SPECIFICATIONS FOR PALLE VELUGU BUS BODIES

HIRE BUSES TEN DERS.2O22

1.0 GENERAL DESIGN:

The general design shall be a streamlined body with pneumatically operated Two jackknife
Passenger service doors on LH side within wheel base and passenger seats facing forward
in 2x3 pattern,

2,O REGULATION:
The general appearance, structure, seat layout etc,, shall be in accordance with respective
drawings. The bus body design should comply with the provisions of latest Central Motor
Vehicle Rules, Andhra Fradesh Motor Vehicle Rules, AIS:052 and any other statutory
requirement that may come in to force during execution of fabrication work order. The
coach interior shall meet the standard of IS: 15061-2002or latest amended one'
2.L The firms shall possess Bus Body Accreditation Certificate issued by CIRT/ARAI or any other
Agency approved by GOI and shall be registered with APSRTC.

3.0 MAIN BODY DIMENSIONS: (ALL DIMENSIONS ARE IN MILLIMETERS)

SL AL TATA EICHER
CHASSIS MODEL _DESCIPRTION 224',W8 230'WB
NO 222',W8
1 Wheelbase s639 5700 5840
2 Rear overhanq 3383(60olo) 3420(600/o) 3s04(60%)
3 Front overhanq 2265 1845 2370
4 Overall lenqth (excluding bumpers) 11287 10965 11714
5 Overall width (structure) 2590
6 Pillar centers (standard) 1130
Window sill(waist rail)height from top 610
7
of the cross bearer
B Waist rail heiqht from Skirt level 1200
9 Cant rail heiqht from waist level 1010
10 Interior saloon clear heiqht 1900
Clear aperture of passenger service
11 door (minimum when measured from 1100
the edqe of door flap)
12 Clear aperture of Driver door 650
13 Seatinq capacity 55+1 Driver 58+l- Driver
T4 Emerqencv Door Dimensions 1250X762

4.0 DRAWINGS: The list of drawings to be followed are shown at ANNEXURE-I

5,0 MATERIAL: The fabrication of bus bodies shall be as per the specifications and the material
shall be procured from the recommended sources/brands of material as mentioned in
ANNEXURE-II.

M,. M
6.0 CHASSIS POSITIONING:

6.I" All chassis received by the firm for fabrication of bus bodies should be kept safely in a
covered area. The chassis should not be kept open to atmosphere without any protection
to avoid damage to chassis and its units due to rain, dust and heat.
6.2 Before commencement of bus body fabrication, all important units of chassis viz.
Alternator, Self-starter, Radiator, Tyres and Batteries should be protected by providing
suitable covering and disconnect the wiring connections to Vehicle ECU, ABSECU, Vehicle
Tracking Unit and wiring harness ends shall be protected to prevent from damages
that may occur due to welding, drilling, cutting, hammering, riveting& falling of metal
scrap or dust during the course of fabrication. Driver seat, Steering wheel, Hand brake
valve etc., shall also be protected from any damage or paint spray.
6.3 Chassis number on long members and identification plates provided by the Chassis
manufacturer shall be properly covered and protected before commencing the fabrication
work.
6,4 The Ashok Leyland, TATA and Eicher chassis are supolied with following items as
OE fitment.
1. Cabin floor
2. Bulk head structure (AL/EICHER)
3. Out riggers (AL/EiCHER)
4. Anti-sag channel (TATA)
5. Bonnet and Front bumper (ALiTATA/EiCHER)
6. Knitted Driver seat
7. Head lights E2
B. Front indicators E2
9. Tail LamPs E2
10. Battery cut off switch
11. Reflective warning triangles with stands
12. Wheei stoPPers
13" Spare wheel carrier- Cage typei Rope Type
t4. First aid kit
15. Tools as per CMVR
16. Rean view mirrors with brackets (E2 plus 1 small mirror )
t7. Electrical horn
18. ELR safety belt

7.0 PROTECTIVETREATMENT:

7.L All Milcl Steel components used for fabrication shall be carefully de-greased, de-
rusted with three in one solution by dipOing and wiped with dr-y cloth to remove all dirtl oil
etc. Then the material shall be applied imrnediately (without any time lag) with Zinc
Phosphate epoxy primer "Rust-O-Cap" (part no.24570608320) of M/s. Asian Paints or
'60 BT PRfiME GREY'of M/sAkzo-Nobel Coatings before assembly.
1.2 All Aluminum Components shall be carefully cleaned with thinner. Bi-Metallic Paint shall be
used at joints of dissimilar metals. The interior and exterior panels should be cleaned with
thinner and then self-etching primer shall be applied.

B.O BODY STRUCTURE:

8.1 Aluminum Structure: All principal structural members should be in Aluminum extruded
sections of Alloy designation 64430, 63400 and 65032, condition WP as per IS: 733-
1983. The structural joints shall be by riveting, bolting and combjnation of both. The rivets

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 shall be of Aluminum alloy wire of IS:740 - L977. Alloy condition 64430 (HR-30)-OD.
Aluminum 5-bar chequared plate with 3.012.0 mm base thickness shall conform to alloy
designation 65032 and condition WP of IS:737 of 1986.4ll Aluminum sheets shall conform
to alloy designation 19000, conditionH2 of lS:737 of 1986.
9.2 Chart no. CB22CTG132 and Drg. no. CB22AEG112 (sheet 1&2) containing the details of
specifications of Aluminum extruded sections and sheets to be used and it shall be
followed.
8.3 Other Mild Steel Structural members: Galvanized Steel sheets should be as per grade 175
of IS: 277- 2AIB. R.olled sections should be as per 15-2062 of 2006. The structural ioints
shall be by riveting, bolting or combination of both and MIG welding in case of Gi
structural members. The welding should be for full length of joint. Welding area has to be
ground to smooth finish in order to avoid sharp edges.
8.4 All bolts used shall be of sizes reckoned in Metric system. The bolts shall be of high tensile
hexagonal head bolts of fine thread, conforming to property clause B.B of IS: 1367 of
lg7g. The nuts shall be of approved anti-vibrate type such as nyloc conforming to IS:
t364 of 1983. All bolts nuts and washers should be Ealvanized. Each bolt and nut shall be
provided with a flat washer. A spring washer should accompany every tapped bolt. The
approved brands of bolts are WS/STL/HINDUSTAN FASTENERS/KFL/UNBRAKO/IMPERIAL
FASTENERS brands only.

9.0 PARTICULARS OF IMPORTANT STRUCTURAL MEMBERS:

Sl,no. Description Material

1 Cross bearers Rolled steel channel ISMC 100x50x6 mm
2 Anti-saq bar Rolled steel channel ISMC 75x40x6 mm
3 Floor lonqitudes G.I'U'section25x75x25x3 mm thick ( 5 rows )
4 Pillars and Horizontal Indal2654 section, All pillars including wheel arch
supports horizontal supports shall be reinforced with formed
'U' inserts of GI sheet 3.0 mm thick.
5 Roof sticks & roof longitudes Indal 2651 Sections (5 rows roof longitudes)
6 Crib rail and seat rail inda 1756 section
7 Cant rail Inda 2800 section
B Waist rail Inda 2613 section
9 Waist rail stiffener Indai 3402 section & 3.0 mm Aluminium 5-bar
chequared plate 100 mm wide with minimum joints
one LH side and two on RH side with in wheel base
10 Panel stiffener Indal 3405 section
11 Skirt rail MS Anqle 40x40x3 mm
L2 Water channel
a) On cant rail a) Indal 6250 section
b) Front & rear end b) Hinclalco WC-695 section
13 Step edse beadinq Indal 5700 section
74 Flat beadinq Indal 5505 section
15 Decorative beading As per Drawing.
a) Exterior waist level a) Indal 272l section
front b) Indal 2684 Aluminium section with plastic filler
b) interior waist level and ends
and ceilinq
16 Window sections
a. Window guide a. Hindalco 6482 section

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b. Split section 1 b. 'T'section

