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PRICE BID
(This price bid to be enclosed in a separate envelop with seal)
(On Original Letter Head of the Bidder)
PRICE BID FOR MAINTENANCE AND OPERATIONS OF MATERIAL HANDLING EQUIPMENT AT VALF AND SPROB
Note:
1. The evaluation will be based on the total price for maintenance & operational services for two years.
2. PO VALUE FOR SECOND YEAR (FIRST YEAR PO VALUE as Sl. No: 5 + VARIATION AS PER FORMULA of clause 35 in annexure-1) will be arrived at suitably.
3. In case the quoted amount for maintenance is less than the sum of minimum wages of the minimum deployment staff and their PF, ESI, Bonus & other leverages the quote will be considered only after clarification/breakup.
4. In case of an extension for a period less than one year, the unit rate of the
contract for the extended period shall be based on the proportionate increase between Unit rate for First Year and Unit rate for Second year of the contract on mutual consent basis.
5. In case of an extension for a period of one year, the unit rate of the contract for the extended period shall be based on the Second year PO value + VARIATION AS PER FORMULA of clause 35 in annexure-1.
6. Proportionate revision in Minimum wages, EPF & ESI as applicable shall be paid to the Service Provider staff and respective agencies as and when there is a revision in Minimum wages, EPF & ESI. There shall be no revision of order value on this account other than price variation clause.
Signature of service provider
Date: Full Name:
Place: Seal:
Sl.No. Particulars AMOUNT
1 Total Maintenance cost of 216 Material Handling Equipment
2 Operational cost for deployment of 11 nos. of Sr.HVDs for driving operation within SDSC SHAR for one shift (Cost of 1 Sr.HVD * 26 days * 12 months * 11 nos.)
3 SUB TOTAL ( SUM OF SL NO: 1&2)
4 APPLICABLE GST @ 18%( FOR SL NO: 3 )
5 FIRST YEAR PO VALUE ( SUM OF SL NO: 3&4)
6 TOTAL PO VALUE (FIRST YEAR PO VALUE MULTIPLIED BY TWO)
Quotation format - 1
SATISH DHAWAN SPACE CENTRE SHAR, SRIHARIKOTA
FILE NO:
MAINTENANCE AND OPERATION / DRIVING OF MATERIAL HANDLING EQUIPMENT
Quotation format-1 for providing Operators / Drivers at Work Station A & B
S.NO DESCRIPTION OF WORK UNIT RATE in
Rs. /-
1
Rate per Shift per Sr. Heavy Vehicle Driver/Operator for driving/operation of Material Handling equipment as listed in the point 4.1 of Annexure-1, within SDSC SHAR, Sriharikota during normal working days, Saturdays and all public holidays including Sundays One shift – 8 1/2 hours (Refer condition no: 4.3 of Annexure-1)
PER DAY
PER ND
2
Rate per hour for Sr. Heavy Vehicle Driver/Operator for operating/driving of Material Handling equipment as listed in the point 4.1 of Annexure-1, within SDSC SHAR Sriharikota during normal working days, Saturdays and all public holidays including Sundays beyond one shift. (Refer condition no: 4.4 of Annexure-1)
OT PER
HOUR
OT PER ND
3
Rate per Shift per Sr. Heavy Vehicle Driver/Operator for operating/driving of Material Handling equipment as listed in the point 4.1 of Annexure-1, Outside SDSC SHAR Sriharikota during normal working days, Saturdays and all public holidays including Sundays as and when required while on duty. (Refer condition no: 4.5 of Annexure-1)
PER DAY
PER ND
4
Rate per hour for Sr. Heavy Vehicle Driver/Operator for operating/driving of Material Handling equipment as listed in the point 4.1 of Annexure-1, Outside SDSC SHAR Sriharikota during normal working days, Saturdays and all public holidays including Sundays beyond one shift. (Refer condition no: 4.5 of Annexure-1)
PER HOUR
PER ND
HOUR : RATE/HOUR WITHIN ONE SHIFT ND : RATE/NIGHT DUTY
QUOTATION FORMAT - 2
MAINTENANCE SCHEDULE, M-3, Q-2, A-1 WITH DETAILED ESTIMATE
Quotation format -2 for Maintenance of Material Handling Equipments at Work Station A & B
S.NO NAME OF THE
EQUIPMENT
NO.
OF EQPT.
AT WS-A
NO.
OF EQPT.
AT WS-B
TOTAL EQPT.
(A)
SERVICE SERVICES
/ YEAR
(B)
RATE PER
SERVICE (C)
RATE PER
YEAR D=A*B*C
1 2T GODREJ
FORKLIFT 1 0 1
MON 3
QTY 2
ANN 1
2 3T GODREJ FORKLIFT
3 1 4
MON 3
QTY 2
ANN 1
3 5T GODREJ
FORKLIFT 1 1 2
MON 3
QTY 2
ANN 1
4 8T GODREJ FORKLIFT
0 1 1
MON 3
QTY 2
ANN 1
5 10T GODREJ
FORKLIFT 1 0 1
MON 3
QTY 2
ANN 1
6 12T GODREJ FORKLIFT
0 2 2
MON 3
QTY 2
ANN 1
7 16T VOLTAS
FORKLIFT 1 0 1
MON 3
QTY 2
ANN 1
8 20T GODREJ FORKLIFT
0 1 1
MON 3
QTY 2
ANN 1
9 SAME TRACTOR
(GCW 30T) 1 0 1
MON 3
QTY 2
ANN 1
10 NEW HOLLAND TRACTOR (GCW
30T)
1 0 1
MON 3
QTY 2
ANN 1
11
NEW HOLLAND
TRACTOR
PRT/2031
0 1 1
MON 3
QTY 2
ANN 1
12 EICHER TRACTOR (GCW 15T)
2 0 2 MON 3
QTY 2
ANN 1
13 SAME TRACTOR (GCW 10T)
0 3 3
MON 3
QTY 2
ANN 1
14 ASHOK LEYLAND
HIPPO HAULER 1 0 1
MON 4
HALF 1
ANN 1
15 TATA SIGNA 49T HAULER
1 0 1
MON 4
HALF 1
ANN 1
16 VOLVO HAULER
400/420 HP 2 3 5
MON 4
HALF 1
ANN 1
17 VOLVO HAULER 520 HP
1 1 2
MON 4
HALF 1
ANN 1
18 AMW HAULER 215
HP 2 0 2
MON 4
HALF 1
ANN 1
19 TATA PRIMA HAULER
1 0 1
MON 4
HALF 1
ANN 1
20 70T BEML HAULER 2 5 7
MON 4
HALF 1
ANN 1
21
TATA ACE
CYLINDER TRANSPORTER
1 1 2
MON 4
HALF 1
ANN 1
22 TATA ACE AGNI
TRANSPORTER 1 0 1
MON 4
HALF 1
ANN 1
23
TATA ACE
PROPELLANT TRANSPORTER
1 0 1
MON 4
HALF 1
ANN 1
24 TATA 207 0 1 1
MON 4
HALF 1
ANN 1
25 TATA 407 MINI EXPLOSIVE VAN
1 1 2
MON 4
HALF 1
ANN 1
26 TATA 407 UP LINK VEHICLE
1 0 1
MON 4
HALF 1
ANN 1
27 TATA XENON
VEHICLE 0 1 1
MON 3
QTY 2
ANN 1
28 TATA 807 SAFETY VAN
1 0 1
MON 3
QTY 2
ANN 1
29 TATA 709 EX
SAFETY VAN 1 0 1
MON 3
QTY 2
ANN 1
30
TATA 709 EX
INDUSTRIAL MINI TRUCK
1 0 1
MON 3
QTY 2
ANN 1
31 TATA 1613
EXPLOSIVE VAN 1 1 2
MON 3
QTY 2
ANN 1
32 TATA 1210E PLATFORM TRUCK
1 0 1
MON 3
QTY 2
ANN 1
33 10T HYDRA PICK
‘N’ CARRY CRANE 1 0 1
QTY 3
ANN 1
34
15T TYRE
MOUNTED TIL CRANE
1 0 1 QTY 3
ANN 1
35 PICK AND CARRY
TRUCK -10T 0 1 1
MON 3
QTY 2
ANN 1
36 BATTERY OPERATED TRUCK
29 0 29 QTY 3
ANN 1
37 10T AIR SUSPENSION
TRAILER
1 0 1 ANN 1
38
15T AIR
SUSPENSION
TRAILER
1 0 1 ANN 1
39
18T AIR
SUSPENSION TRAILER
1 0 1 ANN 1
40 GOLDHOFER TRAILER MODULE
3 0 3 QTY 3
ANN 1
41 COMETTO TRAILER MODULE
1 2 3 QTY 3
ANN 1
42 4T FLAT BED FULL
TRAILER 1 0 1 ANN 1
43 5 T FLATBED FULL TRAILER
1 0 1 ANN 1
44 8 T FLATBED FULL TRAILER
1 0 1 ANN 1
45 10T FLAT BED FULL TRAILER
2 0 2 ANN 1
46 10T WELL BED
TRAILER (2 AXLES) 1 0 1 ANN 1
47 15T FLAT BED FULL
TRAILER 2 0 2 ANN 2
48 30T DEAD WEIGHT
TRANSPORTER 1 0 1 ANN 1
49 30T FLATBED SEMI TRAILER
1 0 1 ANN 1
50 PS0 TRANSTILT 1 0 1 ANN 1
51 CRYO TRANSTILT C12.5
1 0 1 ANN 1
52 CRYO TRANSTILT C
25 1 0 1 ANN 1
53 L-40 TRANSTILT 1 0 1 ANN 1
54 L-110 TRANSTILT 1 0 1 ANN 1
55 PS0 - XL TRANSTILT
1 0 1 ANN 1
56 LIQUID HYDROGEN TANKER
2 0 2 ANN 1
57 LIQUID OXYGEN TANKER
1 0 1 ANN 1
58 ADITHYA MOTOR
TRANSPORTER 1 0 1 ANN 1
59 AGNI MOTOR
TRAILER 2 0 2 ANN 1
60 JEEP TRAILER 2 0 2 ANN 1
61 RH 200 TRANSPORTER
1 0 1 ANN 1
62 RH 560 TRANSPORTER-1
1 0 1 ANN 1
63 RH 560 TRANSPORTER-2
1 0 1 ANN 1
64 N2 MODULE-1 1 0 1 ANN 1
65 N2 MODULE-2 1 0 1 ANN 1
66 DM WATER
TANKER-1 1 0 1 ANN 1
67 DM WATER TANKER-2
1 0 1 ANN 1
68 DM WATER TANKER-3
1 0 1 ANN 1
69 EFFLUENT TANKER-1
1 0 1 ANN 1
70 SITVC TANKER 2 0 2 ANN 1
71 PROPELLANT
TRANSFER UNIT 2 0 2 ANN 1
72 DOLLEY (2 AXLE) 3 0 3 ANN 1
73 DOLLEY (SINGLE AXLE)
1 0 1 ANN 1
74 NITROGEN TANKER (8CM)
1 0 1 ANN 1
75 10T N2 MODULE
TRAILER 4 0 4 ANN 1
76 12T NITROGEN
TANKER 2 0 2 ANN 1
77 12T HELIUM
MODULE 3 0 3 ANN 1
78 15T DM WATER TANKER
1 0 1 ANN 1
79 IMT TANKER 4 0 4 ANN 1
80 RT TANKER 4 0 4 ANN 1
81 12T SEMI TRAILER 4 0 4 ANN 1
82 N2 MODULE
TRAILER - 1 1 0 1 ANN 1
83 NITROGEN TANKER
- 1 1 0 1 ANN 1
84
15 KL LIQUID
HYDROGEN TANKER
1 0 1 ANN 1
85
40 KL LIQUID
HYDROGEN TANKER
1 0 1 ANN 1
86 40 KL LIQUID
HELIUM TANKER 1 0 1 ANN 1
87 12T SEMI TRAILER
(2D HAT) 2 0 2 ANN 1
88
MOBILE MOTR
AIRSUSPENSION SEMI TRAILER
1 0 1 ANN 1
89
PS2/GS2
TRANSPORTATION SEMI TRAILER
1 0 1 ANN 1
90 20T WELL BED AIR SUSPENSION FULL
TRAILER
1 0 1 ANN 1
91 DIESEL OPERAED TRUCK
0 5 5 HALF 1
92 WELL BED TRAILER
(25T) 0 1 1
HALF 1
ANN 1
93 25T PS0-XL TRAILER
0 2 2 HALF 1
ANN 1
94 LOW BED TRAILER
(20T) 0 1 1
HALF 1
ANN 1
95 15T BOWL TRAILER 0 4 4 HALF 1
ANN 1
96 5T AP BIN TRAILER 0 4 4 HALF 1
ANN 1
97 0 4 4 HALF 1
2T LOW BED
TRAILER ANN 1
98 APPLE TRAILER 0 10 10 HALF 1
ANN 1
99 20T BOWL TRAILER 0 1 1 HALF 1
ANN 1
100 PS0-XL TRAILER 0 1 1 HALF 1
ANN 1
101 4T BOX / FLAT BED
TRAILER 0 7 7
HALF 1
ANN 1
102 12T FLAT BED
TRAILER 0 2 2
HALF 1
ANN 1
103 20T CANOPY TRAILER
0 3 3 HALF 1
ANN 1
104 30T FLAT BED
TRAILER 0 1 1
HALF 1
ANN 1
SUB-TOTAL 143 73 216 Total cost of maintenance
Quotation Format - 3
SATISH DHAWAN SPACE CENTRE SHAR, SRIHARIKOTA
Tender No: MAINTENANCE AND OPERATION / DRIVING OF MATERIAL HANDLING EQUIPMENT
Quotation Format – 3 for Manpower Deployment for Maintenance works and Major Break-downs for both Work Stations –A & B – VALF & SPROB
S. NO WORK DETAIL FIELD UNIT QTY RATE
1. SUPERVISOR-INTERNAL WORK (MAINTENANCE/OPERATIONAL SUPPORT) (Refer Point 9.3 of Annexure-1)
HYDRALICS, AUTOMOBILE & GENERAL
HOUR
A.R
2. DAY
3. OT
4. ND
5. SR MECHANIC – INTERNAL WORK (MAINTENANCE/OPERATIONAL SUPPORT) (Refer Point 9.3 of Annexure-1)
HYDRALICS, AUTOMOBILE & GENERAL
HOUR
A.R
6. DAY
7. OT
8. ND
9.
MECHANIC – INTERNAL WORK (MAINTENANCE/OPERATIONAL SUPPORT) (Refer Point 9.3 of Annexure-1)
HYDRALICS, AUTOMOBILE & GENERAL
DAY
A.R
10.
HOUR
11. OT
12. ND
13. JR.TECHNICIAN – INTERNAL WORK (MAINTENANCE/OPERATIONAL SUPPORT) (Refer Point 9.3 of Annexure-1)
AUTOMOBILE & GENERAL
DAY
A.R
14. HOUR
15. OT
16. ND
17. AUTO ELECTRICIAN – INTERNAL WORK (MAINTENANCE/OPERATIONAL SUPPORT) (Refer Point 9.3 of Annexure-1)
AUTO ELECTRICAL
DAY
A.R
18. HOUR
19. OT
20. ND
21. SUPERVISOR - OUT STATION WORK (MAINTENANCE/OPERATIONAL SUPPORT) (Refer Point 9.3 of Annexure-1)
HYDRALICS, AUTOMOBILE & GENERAL
HOUR
A.R
22. DAY
23. OT
24. ND
25. SR MECHANIC – OUT STATION WORK (MAINTENANCE/OPERATIONAL SUPPORT) (Refer Point 9.3 of Annexure-1)
HYDRALICS, AUTOMOBILE & GENERAL
HOUR
A.R
26. DAY
27. OT
28. ND
29. MECHANIC – OUT STATION WORK (MAINTENANCE/OPERATIONAL SUPPORT) ((Refer Point 9.3 of Annexure-1)
HYDRALICS, AUTOMOBILE & GENERAL
HOUR
A.R
30. DAY
31. OT
32. ND
33. JR.TECHNICIAN – OUT STATION (MAINTENANCE/OPERATIONAL SUPPORT) (Refer Point 9.3 of Annexure-1)
AUTOMOBILE & GENERAL
HOUR
A.R
DAY 34.
35. OT
36. ND
37. AUTO ELECTRICIAN – OUT STATION WORK (MAINTENANCE/OPERATIONAL SUPPORT)
(Refer Point 9.3 of Annexure-1)
AUTO ELECTRICAL
DAY
A.R
HOUR 38.
39. OT
40. ND
41.
PAINTER – INTERNAL WORK (Refer Point 9.3 of Annexure-1)
PAINTING
DAY
A.R
42. HOUR
43. OT
44. ND
HOUR = RATE /HOURS WITHIN ONE SHIFT DUTY A.R = AS REQUIRED
OT = RATE/HOUR AFTER ONE SHIFT DUTY ND = RATE / NIGHT DUTY
Annexure - 1
GOVERNMENT OF INDIA DEPARTMENT OF SPACE
INDIAN SPACE RESEARCH ORGANISATION
SATISH DHWAN SPACE CENTRE SHAR SRIHARIKOTA – 524 124 (AP)
SPECIFICATIONS FOR MAINTENANCE AND OPERATION / DRIVING FOR
MATERIAL HANDLING EQUIPMENT IN SDSC SHAR 1. SCOPE OF WORK:
1.1 MAINTENANCE
1.1.1 Maintenance of Material handling equipment like Mobile cranes, Forklifts, light duty and
heavy duty Tractors, Tata vehicles, Ashok Leyland, Volvo, AMW & TATA make prime
movers, Cometto & Goldhofer make Hydraulic suspension semi-trailers, Pneumatic
suspension semi-trailer, Diesel/Battery operated trucks and general purpose trailers such
as full and semi-trailers. Maintenance works are to be carried out within the SDSC SHAR,
Sriharikota Island and also outside the SDSC SHAR, Sriharikota as and when required.
1.1.2 Load testing support of equipment after completion of Annual Maintenance Once in a year.
1.1.3 Attending to Minor & Major Breakdown maintenance as and when required.
1.1.4 Painting/Repainting of Interior, Exterior, Under Chassis, Drivers Cabin etc., of Material
Handling Equipment such as Trailers, Tractors, Forklifts, Prime movers, Cranes etc. and
Painting/Repainting of MS structures, Storage racks, pallets etc.
1.2 OPERATION / DRIVING
Operating/Driving of tractor/heavy duty haulers, hydraulic suspension/mechanical
suspension/pneumatic suspension trailers, Explosives Van, Safety Van, Tankers,
Open/Closed trucks, forklifts within Satish Dhawan Space Center SHAR, Sriharikota
Island and also outside Sriharikota Island as and when required.
1.3 OPERATIONAL SUPPORT
Providing Services for loading & unloading of materials, lashing accessories, segregation
of stores racks etc., in between facilities and outside as and when required.
1.4 The Scope of work cannot be split into parts and all the above mentioned works will be
awarded to Single Agency on overall L1 basis.
2. WORK STATIONS:
2.1 SDSC SHAR Sriharikota is located at 17 kilometers East of Sullurupeta. Sullurupeta is 83
kilometers from Chennai, Tirupati & Nellore.
2.2 Maintenance & operation works in SDSC SHAR, Sriharikota are to be carried out at two
work stations viz. WORK STATION-A (VALF) & WORK STATION-B (SPROB) within
SDSC SHAR.
S.NO Work Station Location Distance from SDSC SHAR
Sriharikota Security Gate –I
1. Work Station-A,
VALF
Material Handling Facility
FLP Complex 8 kms
MAHAN Building,
SMP & EFT 9 kms
2. Work Station-B,
SPROB No.4 Building, SPROB 11 kms
2.3 Equipment to be maintained are located at various places within SDSC SHAR distance
ranging from 1 to 10 km from respective Work Stations, hence, the Service Provider staff
must move about a distance of 20/30 Km every day from respective Work Stations to attend
to Maintenance works. The Service Provider must arrange his own transport for material
& maintenance team mobility.
3. MAINTENANCE OF MH EQUIPMENT: 3.1. Number of equipment/vehicles, make, type, capacity, tyre size and frequency of Scheduled
maintenance which are to be carried out is mentioned in annexure-2.
