Best Practices in

Maintenance Management

Fleet Health is secret of our Strength

Fleet Maintenance in APSRTC
1st TIER
 At depots, preventive maintenance
schedules, attention of running repairs,
unit changes & fitness work and Coach
work & Upkeep
2nd TIER
 At workshops - major overhaul of units
& buses
 At Tyre Retreading shops - retreading
and repair of tyres
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
 PARAMETER 2010-11 2011-12 Upto
Target Jan’12
1 HSD KMPL (Total) 5.17 5.30 5.13
HSD KMPL
5.26 5.40 5.26
(Excl.Spl type)
2 Breakdown Rate 0.10 0.07 0.08
3 % Mech. Cancelation 0.23 0.11 0.19
4 Total Tyre Life 1.68 1.84 1.70
5 % New Tyre Scrap 2.37 1.30 3.17
6 New Tyre Mileage 62897 -- 67282
7 RT Factor 2.70 -- 2.58
8 Lub KMPL 1117 1189 1174
9 Spring Consumption 78 50 55
10 Fleet Utilization 99.45 99.60 95.40
 APSRTC has established very precise
Preventive Maintenance Policies which are
flexible in design and rigid in
implementation.
 The Maintenance Policies are primarily
designed based on the manufacturers’
recommendations, product duty cycles and
application environment.
 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
 Basic Requirements for
Effective Fleet Maintenance

Tools, Plants
& Machinery

Spare Parts
Manpower Fuel & Lub
to Provide a Safe,
Clean, Comfortable,
Environment friendly,
Reliable and
Cost effective Bus
Unit for Operation Computers &
aggregates Software
Infrastructure –
Yard, Sheds,
Maintenance Pits,
Illumination
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.Sch-III/IV floor
7
Delegation of various responsibilities in a Depot Garage
Function
Security of Premises, Property &
assets
Indenting, Receipts, Issues &
Accountal of HSD Oil & Lubricants
Tools, Plants & Equipment
Tyres indenting, Receipt, issues &
Accountal
Stores & Inventory
Shift Maintenance
General Shift
Maintenance of records,
documentation & correspondence
Custodian/ Incharge
Security SI/Head Guard &
Security Guards in three shifts
Depot Clerk &
Asst.Depot Clerk (Oils)
Depot Clerk/
Asst.Depot Clerk (T&P)
Asst. Depot Clerk (Tyres)
Stores Supervisor &
Asst.Depot Clerk (Stores)
Superintendent(Mech)/
Dy.Supdt (M)/Leading Hand
Superintendent (M)/ Dy.Supdt(M)
Asst.Depot Clerk (Gen)
HSD OIL DISPENSING STATION & WASHING PLANT

9
SCHEDULE-I/II MAINTENANCE GARAGE

13
PITS FOR VEHICLE INSPECTION & MAINTENANCE

14
TYPICAL SCHEDULE-III/IV MAINTENANCE GARAGE

17
 OVERHAULING ACTIVITIES AT
WORKSHOPS
There are 7 workshops situated at Uppal,
Karimnagar, Vijayawada, Vizianagaram,
Kadapa, Nellore and Tirupathi
The main functions of Workshops are :
i) Complete Overhauling of Buses.
ii) Sundry repairs of Buses.
iii) Reconditioning of aggregates like
Engine, Gear box, Front Axle,
Rear Axle, FIP etc, and supply to
depots on counter exchange basis.
21
Zonal workshops - Uppal

22
Zonal workshops – Engine Section

Zonal workshops – Body Section

23
Tyre Retreading Shop

24
Tyre Retreading Process

25
 Preventive Maintenance Schedules
adopted at Depots
S. Maintenance Periodicity of Maintenance
No Schedule District Operation City Operations
1 Sch-I Daily Daily
2 Sch-II Weekly Weekly
3 Sch-III 12,000 Kms for Ord 9,000 Kms for all
15,000 kms for New 12,000 kms for New
& special type
4 Sch-IV 36,000 Kms for Ord 27,000 Kms for all
45,000 kms for New 36,000 kms for New
& special type
5 F.C. Initially after 2 yrs Initially after 2 yrs
Attention of commissioning of commissioning
& annually thereafter & annually thereafter
 Oil, Filter & Coolant changes
Description of Lubricant LEYLAND TATA
36,000
36,000 for Dist
Engine Oil Long Life CH4 (18,000 for
24,000 for City
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
3.00 lakhs
Coolant 75,000
(or) 2Yrs
Contd..
 Filter Changes
Description of Filter LEYALND TATA
Fuel Filter Felt 20,000 27,000
30,000 & 36,000 &
Fuel Filter Paper
20,000 for BS-II 18,000 for BS-II
Spinon Fuel filters 25,000 BS-II 18,000 TC
Fuel Strainers (Baby filters) 50,000 clean at 9,000
Dry Air Filter element
72,000 72,000
Primary
Dry Air Filter element
2,16,000 2,16,000
Secondary
• In addition to the above certain
periodical works like Refurbishing of
Special type vehicles, Chemical washing
of Seats are also incorporated in the
Preventive maintenance programmes

