Body Building Manual

7. Body building

7.01

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.

7.03Body building

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.

A - ANGLE OF APPROACH D - ANGLE OF DEPARTURE

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.

7.05Body 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.

- 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

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.

a b

c d

Note: For better air flow across the radiator and engine, the

front grill should be retained as it is.

All Dimensions are in mm


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.

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.All Dimensions are in mm

7.07Body 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.).

7.08

a b

c d

e f

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

7.09Body building

c

e f

a b

d

Don'ts

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).

7.11Body building

Precautions before/during body fabrication

D Cylinders are filled with CNG gas which is inflammable. It is veryimportant 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 thethread and tighten to arrest the leak.

D Welding should not be done over the gas cylinders or anywhere near.

D Proper shielding of gas cylinder should be done so as to isolate fromwelding sparks.

D Battery isolator switch should be cut off.

D Battery removed from the chassis should be properly stored and puton charge.

D Provide flap door with louvers on either side of the chassis to haveaccess 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.

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

GAS ESCAPE SLOT DIMENSION

30 mm

80 mm

7.12

D To ensure protective sleeve for the battery cable. Battery cable should be routed in such a way that cables arenot 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.

D Radiator should be properly covered to prevent it from any damage from welding splatter.

D All electronic components / wiring harness should be properly shielded / earthed in order to prevent damagesduring body building.

D Provision for fire extinguisher mounting (with 1 kg dry chemical powder and refill as per IS:2171) to be providedin both, driver and passenger compartment in a visible and well accessible position.

D Trap door in floor with rubber sealing to provide access to tighten the cylinder straps nut on either side.

D Removable shielding guard below cylinder valve and piping and connection points for safety against flying stonesto be provided.

D Shielding of exhaust silencer from cylinders and piping.

D The four Gas cylinder mounting X-bearers have to be integrated with bus body.

D Drilling of holes or welding on the frame side members are not allowed.

D Flap door for checking first / second stage regulator below the driver seat area to be provided and hence halfdoor to be provided for driver.

D Bonnet should have insulation inside - 40 mm fibre glass wool or PU foam and outside Foam and Rexene to beensured.

D Ceramic fibre insulation to be provided in the dashboard, driver cab floor and bonnet base vertical walls.

7.13Body building

D Body building structure material used should not carry leaking gas if any. E.g. through pipes or hat section in thepassenger compartment. Proper sealing at entry point to be done.

D There should not be any open holes on the floor to avoid entry of leaking gas, if any. This is a safety precaution.

D Provide suitable trap door for inspection of timing. No cross bearer should come exactly over the timingwindow.

D Water drainage holes should be at the rear end of the body floor and should be properly plugged.

D Bonnet / Floor area around the engine should ensure proper ventilation of the engine.

D LH / RH louvers at the front grille provided to ensure air entry to air cleaner on LH side and for ventilation ofdriver leg space in the front on RH side, to be utilised.

D In front grille opened position, water filling, oil filling and oil level checking and radiator removing should beaccessible.

D Body builder not to tamper with ignition system wiring and tail lamp connecting wire to extend its length.

D High voltage wiring should not rub with any body structure.

D Fixed first aid box with ointment, bandage, medicines, etc should be provided on dash board near the driver.

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

D 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 Requirement Reason

Front grille Sufficient louvres/slotted holes to be For better air flow on to theprovided to cover the complete radiatorradiator overall size (Refer fig. 1)

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 For fresh air entry to bottom oflouvres driver floor

Front grille in locked condition Min. 25 mm clearance to be ensured To avoid fouling and subsequentbetween inner panel and projecting damageparts of radiator/engine.

Front grille in open condition Proper accessibility should be ensured For proper service accessibility andfor radiator water filling, engine oil filling, maintenance (SAM)engine oil checking and mounting brackets.

Floor height in the engine 210 mm from frame top without flooring This is to ensure ease of dissipationcompartment area sheet on both driver and entrance side of hot air circulation under the floor.

Bonnet bottom channel For better dissipation of hot aircirculation in engine compartment.

Engine tunnel, bonnet and bonnet For better dissipation of hot airbottom circulation.

Engine bonnet insulation Insulation to be 25 mm thick Supercera For heat insulation.ceramic fibre insulation compressed anddensity of 126 kg/m3. Refer fig. 2

Louvres on bus body skirt on LH To allow escape of any minor gas leak.and RH in the cylinder valve area

SPECIFIC FEATURES REQUIRED ON BUS BODY

7.15Body building

Fig - 1 Front Grille Fig - 2 Engine Bonnet

7.16

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 To have access to cylinder valves/body skirt at cylinder valve area. pipe joints adaptors/leak check.

