Over-hauling of Engine (6R-1080) and other allied works of 125KVA Water Cooled DG set of Kirloskar make at WSS Chuntwaliwar Stage 2nd

Amount

Repairs to 125KVA D.G.set at Chuntwaliwar Stage 2nd by way of:- Complete dis-Engaging of Engine assembly from common base frame coupled with alternator, Dis-engaging Diesel Tank, Main inlet diesel pipe line, Radiator assembly etc by technicians skilled labours, by using tools tachels, Hydra Jack/ crane involved in Job shall be arranged by contracting agency, the job involves shifting of the equipment to work shop for conducting repairs.

Complete checking of Engine by way of Dis-assembling of all parts from engine assembly (i.e seized sleeves, pistons from cylinder block, crank shaft, cam shaft, connecting rods, head block assembly, tappet cover assy, Richers, F.I pump assembly, injectors and injector pipes etc. washing all parts by using HSD, Dhoti cloth etc.

Machining job by way of:-

Grinding of Crank shaft assembly to next immediate size, the job includes finishing of crank shaft on bench Machine.

Honing/Finishing and tapping of new cylinder liners on cylinder block.

P/F of head seats (SS) properly grinding of head seats and providing and fitting of ;head guides (1set = 12nos) are also involved in the job.

Checking of cam shaft and its alignment, checking of connecting rods and P/F of cam shaft bushes and connecting rod bushes, and then re-assembling of engine parts.

Providing and Fitting of spare parts (All parts replaced shall be recommended by OEM i.e, Kirlosker.)

P/F of Piston

Sleeves (liners)

Main and big end bearings 1set

Piston ring set

Head gasket

Complete gasket set, including adhesive bonding tubes, spring washers, plate washers and nuts and bolts etc.

Main oil seal, timing oil seal, rubber washers, rubber rings for sleeves and head caps.

Inlet and exhaust valves

Valve guides

Complete calibration of fuel pump and injectors (6No’s) by way of replacing damaged quadrants, delivery values, bearing gaskets, ;nozzles and other damaged parts,. The job further includes calibration of fuel infection pump on calibrating bench of machine includes replacement of plunger pipes.

Complete M.oil change of the Engine by way of P/Filling of fresh M.oil (20 litres) M.oil filters (2Nos) diesel filters (1set), Air filters (1set). ( As recommended by OEM)

Checking and complete repairs to turbo charger of engine to be carried out by replacing damaged turbo kit set, bearings etc.

Servicing of self starter assembly by way of dis-assembling of its parts, washing and cleaning of all parts, by using petrol, Dhoti cloth, and then replacing worn out carbon brush set, bushes and bending Gear and refitting and testing the same on full load.

Complete repairs/servicing to Radiator assembly by draining out water from the water body and then washing and cleaning of pipes, valves, fins with chemical solution, soldering wherever necessary. The job includes cleaning of upper and lower tanks etc, fitting back the same with engine . .Providing/Filling of Anti-freeze (Standard make) as per requirement and as per guide-lines. The job also includes replacement of damaged water hose pipes

Complete Re-assembling of Engine followed by bench test of same on no-load and shifting back to installation site in a private load carrier, loading the Equipment by lifting crane, tools, tackles involved are to be arranged by the firm. Unloading of the Equipment at WSS Chuntwaliwar Stage 2nd using Hydra(10 ton) crane and dragging the same by skilled labours upto the canopy of D.G. set.Re-assembling and coupling of Engine and Alternator on common base frame and fastening of all foundation/Mountings nuts and bolts to avoid any vibration.

Complete checking and servicing of Alternator assy, which includes repairs to the Exciter coil of Alternator by dis-assembling of damaged exciter coil by Technicians, using tools/tackles/puller Cu-wire of required gauge and quality, Refitting back the same on alternator. The job also includes P/F of Diodes of required Amperage. After replacing damaged ones, worn out carbon brush rectifiers, bearings are to be replaced as per sample.

Testing of D.G. set on No-load for at least three Hrs. (for idling purpose) followed by on full load on two Hours. ( HSD to be arranged by the firm)

M/S ASHRAF AUTO ELECTRIC WORKS