Section 3 in Technical Specifications of HVAC Ordinary Bus

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State of Punjab - Section

Section 3 in Technical Specifications of HVAC Ordinary Bus

3. Engine.

- 3.1 The engine system shall have adequate horse power to obtain desired performance in respect of its adequacy of power, acceleration levels, emission norms, specific fuel consumption etc. The engine should have adequate horse power not only to propel the bus but also to operate efficiently all other auxiliary devices including HVAC system fitted to the bus. The minimum Horse Power of the Engine to propel bus and to directly operate HVAC system should not be less than 160 HP.

3.2Engine should be able to operate efficiently at ambient temperatures of approximately 0 to 50 C, humidity level from 5% to 100% and altitude up to 300 metres on plain areas and maximum up to 3000 metres on the hill areas.

3.3The engine and its accessories shall be easily replaceable. The engine mounting shall be such as to minimize transmission of vibrations to the bus structure. The engine foundation and mounting shall be so located as to facilitate easy accessibility and replacement. Engine design shall be such that it shall not be overheated during normal operating conditions of vehicle. An arrangement for audio-visual signal shall be provided in the event of engine getting overheated excessively. This arrangement shall indicate the temperature at which the signal operates. Similar arrangement for other sub- system of engine with their monitorable indicators be made on the dashboard.

3.4The engine compartment shall be insulated to avoid transmission of heat and noise to saloon area. The passenger and engine compartments shall be separated by bulkhead(s) that shall by incorporation of fire proof material preferably of ceramic fibre of minimum density of 128 Kgs/M3 in its construction, be a firewall. The engine compartment shall include areas where the engine and exhaust systems are housed including the muffler, if mounted above the horizontal shelf. This firewall shall preclude or retard propagation of an engine compartment fire into the passenger compartment. Only necessary opening shall be allowed in the firewall, and these shall be fireproofed. Wiring may pass through the bulkhead only if connectors or other means are provided to prevent to retard fire propagation through the firewall. Engine access panels in the firewall shall be fabricated of fireproof material and secured with fireproof fasteners. These panels, their fasteners and the firewall shall be constructed and reinforced to minimize warping of the panels during a fire that will compromise the integrity of the firewall.

3.5The engine should be suitably designed to operate optimally under peak summer heat and dust. Suitable lighting arrangement with separate switch shall be provided for the engine compartment.

3.6Engine noise and emission levels must confirm to the Central Motor Vehicle Rules, 1989.

3.7For soundproofing and for protection against fire risk in engine compartment, no flammable material or material liable to soak fuel, lubricant or any combustible material shall be used in the engine compartment unless the material is clad by an impermeable fireproof sheet. A partition of heat- resistant material shall be fitted between the engine compartment and any other source of heat.

3.8In case of rear engine vehicle shall have air intake location in a manner as to provide dust free, restriction-free adequate quantity of air so as to avoid any operational problem of the engine.

3.9A mechanism in the engine compartment shall be provided to prevent start of the engine from the driver's seat while maintenance is being carried out near the engine compartment area.

3.10Exhaust gases and waste heat shall be discharged from the rear corner of the driver side. The entire exhaust system shall be adequately shielded to prevent heat damage to any bus component. The exhaust outlet shall be designed to minimize rain or water generated from high-pressure washing system from entering into the exhaust pipe and causing damage to the catalyst.

4.0

(A)HVAC System .

- 4.1 The bus shall have heating, ventilation and air-conditioning system of appropriate size, type and capacity as prescribed under Para 4.9 and as per the operating/environmental conditions given at Para 2.3 and 3.2 for carrying up to 72 passengers. The nominal temperature of 23 to 25 degree centigrade must be achieved in the saloon before boarding of the passengers.

4.2The HVAC bus installed in the bus should allow intake of minimum 10% fresh air.

4.3The bus shall be provided with roof mounted HVAC system driven by main engine comforming to Indian/International standards. The system shall be so mounted to facilitate ease of access for repair and maintenance. Proper care shall be taken for insulating the system for optimum efficiency. Proper AC ducting shall be installed inside saloon for uniform distribution of air conditioned flow. Air-conditioning system shall be CFC free.

