Ts 001 veihcle en

TECHNICAL SPECIFICATION

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INDIA TOPAZ Bus

VEHICLE

Author:

INI – Calapai

Verified:

INI - Besteghi

QUA - Galasso

SVP - Minelli

Approved:

BMB - PRT – Sanna

JBM - Rusia

0 2011/11/21 First release

REV. DATE DESCRIPTION


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INDEX

1 PURPOSE & OBJECT.......................................................................................................32 APPLICABILITY.................................................................................................................33 TECHNICAL STANDARDS AND REFERENCES.............................................................34 TECHNICAL DESCRIPTION.............................................................................................45 VALIDATION PROCEDURES.........................................................................................236 TECHNICAL DOCUMENTATION TO BE PROVIDED....................................................247 PRODUCTION DATA......................................................................................................248 WARRANTIES.................................................................................................................249 ATTACHMENTS..............................................................................................................25


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1 PURPOSE & OBJECT

This document has as its object the Technical Specification of the vehicles India TOPAZ Bus. The Vehicle includes all the aggregates and accessories.The purpose of this Technical Specification is to describe and to document the technical characteristics of the vehicle and its aggregates.

2 APPLICABILITY

This technical specification applies to the vehicle India TOPAZ Bus – project code 2406M4ILS2-I00.

3 TECHNICAL STANDARDS AND REFERENCES

3.1.1 Quality Standards and General Rules

The list of the BMB quality standards applicable to the process of production of the India TOPAZ Bus are listed in annex n°1

3.1.2 BMB technical regulations

The list of the BMB technical standards applicable to India Bus project are listed in annex n°2.List of the feasibility studies reported in annex 5):.Drawing n° D334934 – General layout and overall dimensions of the vehicle.Drawing n° A2195 – Engine compartment layout (ISB5.9 G 230 hp).Drawing n° A2193 – General cross section.Drawing n° A2194 – CNG cylinders arrangement.Drawing n° A2197 – Driver’s working area arrangement.

3.1.3 Approval standards:

The list of the standards & tests approval applicable to India TOPAZ Bus project are listed in annex n°3 “Reference list Homologation – Vehicle & Component level”AIS – 052 – Bus Code & latest amendment

3.1.4 Reference Technical Specifications:

TS 002 - Front axle; TS 003 - Rear axle; TS 004 - Shock absorber; TS 005 - Air spring; TS 006 - Tyres; TS 007 - Steering gear; TS 008 - Engine; TS 009 - Transmission; TS 010 - Propeller shaft;-= TS 011 - Air filter;


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TS 012 - Cooler; TS 013 - Air conditioning system; TS 014 - Service doors; TS 015 - Emergency door; TS 016 - Folding manual ramp;TS 017 - Passengers windows; TS 018 - Electrical & Electronic equipment.TS 020 – Vehicle Mission.TS 021 – Bus structure requirements.

4 TECHNICAL DESCRIPTION

4.1 General:

The vehicle India TOPAZ Bus is a low floor city bus for daily service under the operating conditions and mission of the vehicle reported in annex 4) (TS-020 “Vehicle Mission”).The vehicle India TOPAZ Bus is categorised as “TYPE I – NDX – Medium Capacity – Standard bus as defined in AIS 052.The vehicle India TOPAZ Bus is a CNG fuelled conforming to BS-IV norms and it shall be fitted with an Air Conditioned system.The vehicle India TOPAZ Bus shall be fitted with Automatic Transmission, Air Suspension, Power Steering and Electro-Pneumatically operated doors.

4.2 Technical features:

4.2.1 General features:

The India TOPAZ Bus shall have right hand drive and be fitted with engine at the rear of the bus. The bus shall be designed and manufactured in accordance with the specifications & “Code of Practice for Bus Body Design and Approval” as per prevailing version of AIS 052.The bus structure should meet the requirements of structural strength, stability, deflection, vibration, and roll over protection etc according the specifications TS-021 “Bus structure requirements”.


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Referring to the Drawing n° D334934 – “General layout and overall dimensions of the vehicle”, the main dimensions are as the table n°1) below:


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TABLE n°1): Overall dimensions vehicleMaximum length 1

2.000 mm

Maximum width 2.550 mm

Maximum height (with cng cylinders system) 3390 mm

Wheel base 6.320 mm

Front overhang 2.560 mm

Rear overhang 3080 mm


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Axle clearance 190 mm

Ground clearance within the wheelbase 270 mm

Wheel area clearance (parts fixed to the body) 254 mm

Wheel area clearance (parts vertically moved with axle)

203 mm

Approach angle 8°

Departure angle 9°

Turning circle (external wheel) 19.049 mm

Turning circle (betweens walls) 22.350 mm

Internal wheel steering angle 52°


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Floor height from ground 1st & 2nd door 340 mm

Gangway front wheel arch 890 mm

Gangway (between armrests of seats) 515 mm

Ramp over angle required for clearing ramp height of 270 mm shall be 4,8° to 5,1° as given below:

Sr .No Wheel base (mm) Ramp over angle (degrees)1 6100 5,12 6300 4,93 6500 4,8

Note: Ramp over angle is defined as tangent inverse of 270mm divided by half of the wheelbase.

