ Am`m_ 835�400 [_._r. Ý`yZV_ h¡ ~¡Q>ar g{d©qgJ VH$ gwJ_Vm go nhþ±M h|Vw&

- ~¡Q>ar H$Q>-Am\$, ~¡Q>ar, _¡Šgr â`yO H$mo EH$ hr H§$nmQ>©_|Q> _| gabVm go g{d©qgJ H$s Ð{ï> go aIZm Mm{hò&

- ~¡Q>ar ~XbZo hoVy AZwe§{gV dmQ>a doqS>J CMm±B© 500 [_._r. h¢&

- ~¡Q>ar Ho$ D$nar joÌ na dm`m`Z / {_bm{_br hmoZm Mm{h`|&

- Battery compartment dimensions – 835 x 400 mm min. for the accessibility of Battery servicing.

- Sufficient space at top for ease of service.

- Battery cut off, Battery, Maxi Fuse to be accommodated in single compartment for ease of servicing.

- Recommended water wading height is 500mm for battery placement

- ventilation or louvers to be provided in top area of Battery compartment.



l Spare Tyre

Stc Mtg

- STC to be mounted on LH side or in

between Frame. Not to be mounted on

RH side of Vehicle.

- Care to be taken while STC MTG so as to

maintain the required Departure, ramp

over angles and ground clearance.

- The image below indicates an openable

side panel behind the tyre to access the

spare tyre.

l A{V[aŠV Q>mà

- STC MTG

- STC H$mo \«o$_ Ho$ _mÜ` _| ~mB© Amoa M‹T>mZm Mm{hò&

- STC MTG Ho$ g_` Adí`H$ {S>nmM©am|, a¡ån Amoìha E§Jbm| Am¡a J«mCÝS> Šbrà|g H$m Ü`mZ aIZm Mm{hò&

- ZrMo H$r N>{d _| Q>mà Ho$ nrN>o H$m IwbZo dmbm n¡Zb {XIm`m J`m h¡, Omo A{V[aŠV Q>mà VH$ nhþ±M H$mo Xem©Vm h¡&

11-21


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R076



l Service Cutouts

Transmission Hatch

- Transmission Hatch to be provided for

Transmission service purpose.

- Min opening required is of size - 500 x

600 mm

l Hatch For Transmission Removal

- Openable panel required of size min.

700 mm behind front axle area for

transmission removal from LH side of

vehicle.

l g{d©g H$Q> gmCQ²>g

Q´>§mg{_eZ h¡M

- Q´>§mg{_eZ H$s g{d©g Ho$ {bò Q´>§mg{_eZ h¡M àXmZ {H$`m OmZm Mm{h`|&

- Amdí`H$ Ý`yZV_ AmonqZJ H$m AmH$ma-500�600 [_._r.&

l Q´>§mg{_eZ H$mo {ZH$mbZo hoVy h¡M

IwbZo `mo½` n¡Zb H$m AmH$ma Ý`yZV_ 500 [_._r. AJ« E Šgb joÌ Ho$ nrN>o-dmhZ Ho$ ~mB© Amoa go Q´>§mg{_eZ H$mo {ZH$mZbo Ho$ {bò hmoZm Mm[h`|&

l Service Cutouts

- For easy accessibility of fuel gauge and

Baby filter hatch to be provided at the

floor just above at fuel tank position and

hatch should be clear from seat

mounting.

- This to be ensure at a time of Bus Body

bui ld ing. Refer Given Image for

Minimum opening size for Hatch.

l g{d©g H$Q> AmCQ²>g

- âë`yb JmO Am¡a ~o~r {\$ëQ>a gabVm go A§Xa Om gH|$ Bg _H$gX go, \$bmoa (\$e© ) na h¡M, R>rH$ â`yb Q>¢H$ pñW{V Ho$ D$na hmoZm Mm{hò Am¡a h¡M H$mo grQ> _mCpÝQ>¨J go _wŠV (Clean ) hmoZm Mm{hò§&

- ̀ h ~g ~m°‹S>r ~ZmVo g_` gw{ZpíMV {H$`m OmZm Mm{hò& h¡M Ho$ {bò Ý`yZV_ AmonqZJ gmhO H$h N>{d g§X^m©W© Xr JB© h¢&Fuel tank top view

11-22


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R076

l ELECTRICAL 12V system

Openable panel for chassis fuse box mounting area shown in image, to be provided for service point of view. In closed condition–sufficient sealing to avoid water entry.

Fuse Box sticker to be placed securely in front of Fuse box only, the marking details given on the Sticker to be referred for the correct orientation.

l {dÚwVr` 12V àUmbr

Mo{gg â`wµO ~m°Šg M‹T>mZo H$m joÌ, O¡gm {H$ N>{d _| Xem©`m J`m h¡, g{d©g Ho$ Ñ{ï>H$moU go Imobo Om gH$Zo dmbo n¡Zb H$s µOéaV hmoVr h¡& ~§X pñW{V _| nmZr A§Xa Z Om gHo$, Bg hoVw n`m©ßV gr[b§J hmoZr Mm{hò&

â`wO ~m°Šg pñQ>H$a _µO~wVr go Ho$db â`wµO ~mŠg Ho$ gm_Zo aIZm Mm{hò, ghr Amo[aE§Q>oeZ Ho$ {bò pñQ>H$a na {Xò JE _m{Hª$J {ddaUmo H$moo XoI|&



l Fuel Tank Hatch on top side

- For Fuel tank inlet and outlet pipe and

Electrical gauge service point of view

requirement of opening of min.

590x275mm to top side of tank inside

bus body.

l â`yb Q>¢H$ h¡M Q>mn H$s Amoa

- â`yb Q>¢H$ hÝboQ> Am¡a AmCQ>boQ> nmBn VWm BbopŠQ´>H$b JmO g{d©g H$s Ð{ï> go AmonqZJ H$s Ý`yZV_ Amdí`H$Vm 590�270 [_._r. go ~g ~m°‹S>r Ho$ A§Xa Q>¢H$ Ho$ erI© VH$&

11-23


SE

R076

Do’s & Don’ts:-

Do’s:-

- In case of any spark (fire) or short circuit , battery cut off unit should be turned off immediately.

- For repairing/replacing/rework on any electrical part the battery cut off unit must be in turned off position.