4.4The HVAC system must be so designed to work in compatibility with other vehicle systems. The Air-conditioning system shall have large heavy-duty transit compressor and high capacity alternator. A properly sized alternator/charging system shall be selected to support the Air-conditioning system and to improve reliability and efficiency of the system. The system shall be designed to meet any future regulations on refrigerant etc.

4.5Automatic temperature control arrangement shall be provided for HVAC system.

4.6The HVAC system shall be at center of the passenger saloon of the bus and mounted aesthetically at the roof.

4.7The drivers cab shall be fitted with a 24 VDC, 200mm dia. fan mounted at proper height on side structure. The colour of fan shall match the interior decor of the bus. A high output two speed demister shall also be fitted in the driver's cabin to draw fresh air from roof.

4.8The whole bus body shall be fully thermally insulated with flame retardant Polyurethane or glass wool of minimum 40 Kgs/m3 density as per bus code.

4.9The HVAC system installed in the bus shall have minimum capacity as under :-

(i)	Up to 45 seater bus	10 ton capacity
(ii)	From above 45 seater to max 60 seater	12 ton capacity
(iii)	More than above 60 seater	14 ton capacity

4.10The HVAC system installed in the bus shall be of Thermo King, Carrier, Spheros, Haiger, Denso or of any other make approved by STC, Punjab.

4.0

(B)Cooling System.

- Heavy duty radiator and other subsystems of cooling system shall be so designed as to be capable of efficiently dissipating heat from the engine system. Deaeration tank and pressurized radiator cap shall be provided. It shall be easy for filling and level checking of coolant. Replacement/maintenance of radiator and its items be also easily carried out.

5.0Transmission System .- 5.1 Multi speed manual transmission system shall be provided with gross input power, gross input torque and related speed compatible with engine.

6.0Suspension.- 6.1 The bus shall be fitted with leaf suspension (or beveller suspension or air bellow suspension as optional) at both front and rear. However in case of air suspension, the suspension system shall be fitted with shock absorbers, suitable for trouble free operation and jerk free comfortable ride and should be adequately protected from engine/exhaust pipe heat etc. for minimizing ageing effect on the air bellows.

6.2The full air suspension system both at front and rear shall be with stabilizer bar.

7.0Steering.- Hydraulic power assisted recirculation ball type steering shall be provided.

8.0Braking System .- 8.1 The braking system shall be full pneumatic type with fail-safe dual circuit having four-way protection valve, auto slack adjuster, drum brake (front and rear wheels) with asbestos brake lining etc. The friction material shall be non-asbestos type having temperature and wear characteristic suitable for intensive operation. Brake squeal shall be absent under normal conditions of operation. An air compressor which minimizes oil carry over shall be fitted. The braking system shall be fitted with air dryer and oil/ water separator system. The buses shall also be provided with hand operated pneumatic flick valve type parking brakes at rear wheels. The air pressure line shall be treated for corrosion resistance.

8.2In the event of failure of the engine and or loss of air in the system, adequate provision is made for obtaining effectiveness of service brake system and or for deactivating the spring actuated brakes.

8.3The Anti-skid/Anti-lock braking system (ABS) shall be provided.

9.0Wheel and Tyres.- 9.1 The bus shall be fitted with steel radial tyres conforming to AIS-044 Part I with wheel rims of corresponding size conforming to AIS/BISL 10694 (Part-3)-1991 or latest. The bus shall be supplied with 6 sets of tyres (two on front and four on rear wheels) fitted on the bus plus one set as spare Steppney. The tyre shall be fresh from factories and shall not be more than six months old at the time of delivery.

9.2It shall be possible to safely jack up the bus, at kerb weight, with a capacity of at least 10 Ton (as per design of the bus) jack with or without special adapter, when a tyre of dual set is completely flat and the bus is on a level, hard surface, without crawling under any portion of the bus, jacking from a single point shall permit raising the bus sufficiently high to remove and reinstall a wheel and tyre assembly. Jacking pads located on the axle or suspension near the wheels shall permit easy and safe jacking with the flat tyre or dual set on a 150mm high run-up block not wider than a single tyre. The bus shall withstanding such jacking at any one or any combination of wheel location without pemanent deformation or damage. Jacking pads shall be painted safety yellow or orange for ease of identification.