Figure: Wheel area clearance

All the dimensions reported in the table above are related to the vehicle in un-laden conditionThe turning clearance radius is as per IS 9435-1980/IS 12222 (or latest).


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Referring to the Drawing n° D334934 – “General layout and overall dimensions of the vehicle”, the seating capacity, seat pitch and standees are as the table n°2) below.

TABLE n°2): Seating & standees capacity vehicle

with wheelchair on board

with passengers standing in wheelchair area

Seating capacity 35 35 mm

Standee capacity 14 17Wheelchair 1 --Services seats 1 1TOTAL 53 55


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Referring to the Drawing n° D334934 – “General layout and overall dimensions of the vehicle”, the loads capacity as the table n°3) below.

TABLE n°3): Weight vehicle

GO O

Front axle loads

4.

152

5.681

6.068

6.986

Rear axle loads

8.

383

10.526

10.955

12.349

Total

Wei

ght

12.

535

16.207

17.023

19.335


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Interior noise and pass by noise of the vehicle shall confirm to BIS: 12832:1989 or latest and BIS: 3028:1998,10399: 1998 or latest respectively.

Fire safety: The bus shall be designed and manufactured with all applicable fire safety regulations under CMVR for safety for CNG buses including piping location and layout, location of rubber hose, location of exhaust, sealing from CNG gas entering passenger compartment in case of leakage, catalytic converter location, prescribed upholstery material, fire retardant cable, connectors etc. These provisions shall also include the use of fire retardant material , fire detection, escape of gases in case of any leakage, fire walls and facility for passenger evacuation (doors, windows and escape latches) as per statutory requirements besides bus code. Flammability requirements shall comply with IS 15061.

4.2.2 Technical description:

The bus shall be designed as per Bureau of Indian Standards (BIS) and/or Automotive Industry Standards (AIS) specifications and/or other requirements as given in the Bus Code.

The bus shall be fitted with the main aggregates below:Front axle as per TS 002; Rear axle as per TS 003; Shock absorber as per TS 004; Air spring as per TS 005; Tyres as per TS 006; Steering gear as per TS 007; Engine as per TS 008; Transmission as per TS 009; Propeller shaft as per TS 010; Air filter as per TS 011; Cooler as per TS 012; Air conditioning system as per TS 013; Service doors as per TS 014; Emergency door as per TS 015; Folding manual ramp as per TS 0016Passengers windows as per TS 017; Electrical & Electronic equipment as per TS 018

Additional details of the complete and final configuration of the bus and its aggregates.

Engine. Described in the TS 008, the engine is a Cummins type ISB 5.9 G 230 hp.It is a Compressed Natural Gas (CNG) fuelled engine with electronic ignition system.The engine has adequate horsepower not only to propel the bus but also to operate efficiently the bus & air conditioning system & all other auxiliary devices fitted to the bus. Main features of the engine

Power 172 kW@2800 rpm


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Torque 678 Nm@ 1600 rpmPosition rear longitudinalDisplacement 5,9 ltrs – 6 cylinders in lineBore 102 mmStroke 120 mmmAspiration Turbocharged & charge air cooledEmission Certification BS IV

The engine mounting its accessories are so located as to facilitate easy accessibility & replacement.The engine compartment is insulated to avoid transmission of heat and noise to saloon area. The passenger & engine compartments are separated by an insulated bulkhead.Only necessary openings are in the bulkhead.Suitable lighting arrangement with separate switch is provided for the engine compartment.In the engine compartment the air intake location is in a manner as to provide dust free air, a pre-filter and dry filter is located with a water removal device.The exhaust silencer is located in low position between the gearbox and the left side of vehicle with low exhaust rearwards. The entire exhaust pipeline after exhaust manifold is of stainless steel.

Cooling system. The engine is cooled by a water coolant forced-circulation and controlled by a thermostats easily accessible for replacements. All low points in the water-based cooling system is equipped with drain cocks. Air vent valves shall be fitted at high points in the cooling system. The cooling system shall conform to BIS: 14557-1998 or latestAir ducting and fittings are protected against heat sources. De-aeration tank and pressurized radiator cap is provided. It is easy for filling and level checking of coolant, accessible from outside by a flap door.The coolant group includes the integration of intercooler and coolant radiator and it is cooled by a mechanical fan belt driven by the engine. It is located in the right side of the engine compartment and accessible by the rear flap cover.