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 c. Split section 2 c. 'F'section
d. Sweep rubber section d. Hindalco 2691 section
e. Finqer pull e, Indal 1752 section
T7 Wire casinq Indal2735 section
1B Rub rail on bodY side Hindalco 2676 on G.Iformed"U"section2.0 mm
19 Cleats &Brackets
a) Roof structure a) Indal 1760 section
b) Cant to roof stick and b) 'C'bracket formed in GI sheet 2.5 mm
cant to Pillar c) 'C'bracket formed in GI sheet 2'5 mm at wheel
c) Side structure arches and Indal 1760 cleats
20 Roof grab rail brackets Indal 9638 of 30 mm wide
21 Gussets for Cross bearer to rSllC rbO xSO nrm
Pillar loint
22 JK door frame Tndal9124 section
23 Parcel rack tube Hindalco TtJ-1274,l'tand 2ndStainless steel tube of
16 mm dlameter

1O.O PRECAUTIONS:

10.1 Aluminum extrusions such as Seat rail, Crib rail, Cant rail shall be joined within the
wheelbase onlY.
10.2 "NEGATIVE TOLERANCES" are not allowed either for Aluminum Extruded sections,
Aluminum sheets and GI sheets/tubes. However, tolerances within the limits of
IS

standards may be allowed subject to prior approval of Chief Mechanical Engineer(Chassis

and Bodies)and subjected to the recovery of difference of cost .
arc
10.3 All welding shall be done with MIG welding process only. Under any circumstances,
welding shall not be allowed. Weiding of Stainless steel Components shall be done with
TIG welding process only with same grade Stainless Steel filler rod.
LA.4 All holes in cleats and roof longitudes shall be PUNCHED to close tolerances. Under
any circumstances, drilling of holes is not allowed'
10.S The following workmanship must be carefully followed during the fabrication.
i. All castings must be truly formed and free from blow holes.
ii. All bolts and rivets should be well fastened'
iii. Rigid water test shall be carried before fixing the interior ceiling without applying any
sealant and tapes using pressurized water spray system. The fabricator shall equip
water leak test facility confirming to IS: 11865-1982 at the firm for conducting leak
test in two stages i.e., before fixing the interior ceiling and before dispatch of vehicle.
iv. All welded joints nrust be well ground to get as smooth surface and applied with
EpoxY Primer without anY delaY'
v. Sharp corners shall be grounded and made smooth'
vi. Wherever pitch for rivets / bolts is not speclfied, it shall be 100 mm.
vii. Bolt ends shall protrude at least 2 to 3 threads length above the nuts.
properly
viii. Roof stick, roof longitude, floor longitude and waist rail members shall butt
at mating joints and shall not have gaps at the joints'
using
ix. All tapping bolts at rub rail, handles and assist rail bolts etc., shall be tightened
thread lock adhesive of approved makes'
Roof stick, roof longitude, floor longitude and waist rail notching to be done
on power
x.
\ Pt"ss onlY.

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xi. AII fixed glasses shall be provided with ceramic coating of suitable width on periphery.

11.0 CAB UNDERFRAME STRUCTURE:

11.1 Cab under frame of Ashok Leyland 222" WB chassis shall be fabricated as per the
drg.no.P226OUF22LO3. The OE structure shall be retained and modified accordingly
to suit the fabrication. The cabin floor shall be made in line with saloon floor except at
wheels. The OE floor on RH Side of cabin shall be connected to the l-'tcross bearer by
providing a 'Z'riser in GI sheet3.00 mm. On LH Side, a raised wheel arch box shall
be provided on front wheel duly fabricating in MS flats 40x6 rnm and MS angles
40x40x6 mm. The height of wheel arch box frame shall be 160 mm minimum from top
surface of the tyre.
LL.z The Tata 224" W8 chassis shall be fabricated as per the drg.no.P2460UF22303.The cabin
floor longitudinal members shall be connected to a 'Z' raiser in GI sheet 3.00 mm
'provided on 1st cross bearer to make up the height difference of cabin and
saloon floor. Suitable wheel arch boxes in rectangle shape fabricated in MS flat 40x6 mm
and MS angles 40x40x6 mm shall be provided. The height of wheel arch box frame shall
be 160 mm minimum from top surface of the tyre.
11.3 The Eicher 230" WB chassis wili be supplied with OE cab floor, bulk head structure, out
riggers, driver seat and engine bonnet, The cab under frame shall be fabricated as per
the drg.no,P3O60UF22203.The OE structure shall be retained and modified accordingly to
suit the fabrication. The cabin floor shall be made in line with saloon floor except at
wheels. The OE floor on RH Side of cabin shall be connected to the lstcross bearer by
providing a 'Z' riser in GI sheet 3.00 mm. On LH Side, a raised wheel arch box shall be
provided on front wheel duly fabricating in MS flats 40x6 mm and MS angles 40x40x6 mm'
The height of wheel arch box frame shall be 160 mm minimum from top surface of the
tyre.
1L.4 The dashboard frame shall be fabricated in MS angle 40x40x6 mm to the required profile
and covered with GI sheet of 0.91mm thick. Flap door with suitable stainless steel hinges
and stainless steel tower bolts shall be provided for easy access to fuse box, radiator,
power steering reservoir and clutch oil container.

Lz,O BODY FRAME STRUCTURE:

The bus body frame structure should be fabricated as per the following drawings.
ASHOK LEYLAND 222" WB chassis - P2260SL22I0| and P22605R221.02.
TATA 224',W8 chassis -P24605L22301 and P24605R22302.
EICHER 230" WB chassis - P3060S122201, and P3060SR22202.
Lz.L The Cant rail at the passenger entrance, driver door and emergency door area shall
be reinforced with GI sheet formed channel in 2.0 mm thick and the joint of cant rail
should not be exactly on any pillar or within door bay'
L2.2 A & B pillars on both sides shall be provided in GI 3 mm thick formed section
similar to Indal 2654. First and second roof sticks connecting A& B pillars shall also be
provided in GI formed section similar to Indal 2651 in 3 mm thick. All the structural
members in this bay (Waist rail, Intermediate rail and roof longitudes) shall be in GI
formed sections of 3 mm thick with dimensions of corresponding Aluminum Sections.
L2.3 An opening of size 250mm x 250 mm, fabricated in MS Angles 40x40x6 mm finished witlt
beading in Indal 5505 and a flap shall be provided at fuel oil tank mouth.
L2.4 One Peep window frame in first bay of left side structure is to be provided with
MSL 40x40x3 mm. One fixed clear glass of 5.0 mm thick shall be provided in the
size 490mm(H)X290mm(W) along with frame in indal 6482.

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 12.5 MS tapping plates in 30x6 mm flat of 200 mm length shall be provided wherever
tapping is io be done for fixing body components such as roof continuous beam, roof
hand grab rail, window guard rail, assist rail, driver partition, windows etc.
LZ.6 Pillars on both sides of Passenger entrance shall be reinforced with MS angle 25x25x3 mm
and riveted to the inner flange of pillars.
L2.7 Cant rail on both sides full length shall be reinforced with M.S angle30x30x3 mm.
This angle shall be riveted to pillars flanges at cant level and connected to the cant rail
cluly providing two GI plates of size 75x30 mm of 2 mm thick welded to the angle and
riveted to cant rail in everY baY.
12.8 l-uggage booths from crib level to skirt level are to be provided on both sides duly
prov-idrng E 2 LED Lights& Guard rails in SS of size25x1.6 mm as indicated in structural
clrawings with fiap doors in 1.6 mm thick Alu. sheet and locks.
12.g Rear luggage booth and right-side luggage booth from Crib level to Skirt level are to be
provided with door seal rubber. Right r;ide luggage booth E2 flap doors are to be provided
with Hindalco 9389 and 9390 hinges.
12.10 Rear luggage booth door shall be fabricated with MS angular 40X40X3 mm and to be
provide with 550N E2 gas sPrings.
12.11 Rear luggage booth and side luggage booths inside area should covered with 0.91 GI
sheet with Hammer tone Paint.
L2.LZ Luggage booth flooring area to be covered with 2.00 mm thick Alu. Chq' sheet.
LZ,L3 neli [uggage booth 1o be fabricated as per drawings mentioned in side and rear
structures.
L2.L4 Rear luggage booth to be provide with E 3LED lights for proper illumination.

