Académique Documents
Professionnel Documents
Culture Documents
01
7. Body building
General guidelines
Installation of Horn
Storage of vehicles
7.02
GENERAL GUIDELINES
The frame design adopted by Ashok Leyland is of the ladder type, combining strength and flexibility to ensure that local
loads are distributed evenly throughout the frame.
It is important that some flexibility between the body and the chassis frame be in-built to prevent damage to chassis or
body.
Working clearance required by chassis and body parts must be provided eg, suspension movement, axle articulation,
variations in propeller shaft drive lines, flexible pipes. Life and reliability of units will be impaired if the above factors
are not taken care of.
Any modification to a system on the chassis should only be made on advice from Ashok Leyland
Limited.
Care must be taken to ensure that no body or body anchorage fittings foul or pinch brake pipes, power steering pipes
or electrical harnesses. Any possibility of abrasion between pipes should be avoided and pipes should be adequately
supported/clamped. Any breaks in the wiring insulation should be sealed against ingress of water.
Body positioning
Consideration should be given while designing the bus body to arrive at the optimum body weight and payload and it
is the operators responsibility to ensure that the rated axle weights are not exceeded.
Ideally, the weight should be distributed evenly over the entire body length and care should be taken to position the
centre of gravity of the body on the centre line of the chassis for optimum axle loading and operational stability. This
is achieved by the proper positioning of the battery carrier, luggage-holds, spare wheel carrier, etc.
Body building
A - ANGLE OF APPROACH
7.03
D - ANGLE OF DEPARTURE
Ground clearance
Fitment of additional equipment and modifications to existing units like provision of luggage-holds, repositioning spare
wheel carrier, etc. may curtail ground clearance and impair angles of approach and departure (See Fig.).
Typical ground clearances at the various areas are as under:
1.
Entrance/Exit
2.
Skirt level
Around 450 mm (for easy access to units in the undercarriage; however, the skirt level
should not be kept above the wheel centre line).
The minimum ground clearance is at the axles. Hence clearances for these should be treated as the absolute minimum.
Please refer to the appropriate coach-builders drawing for details.
7.04
Body building
A minimum of 50 mm clearance
should be provided between the
front grille and deaeration header
tank.
7.05
For better air flow across the radiator and engine, the
front grill should be retained as it is.
7.06
In the case of vehicles fitted with power steering, the steering oil reservoir
should be positioned at a level which is above the steering box. ideally, this
may be located inside the front grille whereby the air-draught effectively cools
the steering oil.
Adequate leg-room should be provided for the driver to enable full travel of
the clutch / brake / accelerator pedals and also to minimise driver fatigue.
An angle of 35 is provided for the pedal plate to ensure correct clutch
freeplay. Please refer Fig. The pedal plate should be sealed against entry of
dust, water and heat into the cabin, by providing suitable rubber flaps at the
pedal cut-outs.
Care should be taken, while clamping the steering outer column on to the
instrument panel, not to induce any stress on the steering inner column.
Batteries should not be placed in a confined space (without adequate
ventilation) as this could lead to accumulation of explosive fumes. The
suggested locations for the placement of the batteries are (1) the front LH
corner inside the coach (with suitable wooden enclosure) and (2) in a
suitable battery compartment in the LH side undercarriage.
A cradle
arrangement may be provided whereby the batteries can be pulled out from
its compartment for servicing. Please refer Fig.
Body building
7.07
7.08
Body building
Don'ts
7.09
7.10
Working clearance must be provided for drop-arm movement, axle articulation etc.
Provide hinged door on floor for easy access and removal of unit assembly and accessories like alternator, FIP,
gearbox, body U clamp, etc.
When engine is started after long halt at body building point, ensure that the engine is cranked keeping the off
lever cable in pulled position, so as to wet the moving parts with lub oil. ( especially in case of turbo charged
engine.)
The chassis with cross bearers laid should be supported and levelled on ground at front, middle and rear . The
accuracy should be 5 mm. The supports can be withdrawn only after truss panel work completed.
Ensure that air intake, exhaust and air flow through radiator grill and charge air cooler are not restricted.
Tapping air point for air horn / door closer and windscreen washer should be from an Auxiliary tank or system
protection valve (port no. 24).
Body building
7.11
It is very
In case of a gas leak at cylinder connections use Teflon tape over the
thread and tighten to arrest the leak.
Welding should not be done over the gas cylinders or anywhere near.
Battery removed from the chassis should be properly stored and put
on charge.
Provide flap door with louvers on either side of the chassis to have
access to the cylinders adapters / pipe joints.
Adequate venting
arrangement to be made by the body builder to vent the entrapped
gas if any to the atmosphere. The size of the vent slots should be 80
mm x 30 mm (height x width) with a distance of 75 mm between
two slots.