Transmission. Described in the TS 009, the automatic transmission is an Allison T270 R type with 5 (or 6) forward.

Front Axle. The bus is fitted with an independent front suspension of proven design and adequate capacity of load to take care of maximum GVW & dynamic loads, expected during life span of the bus of minimum 12 years or 7,50,000 Kms . Detailed description of main requirements of front suspension is reported in the TS 002.

Rear Axle. The bus is fitted with an inverted portal axle of proven design and adequate capacity of load to take care of maximum GVW & dynamic loads, expected during life span of the bus of minimum 12 years or 7,50,000 Kms.


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Detailed description of main requirements of front suspension is reported in the TS 003.

Suspension. The front and rear axle are fitted with air bellow suspension and shock absorbers, suitable for trouble free operation and jerk free comfortable ride. The air suspension are adequately protected from engine/ exhaust pipe heat. The full air suspension system at rear axle is with stabilizer bar. A kneeling arrangement of minimum 60 mm of the left side simultaneously is provided. ECAS system is not required.

Steering. An hydraulic power steering, recirculating ball type, is provided. It's the ZF model 8098 955 890, with axle inclined of 20° with respect to the vertical plane and adjustable in inclination and height through pneumatic control.

Braking system. The braking system is a full pneumatic type, with a fail-safe dual circuit having four-way protection valve, auto slack adjuster, front & rear disc brake and brake linings free asbestos. The braking system is fitted with air dryer and oil/water separator. The buses is provided with parking brakes at rear wheels.It is provided a four channel antilock wheel system in brake phase is provided.The signal of the wear of the braking seals and automatic recovery of the clearances is provided.

CNG Cylinders. A package of 6/4 CNG cylinders type 1 is roof mounted and aesthetically enclosed with proper ventilation The CNG cylinders have a total capacity of 1080 / 720 litters to facilitate a daily operation of over 300 km. per filling of CNG in cylinders of the bus at initial gas settled pressure of 200-bar at 15o C. The CNG cylinders fitted in the bus is supplied along with certificates of approval from Chief Controller of Explosives (CCOEThe CNG inlet/filling system for the bus is accessible only from exterior of the bus & is properly located on the right side (Driver side) of the bus at a convenient safe level with appropriate flap size with lock in skirt panel. The height from ground of filling system is between 800 mm to 100 mm.Suitable escape system is provided in the engine compartment for CNG leakageThe entire CNG system accessories, components, piping joints etc. be located, routed and encased in a manner as to prevent ingress of natural gas inside the bus. The cylinders shall be fitted in such a manner that the punched number i.e. serial number, name of the manufacturer etc be visible clearly from topside when fitted in the buses.The cylinders be inter-changeable/replaceable with other cylinders same type and size without any modification of the system.All CNG system items are conform to the relevant CMVR/CCOE, Government of India/BIS/ AIS024 & 028Gas, air and electrical lines are separated out with no jumbling/intermixing in the engine compartment


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Structure: The bus body frame is an integral construction as defined in Bus Code with the super structure fabricated using steel tubing conforming to BIS 4923-1985. Quality steel type S 420 MC or equivalent.The comprehensive multi-stage anti-rust treatment is provided to bus flooring, sides, roof, under -structure, as per BIS 3618 Class-A2.All the structural members of the bus are treated for corrosion prevention internally as well as externally and painted wherever required. The Polyurethane (PU) painting conforming to BIS: 13213- 1991The bus structure is designed to meet the requirements of structural strength conforming to NT 182. MIG welding shall be used for steel structural member’s fabrication according welding procedure n° SQU-279 of BMB.

Ventilation and Air conditioning (VAC) climate control system A VAC system is provided for ventilation as well as cooling of the interior whole compartment of the BusThe design of the air conditioning system is of appropriate size, type and capacity as per the operating/ environmental conditions given at “Operating conditions and mission of the vehicle” reported in attachment (annex 4). The noise levels of AC system is as required under the Central Motor Vehicle Rules (CMVR)/AIS /any other Indian standardsThe bus is provided with aesthetically roof mounted Air-conditioning system.The system is so mounted to facilitate ease of access for repair & maintenance. Proper AC ducting is installed inside saloon for uniform distribution of air-conditioned flow. Air conditioning system is CFC free.The Air-conditioning system has a large heavy-duty transit compressor and high capacity alternator. A properly sized alternator/charging system is provided to support the Air-conditioning system and to improve reliability & efficiency of the system.Automatic Electronic temperature control arrangement is provided for AC systemThe aeration of driver area uses airflows distributed by the ventilation system set up for the defrosting of the windshield and is equipped with a serial anti-pollen filter.The whole roof of the bus body is fully thermally insulated with flame retardant Polyurethane or glass wool of suitable density.A suitable & proper AC ducting is provided for the centralized air conditioning for effective and smooth air flow to cover the entire saloon area with proper insulation.The Ventilation and Air conditioning (VAC) climate control system maintains inside temperature of the bus within a range of 18 °C to 30 °C.The air conditioning system is capable of reducing the passenger compartment temperature from 43 °C to 32 °C in less than 20 minutes after engine start-up. The air is composed of not less than 20% outside air. Airflow is evenly distributed throughout the bus with air velocity not exceeding 0.508 m/Sec. on any passenger.