List of Vehicles /Equipment to be maintained at each work station are given below:
S. No Equipment Details No. of Eqpt at
WS-A
No. of Eqpt at
WS-B
1. 15T TYRE MOUNTED TIL CRANE 1 0
2. 10T HYDRA PICK & CARRY CRANE 1 0
3. ASHOK LEYLAND HIPPO HAULER 1 0
4. TATA SIGNA HAULER 1 0
5. VOLVO HAULER 400 / 420 HP 2 3
6. VOLVO HAULER 520 HP 1 1
7. AMW HAULER 2 0
8. TATA PRIMA HAULER 1 0
9. BEML HAULER 2 5
10. SAME TRACTOR 30T GCW 1 0
11. NEW HOLLAND TRACTOR 1 1
12. EICHER TRACTOR 2 0
13. SAME TRACTOR 10T 0 3
14. 2T GODREJ FORKLIFT 1 0
15. 3T GODREJ FORKLIFT 3 1
16. 5T GODREJ FORKLIFT 1 1
17. 8T GODREJ FORKLIFT 0 1
18. 10T GODREJ FORKLIFT 1 0
19. 12T GODREJ FORKLIFT 0 2
20. 16T VOLTAS FORKLIFT 1 0
21. 20T GODREJ FORKLIFT 0 1
22. GOLDHOFER TRAILER MODULE 3 0
23. COMETTO TRAILER MODULE 1 2
24. BATTERY OPERATED TRUCKS 29 0
25. DIESEL OPERATED TRUCKS 0 5
26. TATA ACE CYLINDER TRANSPORTER 1 1
27. TAT ACE AGNI TRANSPORTER 1 0
28. TATA ACE SAMPLE PROPELLANT
TRANSPORTER 1 0
29. TATA 207 0 1
30. TATA XENON VEHICLE 0 1
31. PICK AND CARRY TRUCK -10T 0 1
32. TATA 407 MINI EXPLOSIVE VAN 1 1
33. TATA 407 UPLINK VEHICLE 1 0
34. TATA 807 SAFETY VAN 1 0
35. TATA 709 SAFETY VAN 1 0
36. TATA 709 EXINDUSTIAL MINI TRUCK 1 0
37. TATA 1210 E PLATFORM TRUCK 1 0
38. TATA 1613 EXPLOSIVE VAN 1 1
39. TRAILERS : FLAT BED/WELL
BED/FULL/SEMI/ DOLLEYS 77 41
SUB TOTAL 143 73
TOTAL 216
3.2 Service Provider shall carryout the following maintenance works for the above listed
equipment.
Sl.No Type of Maintenance Checklists
1. Daily Maintenance of Vehicles /Equipment Annexure – 3
2. Periodical Preventive Maintenance
(which include Monthly, Quarterly, Half Yearly, Annual)
Annexure – 4
3. Once in a year, Load Testing of Equipment after Annual
Maintenance
Annexure – 5
4. Minor Break Down Maintenance Works Annexure – 6
3.3. The Service Provider shall prepare Maintenance schedule for carrying out periodical
maintenance works and submit the same to Contract Manager for approval before
commencement of works.
3.4. Service Provider should attend to Daily checks to Material Handling Equipment/Vehicles
mentioned in the Annexure - 3 at Workstation-A & Work Station-B every day as a part of
Maintenance schedule. No extra Payment will be paid for Daily checks.
3.5. The Service Provider should bring Periodic maintenance schedule books for carrying out
periodical maintenance works as mentioned in the Annexure – 4 & 5 for each equipment
separately in a Hard bound book form immediately after Commencement of work. (For
Example: Forklift truck maintenance schedule book consists of Daily checks sheet – 01 no,
Monthly Maintenance schedule-3 nos, Quarterly maintenance schedule - 2 nos, Annual
maintenance schedule-1 no and Load test format -1 no). Periodic Maintenance Schedule
checklists will be updated/modified at frequent intervals and the same shall be furnished to
the Service Provider and the Service Provider shall carryout Maintenance checks as per
the revised ones.
3.6. Service Provider shall quote rates per scheduled periodic maintenance for the listed
equipment in the prescribed Quotation Format – 2.
3.7. Tyre & Wheel change:
3.7.1. Wheel change shall be carried out during Annual Maintenance of Equipment.
3.7.2. All Worn-out/aged tyres are to be replaced, re-fitted to equipment/vehicles as and when
required, under additional manpower.
3.7.3. Tyres and tubes will be supplied by the department.
3.8. Essential expertise of Service Provider Maintenance Staff (Sr. mechanic / Mechanic/
Auto Electrician):
Sr. Mechanic: Service Provider should engage Skilled person who can able to guide the
maintenance team and also able to allot Maintenance in a systematic way. He should be
capable of attending to Trouble shooting of Hydraulic system.
Mechanic: It is mandatory that one of the mechanic should have experience in Hydraulic
and Pneumatic systems.
Auto Electrician: Auto electrician should have thorough knowledge of Overhauling Self
Starter, Alternator, Dynamo and Electrical Harnessing and also should have enough
knowledge about AC system to attend repair works to Battery charging unit etc.,
3.9 During the contract period, Department reserves the right to delete or to add some of the
material handling equipment and correspondingly decrease/increase the maintenance
crew. The rates for new equipment to be added shall be the same as mentioned in the
contract for similar equipment for maintenance works. The above decrease/increase of the
maintenance crew need to be mutually agreed by the contract manager of department and
the Service Provider. Agreed crew strength need to be supplied by the Service Provider.
In case of not materializing the enhancement / reduction, the department has the right to
short close the PO.
3.10 During the contract period, Department reserves the right to delete or to add some
maintenance schedules of the material handling equipment and correspondingly
decrease/increase the maintenance crew. The rates for the additional schedule of
maintenance shall be the same as mentioned in the contract for similar equipment for
maintenance works. The above decrease/increase of the maintenance crew need to be
mutually agreed by the contract manager of department and the Service Provider. Agreed
crew strength need to be supplied by the Service Provider. In case of not materializing the
enhancement / reduction, the department has the right to short close the PO.
3.11 By any chance, if the Service Provider fail to complete periodic maintenance of equipment
as per the schedule in the particular month, it is the responsibility of the Service Provider
to mobilize additional manpower to complete the same within the stipulated time. In such
case no extra payment will be made for that additional manpower engaged by the Service
Provider.
3.12. Load Testing:
3.12.1. Service Provider shall extend support for Load testing of equipment Once in a year as a
part of Scheduled Periodic maintenance after completion of Annual Maintenance. No extra
cost will be given for load testing.
3.12.2. Required Dead Weights/Dead loads, dead weight handling slings & Handling equipment
such as Mobile cranes, Forklifts will be provided by Department at Free of Cost.
3.12.3. Service Provider shall depute Necessary manpower i.e., Maintenance staff & Operational
staff for load testing of vehicles/Equipment.
3.12.4. Service Provider shall extend support for Load testing of equipment, based on the need of
Department interest, even though the equipment/vehicle underwent load testing previously
in the same year.
4. OPERATION/DRIVING WORKS:
4.1. The equipment mentioned in sl.no. 3.1 table i.e maintenance of MH equipment, other than
Battery operated trucks and Diesel operated trucks are to be operated at each work station
for transportation of items like Rocket motors, Segments, sub systems used for integration
and testing, hardware, raw materials, fabricated items, cable drums, dead weights, general
hardware, structural items, consoles, handling tackles etc.
4.2. Driving/Operation of these vehicles/equipment within SDSC SHAR Sriharikota in general
and outside SDSC SHAR Sriharikota as and when required.
4.3. Service Provider shall quote rate per Shift per operator/driver (as mentioned in the Sl No:
6 of clause for driving/operation of above equipment within SDSC SHAR Sriharikota
during normal working days including Saturdays, Sundays and on all holidays per Shift (One
shift – 8 1/2 hours). Service Provider shall quote rates in the Quotation Format-1.
4.4. In case, Operator/Driver is engaged for driving/operation within SDSC SHAR Sriharikota
beyond the normal working hours the payment will be made for the extra hours. Service
Provider shall quote rates in the Quotation Format-1.
4.5. For operational works outside SDSC SHAR Sriharikota while driving a vehicle quoted
amount per day per operator will be paid while on duty which is exclusive of TA, but
inclusive of DA, lodging and boarding charges. Service Provider shall quote rates in the
Quotation Format-1.
4.6. Sometimes it is required to take and bring Vehicles/Equipment to & from various ISRO
centers respectively. In such outstation works, the expenditure incurred to the
operators/drivers will be paid subject to 2nd class sleeper fare/bus fare on production of
documentary evidence in addition to the rate quoted per day while on journey. (Means travel
with vehicle will be one side only either onward or return).
4.7. It is the responsibility of the Service Provider supervisor to ensure that assigned & completed
operational/driving works are logged in the respective vehicle log book mandatorily. The
Service Provider supervisor/engineer shall prepare format as specified, maintain a record
for all the operational works carried out by their team and submit the same to respective
department engineer once in a month.
4.8. Service Provider shall engage skilled and experienced driver who are capable of operating
forklifts, heavy duty tractors, 49t haulers of AMW / TATA SIGNA/ TATA Prima / Ashok
Leyland, Volvo make prime movers, articulated semi-trailers and full trailers.
4.9. Driving / operating vehicles in and around Sullurpeta shall be considered as driving within
SDSC
SHAR, Sriharikota.
5. WORKING HOURS:
5.1. General working timings for Service Provider staff including Supervisor, Sr. Mechanic,
Mechanics, Auto Electrician, Jr.Technician and Drivers/operators is 09.00 hrs to 17.30 hrs
or shift (8.30 hours) on working days. (Monday to Saturday - Six days a week).
5.2. Public holidays declared by the Department, saturdays and Sundays are the holidays.
However, at times work will be planned on holidays and also beyond normal working hours
on working days.
5.3. Service Provider Operational & Maintenance staff will be engaged on duty to work on any
shift timing as per the instructions of the Engineer-In-charge of Dept. such shift timings will
be considered as normal working hours.
5.4. Service Provider Operational & Maintenance staff will be engaged on duty to work beyond
normal working hours on working days and also public holidays as and when work demands.
5.5. Service Provider Operational & Maintenance staff will be engaged on duty to work in night
shifts. The Service Provider has to pay the night duty allowance to his staff as per labour
rules.
6. DURATION OF THE CONTRACT:
6.1. The period of contract shall be for TWO years after receipt of Firm Purchase Order.
6.2. Contract may be extended for ONE more year subjected to mutual agreement between
Service Provider and Department after Satisfactory completion of Intended duration of the
Contract.
6.3. The department has the right to terminate the contract at any time, if the quality of the work
is not up to the standard or Service Provider activities is detrimental to the interest of the
department, with prior notice. The department will not be liable to pay any compensation to
the Service Provider for any loss that may happen to him in the event of the termination of
the contract.
6.4. In case the services provided by the Service Provider are not satisfactory or if irregular
services are provided even after two written notices, it will be open to the Department to
terminate the contract and upon such termination, the security deposit will stand forfeited.
6.5. The Service Provider shall make necessary arrangement to depute alternate work force in
case of any absence/ holidays to existing work force.
6.6. SDSC SHAR reserves the right to enter into parallel contract(s) for the same service with
one or more other Service Providers during the currency of the contract. The Service
Provider shall maintain and submit a logbook
7. MANPOWER DEPLOYMENT
7.1 The Service Provider should mobilize qualified and experienced maintenance personnel
and drivers/operators with valid driving license for the above said work along with
technically qualified and experienced Engineer-in-charge. The minimum qualification and
experience for each category and manpower to be deployed at each workstation are given
below.
S.no. Category Qualification and Experience WS-A
(VALF)
WS-B
(SPROB)
1. Supervisor
Minimum Diploma In Mechanical /Automobile
Engineering with Three year experience or
B.Tech with one year experience in relevant
filed.
0
1
2.
Senior
Mechanic
(Highly Skilled)
Minimum ITI Certificate in Motor
Mechanic/Diesel Mechanic with eight year
experience in the maintenance of similar
vehicles/Material handling equipment.
Holding valid driving license is preferable.
1
1
3. Mechanic
(Skilled)
Minimum ITI Certificate in Motor
Mechanic/Diesel Mechanic with Four year
experience in the maintenance of similar
vehicles/Material Handling equipment.
Holding valid driving license is preferable.
5
3
4.
Auto
Electrician
(Skilled)
Minimum ITI Certificate in Electrical trade and
Four year experience in auto electrical area. 1 1
5. Jr.Technician
(Semi Skilled)
Minimum Fifth class with five years or ITI
Certificate in Motor Mechanic /Diesel Mechanic
/ fitter with two year experience in automobile
field.
7 5
6.
Sr. Heavy
Vehicle Drivers
/Operators
Minimum 8th class, should posses valid Heavy
Vehicle Driver License for driving the
equipment / vehicle mentioned at 3.1 and
should have minimum six years experience in
driving Articulated vehicles & Forklifts.
6 5
7. Painter
(Skilled)
Minimum 8th class, should possess two year
experience in automobile vehicles painting. 0 1
Total staff 20 17
7.2 The Service Provider shall submit Documentary evidences for Qualification and
Experience of the Staff engaged by him to the Service Provider Manager for Screening.
7.3 The Service Provider shall furnish complete details of the Manpower deployed (no. of
persons, qualification and experience) to the Contract Manager for approval prior to
commencement of Work (after receipt of confirm Purchase Order).
7.4 The work force shown above is minimum required. Depending on the workload the
Service Provider may have to increase the work force and work beyond office working
hours as per the instructions of the Engineer-in-charge. If Service Provider is not deploying
minimum work force, a penalty will be imposed as per point 16.0.
8. WORK ROUTINES:
8.1 Engineer identified by the department will scrutinize the schedule submitted by the Service
Provider and modify, if required based on the priority. The Service Provider should carry
out the maintenance accordingly.
8.2 For maintenance works, the Service Provider supervisor shall maintain, fill & submit log
sheets/ books/ checklists for all service works and load tests, service/maintenance reports
and data sheets in detail in the prescribed format and hand-over to the Department
Engineer for certification as soon as the works are completed.
8.3 The work details shall be entered by the operators/drivers in the respective
Vehicle/Equipment Log book.
9. MINOR BREAKDOWNS MAINTENANCE
9.1 For Minor breakdowns, the Service Provider should mobilize his team to attend the
breakdown immediately as per the instructions of Engineer-in-charge of respective
workstation. Any breakdown call occurring at any time of the day including holidays should
be attended. The list of minor breakdowns, which should be attended at no extra cost, is
given in the Annexure-6.
9.2 MAJOR BREAKDOWN MAINTENANCE/ADDITIONAL MAINTENANCE WORKS /
FABRICATION WORKS
9.2.1 For major breakdowns such as Engine Overhauling, calibration of fuel Injection pumps,
pressure testing of injectors, major tinkering, upholstery, glass changing, maintenance of
garage equipment like jacks, compressor, car washer, grease guns and auto electrical sub
system repair works, the expenditure incurred towards repair works, labour, handling
transportation and other incidentals, the base price of the spare/material procured +
12% of the base price of the spare/material (excluding GST) will be paid subject to
production of documentary evidence. Since this is reimbursement no GST shall be paid on
handling charges. Service Provider has to get the above works attended preferably at
authorized service stations of that respective equipment.
9.2.2 The Service Provider shall quote separate rates for attending to additional maintenance
requirements and Major breakdowns within SDSC SHAR Sriharikota and outside side
SDSC SHAR Sriharikota. For out station works the rates offered by the Service Provider +
travelling charges as per the actual expenditure incurred to him subject to maximum of II
class sleeper fare will be paid to the Service Provider on production of documentary
evidence for actual expenditure made.
9.2.3 The Service Provider shall undertake fabrication works and machining works if required for
any equipment. The Service Provider shall be reimbursed at the rate of the actual
fabrication/machining charges and the base price of the work carried out + 12% of the
base price of the spare/material (excluding GST) towards handling and transportation
charges. The Service Provider shall produce bill for the actual expenditure made for
fabrication/machining. The payment for the same will be settled considering
reasonableness of the price based on the prevailing market rates. The decision of the
contract manager/Engineer-in-charge is final and binding on the Service Provider.
9.2.4 VOLVO Haulers quarterly / annual maintenance has to be carried out under the supervision
of VOLVO authorized service person without which annual maintenance cannot be
claimed. Deputation, arrangement and charges is in the scope of the Service Provider.
9.3 ADDITIONAL MANPOWER FOR OPERATIONAL SUPPORT WORKS
9.3.1 The Service Provider shall provide additional manpower support for loading/lashing of
rocket motor segments, Propellant Bowls & other materials for handling and transportation
in between facilities and outside as and when required as per the Quotation Format-3.
9.3.2 The quoted rates for Sr.Mechanic / Mechanic / Helpers / Electrician in quotation format -3
are applicable for the support of maintenance & operational works within SDSC SHAR
Sriharikota as per the requirement.
9.3.3 The quoted rates for Sr.Mechanic / Mechanic / Helpers / Electrician in quotation format -3
are applicable for the support of maintenance & operational works outside SDSC SHAR
Sriharikota as per the requirement. For out station works the rates offered by the Service
Provider + traveling charges as per the actual expenditure incurred to him subject to
maximum of II class sleeper fare will be paid to the Service Provider on production of
documentary evidence for actual expenditure made.
9.3.4 Holiday working/Working during final phase of Launch Activities: If the Department
proposes to perform work under this contract at VALF Facilities on holidays for working
during final phase of Launch activities, Service Provider shall obtain prior permission from
concerned authority for the same through Contract manager. Holiday working will be paid
or compensated either by compensatory off or will be adjusted towards absent man days.
10 THE SCOPE OF PAINTING WORK:
10.1 The painting work has to be carried out at work station – A & B as and when required.
10.2 Cleaning of surfaces/Removal of existing damaged paint coating and rust from the
structures, applying metal paste/putty and applying one coat of Primer suitable for
Polyurethane Paint by brush & Duco paints by spray as per the requirements based on the
condition of equipment & structures.
10.3 Spray painting shall be carried out where ever it is required preferably for Haulers, furniture,
cupboards and important critical equipment with Duco paints only.
10.4 The surface preparation with putty application and levelling should cover up all the dents
in order to achieve good surface finish.
10.5 IN ADDITION TO THE ABOVE, THE TENDERER SHALL CARRY OUT:
10.5.1 Covering/protecting the machined surfaces, name plates, applying grease for threaded
surfaces and fasteners, covering Wind shield glasses etc., by grease/mask tape before
commencement of Painting. The same shall be removed after completion of painting work.
10.5.2 Cleaning of spilled over paints on the other parts/floor or unpainted surface to the
satisfaction of the Department.
10.5.3 The dry film thickness of each coat of primer and Polyurethane /Special /Heat Resistant
paints, Duco paint shall be maintained as per the instruction of the Paint manufacturer. If
the desired dry film thickness (DFT) per coat is not achieved due to poor workmanship of
the Tenderer, the same shall be repainted to achieve the desired DFT by the Tenderer
without any additional cost. The dry film thickness of the paint will be measured by the
Engineer-in-charge of the department to check for adequacy.
10.6 CLEANING AND PREPARATION OF SURFACES:
10.6.1 The surface shall be cleaned thoroughly free of dust, dirt, grease, oil, rust etc., by using
wire brush and solvents as per IS: 1477 (Part-I.) (Code of practice for Painting of
Ferrous metals in buildings- Part-I – Pre-treatment). The list of free issue of materials are
indicated in point no.10.7.
10.6.2 Mechanical Cleaning: This may be done by scraping, chipping, wire brushing, rubbing
with abrasive paper. Where heavy rust or scale has formed, this can be usually removed
completely with scarper or chipping hammer or both.
10.6.3 Hand scraping: The correct procedure shall be to scrape thoroughly with a hand scraper
followed by wire brushing and finally sand-papering the surface with coarse sand paper
(No: 3) steel wood (No: 2) or emery paper (No: 3) or emery cloth. This will give a
reasonable assurance that no loose mill scale or heavy rust is left on the surface. For
purpose of examination, the hand cleaned surface shall be wiped finally with mineral
turpentine / TC, which also removes grease and perspiration left by hand marks.
10.6.4 The Service Provider shall obtain clearance of department Engineer-in-charge after
cleaning the surface and before application of primer and painting coats.
10.6.5 Lettering work on equipment body has to be carried out as per existing plan.
10.7 FREE ISSUE MATERIALS:
Department will provide the following free of Cost.
• Polyeurathane / Heat resistant /Epoxy /Special /Duco paints of different colours.
• Primer and thinner suitable for above paints.
• Paint remover / rust remover.
• Ladders / approach platforms to the limited extent, if available
• Air compressor for Spray painting
• Metal Paste and painting Putty
• Emery papers of different grades for painting purpose alone.
10.8 Removal and fitment of vehicle aggregates such as tyres and wheels, which are hindrance
for proper painting, is in the scope of Service Provider.
10.9 Tenderer shall arrange cleaning materials like cotton waste, wire brushes and emery
sheets.
10.10 Skilled workers experienced in Brush Painting as well as Spray Painting shall only be
engaged by the Tenderer.
10.11 Additional manpower shall be mobilized by the Tenderer to work and complete the painting
work of the equipment on priority basis whenever situation demands. Rate per additional
painter shall be paid as per the rate quoted by the tenderer as per Quotation Format – 3.
10.12 Deployment of painters shall be minimum one person and number of sites shall be
maximum TWO only.
10.13 Entire area to be painted, stipulated in the tender will not be provided at a stretch. It will
be provided to the Tenderer as when need arises and depending upon the availability of
equipment for painting. There may be some interruptions to meet the launch/test
schedules.