29
 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”
(VEMAS).
• The due dates, done dates and coverage
of Kms etc for all types of maintenance
activities are generated by VEMAS

30
 A typical VEMAS based report
( FOR DISTRICT DEPOTS )
SCHEDULE II/III/IV DUE STATEMENT F Date: 25-10-2009 PAGE : 1
Circular No. 23/94-MED Dt. 23-07-1994 DEPOT : ONGOLE
===================================================================================================================
VEHICLE LAST LAST KMS KMS KMS FC HSD LUB
SL . NO ENG. VEH. CH-3 SCH III SCH IV SINCE SINCE SINCE ENG. FIP INJ. DUE KMPL KMPL
NO . TYPE TYPE GRP. DATE DATE III IV HGC KMS KMS KMS DATE
====================================================================================================================

ESCHEDULE - IV VEHICLES : F

1. 28Z4606 K HT A 02/10/09 04/08/09 14905 56259 168640 168270 168270 168270 27/01/11 4.73 0

2. 10Z6953 H OR D 18/09/09 17/06/09 11080 36157 140598 327929 30330 30330 30/03/10 5.39 0

3. 11Z1276 J OR B 30/09/09 04/08/09 9918 39030 166512 35016 314366 59630 01/01/10 5.95 0

4. 28Z5069 E HT C 08/10/09 12/08/09 8816 46468 110828 110828 110828 110828 11/05/11 4.93 0

5. 10Z7444 H OR C 24/09/09 26/06/09 8038 37118 149085 322597 306526 52133 12/10/10 5.39 0

6. 28Z2139 K HT B 14/10/09 18/08/09 6786 44172 340465 517491 517491 517491 14/09/10 5.13 15660

ESCHEDULE - III VEHICLES : F

1. 28Z3999 K HT D 22/09/09 22/09/09 17979 17979 215460 215460 215460 215460 03/10/10 4.90 12985

2. 28Z5406 V GD C 22/08/09 22/08/09 16849 16849 37623 37623 37623 37623 27/06/11 2.97 0

3. 28Z2811 K SL D 02/10/09 06/09/09 16470 34438 285570 378820 100886 175626 30/01/10 5.47 0

4. 28Z1447 V GD 0 30/09/09 30/09/09 15460 15460 594300 594300 594300 594300 21/04/10 2.94 16888

5. 28Z2717 K SL B 03/10/09 05/09/09 15020 32152 274849 344637 344637 344637 16/01/10 5.65 16520

6. 28Z1439 V GD 0 30/09/09 30/09/09 14956 14956 596276 596276 596276 596276 21/04/10 3.05 4985
 ( FOR DISTRICT DEPOTS )
SCHEDULE II/III/IV DUE STATEMENT Date: 25-10-2009 PAGE : 2
Circular No. 23/94-MED Dt. 23-07-1994 DEPOT : ONGOLE
==================================================================================================================
VEHICLE LAST LAST KMS DAYS KMS FC HSD LUB
SL . NO ENG. VEH. CH-3 SCH III SCH II SINCE SINCE SINCE ENG. FIP INJ. DUE KMPL KMPL
NO . TYPE TYPE GRP. DATE DATE III II HGC KMS KMS KMS DATE
==================================================================================================================

ESCHEDULE - II VEHICLES : F

* 1. 28Z5406 V GD 22/08/09 22/08/09 16849 64 37623 37623 37623 37623 27/06/11 2.97 0

* 2. 28Z1447 V GD 30/09/09 30/09/09 15460 25 594300 594300 594300 594300 21/04/10 2.94 16888

* 3. 28Z1439 V GD 30/09/09 30/09/09 14956 25 596276 596276 596276 596276 21/04/10 3.05 4985

* 4. 28Z4606 K HT 02/10/09 20/10/09 14905 5 168640 168270 168270 168270 27/01/11 4.73 0

* 5. 10Z6693 H OR 01/09/09 16/10/09 14630 9 162163 261372 262904 718572 20/11/09 5.89 0

* 6. 11Z844 J OR 15/09/09 18/10/09 13630 7 994428 10266 386861 30414 19/08/10 5.61 0

7. 28Z0112 V GD 06/10/09 06/10/09 12410 19 860550 860550 860550 860550 27/01/10 2.93 7918

8. 28Z5123 E HT 08/10/09 18/10/09 11334 7 107356 361190 407452 407452 11/05/11 5.10 0

9. 11Z1165 J
EOILS & FILTER CHANGES DUE STATEMENT
OR DEPOT: ONGOLE
24/09/09 20/10/09 10717 5 160760 265527 267851 267851 09/12/09
DATE : 25-10-2009 PAGE : 4
5.65 0
===================================================================================================================================================================
10. 11Z5717|DOC JPROGRAMOR
EOC PROGRAM
30/09/09
|GOC PROGRAM
19/10/09
|FEC PROGRAM
10492
|PEC PROGRAM
6 4293 102562
|GCC PROGRAM
102563 102563
|POC PROGRAM
19/04/10
|APF PROGRAM
5.69
|ASF PROGRAM
0
VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS
* 11. 11Z1276 J OR 30/09/09 20/10/09 9918 5 166512 35016 314366 59630 01/01/10 5.95 0
===================================================================================================================================================================