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External panelling: The bus exterior side, below windows, is fitted with pre-painted aluminium panels, glued and riveted. The exterior front-end & rear-end panelling are in FRP while roof. The roof is composed of a sole fibre resin laminated sheet. A walkway suitable for two persons is provided longitudinally to enable repairs/ maintenance/ handling of the CNG System/ Items on roof & connected with ladder at rear end near side All side skirt panels below fixed panels line are of such design that any panel can be replaced with a pre-painted panel within a very short period of time. The side skirt are able to withstand the side impact as per the provisions of BIS: 14682-1999 or latest. Similarly the rear end are able to withstand the rear impact as per the provisions of BIS: 14812-2000Roof is thermally insulated with panels in polyester fibre .Rain gutters is provided to prevent water flowing from the roof onto the passenger doors, driver’s side window. windshield, or into the door boarding area.Entire front end of the bus is sealed to prevent infiltration of water and dust, debris accumulation behind the dash.All interior panelling are of Acrylonitrile Butadiene Styrene (ABS) around of windows and of fibre resin or laminated sheet that cover the floor side up to the base of the windows.Interior panels are mounted so that there are no exposed unfinished or rough edges or rough surfaces. Panels & fasteners are not easily removable by passengers.

Service doors: Two service double doors in 1200 mm wide aperture (without flaps) are fitted at front and middle nearside of the bus as per provisions of the Bus Code for Type I, NDX category. The entrance and exit doors are electro-pneumatically controlled by the driver; an internal and external emergency open controls per each door is provided. In the event of an emergency, it is possible to open the doors manually from inside the bus by unlocking the proper device at each door. The unlocking devices are clearly marked as an emergency device & requires two distinct actions to be actuated.The doors are inter-changeable. Overall dimensions, operating conditions and fitments are in accordance with Bus Code requirements.For detailed description see TS014

Emergency Exits & driver doors: Two emergency windows are provided per each side, they are situated in the front & rear half of the vehicle. Overall dimensions of emergency exits are in accordance with Bus Code requirements. A driver door of not less than 1600 mm height and 650 mm wide is provided for entry and exit to driver’s work area. Proper hand holds and steps are provided for easy access to driver’s cabin. All other requirements of driver door (climb facility, hand holds, etc.) are as per the provisions of the Bus Code.The driver doors is capable of operation from both inside and outside when operated manually. However it is provided the possibility of locking the door from outside even if the door can be opened from inside.


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The driver' entrance-cum -exit doors shall be provided as per Bus Code with a provision of maximum width of sliding window using the material like glazing & glass as used in the other side window glasses.The door shall be hinged at the forward edge.The driver door shall be open outward and is capable of remaining open outwards and at an angle of at least 100o, such that aperture is clear of any obstructions.The driver door is provided with an audible device to warn the driver when the driver door is not securely closed. The warning device shall operate due to the movement of the door catch and not by the movement of the door itself.

Guard rails: No guard rails are provided due to the vehicle is fitted with an Air Conditioning system.

Guard: Door apertures are fitted with Hand Rails on each sideSuitable guard are provided in the service doors area close to the seating passengers The guard height is minimum 800mm from the floor, and the width is inward from the wall to the passengers double seat space

Escape hatch: In addition to emergency exits, two hinged type escape hatch are fitted in the roof as per the bus code

Floor: The bus is a low floor type without internal steps, with entrance and exit located within the low floor area at left-hand side. All floor surface is covered with an anti-slip PU carpet.Low floor area of bus is at a maximum height of 400 mm from the ground level; max height of first step from ground shall be maximum 340 mm . Internal saloon height is minimum of 1900 mm in the rear over hang area.The flooring design allows an easy cleaning board of 12 mm thickness conforming to BIS 710-1976 or latest and shall be fire retardant as per BIS 5509-2000 or latest. The said floor is covered with anti-skid type silicon grain material of 3mm thickness meeting Indian/ International standards. Adequate sealing is provided in the floor to prevent ingress of dust, gases, water etc.Suitable traps/openings with appropriate sealing shall be provided for repair and maintenance of various aggregate/ systems/ sub systems of the bus

Gangways: The gangway is as per the provisions of the Bus Code. The gangway dimension is 515 mm at armrest of seats level. No steps are fitted in the gangway; a max slop of 8% is present in the rearward zone. The gangway surface are covered

Handrails and Handholds: The Handrails and Handholds are provided as per provision of bus code. Hand holds complies with AIS 046. The surface of handrails & handholds shall be colour contrasting and slip-resistant. All


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handrails are of tubing of 32 mm dia. and 2 mm thick. covered with PVC sleeve matching with the interior décor.