80 mm
7.12
To ensure protective sleeve for the battery cable. Battery cable should be routed in such a way that cables are
not in contact with any metal parts / metal cutout openings. For metal cutout openings suitable rubber grommet
to be provided. To ensure suitable clipping for the battery cables.
Radiator should be properly covered to prevent it from any damage from welding splatter.
All electronic components / wiring harness should be properly shielded / earthed in order to prevent damages
during body building.
Provision for fire extinguisher mounting (with 1 kg dry chemical powder and refill as per IS:2171) to be provided
in both, driver and passenger compartment in a visible and well accessible position.
Trap door in floor with rubber sealing to provide access to tighten the cylinder straps nut on either side.
Removable shielding guard below cylinder valve and piping and connection points for safety against flying stones
to be provided.
The four Gas cylinder mounting X-bearers have to be integrated with bus body.
Drilling of holes or welding on the frame side members are not allowed.
Flap door for checking first / second stage regulator below the driver seat area to be provided and hence half
door to be provided for driver.
Bonnet should have insulation inside - 40 mm fibre glass wool or PU foam and outside Foam and Rexene to be
ensured.
Ceramic fibre insulation to be provided in the dashboard, driver cab floor and bonnet base vertical walls.
Body building
7.13
Body building structure material used should not carry leaking gas if any. E.g. through pipes or hat section in the
passenger compartment. Proper sealing at entry point to be done.
There should not be any open holes on the floor to avoid entry of leaking gas, if any. This is a safety precaution.
Water drainage holes should be at the rear end of the body floor and should be properly plugged.
Bonnet / Floor area around the engine should ensure proper ventilation of the engine.
LH / RH louvers at the front grille provided to ensure air entry to air cleaner on LH side and for ventilation of
driver leg space in the front on RH side, to be utilised.
In front grille opened position, water filling, oil filling and oil level checking and radiator removing should be
accessible.
D
Body builder not to tamper with ignition system wiring and tail lamp connecting wire to extend its length.
High voltage wiring should not rub with any body structure.
Fixed first aid box with ointment, bandage, medicines, etc should be provided on dash board near the driver.
CAUTION: Do not tamper the arrangement of cylinder mountings, gas pipings, wiring harness of
chassis and engine etc., provided in the chassis by Ashok Leyland as this tampering may
seriously impair the safe operation of the vehicle.
7.14
Feature
Reason
Front grille
Front panel
210 mm from frame top without flooring This is to ensure ease of dissipation
sheet on both driver and entrance side of hot air circulation under the floor.
Body building
7.15
7.16
Compliance plate
Identification label
Fire extinguisher
As per CMVR
Safety instructions
*
*
*
AL to provide
Min. 2 copies to be displayed in
passenger compartment.
Body building
7.17
7.18
Body building
7.19
7.20
Body building
7.21
7.22
Body building
7.23
Note:
Any modification to the chassis for
mounting of auxiliary equipments may
be carried out only with the approval
of AL.
However, it shall be the
responsibility of the bodybuilder to
present to the appropriate authority
the intended modification and seek
their approval wherever called for to
do so by law.
Drilling on the
side member flanges is strictly
forbidden.
7.24
Number
Head Lamp
Dipped HL
Front Fog Lamp
Reverse
FDI
RDI
Hazard
2
2
Optional
1/2
2
2
-
Height from
Ground (mm)
450 - 1200
450 - 1200
250 - 1200
350 - 1500
350 - 1500
-
350 - 1500
Stop Lamp
Rear Registration
Plate Lamp
Front Position Lamp
Rear Position Lamp
Rear Fog Lamp
Parking Lamp
End Marker Lamp
Rear Reflector
Front Reflector
Side Reflector
1
2
2
Optional
Optional
2+2
2
2 on Goods Vehicle
For vehicle of more
than 1.6 m long
Side Marker Lamp
Min 1
Side Repeater Lamp 1 no. on each side
Width from
Distance between Position
Remarks
Outer edge (mm)
lamps (mm)
Nil
Nil
Front
Intensity=22500cd
Not more than 400
Not less than 600
Front
Rear
Not more than 400
Max-1800
Front
1/1a/1b type
Not more than 400
Max-1800
2a/2b type
Combined
FDI & RDI
Not less than 600
Rear
S1/S2 type
Rear
Front
Rear
Front &
Rear
Side
Front
Red
White
Amber
Amber
Amber
The above requirements are ensured for fully built vehicles built by AL. In case of passenger vehicles ensure fitment of Tail
Lamp, Side marker lamp, Side reflector and Roof marker lamp. Refer above table for details.