12.
1 10Z409 10Z5535
H 14084 J J
10Z7851 OR
31509 10Z785123/09/09 20/10/09
J 31509 10Z6693 H 20186 9424 H
10Z3004 298055 10Z7851
162218J 6230928Z0112
74180 123967R 352468
8980 16/07/10
11Z4092 V 111176 6.19 K 215460 0
28Z3999

2 10Z6718 H 14028 11Z0808 J 31928 11Z0808 J 31928 11Z1351 J 19196 10Z9423 J 29514 28Z2447 K 79749 11Z4093 V 109326

3 10Z6953 H 14670 11Z0843 J 31016 11Z0843 J 31016 11Z3590 J 19084 11Z0749 J 30410

4 11Z1337 J 16094 11Z1165 J 31763 11Z1165 J 31763 11Z4349 J 19221 11Z2161 J 29458

5 11Z2411 J 16238 11Z3589 J 31955 11Z3589 J 31955 11Z4968 J 19794 28Z2137 K 49524

6 28Z0112 V 25792 11Z5583 V 101322 11Z5583 V 101322 28Z0112 V 25792

7 28Z3505 K 35346 11Z844 J 31238 11Z844 J 31238 28Z3999 K 24717

8 28Z5069 E 36652 9Z9697 H 20078

Sch-I Maintenance
Schedule-I or Daily Maintenance is carried out in
two shifts.
All the vehicles after completion of the scheduled
operation undergo Sch-I 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 Sch-I.
The works allotted & works attended in Sch-I are
recorded by the Shift Incharge Supervisor duly
obtaining the Signatures of the concerned.
 Vehicle Back History Register
Date Complaints on the Failures Remarks Signature
condition of vehicle of the of AE/ DM
As per As per Supervisor
who
logsheet Tyre Mech.
supervised
Observation the repairs/
maintenance

VBH register is a very important register in maintenance management.

It 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 Sch-
III/IV maintenance incharge before docking the vehicle and ensure that
root cause for the defect is totally eliminated during Sch-III/IV
maintenance.
 Sch-II Maintenance
Every vehicle undergoes Sch-II Maintenance
once in a week (Excluding those undergone
Sch-III/IV) for about 2-3 hours
In addition to all the activities of Sch-I, the
following works are taken up in Sch-II
Complete washing through MWP
Lubricating all grease points
Cleaning of Breathers
Air Cleaner maintenance
Battery Maintenance
Tyres rotation
Steering & Brake test
 Sch-III & IV Maintenance
Sch-III/IV 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 Sch-III/IV maintenance.
Two Mechanics & Two assistants for Sch-III and
Three Mechanics & 3 Assistants for Sch-IV are
deployed per vehicle in addition to the Artisans.
All major repair & maintenance works are carried
out in Sch-III/IV 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
 Important aspects while docking the
vehicles for Sch-III/IV
Take up the vehicle for maintenance at the right
time. Avoid delay/backlog.
Inform the fixed Drivers about docking of vehicles
for Sch-III/IV.
Ensure thorough washing/MWP before docking.
Synchronize other maintenance activities like FC,
Unit changes, Filter/Oil/Coolant changes, Body
attention, Painting etc with Sch-III/IV to save
manpower & vehicle days
 Important Coach works covered during
Sch-III/IV
Tightening of all Body U’bolts, 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 &
Driver’s door
Dicky doors, locks and gas springs in
Special type vehicles Contd..
 Important Coach works covered during
Sch-III/IV
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..
Attention to Antisag bar & out riggers
Replacement of damaged window frames,
broken shutter glasses, windscreen
glasses.
Replacement of terene felt, fitment of
shutter knobs
Attention to battery box
Arresting water leakages
Exterior/ Interior paint touch up
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 Artisans 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
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 Sch-III/IV, H.R.G and
KMPL works.
Senior most supervisor of the Depot next to
Maintenance Incharge shall be assinged to
look after of General Shift maintenance.
 Depot Slabs for Supervisors & Artisans

120 to 149
100 to 109

150 & Abv

45 to 49
50 to 54
55 to 59
60 to 64
65 to 69
70 to 74
75 to 79
80 to 84
85 to 89
90 to 94
95 to 99
up to 44
Category