Stanchions: Vertical stanchions are so positioned to facilitate access to seats for those standing. The stanchions are of 32 mm dia and 2 mm thick steel tubing covered with PVC sleeve matching with the interior decorHigh visibility bell pushes are fitted at a height of 1.2 meters on all alternate stanchions on both sides in the bus

Passenger Seats: The passenger seats layout is a 2x2 type according drawing n° A2193.Seats are comfortable, durable & maintenance free of ‘PPLD/LDPE’ (Polypropylene Low Density) moulded construction meeting the performance requirements of AIS023.. Main features of seats as overall dimensions, backrest height, armrest, available space for eac seating position (G),depth of seat cushion, seat spacing, seat base height, seat base thickness, torso angle and other requirements as per the Bus CodeSeating passengers capacity is 37 nos. (excluding driver) and space for one wheelchair. Standee passengers capacity is 15 nos. as per formula calculation given in the bus code.

Driver’s work area : Driver’s working area is accessible from the passenger compartment by means of a passage. All dimensional requirements of driver’s work area are as per the provisions of the Bus Code (see attachment n° 8)Drawing n° A2197 shows the driver’s working area arrangement and position of the controls as accelerator, gear switches, service brake pedal and general placement of instrumental panel. Dashboard is of PU moulded material. A driver door is provided in the right side of the driver’s working area.

Driver partition: The partition of driver’s working area from the passengers compartment is made by means of an enclosure containing electrical equipment and fresh air duct; the box closes the area rear the driver’s seat from the roof to the floor. In the left side of the driver’s seat the enclosure contains a glass panel in upper position and a metal sheet panel in the lower position.An additional partition made of tubular steel of 32 mm dia. and 2 mm thick. covered with PVC sleeve and glass panels; this partition closes the access of passengers to the driver’s working area.

Air Passage-The aeration for driver’s working area is made by means the ventilation system set up for the defrosting of the front windshield. Suitable airflows is provided along the lower edge of the windshield for a proper inflow of air inside the driver cab especially for the summer season. .


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Driver’s Barrier Assembly: A telescopic bar will be mounted as connection between the front door and the additional partition of driver's working area for the protection of the passenger standing near to the gate.

Dashboard Instrumentation and Control System: The bus is fitted with an ergonomically designed moulded type dash board made out of FRP material and instrument panels.A driver’s liquid crystals display is provided on which, with numerical and graphic indications are reported: engine coolant water temperature, cng fuel pressure, pneumatic system air pressure, engine oil pressure, low pressure and high temperature of transmission oil, engine speed low air pressure, battery weak.Driver’s keys and switches both on the right and left side of driver’s display are installed for danger warning lights with acoustic integration, parking lights, indicator lights, parking brake, passengers stop request and doors open.On the left of the display there is the pushbutton panel for gearshift control.Control pushbuttons doors opening with signalling warning lightsControl lever of Parking brake and emergency control on the right of the driving position

All the dashboard controls and instrumentation system are as per the bus code

Rear-view Mirrors- Interior and Exterior : Rear-view mirrors are provided on both sides of the bus to enable driver to have clear side/rear views. One interior rear-view mirror is fitted for viewing saloon area by the driver. Installation and performance requirements of the rear -view mirrors are conform to AIS 001 and AIS 002

Sun Visor: Adjustable sun visors are provided for the windshield & the driver’s side window.. Visors adjustment are made easily by hand with positive locking & releasing devices. Visors are transparent but it’s not allow a visible light transmittance in excess of 10%.

Electric Horn: An electric horn conforming to BIS: 1884-1993 and installation requirements conforming to AIS 014 is fitted in the bus.

Destination boards: The display system, coloured LED based, are installed at the front, rear and side of bus. It is a display system of variable messages visualization, composed of a monochromatic LED matrix with high resolution. The system is operated with inbuilt software to enable the driver to change the destination. The system is compatible with GPS. Loudspeakers integrated with the display system are fitted one at the front gate and another at the rear gate. Front Destination Board: It is provided an alternating display of destination with options in English and Hindi along with fixed route number in Arabic numeral. Size of the display 1900(L)x270(H)x40(D). Two rows of characters are


