1

INSTITUTE OF URBAN TRANSPORT (INDIA)

Session 4: Maintenance and Management

Training Workshop on City Bus Planning ,13 16 Oct 2014

Structure of Presentation
Division, Hierarchy, Organisation Structure
Function
Maintenance and Management
Manpower Planning
Measures to improve Fuel Efficiency
Measurement Parameters
Management Information System
Environmental Consideration

Depot Division, Hierarchy and Organisation Structure

Main wings of Depot

Traffic/operational Wing

Technical/Mechanical Wing

General/Administrative Wing

DTC Management Hierarchy

CMD

CGM (F)

CGM
(O&T)

Regional Managers (06

RMs)

Depot Managers
(46 Depots)

CGM (Tr.&P)

CGM (Pub.)

CGM (A)

CVO

Depot Level Hierarchy in DTC

DEPOT
MANAGER

Dy. Mgr./Mgr. (Tr. / Op.)

Tr. Sup.
T.I.
A.T.I.
Drivers
Conductors

Mgr. (M) Maintenance Depot

Foreman
A/Foreman
Mechanics
Skilled Workers
Un Skilled Workers

Dy. Mgr. (P/A)

Medical Officer

O.S./Acctt.
A.I.
Sr. Clerk
Jr. Clerk / Cashier/
TTC

Pharmacist
Dresser

Depot Organization Structure in BMTC

Institutional and Organizational setup in a Privately operated

Depot

Function

10

Functioning of Traffic Department in Depot

1.
a)
b)
c)
d)

e)

2.
a)
b)

c)
d)

3.
a)
b)
c)

Schedule section
Allocation of Drivers & Conductors
Preparing of fleet
Preparing of memos
Attendance of Drivers & Conductors
Earning statement
Control Room
Attendance of Drivers & Conductors
Cleanliness of buses
Recording of all messages
Liasoning with officers
Court & Accident cell
Dealing and recording all types of Accidents
Payment of Road taxes
Updating the data of license of Drivers & Conductors

11

Functioning of Mechanical Wing in Depot

1.

Maintenance of Buses

a)

Preventive Maintenance

b)

Dockings

2.

Stores/Inventory management

a)

Raising indents to central work shop & central stores for the requirement
of various spares/assembly.

b)

The issuing spares/assemblies to work shop staff as per the requirement

with proper documentation

3.

Assistant Incharge (workshop) office

a) All the clerical work related to work shop is being done through this section

12

Functioning of Admn./Acctts. Department in the Depot

1.

General Office

2.

Ticket Section

3.

Cash Section

4.

Industrial Relations

5.

Provision of Medical officer: As per factories Act it is statutory on

the part of management to provide immediate medical assistant for
any emergent need.

13

Maintenance and Management

14

Fleet Maintenance

At Depot Level
At depots, preventive maintenance schedules, attention of running
repairs, unit changes & fitness work and Coach work & Upkeep

At Central Workshop level

At workshops - major overhaul of units & buses

At Tyre Retreading shops - retreading and repair of tyres

15

Objectives of Fleet Maintenance

Preventive maintenance to vehicles for roadworthy fleet with good

appearance, upkeep & comfort

Punctuality
Zero Accident
Zero Breakdown & Zero Cancellation
Minimum operational cost to earn profits
Sustainability & growth of organization
Lowest emission levels

16

INDICATORS OF EFFECTIVE FLEET MAINTENANCE

S.no Parameter
Target
1

HSD KMPL (Total)

3.50

Breakdown Rate

0.07

% Mech. Cancelation

0.11

Total Tyre Life

1.84

% New Tyre Scrap

0.00

New Tyre Mileage

70000

RT Factor

3.00

Lub KMPL

1189

Spring Consumption

10

Fleet Utilization

50
95/92

17

Maintenance Policies

STUs should establish very precise Preventive Maintenance Policies

which are flexible in design and easy in implementation.

The Maintenance Policies should be primarily designed based on the

manufacturers recommendations, product duty cycles and are

environment friendly.