AE(M) 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1
SUPDT(M) 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2
DY.SUP(M) 0 0 0 1 1 2 2 2 2 2 2 2 2 2 2
LH 2 2 2 2 2 2 2 2 2 2 3 3 4 4 4
CB/PB 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4
TYRE MECH 1 2 2 2 2 2 2 2 3 3 3 3 3 4 5
ELEC AC/DC 2 2 2 3 3 3 3 4 4 4 4 4 5 5 5
PAINTER 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2
WELD/T.S 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
TRIMMER 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2
B.SMITH 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2
H.MAN 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2
 Typical Man Power Deployment for
maintenance in a Depot with 100 fleet
Category Norm Men
Mechanical Foreman 1
Asst. Mechanical Foreman 0.049 2
Chargeman 2
Leading Hands 0.037 4
Total Supervisors 0.086 9
Mechanics 0.35 35
Helpers/ Shramiks 0.50 50
Artisans 0.21 21
Total 1.15 115
 Deployment of Mechanics & Helpers for
maintenance in a Depot with 100 fleet
Activity Mechanics Helper/ Shramik
@ Norm 0.35 @ Norm 0.50
Sch.I Maintenance 16 18
Sch.II Maintenance 4 4
Sch.III/IV Maintenance 9 10
Heavy Repairs 1 1
KMPL Attention 2 2
Oil changes 2 2
Vehicle Dispatch 1 3
Tyres preparation 2
DGT & Stores 2
Battery maintenance 2
HSD oil top-up 4
Total 35 50
 Deployment Artisans for maintenance in a
Depot with 100 fleet
Category Norm Men
Coach Bulider 0.039 4
DC/AC Electrician 0.047 5
Tyre Mechanic 0.034 3
Welder/ Tinsmith 0.010 1
Trimmer 0.024 2
Painter 0.024 2
Blacksmith 0.022 2
Hammerman 0.022 2
Total 0.21 21
Manpower deployment for shift maintenance
Deployment of manpower for Sch-I/II 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 dis-
proportionate 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 Sch-I/II maintenance during this shift.
 Outsourcing activities at Depots
In order to overcome shortage of manpower, and
difficulties in filling of vacancies, APSRTC is
outsourcing certain maintenance activities like
Cleaning, sweeping & washing of Buses, HSD oil
Top-up, Semi-skilled men as Assistant to
Mechanics etc at Depots for smooth
maintenance of vehicles.
 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.
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.
Important T&P required for smooth maintenance
S. Description Expected life
No in Years
1 D.G.Set 20
2 Air Compressors 15
3 Car washers 7
4 Automatic Washing Plant 15
5 Arc Welding M/c 20
6 Gas Welding equipment 8
7 HP Greasing equipment 10
8 Bucket type Grease Gun 7
9 Jib Crane 10
10 Trolley Jack 10
11 Bench Vice 5
12 Bench Grinder 7
Contd..
Important T&P required for smooth maintenance
S. Description Expected life
No in Years
13 Drilling M/c 10
14 Sewing M/c 10
15 Pop rivet guns 5
16 Paint Spray gun 10
17 Battery Charger 5
18 Cell Tester 3
19 Hydrometer 5
20 Injector Tester 10
21 Wall gauges 3
22 Electronic gauges 5
23 Hand grinding M/c 7
24 Mechanic’s work bench 10
Contd..
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 5
29 Swage Block 10
30 Vehicle Stands 10
31 Compressor Tester 10
31 Well Pump 7
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
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
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 Dy.CME
concerned for obtaining the same.
 Mechanic Tools for TATA Depots
D.E.Flat Ring Tubular Socket Other Tools
55mm single end Flat
6x7 mm 6 x 7 mm 8 x 9mm 10mm Tommy bar 125mm long
8x9 mm 10 x 11 mm 10x11 mm 13mm Tommy bar 250mm long
Extension 6
8x10 mm 12x 13mm 12x13 mm 14mm Extension 12"
9x10 mm 17x19 mm 12x14 mm 17mm Cutting Plier 8"
Cutting plier 10”
10x11 mm 21 x 23 mm 17x19 mm 19mm
Hammer Ball pane 1/2Kg.
10x13 mm 22 x 24 mm 22 x 24 mm 22mm File round smooth 8"
12x 14 mm 27 x 32 mm 27 x 32 mm 24mm File flat smooth 6"
Feeler Gauge Set
14x17 mm 41 x 46 mm 27mm Torque wrench
17x19 mm 3/8’’ (4 to 20 m-Kgs)
Circlip Plier 6’’
22 x 24 mm
Screw Driver 6’’ & 12’’
27 x 32 mm Nose Plier 6’’
 Mechanic Tools for LEYLAND Depots
D.E.Flat Ring Socket Other Tools
3/16’’x1/4’’ 3/16’’x1/4’’ ½’’ 55mm single end Flat wrench
¼’’x5/16’’ ¼’’x5/16’’ 10mm Tommy bar 125mm long
5/16’’x3/8’’ 5/16’’x3/8’’ 11mm Tommy bar 250mm long
Extension 6
7/16’’x1/2’’ 7/16’’x1/2’’ 12mm
Extension 12"
9/16’’ x 5/8’’ 9/16’’ x 5/8’’ 13mm Cutting Plier 8"
11/16’’x3/4’’ 11/16’’x3/4’’ 14mm Cutting plier 10”
6 x 7mm 6 x 7mm 17mm Hammer Ball pane 1/2Kg.
8 x 9mm 8 x 9mm 19mm File round smooth 8"
10 x 11mm 10 x 11mm 21mm File flat smooth 6"
12 x 13mm 12 x 13mm 22mm Feeler Gauge Set
Torque wrench
14x 15mm 14x 15mm 24mm
(4 to 20 m-Kgs)
16 x 17mm 16 x 17mm 46mm
Circlip Plier 8’’
18 x 19mm 18 x 19mm Screw Driver 8’’ & 12’’
20 x 21mm 20 x 21mm Nose Plier 6’’
22 x 23mm 22 x 23mm Mallet
24 x 27mm 24 x 27mm Allen Key set
 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 8 x 9 19 19 x 22 19 x 22 17, 19
BSF 9 x 10 9 x 10
3/16” X ¼” Feeler Gauge
5/16 X 3/8”
Feeler gauge
 Special tools for Tata vehicles
• Crow foot spanner for cylinder
Head Nut tightening with rocker
assembly
• 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
 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)
• Dial gauge (for hub setting
with Magnetic base)
• 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
 Delegation of Powers Pertaining to T&P
S.No Nature of Power
32.i) Standardization of depot
equipment, inclusion of new
items, fixation of norms,
classification of T&P value-wise
fixation of guidelines,
expectancy etc
ii) Inclusion of new equipment on
experimental basis
Authority Extent of powers
MD Full powers with the
concurrence of FA/CAO
on the recommendations
of ED(E)/CCOS/CME/
CFM
ED(E) Powers upto Rs 1.00
lakh per occasion with
the concurrence of
FA/CAO
CME Powers upto Rs 50,000
per annum with the
concurrence of Dy.CAO
WM/ Powers upto Rs 10,000
Dy.CME per annum with the
concurrence of Dy.CAO
Contd..
 Delegation of Powers Pertaining to T&P
S.No Nature of Power
33.i) Sanction for replacement of T&P
equipments including premature
replacements at Depots/
W.shops
ii) Sanction for replacement of T&P
items after their normal
utilization for Depots/ W.shops
as per guidelines issued from
time to time
Authority Extent of powers
CME/ Full powers on the
ED(Z) recommendations of
Dy.CME/ WM with the
concurrence of DyCAO
DyCME/ Full powers with
WM concurrence of DyCAO
DM Powers upto Rs 300/- at
a time subject to a limit
of Rs 2,000 per annum
Contd..
 Delegation of Powers Pertaining to T&P
S.No Nature of Power Authority Extent of powers
34.i) Sanction for replacement of T&P ED(Z)/ Full powers as per
equipments for New Depots/ CME guidelines
W.shops
ii) Sanction of additional T&P for CME/ Full powers with
existing Depots/ W.shops on DyCME/ concurrence of CFM/
account of increase in Fleet WM DyCAO as per
stength/ acitivity as per guidelines
guidelines DM Powers upto Rs 300/- at
a time subject to a limit
of Rs 2,000 per annum