10.14 Painting shall be carried out only when the humidity level in atmosphere is within the
acceptable limits which will be decided by Engineer-In-Charge.
10.15 Painters shall be experienced in Brush & Spray painting with epoxy paints/special paints.
Minimum experience required is 2 years.
11 TOOLS AND FACILITIES:
At respective Work stations, Department will provide the following at Free of cost.
1. Electricity and water.
2. Worktable fitted with bench vise.
3. Spare parts, Lubricants and other materials required subject to availability.
4. Jacks and Handling facilities to the extent available.
5. Grease gun.
6. Battery charger and distilled water.
7. Air compressor.
11.2 The Service Provider should bring the following:
a) Set of hand tools consisting of double end spanners, ring spanners, light and heavy
duty box sockets, hammers, cutting pliers, nose pliers, feeler gauges, leather punches,
crow bars, oil guns, brushes and valve dies.
b) The Service Provider should have minimum six sets and four sets of hand tools at
workstation-A and Workstation-B respectively, in order to carry out two works
simultaneously at each workstation.
c) One complete set of all electrical test meters soldiering iron with lead, test lamps, tools
required for servicing of Lucas TVS & Beacon appliances vehicle electrical items.
d) The tools and materials required for tube repairs, neck repairs and vulcanizing and
compound for vulcanizing of punctures.
11.3 Service Provider shall maintain minimum quantity of consumables for a period of Three
months per Work Station to be brought for servicing and maintenance of Equipment are
listed below i.e., four times the quantities indicated below is required per year for two
centers. However, any additional quantities consumables if required have to be borne by
the Service Provider.
SL.NO DESCRIPTION QTY
1 Cotton waste 100 Kgs
2 Shellac (Gasket compound) 36 Nos
3 Kerosene 30 Liters
5 Emery sheets, Rough 25 Nos
6 Emery sheets, Smooth 25 Nos
7 Electrical Insulation tape in three different colours 10 Nos
8 Teflon tape 10 Rolls
9 M seal / Anabond 10 packs
12 SPARE PARTS, LUBRICANTS AND MATERIALS:
12.1 Spare parts, lubricants and components required for maintenance of Equipment/Vehicles
will be supplied by the Department at free of cost. Service Provider shall arrange spare
parts/components, as per the instructions of the respective work station engineer in charge,
If the same are not available in the Stock of department.
12.2 Payment for such supplies by the Service Provider will be paid by the department at the
base price of the spare/material procured + 12% of the base price of the
spare/material (excluding GST) towards transportation charges and other incidentals
etc., subject to furnishing proper documentary evidences by the Service Provider.
12.3 For the procurement of spares/material, the Non-availability certificate approved by the
Contract Manager will be issued to the Service Provider. The procured material will be
certified by the Engineer-In-Charge and counter signed by the Stores officer.
12.4 Spare Parts / Materials shall be procured from the authorized/reputed dealers.
13 TRANSPORTATION AND ACCOMMODATION:
13.1 The Service Provider shall arrange his own conveyance/transport for his team and
materials etc. Service Provider maintenance staff shall travel around 20 to 25 kms daily
from respective work station for attending to Maintenance and or to attend breakdowns.
Department will not provide any transportation arrangements for the Service Provider staff.
13.2 The Service Provider shall arrange his own arrangements for lodging and boarding of his
staff during the period of contract. Service Provider will not be permitted to construct any
shed inside the range for the purpose. Accommodation may be arranged subject to
availability, on Chargeable Basis. Private accommodation is available at Sullurpeta but not
in SDSC SHAR, Sriharikota (Sullurpeta is 18 kms from Srihariktoa).
14 ENTRY PASSES FOR CONTRACT STAFF
14.1 As SDSC SHAR is a highly restricted and hyper sensitive area, it is the responsibility of the
Contract to deploy Staff with high integrity.
14.2 The Service Provider and his staff need photo entry passes issued by the department to
enter into work spots at SDSC SHAR, Sriharikota. For this purpose, the Service Provider
shall provide 2 Nos of passport size photographs of all his staff and address proof, conduct
certificate from local authorities (Police verification certificate /MLA/MP/MRO etc) to
department. Service Provider should abide by the security restriction imposed by the
department for his personnel, tools and materials from time to time.
14.3 Service Provider personnel if removed from rolls, the entry passes shall be returned to the
Department immediately with a covering note. Non-surrender or misplacement of any entry
pass shall be charged from the Service Provider at the rates prescribed by the Department
from time to time.
14.4 It is the responsibility of the Service Provider to arrange the character and antecedents of
the work-force engaged for duty. The service Provider shall engage the Work-force who is
not having any criminal background. The character and antecedents shall be got verified
through record check by Service Provider at their own cost from the concerned police
authorities (Police Clearance Certificate) and submit the original report.
15 SETTLEMENT OF BILLS AND PAYMENTS
15.1 Payment shall be made once in a month for the works carried out by the Service Provider
during that particular month.
15.2 For arranging payments, Service Provider shall submit invoice, bills to the Department
Engineer-in-charge of respective work station for the works carried out before 5th of every
month:
• Scheduled Maintenance works attended.
• Spare parts supplied.
• Additional man Hours/ man days of Contract staff used.
• No of Operators/drivers deployed.
• Fabrication/Machining works carried out.
• Major works carried out.
15.3 Income tax deduction at source will be done from the payments of the Service Provider as
per IT rules in force and TDS shall be provided along with the Payment.
15.4 Following Documentary proof shall be furnished along with Monthly bills:
• Remittance of EPF of Service Provider staff
• Monthly wages remittance into staff bank accounts
• ESI remittance as applicable
• GST remittance
• Proof of payment of minimum wages
16. PENALTIES
16.1 With regard to maintenance and supervisory staff, the absenteeism for a month should not
exceed 8% of the total man-days in each category. (Total No of staff in particular category
x No of working days for the particular month x 0.08) if the absenteeism exceeds 8%, a
proportionate amount as per the rates quoted for stand by duty per day will be deducted
from the bill.
16.2 In case of any damage to the equipment or tools due to the negligence of the personnel of
the contractor during the course of maintenance the same will be rectified to the satisfaction
of the Department at no extra cost.
16.3 Penalty Clause for Preventive Maintenance: If the Party fails to attend to Scheduled
Periodic Maintenance which is issued by Department, due to the fault of the Contractor, a
Penalty of 0.5% of AMC Rates quoted for that particular equipment maintenance per week
or part thereof will be recovered subjected to maximum of 10% of the value of that particular
equipment Maintenance.
16.4 Party has to deploy manpower for attending to Stand-by duty for critical operations as per
the Quantity of Hours and Category with a prior intimation of 1 day by the department. If
the Party fails to deploy manpower for attending to Stand-by Duties, a Penalty of the Cost
quoted per Hour for each category will be deducted to the extent of requested man hours
of each category.
17. Work Contract / Package general definitions, terms and conditions:
17.1 The term “Service Receiver” means Satish Dhawan Space Centre – SHAR, a centre
under the Indian space research organization(ISRO) of the Department Of Space (DOS)
here in after called “Service Receiver” includes its Units/Entities/Groups/Divisions.
17.2 The term “Service Provider” means any registered establishment which will be performing
the Work package activities.
17.3 The term “Work Package” means a work package contract to provide services at different
entities/groups/divisions of Service Receiver as per the skill set.
17.4 The term “Employees” means all the employees, supervisors and staff of the service
provider deployed by the service provider to carry out the Work package tasks as defined
in the work package orders.
17.5 The term “Focal point” means the designated officials of Service Receiver, who will be
from the technical stream of the units/entities/Groups/Divisions, who will be coordinating
with the Supervisor of the Service provider. The focal point of Service Receiver shall be
mentioned in the respective Work Package Orders.
17.6 The term “Supervisor” means an identified person of the “Service Provider’ who will
supervise the works carried out by the qualified work-force of the “Service Provider”.
17.7 The term “Paying Authority” means the respective Sr. Accounts Officer/Accounts officer
of the Division/Group/Entity of service receiver.
18. GENERAL TERMS & CONDITIONS
18.1 The supervisor of service provider has to supervise the works at work station – A & B,
control all the workforce, responsible for bills preparation & submission, control the
workforce leaves.
18.2 Before quoting, the Service Provider may visit the site, if required, for getting first hand
information on the site conditions, Physical verification & condition of Equipment, location
& other aspects.
18.3 Tenderer shall give a minimum validity period of six months from tender due date for the
bids.
18.4 The Service Provider should issue individual letter of appointments for his staff and the
copies of offer of appointment shall be made available to the Contract Manager at all times.
18.5 The Service Provider shall ensure that all the payments to the Workforce are made through
only their respective Bank Account to the maximum possible extent. The particulars of the salary disbursement shall be made available both to the contract manager and the Accounts Officer, SDSC SHAR.
18.6 The Service Provider staff shall wear Personnel protective equipment (PPE) such as
Helmets, cotton uniform, safety belts, shoes, safety goggles etc.
18.7 Once in a year, the Service Provider shall issue for all his staff (mechanic staff &
operators/drivers) two pairs of Cotton Uniform and One pair of Safety Shoes. Also
Contactor shall issue one pair of Rain coats for his staff once in Two years.
18.8 Disputes, if any, with respect to the quality of the work or schedules, the decision of the
contract manager of the Workstation is final and binding on the Service Provider.
18.9 The Service Provider should not remove or engage any person without the knowledge and
concurrence of the Contract Manager.
18.10 The Department will not be responsible for any type of injury including death caused to the
Service Provider personal during the work.
18.11 Service Provider should abide by the statutory provisions, rules and regulations of Govt. of
India & Govt. of Andhra Pradesh in force from time to time for his personnel including
ensuring of minimum wages, employees contribution towards EPF with EPF account
number, ESI etc. Proof of remittance of EPF submission and employer’s contribution, ESI
etc shall be submitted to the Contract Manager every month. Any liability /compensation
and disputes arising out of employment by Service Provider under any act/statutory
provision shall rest with the Service Provider only.
18.12 The Service Providers shall indemnify the Purchaser/and/or any Officer, employee or any
assignee thereof harmless from any loss, damage, liability or expense, on account of
damage to the property or environment and injuries including death, to any persons not
limited to, employees or agents of the Department, employees of the Service Provider or
its sub-Service Providers, and all other persons performing any part of the work here under
any occurrence caused by any act of commission/omission of the Service Provider or his
sub-Service Providers or any of them. The Service Provider shall at his expense defend
any suits or proceedings brought against the Department on account thereof and shall
satisfy all judgments and pay all expenses which may be incurred by or rendered against
them, or any of them in connection therewith. The Service Provider shall fulfill all the
obligations required under different acts related to labour and as amended from time to
time. The Service Provider shall ensure minimum wages as per relevant act.
18.13 The Department will not accept any liability for the Service Provider, their officers,
employees or agents, servants or assignees or any of them for their property while on the
premises or in the service of the Department.
18.14 The work force deployed by the Service Provider shall remain the employees of Service
Provider and they will not acquire any claim what so ever for employment in SDSC SHAR
or Right for regulations as employees of the department. The Service Provider or staff
engaged by the Service Provider shall not have any right to claim for employment based
on the work done through this contract.
18.15 The Service Provider or his personnel shall adhere to all the security provisions of SDSC
SHAR. Service Provider and his personnel are responsible for any violation of security
provisions and indiscipline/agitation when they are inside the centre. Any resultant
liabilities/damages due to violation /indiscipline /agitation shall be borne by the Service
Provider.
18.16 It is the responsibility of the Service Provider/his staff to maintain cleanliness of the
maintenance bay, office working premises etc.
18.17 Service Provider should mobilize his team within fifteen days from the date of receipt of
Purchase Order.
18.18 The Service Provider shall bear all expenses regarding uniforms, compensations, wages
and allowances (DA), PF, ESI, Bonus as applicable relating to personnel engaged by him
and abide by the provisions of various labour legislations including weekly off and working
hours. The Service Provider shall pay the wages to the engaged personnel on or before
7th of every succeeding month, irrespective of delay in payment of Bill by the
Department for whatever reason. Wages payable shall not be less than the minimum
wages payable.
18.19 Service Provider shall submit workers EPF number and proof of submission of EPF,
ESI etc as applicable, every month for the previous month along with the monthly
bill with respect to all employees deployed by him to the Contract Manager. The Service
Provider shall specifically ensure compliance of various Labour Laws/Acts including with
(but not limited to) the following and their re-enactments/amendments/modifications.
i. Employees Provident fund & Misc. Provisions Act, 1952 and EPF Scheme, 1952
ii. Contract Labour (Regulation & Abolition) Act, 1970 & Central Rules, 1971
iii. Employees State Insurance Act, 1948 & ESI Central Rules/Regulations, 1950
iv. Employee Compensation Act, 1923 (in terms of Section 12 of the Act)
18.20 The Service Provider should maintain all the records and documents under various labour
laws applicable to contract labour / personnel and also Shops & Establishment Act/rules
applicable to his/her establishment and make them available to the Contract Manager at
all times. Indicative list of such records is given for example:
a. Muster Roll b. Wages Register
18.21 Proportionate revision in Minimum wages, EPF & ESI as applicable shall be paid to the
Service Provider staff and respective agencies as and when there is a revision in Minimum
wages, EPF & ESI. There shall be no revision of order value on this account other than
price variation clause.
18.22 The wages shall be paid to workmen without any deduction except those mentioned under
the payment of Wages Act and Minimum Wages act.
18.23 The Service Provider should ensure that his workmen are granted Leave with wages as
per applicable Act/Rules.
18.24 Department reserves its rights to withhold bills, if the Service Provider fails to produce proof
of remittance of GST, ESI, EPF, and Salaries to Contract Staff.
18.25 In case, the Service Provider fails to comply with any statutory/taxation liability under the
appropriate law, and as a result, if Service Receiver is put under any loss/obligation,
monetary or otherwise, Service Receiver will be entitled to get itself reimbursed either out
of the outstanding bills against any of the Work Package Orders or from the Security
Deposit to the extent of the loss or obligation in monetary terms.
18.26 The Service Provider shall be bound by the details furnished by them to the Service
Receiver while submitting the tender or at any subsequent stage (s). In case, any of the
documents furnished by them is found to be false at any stage, it would be deemed to be
a breach of the terms and conditions of the work package order making the Service
Provider liable for legal action besides termination of work packages orders and forfeiture
of security deposit.
18.27 The Service Provider shall be solely responsible for the redress of grievances / revolution
of disputes relating to the work-force engaged by them. Service Receiver shall no way
be responsible for the settlement of such disputes. Service Provider should maintain a
record of grievances received from their work force and action taken for settlement.
18.28 For all the intents and purposes, the Service Provider shall be the “Employer” within the
meaning of different labour legislations in respect of the work-force engaged by the Service
Provider at Service Receivers site. The work-force engaged by the Service Provider to the
Service Receiver shall not claim whatsoever of “Master of Servant” relationship nor have
any “Principal and Agent” relationship with or the Service Receiver for the said services.
18.29 In case of termination of the work package Order(s) on its expiry or otherwise, the work-
force engaged by the service Provider shall not be entitled to and all shall have no claim
whatsoever for any kind of employment in Service Receivers establishment and shall be
made known by the Service Provider to their workforce before being engaged.
18.30 The status of the Service Provider shall be that of an independent service Provider. The
Service Provider and its work-force performing under this Work package shall not be the
employees of Service Receiver. Neither the Service Provider nor its workforce shall be
considered as employees of Service receiver. Such work-force has no right for subsequent
regularization.
18.31 It is the responsibility of the Tenderer to mobilize the additional manpower to complete the
job in various sites.
18.32 No transportation facility will be provided by Purchaser. Hostel/Quarters or any other mode
of accommodation will be provided by the department subject to availability and approval
of Competent Authority.
18.33 It is the responsibility of the Tenderer to keep the place of work neat and tidy. In case of
any spillage of paint during mixing or painting, the Tenderer has to clean properly so that
the original surface is not spoiled.
18.34 All the steps and operations involved in the works are to be carried out strictly as per the
written procedure under Department work instructions and as per the safety and quality
regulations of ISRO and instructions by the departmental staff.
18.35 The concerned area, equipment, tools, vessels, etc., should be made clean after work and
good housekeeping shall be ensured.
18.36 Service Provider will be responsible for the safe custody, usage and return of all materials,
tools, and equipment’s, safety gadgets issued for execution of the work as per the contract.
18.37 Sub-contracting of the work after obtaining the contract will not be allowed.
19. AGE LIMIT
The Service Receivers premises being a High security Area, the work-force engaged for
the work by the Service Provider, will be required to follow the security requirements such
as possessing a valid entry pass issued by the Service Receiver an ID card by Service
Provider while entering the campus, maintaining high order of discipline while on duty. It
should be ensured by the Service Provider that only Indian Nationals between the age of
18 years and up to 60 years are included in the work-force and they should not have any
criminal background. However, the upper age can be relaxed by Five years, if staff is
possessing relevant experience more than 10 years.
20. TAXES & DUTIES: Service Provider shall furnish GST number and Service Accounting
Code in his bid specifically.
21. SECURITY DEPOSIT:
21.1 The Service Provider shall guarantee faithful execution of the contract in accordance with
the terms and conditions specified herein. As a performance security, the Service Provider
shall furnish a Security Deposit in the form of Bank Guarantee / DD / FDR at 10% of
Contract Value for Base year (excluding the GST) within 15 days from the date of signing
the contract in the form of Bank Guarantee /DD / FDR valid for entire contract period with
a claim period of two months beyond the validity of the Contract. The Security Deposit shall
not carry any interest and shall be returned after satisfactory completion of all the
contractual obligations. No execution of the date for submission of the Security Deposit will
be entertained by the Service Receiver and failure to submit in time will result in
cancellation of the Work Package Order(s).
21.2 The Service Provider has to agree for the Security Deposit at 10% of the Revised Order
value with price variation included on issue of amendment.
22. License for Contract Workers: The Service Provider shall wherever applicable, obtain
license under the contract Labour (Regulation & Abolition) Act according to the number of
workers engaged by him on contract basis, depositing the prescribed fees and complying
with the formalities.
23. Legal Terms and conditions:
23.1 The Service provider shall abide by the law of the land including, Contract Labour
(Regulation & Abolition Act, and all labour related laws/acts or any new
regulations/legislations enacted in the regard and its compliance as applicable during the
tenure of the work package order. Service Receiver shall in no way be responsible for any
default of the service provider regarding statuary obligation. The service Provider has to
ensure compliance of the above provisions at the time of submission of bill to the Service
receiver and while making payments to their work-force at all times during the currency of
the work package.
23.2 The Service Provider(s) shall mandatorily undertake to insure their workforce
comprehensively against any risks during the course of work undertaken by them in
Service Receivers Work place through a Comprehensive All Risk Insurance (ARI) Policy
obtained from any of the Insurance companies as approved by Insurance Regulatory &
Development Authority of India (IRDA). The service Providers shall have to furnish
originals of the ARI policy along with premium receipts and other papers related there to
the officer concerned of the service Receiver within 15 days from the date of
commencement of Work Package Orders. Entry Passes will be issued to workforce of the
service provider only after receipt of the original policy documents from the Service
Provider concerned. Individual policies with a minimum coverage of Rs.10 Lakhs per
person in the name of service Providers Workforce shall be taken by the Service Provider.
23.3 The service Provider shall discharge all the legal obligations in respect of the work-force
engaged by them for the execution of the work in respect of their remuneration and Service
conditions and shall also comply with all the rules and regulations and provisions of the
law in force that may be applicable to them from time to time. The Service Provider shall
indemnify the service Receiver from any claim, loss or damages that may be caused to it
on account of any failure to comply with the obligations under various laws. In case of any
dispute, the decision of the service receiver shall be final and binding on the service
Provider.
23.4 The timely payment of remuneration to the work-force, remittance of EPF and ESI shall be
the sole responsibility of the service provider. For any default with regard to any statuary
obligation, the Service Provider is solely responsible.
23.5 The service provider shall also be liable for the remittance of all Taxes, Levies, Cess etc.,
on account of service rendered by them to the concerned authorities from time to time as
per extant rules regulations in the matter.
23.6 The service provider shall completely be responsible to maintain the attendance,
acquaintance of remuneration paid, EPF, ESI and Comprehensive Mediclaim policy of their
workforce, as the case may be. Governmental authorities shall have the right to inspect
these records at any time and take necessary penal action for noncompliance of these
provisions, if any. The service provider is fully responsible for timely claiming and
disbursing monthly payment of remuneration to their work-force engaged in the campus of
the Service receiver, within the time limit prescribed in the relevant Act/rules.
23.7 The service provider shall submit to the respective paying authority of the service receiver,
the details of the monthly remuneration in the form of a pay-slip made by them to their
workforce including the deductions, by 10th of the following month. Payment disbursement
shall be made of the service Provider by the Service Receiver on monthly basis for the
actual units of work completed on test completion and part thereof and on receipt of the
invoice/bill which is duly certified by the Focal points and approved by divisional
Head/Group head in the campus of the Service Receiver and submitted to the respective
Sr. Accounts Officer, as the case may be, in the prescribed format together with the
following documentary proof.