- Check the Battery Conditions regularly & Battery electrolyte level to be monitored .

- During Welding, Cutting, drilling or grinding operation on Body, Wiring should be protected with Suitable cover to prevent damage.

- During Body Operations (Welding), Batteries must be removed.

- Ignition switch should be in OFF position before removing the batteries.

- Proper cover ing to be done on Instrument panel with gauges, Fuse Box.

- Body wiring and fuse box to be separate from the chassis wiring & fuse box.

Š`m H$a| Am¡a Š`m Z H$ao§ …-

Š`m H$a|…-

- { MÝJmar (AmJ) `m emQ>© g{H©$Q> Ho$ _m_bo _|, ~¡Q>ar H$Q> Am°\$ ̀ y{ZQ> H$mo VËH$mb Am°\$ H$a X| &

- {H$gr ^r {dÚwVr` nmQ>© _| gwYmaZm/ ~XbZm/ ardH©$ H$aZm hmo Vmo ~¡Q>ar H$Q> Am°\$ ̀ y{ZQ> H$mo Q>Z© Am°\$ (~§X) pñW{V _| hmoZm Mm{hò &

- ~¡Q>ar H$s hmbV H$s Om±M {Z`{_V én go H$a| Am¡a ~¡Q>ar BboŠQ´>mobmBQ> ñVa H$s _mZrQ>[a§J H$aVo aho§&

- ~m°S>r na dopëS>¨J, H$qQ>J, {S´>qbJ `m J«mB§qS>J Ho$ Xm¡amZ j{V go ~Mmd hoVw dm`[a¨J H$mo Cn`wŠV H$da go T>m±H$ X|&

- ~m°S>r na H$m_ (dopëS>¨J) H$aVo g_`, ~¡Q>[a`m| H$mo {ZH$mb X|&

- ~¡Q>[a`m| H$mo {ZH$mbZo go nhbo Bp½ZeZ pñdM OFF (~§X) pñW{V _| hmoZm Mm{hò &

- JmµOoO g{hV BÝñQ®>_|Q> n¡Zb, â`wµO ~m°Šg H$s Cn`wŠV H$d[a¨J hmoZr Mm{hò&

- ~m°S>r H$s dm`[a¨J VWm â`wµO ~mŠg H$mo Mo{gg H$s dm`[a¨J Am¡a â`wµO ~m°Šg go AbJ hmoZm Mm{hò&



11-24


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R076

- All connections to be done with junction box or connectors.

Don’ts:-

- No Splicing/tapping allowed on vehicle wiring harness.

- Overrated bulbs wattage (Head lamps/fog lamps etc.) not allowed, bulb wattage to be same as that of designed one.

- No tampering allowed for the fuses, if fuse is blown it needs to be replaced with a new one.

- Fuse of designed rating should be only used.

- Overall electrical load should not exceed 240 watt.

- Care should be taken while washing the vehicles, no direct water splash should be there on electrical components.

- g^r H$ZoŠeZ OŠ§eZ ~mŠg ̀ m H$ZoŠQ>amo go hmoZo Mm[h`o&

Š`m Z H$ao§…-

- dmhZ Ho$ dm`[a§J hmZ}g _| ñnbmBqgJ/Q>¡qnJ H$s AZw_[V Zhr h¡&

- A{YH$ aoqQ>J dmbo ~ë~ dmQ>oO (hoS>b¢n /\$m°J b¢n) H$s AZw_{V Zhr h¡, bÅx>Am| H$m dmQ>oO d¡gm hr hmo O¡gm {S>µOmBZ {H$`m J`m h¡&

- â`yOoµO Ho$ gmW AZ{YH¥$V n[adV©Z H$s AZw_[V Zhr h¡, ̀ {X â`wµO C‹S> J`m hmo, Vmo Cgo {g\©$ ZE go ~Xbm OmE&

- Ho$db {S>µOmBZ H$s hþB© aoqQ>J Ho$ â`wµO H$m Cn`moJ H$a|&

- Hw$b (Overall) [dÚwVr` ^ma (Load) 240 dmQ> go A{YH$ Z hmo&

- dmhZ H$mo YmoVo g_` gmdYmZr ~aVo§ nmZr Ho$ N>tQ>o grYo {dÚwV H$månmoZ|Q²>g na Zhr n‹S>Zo Mm{h`o &



11-25


SE

R076



l Servicing Requirement l g{d©qgJ Amdí`H$VmE§

Air filter servicingon RH side

Transmission hatch inside bus

Fuel tank servicing insidebus

Fuse box servicingon LH side

Battery servicingon LH side

Jack to be mounted in vertical direction in tool box area

11-26


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R076

l Parking Brake Lever

- The parking brake lever comes fitted on

the cowl as indicated in the image below.

- The position of parking brake lever

should not be altered.

l Power Steering Oil Reservoir

- The power steering oil tank has been

placed in the front, near the radiator. The

accessibility of the same through the

Front open able flap to be considered for

ease of refilling.

- The position of power steering reservoir

should not be altered.

- Front Power Steering oil Reservoir

service area requirement.

l Engine Coolant Tank

- The coolant tank has been placed in the

f ro n t , a b o v e t h e ra d i a t o r. T h e

accessibility of the same through the

Front open able flap and or through

dashboard to be considered for ease of

refilling and ensure fluid level is visible.

l nm{Hª$J ~«oH$ brda - nm{Hª$J ~«oH$ brda ZrMo Xr JB© N>{d Ho$ AZwgma

H$mCb _| {\$Q> H$aHo$ {X`m OmVm h¡& - nm{Hª$J ~«oH$ brda H$s pñW{V _| H$moB© ~Xbmd Zht

H$aZm Mm{hò&

l nmda ñQ>r`[a¨J A°mBb [aµOadmà - nmda ñQ>r`[a¨J AmBb Q>¢H$ gm_Zo H$r Amoa,

ao{S>òQ>a Ho$ g_rn aIm J`m h¡& AJ« Imobo Om gH$Zo dmbo âbon Ho$ amñVo nhþ±M H$m {dMma gabVm go Vmon ̂ aZo H$r Ñ{ï> go {H$`m J`m h¡&