For installation details refer following figures. Please ensure lamps are from approved sources like Luman, Lumax, JMA etc.,
Body building
7.25
7.26
SL
RL
TL
NPL
:
:
:
:
Stop Lamp
Reverse Lamp
Tail Lamp
Number Plate Lamp
Body building
7.27
NOTE:
Wiper Arm
540 mm
Wiper Blade
660 mm
Sweep Angle :
90
7.28
Body building
7.29
7.30
INSTALLATION OF HORN
The requirements are ensured by AL. Please do not alter Horn positions on any account. Use only approved horns
on the appropriate locations on the cowl recommended by AL.
SEAT BELT INSTALLATION GUIDELINES
The seat belt provided along with the chassis should be installed on the vehicle body structure through anchoring
brackets. Operators are requested to follow the anchoring arrangement drawing and refer the guidelines provided as
follows:
-
Anchoring bracket provided on the backrest of driver seat is temporary and valid only for drive-away chassis.
This point to be shifted to cant rail / 'B' pillar during body building.
Locational dimensions marked thus * for anchoring point on cantrail are indicative only. Minor deviations from
these dimensions are allowed to suit body building style and to have proper support for anchoring brackets on
cantrail / B pillar.
Anchoring brackets to be made as per the drawing and to be welded on all four sides on to cant rail.
welding is preferable with electrode wire to conform ER70S-6 of AWS A5.18.
Adherence to the guidelines is strictly recommended for safety and legal requirements.
CO2
Body building
H1 - Hinge point
H2 - Hinge point
H3 - Hinge point
Dimensions marked
7.31
7.32
Body building
7.33
STORAGE OF VEHICLES
Whenever vehicles are in storage awaiting bodybuilding, proper care should be taken as detailed below:
Storage over a short period
a)
The vehicle must be thoroughly washed, including the under-chassis to remove any deposits of mud as this will
lead to corrosion.
b)
c)
d)
The engine should be started and run for a few minutes atleast once a week. It is advisable that the vehicle is
jacked-up and the gears engaged so that complete oil circulation is effected in the gearbox and differential too.
The battery should be removed from the chassis and prepared for storage in a dry place. The battery should
be topped-up with distilled water and charged at regular intervals. Alternatively, the acid from the battery should
be drained dry and stored, however ensuring that the acid is refilled to the correct level and density and
recharged at the time of recommissioning the battery.
b)
The spark plugs should be removed and about 20 cc of corrosion inhibiting oil (Shell Ensis oil SAE 10 or Castrol
Storage oil 301 or Servo Preserve 30) should be added through the spark plug hole. The engine should be
cranked for about 30 seconds and the spark plugs fitted back.
c)
Anticorrosive oil should be liberally sprayed over rocker levers and push rods.
d)
The lubricating system should be drained and replenished with corrosion inhibiting oil.
e)
It is advisable that the cooling system be drained completely. A board should be suitably displayed to indicate
that the cooling system has been drained in order to avoid accidental starting of the engine.
f)
Turn off the gas feeding valve near the filler valve to stop gas supply to engine.
7.34
g)
All the openings like intake manifold, exhaust tail pipe, engine breather pipe, etc. should be completely sealed with
masking tape.
h)
The vehicle should be jacked-up and supported on suitable props under the axles.
i)
The use of parking brake should not be resorted to, for arresting the movement of the vehicle - instead, chocks
must be used.
Make sure that there is no foreign particle like nail, metal particle wooden pieces etc.
Remove spark plug, through this bore with a small dia longer length nozzle smear a thin film of oil onto the liner
bores.
Before fitting the spark plug dead crank the engine 2/3 times.
Slowly raise the engine and ensure specified oil pressure is attained.
Body building
7.35
2)
The CNG electrical units mounting panel to be mounted inside the drivers cabin in the RH corner above the
driver head.
3)
24V-12 convertor
Trigger box
4)
Ensure the end connections to the above units are properly fixed and are not in strained condition.
5)
6)
7)
Ensure proper tightness of nile switch and push pull switch fitted in the dash board.
connected with 24V DC supply.
8)
7.36
Ignition system
1)
Ignition coil to be mounted on the inside of Drivers cabin on the side panel above the clutch pedal lever.
2)
The ignition coil cable to be routed and clamped suitably without coming in the way of any moving / rubbing
metal parts
3)
The distributor pick up cable should be the imported one with a positive connector and no open Lucar fitment
should be allowed.
4)
On the distributor check the matching of punch mark to ensure proper timing. Ensure pinch bolt tightness.
5)
Ensure proper fixing of HT cable. There will be a tight joint and while fixing click sound will be audibly heard.
6)
Ensure that the HT cable sleeve is symmetrically pressed into the bore.
Carburetion system
1)
2)
3)
4)
All the joints in the piping fuel should be checked for leak.