CBM

Report No 2 Report Date 02-02-2025

ESN 25364550 Equipment No. DZ 4A
Name of Project NMDC Bacheli Name of Site Engineer Ganesh Pradhan
Customer NMDC Bacheli Dealership KSS PVT LTD
Engine Model KTA 1150 Area Office / Zone BILASPUR
Engine Hours 6639 Eqpt Hours 13807
Engine type CWS Overhauled
DOC Engine 27-12-2023 DOC Eqpt 15-07-2006

A Cooling System Parameters / Remarks

1 Coolant level OK / Low (If Low, Confirm Top Up Status) Upto to Neck
2 Cap Radiator Fitted / Sealing OK Sealing Damaged
3 Condition of Shroud , Fan guard Crack/Leakage/Dust Accumulation (Supporting snap) OK
4 Condition of Radiator Fins OK / Chocked Chocked / Damaged - Details Mention in Remarks Column
5 Leakage from Radiator Yes / No No
6 Fan & Blade Condition OK / Damaged / Excessive Play OK
7 Fan Tip Clearance Uniform / Uneven Gap (Measure if uneven) : Uniform in 12, 3, 6, 9 'O' Clocks
8 Coolant Used & Condition (DCA2 / DCA4) Raw Water/Premixed (EG50:50)/DCA2 PH Value: Premixed EG50:50
9 Fan Belt Tension Check by thump rule method - should be <10mm - Yes Yes
10 Condition of Belts Cut / Damaged / OK Condition is Weak - Required replacement
11 Condition of vent hoses / Make up pipe (hose) Damaged / Leak / OK OK
12 Thermostat to Radiator Top tank Hoses / Clamps Condition OK / Damaged / Punctured Not OK - Details Mention in Remarks Column
13 Radiator Botton tank to Engine and Hydraulic Oil Cooler Hoses / Clamps OK / Damaged / Punctured OK
14 Hoses Connected in Engine (Like After Cooler) OK / Damaged / Punctured Not OK - Details Mention in Remarks Column
15 Check the Coolant System Piping allignment - Visually OK / Any hose is geeting misallinged ? OK
16 Coolant leakage from Water Pump weep hole Yes / No OK - Not Chocked
17 Check whether Water Pump weep hole Chocked ? Yes / No OK - Not Chocked
18 Coolant Level Sensor / Switch ? Working / Not Working / Not Applicable Working
19 Last Coolant Replacement N/A 27-12-2023
20 Last Coolant System Hoses Replacement Date and Hours N/A Date:

B Air System
1 Pre Air cleaner Condition OK Cleaning of Dust Accumulator OK
2 Check Air Cleaner Housing for any damages / Cracks Visually OK
3 Manifold Visually OK
4 Check any hose is rubbing with platform / others Visually No
5 Outer element Make/condition/sealing Genuine /Clean / Chocked Non Genuine
6 Inner element Make/condition/ sealing Cleaned / Chocked Genuine - Clean
7 Condition of CAC & its mountings Good / Bad / Damaged, any leakage : Yes / No Not Applicable
8 All Hoses, clamps , Air Pipe for tightness / condition Good / Bad / Damaged OK
9 Vacuum Indicator Working / Plugged / Open Hole / Red Band Red Band
10 Air compressor - pipe and connections for leakages ok / not ok
11 Exh Piping / Silencer Condition Proper / Crack / Leakage Crack / Leakage - Details mention in Remarks Column
12 Turbocharger Housing Bolts / Casing Crack Visual OK - No Discrepancies;
13 Check for blow by Hose Condition Chocked / Clean OK
14 Last Air Filter Replacement Date and Hours 4807 29-09-2024
15 Last Air System Hoses Replacement Date and Hours Hours : Date :

C Fuel System
1 Fuel Line tube /hose conditions OK / Damage / leaky / clamp OK
2 Check Fuel Line hoses clamping / supporting brackets OK / Damage OK
3 Check any Fuel hose is rubbing with other objects OK
4 Diesel tank Cap/ Strainer / breather - Fitted/ Last Cleaned Fitted / sealing/ cleaning OK
5 Drain Water from Water Separator and Check whether water / diesel Water / Diesel OK - Diesel found
6 Fuel Leakages (Hoses, connection etc) Yes / No (if Yes mention area) No
7 Feed pump - harness , relay condition / clamping, any damages ? OK
8 Fuel Analysis done , date and specify condition as accepted / rejected