9.3Suitable guards be provided near wheel to prevent damage/for obtaining safety from stones hurled from tyres.

9.4The bus axles or jacking plates shall accommodate the lifting pads of a 4 post hoist system. Jacking plates, if used as hoisting pads, shall be designed to prevent the bus from falling off the hoist. Other pads or the bus structure shall support the bus on jack stands independent of the hoist.

9.5Splash aprons of minimum 6.50 mm thickness composed of rubberized fabric shall be installed behind of wheels as needed to reduce road splash and protect under floor components. The splash aprons shall extend downward to within 100 mm of the road surface at static conditions. Apron width shall be no less than tyre width, except for the front apron, which shall extend across the width of the bus. Splash aprons shall be bolted to the bus under structure. Splash aprons and their attachments shall be inherently weaker than the structure to which they are attached. The flexible portions of the splash aprons shall not be included in the road clearance measurements. Other splash aprons shall be installed where necessary to protect bus equipment.

10.0Axles.- 10.1 Solid beam axle and grease type front bearings and seals of reliable and proven design adequate capacity to take care of maximum Gross Vehicle Weight (GVW) and crush loading expected during life span of the bus.

10.2The bus shall be driven by a single heavy-duty axle at the rear of proven design adequate capacity to take care of maximum GVW and crush loading expected during life span of the bus. Transfer of gear noise to the bus interior shall be minimized. The lubricant drain plug shall be magnetic type, external hex head. If a planetary gear design is employed, the oil level in the planetary gears shall be easily checked through the plug or sight gauge. The drive shaft shall be guarded to prevent it striking the floor of he coach or the ground in the event of a tube or universal joint failure.

11.0Under frame and Structure.- 11.1 The under frame and super structure shall be suitably designed to carry dense crush load of over 72 passengers (assuming an average weight of 68 kg per passenger) including sitting and standees, the super structure using steel tubing, bus tare weight etc. Moreover the structure shall be designed to withstand the transit service condition of operation throughout its service life.

11.2The comprehensive multi-stage anti-rust treatment shall be provided to bus flooring, sides roof, under structure, axle suspension components etc. for resistance corrosion or deterioration from atmospheric conditions and road salts so as to enable them and frame to last for life span of bus whichever is latest. The samples of all material and connections shall withstand a two weeks (336 hours) Self Spray test in accordance with ASTM procedure B 117 with no structural detrimental effect to normally visible surfaces and/no weight loss of over 1%.

11.3The front and rear structure design shall be energy absorption type to reduce impact stresses into under frame/side structures/other areas of the vehicle. The damaged area of the vehicle shall be easily repairable and/or replaceable in the event of major damage.

11.4The entire surface of bus under floor and sides exposed to ground shall be covered with appropriate corrosion prevention and flame retardant paint coating for protection against harmful effects of water, mud etc. and to retard flames, if any. The wheel housings shall be constructed to contain tyre bursts during operation and be flame retardant in case of tyre fire.

11.5MIG welding shall be used for steel structural member's fabrication.

11.6Sufficient clearance and air circulation shall be provided around the tyres, wheels and brakes to preclude over heating when the bus is operating.

11.7All the structural members shall be MIG welded with suitable gussets/brackets of adequate size and thickness be provided on floor, side, front, rear and roof structure to ensure structure rigidity and integrity.

11.8After anti-corrosive treatment, structural members shall be coated with Red Oxide/Zinc Chromate primer and superior quality black paint.

11.9Under floor to sidewalls shall be sealed to prevent dust ingress.