Contd..
 Delegation of Powers Pertaining to T&P
S.No Nature of Power Authority Extent of powers
35 Sanction the expenditure ED(E) Full powers with
incurred for overhaul repairs and concurrence of FA/CAO
maintenance of tools, plant & CME/ Full powers with
machinery and replacement of ED(Z) concurrence of CFM/
parts thereof in Depots & DyCAO upto Rs 20,000
production units and entering at a time
into contract with authorized
suppliers or manufacturers SSO Full powers upto Rs
5,000 at a time with
concurrence of Dy.CAO
JSO Upto Rs 1,500 at a time
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 onroad.
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
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.
 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
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.
 SUB ASSEMBLIES
S.No UNIT NORM
1 Injectors (set) 1 for 2,000 KMs.
2 P. P. Shafts (set) 1 for 6,000 KMs.
3 Air compressor 1 for 5.000 KMs.
4 Clutch pressure plate 1 for 5,000 KMs.
5 (Leyland)/ Springer (Tata) 1 for 5,000 KMs.
6 Water pump assembly 1 for 5,000 KMs.
7 Cylinder head assembly 1 for 5,000 KMs.
8 Radiator 1 for 5,000 KMs.
 MAJOR SPARES
S.No UNIT NORM
1 Front hub 1 for 15,000 KMs.
2 Rear hub 1 for 15,000 KMs.
3 Clutch housing 1 for 15,000 KMs.
4 Air cleaner complete 1 for 5,000 KMs.
5 Fuel twin filter assembly 1 for 5,000 KMs.
6 Feed pump 1 for 5,000 KMs.
7 Fly wheel ring gear 1 for 10,000 KMs.
8 Unloader valve 1 for 3,000 KMs.
9 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.
 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.
All depots send a periodical statement on
availability of floats to the concerned
Dy.CME once in a year.
The Dy.CME of the region reconciliates
figures with those maintained by
workshops.
The Dy.CME concerned processes cases for
provision of floats for new models and also
for increase of floats on account of
increase in schedules, duly recommending
the surrender of obsolete models.
 Provision of Spare Vehicles to Depots

• Spare vehicles are Norm for Provision of

provided to the Depots to Spare Buses
meet the requirements for
Fleet Held Norm
docking the vehicles for
preventive maintenance Upto 50 8%
(Sch.III/IV), FC attention,
Complete overhauls, 51 to 80 7%
Sundry repairs, Units 81 & above 6%
replacement etc,.