23.8 Proof of payment of remuneration made to the work-force for the preceding month duly
certified by the service Provider.
23.9 Proof of remittance of both employees and Employers contribution towards EPF, ESI or
Medi-claim policy, as the case may be, made for the preceding month.
23.10 The Service Provider, upon being served with the work package Orders shall engage the
work-force as per the requirements sought for by the service receiver.
23.11 In case of rejection of any workforce of the service provider by the service receiver, based
on the bio-data, the Service Provider shall offer alternate workforce without delay.
23.12 The focal point of the service receiver shall verify the bio-data of the workforce submitted
by the Service Provider and engage those workforces, who are having the required
expertise in the respective Skill set. This shall have the concurrence of the Respective
Entity Chief. The list of the selected workforce shall invariably be forwarded by the
respective Focal Point to the Administrative Officer, GAD, P&GA, with necessary
recommendations for arranging Entry pass.
23.13 The Service Provider shall not assign, transfer or convey in whole or in part, this work/work
package order(s) to anyone. The Service Provider shall not delegate any of its obligations
or duties under the work package order(s) to anyone. The Service Provider shall not
assign, pledge as collateral, grant a security interest in, create a lien against or otherwise
encumber any payments that may or will be made to the Service Provider under this Work
Package Order(s).
23.14 The Service Provider shall maintain a register for the execution of the work and get
endorsement of the same from the focal point of the Service Receiver every week for
having completed the work satisfactorily.
23.15 The Service Receiver reserves the right to reject any of the workforce engaged by the
Service Provider, if the presence or activity of such workforce is determine to the interest
or discipline or security of the Service Receiver.
23.16 The Government of India has enacted the micro, small and medium Enterprises
Development (MSMED) Act 2006 and the preferences that are extendable to the MSME
units including women and SC/ST Entrepreneur’s as issued by the government of India
from time to time and whatever feasible, will be applicable for this Work Package Order.
24. Safety and Security:
24.1 The Service Provider shall take all safety precautions required for the execution of the
work. They shall also responsible for any loss or damage caused to Service Receivers
property/personnel due to the negligence of the work-force and shall make good the losses
by the Service Provider at their own cost, failing which cost thereof, shall be recovered
from the outstanding/running bills/Security Deposit of the Service Provider.
24.2 The Service Receiver shall not be responsible for any damages, losses, claims, financial
or other injury to any of the work-force engaged by the Service Provider in the course of
their performing the functions/ duties, or for payment towards any compensation. The work-
force shall adequately be insured by the Service Provider against accidents including loss
of life.
24.3 The Service Provider shall solely be responsible for any theft, pilferage or misbehaviour
committed by any of the work-force while carrying out the Service(s) and the Service
Receiver reserves the right to forefeet the Security Deposit/ Running bills/ any outstanding
payment to the Service Provider.
24.4 In case, the Work-Force engaged by the Service Provider commits any act of commission
that amounts to misconduct/indiscipline/incompetence, the Service Provider shall forthwith
remove the work-force under intimation to the focal point. The Service provider shall
replace immediately any of its work-force who is/are found unacceptable because of
security risks, incompetence, conflict of interest, improper conduct etc. upon receiving
written notice from Service Receiver.
24.5 The work-force engaged by the Service Provider at the Service Receivers Campus shall
not carry any technical/Electronic gadgets inside the Service Receivers campus and shall
follow all security and safety norms a prescribed by the Service Receiver, from time to time.
24.6 The Service Provider shall ensure that the work-force engaged by them are disciplined and
do not participate in any acts prejudicial to the interest of the Service Receiver.
24.7 The Service Provider shall solely be responsible for the redress of grievances/dispute
relating to work-force engaged.
24.8 The work-force engaged by the Service Provider at Service Receivers campus shall wear
cotton Uniform Dresses while they are at work and the colour of the said uniform shall be
decided by the Service Provider in consolation with the Service Receiver.
24.9 It is the responsibility of the Tenderer to take care of safety of his personnel while working
at site. Department is not responsible for any untoward incidents/accidents. Tenderer has
to ensure that all the personnel are working with safety accessories. Painters shall use
hand gloves while painting.
24.10 All personnel of the Tenderer working at site in Sriharikota shall be insured against
accidents causing injury/death during the contract period. Copy of the Insurance policy
shall be made available to the department.
25. Joint and Several liabilities: If the Service Provider is a joint entity, consisting of more
than one, partnership, corporation or other business organization, all such entities shall be
jointly and severally liable for carrying out the activities and obligations of this Work
Package Order(s) and for any default of activities and obligations.
26. Severability: If any provision of this Work Package Order(s) is determined by a court of
component jurisdiction to be invalid or unenforceable, such determination shall not affect
the validity or enforceability of any other part or provision of this Work Package Order(s).
27. Immunity from Liability: Every person who is a party to the Work Package Order(s) is
hereby notified and agrees that the State, Service Receiver and all its employees, agents,
successors and assigns are immune from liability and suit for or from Service Provider
activities involving third parties and arising from the Work Package.
28. Intellectual Property: The Service Provider agrees that they should not use the
Name/logos of the Service Receiver in any manner, including commercial advertising or
as a business reference, including ID cards without the approval of the Service Receiver.
Any violation will result in cancellation of the Work Package Order(s) including forfeiture of
Security Deposit.
29. Down Time Compensation:
29.1 In case of delay in completion of the work as per the work Package contract, Down Time
Compensation @ 0.5% of the Work Package Order(s) value per week or part thereof will
be recovered from the Bill(s) to a maximum limit of 10%. The quantum of down Time
Compensation to be recovered will be decided by the Service Receiver after assessing the
quantum of work delayed and the decision will be final and binding on the Service Provider.
29.2 The Service Provider is responsible to complete the quantum of work as specified in the
Work Package Order(s) and as required by the Service Receiver and in case of absence
of the work-force, the successful Service Provider should provide suitable replacement and
for this purpose to ensure timely completion and the Service Provider shall keep a panel
of work-force whose Character and Antecedents are verified.
30. Termination and Short Closing of Contract:
30.1 Under the normal circumstances, termination/short closing of the Work Package Order(s)
is not foreseen. However, in case of repeated non-performance of the Work Package
Order(s), owing to deficiency of service or breach of Order conditions or cessation of the
requirement, the Service Receiver reserves the right to terminate the Work Package
Order(s) wholly or partly by giving a prior notice of not less than 30 days, without any
obligation on its side.
30.2 If the Service Provider want to withdraw the Work Package Order(s) voluntarily, a prior to
notice of 30 days is required.
30.3 The Work Package Order(s) is liable to be terminated with prior notice and the security
deposit under the Work Package Order(s) shall be liable to be forfeited in the following
circumstances.
30.4 For the breach of any material term, condition or provision of this Work Package Order(s)
by the Service Provider. In case the Service Provider provides any statement,
representation or certification and the same is found false, deceptive or materially incorrect
or incomplete.
30.5 The Service Provider or any of its workforce and agents commits or has committed or
engages/engaged in fraud, misappropriation embezzlement and, malfeasance. The
Service Provider terminates or suspends their business, without going prescribed notice.
The Service Providers license or certification is suspended, terminated, revoked or
forfeited.
30.6 If the Service Provider failed to comply with any applicable law of the land. In the event of
sustenance of loss by the Service Receiver due to the premature termination of Work
Package Order(s) by the Service Provider, the same shall be recovered from the security
deposit.
31. Parallel / Adhoc Work Package Order: The Service Receiver reserves the right to enter
into parallel/adhoc work Package Order(s) with one or more Service Provider(s) in order
to facilitate deployment of work-force during the currency of the Work Package Order(s)
for availing the same or similar Services.
32. Volume of Work: The Requirement of work force purely depends upon the activities of
Service Receiver for work Package. The mere mention of the number of work-force against
this Work Package Order(s) does not by itself confer any right on the Service Provider to
demand that work relating to or any item thereof, should necessarily or exclusively be
entrusted to the Service Provider. The Service Receiver reserves the option for allocation
of work force to meet the works to be carried out and the service Provider shall not have
any right in this regard. The work allocation may not be uniform every month and hence no
guarantee can be given as to the definite volume of work which will be entrusted to the
Service Provider at any time or during the period of the Work Package Order(s).
33. Force Majeure Clause:
In case, completion of job is delayed by any circumstances such as acts of god, sabotages,
civil common, riots, insurrections, revolutions, earthquake, fire, flood or other natural
events beyond the control of the Service Provider, which makes their work-force unable to
complete the tasks assigned to them in time, then the Service Provider shall give notice
within 15 days to the Service Receiver in writing of his claim for an extension of time. The
Service Receiver on receipt of such notice after verification if necessary may agree to
extend the period of Work Package as may be reasonable without prejudice to other terms
and conditions of Work Package Order(s).
34. Applicable Law, Jurisdiction and Arbitration:
34.1 The contract shall be interpreted, constructed and governed by the laws in India. In the
event of any dispute/s, differences or claims arising out of or relating to the interpretation
and application of the Work Package Order(s), such dispute/s or difference/s or claim/s
shall be settled amicably by mutual consultations of the good office of the respective parties
and recognizing their mutual interests attempt to reach a solution satisfactory to both the
parties. If such a resolution is not possible, within 30 days from the date of receipt of written
notice of the existence of such dispute/s, then the unresolved dispute/s or difference/s or
claim/s shall be referred to the sole arbiter appointed by the Parties by mutual consent in
accordance with the rules and procedures of Attribution and conciliation Act 1996 as
amended from time to time. The attribution shall be conducted in Bengaluru in the
Arbitration and Conciliation Centre – Bengaluru (Domestic and International) as per its
rules and regulations. The Expenses for the arbitration shall be shared equally or as may
be determined by the arbitrator. The considered and written decision of Arbitrator shall be
final and binding between the Parties. The applicable language for Arbitration shall be
“English” only.
34.2 Work under the work package Order(s) shall be continued by the Service Provider during
the pendency of arbitration proceedings, without prejudice to a final adjustment in
accordance with the decisions of the Arbitrator unless otherwise directed in writing by the
Service Receiver or unless the matter is such the works cannot be possibly continued until
the decision (whether final or interim) of the arbitrator.
35. PRICE VARIATION PER YEAR:
Price quoted by the party is base price for the first year of the contract and the contract
value will be revised every year based on the following variation formula and no other
formula will be acceptable.
Price Variation Formula for Contract Price per year
Fo = 0.25 X Fi + 0.75 X Fi X (Ro/Ri)
Fo = Revised contract value per year at the current month and year of calculation
Fi = Contract Value per year at the Base month and year
Ro= All India Consumer Price Index (CPI) for labour published by RBI for the current month
year of calculation
Ri = All India Consumer Price Index for labour published by RBI for the base month & year
Contract Value = sum of the maintenance cost of quotation format-2
Price Variation Formula for Man day rates of workforce (Price Schedule)
Mo = 0.25 X Mi + 0.75 X Mi X (Ro/Ri)
Mo = Revised Man day rate (Price Schedule) for the current month & year
Mi = Revised Man day rate (Price Schedule) for Base month & year
Price variation due to escalation is subject to adherence of the following conditions:
Escalation formula is applicable for upward/downward variation in price during Contract
Period excluding the first 12 months.
36. Arbitration: Disputes if any, will be settled mutually, failing which will be referred to one
man Arbitrator to be appointed by Director, SDSC SHAR, in accordance with Arbitration
and Conciliation Act 1996, whose decision shall be final and binding on both parties.
37. INFORMATION TO BIDDERS
37.1 The quotation should be in TWO parts
PART-1 : TECHNICAL & COMMERICAL BID
PART-2 : PRICE BID
37.2 BID SUBMISSION: Bids duly filled in by the Bidder should invariably be submitted as
stipulated in the Letter inviting bid. Bids shall be submitted in the following manner.
37.2.1 Part – I : Un priced Techno-Commercial Part of the Bid
(a) Complete Techno–commercial part of the bid shall be filled online in the vendor Specified
Terms form of the e-tender. Any documents related (demand draft for tender fee & EMD
), technical literature, and any other relevant documents as per the tender shall be
scanned in lower resolution format and uploaded to the e-tender under ‘Documents
solicited from Vendor’ form only in ISRO e-procurement portal (https://
eprocure.isro.gov.in ). In case if the space for uploading is not sufficient, hard copy of
the balance documents shall be submitted before due date.
(b) The following enclosures shall be attached along with the techno-commercial bid as
attachments
1. Confirmation to the pre-qualification criteria
2. Confirmation/ Compliance statement as per Annexure-8
3. Any other techno-commercial information related to the tender
4. Confirmation of submission of price bid as per Quotation Format-1, 2 & 3 along with
‘Price Bid’ (Part-II)
Envelope of Technical Bid shall be marked with following:
PART-I TECHNO-COMMERCIAL BID
Name of client : Satish Dhawan Space Centre SHAR
Indian Space Research Organization
Title of the proposal :
Due date and time of the opening : DD/MM/YYYY
From
(Name of the bidder with address)
:
To:
The Head, Purchase & Stores
Satish Dhawan Space Centre SHAR
ISRO, Dept. of Space, Govt. of India
Sriharikota, SPSR Nellore Dist,
Andhra Pradesh, India - 524124,
The deviation statement and checklist shall be filled online, without which the bid will not be
considered.
37.2.2 Part – II : Price Part of the Bid for the Work
a) Price bid shall be filled in the on-line ‘price bid’ form of the e-tender only in ISRO e-
procurement website https://eprocure.isro.gov.in . The cost of spares and other prices shall
be filled in the respective forms available on-line in the e-portal. Any other terms and
conditions given in this part shall not be considered and if insisted upon by the Bidder, bids
are liable for rejection.
b) SDSC SHAR may open Part – I of the bid on the due date of opening subject to meeting
the minimum evaluation criteria. Price Bids (Part-II) of technically and commercially
acceptable offers shall be opened at a later date. SDSC SHAR reserves the right to reject
any or all the Bids without assigning any reasons thereof.
The break-up of prices as per Quotation Format - 1, 2 & 3 (with prices) shall be enclosed
along with price bid.
37.2.3 Bids / offers with price details in Techno-Commercial Offer (Part –I) will be rejected.
37.2.4 SDSC SHAR reserves rights to place order for either full quantities of all items or
partial quantities and partial items based on the unit rates available.
38. PRE-QUALIFICATION CRITERIA
38.1 Bidder shall meet the following qualification criteria and bidder shall submit all the relevant
documents supporting the qualification criteria. Bids of those who don’t meet the criteria
will not be considered for evaluation.
(a) Tenderer shall have a minimum of Three years of experience in maintaining at least
25 Nos. of Automotive/Forklifts/ Cranes in a year and furnish the list of clients along
with copies of Work orders/Purchase orders (Government & private) along with
Techno-Commercial bid (Part - I).
(b) Tenderer shall have clean chit in the organization where he worked and producing to
this tender has basic Pre-Qualification.
(c) The Bidder should have Average Annual Turnover of minimum 100 lakhs, failing
which his Offer will not be considered for evaluation. And the Bidder should submit
Profit & Loss Accounts, Balance Sheets duly Certified by the auditor and IT
returns for the last THREE financial years.(2016-17, 2017-18 and 2018-19 only)
(d) Department reserves the right to REJECT the OFFER, when the offer is not meeting
the Minimum wages criteria and applicable Statutory Norms.
(e) The Bidder shall have to produce Labour License, EPF registration, ESI
registration and GST registration mandatorily.