13.0 CABIN AND BODY MOUNTING:

18.I" The OE Cabin floor and mounting arrangement shall be retained. The remaining portion of
cabin floor connecting l'tCross bearer and OE floor shall be fabricated as per
drg.no.P2260uF22103 for AL 222" WB, P246OUF223O3 for TATA 224" WB and
P3060UF22203 for Eicher 230" WB chassis.
13.2 The OE anti-sag members shall be retained. If the chassis are not supplied with the anti-
sag members , a 3-piece anti sag channel in ISMC 75x40x6 shall be provided at front
enci of the chassis bottom frame connecting to the 'A' pillars on both sides with welding
(or) bolting (TATA ).
I"3.3 Additional dut riggers in MS angles 50x50x6 mm shall be provided connecting 'B'
pillars to the Chassis long members witlr suitable fitment.
Lg.4 The body should be mounted on the Chassis web duly providing 6 mm (inverted
pressed "L" type) MS plate as per the size shown in the respective drawings over
the Chassis long members. These "1" plates shall be bolted together at every cross
bearer mounting io Long member web with M12x 50 H.T. bolts at least 4 nos. per plate.
OE holes on the chassis long members shall only be picked up for mounting this
plate. Wherever the OE holes are not available for bolting of web mounting plate,
matching holes shall be drilled on the web 40 mm below the top level of long member
with prior approval of competent authority" Over these plates, cross bearers in ISMC
100x50 x 6 mm channels shall be provided as per the respective drawings. If the web
mounting plate position at rear wheels coincide with rear spring bracket, the cross bearers
shall be fastened with 16 mm dia. "U" bolts of approved make and with 150mm x 6 mm
thicl< base plate welded to the bottom of cross bearer. Spacers made of Aluminum casting
"U"
shall be placed between bottom flanges of chassis long member and "U" bolts. The
botts are to be made out of EN-15/148 steel as per IS 55t7'1978(Tensile strength80
, kg/Sq.mm minimum). The "U" bolts should be galvanized and fitted with galvanized nyloc

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\,

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 nuts as per Drg.no. CB22UBG114. The length of bolt shall suit the depth of Chassis long
member and should not project more than 6 mm after tightening the nuts'
13.5 In ASHOK LEYLAND and EICHER vehicles the front bulkhead ends are to be connected to
the A-pillar of the body duly giving suitable support to the members. A tie bar in front of
radiator in 3-piece in ISMC 75x40X6 connectinE A-pillars on both sides and chassis long
members shail be prcvided. This tie-bar to be mounted on MSL 50x50x6 mm angle 'L'
brackets connected to the chassis long members.
13.6 The body mounting must be easily detachable from the chassis during major
overhauls. pillan gussets on four sides of the body shall be provided with 32 mm dia hole
to facilitate liftingof the body during major overhauls as per drawing C822L8115.

14.0 CABIN AND SALOON FLOOR:

L4.L The cabin and saloon floor shall be in Alurninum5-bar cheq.plate of 3.0 mm base thickness
Conforming to alloy designation 65032, Temper WP of IS: 737-1986. The cheq' Plate
should be riveted with M.S rivets of 5mm dia. to the floor longitudes at a pitch of 100
mm and in Zigzag manner at joints. The cabin area and wheel arch boxes shall be
riveted at 7i rnm pitch. The riveting on crib rail shall be done with 6 mm Aluminum alloy
solid rivets of HR -30 and condition OD as per IS: 74A-L977. Intermediate bolting with
MB bolts shall be done on cross bearers and at wheel arch frames'
L4.2 The wheel arches shall be made rectangle shape. The height of rear wheel arch box frame
shall be 160 mm nrinimum from top surface of the tyre'
L4.g The number of cheq. plates used for cabin and saloon flooring should be least in order to
keep the joints at m;nimum possible. The floor cheq. plate shall be joggled at crib level to
get proper seating on crib rail.
L4.4 In TATA and EICHER. vehicles, an inspection cover fitted to a frame in under frame with
tapped bolts, to be provided in saloon floor over fuel tank suction pipe of size 250x250
mm.
L4,S The floor longitudes should be in five rows excluding crib rails. They should be arranged in
such a way that the seat legs are fixed on the floor longitudes. Dust proof rubber
packing of 2mm EPDM quality shall be provided at the joints and ends of
chequ&ed sheet to avoid entry of water/dust in to the saloon from the joints' The
floor cheq. plate laVing shall ensure dust proof. Additional floor longitudes shall be
provided wherever necessary for floor plate joints and stanchions mounting on floor etc'
L4.6 Trap door of 5B0x 520 mm size must be provided in cabin flooring above gearbox with
proper sealing and M6 tapping bolts.
L4.7 Four drain holes c,f 25-mm diameter shall be provided in saloon flooring corners below
seat frames, provicied with bottom extension of 75 mm length ERW pipe for draining of
water while washinq.
15.0 BODY PANELING:
15.1 The exterior portion of body i.e. sides, front end, rear end, mud wings and roof exterior
should be in Aluminum sheet L.22 mm thick of alloy designation 19000 and
condition HZ of IS:737 of 1986.
LS.z Front radiator grill is to be provided in 1.22mm GI sheet (AL type) as per drawing for
Eicher and TATA vehicles.
15.3 TRUSS pANEL FOR. BODY SIDES: Full height truss panel between waist to crib rail for
entire length of body and at rear end including corners shall be provided in stainless
steel sheet of 0.7 mm thick of 430 Grade and in scotch bright/mirror finish' These
panels shall be riveted with 5 mm Aluminum alloy solid rivets to the structural members
at waist rail together with 5 bar Aluminum chequared sheet and Indal 3402 stiffener
 at a pitch of 100 mm in zigzag manner. The riveting pitch on seat rail and crib rail shall be
75 mm. The riveting pitch on pillars shall be 100 mm.
1S.4 BOOF STRUCTURE REIN The roof structure above on each door opening i.e.
passenger entrances, driver door and emergency door between roof longitude and cant
rail shall be reinforced with a truss panel of 0.91 mm thick GI sheet and shall cover three
bays in single piece. The GI sheet has to be formed to the required contour of roof prior to
the assembly and shall be riveted to the roof longitudes and cant rail lower flange and also
to the MS angle 30x30x3 provided above cant rail between 'C'brackets with MS flat head
rivets at a pitch of 100mm.
15.S The roof exterior sheet with 1.22 mm thick Al for center portion should be in full length of
body and laid longitudinally in one single piece of L220 mm wide. The riveting should be
done on the roof longitudes inZIGZAG manner. The exteriorsides (LH & RH) of roof
sheets with 1.22 mm thick Al have to be provided in single piece as required' The
. riveting on cant rail, front and rear end roof sticks should be with flat beading Indal 5505.
The overlap of roof exterior panels should be equal to full width of roof longitude section
ancl should be riveted by 5 mm dia. Aluminum alloy solld rivets (HR-30) at a pitch of 75
mm in two rows ZIG-ZAG manner. While riveting roof side sheet on cant rail, an
Aluminum sheet of 1.6 mm thick and 75 mm wide full length of cant rail shall be provided
on the cant rail for pasting top fixed glasses. The sides of roof shall also be provided with
water channel in Indal 6250 and shall be riveted along with flat beading Indal 5505.
15.6 pU sealant has to be provided at overiapping portion of roof panel joints to avoid water
leakages. The edges along the roof joints shall also be applied with PU sealant for filling
up the gaps. Roof joints should be water leak proof. Approved make weather shield
strip oi tSO mm wide and 2 mm thick shall be laid longitudinally covering roof
center joints from front end to rear end to avoid water leakage from roof.
LS,7 Exterior of roof sticks and longitudes shall be pasted with expanded polyurethane
sheet (heatlan) of 6mm thick.
15.8 The interior roof up to Cant rail should be in Aluminum sheet 0.91 mm thick of alloy
designation 19000, condition H2 of IS:737 - 1986'
l5.g The interior vertical finishers for pillars, horizontal finishers for windows at cant level, waist
level and finishers for intermediate rail shall be in 0.5 mm stainless steel of 430 grade and
Scotch bright finish. The finishers are to be pasted to structural members with 'Metal
to Metal'lype PU sealants. There shouid not be any waviness in finishers and the
sealant should not drip through the joints. All the horizontal finishers shall be in single
piece per two bays and the overlap joints on pillars only. To avoid the expose of sharp
edges and waviness of the SS sheet used, the inner edge of the finisher is to be bent
inside"
15.10 Tlre overlap joint for roof interior ceiling panels should be on the roof sticks. The overlap
of the roof panels shourld be equal to the full width of roof stick section and should be
riveted by 4.76 mm dia. Aluminum alloy multi grip blind rivets at a pitch of 100 mm.
Riveting should be done on roof longitudes and cant rail also"
15.11 Interior ceiling panel joints on every roof stick, cant rail and on all sides of door openings
shall be provided with decorative beading Indal 2684 with plastic filler and end covers.
1S.12 FormediZ'section (size 25x45x25 mm) of 1.22 mm Aluminum sheet shall be provided on
waist rail which shall be riveted to waist rail duly overlappinq the exterior body panel at a
pitch of 100 mm. The ends of 'Z' section shall be bent vertically upwards to overlap the
pillar web. Suitable 30x3mm thick balata packing shall be provided below the 'Z'section
to match the height of rivet heads of waist rail. Ends and corners shall be applied with
P.U.sealant to avoid seepage of water in to saloon'
15.13 A formed 1.6mm thick Aluminum 'Z' section (30x8x30 mm) shall be riveted to
Intermediate rail wlth Aluminum flat head rivets of 5 mm to facilitate bonding of
top fixed glass.