- nmda ñQ>r`[a¨J [aµOadmà pñW{V H$mo ~XbZm Zhr§ Mm[hò&

- AJ« nmda ñQ>r`[a¨J AmBb godm joÌ H$s Amdí`H$VmE±&

l B§OZ Hw$b|Q> Q>¢H$ - Hw$b|Q> Q>§H$s H$mo gm_Zo H$s Amoa, ao{S>EQ>a Ho$ D$na

aIm J`m h¡, Bg VH$ nhþ±M Imobo Om gH$Zo dmbo âb¡n Am¡a / ̀ m S>¡e ~moS>© go hmoH$a na gabVm go {\$qbJ H$s Ñ[ï> go {dMma H$a| Am¡a gw{ZpíMV H$ao§ âë`wS> H$m ñVa {XImB© XoVm h¡ Hw$b|Q> Q> ¢H$ H$s pñW{V _| H$moB© ~Xbmd Z H$a|&

Front power steering oil Reservoir service area requirement



Parking brake lever

11-27


SE

R076

l Battery Cut Off Switch

This chassis is equipped with electronic

battery cut off switch comes fitted near

battery on chassis . The ON /OFF for this is

controlled by a remote switch mounted

on the cowl as shown.

l ~¡Q>ar H$Q> Am°\$ pñdM

Mo{gg _| BboŠQ´>m{ZH$ ~¡Q>ar H$Q> Am°\$ pñdM, Mo{gg

na ~¡Q>ar _o {ZH$Q> {\$Q> {H$`m J`m h¡& BgHo$ ~§X/

Mmbw (ON / OFF) H$m {Z`§ÌU ZrMo Xem©E AZwgma

_m°S>b _| M‹T>mE JE [a_moQ> pñdM Ûmam {H$`m OmVm h¡&

Battery cut off control switch

l Engine Hood

- The engine hood, indicated in the

adjacent s ketch, is the integral part of

the cowl. It provides easy accessibility

to engine and peripheral parts.

- The engine hood facilitates oil filling, dip

stick check, tappet setting, oil filter /

diesel filter removal, and fuel priming

pump etc.

- Recommended not to dismantle Engine

hood & Podest from the cowl as it is

designed for proper service clearances

for the engine service and also for

desired levels of NVH. But Engine hood

& Podest can be Dismantle for Plywood

& Vinyl Fitment.

l B§OZ hþS>

- gmW _| {M[ÌV aoIm{MÌ Ho$ AZwgma B§OZ hþS>, H$mCb H$mo A{d^mÁ` A§J h¡, ̀ h B§OZ d CgHo$ Amg-nmg Ho$ nwOm} VH$ gwJ_Vm go àdoe CnbãY H$admVm h¡&

- B§OZ hþS> AmBb âZo, {S>npñQ>H$ Om±M, Q>onoQ> goqQ>J, AmBb {\$ëQ>a / S>rOb {\$ëQ>a H$mo {ZH$mbZo H$s Am¡a â`wb àmBq_J H$s gw{dYm àXmZ H$aVm h¡&

- AZ we§gm H$s OmVr h¡ {H$ B§OZ hþS> Am¡a nmoS>oñQ> H$mo H$mCb go ImobH$a AbJ Z H$ao§, Š`m|{H$ BgH$s g§aMZm B§OZ H$s g{d©g, Cn`wŠV g{d©g Šbrà|g E§d NV Ho$ dm§{N>V ñVamo Ho$ {bhmO go H$s JB© h¡, {H$ÝVw B§OZ hþS> Am¡a nmoS>oñQ> H$mo ßbm`dwS> VWm {dZmBb {\$Q> H$aZo Ho$ {bò AbJ {H$`m Om gH$Vm h¡&

Battery cut off switch on chassis



11-28


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l Dashboard

- An integrated cockpit type dashboard

can be provided on the cowl. This unit

can be integrated in the full width of

dashboard.

- Please ensure that all the displays and

controls are maintained at their

respective locations and orientations.

Suggested dashboard

l S>¡e ~moS>

- EH$sH¥$V H$mH${nQ> {H$ñ_ H$m S>¡e ~moS>© H$mCb _| CnbãY {H$`m Om gH$Vm h¡, Bg BH$mB© H$mo S>¡e ~moS>© H$s nwar Mm¡‹S>mB© _| EH$sH¥$V {H$`m Om gH$Vm h¡&

- H¥$n`m gw{ZpíMV H$a| {H$ g^r {S>ñßbo Am¡a H§$Q´>mob CZHo$ {ZYm©[aV ñWmZmo§ VWm Amo[aE§Q>oeZmo§ na g§Km[aV {H$`m J`m h¡ &

l Diesel Tank

- Easy accessibility of diesel tank needs to be considered for refilling safety and ease in serviceability.

- The diesel tank refilling flap should be minimum 250x250mm size.

- There should be enough clearance between diesel tank and the body, for easy routing and service of fuel hose.

- Diesel tank and its position should not be altered.

- Refilling flap.

l S>rOb Q>¢H$ - S>rOb Q>§H$s VH$ gabVm go nhþ±M H$m {dMma

[a{\$qbJ gwajm Ed§ godm H$s gw{dYm H$mo XoIVo hþE {H$`m OmZm Mm{hò& S>rOb Q>¢H$ ar{\$qbJ âb¡n H$m AmH$ma Ý`yZV_ 250X250 [_._r.hmoZm Mm{hò&

- â`yb hmoµO H$s AmgmZr go S>mbZo-{ZH$mbZo H$s Ñ{ï> go S>rOb Q>¢H$ Am¡a ~m°S>r Ho$ ~rM n`m©ßV A§Va hmoZm Mm{hò&

- S>rOb Q>¢H$ Am¡a CgH$s pñW{V H$mo ~XbZm Zht Mm{hò&

- ar{\$qbJ âb¡n

Diesel tank and its position should not be altered

Refilling flap



- The gear shift lever is the integral part of

the engine hood and its sealing

prevents hot air entry in the saloon.

