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7.

01

7. Body building

General guidelines

Precautions during body building

Cowl body integration

Installation of lighting and signalling devices

Installation of wind screen wiping system

Installation of Rear View Mirror

Installation of Horn

Seat Belt Installation Guidelines

Storage of vehicles

Coach builders drawing

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

Around 400 mm (for easy boarding and alighting)

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

Safety and legal requirement


Body builders should familiarise themselves with the statutory requirements and be responsible for their adherence.
However, if doubts exist on the understanding of practical application of regulations, assistance may be sought from
Ashok Leyland or Authorised Dealer.
Maintenance and service
The servicing/maintenance accessibility of the various units should not be impaired by improper bodybuilding. The cost
of downtime will be increased if maintenance is difficult to carry out.
Easy access must be provided for the following:
Removal of engine, carburettor, gas pipe, water pump, alternator, gearbox, etc.
Radiator hoses/pipes
Fan belt adjustment/replacement
Removal of exhaust pipe mounting nuts
Checking of flywheel marking.
Battery and starter motor terminals
Checking and topping-up of engine coolant and lubricating oils.
Checking and topping-up of clutch fluid in clutch master cylinder.
Removal of air cleaner and oil filter.
Removal / Fitment of clutch master cylinder, Dual brake valve and power steering reservoir.
Greasing of various points like propeller shaft U/J.
Care should also be exercised in the following areas to ensure safe and efficient functioning of the various units:A minimum of 40 mm clearance should be maintained between the engine and the bonnet for effective heat
dissipation, in addition to providing easy access.
The engine compartment should be provided with effective sound/heat insulation to keep down noise/heat at
acceptable levels.

Body building

A suitable frontal opening and grille


arrangement should be provided to
ensure adequate airflow across the
radiator
and
engine.
The
recommended frontal arrangement
is shown in Fig a.

A minimum of 50 mm clearance
should be provided between the
front grille and deaeration header
tank.

7.05

All Dimensions are in mm

Sufficient space should be provided


around the radiator filler area for
easy water-filling through the frontal
opening.

Wheel arch to tyre clearance should


be so provided as to avoid tyre
fouling the wheel arch even in
extreme conditions. The recommended
vertical clearance between the tyre
top edge and the wheel hump inner
surface is 225 mm as measured in Note:
unladen condition. See Fig. b,c,d for
the
recommended
wheel-arch
dimensions.
Also, the wheel-arch
structure has to be so contoured as
to avoid any fouling of tyre at
extreme turns.

All Dimensions are in mm

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.

All Dimensions are in mm

While removing and repositioning various items like dashboard instruments,


flick valve, power steering oil reservoir, bundy pipes, etc. extreme care should
be exercised to avoid damage. It should also be ensured that all the units
are functional and without any leakage of oil/air.

Body building

PRECAUTIONS DURING BODY BUILDING


During bodybuilding the following precautions must be taken to avoid any
undue damage to the various components:Frame
Any welding or drilling of holes on the frame without the consent of AL is
strictly prohibited.
Protection of Piping & Wiring
During welding, cutting, drilling or grinding operations on body work, all piping
and electrical wiring should be kept well clear of the immediate working area
or adequately covered to prevent damage.
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 removed from the vehicle whilst bodywork is
being carried out. See fig.
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 the earth clamp is not attached to the spring. When
welding, the springs should be covered to avoid weld splatter falling on the spring
surfaces. Springs should not be subjected to sharp impacts (Please refer to Fig.).