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 LS.L4 Two rows of panel stiffeners in Indal 3405 should be provided at Seat Rail level and in
between Crib rail to Skirt level'
15.15 The exterior body panels from Waist to Skirt should be without joints inl'22 mm thicl<
Aluminum Sheets oi alloy designation 19000, condition H2 of IS: 737 of 1986. The vertical
butt joint of panels should be on Structural members and to be pasted with approvecl
make sealant of 'rnetal to metal' type and two sided VHB tape of 3M make on all sides
i.e., vertical joint, on waist rail and on skirt rail. End portion of panels at wheel arches and
skirt rail stritt ne folded inside by ZO mm and should be fixed with flat beaclinE ancl
Aluminum alloy head solid rivets of 5.0 mrn dia. at a pitch of100 ntm.
15.16 Rear end exierior paneling from Waist to Skirt and between rear end pillars shall
be provided with Aluminum sheet 1.22 mrn sheet in single piece. This panel shall be
bonded to the rear end structure with PU sealant of 'Metal to Metal'type and two
sided VHB tape of 3M make. The rear end Saloon glass frame shall be covered with
0.91mm finishers from outside and 0.5 rnm stainless steel from inside. Body structural
'members and Aluminum sheet surfaces where the sealant has to be applied shall be
cieaned thoroughly for oil/dirt etc., before applying sealant'
LS.LI The body sidei have to be provided with rub rail in Indal 2676 with EPDM rubber inset
with end covers on 2mm GI sheet formed U section of 30x60x30xZsize. The rub rail ends
shall be black powder coated'
15,1g The front end exterior panels shall be provided with decorative beading Indal 2721. at
waist rail. The beading shall be anodized and fixed with blind rivets. The rear end waist
level shall be provided with Aluminum flat beading in Indal 5505 with blind rivets'
15.19 The exterior corner dooms both at front and rear on off side and near side from
Cant rail to Waist and Waist to Skirt rail shall be provided in 0.91 mm G.I sheet over laid
with Aluminum sheet of l.22mm thick and Indal5505 beading on full length of pillars.
15.20 The area between exterior and interior panels of Waist rail to Crib rail in side structure,
Cant rail to Cant rail in roof structure shall be provided witlr 40 mm thick FR gracle
Thermocole insulation.

16.0 FOOT BOARD:

The wider foot board of 1390 mm within wheel base structure as shown in the drawing to
suite two Jack Knife doors shall be in three steps built in MS. Angles 40x40x3 mm and over
laid with Aluminum 5-bar chequared sheet of 2.0 mm base thickness on sides and 3.0 t"trttr
base thickness on tread and riser portion. The footboard should be given a support under
the lowest tread by providing a 'U' type bracket made of MS angles 40x40x6 mm. The
arms of 'U'bracket should be 230 mm long and secured to pillars with M10x 4numbers
bolts on each pillar. Step edge beading in Indal 5700 shall be provided along the edges.
The bottom tread height from ground shall not be more than 400 mm' The treacl
depth should not be less than 300mm. Maximum step height allowed is 250 mm.

L7.O WHEEL ARCH FRAMES AND BOXES:

The front and rear wheel arch box frames should be fabricated in M S angles
4Ox4Ox6 mm and M S flats 40x6 mm in rectangle shape. The height of box frarne shall be
160 mm above the top surface of the tyre. The boxes should be designed to accorlmodate
10.00 x 20 size tyres.

Aluminum 5- bar chequared plate of 3.0-mm base thickness in single piece shall be usecl ott
top for covering wheel arch box frames. Step edge beading shall be provided at tlre riser
and along the Ldges of wheel arch. Mud guard shall be provided in I.22 mm tlricl< AlLt'

M*c
-

Sheet half round along wheel arch area with proper clamping and a clear gap of 100 mm
shall be ensured from the edge of tyres.

1B.O DRIVER'S PARTITION:

l-he driver's partition shall be fabricatecl with stainless steel tubes 30x30x1.6 mm as per
drg.no.CB22DRGl19. It should be fixed behind driver seat and shall be supported on
structural members duly reinforced in the floor as well as roof. The minimum distance from
the Bonnet to partitlon wall shall be as per seat layout drawing. A timing board of size 500
X 500 mm shall be provided in Aluminum sheet L22mm duly painted white. The board
should be provided in a sliding channel frame on 3 sides made of Indal 3620 section and
fixed to the partition on saloon side'

19.0 DESTINATION BOXES AND BOARDS:

19.I" at front and rear end of bus

LED clestination boards of size 27OX}6O mm shall be provided
with proper tapping & secured clamping and as per UBS-II specification with built in
cont.roller and ;iO aisplay for frorrt LED destlnation board with a provision of numbers from
0 to 9 and Up & Down buttons to select service number & route. Communication cable to be
provided from Front master LED board [o rear LED board for display of same route course
cletails in both the boards.
Lg.2 The side destination box shall be in first 1130 mm bay on LH side at window top fixed glass
area after passenger entrance.
1g.B One flap door in 0.7 mm stainless steel sheet in size 1180 mrn x330 mm is to be riveted
with Stainless Steel piano hinge for full length at bottom and to be blind riveted on
intermediate rail in 1't1130 mm window after passenger entrance on LH side of body.
Bracket in indai 3620 is to be fitted on inner face of the door for holding the destination
board of size 910 mm x210 mm. LED type light to be provided for illumination' Two
locl<ing latches and chain in stalnless steel are to be provided on both side for locking the
door and to hold it at convenient angle to change board. E 1 tower bolt has to be provided
at rniddle of top centre and E 1 at centre areas on both sides for side destination board
door.
tg. Two destination boards in 0.91 mm thick GI sheet have to be supplied along with the
vehicle dr-riy painted in white color.
t 9.S The side clestination board shall be illLrminated by LED lights of 600-mm length of approved
design and made with luminoslty of 150 to 200 lux.

2O.O PARCEL RACI(S: I

i
r.
[ ,r

Tubular type Parcel racks shall be provided on both sides of saloon above windows. The
parcel rack tubes shoulcl be provided in 16 mm dia. & 1.6 mm thick stainless-steel tubes
of 304 grade placed longitudinally at a pitch of 65 mm in the Stainless Steel (304 grade)
rectangular tube brackets of 40x20x1.6 mm provided at each pillar. The pipes shall
be spot welded to the rectangular tube brackets.

20.1 Intermediate brackets in same material, shall be provided in between two main
brackets. These brackets shall be conrrected to the Cant reinforced MS angle 30x30x3
mm and roof sticks.
 2O,2 The interior width of the racks shall not be less than 460 mm. There shall be a clear
vertical gap of 230 ;nm between roof ceiling and parcel rack end tube. Parcel rack end
brackets shall be p,-c'vided with a stay bar in same tube'
20.3 The Courier box tc, be provided at left side of Parcel rack in first bay in front of entrance
door with suitable locking system as per drawing no cB22cRB140.