- {Jà {eâQ> brda, B§OZ hþS> H$m A{d^mÁ` A§J h¡, Am¡a BgH$s grqbJ gobwZ J_© hdm Ho$ àdoe H$mo amoH$Vr h¡&

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l Assembly Fitments

Various assemblies like front bumper, rear

bumper recommended to be mounted

with positive fasteners rather than

welding to facilitate easy serviceability.

l Ag§o~br {\$Q>_|Q²>g

AZoH$ Ag|~{b`m| H$mo O¡go AJbm ~åna, {nN>bm ~åna H$mo n{µO{Q>d \$mgZg© go MT>mZo H$s AZwe§gm H$s OmVr h¡, dopëS>¨J H$s Zht, Vm{H$ g{d©g H$aZo _o§ AmgmZr hmo &Front bumper

Rear bumper

l Exhaust Pipe

- Exhaust pipe position should not be

Change.

- Body skirt panel location to be ensure

clear flow of exhaust gases and avoid

any blackening of body.

- The bus skirt level should be so

maintained that there is clear gap of

50mm from the tail pipe end.

l E½µOmñQ> nmBn

- E½µOmñQ> nmBn H$s OJh H$mo Z ~Xbm OmE§&

- ~°mS>r ñH$Q>© n¡Zb H$m ñWmZ (Loca�on) Eogm hmo {H$ {Oggo CËgO©Z J¡g§o R>rH$ go {ZH$bo§ Am¡a CZgo ~m°S>r H$mbr Z nS>o&

- ~g ñH$Q>© H$m ñVa Bg àH$ma g§Km[aV hmo {H$ Q>ob nmBn {gao go CgH$s ñnï> Xþar 50 [_._r. hmo&

Exhaust pipe



11-30


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l Harness Routing

- To avoid damage / cutting of the cable

harness while routed through sheet

metal panel, it is advisable to provide

rubber grommet first on the sheet metal

panel as indicated below .These should

be securely hold there place through out

life of vehicle.

- Fire retardant sleeve/corrugated cover

to be provided for the wiring harness.

l hmZ}g H$m amñVm {ZH$mbZm (Rou�ng)

- O~ erQ> _¡Q>b n¡Zb go hmoH$a Ho$~b hmZ}g {ZH$mbr OmVr h¡, V~ j{V/H$Q>Zo go ~Mmd hoVw, `h gbmh Xr OmVr h¡ {H$ ZrMo Xem©E AZwgma nhbo a~a J«mo_oQ> bJm`m OmE& BÝh| BVZr _O~yVr go bJm`m Om` {H$ do dmhZ Ho$ nwao OrdZ VH$ AnZo ñWmZ na pñWa aho§&

- \$mà [aQ>mS>]Q> ñbrd / H$méJoQ>oS> H$da dm`[a¨J hmZ}g Ho$ {bò hmoZm Mm{hò&

Cable

Rubber grommet

Sheet metal

l Fire Extinguisher

- Vehicle should be equipped with

minimum two fire extinguisher of 2 Kg

each, totaling to 4Kg .

- Fire Extinguisher shall comply with

IS:13849 OR IS:2171 as amended from

time to time, as may be applicable.

- Halogenated hydrocarbon type of

extinguisher shall not be used as

extinguisher . Refer AIS-052 for further

detail.

l Ap½Z em_H$ (Fire Exinguisher)

- dmhZ _| H$_ go H$_ Xmo Ap½Z em_H$ àËòH$ 2kg Ho$, Bg Vah Hw$b 4kg Ho$ hmoZm Mm{hò&

- Ap½Z em_H$ IS: 13849 `m IS: 2171 Ho$ AZwén hmo, O¡gm CZ_| g_`-g_` na g§emoYZ hmoVm aho Am¡a Omo bmJy hmo&

- h¡bmoOoZQ>oS> hmBS´>moH$m~©Z àH$ma Ho$ Ap½Zem_H$ H$m Cn`moJ Ap½Zem_H$ hoVw Zht {H$`m OmE& A{YH$ {ddaU hoVw AIS-052 XoI|&

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- Placement of Fire extinguisher should

be vertical upright position & such that

one in easy reach of Driver and another

in easy reach of passengers.

l Hammer

- The emergency safety glass shall be

readily break on impact when it hit by a

hammer in the event of an emergency .

One hammer should be provide near to

the emergency safety glass. To be

consider at a time of bus body built.

l Emergency Exit

- Design, posit ion and number of

emergency exit as per AIS 052.

l Welding Precaution

- Metal pipes, Hoses, Nylon tube, Wiring

harness, fuel lines, fuel tank, tyre and

Radiator, etc to be completely covered

with fire resistant material.

- This is to ensure safety against any fire or

damage due to weld spatter.

- ~Vm¡a Ap½Z em_H$ H$s pñW{V I‹S>r-grYr Am¡a Eogr hmo {H$ EH$ MmbH$ H$s AmgmZ nhþ±M na Am¡a Xþgam ̀ m{Ì`mo§ H$s gab nhþ±M _| hmo&

l hWm¡‹S>m - AmnmV pñW{V _| g§H$Q>H$mbrZ gwajm H$m±M hWm¡‹S>o

Ho$ àhma go Qw>Q> OmZm Mm{hò, EH$ hWm¡‹S>m g§H$Q>H$mbrZ gwajm H$m±M Ho$ {ZH$Q> aIm OmE & BgH$m {dMma ~g ~m°S>r Ho$ {Z_mU© _o g_` {H$`m OmZm Mm{hò&

l g§H$Q> H$mbrZ {ZJ©_ - g§H$Q>H$mbrZ {ZJ©_ H$s ~ZmdQ>, pñW{V Am¡a

g»§`m AIS-052 Ho$ AZwén hmo &

l dopëS>¨J gmdYmZr - YmVw H$s nmBßg, hmoµOoO, Zm`bmZ Q²>`y~, dm`[a§J

hmZ}g, BªYZ bmBZ|, Q>mà d ao{S>EQ>a Am{X H$mo nyar Vah go Ap½Z amoYr gm_J«r go H$da H$aZm Mm{hò&

- Eogm doëS> H$aVo g_` C‹S>Zo dmbo N>tQ>mo go AmJ AWdm j[V go gwajm gw{ZpíMV H$aZo Ho$ {bò µOéar h¡&

Hammer

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R076

l Precaution during Body Building

During bodybuilding the following

precaution must be taken care, To avoid

any undue damage to the various

component.

l Protection of piping & wiring

During welding, cutting, drilling or

grinding operation on body work, all

piping and electrical wiring should be kept

well clear and to be covered properly to

avoid damage.