The vehicles undergo preventive maintenance schedules at Depots

with the material support from Zonal Stores, aggregates support from
Zonal Workshops and Tyres from Tyre Retreading shops

18

Basic Requirements for Effective Fleet Maintenance

Tools, Plants
& Machinery
Manpower

Unit
aggregates

to Provide a Safe,
Clean, Comfortable,
Environment friendly,
Reliable and
Cost effective Bus
for Operation
Infrastructure
Yard, Sheds,
Maintenance Pits,
Illumination

Spare Parts
Fuel & Lub

Computers &
Software

19

STANDARD DEPOT LAY OUT

1. Security
2. Vehicle dispatch
3. Gentset
4. Cycle stand
5. Oil Bunk
6. DC(oils)
7. Washing Plant
8. Toilets
9. Smithy
10. Electrical
11. Painter & Trimmer
12. Tyres
13. DC(T&P)
14. Dining hall
15. Stores
16. MF/AMF room
17. Maintenance Pits
18. Dockings floor

20

Parking of Buses in a Depot

21

MAINTENANCE GARAGE

22

OVERHAULING ACTIVITIES AT CENTRAL WORKSHOPS

The main functions of Workshops are :

Complete Overhauling of Buses.

Miscellaneous repairs of Buses.

Reconditioning of aggregates like Engine, Gear box, Front Axle,

Rear Axle, FIP etc, and supply to depots on counter exchange
basis.

23

Tyre Retreading Process

24

Preventive Maintenance Schedules adopted at Depots

S.
No

Periodicity of Maintenance
City Operations

Daily

Weekly

9,000 Kms for all

12,000 kms for New

27,000 Kms for all

36,000 kms for New

Initially after 2 yrs

of commissioning
& annually thereafter

25

Oil, Filter & Coolant changes

Description of Lubricant

LEYLAND

TATA

Engine Oil Long Life CH4

36,000 for Dist

24,000 for City

36,000
(18,000 for
Cummins)

Engine oil other than CH4

15,000/ 16,000

18,000

Gear Box oil Ordinary

32,000

18,000

Gear Box oil Extra Long life

40,000

72,000

Differential oil Ordinary

32,000

18,000

Differential oil Extra long life

48,000

72,000

P.Steering oil & Filter

80,000

80,000

Clutch Kits & Clutch Fluid

40,000

72,000

Coolant

75,000

3.00 lakhs
(or) 2Yrs

Contd..

26

Filter Changes

Description of Filter

LEYALND

TATA

20,000

27,000

30,000 &
20,000 for BS-II

36,000 &
18,000 for BS-II

25,000 BS-II

18,000 TC

Fuel Strainers (Baby filters)

50,000

clean at 9,000

Dry Air Filter element Primary

72,000

72,000

2,16,000

2,16,000

Fuel Filter Felt

Fuel Filter Paper
Spinon Fuel filters

Dry Air Filter element Secondary

27

Programming of Preventive Maintenance Schedules at

Depots
The advance planning of vehicles for various preventive maintenance

activities is obtained through computer software called Vehicle

Maintenance System.

The due dates, done dates and coverage of Km etc for all types of

maintenance activities are generated by Vehicle Maintenance System

28

Daily Maintenance

Daily Maintenance is carried out in three shifts.

All the vehicles after completion of the scheduled operation undergo Daily

Maintenance.
Sweeping, Cleaning & Washing of buses, Arresting leakages of water, fuel, oils,

replenishing the levels, tightening of all bolts and nuts, Checking of road springs
& their mountings, Rectification of defects pointed out by Drivers, Inspection of
Tyres and minor coach works are taken up in Daily maintenance.
The works allotted & works attended daily are recorded by the Shift Incharge

Supervisor duly obtaining the Signatures of the concerned.

29

Vehicle Back History Register

Date

Complaints on the
condition of vehicle
As per
logsheet

As per
Tyre Mech.
Observation

Failures

Remarks
Signature
of the
of AE/ DM
Supervisor
who supervised
the repairs/
maintenance

It is important register in maintenance management.

Gives complete picture of the health of the vehicles.
The repetitive nature of complaints depicts the quality of scheduled
maintenance at the depot.
The vehicle defects shall be thoroughly reviewed by the docking maintenance
incharge before docking the vehicle and ensure that root cause for the defect
is totally eliminated during docking maintenance.

30

Weekly Maintenance

Every vehicle undergoes Weekly Maintenance once in a week (Excluding those

undergone docking) for about 2-3 hours

In addition to all the activities of daily, the following works are taken up in weekly
Complete washing
Lubricating all grease points
Cleaning of Breathers
Air Cleaner maintenance
Battery Maintenance
Tyres rotation
Steering & Brake test

31

Dockings
Docking Maintenance is carried out based on the prescribed mileage.

The vehicle is docked for 8 hrs in General shift.