76
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 Sch-II maintenance,
10 vehicles undergone Sch-III and 5 vehicles
undergone Sch-IV maintenance.
This is highly essential to ensure effective
execution of preventive maintenance
schedules
Check-list for inspection of vehicles
S.No System Item
1 Engine Air cleaner maintenance
2 ,, A/c Suction hose
3 ,, Engine mounting
4 ,, Engine oil leakages
5 Fuel HSD tank cap seals
6 ,, Fuel pipe clamping
7 ,, Fuel leakages
8 Cooling Radiator Cap
9 ,, Coolant concentration
10 ,, Radiator mountings
Contd..
S.No System Item
1 Steering Tie-rod/ drag link end play
2 ,, ATF oil leakages
3 ,, King pin lubrication
4 Susp. Broken spring leaves
5 ,, Spring side clamps/ ferrules
6 ,, Welded side clamps
7 ,, Spring brackets/ shackles
Air suspension mounting bolts
8 ,,
Tightness
Condition of rubber bushes
9 ,,
in Air suspension
Contd..
S.No System Item
1 Transmission Clutch free play
2 ,, Gear lever play
3 ,, Gear Box oil leakage
4 ,, Loose CJ check nuts
5 ,, CJ bearings condition
6 ,, UJ Crosses condition
7 ,, Sleeve yokes condition
8 ,, CJ rubber beds condition
9 ,, Slip joint Rubber boot
10 ,, PP shafts alignment
11 ,, Missing grease nipples
12 ,, Chassis greasing
13 ,, Differential oil leakage
14 ,, Cleanliness of breathers
S.No System Item
1 Brakes Air tank condensate
2 ,, Brake pipe clamps
3 ,, Air leakage
4 ,, Air Dryer working
5 ,, Hand brake condition
6 ,, Brake dust covers
7 Tyres Wheel alignment
8 ,, Matching of duals
9 ,, Less than 2mm NSD tyres
Contd..
S.No System Item
1 Electrical Battery Maintenance
2 ,, Head Lights
3 ,, Signal Lights
4 ,, Self condition
5 ,, Saloon Illumination
6 Body Exterior/ Interior cleanliness
7 ,, Body damages
8 ,, Painting
9 ,, 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
 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 Driver’s Door Damages/ locks
EXT-8 Ladder Damages/ missing
EXT-9 Rear Luggage Booth (Dicky) Damages/ locks
EXT-10 Exterior Paint Faded
EXT-11 Roof Leakage Area of Leakage
DEST-1 Destination Board Frame Size and condition
DEST-2 Destination Lettering/Paint Faded
DEST-3 Destination Board lighting Visibility
DEST-4 LED Destination Condition
 Checklist for Body condition
Code Item Description Remarks
INT-1 Stepwell 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 Dirt & cobwebs
GLS-1 Window Glasses 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
 Checklist for Body condition
Code Item Description Remarks
SEAT-1 Seat Frames Loose/broken
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 Damaged
CAB-1 Bonnet Damaged
CAB-2 Dash Board Damaged
CAB-3 Vision Mirrors Damaged
CAB-4 Cabin Cleanliness Dirty
 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
 Indicators for Quality of
Sch-III/IV maintenance
• Backlog in Sch-III/IV maintenance and failures within
15 days after maintenance are the key indicators for
Standards of preventive maintenance at the depot.
Failures within
Fleet Optd Sch-III
Type 15 days
Held Kms
Due Done Backlog % Backlog Nos %
ORD
EXP
Total