l Electrical Equipment

All electrical equipment like alternator,

batteries starter motor, wiper motor, etc

should be isolated from the circuit to

avoid possible damage due to high

currents from welding equipments. The

batteries may be preferably removes

from the vehicle while body work is being

carried out.

l ~°mS>r {Z_m©U Ho$ g_` gmdYm{Z >̀>m±

~m°S>r ~ZmVo g_` {ZåZm§{H$V gmdYm{Z`±m, {d{dY

H$m°ånmoZoÝQ²>g H$mo ì`W© H$s hm{Z go ~MmZo Ho$ {bò

~aVZm Mm{hò&

l nmBqnJ Am¡a dm`[a¨J H$m ~Mmd

~m°S>r H$m`© _| dopëS>¨J, H${Q>§J, {Q´>qbJ `m J«mBqS>J Ho$

Xm¡amZ, g^r nmBqnJ, {dÚwV dm`[a¨J H$mo gm\ aIZm

Am¡a CÝho§ j{V go ~Mmd hoVw H$da H$aZm Mm{hò&

l Bbo[ŠQ´>H$b B[Šdn_|Q>

g^r {dÚwV B[Šdn_|Q>mo§ O¡go AmëQ>aZoQ>a, ~¡Q>[a`m|,

ñQ>mQ©>a _moQ>a Am{X, H$mo g{H©$Q> go n¥WH$ ahZm Mm{hò

Vm[H$ dopëS>¨J B[Šdn_|Q Ho$ CÀM H$a|Q> go CÝho H$moB©

g^§m{dV hm{Z Z nhþ±Mo, ~ohVa hmoJm {H$ O~ ~°mS>r H$m

H$m_ hmo ahm hmo, Vmo V~ ~¡Q>[a`mo H$mo dmhZ go { ZH $ mb

{X`m Om`&



11-33


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l Welding Precaution

Serious structural damage can be caused

by improper use of welding equipment.

Care must be taken to ensure that the

welding gun is not flashed off on the

spring leaves and that earth clamp is not

attached to the spring. when welding, the

springs should be covered to avoid weld

splatter falling on the spring surface.

spring should not be subjected to sharp impacts.

l dopëS>¨J gmdYmZr

dopëS>¨J CnH$aUmo§ Ho$ JbV Cn`moJ go J§^ra T>m§MmJV

j{V hmo gH$Vr h¡& Bg ~mV H$m Ü`mZ aIm OmZm

Mm{hò {H$ `h gw{ZpíMV {H$`m OmE {H$ dopëS>¨J JZ

pñà¨J Ho$ nÎmmo na Z âb¡e hmo, Am¡a AW© b¡ån pñà¨J go

Ow‹S>m Z hmo& O~ dopëS>¨J H$a aho hm|, V~ H$_m{Z`mo§ H$mo

T>H$ XoZm Mm{hò, {Oggo H$s dopëS>¨J Ho$ N>tQ>o pñà¨J H$s

gVh na Z {Jao, pñà¨J H$m VoO Q>ŠH$amo§ go ~Mmd

H$aZm Mm{hò&

l Care to be taken while body building

Before Starting the body work, remove

the following

- Battery.

- Driver Seat.

- Windscreen washer, Wiper arm and

blade.

- Spare Wheel tyre.

l Proper covering should be done, of the

following

- Dash board.

l ~°mS>r {Z_m©U H$aVo g_` gmdYm{Z`±m

~°mS>r H$m`© àma§^ H$aZo go nwd©, {ZåZm§{H$Vm| H$mo hQ>m X|

- ~¡Q>ar

- MmbH$ grQ>

- qdS> ñH«$sZ dmea, dmhna Am_© Am¡a ãbo‹S>

- A{V[aŠV (ñnoà) Q>mà

l {ZåZm§{H$Vmo H$mo C{MV ar{V

- S>¡e ~moS>©



11-34


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- Instrument panel with gauges.

- Steering wheel.

- Fuse box.

- Nylon and rubber hoses.

- Control linkages.

- Brake pipes, fuel lines, steering , clutch

pipe and hoses-

- Electrical wiring & components.

*All wiring connection should be disconnected.

- JmµOoO g{hV B§ñQ¯>_|Q> n¡Zb

- ñQ>r`[a¨J ìhrb

- â`wO ~mŠg

- Zm`bmZ d a~a hmoµOog

- H$§Q´>mob {b§Ho$Oog

- ~wH$ nmBßg, â`wb bmBÝg, ñQ>r`[a¨J, ŠbM

nmBßg Am¡a hmoµOog

- {dÚwV dm`[a¨J, d H$moånmoZ|Q²>g

* g^r dm`[a§J H$ZoŠeZ Imob {X`o OmE§&

11-35


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R076



l Masking Requirements

l _mpñH¨$J Amdí`H$VmE§

11-36


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11-37


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11-38


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11-39


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R076

l Driver Ocular Point

l MmbH$ AmHw$ba ßdmB§Q>



11-40


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R076

l Suspension Shackle Pins

There should not be any Constrain on

front and Rear suspension Shackle pins

accessibility. So Proper clearance to be

given on Mudguard area for Easy

Accessibility of Shackle pins. This to be

ensure at a time of Bus Body building.

l gñn|eZ e¡H$b {nÝg

Ajbr Am¡a {nN>br gñn|eZ e¡H$b {nZm| VH$ nhþ±MZo

_| H$moB© ì`dYmZ Zhr hmoZm Mm{hò, AV… _S>JmS>© joÌ

_| e¡H$b {nZm| VH$ gabVm go nhþ±M hoVw C{MV AV§a

XoZm Mm{hò & ~m°S>r ~ZmVo g_` Bgo gw{ZpíMV H$aZm

Mm{hò &

Shackle pin

l External / Internal Cladding

- The external paneling on structure can

be in aluminum or GI sheet and as per

the prevailing design.

- Front Windshield should be made of

laminated glass.

- Window glasses and rear windshield to

be made of toughened glass.

- The interior paneling can be as per the

prevailing design or depends entirely on

bus segment. Same is the case with

seats & hat-rack.