Annexure- 2
Page 1 of 18
DETAILS OF MATERIAL HANDLING EQUIPMENT
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
EQUIPMENT TO BE MAINTAINED AT WORK STATION – A (VALF)
1 2T GODREJ FORKLIFT VALF/FL/2T/01
2 T
GODREJ GX 200D
7.00 X 12 (SOLID TYRES)
02 6.50 X 10
(SOLID TYRES) 02
MON 8
QTY 3
ANN 1
2 3T GODREJ FORKLIFT-1 VALF/FL/3T/01
3 T
GODREJ GX 300D
7.00 X 12 – 12 PR 04 6.50 X 10 – 10 PR 02
MON 8
QTY 3
ANN 1
3 3T GODREJ FORKLIFT-2 VALF/FL/3T/02
3 T
GODREJ GX 300D
7.00 X 12 – 12 PR 04 6.50 X 10 – 10 PR 02
MON 8
QTY 3
ANN 1
4 3T GODREJ FORKLIFT-3 VALF/FL/3T/03
3 T
GODREJ GX 300D
7.00 X 12 (SOLID TYRES)
02 6.50 X 10
(SOLID TYRES) 02
MON 8
QTY 3
ANN 1
5 5T GODREJ FORKLIFT VALF/FL/5T/01
5 T
GODREJ GX 500D
7.50 X 20 – 12 PR 04 7.50 X 20 – 12 PR 02
MON 8
QTY 3
ANN 1
6 10T GODREJ FORKLIFT VALF/FL/10T/01
10 T
GODREJ GX 1000D
9.00 X 20 – 16 PR 04 9.00 X 20 – 16 PR 02
MON 8
QTY 3
ANN 1
7 16T VOLTAS FORKLFIT VALF/FL/16T/01
16 T
VOLTAS DV
1612
12.00 X 20 – 20
PR
04
12.00 X 20 – 20
PR
02
MON 8
QTY 3
ANN 1
8 EICHER TRACTOR-1 VALF/HA/15T/01
15 T
EICHER EURO
POWER 6100
7.50 X 16 – 8 PR 02 16.9 X 28 – 12 PR 08
MON 8
QTY 3
ANN 1
Annexure- 2
Page 2 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
9 EICHER TRACTOR-2 VALF/HA/15T/02
15T
EICHER EURO
POWER 6100
7.50 X 16 – 8 PR 02 16.9 X 28 – 12 PR 08
MON 8
QTY 3
ANN 1
10 EICHER TRACTOR-3
VALF/HA/15T/03
15T
EICHER EURO
POWER 6100
7.50 X 16 – 8 PR 02 16.9 X 28 – 12 PR 08
MON 8
QTY 3
ANN 1
11 EICHER TRACTOR-4 VALF/HA/15T/04
15T
EICHER MAKE 5660
7.50 X 16 – 8 PR 02 16.9 X 28 – 12 PR 08
MON 8
QTY 3
ANN 1
12 ASHOK LEYLAND HIPPO HAULER 1/13 VALF/HA/49T/01
49T GCW
ASHOK LEYLAND
11.00 X 20 – 16 PR
02 11.00 X 20 – 16
PR 08
MON 10
HALF 1
ANN 1
13 ASHOK LEYLAND HIPPO HAULER ¼ VALF/HA/49T/02
49T GCW
ASHOK LEYLAND
11.00 X 20 – 16 PR
02 11.00 X 20 – 16
PR 08
MON 10
HALF 1
ANN 1
14 VOLVO HAULER -1 VALF/HA/49T/03
49T GCW
VOLVO FM 400
11.00 R 20 – 16 PR
02 11.00 R 20 – 16
PR 08
MON 10
HALF 1
ANN 1
15 VOLVO HAULER -2 VALF/HA/49T/04
49T GCW
VOLVO FM 400
11.00 R 20 – 16 PR
02 11.00 R 20 – 16
PR 08
MON 10
HALF 1
ANN 1
16 VOLVO HAULER -3 VALF/HA/49T/05
250T GCW
VOLVO FH 520
11.00 R 20 – 16 PR
02 11.00 R 20 – 16
PR 08
MON 10
HALF 1
ANN 1
17 AMW HAULER - 1 VALF/HA/49T/06
49T GCW
AMW 4923 TR
11.00 R 20– 16PR 02 11.00 R 20 – 16
PR 08
MON 10
HALF 1
ANN 1
18 AMW HAULER - 2 AMW 11.00 X 20 – 16 02 11.00 X 20 – 16 08 MON 10
Annexure- 2
Page 3 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
VALF/HA/49T/07 49T GCW
4923 TR PR PR HALF 1
ANN 1
19 TATA PRIMA HAULER VALF/HA/49T/08
49T GCW TATA
10.00 X 20 –16 PR
02 10.00 X 20 –16 PR 08
MON 10
HALF 1
ANN 1
20 70T BEML HAULER - 1 VALF/HA/70T/01
70T BEML 9.00 x 20 – 16 PR 02 9.00 x 20 – 16 PR 04
MON 10
HALF 1
ANN 1
21 70T BEML HAULER - 2 VALF/HA/70T/02
70T BEML 9.00 x 20 – 16 PR 02 9.00 x 20 – 16 PR 04
MON 10
HALF 1
ANN 1
22 TATA ACE CYLINDER TRANSPORTER AP 26 X 7113
1.0T
TATA
TATA ACE
145 / 80 R 12 02 145 / 80 R 12 02
MON 8
QTY 2
HALF 1
ANN 1
23 TATA ACE AGNI MOTOR TRANSPORTER AP 26 X 7116
1.0T
TATA
TATA ACE
145 / 80 R 12
02
145 / 80 R 12
02
MON 8
QTY 2
HALF 1
ANN 1
24
TATA ACE SAMPLE PROPELLANT TRANSPORTER AP 26 TT 5148
1.0T TATA
TATA ACE 155/80 D 12 8
PR
02 155/80 D 12 8 PR
02
MON 8
QTY 2
HALF 1
ANN 1
25 TATA 407 MINI EXPLOSIVE VAN AP26 TT 0510
5.0 T
TATA 407
EX 8.25 X 16 - 16PR 02 8.25 X 16 - 16PR 02
MON 8
QTY 2
HALF 1
ANN 1
26 TATA 407 UPLINK VEHICLE
5.0 T
TATA 407 EX
8.25 X 16 - 16PR 02 8.25 X 16 - 16PR 02
MON 8
QTY 2
HALF 1
ANN 1
Annexure- 2
Page 4 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
27 TATA 807 SAFETY VAN AP26 T 2240
TATA 807 7.50 X 20 - 12PR 02 7.50 X 20 - 12PR 04
MON 8
QTY 2
HALF 1
ANN 1
28 TATA 709 SAFETY VAN AP26 X 7114
TATA 709 EX
7.50 X 16 - 16PR 02 7.50 X 16 - 16PR 04
MON 8
QTY 2
HALF 1
ANN 1
29 TATA 709 EXINDUSTIAL MINI TRUCK AP26 W 9868
4 T TATA 709
EX 7.50 X 16 - 16PR 02 7.50 X 16 - 16PR 04
MON 8
QTY 2
HALF 1
ANN 1
30 TATA 1210 E PLATFORM TRUCK, AP26 T 791
10T TATA 1210
E 7.50 X 16 - 16PR 02 7.50 X 16 - 16PR 04
MON 8
QTY 2
HALF 1
ANN 1
31 TATA 1613 EXPLOSIVE VAN AP26 X 1954
7.0 T
TATA 1613 10.00 X 20 – 16
PR 02
10.00 X 20 – 16 PR
04
MON 8
QTY 2
HALF 1
ANN 1
32 10T HYDRA PICK ‘N’ CARRY CRANE VALF/MC/10T/01
10 T TIL
11.00 X 20 – 16 PR
04 13.00 X 24 – 12
PR 02
QTY 3
ANN 1
33 15T TYRE MOUNTED TIL CRANE, VALF/MC/15T/01
15 T TIL
14.00 x 25 – 24 PR
02 14.00 x 25 – 24
PR 02
QTY 3
ANN 1
34 10T AIR SUSPENSION TRAILER VALF/ST/AST/10T/01
10 T
PL HAULWEL TRAILER
- - -
- -
7.50 X 16 – 16 PR
08
HALF 1
ANN 1
35 15T AIR SUSPENSION TRAILER VALF/FT/AFT/15T/01
15 T
PL HAULWEL TRAILER
8.25 R 15 – 18 PR
04
8.25 R 15 – 18 PR
04
HALF 1
ANN 1
Annexure- 2
Page 5 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
36 18T AIR SUSPENSION TRAILER VALF/AST/18T/01
18 T
PL
HAULWEL TRAILER
8.25 R 15 – 14 PR
04
8.25 R 15 – 14 PR
04
HALF 1
ANN 1
37 GOLDHOFER TRAILER-2 VALF/HT/65T/02
65 T
HYDRAULIC TRAILER
7.50 R 15 – 16 PR
32
- - -
- -
QTY 3
ANN 1
38 GOLDHOFER TRAILER-3 VALF/HT/65T/03
65 T
HYDRAULIC TRAILER
7.50 R 15 – 16 PR
32
- - -
- -
QTY 3
ANN 1
39 COMETTO TRAILER-1 VALF/HT/70T/01
70 T
HYDRAULIC TRAILER
7.50 R 15 – 16 PR
32
- - -
- -
QTY 3
ANN 1
40 4T FLAT BED FULL TRAIER VALF/FT/4T/01
4.0 T
- - -
7.50 X 16 (SOLID TYRES)
02
7.50 X 16 (SOLID TYRES)
02
HALF 1
ANN 1
41 5T FLAT BED FULL TRAILER VALF/FT/5T/01
5.0 T
- - -
7.00 x 12 (SOLID TYRES)
02
7.00 x 12 (SOLID TYRES)
02
HALF 1
ANN 1
42 8T FLAT BED FULL TRAILER VALF/FT/8T/01
8.0 T
- - -
7.50 X 16 – 16 PR 04 7.50 X 16 – 16 PR 04
HALF 1
ANN 1
43 10T FLAT BED FULL TRAILER-1 VALF/FT/10T/01
10.0
T
- - -
7.00 X 12 – 12 PR
04
7.00 X 12 – 12 PR
04
HALF 1
ANN 1
44 10T FLAT BED FULL TRAILER-2
VALF/FT/10T/02
10.0
T
PL HAULWEL
TRAILER
7.50 X 15 – 16 PR
04
7.50 X 15 – 16 PR
04
HALF 1
ANN 1
45 10T WELL BED TRAILER-1 VALF/LT/10T/01
10.0
T
PL HAULWEL TRAILER
7.50 x 20 – 12 PR
04
7.50 x 20 – 12 PR
08
HALF 1
ANN 1
46 10T WELL BED TRAILER-2 VALF/LT/10T/02
10.0 T
PL HAULWEL
8.25 R 15 – 14 PR 04 8.25 R 15 – 14 PR 04 HALF 1
ANN 1
Annexure- 2
Page 6 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
47 15T FLAT BED FULL TRAILER-1 VALF/FT/15T/01
15.0
T
PL HAULWEL TRAILER
7.00 X 12 – 12 PR
04
7.00 X 12 – 12 PR
04
HALF 1
ANN 1
48 15T FLAT BED FULL TRAILER-2 VALF/FT/15T/02
15.0
T
SATRAC TRAILER
7.50 X 15 – 16 PR
04
7.50 X 15 – 16 PR
04
HALF 1
ANN 1
49 30T DEAD WEIGHT TRANSPORTER VALF/FT/30T/01
30.0T
PL HAULER
TRAILER
10.00 X 20 – 16
PR
04
10.00 X 20 – 16
PR
08
HALF
1
ANN 1
50 30T FLAT BED SEMI TRAILER VALF/ST/30T/01
30.0T
PL HAULER TRAILER
- - -
04
10.00 X 20 – 16 PR
12
HALF 1
ANN 1
51 PS0 TRANSTILT VALF/ST/PS0/01
20 T SEMI
TRAILER
- - -
- -
10.00 X 20 – 16 PR
08 HALF 1
ANN 1
52 CRYO TRANSTILT VALF/ST/CT/01
25 T SEMI
TRAILER - - - - - 7.50 X 20 – 12 PR 12
HALF 1
ANN 1
53 CRYO TRANSTILT C25 VALF/ST/CT/02
50 T SEMI
TRAILER - - - - - 7.50 X 20 – 12 PR 12
HALF 1
ANN 1
54 L40 TRANSTILT VALF/ST/L40/01
25 T SEMI
TRAILER
- - -
- -
10.00 X 20 – 16 PR
12 HALF 1
ANN 1
55 L110 TRANSTILT VALF/ST/L110/01
50 T SEMI
TRAILER
- - -
- -
10.00 X 20 – 16 PR
16 HALF 1
ANN 1
56 PS0M – XL TRANSTILT VALF/ST/PS0-XL/01
30 T SEMI
TRAILER
- - -
- -
10.00 X 20 – 16 PR
12 HALF 1
ANN 1
57 12T SEMI TRAILER – 1 VALF/HAT/N2-2X2/01 12T
SEMI TRAILER
- - - - - 8.25 X 20 – 14 PR 04 HALF 1
ANN 1
58 12T SEMI TRAILER – 2 VALF/HAT/N2-2X2/02
12T SEMI
TRAILER - - - - - 8.25 X 20 – 14 PR 04
HALF 1
ANN 1
59 LIQUID HYDROGEN TANKER-I LSSF/ST/LH-2/45CM/01
20T SEMI
TRAILER - - - - -
10.00 X 20 – 16 PR
08 HALF 1
ANN 1
Annexure- 2
Page 7 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
60 LIQUID HYDROGEN TANKER-II LSSF/ST/LH-2/45CM/02
20T SEMI
TRAILER - - - - -
10.00 X 20 – 16 PR
08 HALF 1
ANN 1
61 LIQUID OXYGEN TANKER LSSF/ST/OXY/45CM/01
10T SEMI
TRAILER - - - - -
10.00 X 20 – 16 PR
08 HALF 1
ANN 1
62 15 KL LIQUID HYDROGEN TANKER-I LSSF/ST/LH-1/15KL/01
15T
SEMI TRAILER
- - - - - 7.50 R 15 – 16 PR 08 HALF 1
ANN 1
63 40 KL LIQUID HYDROGEN TANKER-I LSSF/ST/LH-1/40KL/01
30T
SEMI TRAILER
- - - - - 8.25 R 16 – 16 PR 12 HALF 1
ANN 1
64 40 KL LIQUID HELIUM TANKER-I LSSF/ST/LHE-1/40KL/01
30T
SEMI TRAILER
- - - - - 8.25 R 16 – 16 PR 12 HALF 1
ANN 1
65 ADITHYA MOTOR TRANSPORTER VALF/FT/1T/01
1 T
- - -
7.50 X 16 – 16 PR
02
- - -
- -
HALF 1
ANN 1
66 AGNI MOTOR TRAILER-1 VALF/AT/1T/01
1 T FULL
TRAILER 4.00 X 8 – 6 PR 2
- - -
- -
HALF 1
ANN 1
67 AGNI MOTOR TRAILER-2 VALF/AT/1T/02
1 T FULL
TRAILER 4.00 X 8 – 6 PR 2
- - -
- -
HALF 1
ANN 1
68 JEEP TRAILER-1 VALF/JT/1T/01
1 T
TRAILER
6.00 X 16 – 8 PR
2
- - -
- -
HALF 1
ANN 1
69 JEEP TRAILER-2 VALF/JT/1T/02 1 T
TRAILER
6.00 X 16 – 8 PR
2
- - -
- -
HALF 1
ANN 1
70 RH 200 TRANSPORTER VALF/FT/RH200/2T/01
2 T SEMI
TRAILER - - - - - - - - - -
HALF 1
ANN 1
71 RH 560 TRANSPORTER-2 VALF/FT/RH560/3T/01
3 T FULL
TRAILER - - - - - - - - - -
HALF 1
ANN 1
72 RH 560 TRANSPORTER-1 VALF/FT/RH560/6T/01
6 T FULL
TRAILER - - - - - - - - - -
HALF 1
ANN 1
Annexure- 2
Page 8 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
73 NITROGEN TANKER (8CM) LSSF/FT/N2-8CM/01
10T SEMI
TRAILER - - - - -
10.00 X 20 – 16 PR
04 HALF 1
ANN 1
74 10T N2 MODULE TRAILER-I LSSF/FT/N2-10T/01
10T FULL
TRAILER 8.25 X 20 – 14 PR 04 8.25 X 20 – 14 PR 04
HALF 1
ANN 1
75 10T N2 MODULE TRAILER-II LSSF/FT/N2-10T/02
10T FULL
TRAILER 8.25 X 20 – 14 PR 04 8.25 X 20 – 14 PR 04
HALF 1
ANN 1
76 10T N2 MODULE TRAILER-III LSSF/FT/N2-10T/03
10T FULL
TRAILER 8.25 X 20 – 14 PR 04 8.25 X 20 – 14 PR 04
HALF 1
ANN 1
77 10T N2 MODULE TRAILER-IV LSSF/FT/N2-10T/04
10T FULL
TRAILER 8.25 X 20 – 14 PR 04 8.25 X 20 – 14 PR 04
HALF 1
ANN 1
78 12T SEMI TRAILER – I CTF/N2-2X2/01
12T SEMI
TRAILER - - - - - 8.25 X 20 – 14 PR 04
HALF 1
ANN 1
79 12T SEMI TRAILER – II BS/N2-2X2/02
12 T SEMI
TRAILER - - - - - 8.25 X 20 – 14 PR 04
HALF 1
ANN 1
80 12T SEMI TRAILER – III CTF/03
12 T SEMI
TRAILER - - - - - 8.25 X 20 – 14 PR 04
HALF 1
ANN 1
81 12T SEMI TRAILER – IV CTF/04
12 T SEMI
TRAILER - - - - - 8.25 X 20 – 14 PR 04
HALF 1
ANN 1
82 DM WATER TANKER – I LSSF/FT/DMW-1.5KL/0.1
5 T FULL
TRAILER 7.50 X 16 – 16 PR 02 7.50 X 16 – 16 PR 02
HALF 1
ANN 1
83 DM WATER TANKER - II LSSF/FT/DMW-5KL/0.2
5 T FULL
TRAILER 10.00 X 20 – 16
PR 02
10.00 X 20 – 16 PR
02 HALF 1
ANN 1
84 DM WATER TANKER - III LSSF/FT/5KL/02
5 T FULL
TRAILER 10.00 X 20 – 16
PR 02
10.00 X 20 – 16 PR
02 HALF 1
ANN 1
85 15T DM WATER TANKER –
IV LSSF/ST/DMW-10KL/01
15 T SEMI
TRAILER - - - - -
10.00 X 20 – 16 PR
04
HALF 1
ANN 1
86 EFFLUENT TANKER – I LSSF/FT/EF-7KL/01 5 T
FULL TRAILER
9.00 X 20 – 16 PR 02 9.00 X 20 – 16 PR 02
HALF 1
ANN 1
ANN 1
Annexure- 2
Page 9 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
87 N2 MODULE – I LSSF/FT/N2-1X2/01
5 T FULL
TRAILER 7.50 X 16 – 16 PR 02 7.50 X 16 – 16 PR 02
HALF 1
ANN 1
88 N2 MODULE – II LSSF/FT/N2-1X2/02
5 T FULL
TRAILER 7.50 X 16 – 16 PR 02 7.50 X 16 – 16 PR 02
HALF 1
ANN 1
89 SITVC TANKER - 1 LPSC/FT/SITVC-5KL/01
10 T FULL
TRAILER 8.25 X 20 – 12 PR 04 8.25 X 20 – 12 PR 04
HALF 1
ANN 1
90 SITVC TANKER -2 LPSC/FT/SITVC-5KL/02
10 T FULL
TRAILER 8.25 X 20 – 12 PR 04 8.25 X 20 – 12 PR 04
HALF 1
ANN 1
91 PROPELLANT TRANSFER UNIT – I LSSF/FT/MON-3.5KL/01
10 T FULL
TRAILER 9.00 X 20 – 16 PR 04 9.00 X 20 – 16 PR 04
HALF 1
ANN 1
92 PROPELLANT TRANSFER UNIT – II LSSF/FT/MMH-3.5KL/02
10 T FULL
TRAILER 9.00 X 20 – 16 PR 04 9.00 X 20 – 16 PR 04
HALF 1
ANN 1
93 N2 MODULE TRAILER – I LSSF/FT/N2-0.5X2/01
10 T FULL
TRAILER 9.00 X 20 – 16 PR 04 9.00 X 20 – 16 PR 04
HALF 1
ANN 1
94 12T NITROGEN TANKER – I LSSF/ST/N2/2X2/01
12 T SEMI
TRAILER - - - - - 8.25 X 20 – 16 PR 04
HALF 1
ANN 1
95 12T NITROGEN TANKER - II LSSF/ST/N2/2X2/02
12 T SEMI
TRAILER - - - - - 8.25 X 20 – 16 PR 04
HALF 1
ANN 1
96 NITROGEN TANKER – I LSSF/ST/N2/0.5X4/01
5 T SEMI
TRAILER - - - - - 8.25 X 20 – 16 PR 04
HALF 1
ANN 1
97 12T HELIUM MODULE-I LSSF/ST/HE-2x2/01
10 T SEMI
TRAILER - - - - - 8.25 X 20 – 16 PR 04
HALF 1
ANN 1
98 12T HELIUM MODULE-II LSSF/ST/HE-2x2/02
10 T SEMI
TRAILER - - - - - 8.25 X 20 – 16 PR 04
HALF 1
ANN 1
99 12T HELIUM MODULE-III LSSF/ST/HE-1x4/01
10 T SEMI
TRAILER - - - - - 8.25 X 20 – 16 PR 04
HALF 1
ANN 1
100 IMT TANKER-1(New) N2O4 LSSF/ST/30KL/E-5003/01 20 T
SEMI TRAILER
- - - - - 10.00 X 20– 16 PR 08
HALF 1
ANN
1
Annexure- 2
Page 10 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
101 IMT TANKER -2 N2O4 LSSF/ST/30KL/02
20 T SEMI
TRAILER - - - - - 10.00 X 20– 16 PR 08
HALF 1
ANN 1
102 IMT TANKER -1(New) UH25 LSSF/ST/30KL/E-4003/01
20 T SEMI
TRAILER - - - - - 10.00 X 20– 16 PR 08
HALF 1
ANN 1
103 IMT TANKER -2 UH25 LSSF/ST/30KL/02
20 T SEMI
TRAILER - - - - - 10.00 X 20– 16 PR 08
HALF 1
ANN 1
104 RT TANKER -1 UH-25 LSSF/BS/UH-25/01
10 T SEMI
TRAILER - - - - - 10.00 X 20– 16 PR 04
HALF 1
ANN 1
105 RT TANKER -2 UH-25 LSSF/BS/UH-25/02
10 T SEMI
TRAILER - - - - - 10.00 X 20– 16 PR 04
HALF 1
ANN 1
106 RT TANKER -1 N2O4 LSSF/BS/N2O4/01
10 T SEMI
TRAILER - - - - - 10.00 X 20– 16 PR 04
HALF 1
ANN 1
107 RT TANKER -2 N2O4 LSSF/BS/N2O4/02
10 T SEMI
TRAILER - - - - - 10.00 X 20– 16 PR 04
HALF 1
ANN 1
108 MOBILE MOTR AIR SUSPENSION SEMI TRAILER
-- SEMI
TRAILER ---- -- 10.00 X 20– 16 PR 12
HALF 1
ANN 1
109 PS2/GS2 STAGE TRANSPORTATION TRAILER --
SEMI TRAILER
---- -- 10.00 X 20– 16 PR 8 HALF 1
ANN 1
110 BATTERY OPERATED TRUCK-1 VALF/BOT/2T/01
2.0T JOST SOLID TYRES 02 02
MON 8
QTY 3
ANN 1
111 BATTERY OPERATED TRUCK-2 VALF/BOT/2T/02
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
112 BATTERY OPERATED TRUCK-3 VALF/BOT/2T/03
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
113 BATTERY OPERATED TRUCK-4 VALF/BOT/2T/04
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
Annexure- 2
Page 11 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
114 BATTERY OPERATED TRUCK-5 VALF/BOT/2T/05
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
115 BATTERY OPERATED TRUCK-6 VALF/BOT/2T/06
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
116 BATTERY OPERATED TRUCK-7 VALF/BOT/2T/07
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
117 BATTERY OPERATED TRUCK-8 VALF/BOT/2T/08
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
118 BATTERY OPERATED TRUCK-9 VALF/BOT/2T/09
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
119 BATTERY OPERATED TRUCK-10 VALF/BOT/2T/10
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
120 BATTERY OPERATED TRUCK-11 VALF/BOT/2T/11
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
121 BATTERY OPERATED TRUCK-12 VALF/BOT/2T/12
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
122 BATTERY OPERATED TRUCK-13
VALF/BOT/2T/13
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
123
BATTERY OPERATED TRUCK-14 VALF/BOT/2T/14
2.0T
JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
Annexure- 2
Page 12 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
124 BATTERY OPERATED TRUCK-15 VALF/BOT/2T/15
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
125 BATTERY OPERATED TRUCK-16 VALF/BOT/2T/16
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
126 BATTERY OPERATED TRUCK-17 VALF/BOT/2T/17
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
127 BATTERY OPERATED TRUCK-18 VALF/BOT/2T/18
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
128 BATTERY OPERATED TRUCK-19 VALF/BOT/2T/19
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
129 BATTERY OPERATED TRUCK-20 VALF/BOT/2T/20
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
130 BATTERY OPERATED TRUCK-21 VALF/BOT/2T/21
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
131 BATTERY OPERATED TRUCK-22 VALF/BOT/2T/22
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
132 9 BATTERY OPERATED TRUCK-23 VALF/BOT/2T/23
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
133 9 BATTERY OPERATED TRUCK-24 VALF/BOT/2T/24
2.0T
JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN
1
Annexure- 2
Page 13 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
134
BATTERY OPERATED TRUCK-25 VALF/BOT/2T/25
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
135
BATTERY OPERATED TRUCK-26 VALF/BOT/2T/26
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
136
BATTERY OPERATED TRUCK-27 VALF/BOT/2T/27
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