One senior most Supervisor is deployed at each depot to look after

docking maintenance.
Two Mechanics & Two assistants for docking-I and Three Mechanics &

3 Assistants for Docking-II are deployed per vehicle in addition to the

Artisans.
All major repair & maintenance works are carried out in Dockings

maintenance.
The vehicles are inspected before docking & after completion to ensure

quality
The workdone along with signature of the concerned are recorded in a

register

32

Important aspects while dockings the vehicles

Take up the vehicle for maintenance at the right time. Avoid

delay/backlog.

Inform the fixed Drivers about docking of vehicles.

Ensure thorough washing before docking.

Synchronize other maintenance activities like FC, Unit changes,

Filter/Oil/Coolant changes, Body attention, Painting etc with dockings
to save manpower & vehicle days

33

Important Coach works Covered during Dockings

Tightening of all Body Ubolts, cabin foundation bolts.
Repairs to damaged body panels, exterior & interior roof panels, parcel

racks, Luggage carrier, ladder & unloader.

Repairs to Stepwell, stanchions, Passenger Assist rails, Driver

partition, flooring, Dashboard, Engine hood, Entrance door & Drivers

door.

Dicky doors, locks and gas springs in Special type vehicles.

Contd..

34

Important Coach works covered during Dockings

Repairs to broken pillars & cross bearers

Attention to Destination frames & boards

Replacement/ repairs to broken seat frames, torn seat cushions &

upholstery
Attention to Seats inclining mechanism, Hand rests, foot rests,

pouches, bottle holders etc in special type vehicles

Attention to Driver Seat and adjusting mechanism

Contd..

35

Important Coach works covered during Dockings

Attention to Antisag bar & out riggers
Replacement of damaged window frames, broken shutter glasses,

windscreen glasses.
Attention to battery box
Arresting water leakages
Exterior/ Interior paint touch up

36

Manpower Planning for Preventive Maintenance at

Depots
Manpower planning is an essential prerequisite in Depot Maintenance
Head Office communicates sanctions for each category of manpower by

working out the requirement based on the average schedules operated

by an unit during the period from July to December.
The requirement of Supervisors and Workers is worked out based on

the slabs in schedules.

The arrived norm based on the slabs is generally adopted for staff

requirement at depots
Filling of vacancies either through direct recruitment or through

promotion is strictly based on sanctions only

37

Manpower planning

38

Manpower Planning
The success of Depot Maintenance management primarily depends on

proper deployment of manpower and effective utilization of their

services.

Highly skilled and experienced men shall be deployed in major

maintenance programmes like dockings and KMPL works.

Senior most supervisor of the Depot next to Maintenance Incharge shall

be assinged to look after of General Shift maintenance.

39

Manpower Requirement on Fleet of 100 Vehicles

Annual intake
Additional
If no
Requirement if
expansion
5% expansion
Of fleet
Of fleet
contemplated
planned

Total
Men
Employed

Assumed
Rate of
attrition

Administration
(105 per bus

150

6%

7.5 (8)

Traffic
(6 per bus)

600

10%

60

30

Workshop
(2.5 per bus)

250

6%

15

12.5 (13)

Total

1000

Category

84

51

40

Requirement of Manpower for Depot Workshop

41

Requirement of Manpower for Workshop in a smaller

depot (25 Buses)

42

Requirement of Manpower in a 100 bus Depot on 90% Outshedding of Buses

43

Manpower deployment for shift maintenance

Deployment of manpower for daily and weekly maintenance shall be

done carefully keeping the number of vehicles to be maintained in each

shift into consideration
The allocation of man power should match the buses to be maintained

in that shift based on bus schedules. Allocation of manpower disproportionate to the number of buses will lead to underutilization of men
and ineffective maintenance
Care shall be taken to ensure adequate manpower during night shifts as

majority of the vehicles undergo daily and weekly maintenance during

this shift.

44

Outsourcing activities at Depots

In order to overcome shortage of manpower, and difficulties in filling of

vacancies, STUs can outsource

certain maintenance activities

like

Cleaning, sweeping & washing of Buses, HSD oil Top-up, Semi-skilled men
as Assistant to Mechanics
vehicles.

etc at Depots for smooth maintenance of

45

Monitoring of the Outsourcing activities at Depots

It is equally important for Supervisors to monitor the deployment of men

by the outsourcing agencies and their quality of work.

It is the responsibility of the Supervisors to ensure proper work

allocation to the outsourced men.