2L.O CONTINUOUS BEAM:

A longitudinal continuous beam in pressed top hat section of GI sheet of2.0 mm thick
sinrilar to roof stick profile should be provided. This beam in inverted position shall connect
all the roof sticks frorn front end to the rear as shown in the seat layout drawing. The joints
should not be more than three with reinforcement using 30x25x2 mm thick 50 mm long'U'
channel welded at joints from inside. The cross sectional dimensions of each extended top
hat section should ccincide without mismatching. Welded joints to be Eround for even
surface and ends should be tapered to a length of 150 nnm. Reinforcement Is to be
provided in the bearn with M.S"30X6mm in 200 mm length flats for fitment of stanchions.
This beam shall be fitted with M6 tapping bolt at every roof stick on both sides and the
remaining beam shall be riveted inZigzag manner at 100 mm pitch.

22.O STANCHIONS:

Four stainless steel 'liibe stanchions in 304 grade of 38 mm OD x 1.6mm thickness as per
IS: 6913-1992 should be provided in between the saloon continuous beam and saloon floor
as per seat layout plarr. SS Flat 4 mm with 3 mm balata packing shall be provided at bottom
ends of the stancl-rions and SS 40x40x4 mm angle on roof continuous beam .The
stanchions have to be fitted on floor longitudinal members and to roof continuous
beam with M6 size thretugh bolts. The stanchions shall be fitted rigidly with dome nuts.

23.O CONTINUOUS ROOF HAND RAIL:

Two rows of continuous roof hand rails (grab rails) in stainless steel tube of 25 mtn OD x
1.6 mm thick in 304 grades and 28 finish has to be provided as shown in seat layout
drawing. The intermediate support brackets to be in Aluminum extruded section Indal 9638
of 30mm width. These brackets are to be grey powder coated. These hand poles are to be
provided withlB nos. plastic molded swiveling type hand holds with nylon ribbon arm slings
in Green/Yellow colour, one per bay. Ends of these pipes shall be joined together duly
inserting a pipe of 100mm long.

24,O WINDOW GUARD RAIL:

Two rows of window guard rails of stainless steel tube in 304 grade and 28 finish of 20mrn
OD x 1,6 mm thick as per iS: 6913-1992 has to be provided at a height of 75 mm and 175
mm above waist level from outside on both sides of the vehicle. The pipes shall be bolted
to the pillars with intermediate support brackets, end sockets and M6 bolts as per
drg.no.CB22LBG115. Tapping plates in M.S. flat 30x6 mm x 125-mm long shall be provided
inside the pillar for fitment of guard rails.

25.0 CABIN FRONT WINDSCREEN, SALOON REAR GLASSES AND WINDOWS:

2S.L The cabin front-end shall be fitted with two-curved windscreen glasses of size 722OxI02O
mm. The windshield glass frame assemblies shall be made in MSL 25x25x3 mm to
match the profile of the curved glasses. The wind shield frame shall be provided

ffi* ilc^ffi
 between front cant rail and dash structure duly welded on all sides. A center post
reinforcement of formed 'U' section in GI sheet 25x75x25x3 mm shall be provided duly
welding on the dash structure and front cant. The complete l'r'ame including center post
from inside shall be coveredwitl'tl.22 mm Aluminum sheet from outside and 0.5 mm
stainless steel sheet in scotch bright finish from inside. The curved laminated glasses
shall be of 5.76 mm thick with minimum 0.76 mm PVB fiim, select float quality, safety
clear WAVE FREE as per IS: 2553 - 1"971 and to be fitted with 47.5 mm EPDM synthetic
rr-rbber extruded section. The approved brands for glasses are DURASAFE, DURATUF,
ATULTEMP, REALSAFE, SEKURE, SEKURIT, and GSC. All corners of windshield glasses
shall be provided with clamps in Aluminum sheet 1.6 mm in black powder coating.
ZS.Z The saloon rear end glass shall be bonded to the MS angle 30x30x3 mm frame provided in
the rear body structure with P.U. sealant. The singie piece glass shall be of 1760(L) x
800(H) mm size in 5.0 mm thick, toughened safety bronze tinted glasses as per IS:
2553 - 1990 & IS: 2835 -LgB7. The lettering work to be done on the glasses and at cant
level as mentioned below with 50mm size.
"BREAKANY GLASSES IN EMERGENCY FOR EXIT"

In Telugu:
" trqatl5 Xiany"iod 3 mfiArQfl.trr ilntHt't]}ar}"
25.3 The window frames in Hindalco 6482 extruded section as per drg no: CB22WDGl2Bshall
be provided between waist rail and intermediate rail. For a standard bay of 1130 mm, the
window frame size shall be 1125 x673 mm. The window franie shall have two horizontal
sliding glasses of600(H)x540(L)mm size with flock channel of EPDM rubber quality.
The area between cant rail to intermediate rail shall be provided with 5.0 mm toughened
bronze tinted fixed glass of size I727x330 mm, The glass shal lbe bonded to the 1.6
mm Aluminum sheet on cant rail and 1.6 mm Aluminum sheet 'Z' flange on the
intermediate rail by applying PU sealant of approved :nake/ brands. The window
glasses shall be of 5.0 mm thick toughened float quality, safety bronze tinted glasses as
per IS:2553 - 1990 & IS: 2835 1987. Window frames shall be black powder
coated.
ZS.4 All window frames to be provided with corner cleats with flat rivets besides welding
to the window frame corners. They should be fitted with M6x30 mm CSK head screws-E 2
nos. on each vertical side on pillars Galvanized M.S. flat 30x6 mm tapping plates shall be
provided on pillars, Four drain slots of 50X3 mm shall be punched on bottom side of
window frame to drain out water collected in frame grooves'
2S.5 All the edges of all sliding glasses shall be ground, chamfered and polished to smooth
surface.
25.6 All Seat frames MS pipe at welding portion should be cup cutting in order to facilitate full
welding at joints instead of pressing.
25.7 All siiding shutters are to be provided with finger pulls in Indal 1752 section 100 mm long
powder coated in black colour.
25.8 Vertical overlap of window frames on pillars shall be pnoi'ided with a sealing rubber
profile as shown in the drawing. The fixed glasses are to be secured intact.
ZS.g Approved makes of EPDM rubber profiles are Rubber Extrusions &Molding/ASP/ALP/ Sri
Venkateswara Rubbers, BNGLR and any other approved by APSRTC.
25.I0 Approved makes of P.U sealants are Total seal/Sikaflex/3M India/Bostik/ Anabond and
Henkeland any other approved by APSRTC.

26.0 pAssENGER ENTRANCE, ASSTST RArLS AND DRTVER',S DOOR:

26.1 The passenger entrance cum exit on LH side as shown in ttre drawings shall be provided
with two pneumatically operated Jack knife doors.E-2Pneumatic cylinders are to be

%- M#-
 provided for opening & closing of passenger doors. These are to be mounted at both sides
of center wider foot board at floor level without obstructing the passenger movement at
entrance door and also to take necessary arrangement for safety of passengers.
26.2 The Jack Knife doors design with pneumatic operation should be as per drawing
No.CB22JKG121 has to be provided. Tlre door glasses shall be 5.0 mm clear
toughened float glass in 1500 mm x 190 mm size and to be pasted with PU sealant to the
door frame. Two railway type latches in MS flat 30x6 mm shall be provided from inside
for locking the door in closed and open position. The latch items shall be galvanized.
Two SS handles of 100mm long shall also be provided for the lK doors. The lK doors
mountinE shall be with 3 forged hinges on both side pillars. Two flaps shall be
joined with 3 forged hinges with reinforcement of 3.00 mm GI sheet" E 4 No's of GI
25X25X2mm Tubes are to be inserted in JK Door end flap vertical indai sections9L24for
additional strength and to with stand the pneumatic cylinders force while operating the
door with pneumatic mechanism.
z1.g At entrance on both sides of step weli, assist raiis in stainless steel tube in 304 grade 32
OD x 1.6 mm thick shall be fitted from roof stick to floor SS Fiat 50X4 mm with 3 mrn
balata packing provided in roof sticks at top and on cross bearers at bottom. Two
horizontal support pipes and one diagonal support pipe in stainless steel tube 304 grade
32 OD xl-.6 mm thick shall be provided on both sides of step weil. One additional
stanchion in 304 grade 38 OD x 1.6 nrm thick is to be provided at center of step well on
floor. One assist rail in 32mm diaX1.6 mm is to be provided on 2nd step and to be
connected to step well middle stanchion as per the design given. The pipes shall be
fitted with approved make with suitable SS flat 50X4 mm. The joints of stanchions and
assist rails shall be provided with M6 steel bolts and steel doom nuts. Passenger door
should be provided with E 2 pneumatically operated JK doors which are operated by 63
mm dia pneumatic cylinders.
26.4 DRIVER'S DOOR:
The driver's cabin door shall be provided with a full drop type window duly extending up
to floor level as per sketch no.CB22DRG119. The window frame shall be in Hindalco 6482
section as per the window design. The door shall be provided with one heavy-duty door
lock of MSL make only with outer handle, one locking latch from inside, striking plates and
dovetail catches. The door shall be fitted with two forged hinges on'A'pillar. Driver door
frame shall be pror,lded with one horizontal bar in stainless steel 25x1.6 pipe from
inside for holding.
26.5 EMERGENCY DOOR:
One Emergency rJoor of min I25O mm height X 71,5 mm width exterrding fronr
intermediate cant rarl to saloon floor on riglrt side shall be provided as per the layout and
drawings. The door is to be provided with one horizontal sliding window and one heavy
duty lock operable from inside, dovetail catches. The location of the emergency door
is to be exhibited from inside& outside with vinyl stickers and outer periphery is to
be provided with red color reflective radium sticker. Red colour LED light has to be
provided at Emergency door area inside the saloon. It should have railway type latclt
made of Stainless steel apart from Stainless steel/Brass tower bolt.