7.07

7.08

Do's and Don'ts


Do's
"U" Bolt should be placed atleast 200
mm away from cross members. Fig. a
Wheel arch should not be less than
225 mm (unladen condition). Fig. b

Cross member should be fixed with


runner and runner should be fixed with
frame. Fig. c
Spacer to be used between frame and
flanges as recommended. Fig. d
Minimum clearance of 40 mm to be
maintained around the engine, excluding
insulation thickness. Fig. e

Height of cabin floor from top flange


of long member (A) to be maintained
as shown. Fig. f
Floor board inclination (B) for proper
clutch play should be maintained as
shown. Fig. f

Body building

Don'ts

7.09

Do not drill holes on top flange to


mount runner or cross bearer. Fig. a
Do not weld on long member. Fig. a
Do not end the runner abruptly, refer
recommended dimension for runner
front end as shown. Fig. b
Do not fit U-bolt close to spring
bracket. "A" should not be less than
200 mm (8"). Fig. c
Do not fit U bolt (A) without spacer
between flanges.
Aluminium profile
spacer between bottom flange and U
bolt should be used. Fig. d
Do not fasten mud guard support
bracket as shown.
This is to be
fabricated on the body of the vehicle.
Fig. e.
Do not alter the suspension by adding
extra leaves or altering the camber as
this will exert extra strain on frame
leading to frame failure. Fig. f

7.10

Care to be taken while body building


*

Before starting the body work, remove the following:


1. Battery, 2. Driver seat, 3. Windscreen washer, wiper arm and blade, 4. Spare wheel tyre.

Proper covering should be done, of the following:


1. Dash board, 2. Instrument panel with gauges, 3. Steering wheel, 4. Fuse box, 5. Nylon and rubber hoses
6. Control linkages, 7. Brake pipes, 8. Power steering connecting hoses.

All wiring connections should be disconnected.

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.)

Remove fabrication waste from chassis before delivery.

Do not extend the frame or cabin without Ashok Leyland concurrence.

Always consult Ashok Leyland service / dealer in case of any doubt.

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

Precautions before/during body fabrication


D

Cylinders are filled with CNG gas which is inflammable.

It is very

important that individual valve provided on each cylinder should be


closed completely during the entire body building stage and can be only
opened for moving the finished bus. The residual gas in the pipeline
after closing the valve should be removed by starting the engine.
D

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.

Proper shielding of gas cylinder should be done so as to isolate from


welding sparks.

Battery isolator switch should be cut off.

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.

Provide opening to gas filling points (size 250 mm x 250 mm)

GAS ESCAPE SLOT DIMENSION


30 mm

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.

Shielding of exhaust silencer from cylinders and piping.

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.

Provide suitable trap door for inspection of timing.


window.

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

No cross bearer should come exactly over the timing

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.

Provision of the emergency door at rear on driver side should be provided.

Ensure driver is educated and trained on CNG bus safety / operation.

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

SPECIFIC FEATURES REQUIRED ON BUS BODY


Requirement

Reason

Front grille

Sufficient louvres/slotted holes to be


provided to cover the complete
radiator overall size (Refer fig. 1)

For better air flow on to the


radiator

Front panel

Sufficient louvres/slotted holes to be provided


*
At LH for foot pedal area
For air circulation on to driver's leg area
*
At RH for air cleaner intake
For effective air suction.

Driver doorv ventilation

Sliding door below driver's seat with


louvres

For fresh air entry to bottom of


driver floor

Front grille in locked condition

Min. 25 mm clearance to be ensured


between inner panel and projecting
parts of radiator/engine.

To avoid fouling and subsequent


damage

Front grille in open condition

Proper accessibility should be ensured


For proper service accessibility and
for radiator water filling, engine oil filling, maintenance (SAM)
engine oil checking and mounting brackets.

Floor height in the engine


compartment area

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.

Bonnet bottom channel

For better dissipation of hot air


circulation in engine compartment.

Engine tunnel, bonnet and bonnet


bottom

For better dissipation of hot air


circulation.

Engine bonnet insulation

Louvres on bus body skirt on LH


and RH in the cylinder valve area

Insulation to be 25 mm thick Supercera


ceramic fibre insulation compressed and
density of 126 kg/m 3. Refer fig. 2

For heat insulation.

To allow escape of any minor gas leak.