Supervisors shall also ensure the safety of the workers engaged through

outsourcing
The records of attendance, details of work done etc, pertaining to

outsourcing shall be maintained properly by the Supervisor concerned.

46

Measures to improve the fuel efficiency

The economy in fuel consumption can be achieved by improving:

Maintenance practices,

Controlling driving habits,

Introducing modifications in the fuel injection systems,

Improving systems for refueling,

Enforcing proper maintenance of fuel consumption records of each

vehicle.

47

Fuel Management

By adhering to the proper maintenance schedules, considerable

economy in the actual propulsion cost is easily possible.

The cost of fuel and lubricants alone comes to 50% of the propulsion
cost.

If the propulsion cost is 140 paise per km. then the cost of alone fuel
and lubricants comes to the tune of 80 paise per km.

48

Measures to improve Fuel Efficiency

49

Practices adopted in Maintenance

By the Corporation through its own staff.

Through Annual Maintenance Contract.

Blend of own maintenance versus AMC.

Salient Features of Annual Maintenance Contract (AMC) of

Low Floor Buses
Comprehensive AMC for 7.5 lakhs Kms. to be provided by the Vehicle

Manufacturers.
Comprehensive AMC Charges include supply of Consumables, Spares/ Body
Parts etc. for complete Bus.
Only CNG Fuel shall be provided by DTC during AMC Period for Operation of
the Buses.
Bus-wise maintenance on regular basis to ensure 95/92% availability during
AMC period.
In case of failure to give 95/92% availability contractor will be liable for pre
estimated damage of Rs 2000/- per shift per bus. This figure of Rs. 2000/- will
be reviewed every financial year and re-fixed based upon gross earning per
bus per shift during last financial year.
In case of breakdown of bus which have covered 90% of scheduled kms the
bus will be treated as non available.
If the response time is more then 4 hrs for attending breakdown bus fine is
also imposed.
50

51

Tools, Plants & Machinery

Provision of required tools, plants and equipment for smooth maintenance of

vehicles is of highest importance in Depot Maintenance management.

Depot Clerk is the custodian of all Mechanic tools, special tools, plants and

machinery available in the Depot. The T&P Return shall be maintained

properly indicating the locality of each & every item of the Garage.

52

Important T&P required for smooth maintenance

S. Description
No

Expected life
in Years

1 D.G.Set

20

2 Air Compressors

15

3 Car washers

4 Automatic Washing Plant

15

5 Arc Welding M/c

20

6 Gas Welding equipment

7 HP Greasing equipment

10

8 Bucket type Grease Gun

9 Jib Crane

10

10 Trolley Jack

10

11 Bench Vice

12 Bench Grinder

7
Contd..

53

Important T&P required for smooth maintenance

S. Description
No

Expected life
in Years

13 Drilling M/c

10

14 Sewing M/c

10

15 Pop rivet guns

16 Paint Spray gun

10

17 Battery Charger

18 Cell Tester

19 Hydrometer

20 Injector Tester

10

21 Wall gauges

22 Electronic gauges

23 Hand grinding M/c

24 Mechanics work bench

10
Contd..

54

Important T&P required for smooth maintenance

S.No Description

Expected life in Years

25 Hand Platform Trolley

10

26 Bench Arbor Press

10

27 Anvil

10

28 Torque Wrench

29 Swage Block

10

30 Vehicle Stands

10

31 Compressor Tester

10

31 Well Pump

33 Automatic Tyre inflators

34 Ralli-wolf end mill kit
35 Dial gauge with magnetic base
36 Spring Cambering M/c
37 Diamond Glass cutter
38 Smoke Meter

55

Maintenance of Tools, Plants & Equipment's

A separate Log book is maintained for each plant & machinery and the entries

are made in the Log book as and when repairs and maintenance are carried
out.

It is the responsibility of Mechanical Supervisors to ensure preventive

maintenance to the Plants & Equipment at the prescribed intervals

56

Maintenance of Tools, Plants & Equipments

The Mechanical Supervisors ensure periodical calibration of certain T&P items

like Dial gauges, Injector testers, Wall gauges, Torque wrenches etc, as per the
stipulated periodicity.

The worn out and defective T&P are replaced in time so that the work is not

hampered.

Additional requirement of T&P owing to increased number schedules or

introduction of new models are submitted to the Authority concerned for

obtaining the same.