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available with different numbers of characters with proportional fonts. The display is clearly visible in day & night at a distance of 5 mSide Destination Board: It is provided a scrolling display of destination in English and Hindi alternatively along with fixed route number in Arabic numeral. Size of the display 900(L)x270(H)x40(D). Two rows of scrolling characters are available with different numbers of characters with proportional fonts. Simultaneously the route number and destination are announced so as to make audible to the passengers on the bus stop. The display is clearly visible in day & night at a distance of 15 mRear Destination Board: It is provided a fixed display of destination in English and Hindi along with route number in Arabic numeral. Size of the display 900(L)x270(H)x40(D There shall be one loud speaker fitted at rear of the bus (inside the bus – rear right side). The display is clearly visible in day & night at a distance of 50 mInside Display Board: It is provided a display of name of approaching bus stops in Hindi & English alternatively with announcement system. The system is compatible with GPS. The system is able to store onboard up to 100 messages of 50 characters each on an average. The messages can be scrolling type, flashing (fully or selectively) in Hindi/English/symbols as per pre-programmed system. The announcement can be made for both current and next bus stop/destination synchronized with the display alternatively in Hindi and English. The display size is 800(L)mm x 100(H) mm. The display is mounted behind the driver at an appropriate height for clear visibility to all passengers. The display time, frequency and sequencing of advertisements/ messages are programme controlled. The system has a programming for minimum 150 numbers of routes and 300 numbers of destinations. Further the system has also a programming for minimum 150 nos. of bus stops on each route.

Integrated voice announcement system: an integrated system of voice announcement (4 watt, 2 nos.) is fitted one at the front (behind the driver along with LED display) and one at the rear side-inside. Two additional speakers are fitted for exclusive use of the passengers outside the bus - one speaker is mounted near the front gate along with LED display and the other near the rear gate. Voice messages / announcements are synchronised with the visual displays.

Stop requests: Sufficiently audible electronic type Stop Chimes is provided in the bus - one in driver’s compartment & one near exit door. The interval between chimes is 3 to 4 seconds. In addition, a red pilot light is also provided on driver’s dashboard when the bell push is pressed.

Bumpers: The bus is provided with rear bumper of FRP moulded hinged and removable. The bumper is easily repairable/ replaceable. The bumpers shall conform to the requirements of CMVR, Bus CodeThe reflective tape of colour as per CMVR shall be pasted over the full length of the rear bumper.


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Towing device: Heavy-duty ring type towing devices is provided in the front and rear end of the bus with load transfer to bus structural members. The capacity of each towing device shall be 1.2 times (minimum) the kerb weight of the bus within 30 degrees of the longitudinal axis of the bus.

Wind screen: Front and Rear: Front wind screen in the bus is in single piece design, doubled curved surface; PVB film laminated safety glass of thickness of 6.76 mm. Rear windscreen is also in single piece design, flat, toughened glass of thickness of 6.0 mm. Windscreen glasses meets the requirements of BIS 2553: Part II-1992The grazing used for fitment of front wind screen is EPDM rubber of black colour. Rear wind screen is glued to the rear head resin.

Wind screen wipers: Electrically operated windscreen wiper system having two wiper arms with blades is provided. The wiper motor is heavy-duty steel body for minimum of two-speed operations. The sweep angle is sufficiently wide for clear view during rainy days. The windscreen wiping system is 24V, having two operational speed, with fitment of time delay relay. The windshield washer system has a 5 litres tank located for easy refilling and two Nozzles at suitable location for proper spray of fluid. Reservoir pumps, lines & fittings are corrosion resistant & reservoir itself is translucent for easy determination of fluid level. The windscreen wiping system is in accordance with CMVR/ BIS: 7827 Part1, 2, 3 (section 1, 2)

Fire extinguishers: a fire extinguishers of 6 Kg. capacities are ISI marked conforming to BIS: 13849-1993, dry powder type (Stored pressure) duly filled. Fire extinguishers are fitted with proper reinforcement.

First aid kit: First aid box is provided as per the provisions of CMVR and Bus Code fitted near driver seat at appropriate position and level on side with proper reinforcement.

Persons with disabilities: It is provided a manual operated ramp at entrance door for wheelchair disabled friendly access of Persons with Disabilities (PWDs). The PWD system meets the requirements as given in the Bus Code and CMVR.The ramp is usable only when the vehicle is at stand still.The ramp is at least 1000 mm wide.The ramp when ready for use exceeds 800 mm in length.The ramp is capable of operating safely with a load of 300 Kgs

Battery: The battery system (2x12V), is 220 Ah capacity, low maintenance type lead acid batteries. The batteries are well secured to a hinged/ pivoted type carrier for ease of access for repair & maintenance, replacement.