137
BATTERY OPERATED TRUCK-28 VALF/BOT/2T/28
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
138
BATTERY OPERATED TRUCK-29 VALF/BOT/2T/29
2.0T JOST SOLID TYRES 02 SOLID TYRES 02
MON 8
QTY 3
ANN 1
139 DOLLEY – 1 (2 AXLES) VALF/DL/20T/01
20T
PL HAULWEL TRAILER
11.00 X 20 – 16 PR
08
- - -
- -
HALF 1
ANN 1
140 DOLLEY – 2 (2 AXLES) VALF/DL/20T/02
20T
PL HAULWEL TRAILER
11.00 X 20 – 16
PR
08
- - -
- -
HALF 1
ANN 1
141 DOLLEY – 3 (2 AXLES) VALF/DL/20T/03
20T
PL HAULWEL TRAILER
11.00 X 20 – 16 PR
08
- - -
- -
HALF 1
ANN 1
142 DOLLEY – 4 (SINGLE AXLE) VALF/DL/10T/01
10T
- - -
10.00 X 20 – 14
PR
04
- - -
- -
HALF 1
ANN 1
EQUIPMENT TO BE MAINTAINED AT WORK STATION – B (SPROB)
143 HMT TRACTOR PRT/2031
10 T HMT 6.00 X 16 – 8 PR 02 12.4 X 28 – 12 PR 02 MON 8
QTY 3
Annexure- 2
Page 14 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
ANN 1
144
SAME TRACTOR-1 AP 26 Y 2900
10 T
SAME 7.50 X 16 – 8 PR 02 16.9 X 28 – 12 PR 02
MON 8
QTY 3
ANN 1
145
SAME TRACTOR-2 AP 26 Y 2901
10 T SAME 7.50 X 16 – 8 PR 02 16.9 X 28 – 12 PR 02
MON 8
QTY 3
ANN 1
146
SAME TRACTOR-3 AP 26 AC 2503
10 T
SAME 12.9 X 20 – 8 PR 02 16.9 X 28 – 12 PR 02
MON 8
QTY 3
ANN 1
147
VOLVO HAULER 520 HP AP 26 Y 7685
135 T
VOLVO FM 520
11.00 R 20 – 16 PR
02 11.00 R 20 – 16
PR 08
MON 10
HALF 1
ANN 1
148
VOLVO HAULER 400 HP
49 T VOLVO FM 400
11.00 R 20 – 16 PR
02 11.00 R 20 – 16
PR 08
MON 10
HALF 1
ANN 1
149
70T BEML HAULER-1-SPROB/1745
75 T
BEML 9.00 X 20 – 16 PR 02 9.00 X 20 – 16 PR 04
MON 10
HALF 1
ANN 1
150
70T BEML HAULER-2 PRT/2229
75 T
BEML 9.00 X 20 – 16 PR 02 9.00 X 20 – 16 PR 04
MON 10
HALF 1
ANN 1
151
70T BEML HAULER-3 PRT/7003
75 T
BEML 9.00 X 20 – 16 PR 02 9.00 X 20 – 16 PR 04
MON 10
HALF 1
ANN 1
152
3T GODREJ FORKLIFT PRT/2278
3 T
GODREJ 7.00 X 20 – 16 PR 04 6.50 X 10 – 12 PR 02
MON 8
QTY 3
ANN 1
153
5T GODREJ FORKLIFT SPROB/FL/5T/01
5 T
GODREJ 7.50 X 20 – 12 PR 04 7.50 X 20 – 12 PR 02
MON 8
QTY 3
ANN 1
Annexure- 2
Page 15 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
154
8T GODREJ FORKLIFT
8 T
GODREJ 9.00 X 20 – 16 PR 04 9.00 X 20 – 16 PR 02
MON 8
QTY 3
ANN 1
155
12T GODREJ FORKLIFT-1 PRT/2279
12 T
GODREJ 12.00 X 20 – 18
PR 04 12.00 X 20– 18 PR 02
MON 8
QTY 3
ANN 1
156
12T GODREJ FORKLIFT-2 SPROB/FL/12T/02
12 T
GODREJ 11.00 X 20 – 16
PR 04 11.00 X 20– 16 PR 02
MON 8
QTY 3
ANN 1
157 TATA 207 AP 26 Y 7152
0.5 T CLOSED TRUCK
7.00 X 16 – 10 PR 02 7.00 X 16 – 10 PR 02
MON 8
QTY 2
HALF 1
ANN 1
158 TATAACE CYLINDER TRANSPORTER
0.8 T
TATA
TATA ACE
145 / 80 R 12 PR
02
145 / 80 R 12 PR
02
MON 8
QTY 2
HALF 1
ANN 1
159 TATA 407 EXPLOSIVES VAN-2 AP 26 X 7614
2.5 T TATA 407 8.25 X 16 – 16 PR 02 8.25 X 16 – 16 PR 02
MON 8
QTY 2
HALF 1
ANN 1
160 TATA 1613 EXPLOSIVES VAN-1 AP 26 U 7150
8T TATA 1613C 10.00 X 20 – 16
PR 02 10.00 X 20– 16 PR 04
MON 8
QTY 2
HALF 1
ANN 1
161 COMETTO TRAILER-1
70 T
HYDRAULIC SUSPENSION TRAILER
7.50 R 15-16 PR 32 - - - - -
QTY 3
ANN
1
Annexure- 2
Page 16 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
162 COMETTO TRAILER-2
70 T
HYDRAULIC SUSPENSION TRAILER
7.50 R 15-16 PR 32 - - - - - QTY 3
ANN 1
163 APPLE TRAILER-1SXC 1601 1 T
LOW BED TRAILER
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
164 APPLE TRAILER-2 SXC 1801
1 T LOW BED TRAILER
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
165 APPLE TRAILER-3 SXC 2201
1 T LOW BED TRAILER
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
166 APPLE TRAILER-4 SXC 2301
1 T LOW BED TRAILER
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
167 APPLE TRAILER-5 SXC 2501
1 T LOW BED TRAILER
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
168 APPLE TRAILER-6 SXC 2601
1 T LOW BED TRAILER
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
169 APPLE TRAILER-7 SXC 3001
1 T LOW BED TRAILER
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
170 APPLE TRAILER-8 SXC 3101
1 T LOW BED TRAILER
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
171 APPLE TRAILER-9 SXC 3201
1 T LOW BED TRAILER
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
172 APPLE TRAILER-10 SXC 3301
1 T LOW BED TRAILER
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
173 DIESEL OPERATED TRUCK-1 SPROB/DOT/2T/01
2 T PLATFORM TRUCK
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 2
174 DIESEL OPERATED TRUCK-2 SPROB/DOT/2T/02
2 T PLATFORM TRUCK
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 2
Annexure- 2
Page 17 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
175 DIESEL OPERATED TRUCK-3 SPROB/DOT/2T/03
2 T PLATFORM TRUCK
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 2
176 DIESEL OPERATED TRUCK-4 SPROB/DOT/2T/04
2 T PLATFORM TRUCK
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 2
177 DIESEL OPERATED TRUCK-5 SPROB/DOT/2T/05
2 T PLATFORM TRUCK
4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 2
178 LOW BED TRAILER SXC 4202
2 T TRAILER 4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
179 LOW BED TRAILER SXC 4302
2 T TRAILER 4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
180 LOW BED TRAILER SXC 4402
2 T TRAILER 4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
181 LOW BED TRAILER SXC 4802
2 T TRAILER 4.00 X 8 – 8 PR 02 4.00 X 8 – 8 PR 02 HALF 1
ANN 1
182 AP BIN TRAILER SXC 4005
5 T FULL TRAILER
7.00 X 16 - 14 PR 02 7.00 X 16 - 14 PR 02 HALF 1
ANN 1
183 AP BIN TRAILER SXC 4105
5 T FULL TRAILER
7.00 X 16 - 14 PR 02 7.00 X 16 - 14 PR 02 HALF 1
ANN 1
184 AP BIN TRAILER
5 T FULL TRAILER
7.00 X 16 - 14 PR 02 7.00 X 16 - 14 PR 02 HALF 1
ANN 1
185 AP BIN TRAILER
5 T FULL TRAILER
7.00 X 16 - 14 PR 02 7.00 X 16 - 14 PR 02 HALF 1
ANN 1
186 BOWL TRAILER SXC 4615
15 T FULL TRAILER
7.00 X 20 - 16 PR 04 7.00 X 20 - 16 PR 04 HALF 1
ANN 1
187 BOWL TRAILER-1 SXC 2115
15 T FULL TRAILER
7.00 X 20 – 16 PR 04 7.00 X 20 – 16 PR 04 HALF 1
ANN 1
188 BOWL TRAILER-2 SXC 2915
15 T FULL TRAILER
7.00 X 20 – 16 PR 04 7.00 X 20 – 16 PR 04 HALF 1
ANN 1
Annexure- 2
Page 18 of 18
Sl No
Equipment Name & Equipment Number
Capacity
MAKERS NAME & MODEL
Tyre size Periodicity of Maintenance (MON/QTY/ HALF/ANN)
Qty per Yea
r Front
Qty
Rear Qty
189 BOWL TRAILER-3 SXC 3215
15 T FULL TRAILER
7.00 X 20 – 16 PR 04 7.00 X 20 – 16 PR 04 HALF 1
ANN 1
190 LOW BED TRAILER (20T) SXC 2820
20 T FULL TRAILER
10.00 X 20 – 16 PR
04 10.00 X 20 – 16 PR
04 HALF 1
ANN 1
191 PS0-XL TRAILER - 1 SXC 4725
25 T FULL TRAILER
9.00 X 20 - 16 PR 08 9.00 X 20 - 16 PR 08 HALF 1
ANN 1
192 PS0-XL TRAILER - 2
25 T FULL TRAILER
9.00 X 20 - 16 PR 08 9.00 X 20 - 16 PR 08 HALF 1
ANN 1
193
WELL BED TRAILER SXC 4825
25 T WELL BED TRAILER
9.00 X 20 – 16 PR 08 9.00 X 20 - 16 PR 08
HALF 1
ANN 1
ANN 1
194 20T BOWL TRAILER 20T FULL TRAILER
10.00 X 20 – 16 PR
08 10.00 X 20 – 16PR 08 HALF 1
ANN 1
195 PS0-XL TRAILER 30 T
FULL TRAILER
9.00 X 20 - 16 PR 08 9.00 X 20 - 16 PR 08 HALF 1
ANN 1
LEGEND:
MON : MONTHLY (EVERY MONTH) QTY : QUARTERLY (ONCE IN 3 MONTHS) HALF : HALF YEARLY (ONCE IN 6 MONTHS) ANN : ANNUALLY (ONCE IN A YEAR)
ANNEXURE-3
15t TYRE MOUNTED TIL CRANE
WORK STATION – A
(Equipment Ref. As per Annexure – 1)
WORK STATION – B
(Equipment Ref. As per Annexure – 1)
Eqpt Identification
no. Equipment
Eqpt Identification
no. Equipment
VALF/MC/15T/01 15T TYRE MOUNTED TIL
CRANE
- -
ANNEXURE-3
TIL CRANE
SL No.
System Status
1. Check Engine oil level in the Sump (marked on the dip-stick), top-up if required
2. Check Radiator water level in the Radiator, top-up if required
3. Check the condition of the Radiator cap
4. Diesel Level in Tank & fill the tank to 3/4th
5. Functioning of dash board parameters
Engine oil pressure gauge
Hour meter, Tachometer, Speedo meter & odo meter
Air reservoir pressure gauge
Fuel Guage & Mile gauge
6. Check Functioning of clutch
7. Check the Clutch oil reservoir, top-up if required
8. Check Gear oil level in the Gear box (marked on the dip-stick)
9. Check Functioning of Transmission system
10. Check Oil level in Differential, top-up if required
11. Check the Tightness of wheel bolts
12. Condition of Tyre
13. Tyre Inflation Pressure (8ksc)
14. Function of Hydraulic steering system
15. Check Hydraulic oil level in tank , top-up if required
16. Functioning of Brakes – Hydraulic Braking system
Fail safe Parking Brake
17. Functioning of Electrical appliances
Head lights
Tail lights
Revolving lights
Side indicators
Charging system
Starting system
Wiper motor
Air Horn
18. Check the Functioning of Battery Isolation switch
19. Functional checks of Crane Boom Telescopic section and Out riggers
20. Check the condition of wire rope & rope drum
21. Check for any physical damages to the crane
22. Availability & condition of Spark Arrester
23. Any other Remarks
ANNEXURE-3
10t HYDRA PICK & CARRY CRANE
WORK STATION – A
(Equipment Ref. As per Annexure – 1)
WORK STATION – B
(Equipment Ref. As per Annexure – 1)
Eqpt Identification no.
Equipment Eqpt Identification no. Equipment
VALF/MC/10T/01 10T HYDRA PICK ‘N’ CARRY CRANE
- -
ANNEXURE-3
10T HYDRA
SL No.
System Status
1. Check Engine oil level in the Sump (marked on the dip-stick), top-up if required
2. Check Radiator water level in the Radiator, top-up if required
3. Check the condition of the Radiator cap
4. Diesel Level in Tank & fill the tank to 3/4th
5. Functioning of dash board parameters
Engine oil pressure gauge
Hour meter, Tachometer, Speedo meter & odo meter
Air reservoir pressure gauge
Fuel Guage & Mile gauge
6. Check Functioning of clutch
7. Check the Clutch oil reservoir, top-up if required
8. Check Gear oil level in the Gear box (marked on the dip-stick)
9. Check Functioning of Transmission system
10. Check Oil level in Differential, top-up if required
11. Check the Tightness of wheel bolts
12. Condition of Tyre
13. Tyre Inflation Pressure (FRONT - 6ksc) (REAR - 2 ksc)
14. Function of Hydraulic steering system
15. Check Hydraulic oil level in tank , top-up if required
16. Functioning of Brakes – Pneumatic Braking system
Fail safe Parking Brake
17. Functioning of Electrical appliances
Head lights
Tail lights
Revolving lights
Side indicators
Charging system
Starting system
Wiper motor
Air Horn
18. Check the Functioning of Battery Isolation switch
19. Functional checks of Boom Telescopic section
20. Check the condition of wire rope & rope drum
21. Check for any physical damages to hydra
22. Any other Remarks
ANNEXURE-3
PRIME MOVERS
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Eqpt Identification no. Equipment Eqpt Identification
no. Equipment
VALF/HA/49T/01 ASHOKLEYLAND HIPPO
HAULER - 1 AP 26 Y 7685 VOLVO HAULER 520 HP
VALF/HA/49T/02 ASHOKLEYLAND HIPPO
HAULER - 2 AP 26 TB 5085 VOLVO HAULER 400 HP
VALF/HA/49T/03 VOLVO HAULER - 1 - -
VALF/HA/49T/04 VOLVO HAULER - 2 - -
VALF/HA/49T/05 VOLVO HAULER - 3 - -
VALF/HA/49T/05 AMW HAULER -1 - -
VALF/HA/49T/05 AMW HAULER -2 - -
VALF/MHS/49T/06 TATA PRIMA - -
ANNEXURE-3
AMW-1&2/ HIPPO-1&2 / VOLVO-1,2&3 PRIME MOVER
SL
No.
System Status
1. Check Engine oil level in the Sump (marked on the dip-stick), top-up if
required
2. Check Radiator water level in the Radiator, top-up if required
3. Check the condition of the Radiator cap
4. Diesel Level in Tank & fill the tank to 3/4th
5. Functioning of dash board parameters
Engine oil pressure gauge (GREEN ZONE)
Hour meter, Tachometer, Speedo meter & odo meter
Air reservoir pressure gauge ( GREEN ZONE)
Digital Fuel & Mile gauge
6. Check Functioning of clutch
7. Check the Clutch oil reservoir, top-up if required
8. Check Gear oil level in the Gear box (marked on the dip-stick)
9. Check Functioning of Gear Splitter
10. Check Functioning of Transmission system
11. Check Oil level in Differential, top-up if required
12. Check the Tightness of wheel bolts
13. Condition of Tyre
14. Tyre Inflation Pressure (6ksc)
15. Function of Hydraulic steering system
16. Check Hydraulic oil level in tank , top-up if required
17. Functioning of Brakes – Pneumatic Service brakes
Fail safe Parking Brake
18. Functioning of Electrical appliances
Head lights
Tail lights
Revolving lights
Side indicators
Charging system
Starting system
Wiper motor
Electric Horn & Siren
Check the Functioning of Battery Isolation switch
19. Check the tightness of fifth wheel coupler mounting bolts & nuts
20. Check function of Fifth wheel coupler
21. Check for tightness of hauler trailer Pneumatic connections (palm couplings)
22. Availability & condition of Spark Arrester
23. Lubrication and Greasing of all greasing points of prime mover
24. Performance on road trial
25. Any other Remarks
ANNEXURE-3
BEML TOW TRACTORS
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Eqpt Identification no. Equipment Eqpt Identification
no. Equipment
VALF/HA/70T/01 70T BEML HAULER-1-
SPROB/1745 70T BEML HAULER-1
VALF/HA/70T/02 70T BEML HAULER-2
PRT/2229 70T BEML HAULER-2
- - PRT/7003 70T BEML HAULER-3
ANNEXURE-3
BEML TOW TRACTOR
SL
No.
System Status
1. Check Engine oil level in the Sump (marked on the dip-stick), top-up if required
2. Check Radiator water level in the Radiator, top-up if required
3. Check the condition of the Radiator cap
4. Diesel Level in Tank & fill the tank to 3/4th
5. Functioning of dash board parameters
Engine oil pressure gauge (Green Zone)
Hour meter / Tacho meter
6. Charging system
7. Fuel Gauge indicator
8. Pneumatic Pressure Gauge (6.0 ksc)
9. Check the Functioning of clutch
10. Check the Functioning of Battery Isolation Switch
11. Check Gear oil level in the Gear box (marked on the dip-stick)
12. Check the Functioning of Transmission system
13. Tightness of wheel bolts
14. Check the Condition of Tyres
15. Tyre Inflation Pressure (Rear 6ksc & Front 5ksc)
16. Check Hydraulic oil level in the tank (marked on the dip-stick)
17. Check the Function of Hydraulic steering system
18. Functioning of Brakes – Pneumatic Service brakes Fail safe Parking brake
19. Functioning of Electrical appliances
Head lights
Tail lights
Side indicators
Starting system
Wiper motor
20. Check the condition of Tow Bar
21. Check the tightness of multi-point tow hook & mounting bolts & nuts
22. Availability & condition of Spark Arrester
23. Lubrication and Greasing of all greasing points
24. Availability of Rear View Mirror
25. Performance on road trial
26. Any other Remarks
ANNEXURE-3
TOW TRACTORS
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Eqpt Identification
no. Equipment Eqpt Identification no. Equipment
VALF/HA/15T/01 EICHER TRACTOR - 1
PRT/2031 HMT TRACTOR
VALF/HA/15T/02 EICHER TRACTOR - 2
PRT/2229 SAME TRACTOR -1
VALF/HA/15T/01 EICHER TRACTOR - 3
PRT/7003 SAME TRACTOR -2
VALF/HA/15T/01 EICHER TRACTOR - 4
AP 26 AC 2503
SAME TRACTOR-3
ANNEXURE-3
EICHER – 1/2/3/4 HMT-1 SAME -1/2/3 PRIME MOVER
SL
No.
System Status
1. Check Engine oil level in the Sump (marked on the dip-stick), top-up
if required
2. Check Radiator water level in the Radiator, top-up if required
3. Check the condition of the Radiator cap
4. Diesel Level in Tank & fill the tank to 3/4th
5.
Functioning of dash board parameters
Engine oil pressure gauge (Green Zone)
Hour meter / Tacho meter
Charging system
Fuel Gauge indicator
6. Check the Functioning of clutch
7. Check the Functioning of Crawler Gear
8. Check the Functioning of Battery Isolation Switch
9. Check Gear oil level in the Gear box (marked on the dip-stick)
10. Check the Functioning of Transmission system
11. Tightness of wheel bolts
12. Check the Condition of Tyres
13. Tyre Inflation Pressure (Rear 1.5ksc & Front 2ksc)
14. Check Hydraulic oil level in the tank (marked on the dip-stick)
15. Check the Function of Hydraulic steering system
16. Functioning of Brakes – Service Parking
17.
Functioning of Electrical appliances
Head lights
Tail lights
Side indicators
Starting system
Wiper motor
18. Check the condition of Tow Bar
19. Check the tightness of multi-point tow hook & mounting bolts & nuts
20. Availability & condition of Spark Arrester
21. Lubrication and Greasing of all greasing points
22. Availability of Rear View Mirror
23. Performance on road trial
24. Any other Remarks
ANNEXURE-3
2T / 3T FORKLIFTS
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Eqpt Identification no.