57

Mechanic Tools for TATA Depots

D.E.Flat

Ring

Tubular

Socket

6x7 mm

6 x 7 mm

8 x 9mm

10mm

8x9 mm

10 x 11 mm

10x11 mm

13mm

8x10 mm

12x 13mm

12x13 mm

14mm

9x10 mm

17x19 mm

12x14 mm

17mm

10x11 mm

21 x 23 mm

17x19 mm

19mm

10x13 mm

22 x 24 mm

22 x 24 mm

22mm

12x 14 mm

27 x 32 mm

27 x 32 mm

24mm

14x17 mm

41 x 46 mm

17x19 mm
22 x 24 mm
27 x 32 mm

27mm
3/8

Other Tools
55mm single end Flat
Tommy bar 125mm long
Tommy bar 250mm long
Extension 6
Extension 12"
Cutting Plier 8"
Cutting plier 10
Hammer Ball pane 1/2Kg.
File round smooth 8"
File flat smooth 6"
Feeler Gauge Set
Torque wrench
(4 to 20 m-Kgs)
Circlip Plier 6
Screw Driver 6 & 12
Nose Plier 6

58

Mechanic Tools for LEYLAND Depots

D.E.Flat

Ring

Socket

Other Tools

3/16x1/4

3/16x1/4

x5/16

x5/16

10mm

5/16x3/8

5/16x3/8

11mm

7/16x1/2

7/16x1/2

12mm

9/16 x 5/8

9/16 x 5/8

13mm

11/16x3/4

11/16x3/4

14mm

6 x 7mm

6 x 7mm

17mm

8 x 9mm

8 x 9mm

19mm

10 x 11mm

10 x 11mm

21mm

12 x 13mm

12 x 13mm

22mm

55mm single end Flat wrench

Tommy bar 125mm long
Tommy bar 250mm long
Extension 6
Extension 12"
Cutting Plier 8"
Cutting plier 10
Hammer Ball pane 1/2Kg.
File round smooth 8"
File flat smooth 6"
Feeler Gauge Set

14x 15mm

14x 15mm

24mm

16 x 17mm

16 x 17mm

46mm

18 x 19mm

18 x 19mm

Screw Driver 8 & 12

20 x 21mm

20 x 21mm

Nose Plier 6

22 x 23mm
24 x 27mm

22 x 23mm
24 x 27mm

Mallet
Allen Key set

Torque wrench
(4 to 20 m-Kgs)

Circlip Plier 8

59

Fast moving Mechanic Tools

ASHOK LEYLAND

TATA

DE

Ring

Socket

DE

Ring

Socket

10 x 11

14 x 15

12,13

17 x 19

17 x 19

9, 10

14 x 15

19 x 22

14, 17

13 x 14

13 x 14

13, 14

19 x 22

8x9

19

19 x 22

19 x 22

17, 19

BSF

9 x 10

9 x 10

3/16 X

Feeler Gauge

5/16 X 3/8
Feeler gauge

60

Special tools for Tata vehicles

Check nut spanner on front hub

Check nut spanner on rear hub
Front Hub puller
Rear Hub Puller
Water pump flange puller
Drift for oil seal on Hub (outer)
Steering ball joint puller
Drift for oil seal on hub (inner)
Holders for coupling flange
Drift for removal of Rear hub inner
oil seal
Puller for clutch release bearing

Adopter for checking engine

compression
Puller for spigot bearing in crank
shaft
Puller for C.J. Bearing
Puller for Rear hub Bearing outer
race
Puller for water pump inner bearing
Drift for oil seal in timing case

Spanner for wheel nut

Socket wrench for removal of
Injectors
Piston ring compressor
Strap wrench for Spin-on filters

61

Special tools for Leyland vehicles

Retainer for Liners (for Hino)

Cylinder Head Bolt wrench
(for Hino)
Cylinder liner puller
Injector Extractor
Piston Ring Compressor
Drift King Pin bush bottom
Drift King Pin Bush bottom
Centre bearing Nut Spanner
Puller steering wheel
Spanner set rocket shaft
Spanner spring clamp nut
Clutch alignment tool
Clutch Height setting gauge
(Z-gauge)

Strap wrench for Spin-on

filters
Drop arm puller ZF
Drop arm puller Rane
Drift for Rear hub oil seal
Drift for F.Hub inner bearing
Drift for Bearing outer race
Rear Hub nut spanner
Front Hub nut Spanner
Guide F.Hub inner bearing
Puller Stub axle inner brg

62

FLOAT UNITS
Float aggregates are essential resource inputs for depot

maintenance.