26,6 LUGGAGE CARRIER AND LANDING PLATFORM:

A luggage carrier fabricated on the lines of drawing no. CBz2LCGLZ4covering four bays
including a landing platform up to rear end shall be provided on the roof top. The Luggage
carrier frame and siCe railing shall be provided in MS angle 30x30x3 mm' The cat walk
arrangement in 270 mm wide is to be provided on the LH side. The floor of luggage
carrier and catwalk should be covered with 2.0mm base thickness 5-bar Aluminum cheq.
sheet conforming to alloy 65032, Temper WP of IS: 737-l9BG and riveted to Cross

Gc*\ M#?
 members and frame of luggage carrier with MS solid rivets . The luggage carrier legs to be
mounted on the galvanized MS 6mm base plates attached to the roof sticks. The mounting
of the luggage carrier shall be by means of bolting to the qalvanized formed 'L' bracket
that is wetOed to the base plate. PU sealant shall be applied around mounting legs to
prevent water entrY.
26.7 Lancling platform: A landing platform on the rear side cf roof top should be provided
as per drawing no.CB22LDG113. The platform floor should Lre in 5-bar Aluminum cheq.
Plate of 2.0 mm base thickness,
26.8 Access Ladders: Access ladder should be in two pieces from luggage carrier to RLB top
side and a foldable piece up to skirt level with two railwa!' locks provision in folding
position has to be provided.
26.9 Unloader Grill: An un-loader grill on LH side above rear tvheel arch area has to be
provided in ERW 19 OD x 1.6 mm as per drawing no. CB22LDG113. It shall be covered
with1.22 mm AL chequered sheet, duly covering the half of top fixed glass'

27,O PASSENGER SEATS:

The seat layout plan and seating arrangement shall be as per the respective
drawingsno .P226OSG22tO4for AL, P2460SG223O4for TATA and P3060SG22204 for Eicher'
Z7.L SEAT FRAMES: The seat frames for singie, twin and t.iple seater shall be as per
the drg.no.cB22sFT130& CB22SFp130.The legs of seat frames should be located on floor
longitudes and seat rail only. Belting fabric 3 mm thick (one piece) shall be provided in
between the floor and seat ieg foot piece. The seat legs shall be fastened with MB X
1.0 mm hexagonai head H.i. botts using plain washers and Nyloc nuts. Provision to be
made for advertisement on seat back rests as shown in the drawing. The seat frames
should be black powder coated. Ladies seat frames should be yellow powder coated. All
Seat frames MS pipe at welding portion should be cup cuiting in order to facilitate full
weiding at joints instead of pressing.
27.Z SEAT BOTTOM CUSHIONS: Seat bottom cushions shall be provided in P.U. molded
foam conforming to grade "J" of IS: 8255 - L976. The density of P.U'foam shall be
between45 to 50 kg/cu.m. and indentation hardness shall be between 15-17 Kgf atZ\o/o
deflectlon.
Sizes: Three seater :1200x 3B0x 90/65 mm
Twin seater : 813 x 380 x 90/65 mm
Single seat : 406 x 380 x 90/65 mm
Conductor seat : 500 x 400 x 90/65 mm
The cr,rshions to be mounted on 8.0 mm thick ply wood conforming to Grade-MR, type-AA,
as per IS: 303 - 1989. The upholstery shall be with expanded vinyl coated fabrics as per
RDSO specifications at Annexure-il. The color of Rexene shall be in charcoal grey with
prior approval of CME(C&B) only. The bottom plywood shall have 4 vent holes of 10 mm
dia. pe rpassenger seat. The bottom of plywood should be pasted with 1.0 mm thick ABS
panel. The bottom cushion should be fitted 25 mm ahead of seat frame front end'
27.3 SEAT BACK SQUABS: The P.U.molded foam back cushion of 30mm base thickness as
\\E'l of IS: 8255-1976 shall be
shown in the drawing and conforming to grade
mounted on 8.0 mm thict plywood of grade - MR, Wpe-AA, of IS: 303-1989and
upholstered with same expanded vinyl coated fabric mentioned above.
Sizes: Three seater :1200x455 x 30 mm
Twin seater : 813 x 455 x 30 mm
Single seat :406 x 455 x 30 nrrn
Conductor seat :500 x 455 x 30 rnm
The back of plywood (B mm) shall be pasted with 1.Omm ABS s;heet of matching shade.
27.4 A sample seat shali be produced for approval of Chief Mechanical Engineer (C&B)
1 before manufacturing in bulk and fitting in the vehicles'

+m},qu*u'W M
 27,5 AII upholstery worl.: shall be carried out with 3mm piping at all joints. A margin of 12 mm
shall be provided for Rexene along the stitching lines and double stitching to be provided
duly folding the Rexene edge by6 mm. The tacking of Rexene to Plywood to be by folding
the Rexene bV 12 nirn with a pitch of 50mm in between nails'
*MODI/ COATS", Variety No.3B as perIS:1720-L978.
27.6 The sewing threac nrakesto be of

28.0 DRIVER'S SEAT:

The OE knitted t),pe driver seat supplied with chassis shall be retained. The driver
seat frame mounting on cabin floor shall match the OE mounting position.
28.1 In case of non-supply of OE knit[ed driver seat with the chassis, HDPE knitted
driver seat of approved make shall be fitted, The seat shall have fore and aft, up and
down adjustment of 100mm with reclinirrg back and to be fitted 350 rnm away from
steering wheel edge when the seat is fully forwarded'
2a.2 'The height of driver seat bottom shall be 450 mm when measured in fully lowered
position.
28.3 There shall be a thigh clearance of 200 to 260mm between steering wheel edge and driver
seating position.
28.4 The driver seat shall be so located that the center line of driver seat shall be 705 mm
away from the center line of bodY.
28.5 The driver seat shall be provided with "ELR' type safety belt of M/s.Autoliv or
Rane make I any other make approved by APSRTC. (Conforming to AIS 052).The middle
seat in six seater and single seat shall be provided with static type seat belts.

29.O BATTERY BOX:

The battery box shall be provided on LH side below floor level to accommodate two no's
12V batteries of size57LLx292Wx249l1 mm with slider arrangement, The battery box is to
be fabricated with MSL 40X40X6mm and MS Flat 40x6 mm and is to be paneled with 0.91
mm GI sheet on floor and three vertical sides followed by Hammertone coating. The
bottom of the batteries shall be provided with 12 mm-compressed plywood and acid
resistant rubber mat.

Complete Interior surface(except bottom side) of the battery box is to be overlaid with
0.5 mm stainless steel sheet of 430 grade. Batteries shall be provided with suitable
clamping, wood packing to prevent vibrations when the vehicle is in operation. One cutout
is to be done on longitudinal wall for passage of battery cables and is to be provided with 6
mm balata with an 'X' type cutting. Four rows of full-length battery cables without joints
shall be connected to the battery cut-off switch terminals to self-starter and batteries, The
terminals and cables should be firmly clipped in position with cable tie and soldered. One
LED light shall be provided in Battery Box for illumination. One guard rail of SS 25 X 1.6mm
pipe with brackets to be provided at front side to safeguard them.