Body building

Fig - 1 Front Grille

Fig - 2 Engine Bonnet

7.15

7.16

SPECIFIC FEATURES REQUIRED ON BUS BODY


Feature
Requirement
Reason
Opening on bus body skirt at LH
Opening size tobe 250 x 250 mm
For gas filling.
side - filler recepticle.
Flap doors on both sides LH/RH bus
body skirt at cylinder valve area.

To have access to cylinder valves/


pipe joints adaptors/leak check.

Trap doors in the floor with rubber


seating

To provide access to tightening the


cylinder mounting strap nuts on either side.

Cylinder mounting cross bearers

4 cross bearers to be integrated with


the bus body.

Clearance between cylinder/vehicle


body structure

Ensure min. 5 mm clearance

Distance between cylinder valve and


bus body

Ensure min. 200 mm.

Compliance plate

Will be provided by AL. To be installed


by the body builder near the gas filling area.

Identification label

Material for seat/uphoistry/roof and


side lining

Fire retardant material shall be used.

Fire extinguisher

One no. each of dry powder type to be


provided in driver and passenger compartment

First aid kit

As per CMVR

Safety instructions

*
*
*

AL to provide
Min. 2 copies to be displayed in
passenger compartment.

For better integration and rigidity.

Locate on left side of the front and


rear safety glass and shall ensure
visibility from front and rear sides.

Body building

SCHEMATIC SHOWING LOCATION OF NOISE SHIELD


INSIDE TUNNEL DURING BODY BUILDING

7.17

7.18

COWL BODY INTEGRATION

All Dimensions are in mm

The cowl fitted on the chassis


should be integrated with bus
body structure as shown. For
integration of A post extension,
details as given in the drawing
should be followed.

Structure for front show panel


should be so located to mount
headlamps
as
per
IS:8415
Mounting Dimensions for Head
lamps for automobiles.
All
these
members
can
take
support from A post at
respective ends & from grille
support angle of cowl. It can
also be supported from bulk
head
in
the
longitudinal
directions.

In order to retain structural


rigidity of cowl do not tamper
any bulk head members.

Body building

Do not tamper the positions of


operating pedals as these are
positioned for comfortable &
safe driving condition.

Footstep has been provided on


RH side for use on drive - away
chassis only. Suitable footstep
can be constructed for drivers
entry as per current practice.

The cowl has been designed to


enable body builder to build
stepless saloon floor from front
to rear of bus except drivers
platform. Please note that floor
level of cowl on LH side is kept
at a level of 90 mm from top
of frame to facilitate this.

No structural members are


provided on LH side of the
COWL beyond longitudinal LH
on transverse direction to
provide flexibility of building
front / middle entrance.

7.19

All Dimensions are in mm

7.20

All Dimensions are in mm

STRUCTURE DETAIL FOR FRONT SHOW PANEL


(BULKHEAD STRUCTURE, CENTRE GRILLE ARE NOT SHOWN FOR CLARITY PURPOSE)

Longitudinal LH of the cowl is


so positioned to serve as a
strong support member for front
footstep structures in the case
of front entrance type bus.

Structures for front entrance are


not pictorially shown.
Body
builders to follow the existing
practice.

Anti-sag members on RH & LH


must be retained as part of
body structure. When skirt level
of bus body goes below the
bottom of cowl A post an
extension member (40 sq. tube
- 3 mm thick) may be welded
to the bottom of A post
without disturbing the anti-sag
member arrangement.

Body building

7.21

All Dimensions are in mm

7.22

All Dimensions are in mm

Body building

7.23

Body structural details are


shown only as general guidelines.

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.