The purpose of providing float aggregates is to make available

important units readily available at the depots at all times so that the
defective units are replaced immediately and the vehicles are put on
road.

Inadequacy/ non-availability of float units affect the Fleet utilization,

punctuality of operations and earning potentiality of a depot.

Over-provisioning of floats leads to excessive inventory lock-up

63

FLOAT UNITS
The requirement of Float aggregates depends on the volume of

operations, lead time of supply and the average life of the aggregates.
The Mechanical Engineering Department, from time to time; decide the

list of float aggregate units to be provided to the depots.

Floats are also provided for Workshops as an in-process inventory for

uninterrupted supply to the depots and maintain optimum service levels.

64

The following formula is adopted in assessing the requirement of floats for a depot.
No.of Float aggregates

=(N/n - C) x t x a (Subject to a minimum of 1)

Where,
N = Operated Kms
n = average life of aggregate in Kms
t = Lead time replenishment in days which is the period that elapses
between the day of removal of defective unit to the day of replacement
being received from workshops or the day of completion of repair in the
depot if such repair is within the permissible repairs of depot.
C = Complete overhauls demand per day
a = Number of units per vehicle

65

Provisioning of Float Units to Depots

MAJOR UNITS

S.No UNIT

NORM

1 Engine

1 for 10,000 KMs.

2 Front Axle

1 for 14,000 KMs.

3 Rear Axle

1 for 14,000 KMs.

4 Gear Box

1 for 8,500 KMs.

5 Steering Box

1 for 10,000 KMs.

6 FIP

1 for 5,000 KMs.

7 Self Starter

1 for 4,000 KMs

8 Alternator

1 for 4,000 KMs.

66

SUB ASSEMBLIES
S.No UNIT

NORM

Injectors (set)

1 for 2,000 KMs.

P. P. Shafts (set)

1 for 6,000 KMs.

Air compressor

1 for 5.000 KMs.

Clutch pressure plate

1 for 5,000 KMs.

(Leyland)/ Springer (Tata)

1 for 5,000 KMs.

Water pump assembly

1 for 5,000 KMs.

Cylinder head assembly

1 for 5,000 KMs.

Radiator

1 for 5,000 KMs.

67

MAJOR SPARES

S.No UNIT

NORM

Front hub

1 for 15,000 KMs.

Rear hub

1 for 15,000 KMs.

Clutch housing

1 for 15,000 KMs.

Air cleaner complete

1 for 5,000 KMs.

Fuel twin filter assembly

1 for 5,000 KMs.

Feed pump

1 for 5,000 KMs.

Fly wheel ring gear

1 for 10,000 KMs.

Unloader valve

1 for 3,000 KMs.

Set (4) of slack adjusters

1 for 3,000 KMs.

10

Set (4) of spring brake chambers

1 for 5,000 KMs.

11

Hand brake valve

1 for 10,000 KMs.

12

A. C. Head

1 for 5,000 KMs.

68

MAJOR SPARES
S.No UNIT

NORM

13

Air tank

1 for 10,000 KMs.

14

Clutch disc

1 for 5.000 KMs.

15

U. J. Cross

1 for 6,000 KMs.

16

Set of brake drums front (2 off)

1 for 5,000 KMs.

17

Set of brake drums rear (2 off)

1 for 5,000 KMs.

18

Set of spring brackets front (2 off)

1 for 5,000 KMs.

19

Set of spring brackets rear (2 off)

1 for 5,000 KMs.

20

Axle shafts 2 off

1 for 5,000 KMs.

21

H. S. D. Oil Tank

1 for 6,000 KMs.

22

Wiper Machine

1 for 5,000 KMs.

23

Batteries

10% of the batteries

24

Hydraulic jacks

1 for 2,000 KMs.

69

MAJOR SPARES

S.No UNIT

NORM

13

Air tank

1 for 10,000 KMs.

14

Clutch disc

1 for 5.000 KMs.

15

U. J. Cross

1 for 6,000 KMs.

16

Set of brake drums front (2 off)

1 for 5,000 KMs.

17

Set of brake drums rear (2 off)

1 for 5,000 KMs.

18

Set of spring brackets front (2 off)

1 for 5,000 KMs.

19

Set of spring brackets rear (2 off)

1 for 5,000 KMs.

20

Axle shafts 2 off

1 for 5,000 KMs.

21

H. S. D. Oil Tank

1 for 6,000 KMs.