3O.O ELECTRICAL WIRING AND OTHER FITMENTS:

30.1 The earth return system of wiring should be used. All automotive cables used shall be of
15: 2465 - 1984 quality covered with PVC sleeve as per IS: 1951-1961. Wherever the
cables have to pass through roof and side structures, PVC conduits of 1/2" dia. shall be
provided. There shall not be any loose or hanging cables, and if they pass through holes
in panels or structural members other than roof and side structures, rubber grommets

qs",
W
 shall be provided in the holes of such panels and structural members and shall be securely
clipped as near as practicable to such rubber grommets to avoid chaffing.
30.2 All wiring shall be carried through Aluminum extruded section wire casing Indal 2735 in
two rows along the cant rail offside and near side in such a way that it shall be easily
accessible at all points without the need to strip major paneling of body. The extruded
section shall be so located and fitted as not to affect the appearance of body' Any wiring,
which has to run along the chassis frame shall be securely, clipped to ensure that there
shall be no chaffing with any of the rnoving parts. Further care shall be taken to route
such wiring in suchl way that it is not subjected to splashing of oil, water, mud etc.
30.3 The battery main cable of size 3g}lO.40 mm shall be provided as required duly using good
quality lugs with proper soldering, bolting and insulation etc., there shall be no joint in
battery cables.
S0.4 The saloon ancl cabin are to be provided with B nos. of 390x130 mm long LED liqht
assemblies of approved makes as per layout drawing. Out of these, two shall be with
in-built night lamp of blue colour.
30.5 All OE electrical fitments shall be retained and kept in working Condition. Any extension of
wiring harness should be done by providing male female connectors only. Tapping of
po*"r for saloon lighting etc., shall be taken from the OE female sockets provided by the
chassis manufacturers. there should not be any tapping of power by slashing the main
harness.
30.6 The OE wiper machine, arm and blade supplied with the chassis shall be provided at Cant
level. Washer tank, if included in the system and supplied with chassis, is to be fitted on
left side of front end structure at a convenient location" In case wiper assemblies are not
supplied with the chassis,lT W Lucas WS electrical wiper machine with E 2 blades of 610
mm length (min) shall be provided by the fabricator'
gO.7 One single tone Air horn of Rootsi ELGI make shall be provided. In addition to the
OE electrical horn, one more electrical horn conforming to type -3 of IS 1BB4- 1993 shall
be provided for AL vehicles. The noise levels of these horns should be between 93 dB to
l12d9.
30.8 Modular switches as per IS: 9433 -1980, 230Vx5 amps shall be used. A 6-pole disc type
fuse box with indepenclent fuse designated for every electrical circuit shall be fitted on
switch board provided at cant level. Maximum current capacity of a circuit shall not exceed
15 Amps. The current carrylng capacity shall be 1.5 times the load current of the
electrical circuit. The fuses used shall conform to 15-4063 ,ttg9z. Switches and fuse box
are to be fitted on hylam/decolam sheet of 3 mm thick and to be fitted on sunken
tray located above the driver door with nonmetallic shielding to avoid short circuits.
g6.9 Cable encls shall be suitably crimped with lugs/soldered so as to with stand
vehicle vibrations. The inter connections shall be made throurgh couplers/junction boxes/
terminal blocks oniy. Weather proof connectors shall be use,l ior connecting cables which
are exposed to atmosphere to avoid water/moisture ingress during use.
30.10 Two additional head light assemblies of "B" dia with suitable reinforcement for fltment on
front end structure, are to be provided with OE head lamp assemblies on AL buses. Four
round type head lights of approved nrake shall be provided on Eicher and Tata vehicles
wlth proper reinforcement structure for fitment. They shall be fitted at a dlstance not more
than 400 mm from the extreme outer edge body and not more than 1200 mm height from
the ground.
30.11 In Ashok Leyland buses, OE front direction indicator lamps shall be retained and to
be provided below 1500 mm height on the outer edge of body in amber color' For
TATA and Eicher buses, approved type front indicators shall be provided. In addition
to this, four LED type dlrection indicator lamps (flat type) in amber color shall be provided
on the lateral side'of the body at wheels and below 1500 mm height from the ground. E1
AMW type indicator light to be provided on both sides at front wheel arch top area'

M
 30,12 LED type height marker lamps in white color at front and in red at rear shall be provided.
The marker lamps strall be above windshield glass at front and above cant level at rear on
maximum possible outer edges.
30.13 LED type tail lamps in 5" dia of 4no'sshall be provided on each side (Two -red, one-white
and one -amber) .The mounting shall be below 1500 mm from ground and 400 mm from
the outer edge. The red lights shali have individual circuits for parking and brake lights'
30.14 Rear number plate shall be provided with LED type light assembly of 300 mm length itr
rear bumper.
30.15 Electrical side flashers of LED type (Flat type)blinkers in amber colour shall be provided at
cant level on all four corners.
30.16 OE battery cut-oft switch supplied with chassis shall be provided with separate fuse
control. In case of non-supply of battery cut-off switch along with the chassis,
IGSA-552 or part no. LP-134l3 of Lucas India Services Ltd., make shall be fitted in
driver's cabin with a label "Battery Cut-off switch". The battery cut-off switch to be
'located 300mm ab,cve the cabin floor on 3.00 mm GI piate provided in side structure.
gO.L7 Six 6" dia speaker:; ,:rf Boston (Si-600) or Pioneer (TS 1641 GS) make shall be provided in
parcel racks with FFIP speaker boxes with separate switch control for LH/RH side speakers.
30.18 One 12V convert€:r has to be provided at conductor seat area on intermediate rail for
connecting TIMS. Cne LED type light with separate switch of approved design shall
be provided at condttctor seat.
30.19 Conductor's buzzer rrrith bell switches 4 nos. to be provided.
30.20 One reverse gear Horn / alarm (with 4 tones) shall be provided with noise level not more
than 100 dB if not supplied with the chassis.
30.21 In the driver cabin, [nstrument panel with all gauges, OE switches& indicators with labels
shall be provided at 45-degree angle and shall be within the reach of driver from his seat.
The frame shall be rabricated in MS angle 25x25x3 mm covered with 0,91 mm thick GI.
Sheet,
30,22 Power for connecting Wiper, indicators and Fog lamps shall be drawn from the OE fuse
box supplied by Chassis manufacturer only duly providing male/female sockets.
30.29 Never connect the circuits with twists & knots. Never tap power by slashing the main
harness.
90.24 LED Lights of L2 leads, 5W capacity shall be provided in luggage booths (04nos), in
battery box(01 no) and in Spare wheel carrier area (01 no)'

31.0 BODY PAINTING AND COLOR SCHEME:

31.1 Body to be painte,Jion the exterior and interior with synthetic air-drying coat type enamel
paints. The body under frame and chassis shall be painted with anti-corrosive
rubberized paint of approved make only. The exterior painting process shall consist of
carefully cleaning and etching followed by self-etch primer coat, an under coat, finish
coat and glaze coat.
3L.2 Approved paint(SE) brands are: 'Autostar' ofAkzo Nobel Ltd / 'Aspa'of Asian Paints/Nova
plus'of Kansai Nerolac or any other approved brand by APSRTC'
31.3 Color Scheme - Color scheme should be as per Sketch furnished. The paints shade
reference is given below:
a) Exterior poftion
Shade Shade reference
Crystal white rcr-199037
Satin black rcI-169003
Eco qreen ASPA-OG185
Tata Grav ASPA.O636
Interior portion

&- M
 i. Interior roof including front Francoise white rcl-169012
and rear destination boxes
trom cant to crib level
ii. Seat frames Powder coatinq
iii. Destination boards, inside White ICI-i69001
portion of boxes
iv. Number plates Golden Yellow back groundSize 65Hxl"0TH and
wlth black color 10 mm spacing
letterslnumbers
The color scheme may be modified or changed at the time of execution of bus body
fabrication as per the instructions of Chief Mechanical Engineer (C&B).
31.4 APSRTC monogram shall be provided on both sides of body as perSKETCH1916 in
image transfer stickers.