- It is important to use Fire retardant

materials for the internal cladding for

the safety of the passengers.

l ~mhar / A§Xê$Zr Šb¡qS>J

- T>m§Mo na ~mhar n¡ZqbJ Eë`y{_{Z`_ ̀ m GI erQ> _| àM{bV {S>µOmBZ Ho$ AZwén hmo gH$Vr h¡&

- AJ« qdS> erëS> bo{_ZoQ>oS> H$m±M H$m ~Zm hmoZm Mm{hòo&

- {I‹S>H$s Ho$ H$m±M Am¡a {nN>bm qdS> erëS> _O~wV ½bmg Ho$ hmo&

- A§XéZr n¡ZqbJ àM{bV {S>µOmBZ Ho$ AZwén `m {\$a nwU©V… ~g goJ_|Q> na {Z^©a hmoJr& grQ>mo VWm h¡Q> a¡H$ na ̂ r ̀ hr bmJy hmoJm&

- A§XéZr ½b¡qS>J hoVw \$mà [aQ>mS>]Q> gm_J«r H$m Cn`moJ ̀ m[Ì`m| H$s gwajm Ho$ {bò _hËdnwU© h¡ &



11-41


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l Rear Under run Protection Device

- 1 Rear Under run protective Device

(RUPD) fitment as per IS 14812 :2005.

- RUPD already meeting requirement is

provided in chassis. Should not be

change During Bus Body Building.

- Rear under run protection device.

l [aà A§S>aaZ àmoQ>oŠeZ {S>dmBg

- [aà A§S>aaZ àmoQ>opŠQ>d {S>dmBg (RUPD)

{\$Q>_|Q> IS 14812 :2005 $Ho$ AZwgma&

- Mo{gg _| nhbo go hr RUPD Amdí`H$VmAm| H$m

AZwnmbZ {H$`m J`m h¡, ~g ~m°S>r ~ZmVo g_`

Bg_o§ ~Xbmd Zhr§ H$aZm Mm[hò&

- [aà A§S>aaZ àmoQ>oŠeZ {S>dmBg&

Rear under run protection device

l Lights Installation

- Height of all lamps fitted on the bus

should be between 500mm to 1200mm

measured from ground.

- Height of the end outline marker lamps

shall be on top most four corner of the

vehicle.

- Height of side reflector should be

between 250mm to 900mm measured

from the ground.

- All lamps and reflectors fitted on front

and rear of the bus except main beam

headlamp, reversing lamp and rear

registration plate lamp should be within

400mm measured from the outer side

edge of the bus.

l ~{Îm`m± bJmZm

- g^r ~{Îm`m| H$s D±$MmB© Omo ~g _| [\$Q> h¢ \$e© go ZmnZo na 500 [_._r. go 1200 [_._r. Ho$ ~rM hmoZr Mmhrò&

- EÝS> AmCQ>bmBZ _mH©$a b¡§nmo H$s D$±MmB©, ~g Ho$ CÀMV_ Mma H$moZm| VH$ hmoJr&

- gmBS> [aâboŠQ>a H$s D$±MmB© \$e© go ZmnZo na 250 [_._r. go 900 [_._r. Ho$ ~rM hmoJr&

- _oZ ~r_ h¡S> b¢n, [ad{gªJ b¢n Am¡a níMn§Or`Z n{Å>H$m b¢n H$mo N>moS>H$a AÝ` g^r ~{Îm`m± VWm [aâboŠQ>g© Omo ~g Ho$ AJ« d níM ̂ mJ _| {\$Q> h¡, do ~g Ho$ ~mhar N>moa Ho$ {H$Zmao go ZmnZo na 400 [_._r. Ho$ A§Xa hmoJr &



11-42


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R076

- The minimum gap between all lamps

and reflectors fitted on front and rear of

bus should be 600mm except reversing

lamp and rear registration plate lamp.

- Main-beam headlamp quantity can be 2

or 4 in numbers and dipped beam

headlamp should be 2 in numbers.

- Side indicator lamps has to be fitted on

the front half of the bus.

- The front end-outline marker lamp

should be white in color and rear end

outline marker lamp should be red in

color.

- Gap between the front edge of the

vehicle and side reflector or side

marker lamp should not be more then

2000mm.

- Gap between the rear most edge of

vehicle and rear most side reflector or

lamp should not be more than

1000mm.

- Distance between two adjacent side

reflector or side marker lamp should

not exceed 3000mm.

- [ad{gªJ ~Îmr Am¡a níM n§Or`Z n{Å>H$m ~Îmr H$mo N>mo‹S> H$a ~g Ho$ AJ« Ed§ níM _| {\$Q> n§Or`Z n{Å>H$m ~Îmr Ho$m N>mo‹S> H$a ~g Ho$ AJ« Ed§ níM _o§ {\$Q> H$s JB© g_ñV ~{Îm`m| Am¡a [aâboŠQ>am| Ho$ ~rM Ý`yZV_ A§Va 600[_._r. hmoZm Mm{hò&

- _oZ ~r_ h¡S>b¢n H$s g§»`m 2 ̀ m 4 hmo gH$Vr h¡, VWm {S>ßS> ~r_ b¢n H$s g§»`m 2 hmoZr Mm{hò&

- ~g Ho$ \«§$Q> hm\$ na gmBS> B§{S>H$oQ>a ~{Îm`m± {\$Q> H$s OmZr Mm{hò&

- \«$§Q> EÝS>-AmCQ> bmBZ _mH©$a ~Îmr H$m a§J ídoV Am¡a [aà EÝS> AmCQ>bmBZ$_mH©$a ~Îmr H$m bmb hmoZm Mm{hò&

- dmhZ Ho$ AJbo {gao Am¡a gmBS> [aâboŠQ>a `m gmBS> _mH©$a b¢n Ho$ ~rM H$m A§Va 2000 [_._r. go A{YH$ Zhr hmoZm Mm{hò&

- dmhZ Ho$ EH$X_ {nN>bo {gao Am¡a g~go nrN>o Ho$ gmBS> [aâboŠQ>a ̀ m b¢n Ho$ ~rM H$m A§Va 1000 [_._r. go A{YH$ Zhr hmoZm Mm{hò&

- Xmo g_rndVu (Adjacent) gmBS> namdV©Z (Reflector) ̀ m gmBS> _mH©$a ~{Îm`m| Ho$ ~rM H$m AÝVa 3000 [_._r. go A{YH$ Zhr§ hmoZm Mm{hò&



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R076

- The point on the illuminating surface of

head lamp which is farthest from the

vehicle median longitudinal plan shall

not be more than 400mm from the

external outer edge of the vehicle. The

inner edge of the retro reflector shall

not be less than 600mm apart.