12.0Panelling.- 12.1 The bus exterior side panels shall be fitted with stretched steel sheet at waist level. The exterior front-end, panelling shall be of steels roof, rear and skirt paneling shall be of alumnium. Roof, exterior paneling shall be suitably provided with platforms for movement of technicians for repair and maintenance of roof mounting systems to avoid direct load on roof alumnium panelling. The platform shall be fitted to roof structure with proper reinforcement. All interior paneling shall be Acrylonitrile Butadiene Styrene (ABS) conforming to relevant National or International Standards. Wherever alumnium is joined with steel or with any dissimilar metals together, the involved joints shall be treated with thick layer of approved quality dielectric paint conforming to relevant Indian standards, before assembly. Adequate treatment be also provided to avoid any incidence of galvanic corrosion between dissimilar metals. Panels shall be so mounted as to present smart aesthetic exteriors.

12.2All skirt panels below stretch panel line must be no long than 1500 mm. The said skirt shall be able to withstand the side impact as per the provisions of BIS: 14682-1999 or latest. Similarly the rear end shall be able to withstand the rear impact as per the provisions of B 18: 14812-2000 or latest.

12.3Anti-drumming compound shall be applied on inner side (enclosed surfaces) of entire paneling.

12.4Roof structure shall be thermally insulated with flame retardant polyurethane or glass wool of minimum 40 kgs/m density.

12.5TIG welding for fabrication of aluminium components shall be used.

12.6Rain gutters shall be provided to prevent water flowing from the roof on to the passenger doors, driver's side window; and exterior mirrors. When the bus is decelerated, the gutters shall not drain onto the windshield, or driver's side window, or into the door boarding area. Cross sections of the gutters shall be adequate for proper operation.

12.7Entire front end of the bus shall be sealed to prevent debris accumulation behind the dash and to prevent drive's feet kicking or fouling wiring and other equipments. Front end shall be free of protrusions that are hazardous to passengers standing or walking in front of the bus during rapid acceleration.

12.8Interior panels shall be attached so that there are no exposed unfinished or rough edges or rough surfaces. Panels and fasteners shall not be easily removable by passengers.

13.0Paints.- 13.1 All the structural members of the bus shall be treated for corrosion prevention internally as well as externally and painted wherever required. The polyurethane (PU) painting conforming to 818: 1321-1991 or latest international standards as applicable shall be used for exteriors painting of the bus including interiors. Wherever required Color shade shall match to the shades as per BIS:' 5-1978 or latest.

13.2All exterior surfaces shall be smooth and free of wrinkles and dents. Exterior surface to be painted shall be as required by the paint system supplier, prior to application of paint to assure a proper boner between the basic surface and succession coat of original paint for the service life of the bus. Paint shall be applied smoothly and evenly with the finished surface free of dirt and the following other imperfections :A. Blisters of bubbles appearing in the topcoat film.B. Chips, scratches or gauges of the surface finish.C. Cracks in the paint film.D. Craters where paint failed to cover due to surface contamination. E. Overspray.F. Peeling.G Run or sags from excessive flow and failure to adhere uniformly to the surface.H. Chemical stains and water spots.

14.0Service doors.- 14.1 One service door (To be used as both Entrance and Exit) in minimum 900 mm wide aperture (without flaps) to be fitted at front of the bus or two separate doors (one at front for exit and another at rear for entrance) with minimum 750 mm wide aperture must be as per provisions of the Bus Code. The door system shall be electropneumatically controlled by the driver and/or the conductor with internal and external emergency open controls. In the event of an emergency, it shall be possible to open the door manually from inside the bus by using a force no more than about 10 Kg after actuating and unlocking device. The unlocking devices shall be clearly marked as an emergency device and shall require two distinct actions to actuate. Door, door hinges and locks shall comply with safety requirements as per Indian/International standards. The closing and opening time of the door should be in the range of 4 seconds. There shall be maximum opening area in longitudinally and vertically directions in fully open condition. The door hinges and brackets shall be maintenance free. A pilot lamp on the driver's dashboard shall be provided to warn that the door is `Open' or not fully closed.

14.2The door shall be of double jack knife type and shall be provided with suitable support in the form of grab handles, for boarding/alighting passengers on JK door flaps. Electronic sensors shall be installed at door to retract the door automatically if any obstruction to door occurs during door closing. It must be effective until door is fully closed.