Equipment Eqpt Identification no. Equipment
VALF/FL/2T/01 2T GODREJ FORKLIFT
PRT/2278 3T GODREJ FORKLIFT
VALF/FL/3T/01 3T GODREJ FORKLIFT - 1 - -
VALF/FL/3T/02 3T GODREJ FORKLIFT - 2 - -
VALF/FL/3T/03 3T GODREJ FORKLIFT - 3 - -
ANNEXURE-3
Daily checks Sheet
Equipment: 2t/3t Forklift
Sl No
Description of the work
Remarks
1. Check coolant level in the radiator and top-up, if required
2. Check Engine Oil level and top-up, if required (SAE 15W40)
3. Check Gear Oil level and top-up, if required (ATF)
4. Check Hydraulic Oil level and top-up, if required (Enclo 68)
5. Check Differential Oil level and top-up, if required (140)
6. Check the condition of Wheel Hubs and apply Grease if
required.
7. Check the fan belt condition and adjust the tension, if
required
8. Check the condition of Solid tyres for both Steering and Drive wheels
9. Check the tightness of drive wheel torque and adjust if required
10. Check the tightness of steer wheel torque and adjust if required
11. Check the diesel fuel level in the tank, top up if required
12. Check the electrolyte level in the battery and top-up if
required
13. Check the battery and cable clamps and retighten, if required
14. Clean & apply petroleum jelly to battery connecting terminals
15. Check the battery mounting and tighten battery tie-down
clamps, if required
16. Start the engine and check for the following dash board
gauges:
Engine oil Pressure
Coolant Temperature
Fuel level indicator
Charging Indicator
Hour meter
17. Check for the function of electrical appliances:
Starter switch
Battery charging indicator
Head lights
Tail lights
Brake lights
Parking lights
Hazard indication / revolving light
Reverse light
18. Functioning of Battery Isolation Switch
19. Functioning of Neutral Start Switch
20. Checking the functioning of brake system:
Hydraulic Brakes
ANNEXURE-3
Sl No
Description of the work
Remarks
Mechanical Parking Brakes
21. Condition of Steering cylinders
22. Condition of Lift cylinders
23. Condition of tilt cylinders
24. Condition of Fork Shifter cylinders
25. Check the condition of Over Head Guard (FOPS- falling objects protection structure)
26. Check the condition of Load Back Rest (LBR)
27. Check the condition of Forks
28. Check the condition of lift chain tightness and tighten if required.
29. Switch “ON” the forklift engine and Operate the following:
Lift / lowering system
Forward / backward Tilt system
Forward / reverse movement
HI / LO
Auxiliary Shift lever
Steering system
30. Functioning of reverse horn
31. Functioning of Electric horn
32. Availability and functioning of Spark Arrestor
33. Availability of Load chart (data plate)
34. Check for hydraulic oil leaks in the hydraulic system and
rectify if any
35. Check for proper greasing of all lubricating points
36. Availability of rear view mirror
37. Check the condition of Adjustable seat
38. Check functioning of seat back rest
39. Apply a thin film of lubricating oil over the Mast & Fork guide for easy sliding of forks
40. Cleaning the equipment with cloth
41. Visual inspection of the overall condition of the equipment and report if any abnormality is noticed.
ANNEXURE-3
5T / 8T FORKLIFTS
WORK STATION – A
(Equipment Ref. As per Annexure – 1)
WORK STATION – B
(Equipment Ref. As per Annexure – 1)
Eqpt Identification no. Equipment Eqpt Identification
no. Equipment
VALF/FL/5T/01 5T GODREJ FORKLIFT - 8T GODREJ FORKLIFT
ANNEXURE-3
Daily checks Sheet
Equipment: 5t/8t Forklift
Sl No
Description of the work
Remarks
1. Check coolant level in the radiator and top-up, if required
2. Check Engine Oil level and top-up, if required (SAE 15W40)
3. Check Gear Oil level and top-up, if required (ATF)
4. Check Hydraulic Oil level and top-up, if required (Enclo 68)
5. Check Differential Oil level and top-up, if required (140)
6. Check oil level in Wheel Hub reduction unit and top-up, if
required (140)
7. Check the fan belt condition and adjust the tension, if
required
8. Check inflation pressure in the drive wheel tyres and inflate
them to uniform pressure, if required
9. Check the tightness of drive wheel torque and adjust if
required
10. Check inflation pressure in the steer wheel tyres and inflate
them to uniform pressure, if required
11. Check the tightness of steel wheel torque and adjust if required
12. Remove trapped stones from the tyre threads
13. Check the diesel fuel level in the tank, top up if required
14. Check the electrolyte level in the battery and top-up if
required
15. Check the battery and cable clamps and retighten, if required
16. Clean & apply petroleum jelly to battery connecting terminals
17. Check the battery mounting and tighten battery tie-down
clamps, if required
18. Start the engine and check for the following dash board gauges:
Engine oil Pressure
Coolant Temperature
Fuel level indicator
Charging Indicator
Hour meter
Ammeter
Air pressure gauge
19. Check for the function of electrical appliances:
Starter switch
Battery charging indicator
Head lights
Tail lights
Brake lights
Parking lights
Hazard indication / revolving light
Reverse light
ANNEXURE-3
Sl No
Description of the work
Remarks
20. Functioning of Battery Isolation Switch
21. Functioning of Neutral Start Switch
22. Checking the functioning of brake system:
Pneumatic Service Brakes
Pneumatic Parking Brakes
23. Condition of Steering cylinders
24. Condition of Lift cylinders
25. Condition of tilt cylinders
26. Check the condition of Over Head Guard (FOPS- falling
objects protection structure)
27. Check the condition of Load Back Rest (LBR)
28. Check the condition of Forks
29. Check availability and functioning of Fork locks
30. Check the condition of Extension Forks
31. Check the condition of lift chain tightness and tighten if required.
32. Switch “ON” the forklift engine and Operate the following:
Lift / lowering system
Free lift system
Forward / backward Tilt system
Forward / reverse movement
HI / LO
Auxiliary Shift lever
Steering system
33. Functioning of reverse hron
34. Functioning of Pneumatic horn
35. Functioning of STOP cable
36. Availability and functioning of Spark Arrestor
37. Availability of Load chart (data plate)
38. Check for hydraulic oil leaks in the hydraulic system and rectify if any
39. Check for proper greasing of all lubricating points
40. Availability of rear view mirror
41. Availability of Load test details
42. Check the condition of Adjustable seat
43. Check functioning of seat back rest
44. Apply a thin film of lubricating oil over the Mast & Fork guide
for easy sliding of forks
45. Cleaning the equipment with cloth
46. Visual inspection of the overall condition of the equipment and report if any abnormality is noticed.
ANNEXURE-3
10T / 12T FORKLIFTS
WORK STATION – A
(Equipment Ref. As per Annexure – 1)
WORK STATION – B
(Equipment Ref. As per Annexure – 1)
Eqpt Identification no.
Equipment Eqpt
Identification no. Equipment
VALF/FL/10T/01 10T GODREJ FORKLIFT - 12T GODREJ FORKLIFT - 1
- - - 12T GODREJ FORKLIFT - 2
ANNEXURE-3
Daily checks Sheet
Equipment: 10t/12t Forklift
Sl No Description of the work Remarks
1. Check coolant level in the radiator and top-up, if required
2. Check Engine Oil level and top-up, if required (SAE 15W40)
3. Check Gear Oil level and top-up, if required (ATF)
4. Check Hydraulic Oil level and top-up, if required (Enclo 68)
5. Check Differential Oil level and top-up, if required (140)
6. Check the condition of Wheel Hubs and apply Grease if
required.
7. Check the fan belt condition and adjust the tension, if
required
8. Check inflation pressure in the drive wheel tyres and inflate them to uniform pressure, if required
9. Check the tightness of drive wheel torque and adjust if required
10. Check inflation pressure in the steer wheel tyres and inflate them to uniform pressure, if required
11. Check the tightness of steer wheel torque and adjust if required
12. Remove trapped stones from the tyre threads
13. Check the diesel fuel level in the tank, top up if required
14. Check the electrolyte level in the battery and top-up if required
15. Check the battery and cable clamps and retighten, if required
16. Clean & apply petroleum jelly to battery connecting terminals
17. Check the battery mounting and tighten battery tie-down clamps, if required
18. Start the engine and check for the following dash board gauges:
Engine oil Pressure
Coolant Temperature
Fuel level indicator
Charging Indicator
Hour meter
Air pressure gauge
19. Check for the function of electrical appliances:
Starter switch
Battery charging indicator
Head lights
Tail lights
Brake lights
Parking lights
Hazard indication / revolving light
ANNEXURE-3
Sl No Description of the work Remarks
Reverse light
20. Functioning of Battery Isolation Switch
21. Functioning of Neutral Start Switch
22. Checking the functioning of brake system:
Pneumatic Service Brakes
Pneumatic Parking Brakes
23. Condition of Steering cylinders
24. Condition of Lift cylinders
25. Condition of tilt cylinders
26. Condition of Fork Shifter cylinders
27. Check the condition of Over Head Guard (FOPS- falling objects protection structure)
28. Check the condition of Load Back Rest (LBR)
29. Check the condition of Forks
30. Check the condition of lift chain tightness and tighten if required.
31. Switch “ON” the forklift engine and Operate the following:
Lift / lowering system
Forward / backward Tilt system
Forward / reverse movement
HI / LO
Auxiliary Shift lever
Steering system
32. Functioning of reverse horn
33. Functioning of Pneumatic horn
34. Availability and functioning of Spark Arrestor
35. Availability of Load chart (data plate)
36. Check for hydraulic oil leaks in the hydraulic system and rectify if any
37. Check for proper greasing of all lubricating points
38. Availability of rear view mirror
39. Check the condition of Adjustable seat
40. Check functioning of seat back rest
41. Apply a thin film of lubricating oil over the Mast & Fork guide for easy sliding of forks
42. Cleaning the equipment with cloth
43. Visual inspection of the overall condition of the equipment
and report if any abnormality is noticed.
ANNEXURE-3
16T FORKLIFT
WORK STATION – A
(Equipment Ref. As per Annexure – 1)
WORK STATION – B
(Equipment Ref. As per Annexure – 1)
Eqpt Identification no.
Equipment Eqpt
Identification
no.
Equipment
VALF/FL/16T/01 16T VOLTAS FORKLIFT - -
ANNEXURE-3
Daily checks Sheet
Equipment: 16t Forklift
Sl
No
Description of the work
Remarks
1. Check coolant level in the radiator and top-up, if required
2. Check Engine Oil level and top-up, if required (SAE 15W40)
3. Check Gear Oil level and top-up, if required (ATF)
4. Check Hydraulic Oil level and top-up, if required (Enclo 68)
5. Check Differential Oil level and top-up, if required (140)
6. Check oil level in Wheel Hub reduction unit and top-up, if required (140)
7. Check the fan belt condition and adjust the tension, if required
8. Check brake fluid level in the containers and top-up, if required
9. Check inflation pressure in the drive wheel tyres and inflate them to uniform pressure, if required
10. Check the tightness of drive wheel torque and adjust, if required
11. Check inflation pressure in the steer wheel tyres and inflate
them to uniform pressure, if required
12. Check the tightness of steer wheel torque and adjust if required
13. Remove trapped stones from the tyre threads
14. Check the diesel fuel level in the tank, top up if required
15. Check the electrolyte level in the battery and top-up if required
16. Check the battery and cable clamps and retighten, if required
17. Clean & apply petroleum jelly to battery connecting terminals
18. Check the battery mounting and tighten battery tie-down clamps, if required
19. Start the engine and check for the following dash board gauges
Engine oil Pressure
Coolant Temperature
Air Pressure in the air reservoir
Transmission oil temperature gauge
Fuel level indicator
Charging Indicator
Hour meter
Ammeter
20. Check and measure Pneumatic system pressure
Cut-in pressure
Cut-out pressure
21. Check for the function of electrical appliances
Starter switch
Battery charging indicator
Head lights
Tail lights
Brake lights
Parking lights
Hazard indication / revolving light
ANNEXURE-3
Sl No
Description of the work
Remarks
Reverse light
22. Functioning of Battery Isolation Switch
23. Functioning of Neutral Start Switch
24. Checking the functioning of brake system
25. Pneumatic assisted Hydraulic Service Brakes
Pneumatic Parking Brakes
26. Condition of Steering cylinders
27. Condition of Lift cylinders
28. Condition of tilt cylinders
29. Condition of Mast Shifter cylinders
30. Check the condition of Over Head Guard (FOPS- falling objects protection structure)
31. Check the condition of Load Back Rest (LBR)
32. Check the condition of Forks
33. Check availability and functioning of Fork locks
34. Check the condition of lift chain tightness and tighten if
required.
35. Switch “ON” the forklift engine and Operate the following
Lift / lowering system
Steering system
Forward / backward Tilt system
Forward / reverse movement
HI / LO
Auxiliary Shift lever
36. Functioning of reverse horn
37. Functioning of Electric horn
38. Functioning of STOP cable
39. Availability and functioning of Spark Arrestor
40. Availability of Load chart (data plate)
41. Check for air leaks in the pneumatic system and rectify if any
42. Check for hydraulic oil leaks in the hydraulic system and rectify
if any
43. Check for proper greasing of all lubricating points
44. Availability of rear view mirror
45. Check the condition of Adjustable seat
46. Check functioning of seat back rest
47. Apply a thin film of lubricating oil over the Mast & Fork guide
for easy sliding of forks
48. Cleaning the equipment with cloth
49. Visual inspection of the overall condition of the equipment and report if any abnormality is noticed.
ANNEXURE-3
GOLDHOFER / COMETTO TRAILER
WORK STATION – A
(Equipment Ref. As per Annexure – 1)
WORK STATION – B
(Equipment Ref. As per Annexure – 1)
Eqpt
Identification no. Equipment
Eqpt Identification
no. Equipment
VALF/HT/65T/01 GOLDHOFER TRAILER-1 -
COMETTO TRAILER-1
VALF/HT/65T/02 GOLDHOFER TRAILER-2 - COMETTO TRAILER-2
VALF/HT/65T/03 GOLDHOFER TRAILER-3 - -
VALF/HT/70T/01
COMETTO TRAILER-1
- -
ANNEXURE-3 HYDRAULIC SUSPENSION GOLDHOFER / COMETTO TRAILER
Sl
No
Item Status
1. Functioning of Hydraulic Power Pack
2. Availability of spark arrester for power pack engine
3. Engine oil level in the Power pack engine, top up if required
4. Diesel fuel level in the Power pack diesel tank , top up to 3/4th of tank , if required
5. Hydraulic Oil level in goose neck (level indicator)
6. Check the condition of Fifth wheel king pin
7. Check the condition of Rubbing plate
8. Check the condition of Steering wedge and wedge bolt
9. Check tightness of fifth wheel king pin mounting bolts & tighten
if required
10. Correctness of hydraulic hose connections in between gooseneck and intermediate piece
11. Correctness of hydraulic hose connections in between intermediate piece and single module trailer
12. Correctness of hydraulic hose connections in between single module and two module trailer
13. Tightness of module connecting Allen screws, connecting bolts and nuts & spacers
14. Correctness of steering track rod connections for two module version
15. Correctness of valve positions on the trailer panel for two module version
16. Check tightness of module connecting bolts and tighten if required.
17. Condition of trailer platform
18. Condition of the radial tyres
19. Check Tyre Inflation Pressure, fill to 8ksc, if required
20. Functioning of Pneumatic Brake system
21. Check high pressure hydraulic hoses for oil leaks and replace if required
22. Check pneumatic hoses for leaks and replace, if required
23. Check the condition of hydraulic cylinders such as Lift /
suspension cylinders, steering cylinders, gooseneck cylinders
ANNEXURE-3
Sl No
Item Status
etc.,
24. Check for proper functioning of pressure gauges
25. Functioning of steering system
Extreme right side
Extreme left side
26. Functioning of Gooseneck
Lifting
Lowering
27. Functioning of Lift system of trailer
Rear left
Rear right
Front
28. Level the trailer platform to 1165 + 5 mm max.
29. Check availability of earth chain
ANNEXURE-3
TATA ACE CYLINDER / AGNI TRANSPORTER
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Eqpt Identification
no. Equipment Eqpt Identification no. Equipment
AP 26 X 7113 TATA ACE CYLINDER
TRANSPORTER AP 26 TT 1304
TATA ACE CYLINDER TRANSPORTER
AP 26 X 7116 AGNI TRANSPORTER - -
ANNEXURE-3
CYLINDER /AGNI TRANSPORTER
SL No.
System Status
1. Check Engine oil level in the Sump (marked on the dip-
stick), top-up if required
2. Check Radiator water level in the Radiator, top-up if required
3. Check the condition of the Radiator cap
4. Diesel Level in Tank & fill the tank to 3/4th
5.
Functioning of dash board parameters
Engine oil pressure Indicator
Speedo meter & odo meter
Fuel gauge
Radiator water temp gauge < 80 deg Celsius
6. Check Functioning of clutch
7. Check Gear oil level in the Gear box (marked on the dip-
stick)
8. Check Functioning of Transmission system
9. Check the Tightness of wheel bolts
10. Condition of Tyres
11. Tyre Inflation Pressure (3.0 ksc)
12. Function of Steering system
13. Functioning of Brakes – Hydraulic Service brakes Mechanical Parking Brake
14.
Functioning of Electrical appliances
Head
lights
Tail lights
Side indicators
Charging system
Starting system
Wiper motor
Electric Horn
15. Lubrication and Greasing of all greasing points of Truck
16. Performance on road trial
17. Any other Remarks
ANNEXURE-3
SAMPLE PROPELLANT TRANSPORTER
WORK STATION – A
(Equipment Ref. As per Annexure – 1)
WORK STATION – B
(Equipment Ref. As per Annexure – 1)
Eqpt Identification no. Equipment Eqpt Identification no. Equipment
AP 26 TT 5148 TATA ACE SAMPLE
PROPELLANT TRANSPORTER
- -
ANNEXURE-3
SAMPLE PROPELLANT TRANSPORTER
SL
No.
System Status
1. Check Engine oil level in the Sump (marked on the dip-stick), top-up if required
2. Check Radiator water level in the Radiator, top-up if required
3. Check the condition of the Radiator cap
4. Diesel Level in Tank & fill the tank to 3/4th
5.
Functioning of dash board parameters
Engine oil pressure Indicator
Speedo meter & odo meter
Fuel gauge
Radiator water temp gauge < 80 deg Celsius
6. Check Functioning of clutch
7. Check Gear oil level in the Gear box (marked on the dip-stick)
8. Check Functioning of Transmission system
9. Check the Tightness of wheel bolts
10. Condition of Tyres
11. Tyre Inflation Pressure (3.0 ksc)
12. Function of Steering system
13. Functioning of Brakes – Hydraulic Service brakes Mechanical Parking Brake
14.
Functioning of Electrical appliances
Head lights
Tail lights
Side indicators
Charging system
Starting system
Wiper motor
Electric Horn
15. Lubrication and Greasing of all greasing points of Truck
16. Check the Water tank Mounting Bolts tightness in the Sample Transportation carriage
17. Performance on road trial
18. Any other Remarks
ANNEXURE-3
TATA 207/TATA 407
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Eqpt Identification
no. Equipment Eqpt Identification no. Equipment
- - AP 26 Y 7152
TATA 207
AP 26 TT 0510 TATA 407 EXP VAN AP 26 X 7614 TATA 407 EXP VAN
- TATA 407
UP LINK VEHICLE - -
ANNEXURE-3
TATA 207 / TATA 407 EXP VAN / TATA 407 UPLINK VEHICLE
SL No.
System Status
1. Check Engine oil level in the Sump (marked on the dip-stick), top-up if required
2. Check Radiator water level in the Radiator, top-up if required
3. Check the condition of the Radiator cap
4. Diesel Level in Tank & fill the tank to 3/4th
5.
Functioning of dash board parameters
Engine oil pressure Indicator
Speedo meter & odo meter
Fuel gauge
Radiator water temp gauge < 80 deg Celsius
6. Check Functioning of clutch
7. Check Gear oil level in the Gear box (marked on the dip-stick)
8. Check Functioning of Transmission system
9. Check the Tightness of wheel bolts
10. Condition of Tyre
11. Tyre Inflation Pressure (4.5 ksc)
12. Function of Steering system
13. Functioning of Brakes – Hydraulic Service brakes Mechanical Parking Brake
14.
Functioning of Electrical appliances
Head lights
Tail lights
Revolving Lights
Side indicators
Charging system
Starting system
Wiper motor
Electric Horn
Battery Isolation switch
15. Availability & condition of Spark Arrester
16. Lubrication and Greasing of all greasing points of Truck
17. Performance on road trial
18. Any other Remarks
ANNEXURE-3
TATA 807/TATA 709 SAFETY VAN
WORK STATION – A
(Equipment Ref. As per Annexure – 1)
WORK STATION – B
(Equipment Ref. As per Annexure – 1)
Eqpt
Identification no. Equipment
Eqpt
Identification no. Equipment
AP 26 T 2240 SAFETY VAN - 1 - -
AP 26 X 7114 SAFETY VAN - 2 - -
ANNEXURE-3
TATA 807 SAFETY VAN – 1/TATA 709 SAFETY VAN - 2
SL No.