32,0 MISCELLANEOUS FITTINGS TO BE PROVIDED:

32.1 Two Fiber handles of 100 mm size are to be provided at waist level of cabin front end'
Two footsteps on the bumper shall be provided for giving feasibility to clean the
front windshield glasses. Footsteps should not protrude outside the bumper.
3Z.Z Two OE fully adjustable rear view mlrrors of convex type shall be fitted with brackets of as
per drawing CB22RVM140,One convex mirror to be fitted inside driver cabin at center
pillar between front giasses &one convex type mirror to be fitted at outside (at top side
between two wind screen glasses) of front end for near visic,n of road in front of bus. The
location of rear view mirrors shall be so located to have at least 2500 mm wide vision from
the body line of vehlcle when viewed from driver seat.
32.3 The front Registration number plate in Aluminum sheet 1.6 mm to be provided on
the front bumper at right side with Indal 5505 beading arot;nr.l registration number plate.
It shali be exhlbited in black alphabets/numerals rvith golden yellow back
ground. The size of the number plate shall be 450x250 mm, The rear registration number
plate shall be at rear bumper center area.
32.4 Two fire extinguishers of approved mal<e and dry chenrit:al type of 5.0 kg capacity
each conforming to IS: 2I7lof 1985 suitable for A,B&C class of fires shall be provided with
suitable MS clamping arrangement.
32.5 Rubber mud splashguards of size 650x456 mm are to be provided for front and rear
wheels.
32.6 First aid box in Stainiess steel and size 310X220X128mm vt'ith leather straps and locking
arrangement shall be provided in driver's cabin. First aid medicine kit containing the items
mentioned under Rule 138(4Xd) of the latest M.V.Rules shali be provided in the box.
a. Antiseptic cream of 0.5 7o Centrimide LP.in nonrgreasy base 5 mg - 2pcs
b. Sterile Surgical Gauge dressing - 1 pack of 4 pcs.
c. Wash proof plaster - 5 pcs.
d. Sterile elastic plaster - Size: 6 cm x 30 cm -1pc.
e. Gauge rolled - Size:7.5 cm x 2.5 mtrs. - 3 pcs.
f. Elasuc bandage for wounds and Burns size: B cm x 1.5 nitrs. - 1 pc.
SZ.7 One pair of towing hooks with 36 mm eye dia. punched in IvlS flat75xL2 shall be provided
at the rear end, to be attached to chassis long membr:r with04nos.ofM12 bolts.
B2.B All lettering works in Vinyl Radium stickers shall be done as per the guidelines with 25H X
6T.
32.g The rear bumper should be in GI sheet 2.0 mm thick-formed channel section of
size 50x175x50 mm in single piece with brackets in MSL40x40x6mm and to be fitted

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I lEll llJcl r. The ends of the bumper to be cur.ved. The center
portion of
r\ to
a, the Ll lo>>l> long
Ll ltr chassis lul 19 Imembers.

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-

the bumper shall be made sunken to accommodate a registration number plate and
Number plate light.
32.LO The OE front burnper supplied with the chassis shall be retained. Front bumper length
shall be increased to suite the body width i.e., 2590 mm. If the chassis is not suppliecl
with front burr,per, the bumper shall be fabricated in GISheet2.O mm of size
40x300x40 mm to suite the body width by the fabricator'
32.LL The mounting shall be attached to chassis long members with MS angle50x50x6 mm 400
mm long.
32.L2 Two sunken offset footsteps of size 150x150mm shall be provided in offset below
the driver door on,:r at 700 mm height from the ground and another at950 mm.
32.13 The entrance door, emergency door and driver door shall be provided with water
drain canopies at cant level with L.22 mm Aluminum sheet '
32.L4 Pure rubber matting of 3.0mm thick shall be provided for foot control pedal in driver's
cabin.
32.15'A footstool for driver to be provided in 3 mm Aluminum 5-bar cheq. Sheet and
Indal 2651 used fon legs preparation.
32,L6 Tapping of compressed air for windscreen wiper and air horn should be from port no.24 of
system protection valve with proper unions, 'T' joints. Polyamide pipe of 6 mm shall be
used for tapping of air. The pipeline shall be firmly clamped in position.
32.L7 Cne safe locker for keeping conductor's cash, tickets etc., with locking arrangement shall
be provided atlsttwinseater immediately after middle passenger entrance.
32.18 One roller type Sun Visor of 24" size to be provided in driver cabin.
32.L9 The OE Spare wheel carrier if supplied with the chassis shall be located as shown in the
structural drawing. In case of non-supply of carrier type bracket, one Spare wheel
carrier arrangement shall be provided as per Drg.no,CB22SWG131 on LHS at rear of
rear wheels. If the chassis are not supplied with carrier type bracket, the firrn shall
provide one Spare lvheel carrierfabricated in MS flat75x72 mm and 6.0 mm MS sheet.
32.20 Care shall be taken to avoid fouling of Spare tyre with any of chassis units/parts
under any circum:;tances. The Spare Wheel carrier shall be provided with flap door with
full length stainles;s steel hinge 1.6 mm thick and 30 mm wide from the bottom of the
cross bearer to skirt rail with locks and 6 rnm MS stay rods. The Spare wheel carrier shall
suit 10R20 size Tyre.El LED light shall be provided at spare wheel carrier.
32.2L Driver & engine boniret to be separated from passengers by providing one partition with a
row of stainless steel pipe in 304 grade,32 OD x 1.6 mm thick vertical supports
and Stainless Steel Flats with balata packing.
32.22The seats earmarked for Ladies, PHC persons, Senior citizens are to be very clearly
exhibited on seat back rests and at Intermediate rail.
32.23 Retro-Reflective Conspicuity Marking tapes of Diamond grade 50 mm wide conforming to
AIS: 90 of approved make shall be bonded to the body sides as per the sketch provided.
The cumulative length of tapes provided shall not be less than B0% of length of that side.
These tapes shall be white in color at front, yellow on sides and in red at rear of the body.
32.24 One Stainless steel assist rail of 25xL.6 OD (304 grade ) up to a height of 600 mm frorn
floor level shall be pr:ovided on rear pillar from inside at driver door bay.
32.25 Guard rails in SS of size 25x1.6 mm shall be provided in side luggage booths.
32.26 G.I. sheet 0.50 mm thickness shall be provided inside the bonnet to avoid heat dissipation.
32.27 Provision of Single seat to conductor instead of twin seater at specified area as per
drawing no. CB22CNiD001.
32.28 Rear Luggage Bootir & a luggage booth behind ROS tyres to be provided asper tlre
drawing.
32.29 One 200 mm SS handle to be provided on outer side of driver door.
92,30 Stainless steel sl-reets, tubes, pipes etc. should be of lindal make/any other source
by APSRTC

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32.81 "Break any glass in Emergency" stickering to be displayed on rear saloon glass both in
English and Telugu.
32.32 JK doors with pneumatically operated 63mm bore dia cylinders of Janatic make should be
provided. The cylinders are to be placed on both sides of center foot board at Saloon floor
area which are covered with Aluminum chequared sheet box with trap doors fastened by
tapping bolts.
32.33 On Dash board area front left side, where it is clearly visible to passengers, provide
stickering of "Book Your Tickets Online @www.apsrtconline.in"in 3" of font size with
"Times New Roman" lettering font.
32.34 One Amplifier of approved make i.e. AHUJA/SONY shall be provided.
82.35 Support pipe of SS 25x1.6 mm has to be provided attop of the 6seater area.
32.36 LED Lights of 12 leads, 5W capacity are provided at luggage booths.
j2.g7 REMI make one electric fan of 24Yx B" dia. shall be provided in cabin for driver.
32.38 A slogan in Telugu to be exhibited as follows on the back side of Front destination box flap
door. Slogans in Telugu to be exhibited as follows
1. dsae.pd S 15c[reoodd o, es o 4D Sldr. 500/- 5 6 Sua o Jvo-
z.6aaX>: JJo Jo6O6 6SCb0{rLdon"6oJ,loo
I !|

3,z.lg Tim machine Box, Water bottle holder are to be provided at conductor seat area to Truss
panel and a 3 pin socket with switch for Tim machine charging also to be provided.
g2.4O'peep window of size 250 X 250mm with sliding glasses to be provided in front of driver
door at crib level.
3,Z.4L All Slogans &Stickering to be done as per the instructions from time to time
given by
APSRTC with size of 25H X6T.
g2.42If there are any modifications in specifications are proposed during fabrication, it will be
communicated by APSRTC from time to time and to be implemented immediately.

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