D Lube Oil System

1 Lube Oil Level H / L / Not Visible in Dipstick Up to H
2 Lube oil system tube / hose conditions OK / Damage
3 Turbo Oil Supply hose Condition Check whether rubbing with OK
4 Lube oil brand / grade with B check interval followed Brand - HPCL Grade - 15W40 CH4 B Check Interval - 500 HOURS
5 Lube Oil Leakages if any (Hoses, Conn.) Yes / No (if Yes mention area) OK
6 Gauge Oil press/Oil temp/Safeties Fitted /working Yes / No Some Gauges not working, details mentioned in remarks column
7 Oil Consumption record from log-book Ltr/hr (B to B check) Data not Found.
Check for fouling of Lube oil hoses to Engine/Chassis to avoid hose burst.
8 Any discrepancies noticed ?
OK
9 Oil Priming Pump and Oil Pressure Switch Working / Not working / NA NA
10 Check for any Oil leakage from Rear / front Oil seal OK / Any leakage found Yes - Mention Leakage area in Remarks column

E Electrical System
Good / Bad Good in Condition
1 Condition of Engine Wiring Harness
Properly Clamped / Not Clamped
Good / Bad Good in Condition
2 Condition of OEM Wiring Harness
Properly Clamped / Not Clamped
3 Battery condition - lead sulphation / corroded, cable condition OK OK
4 Starter condition - lead loose , connected properly CONNECTED PROPERLY OK
5 Magnetic switch position , connection , mounting OK OK
6 Engine Panel / Murphy condition Working / Not working / Any Gauge blurr Not OK - Details Mention in Remarks Column
7 Charging alternator belt tension , belt condition OK OK
8 Throttle Pedal Condition and Harness Good / Bad / Damaged OK
9 Buzzer Working for Critical Fault Codes Yes / No (Simulate Low Lube Oil Pressure) Not Checked

F ECM Image Analysis Remarks

 1 ECM Image Collected ? Yes / No (If No, Mention Reason) Not Quantum
2 Any Active Fault Codes are there ? Yes / No (If Yes, Mention Code) Not Quantum
Any Critical Inactive fault codes are there ? Fault Code - Count - Duration NOT QUANTAM
Example : Example :
3 1) Engine Coolant Temperature is High. 1) FC 123 - 4 - 20 mins
2) Engine Oil Pressure is Low. 2) FC 321 - 4 - 60 mins
3) Coolant Level Low. 3) FC 543 - 10 - 2 mins

4 Fault Code Reset after ECM Image Collection Done / Not Done (If not, Mention Reason) Yes
Data Login Monitoring Collected ? Yes / No Yes, No abnormalities in parameters.
5 (Connect Insite, Start DML, Crank Engine, Run 2 mins on Low idle, Run
2mins on High Idle) (If collected mention any abnormalities noticed)

G Others Check points

1 Last 2 Maintenance Carried Date / HMR 6441 28-11-2024
2 Whether B Check is being carriedout as per Schedule ? Yes /No Yes

3 Damper Assembly Replacement Hours & Date N/A 27-12-2023

4 Last Overhead Setting done - date / hrs (Only for Mechanical Engines) Hours : Date: 0
5 Engine Crank End Play Inches 10
6 Blowby Inches of H2O Not Checked
visual inspection for any bolts loss and avm pads
7 Engine & Radiator Mtg. bolt / AVM pad condition
damage
8 Vibration of the engine -
Air System Hoses are Hard, need to be replaced.;Cooling System Hoses are Hard, need to be replaced.;Radiator Cap Seal / Thread damage ;Fan
Final Remark:- belt need to be replaced;

During The Inspection The Following Deficeancy Were Found

1. Air cleaning element was not genuine
2. Air cleaning element was choked
3.Rubber hose for the air system and coolant system were found hard and need to be replaced
4. Minor oil seepage was found from the 6th cylinder head .
Recommendation / improvement action
5. Oil filler cap was found too loose bcz the cap thread was damaged
plan :

Parameters to be noted during load testing, If not feasable do it under high idle
SN PARAMETERS VALUE Comment (accepted / beyond limit / alarming)
 1 Engine Speed (HI / LI) 2248/700 Accepted
2 Lube Oil Pressure @ High idle RPM3.8@750,3.8@2000 Accepted
3 Lube Oil Pressure @ Low idle RPM3.8@750,3.8@2000 Accepted
4 Lube Oil Temp @ Temperature 75@750,80@2000 Accepted
5 Coolant Temp. 60@750,65@2000,75@1700 Accepted

Service Engineer
Name Ganesh Pradhan
Dealership / DBU KSS PVT LTD
Check list Audited by : ASM Name , Office BILASPUR

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