Failures within
Fleet Optd Sch-IV
Type 15 days
Held Kms
Due Done Backlog % Backlog Nos %
ORD
EXP
Total
 Important Registers maintained in
Preventive Maintenance Management
 Daily RG Register RTC-126
 Vehicle Back History RTC-109
 Sch-I Maintenance RTC-127
 Sch-II Maintenance RTC -128
 Sch-III work done MTD -194
 Preventive Maintenance Master register RTC-110
 Unit changes register
 Register for Inspection of vehicles
 FC Register
 Breakdowns RTC-129
 Cancellation of Kms RTC-130
88
 Vehicle Replacement Policy
APSRTC replaces Mofussil buses at 11.00 lakh
kms and City Buses at 11.50 lakh kms or 15
years (whichever is earlier) against scrap.
Ghat Buses & Super Luxury buses are
replaced at 5.50 lakh kms and Volvo Buses
at 10.00 lakh kms
The other special type buses like Express,
Deluxe, Metro Exp etc are replaced at 6.50
lakh kms
 2010-11 2011-12 (Jan’12)
Type
Aug. Rep. Total Aug. Rep. Total
S.Luxury 137 109 246 57 778 835
Indra -- -- -- 8 61 69
Garuda/ Garuda+ 0 30 30 27 41 68
Deluxe 32 89 121 169 69 238
Express 274 330 604 174 904 1078
Pallevelugu -- -- -- 152 547 699
Sap.Express & Ord 27 123 150 22 57 79
City Ordinary -- -- -- 10 55 65
City Ord (CNG) -- -- -- 0 138 138
LF A/C Diesel 28 0 28 51 0 51
LF A/C CNG 0 0 0 8 0 8
LF N-A/C Diesel 16 80 96 3 1 4
LF N-A/C CNG 0 0 0 33 0 33
SLF Diesel 75 118 193 9 0 9
SLF CNG 12 58 70 5 0 5
Mini Buses 52 0 52 48 0 48
Total 653 937 1590 676 2751 3427
 Green initiatives &
Use of Alternate fuels
in APSRTC
 APSRTC’s Environmental Concerns

APSRTC always takes lead in sharing the public

concern on automobile pollution and climate
change.

APSRTC is a forerunner in introducing

environment friendly vehicles through product
upgradation and innovative measures
especially in the area of alternate fuels and
pollution control.
Continued…
92
 APSRTC’s Environmental Concerns

Sophisticated Electronic Smoke Meters are

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,
APSRTC has started using Biofuels and
Compressed Natural Gas on large scale.

APSRTC installed 40 Wind Turbines to generate

green power to an extent of 10 Mw of
Electrical energy
93
APSRTC launched 100 CNG buses in
Vijayawada City during the year 2006,
which is first of its kind in South India.
The number of CNG buses has been
increased to 300 in Vijayawada.
Introduced 120 CNG buses recently in
Hyderabad which include Ultra Low Floor
Buses with BS-III/IV compliant CNG rear
Engine model is under progress.
The Fuel efficiency of CNG buses in VJA is
4.40 km/kg and in Hyd it is 4.49 km/kg
 Experiences with Biodiesel
As a stake holder in promoting the use of
biofuels, APSRTC had promptly responded to
the call given by the Govt. of Andhra Pradesh
and started trials using Biodiesel blended fuel
on one City bus, in June’2005.

The vehicle was operated with B20 fuel for 8

months to assess the operational feasibility
and performance in respect to fuel efficiency
and emission reduction. Intermittently the
vehicle was also operated with 100% HSD fuel
for 2 months for comparison
101
 Emission levels of Biodiesel Vehicle
during trial period
Against the maximum permissible smoke
density of 65 Hatridge units, the following
emission levels were observed on the vehicle
when operated with 20% Bio-diesel.

Jun-05 41.3 Nov-05 35.0

Aug-05 35.4 Dec-05 11.8

Sep-05 36.2 Feb-06 25.0

Oct-05 32.6 Mar-06 11.7

102
 Emission Levels of trial vehicle
When operated with 100% HSD oil

During Trial period Before Trial

Jul-05 33.3 Jan-05 35.0

Jan-06 34.0 Feb-05 32.6

Mar-05 11.2

Apr-05 37.3

May-05 45.4

103
 Comparative Fuel Performance* of
Vehicle during trials

With 100% HSD oil With Biodiesel

Jul-05 4.627 Jun-05 4.355
Jan-06 5.193 Aug-05 4.538
Sep-05 4.662
Oct-05 4.778
Nov-05 4.430
* Fuel Performance in Kms/Lit
Dec-05 4.516
Feb-06 4.797
Mar-06 5.008
104
 Extended trials with Biodiesel

The trial was extended to three more

vehicles at the same Depot with 5%, 10%
and 20% blends respectively. It was
observed during the trials that the vehicle
with 20% blend shown improvement in fuel
efficiency by 0.27 Km/Lt.
The trials were conducted with the
Biodiesel supplied by M/S Southern Online
Biotechnologies Limited.

105
 Comparative Emission Levels
Before Trials During Trials
Vehicle Bend Avg of Avg of % Emission
Mar Apr May Jun Jul Aug Reduction
No % three three
2006 2006 2006 2006 2006 2006
Months months
AP11Z
5% 44.3 55 30.4 43.23 35.4 41 30.6 35.67 17.49
3845
AP11Z
10% 29.3 33.7 40.1 34.37 32.7 22.1 20.1 24.97 27.35
4045
AP11Z
20% 27.7 31.9 20.9 26.63 11.7 21.6 16.67 16.67 59.75
4037

Comparative Fuel Efficiency

Avg Km/Lit Avg Km/Lit
Vehicle No Bend % % Improvement
Before Trial During Trial
AP11Z 3845 5% 5.29 5.33 0.76%
AP11Z 4045 10% 5.20 5.38 3.46%
AP11Z 4037 20% 4.91 5.21 5.47%
106
Several firms like M/s Cleancities Bio-diesel
India limited, M/S Naturol Bioenergy
Limited and M/S Universal Biofuels Pvt.
Limited have come forward to offer Bio-
diesel for conducting wider trials.
The trials were extended to other regions
like Visakhapatnam and East Godavari,
where all the vehicles of 4 depots were
operated with Biodiesel blended in 1:9 ratio
for about one month.