Trap doors in the floor with rubber To provide access to tightening theseating cylinder mounting strap nuts on either side.

Cylinder mounting cross bearers 4 cross bearers to be integrated with For better integration and rigidity.the bus body.

Clearance between cylinder/vehicle Ensure min. 5 mm clearancebody structure

Distance between cylinder valve and Ensure min. 200 mm.bus body

Compliance plate Will be provided by AL. To be installedby the body builder near the gas filling area.

Identification label Locate on left side of the front andrear safety glass and shall ensurevisibility from front and rear sides.

Material for seat/uphoistry/roof and Fire retardant material shall be used.side lining

Fire extinguisher One no. each of dry powder type to beprovided 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.

Feature Requirement Reason

SPECIFIC FEATURES REQUIRED ON BUS BODY

7.17Body building

SCHEMATIC SHOWING LOCATION OF NOISE SHIELD

INSIDE TUNNEL DURING BODY BUILDING

7.18

COWL BODY INTEGRATION

- 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.All Dimensions are in mm

7.19Body 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.


7.20

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.


7.21Body building


7.22


7.23Body building

- 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.


7.24

INSTALLATION OF LIGHTING AND SIGNALLING DEVICES

Furnished below are the requirements for lighting and signalling devices.

Lamp Number Height from Width from Distance between Position RemarksGround (mm) Outer edge (mm) lamps (mm)

Head Lamp 2 450 - 1200 Nil Nil Front Intensity=22500cd

Dipped HL 2 450 - 1200 Not more than 400 Not less than 600 Front

Front Fog Lamp Optional - - - - -

Reverse 1/2 250 - 1200 - - Rear

FDI 2 350 - 1500 Not more than 400 Max-1800 Front 1/1a/1b type

RDI 2 350 - 1500 Not more than 400 Max-1800 - 2a/2b type

Hazard - - - - - CombinedFDI & RDI

Stop Lamp 2 350 - 1500 - Not less than 600 Rear S1/S2 type

Rear RegistrationPlate Lamp 1 To illuminate the Rear Registration Plate Rear -

Front Position Lamp 2 350 - 1500 Not more than 400 Not less than 600 Front -

Rear Position Lamp 2 350 - 1500 Not more than 400 Not less than 600 Rear -

Rear Fog Lamp Optional Wiring and Non Flashing Light Tell Tale Mandatory -

Parking Lamp Optional - - - - -

End Marker Lamp 2 + 2 AS close to the outer top edge of vehicle Front & -Rear

Rear Reflector 2 250 - 900 Not more than 400 Not less than 600 - Red

Front Reflector 2 on Goods Vehicle 250 - 900 Not more than 400 Not less than 600 - White

Side Reflector For vehicle of more With in 3 M of Front of Vehicle, last one not more than - Amberthan 1.6 m long 1 m from rear and not less than 3 m in between.

Side Marker Lamp Min 1 250 - 1500 from ground. Not mandatory for drive away chassis - Amber

Side Repeater Lamp 1 no. on each side 500 - 1500 Not more than 1800 mm from front Side AmberFront

The above requirements are ensured for fully built vehicles built by AL. In case of passenger vehicles ensure fitment of TailLamp, 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.,

7.25Body building

LAMP MOUNTING DETAILS


7.26

LAMP MOUNTING DETAILS

SL : Stop LampRL : Reverse LampTL : Tail LampNPL : Number Plate Lamp


RPL : Rear Position LampRRR : Rear Retro ReflectorRDI : Rear Direction Indicator

7.27Body building

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

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


7.29Body building

RECOMMENDED REAR VIEW MIRROR INSTALLATION SCHEME


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. CO2

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.

7.31Body building

SEAT BELT INSTALLATION DIAGRAM

H1 - Hinge point on side cant rail of cabH2 - Hinge point on driver seat (RH side)H3 - Hinge point for buckle belt assy.Dimensions marked thus "*" are indicative only.

7.32

SEATING / HORN MOUNTING LAYOUT


7.33Body building

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.

7.35Body building

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. The Nile switch to be

connected with 24V DC supply.

8) Check and ensure tightness of O2 sensor in the exhaust.

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.

Body Building Manual

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