22

Wiper Machine

1 for 5,000 KMs.

23

Batteries

10% of the batteries

24

Hydraulic jacks

1 for 2,000 KMs.

70

Provision of Spare Vehicles to Depots

Norm for Provision of Spare Buses

Spare vehicles are provided to the Depots to

meet the requirements for docking the vehicles

for preventive maintenance (dockings), FC
attention, Complete overhauls, Sundry repairs,
Units replacement etc,.

Fleet Held

Norm

Upto 50

8%

51 to 80

7%

81 & above

6%

71

Physical Inspection of Buses by Depot Manager &

Maintenance Incharge
The Depot Manager shall inspect atleast 30 vehicles (1/3rd Fleet)

every month covering 15 vehicles undergone weekly maintenance,

10 vehicles undergone docking-I and 5 vehicles undergone docking-II
maintenance.

This is highly essential to ensure effective execution of preventive

maintenance schedules

72

Measurement Parameters

73

Check-list for inspection of vehicles

S.No System

Item

Engine

Air cleaner maintenance

,,

A/c Suction hose

,,

Engine mounting

,,

Engine oil leakages

Fuel

HSD tank cap seals

,,

Fuel pipe clamping

,,

Fuel leakages

Cooling

Radiator Cap

,,

Coolant concentration

10

,,

Radiator mountings

Contd..

74

Check-list for inspection of vehicles

S.No System

Item

Steering

,,

ATF oil leakages

,,

King pin lubrication

Susp.

,,

Spring side clamps/ ferrules

,,

Welded side clamps

,,

Spring brackets/ shackles

,,

Air suspension mounting bolts

Tightness

,,

Condition of rubber bushes

in Air suspension

Tie-rod/ drag link end play

Broken spring leaves

Contd..

75

Check-list for inspection of vehicles

S.No System

Item

Transmission

Clutch free play

,,

Gear lever play

,,

Gear Box oil leakage

,,

Loose CJ check nuts

,,

CJ bearings condition

,,

UJ Crosses condition

,,

Sleeve yokes condition

,,

CJ rubber beds condition

,,

Slip joint Rubber boot

10

,,

PP shafts alignment

11

,,

Missing grease nipples

12

,,

Chassis greasing

13

,,

Differential oil leakage

14

,,

Cleanliness of breathers

76

Check-list for inspection of vehicles

S.No System

Item

Brakes

Air tank condensate

,,

Brake pipe clamps

,,

Air leakage

,,

Air Dryer working

,,

Hand brake condition

,,

Brake dust covers

Tyres

Wheel alignment

,,

Matching of duals

,,

Less than 2mm NSD tyres

Contd..

77

Check-list for inspection of vehicles

S.No System

Item

Electrical

,,

Head Lights

,,

Signal Lights

,,

Self condition

,,

Saloon Illumination

Body

,,

Body damages

,,

Painting

,,

Seat Mounting

10

,,

Seat Upholstery

11

,,

Inclining mechanism

12

,,

Shutter glasses

13

,,

Doors

14

,,

Window Shutter Knobs

15

,,

Tightness of body U bolts

16

,,

Under chassis cleanliness

Battery Maintenance

Exterior/ Interior cleanliness

78

Checklist for Body condition

Code

Item Description

Remarks

EXT-1

Body Panels

Dents, Scratches, Damages

EXT-2

Front/ Rear Bumpers

Broken/missing

EXT-3

Front Grill

Damages/ missing

EXT-4

Front Cowls

Damages

EXT-5

Corner Domes

Dents

EXT-6

Passenger Doors

Damages/ missing

EXT-7

Drivers Door

Damages/ locks

EXT-8

Ladder

Damages/ missing

EXT-9

Rear Luggage Booth (Dicky)