107
With the encouraging trial performance,
Corporation has taken a decision to use Bio-
diesel at 10% blend on regular basis for all
vehicles in the 12 Depots of Hyderabad City
Zone in the first phase by procuring the
Bio-diesel from M/S Southern Online
Biotechnologies Limited
The supplier had installed a separate
overhead tank for biodiesel storage and
made necessary arrangements to mix the
Biodiesel with the HSD oil in the fixed
proportion.
108
In the second phase, tenders were floated
in September 2009 for bulk procurement of
Bio-diesel at an estimated quantity of 30
Million liters for regular blending at 129
Depots in 14 Regions.
The supply contract was awarded to three
firms viz, M/S Cleancities Bio-diesel India
limited (108 Depots), M/S Southern Online
Biotechnologies Limited (12 Depots) and
M/S Universal Biofuels Pvt (9 Depots)

109
 Biodiesel Stocking & Blending Arrangement
at Depots

Biodiesel Dip Rod

Storage Tank

1 ½’’ MS Line
Tank Level
Gauge

1’’ Flexible Hose

1’’ MS Line

Truck with Biodesel Transfer Pump

Ground Level
Underground
HSD Oil Tank

110
Procedure of Blending Biodiesel with HSD Oil
Blending Biodiese with HSD for first time
1. Know the quantity of (Q1) of HSD in Ground Tank
2. Calculate required qty (Q2) of Biodiesel @10% blend with
HSD (Q1x10/90)
3. Transfer calculated qty (Q2) of Biodiesel from Storage tank
by gravity using Flowmeter F1

Procedure for subsequent replenishments

1. Ignore the quantity of B10 blend existing in the storage
tank on fresh receipt of HSD oil
2. Know the fresh quantity (Q3) of HSD that is being decanted
into the underground tank
3. Calculate the required quantity (Q4) of Biodiesel to mix by
using the formula Q3 x 10/90
4. Transfer the quantity Q4 of Biodiesel from Storage tank to
the Underground tank with the help of Flow meter F1 111
 Reduction of Pollutants with B20 Fuel
Reduction with
The values with
POLLUTANT 20% Blended
Pure HSD Oil
Bio-diesel
Total Unburned Hydrocarbons 1.1gms/kwh 20%
Carbon monoxide 4.5 gms/kwh 12%
Particulate Matter 0.36 gms/kwh 12%
Oxides in Nitrogen 8 gms/kwh + 2%
Sulphates -- 20%
Polycyclic Aromatic
-- 13%
Hydrocarbons (PAH)
Nitrated PAHs -- 50%
Ozone Potential
-- 10%
Speculated Hydrocarbons
112
 Comparative Specifications of HSD & Biodiesel
ASTM Pure Bio- Normal
Parameter Unit
Method Diesel HSD Oil
Flash Point D93 OC 130 min 66 min
Water & Sediment D2709 % Volume 0.05 max 0.05 max
Kinematic Viscosity 40oc D445 mm/Sec 1.9 – 6.0 2-5
Sulphated Ash D874 % mass 0.02 max 0.01 max
Sulphur D5453 % mass 0.05 max 0.035 max
Not worse
Copper Strip Corrosion D130 No.3 max
than No.1
Cetane Number D613 47 min 46 min
Cloud Point D2500 OC Report
Continued…
113
 Comparative Specifications of HSD & Biodiesel
ASTM Pure Bio- Normal HSD
Parameter Unit
Method Diesel Oil
Carbon Residue 0.03 max
D4530 % mass 0.05 max
100% Sample on 10%
mg
Acid Number D664 0.8 max --
KOH/gm
Free Glycerin D6584 % mass 0.02 max --
Total Glycerin D6584 % mass 0.24 max --
Phosphorus D4951 % mass 0.001 max --
Distillation Temp.
Atmospheric
D1160 Degrees C 360 max --
Equivalent Temp
90% Recovered
114
 Some of the barriers in
large scale application of Biodiesel
Availability and uninterrupted supply of
biodiesel is a major constraint for large scale
application in APSRTC.
Very few firms have come forward to supply
the Biodiesel in bulk quantity at a viable price
It is difficult to assess the quality of the
product at the user level
There is scope for non-adherence to the
prescribed specifications by the suppliers in
the absence of required testing facilities.
115
Contd…
It is difficult to send the samples to the
laboratories too frequently.

The blending becomes uneconomical if the

suppliers quote exorbitant prices due to
monopoly

Premature clogging of filters is more prevalent

while using Biodiesel

116