Please refer AIS-008 for all lighting

installations.

- h¡S>b¢n H$s amoeZr XoZo dmbr gVh na ßdmB§Q> Omo {H$ dmhZ _o{S>`Z bm§JrQ²>`wS>Zb ßbmZ go g~go A{YH$ Xþa h¡, Cgo dmhZ Ho$ ~mhar {H$Zmao go 400 [_._r. go A{YH$ Zhr§ hmoZm Mm{hò& aoQ´>mo [aâboŠQ>a H$s ̂ rVar H$moa 600 [_._r. go H$_ Xþar na Zht hmoZm Mm{hò&

g^r bmBqQ>J BÝñQ>mboeÝg Ho$ {bò XoI| AIS- 008&

l Rear View Mirrior

- As per the requirement of Motor vehicle

act, the buses built on these chassis

should be fitted with the rear view

mirror unit ( low convex and high convex

mirrors in single casing) on LH / RH side

of the vehicle.

- The rear view mirror should be fitted in

such a way to get the field of vision to

driver as per the following sketch.

- The adjacent image shows typical RVM

installation on the EICHER built buses.

l [aà ì`w {_aa

- _moQ>a `mZ A{Y{Z`_ H$s Amdí`H$VmAm| Ho$

AZwgma B Z Mo{ggm| na {Z{_©V ~gmo§ _| níMÐí`

Xn©U ̀ y{ZQ> {ZåZ CÎmb (Low conves) Am¡a

CÀM CÎmb (High convex) Xn©U EH$b Ho$qgJ

_|, dmhZ Ho$ ~mE§ & Xm{hZo Amoa hmoZm Mm{hò&

- níMÐí` Xn©U Bg àH$ma go {\$Q> {H$`m OmZm

Mm{hò {H$ {Oggo MmbH$ H$mo joÌ Ho$ Ðí`, {ZåZ

aoIm{MÌ Ho$ AZwgma {XImB© X|&

- g_rndVu N>{d Amèa {Z{_©V ~gm| _| bJmE JE

{d{eï> RVM H$m Ðí` àñVwV H$aVr h¡ &

Please refer AIS-002 for RVM installations



11-44


SE

R076

l Driver Seat Belt Installation

- As per the requirement of Motor vehicle

act, the driver seat belt provided with

the chassis should be fitted on the B-

Pillar structure with 4mm thick welded

mounting plate.

- The adjacent image indicates the

recommended location of the fitment of

seat belt anchoring point behind the

driver door.

- For seat belt mounting position refer

given image.

l MmbH$ grQ> ~oëQ> bJmZm

- _moQ>a `mZ A{Y{Z`_ H$s Amdí`H$VmAm| H§$

AZwgma Mo{gg Ho$ gmW àXÎm MmbH$ grQ> ~oëQ> H$mo

B-[nba T>m§Mo na 4 [_._r. _moQ>r doëS> H$s hþB©

_mC§{Q>§J ßboQ> Ho$ gmW bJmZm Oéar h¡&

- gmW H$s N>{d AZwe§{gV grQ> ~oëQ> H$m ñWmZ

E§H$[a¨J q~Xþ MmbH$ S>moa Ho$ nrN>o Xem©Vr h¡&

- grQ> ~oëQ> M‹T>mZo H$s pñW[V hoVw N>{d H$mo XoI|&

l Wiper Installation

- As per the requirement of Motor

vehicle act, the wiper installation

should confirms to the wiping area

requirements as specified in the AIS-

011 document.

l dm`na bJmZm

_moQ>a `mZ A{Y{Z`_ H$s Amdí`H$VmAm| Ho$ -

AZwgma dm`na H$mo dm`qnJ joÌ H$s OéaVmo§ Ho$ AZwén bJmZm Mm{h`o, O¡gm AIS-011 XñVmdoO _| {Z{X©ï> {H$`m J`m h¡&

Wiper



11-45


SE

R076

l Seating Layout

The bus seats and seating layout must

confirm to state RTO regulations and AIS-

023.

l grqQ>J boAmCQ> (grQ> aMZm)

~g H$s grQ>| CZH$s aMZm (layout) H$mo RTO

[d{Z`_m| VWm AIS-023 Ho$ AZwgma hmoZm Mm[h`o &



- The wiping area requirement depends

on the type of windshield used and its

bottom location. Select the proper

wiper system as per the windshield

design. A typical wiper installation for

these type of vehicles is shown in the

adjacent image.

dmBqnJ joÌ Amdí`H$Vm {H$g àH$ma H$s qdS>erëS> -

à`wŠV hþB© h¡ Am¡a CgHo$ Vbo (bo�om) Ho$ ñWmZ na {Z^©a h¡, qdS>erëS> H$s ~ZmdQ> Ho$ AZwén C{MV dmBna nÕ{V H$m M`Z H$a|& gmW H$s N>{d _| Bg àH$ma Ho$ dmhZmo§ Ho$ {b`o {derï> dm`na BÝñQ>mboeZ Xem©`m J`m h¡&

11-46


SE

R076


- As the performance of vehicle is evaluated

with poly V groove 8Pk belt, with valeo AC

compressor (TM43 for Pro 3009 & TM 31

for Pro 3008) (Model details mentioned

below).

- It is an essential to install above mentioned

AC compressor, AC polly V belt 8Pk only for

AC fitment requirement.

- If any other make/model AC compressor

and AC belt used on chassis, warranty for

engine, battery, alternator shall be void.

- It is required to install AC compressor

engine mounted only, if chassis mounted

AC compressor installed on chassis

warranty of frame shall void.

- It is recommended to use eberspaecher AC

unit.