14.3A suitable device to prevent the door from opening as long as the bus is in motion shall be provided.

14.4Service Door operation shall be controlled with the help of push buttons and switch.

14.5All buttons and switches shall be labelled on a panel to the right side of driver.

14.6Access door shall be provided with heavy duty sealing to avoid ingress of dust into the passenger compartment. The upper and lower section of door shall be glassed for no less than 45% of the door opening area of each Section. The glazing material and glass in the door shall be the same as in the side windows.

14.7Door shall be fitted with heavy duty hinges as per bus code.

14.8Door shall be fitted with heavy duty locks with and without lock and key depending upon their use. Striker plate shall be fitted at the closing end of locks.

14.9All the handles shall match to the decor of its fitment location or shall be chrome plated.

14.10Door shall open or close completely in no more than 4 seconds from the time of control actuation and shall be subject to the closing force requirements and the adjustment requirements. The door shall remain in commanded state position even if power is removed or lost. Operation of and power to the passenger door shall be completely controlled by the driver. A control or valve in the driver's compartment shall shut off of the power to, and/or dump the power from, the front door mechanism or both front and rear door mechanism to permit manual operation with the bus shut down.

15.0Guard/Guard rails.- Where seated passengers are likely to be thrown into service door area as a result of heavy braking suitable guard shall be provided. The guard height shall be minimum 800 mm from the floor, and the guard shall extend inward from the wall at least 100 mm more than the centre line of the seating position of the passengers who are prone to. The suitable guardrails shall also be provided on front wheel boxes over suspension system. The guarding shall be as per the provisions of the Bus Code.

16.0Windows.- 16.1 The windows shall be in single piece fixed glass type design. "The toughened glass wherever used in the body shall be 8 mm to 10 mm thickness and shall be light tinted. The window glasses'shall be fitted/pasted aesthetically. The size and shape of the glasses shall enable the passengers to have maximum outside view. The general requirements of window shall be as per the provisions of bus code.

16.2Windows shall have provision of suitable sealing to avoid ingress of dust and water and shall have proper efficient drainage system.

17.0Emergency Exit.- Emergency exits shall be provided in the bus as per the provisions of the Bus Code/CMVR.

18.0Escape hatch.- In addition to emergency exits, at least one escape hatch be fitted in the roof as per the bus code.

19.0Floor.- 19.1 Internal saloon height shall be minimum of 1900 mm.

19.2The flooring design should allow easy cleaning including that sweeping and drainage of water.

19.3The floor shall be fitted with fire retardant marine board of 19 mm thickness conforming to BIS 710-1976 or latest and shall be fire retardant as per BIS 5509-2000 or latest. The said floor shall be coveted with anti-skid type with silicon particles material of minimum 3mm thickness meeting Indian/International standards. Adequate sealing shall be provided in the floor to prevent ingress of dust, gases, water, etc.

20.0Gangways.- The gangway shall be as per the provisions of the Bus Code and would meet the statutory requirements.

21.0Handrails and Handholds.- The Handrails and Handholds shall be provided as per the provision of bus code. The surface of handrails and handholds shall be of colour contrasting and slip-resistant. All handrails shall be of aluminium tubing of 32 mm dia and 3 mm thick. Depending upon the size of the bay (i.e., between two consecutive roof hand rail brackets), minimum 2 to 4 numbers handholds per bay shall be provided so that every standee passenger even during crush load, is able to grab a handhold.

22.0Stanchions.- 22.1 Vertical stanchions shall be so positioned to facilitate access to seats for those standing. The stanchions shall be of 40.0 mm dia and 3.15 mm thick aluminium tubing with surface of colour constrasting and slip resistant.

22.2High visibility bell pushes shall be fitted at a height of 1.2 metres on all alternate stanchions.