Damages/ locks

EXT-10 Exterior Paint

EXT-11 Roof Leakage

Faded

DEST-1 Destination Board Frame

DEST-2 Destination Lettering/Paint

Size and condition

DEST-3 Destination Board lighting

DEST-4 LED Destination

Visibility

Area of Leakage
Faded
Condition

79

Checklist for Body condition

Code
INT-1

Item Description
Stepwell

Remarks
Damages

INT-2

Flooring

Condition

INT-3

Stanchions

Broken/missing/loose

INT-4

Parcel Rack

Broken/loose

INT-5

Grab rails/ Assist rails

Broken/loose

INT-6

Cabin Partition door

Condition

INT-7

Interior Roof/ side panel Fabric

Condition

INT-8

Interior painting

Faded

INT-9

Saloon Cleanliness

GLS-1

Window Glasses

Dirt & cobwebs

Missing/ Broken

GLS-2

Terene felt/Flock channel Rubber

Worn out/ missing

GLS-3

Window shutter knobs

Missing/loose

GLS-4

Windscreen Glasses

Broken

GLS-5

Top-fixed glasses

Broken/missing

GLS-6

Windows leakage

Condition of Rubber flap

80

Checklist for Body condition

Code

Remarks

SEAT-1

Item Description
Seat Frames

SEAT-2

Seat Cushions

Hard/missing/damaged

SEAT-3

Seat rexine/fabric

Torn

SEAT-4

Back rests

Missing/loose

SEAT-5

Reclining mechanism

Condition

SEAT-6

Arm Rests

Broken/missing/loose

SEAT-7

Head Rest Covers

Missing/dirty

SEAT-8

Bottle Holders

Damged/missing

SEAT-9

Magazine Pouches

Damaged

SEAT-10 Foot Rests

Bonnet
CAB-1

Loose/broken

Damaged
Damaged

CAB-2

Dash Board

Damaged

CAB-3

Vision Mirrors

Damaged

CAB-4

Cabin Cleanliness

Dirty

81

Checklist for Body condition

Code

Item Description

Remarks

LHT-1

Interior Lightining

Condition

LHT-2

Head Lights

Condition

LHT-3

Tail lights/ signal indicators

Condition

SPL-1

Speakers

Condition

SPL-2

TV/Audio System

Condition

SPL-3

Cell phone chargers

Condition

STR-1

Body U Bolts

Loose/missing

STR-2

Ballata Packing

Loose/missing

STR-3

Cabin Foundation

Loose

STR-4

Antisag Bar

Loose

STR-5

Out Riggers

Loose

STR-6

Battery Box

Condtion

82

Important Registers maintained in Preventive Maintenance

Management
Daily Report Register
Vehicle Back History
Daily Maintenance

Weekly Maintenance
Dockings work done
Preventive Maintenance Master register
Unit changes register
Register for Inspection of vehicles
FC Register
Breakdowns
Cancellation of Kms

83

Environmental Concerns

84

Environmental Concerns
Sophisticated Electronic Smoke Meters should be provided to Depots to
check the smoke emission levels of buses at regular intervals.

With a commitment towards mitigation of GHG emissions and reduction of

smoke levels, STUs can start using Biofuels and Compressed Natural Gas
on large scale.

Many STUs has started inducting CNG and Bio Fuel operated vehicles in
their fleet. DTC is the best example where total fleet is switched over to
CNG propelled buses and has become largest CNG bus operator in the
world.

85

Salient Features of Low Floor CNG Buses

Rear mouBarrier Free Access & Environmental Friendly Full Forward

Control Non-AC Low Floor CNG City Bus.

nted CNG Propelled Bharat Stage-III and IV (Euro-III and IV) Compliant

230 Horsepower Engine.

Roof Mounted CNG Cylinders of adequate capacity for daily operation of

over 300 Kms. per filling.

Full Air Suspension System Both at Front & Rear wheels.
Automatic Transmission System with Retarder.`lower near-side Entrance

& Exit Doors by 60mm minimum.

Provision of Wrap-around type Ramp for Wheelchair Disabled Persons.
Alpha Numeric Dual Display Technology coloured LED Based Electronic

Route Display System for Front, Side & Rear Destination Boards and
inside Display Board.
86

87

Management Information System (MIS)

88

Management information System (MIS)

Bus operators must develop their own MIS for Maintenance

Management.
Purpose : To ensure, safety of bus and roadworthy whenever it
is carrying passengers.
It is applicable to all bus operators who operate a commercial
or a local bus service and persons who are accountable for the
maintenance and repair of buses.
It may assist a bus operator to meet its obligations under the
Bus Safety Rules and associated regulations.
Requirements :
accountabilities and authorities
competence
maintenance
inspections
defect reporting and clearance
records.

89

Thank You

Office Address
1st Floor, Anand Vihar Metro
Station Building,
(Entry adjacent to Gate No 1)
Delhi - 110 092.
Tel.: (91) 11 66578700-09,
Fax.: (91) 11 66578733
www.iutindia.org

Training room (1) with U shape seating arrangement

IUT Member library with reading tables

Training room (2) with group seating arrangement IUT administration section