All Dimensions are in mm

7.24

INSTALLATION OF LIGHTING AND SIGNALLING DEVICES


Furnished below are the requirements for lighting and signalling devices.
Lamp

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

To illuminate the Rear Registration Plate


350 - 1500
Not more than 400
Not less than 600
350 - 1500
Not more than 400
Not less than 600
Wiring and Non Flashing Light Tell Tale Mandatory
AS close to the outer top edge of vehicle
250 - 900
Not more than 400
Not less than 600
250 - 900
Not more than 400
Not less than 600
With in 3 M of Front of Vehicle, last one not more than
1 m from rear and not less than 3 m in between.
250 - 1500 from ground. Not mandatory for drive away chassis
500 - 1500
Not more than 1800 mm from front

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

LAMP MOUNTING DETAILS

All Dimensions are in mm

7.25

7.26

LAMP MOUNTING DETAILS

All Dimensions are in mm

SL
RL
TL
NPL

:
:
:
:

Stop Lamp
Reverse Lamp
Tail Lamp
Number Plate Lamp

RPL : Rear Position Lamp


R R R : Rear Retro Reflector
RDI : Rear Direction Indicator

Body building

7.27

INSTALLATION OF WIND SCREEN WIPING SYSTEM


While body building, ensure installation of wiping system as per the recommendations given below.
RECOMMENDED WIND SCREEN WIPER ARRANGEMENT

NOTE:
Wiper Arm

540 mm

Wiper Blade

660 mm

Sweep Angle :

90

Seat at Rear most


All Dimensions are in mm

and Lowermost position

7.28

INSTALLATION OF REAR VIEW MIRROR


All the passenger vehicles above 12T GVW should be fitted with 2 twin mirrors (one on each side - LH and RH)
with low convex and high convex in a single casing. The body builder has to ensure installation of these mirrors on
LH and RH as per the recommendations given below.
REAR VIEW MIRROR BRACKET

All Dimensions are in mm

Body building

7.29

RECOMMENDED REAR VIEW MIRROR INSTALLATION SCHEME

All Dimensions are in mm

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.

Arrangement of anchorage brackets for driver side (RH) is shown.

Adherence to the guidelines is strictly recommended for safety and legal requirements.

CO2

Body building

SEAT BELT INSTALLATION DIAGRAM

H1 - Hinge point
H2 - Hinge point
H3 - Hinge point
Dimensions marked

on side cant rail of cab


on driver seat (RH side)
for buckle belt assy.
thus "*" are indicative only.

7.31

7.32

SEATING / HORN MOUNTING LAYOUT

All Dimensions are in mm

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)

The vehicle should be parked in a covered area, on a plain hard surface.

c)

The battery terminals should be disconnected.

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.

Storage over a prolonged period


a)

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.

CNG Vehicle Check List After Building


Engine recommissioning
Before starting the vehicle, ensure that the recommissioning procedure strictly followed:
Recommissioning procedure of engine after long storage.
-

Clean the engine externally using compressed air.

Make sure that there is no foreign particle like nail, metal particle wooden pieces etc.

Drain sump oil and refill with recommended oil.

Clean/change oil filter element

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.

Crank the engine and ensure oil reaches rocker levers.

Start the engine and run at idle for five minutes.

Slowly raise the engine and ensure specified oil pressure is attained.

Body building

7.35

Engine wiring harness


1)

Check and ensure the connections are as per wiring diagram.

2)

The CNG electrical units mounting panel to be mounted inside the drivers cabin in the RH corner above the
driver head.

3)

On this panel, the following units are mounted:


-

24V-12 convertor

End speed governor relay (only interface make)

Trigger box

4)

Ensure the end connections to the above units are properly fixed and are not in strained condition.

5)

Routing of wiring should be away from exhaust pipe.

6)

Routing of cables to be uniform with proper clipping.

7)

Ensure proper tightness of nile switch and push pull switch fitted in the dash board.
connected with 24V DC supply.

8)

Check and ensure tightness of O2 sensor in the exhaust.

The Nile switch to be

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)

Ensure throttle lever is in 10 O'clock position.

2)

Ensure locking screw of throttle lever is fully tightened.

3)

All hoses to be evenly routed with proper tapping.

4)

All the joints in the piping fuel should be checked for leak.