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The battery box is mounted near to the engine compartment and is well secured, easily accessible & ventilated. Performance requirements of the batteries are conform to BIS: 7372-1995 Each battery cable is covered with flame retardant corrugated flexible pipe and is properly encased & clamped.A switch of the relay controlled battery cut off (Remote Control Current isolating switch) is provided near the driver seat on side panelling at appropriate level for disconnecting the power supply from the battery except for safety devices.The Remote Control Current isolating switch is capable of carrying & interrupting the total circuit load.The bus is fitted of a 24 Volt D.C electrical equipment. An alternator of 24V DC with total capacity of 90Ah consistent output to take care of high idling periods of city operation is provided and so located as to minimise ingress of oil or rain water into it.. A pre-engaged type 24V DC Self-starter of adequate capacity with relay shall be fitted in the bus and so located as to minimise ingress of oil or rain water into it.

Electrical equipment and wiring: Electrical equipment and wiring are conforming to Indian Standards. All cabling are as per the provisions of the Bus code/CNG safety requirements as provided in CMVR. The wiring are flame proof, ISI marked conforming to BIS: 2465-1984. The cross section of the battery cable are then 70 mm2. Wiring is grouped, numbered & colour coded. Wiring harnesses does not contain wires of different voltage. Kinking, grounding at multiple points, stretching & exceeding minimum bend radius are prevented. The wiring looms/ harness for vehicle system of the bus are properly routed, encased/ concealed type so mounted to eliminate chances of any spark. Wiring support are protective & non-conducted at areas of wire contact & are not damaged by heat, water, solvents or chafing.All electrical fittings and lights are fully wired up, running in flame retardant black colour PVC sleeves as per applicable Indian standards and installed in a manner to facilitate easy inspection/ rectification/ replacement etc as & when required without disturbing internal finish/ décor of the bus. Whenever any wire or cable or PVC sleeve carrying cable etc passes through holes in the sheet metals/ structural member, suitable rubber grommets inserts are provided in these holes to avoid direct contact between cables and sheet metal causing damage to the insulation coating. Design of the electrical, electronic & data communication systems are modular so that each major component, apparatus panel or wiring bundle is easily separable with standard hand tools or by means of connectors. Each module except the main body wiring harness is removable & replaceable. Power Plant wiring is an independent wiring module. Replacement of engine compartment wiring module does not require pulling wires through any bulkhead or removing any terminals from the wires.No vehicle component does generate or is affected by electro-magnetic interference or radio frequency interference (EMI/ RFI) that can disturb the performance of electrical / electronic equipments. The complete bus is conforming to AIS 004.All electrical & electronics hardware are accessible & replaceable easily. It is mounted on an insulating panel to facilitate replacement. The mounting of the


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hardware does not be used to provide the sole source ground and all hardware are isolated from potential EMI/ RFI.All electrical/ electronic hardware mounted in the interior of the bus are inaccessible to passengers & hidden from view .All electrical/ electronic hardware & its mountings comply with the shock & vibration requirements.It shall be provided a preliminary analysis of the estimated electrical load for each system at the time of prototype. Alternator over voltage output protection is provided.All branch circuits except battery to starting motor & battery to generator/ alternator circuits shall be protected by circuit breakers or fuses sized to the requirements of the load. Electronic Circuit protection for the cranking motor shall be provided to prevent engaging of the motor for no more than 30 seconds at a time to prevent overheating.The current rating for the wire used for each circuit must exceed the size of the circuit protection being used.To the extent practicable, wiring shall not be located in environmentally exposed locations under the vehicle. Wiring & electrical equipments necessarily location under the vehicle shall be insulated from water, heat, corrosion & mechanical damage. Where feasible front to rear electrical harnesses should be installed above the window line of the vehicle.Two separate additional out-lets are to be provided with appropriate relays & fuses in wiring harness for fitment of electrical auxiliary devices/ systems to be added later on in the buses, if required. Suitable three out-let of 12V/24V is also to be provided at suitable location for charging of electrical/electronic equipment like Mobile Phone, Electronic Ticketing Machine If any electronic components have an internal clock, it shall provide its own battery back up to monitor time when battery power is disconnected.All electronic component suppliers shall ensure that their equipment is self-protecting in the event of shorts in the cabling and also in over voltage and reverse polarity conditions.RF components such as global positioning system (GPS) etc. whenever provided shall use coaxial cable to carry the signal. The RF systems require special design consideration for losses along the cable. Connectors shall be minimized, since each connector & crimp has a loss, which will attribute to attenuation of the signal. Cabling should allow for the removal of antennas or attached electronics without removing the installed cable between them.

Lights and lighting system: Interior saloon lighting is type tube light assembly fitted with suitable nos. of transistorized inverter as per BIS 7027:1984 with long slim type fluorescent tube as per BIS: 2418(part I)- 1977, and mounted in staggered formation for uniform lighting in two separate circuits.In order to avoid glare to the driver while in motion, illumination of the area at least up to the driver partition is shut off while in motion by an appropriate separate switching mechanism linked with the opening & closing of the exit door.White and Red height marker lights each are fitted at both top side corners of the front and rear end of the bus respectivelySide Indicator , Brake, Reverse & parking light are fitted as per CMVR.