Pro 3008 H Make ValeoName TM31 with 156 dia. 8PK pulleyType Swash plate CC / Rev 313RPM (max.) 5000Weight (Kg) 15.5Compressor oil PAG oil 800cc

AC Compressor Details

INSTALLATION GUIDELINE FOR CWC CHASSIS AC COMPRESSOR

11-47

- do{b`mo H$åàoea Ho$ gmW nmobr -J«yd 8 ~oëQ> AC V Pk

go dmhZ Ho$ àXe©Z H$m _ë`m§H$Z {H$`m OmVm h¡, ( 3009 Ho$ {b`o d Ho$ {b`o Pro TM43 Pro 3008

TM 31)&

- bJmZo na D$na CëboI H$åàoea, nm|br AC AC AC

dr-~oëQ>> 8 H$s Amdí`H$Vm h¡&Pk

- Mo{gg na {H$gr AÝ` _oH$ `m _m°S>b H$m Ho$ AC

H$åàoea bJZo na B§OZ ~¡Q>ar AëQ>aZoQ>a H$s dma§Q>r Zhr _mZr OmEoJr&

- Ho$db B§OZ _mD±$Q>oS> H$åàoea hr _mÝ` h¡ AJa AC

Mo{gg _mD±$Q>oS> H$åàoea h¡ Vmo Mo{gg \«o$_ H$s AC

dma§Q>r _mÝ` Zht hmoJr&

- `w{ZQ> H$m hr Cn`moJ H$aZo H$s Eberspaecher AC

{g\$m[ag H$s OmVr h¡&

_oH$ do{b`moZm_ TM31 with 156 dia. 8PK pulleyQ>mB©n ñdmg ßboQ>CC / Rev 313RPM (max.) 5000^ma (Kg) 15.5

H$åàoea Am°`b PAG oil 800cc

AC H$åàoea {ddaUPro 3008 H

CWC AC H$åàoea H$o [bE Mo[gg B§ñQ>m°boeZJmB©S>bmB©Ýg

Pro 3009 LMake ValeoName TM43 with 160 dia. 8PK pulleyType Swash plate CC / Rev 425RPM (max.) 5000Weight (Kg) 20.7Compressor oil PAG oil 800cc

- The AC compressor to be fitted on engine

mounting bracket with bolt refer below

specification table:-

- The manual tensioner to be adjust and belt

wrapped on AC compressor and crank

pulley through manual tensioner pulley.

- Manual tensioner screw to be adjusted till

belt tension reaches between 136+5Hz

between crank pulley and AC compressor

span at point P.

INSTALLATION GUIDELINES FOR AC BELT AND COMPRESSOR


P

TM31

TM43

Model Bolt

M10X1.5X30

M12X40X1.5

Grade

7t

7t

Torque

3.5~5.5kgf

7~9.5kgf

11-48

_oH$ do{b`moZm_ TM43 with 160 dia. 8PK pulleyQ>mB©n ñdmg ßboQ>CC / Rev 425RPM (max.) 5000^ma (Kg) 20.7

H$åàoea Am°`b PAG oil 800cc

- H$åàoea H$mo bJmZo Ho$ {bE ZrMo {X`o JEo AC

ñno{g{\$Ho$eZ Q>o~b Ho$ AZþgma ~moëQ> H$m Cn`moJ H$a|&

TM31

TM43

_m°S>b ~moëQ>M10X1.5X30

M12X40X1.5

J«oS7t

7t

> Q>mH©$ 3.5~5.5kgf

7~9.5kgf

- _oÝ`wAb Q>|eZa nwëbr H$s ghm`Vm go H$åàoea Ho$ AC

~oëQ> d H«|$H$ nwëbr _oÝ`wAb Q>|eZ H$m gwYma H$a|&

- H«|$H$ nwëbr d H$åàoea ñn°Z nmBªQ> Ho$ {b`o ~oëQ> AC P

IrMmd AmZo VH$ _oÝ`wAb Q>o§eZ ñH«$w H$mo 136+5Hz

ES>OñQ> H$a|&

Pro 3009 L

«

INSTALLATION GUIDELINE FOR CWC CHASSIS AC COMPRESSOR

CWC AC H$åàoea H$o [bE Mo[gg B§ñQ>m°boeZJmB©S>bmB©Ýg

AC Am¡a H$åàoea H$o [bE ~oëQ> B§ñQ>m°boeZJmB©S>bmB©Ýg


11-49

AC compressor to crank pulley

Crank pulley to manual tensioner

3.66 Max 3.64 Max

1.00 Max 1.07 Max

S.No.Adjacent grooved

pulleys

1.

2.

Axle offset allowance

(mm) (TM43)

Axle offset allowance

(mm) (TM31)

*For further details, installation to be referred.

- Permissible axial offset allowances values are.

- EopŠg`b Am°âgoQ> AbmC§g H$m C[MV _yë`mH$§Z H$ao§&

AC H$åàoea go H«|$H$ nwëbrH«|$H$ nwëbr go _oÝ`wAb Q>|eZa

3.66 Max 3.64 Max

1.00 Max 1.07 Max

1.

2.

EŠgb Am°âgoQ> AbmC§g

(mm) (TM43) (mm) (TM31)

* A{YH$ OmZH$mar Ho$ {bE B§ñQ>m°boeZ {ZX©o{eH$m XoI|&

EoS>Oog|Q> J«yìS> nwbrEŠgb Am°âgoQ>

AbmC§g H«$. g§.

INSTALLATION GUIDELINES FOR AC BELT AND COMPRESSOR

AC Am¡a H$åàoea H$o [bE ~oëQ> B§ñQ>m°boeZJmB©S>bmB©Ýg


11-50

COMPRESSOR MOUNTING DETAILS TM43 & TM31

- The AC compressor has to be fitted on engine mounting bracket with bolt of specification mentioned below.

For TM43 compressorBolt flange M12X1.75X45 8.8tTorque - 7~9.5kgf

For TM31 compressorBolt flange M10X1.5X50 7tTorque - 3.5~5.5kgf

For TM43Plain washer M12For TM31Plain washer M10

For TM31 Compressor on Pro 3008 HBolt M10X1.5X30Grade - 7TTorque required - 3.5~5.5kgf

For TM43 Compressor on Pro 3009 LBolt M12X1.75X45Grade - 8.8TTorque required - 7~9.5kgf

- H$åàoea H$mo bJmZo Ho$ {bE ZrMo {X`o JEo AC

ñno{g{\$Ho$eZ Q>o~b Ho$ AZþgma ~moëQ> H$m Cn`moJ H$a|&

H$åàoea _mC[ §J {ddaU Q> TM43 & TM31

bus body building guidelines for body builder - …dealer.vecv.net/dcs/pdf/annexure 08_eicher...

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