23.0Passenger Seats.- 23.1 The passenger seats shall be front facing, comfortable, durable and maintenance free and of `PP-LD' (Polypropylene Low Density) moulded construction meeting the performance requirements of AIS023 and other requirements as per the Bus Code. The PP-LD moulded seat shall be appropriately fitted with flame retardant Polyurethane (PU) seat cushion of 25 mm thickness upholstering in waterproof expanded vinyl coated fabric to match the seat and interior decor conforming to relevant BIS/International standards. The seat cushion shall be provided with vent holes appropriately. Similarly, PP-I D moulded seat backrest shall be appropriately fitted with flame retardant Polyurethane (PU) backrest cushion of 10 mm thickness upholstered in waterproof expanded vinyl coated fabric. Suitable integral type seat hand grab rails shall be provided one on top of backrest and one at the back of backrest for seated passengers. However, the seat pitch shall be maintained at 686 mm (minimum).

23.2The seats shall be covered with water and dust proof flame retardant upholstery. The construction of the seat shall be of easy replaceable and repairable.

24.0Seat Belts and its anchorages.- Seat belts shall be provided for the seats as per the provisions of CMVR and the Bus Code. In case of six seats provided at the rear end of the bus, the two seats in the centre (facing the gangway) be provided with seat belts. Seat belts and its anchorages shall conform to the requirements of AIS 005 and AIS 015.

25.0Driver's work area.- A driver door of not less than 1600 mm height and 650 mm wide shall be provided for entry and exit to driver's work area. Proper handholds and steps shall be provided for easy access to driver's cabin. All other requirements of driver's work area shall be as per the provisions of the Bus Code. The driver's work area shall have a light to provide general illumination and it shall illuminate the half of the steering wheel nearest the driver. Brake Pedal Angle shall be determined from a horizontal plane regardless of the slope of the cab floor. The brake pedal shall be positioned at an angle of 27-35 degrees at the point of initiation of contact and extend downward to an angle of 20-28 degrees at full depression. Brake pedal shall be 254-305 mm long and 75-100 mm wide. The driver's 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 and glass as used in the other side window glasses. The driver cab shall be fitted with a 24 V DC; 200 mm dia fan mounted at proper height on side structure. The color of fan shall match the interior decor of the bus.

25.1Driver's seat : Driver's seat shall meet the requirements of AIS 023.

25.2Driver partition : Driver partition shall be provided as per the Bus Code.

25.3A barrier of bulkhead between the driver and the front passenger seat shall be provided. The barrier shall minimize the glare and reflection in the windscreen directly. In front of the barrier from interior light during night operation.

26.0Dashboard Instrumentation and Control System.- 26.1 The bus shall have dashboard with full instrumentation panel containing meters and gauges to indicate important parameters like air pressure, coolant temperature, battery charging current, fuel level, side indicators, head lights, hand brakes, engine oil pressure etc. In addition warning lights for low engine oil pressure, high cooling system temperature and low coolant level, low pressure and high temperature of transmission oil, low fuel level, low air pressure and battery weak shall be provided at the driver's dash board. All the dashboard controls and instrumentation system shall be as per the bus code.

26.2Rear-view Mirrors-Interior and Exterior. - Rear-view mirrors shall be provided on both sides of the bus to enable driver to have clear side/rear views. One interior rear-view mirror shall also be fitted for viewing saloon area by the driver. Installation and performance requirements of the rear-view mirrors shall conform to AIS 001 and AIS 002. The exterior rear-view minors shall also enable the driver to view the object near the bumper area.

26.3Sun Visor. - 26.3.1 Adjustable sun visors shall be provided for the windshield and the driver's side window Visors shall be shaped to minimize light leakage between the visors and windshield. Visors adjustment shall be made easily by hand with positive locking and releasing devices and shall not be subject to damage by over-tightening. Sun visor construction and material shall be strong enough to resist breakage during adjustment. Visors may be transparent but shall not allow visible light transmittance in excess of 10%. Visors where deployed shall be effective in the driver's field of views at angles more than 50 above horizontal.

26.3.2An electric horn conforming to BIS: 1884-1993 or latest and installation requirements conforming to AIS 014 shall be fitted in the bus and further conforming to the provisions of CMVR. No pressure horn will be fitted.

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State of Punjab - Section

Section 3 in Technical Specifications of HVAC Ordinary Bus

3. Engine.