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Side markers are provided on both sides as per bus code/ AIS 008Lights are provided for illuminating exit/entrance door area, the lights illuminates the outside area up when door/doors is/are opened.Fog Lamps: The bus is fitted with fog lamps as prescribed in CMVR.Exterior door lights: Lights are automatically switched off when the door is closed.Electrical fittings are not mounted on both front and rear bumpers.A suitable light is provided in the engine compartment for ease of maintenance/ emergency repairing

4.2.3 Options:

Main options available on request:

GSM / GPS module for off-board diagnostics and self-localisation;Engine compartment fire fighting system;A gas leakage detection alarming system to alert the driver to take appropriate action in the event of leakage of CNG in the system like engine area & cylinders package;Air courtain for both the front and central doors with an automatic switch 'on' & 'off' for operation of air curtains with opening and closing of the service doors respectively. The automatic switch 'on' & 'off' of the air curtain is linked with the service door on which it is fitted. The air curtains operates only with the operation of H VAC system.

5 VALIDATION PROCEDURES

5.1 Instrumental tests

Validation checks of installation of all aggregates on the vehicle: when the vehicle is fully built, and before starting any other vehicle function tests, it should be performed the validation checks of the installation of all aggregates as engine, automatic transmission, independent front suspension, rear axle, AC system, electronic equipment. This verification shall be performed in accordance with a specification that the supplier of each aggregates shall define in advance and share with the vehicle manufacturer. Verification shall include at least the following activities:

• Visual inspection for proper performance of installation and accessibility to the all aggregates in accordance with the “Mounting Instructions” mentioned above.


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• Document review and check of compliance of all aggregates and their accessories to the “Regulatory approval” (if any).

5.2 Functional Tests

Functional tests of the installation of the all aggregates on the vehicle. This test consists of mileage on track and road for at least 5.000 km in a variety of driving conditions and vehicle load according a specific procedure that the vehicle manufacturer must define in advance and share with the suppliers of the main aggregates.

6 TECHNICAL DOCUMENTATION TO BE PROVIDED

6.1 Drawings

A complete set of drawings of the project of the bus and the BoM shall be provided in the final release.

6.2 Mounting instructions

A complete set of mounting instruction for production process of the bus shall be provided in the final release.

6.3 User and Maintenance manual

A complete set of user & maintenance manual of the bus shall be provided in the final release.

6.4 Spare parts catalog

A complete set of spare parts catalog of the bus shall be provided in the final release.

7 PRODUCTION DATA

It’s to be considered the Start of Production on June 2013; with a ramp of the volume of production of 300 buses produced by the 1st year, 600 buses by the 2nd year and 1500 buses/year at full capacity.The delivery of the first vehicle is required by August.10th, 2012 in Italy.The delivery of the second vehicle is required by February .8th, 2013.Validation tests on the first bus prototype by November 30th, 2012.

8 WARRANTIES

The bus & all main aggregates shall be provided with a guarantee of at least three years or operation of buses up to 210.000 kms, individually for each bus whichever is later from the date of placement in service after registration.


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9 ATTACHMENTS

ANNEX 1) BMB quality standards applicable to the process of production of the India TOPAZ Bus.ANNEX 2) BMB technical standards applicable to India Bus project.ANNEX 3) Reference list Homologation – Vehicle & Component level ANNEX 4) TS-020 – Vehicle Mission ANNEX 5) Drawing n° D334934 – General layout and overall dimensions of the vehicle.Drawing n° A2195 – Engine compartment layout (ISB5.9 G 230 hp).Drawing n° A2193 – General cross section.Drawing n° A2194 – CNG cylinders arrangement.Drawing n° A2197 – Driver’s working area arrangement.


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ANNEX 1)

Quality Specifications

List of BMB reference procedures applicable to the process of production of the India TOPAZ Bus


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ANNEX 2)

Technical Norms

List of BMB Technical Norms applicable to the process of production of the India TOPAZ Bus


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ANNEX 3)

Reference list Homologation – Vehicle & Component level


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ANNEX 4)


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ANNEX 5)

Drawing n° D334934 – General layout and overall dimensions of the vehicle. (in progress) .


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ANNEX 5 a)-b)-c)-d)

TS 020 – Vehicle Mission.

Drawing n° A2195 – Engine compartment layout (ISB5.9 G 230 hp). (in progress)

Drawing n° A2193 – General cross section. (in progress)

Drawing n° A2194 – CNG cylinders arrangement. (in progress)

Drawing n° A2197 – Driver’s working area arrangement. (in progress)

Ts 001 veihcle en

Design

Transcript of Ts 001 veihcle en