System Status
1. Check Engine oil level in the Sump (marked on the dip-stick), top-up if required
2. Check Radiator water level in the Radiator, top-up if required
3. Check the condition of the Radiator cap
4. Diesel Level in Tank & fill the tank to 3/4th
5.
Functioning of dash board parameters
Engine oil pressure Indicator
Speedo meter & odo meter
Air reservoir pressure gauge 6 bar
Fuel gauge
Radiator water temp gauge < 80 deg Celsius
Parking Brake indicator
6. Check Functioning of clutch
7. Check the Clutch oil reservoir, top-up if required
8. Check Gear oil level in the Gear box (marked on the dip-stick)
9. Check Functioning of Transmission system
10. Check the Tightness of wheel bolts
11. Condition of Tyre
12. Tyre Inflation Pressure (5 ksc)
13. Function of steering system
14. Functioning of Brakes – Pneumatic Service brakes
Fail safe Parking Brake
15.
Functioning of Electrical appliances
Head lights
Tail lights
Revolving light
Side indicators
Charging system
Starting system
Wiper motor
Electric Horn
Battery Isolation switch
16. Check the Functioning of Power generator
17. Check the Functioning of Air Conditioning Unit
18. Availability & condition of Spark Arrester
19. Lubrication and Greasing of all greasing points of Truck
20. Performance on road trial
21. Any other Remarks
ANNEXURE-3
TATA 709 MINI TRUCK
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Eqpt Identification no.
Equipment Eqpt
Identification no. Equipment
AP 26 W 9868 TATA 709
MINI TRUCK - -
ANNEXURE-3
TATA 709 MINI TRUCK
SL No.
System Status
1. Check Engine oil level in the Sump (marked on the dip-stick), top-up if required
2. Check Radiator water level in the Radiator, top-up if required
3. Check the condition of the Radiator cap
4. Diesel Level in Tank & fill the tank to 3/4th
5.
Functioning of dash board parameters
Engine oil pressure Indicator
Speedo meter & odo meter
Air reservoir pressure gauge 6 bar
Fuel gauge
Radiator water temp gauge < 80 deg Celsius
Parking Brake indicator
6. Check Functioning of clutch
7. Check the Clutch oil reservoir, top-up if required
8. Check Gear oil level in the Gear box (marked on the dip-stick)
9. Check Functioning of Transmission system
10. Check the Tightness of wheel bolts
11. Condition of Tyre
12. Tyre Inflation Pressure (5 ksc)
13. Function of Hydraulic steering system
14. Check Hydraulic oil level in tank , top-up if required
15. Functioning of Brakes – Pneumatic Service brakes Fail safe Parking Brake
16. Functioning of Electrical appliances
Head lights
Tail lights
Side indicators
Charging system
Starting system
Wiper motor
Electric Horn
Battery Isolation switch
17. Availability & condition of Spark Arrester
18. Lubrication and Greasing of all greasing points of Truck
19. Performance on road trial
20. Any other Remarks
ANNEXURE-3
TATA 1210 PLATFORM TRUCK MOBILE NEUTRALIZER
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Eqpt Identification no.
Equipment Eqpt
Identification no. Equipment
AP 26 T 791 TATA 1210
PLATFORM TRUCK - -
ANNEXURE-3
1210 PLATFORM TRUCK MOBILE NEUTRALIZER
SL No.
System Status
1. Check Engine oil level in the Sump (marked on the dip-stick), top-up if required
2. Check Radiator water level in the Radiator, top-up if required
3. Check the condition of the Radiator cap
4. Diesel Level in Tank & fill the tank to 3/4th
5.
Functioning of dash board parameters
Engine oil pressure Indicator
Speedo meter & odo meter
Air reservoir pressure gauge 6 bar
Fuel gauge
Radiator water temp gauge < 80 deg Celsius
Parking Brake indicator
6. Check Functioning of clutch
7. Check the Clutch oil reservoir, top-up if required
8. Check Gear oil level in the Gear box (marked on the dip-stick)
9. Check Functioning of Transmission system
10. Check the Tightness of wheel bolts
11. Condition of Tyres
12. Tyre Inflation Pressure (5 ksc)
13. Function of Steering system
14. Functioning of Brakes – Pneumatic Service brakes
Fail safe Parking Brake
15.
Functioning of Electrical appliances
Head lights
Tail lights
Revolving light
Side indicators
Charging system
Starting system
Wiper motor
Electric Horn
Battery Isolation switch
16. Availability & condition of Spark Arrester
17. Lubrication and Greasing of all greasing points of Neutralizer
18. Performance on road trial
19. Any other Remarks
ANNEXURE-3
TATA 1613 EXPLOSIVES VAN
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Eqpt Identification no.
Equipment Eqpt
Identification no. Equipment
AP 26 X 1954
TATA 1613 EXPLOSIVE
VAN
AP 26 U 7150
TATA 1613 EXPLOSIVE
VAN
ANNEXURE-3
TATA 1613 EXPLOSIVES VAN
SL No.
System Status
1. Check Engine oil level in the Sump (marked on the dip-stick), top-up if required
2. Check Radiator water level in the Radiator, top-up if required
3. Check the condition of the Radiator cap
4. Diesel Level in Tank & fill the tank to 3/4th
5.
Functioning of dash board parameters
Engine oil pressure Indicator
Speedo meter & odo meter
Air reservoir pressure gauge 6 bar
Fuel gauge
Radiator water temp gauge < 80 deg Celsius
Parking Brake indicator
6. Check Functioning of clutch
7. Check the Clutch oil reservoir, top-up if required
8. Check Gear oil level in the Gear box (marked on the dip-
stick)
9. Check Functioning of Transmission system
10. Check the Tightness of wheel bolts
11. Condition of Tyre
12. Tyre Inflation Pressure (5 ksc)
13. Function of Hydraulic steering system
14. Check Hydraulic oil level in tank , top-up if required
15. Functioning of Brakes – Pneumatic Service brakes Fail safe Parking Brake
16.
Functioning of Electrical appliances
Head lights
Tail lights
Side indicators
Charging system
Starting system
Wiper motor
Electric Horn
Battery Isolation switch
17. Availability & condition of Spark Arrester
18. Lubrication and Greasing of all greasing points of Truck
19. Performance on road trial
20. Any other Remarks
ANNEXURE-3
AIR SUSPENSION SEMI TRAILER
WORK STATION – A
(Equipment Ref. As per Annexure – 1)
WORK STATION – B
(Equipment Ref. As per Annexure – 1)
Eqpt
Identification no. Equipment
Eqpt
Identification no. Equipment
VALF/ST/AST/10T/01
10T AIR SUSPENSION
TRAILER
- -
VALF/ST/AST/18T/01
18T AIR SUSPENSION
TRAILER
- -
ANNEXURE-3 10T/18T AIR SUSPENSION SEMI TRAILER
Sl No
Item Status
1. Check the condition of Fifth wheel king pin
2. Check the condition of Rubbing plate
3. Check tightness of fifth wheel king pin mounting bolts & tighten if required
4. Condition of trailer platform
5. Check functioning of air springs
6. Check functioning of air reservoirs, distribution valves, height control valves etc.
7. Check tightness of wheel bolts & tighten if required
8. Condition of the tyres
9. Check Tyre Inflation Pressure, fill to minimum 7.5ksc, if required
10. Check availability of pneumatic palm couplings
11. Check pneumatic hoses for leaks and replace, if required
12. Functioning of Pneumatic Brake system
13. Check effectiveness of Service Brake system
14. Check effectiveness of Parking Brake system
15. Check for proper functioning of electrical accessories such as rear combination lights
16. Check for availability of reflectors on all sides of the trailer
17. Functioning of Two speed landing gears
18. Lubricate with grease wherever applicable
19. Check the availability of earth chain and mount, if required
ANNEXURE-3
MECHANICAL SUSPENSION SEMI TRAILER
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Eqpt Identification no.
Equipment Eqpt
Identification no. Equipment
VALF/ST/30T/01 30T FLATBED SEMI
TRAILER - -
ANNEXURE-3
MECHANICAL SUSPENSION SEMI TRAILER
Sl No
Item Status
1. Check the condition of Fifth wheel king pin
2. Check the condition of Rubbing plate
3. Check tightness of fifth wheel king pin mounting bolts & tighten if required
4. Condition of trailer platform
5. Condition of the tyres
6. Check Tyre Inflation Pressure, fill to 8ksc, if required
7. Check availability of pneumatic palm couplings
8. Check pneumatic hoses for leaks and replace, if required
9. Functioning of Pneumatic Brake system
10. Check effectiveness of Brake system
11. Check effectiveness of Parking Brake system
12. Check the condition of mechanical leaf springs, shackles etc.,
13. Check for proper functioning of electrical accessories such as rear combination lights
14. Check for availability of reflectors on all sides of the trailer
15. Check for proper functioning of container lashing twist locks
16. Lubricate with grease wherever applicable
ANNEXURE-3
AIR SUSPENSION FULL TRAILER
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Eqpt Identification no.
Equipment Eqpt
Identification no. Equipment
VALF/FT/AST/15T/01
15T AIR SUSPENSION
TRAILER
- -
ANNEXURE-3
AIR SUSPENSION FULL TRAILER
Sl No
Item Status
1. Check the condition of Tow bar and tow bar eye
2. Check the condition of turn table
3. Condition of trailer platform
4. Check functioning of air springs
5. Check functioning of air reservoirs, distribution valves, height control valves etc.
6. Check tightness of wheel bolts & tighten if required
7. Check the condition & functioning of tow bar assist spring
8. Condition of the tyres
9. Check Tyre Inflation Pressure, fill to minimum 7.5ksc, if required
10. Check availability of pneumatic palm couplings
11. Check pneumatic hoses for leaks and replace, if required
12. Functioning of Pneumatic Brake system
13. Check effectiveness of Service Brake system
14. Check effectiveness of Parking Brake system
15. Functioning of Two speed landing gears
16. Lubricate with grease wherever applicable
17. Check the availability of earth chain and mount, if
required
ANNEXURE-3
MECHANICAL SUSPENSION FULL TRAILER
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Eqpt
Identification no. Equipment
Eqpt
Identification no. Equipment
VALF/FT/5T/01 5T FLATBED TRAILER SXC 2820 LOW BED TRAILER
(20T)
VALF/FT/8T/01 8T FLATBED TRAILER SXC 4725 PS0-XL TRAILER - 1
VALF/FT/10T/01 10T FLATBED TRAILER-1 -
PS0-XL TRAILER - 2
VALF/FT/10T/01 10T FLATBED TRAILER-2 SXC 4825 WELL BED TRAILER
VALF/FT/15T/02 15T FLATBED TRAILER-2 SXC 2115 BOWL TRAILER-1
VALF/FT/30T/01 30T DEAD WEIGHT
TRANSPORTER SXC 2915
BOWL TRAILER-2
ANNEXURE-3
MECHANICAL SUSPENSION FULL TRAILER
Sl No
Item Status
1. Check the condition of Tow bar and tow bar eye
2. Check the condition of turn table
3. Condition of trailer platform
4. Check tightness of wheel mounting bolts & tighten if required
5. Check the condition & functioning of assist spring.
6. Condition of the tyres
7. Check Tyre Inflation Pressure, fill to 8ksc, if required
8. Check availability of pneumatic palm couplings
9. Check pneumatic hoses for leaks and replace, if required
10. Check the condition of Mechanical Leaf springs, shackles etc.,
11. Functioning of Pneumatic Brake system
12. Check effectiveness of Brake
13. Check effectiveness of Parking Brake system
14. Lubricate with grease wherever applicable
15. Availability of reflectors at all sides of the trailer platform
16. Check the availability of earth chain and mount if required
ANNEXURE-3
DOLLEYS
WORK STATION – A
(Equipment Ref. As per Annexure – 1)
WORK STATION – B
(Equipment Ref. As per Annexure – 1)
Eqpt Identification no.
Equipment Eqpt
Identification no. Equipment
VALF/DL/20T/01
DOLLEY – 1 (2 AXLES)
- -
VALF/DL/20T/02
DOLLEY – 2 (2 AXLES)
- -
VALF/DL/20T/03
DOLLEY – 3 (2 AXLES)
- -
VALF/DL/10T/01
DOLLEY – 4
(SINGLE AXLE)
- -
ANNEXURE-3
DOLLEY – 1/2/3/4
Sl No
Item Status
1. Check the condition of Tow bar and tow bar eye
2. Check the condition of Fifth wheel Coupler
3. Check tightness of Fifth wheel Coupler mounting bolts & tighten if required
4. Check tightness of wheel mounting bolts & tighten if required
5. Check the condition & functioning of assist spring.
6. Condition of the tyres
7. Check Tyre Inflation Pressure, fill to 8ksc, if required
8. Check availability of pneumatic palm couplings
9. Check pneumatic hoses for leaks and replace, if required
10. Check the condition of Mechanical Leaf springs, shackles etc.,
11. Functioning of Pneumatic Brake system
12. Lubricate with grease wherever applicable
ANNEXURE-4
Periodical Preventive
Maintenance
Annexure-4
TIL CRANE– QUARTERLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
01 VALF/MC/15T/01 TIL CRANE
Annexure-4
TIL CRANE - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Check and top up as required.
a. Water in the radiator.
b. Fuel in the tank c. Engine oil in the sump d. Air cleaner oil level e. Brake fluid level in Master Cylinder f. Oil level in the gear boxes & Differential g. Hydraulic oil level in the reservoir h. Transmission oil level i. Electrolyte level in the Battery
2 ENGINE
2.1 Check engine oil pressure as per the recommendation.
Change Engine oil, engine oil filter and Air cleaner oil subjected
to Engine Oil colour change, loss of Viscosity, Sediments in the
oil / for 100 hours of Operations.
2.2 Check the condition of the Engine mounting bed and tighten /
replace if necessary.
2.3 Adjust the Valve Tappet Clearance to recommended value.
Check the condition of Valve door gasket, Engine cylinder head
Gasket, Water pump gaskets, Engine oil sump Gasket etc for
leaks and replace if required.
2.4 Lubricate the Fuel injection pump with engine oil.
Check the condition of Diesel fuel high pressure lines, diesel fuel
over-flow lines for leaks and tighten / replace if required.
2.5 Check the performance and condition of the Turbo Charger (TC),
TC lubrication hoses and rectify leaks if any.
3 COOLING SYSTEM
Annexure-4
TIL CRANE - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
3.1 Check the condition of Radiator Top hose, Bottom hose, Elbow
bend hoses, Hose clips etc., and replace / tighten if required.
3.2 Check the condition of the Radiator cap and replace if required.
3.3 Check the Radiator condition & performance, Radiator
mountings and repair / tighten the same.
3.4 Check the condition of the Radiator cells for leaks and repair the
same.
3.5 Check the condition and performance of the Water pump and
rectify leaks, if any
3.6 Check the condition of Fan belt and tighten / replace the same if
required.
3.7 Check the Radiator fan blade condition and its mounting bolts
for tightness and tighten if required.
3.8 Check the performance of the ATF oil cooling system, clean the
same if required.
3.9 Flush the Radiator water and fill with Fresh water / coolant.
3.10 Move, operate the crane for a period of 1 hour and record
the radiator water temperature.
If water temp. Exceeds more than the operating temp.
Of……. Same may be reported and corrective action to be
taken.
4 HYDRAULIC SYSTEM
4.1 Check Hydraulic oil level in the Reservoir and top-up if required.
Annexure-4
TIL CRANE - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
4.2 Check the condition of the hydraulic oil for oil colour change,
sediment in the oil or recommended hours of operation and
replace.
4.3 Check condition of the Hydraulic hoses and its end fittings
replace / tighten if necessary.
4.4 Check condition of hydraulic oil filter and replace if required.
(Recommended to replace the filter for every 750 hrs of
operation)
4.5 Check the condition of Heat exchanger and fan for proper
functioning
4.6 Check Hydraulic Pump for proper functioning
4.7 Operate the Hydraulic system lines such as Outriggers, Boom
lift cylinder, Boom extractor cylinder and ropes, rectify leaks if
any
4.8 Operate the crane both Boom & Derrick for a period of 1 hour
with load / without load, record Hydraulic oil temperature.
If oil temp. Exceeds more than the operating temp. Of …….
Same may be reported and corrective action to be taken.
5 BOOM & DERRICKS
5.1 Operate the boom for its maximum length and lubricate with
proper grease.
5.2 Visually inspect the crane boom for pitting, dents, weld cracks,
bend, twist / distortion and any damages etc.
Annexure-4
TIL CRANE - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.3 Check the boom hydraulic cylinder for proper functioning and
rectify leaks if any
5.4 Check the boom wire rope condition for bird caging, nesting,
kincking, broken wires replace if damaged.
5.5 Lubricate the Boom rope with Cardium compound.
5.6 Check the functioning of boom brake and adjust the brake if
required.
6 HOIST SYSTEM
6.1 Visually inspect the Hoist rope for bird caging, nesting, kincking,
broken wires etc., and hoist pulleys and replace the same, if
required.
6.2 Check the hoist rope anchoring points and tighten if required.
6.3 Check the rope drum and lubricate properly
6.4 Check the rope drum, hoist pulleys and replace the bearings if
required
6.5 Check the condition of the crane hook for safety latch system,
hook throat opening, distortion etc and record the same.
6.6 Visually inspect the crane hook block and record the same.
6.7 Lubricate the hoist rope with Cardium compound.
7 SLEW SYTEM
7.1 Check the slew brake for effectiveness and adjust if required.
7.2 Check the condition of the Annular gear and lubricate properly.
7.3 Operate the slew system and check for proper functioning.
Annexure-4
TIL CRANE - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
7.4 Apply mechanical swing lock and check for proper functioning.
8 BRAKE SYSTEM
8.1 Visually inspect Brake system Hydraulic hoses and its end
fittings and replace / tighten the same.
8.2 Visually inspect Brake system Pneumatic hoses and its end
fittings and replace / tighten the same.
8.3 Check the performance of the Master cylinder, Wheel cylinder
and connecting hoses and tighten / replace / repair the same.
8.4 Check the condition of the compressor V-belt and V-belt tension,
adjust tension if required.
8.5 Check the performance of the Air compressor, Regulator etc, if
any leak found, tighten / repair / replace the same.
9 WHEEL HUBS
9.1 Jack-up the wheel and check the wheel hub for shake, rectify
the same if found.
9.2 Rotate the wheel and check the condition / performance of the
wheel bearing, replace if required.
9.3 Check the wheel hubs for leaks and replace oil seals & O rings
with new.
9.4 Check the effectiveness of Brakes and adjust if required.
9.5 Top-up the wheel hub with proper lubricant up-to mark.
10 WHEEL DISC AND TYRES
Annexure-4
TIL CRANE - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
10.1 Check the condition of the wheel disc for distortion / cracks etc.,
and replace / repair the same.
10.2 Check the condition of the wheel bolts, tighten to recommended
tightening torque value. Replace wheel bolts and nuts with new
if found thread damages etc.,
10.3 Check the condition of the tyres and Replace with new subjected
to the following: tread cracks, worn out, aged tyres, side wall
cracks etc.
Note : Uneven wear of tyres to be reported and corrective action
to be taken.
10.4 Inflate the tyres to the recommended inflation pressure.
Front tyres inflation pressure :
Rear tyres inflation pressure :
11 STEERING SYSTEM
11.1 Check the performance of the Power steering system, steering
system hydraulic hoses for leaks, cracks etc, tighten / replace if
required.
11.2 Check the condition and performance of the double acting
steering cylinders, replace the O rings, oil seals if hydraulic oil
leak is noticed.
12 TORQUE CONVERTER & TRANSMISSION
12.1 Check the condition and performance of the torque converter &
transmission.
12.2 Check the performance of 2WD and 4WD and record
Annexure-4
TIL CRANE - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
12.3 Check the oil level in the transmission at 82–930 oil
temperature and Top-up oil if required.
Replace the oil filter element every 500 hrs of operation.
12.4 Move the crane for a distance of 5 kms at a max. Operating
speed and record the transmission oil temperature. If oil
temp. Exceeds more than the operating temp. of ……. Same
may be reported and corrective action to be taken.
13 ELECTRICAL SYSTEM
13.1 Check the specific gravity of the electrolyte in the batteries (SG-
1.2). Check the electrolyte level and top-up, if required with
distilled water. Clean the battery terminals and apply petroleum
jelly.
13.2 Check the condition and performance of Self motor and
Alternator for proper functioning, if not attend the same.
13.3 Check functioning of Head lights, tail lights, side indicators,
Parking brake light, charging circuit, battery terminals, battery
cut-off switch etc.,
14 DASH BOARD PARAMETERS
(NO LOAD / AT RATED CAPACITY)
Engine oil pressure gauge
Engine coolant temperature gauge (max. 900C)
Transmission oil temperature gauge (max. 900C)
Hydraulic oil temperature (max. 950C)
Rpm / Hour meter
Annexure-4
TIL CRANE - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
Fuel gauge
Volt meter
Functioning of Safety Display System & Program system
(with out-riggers & without out-riggers)
Overload alarm
Boom Over hoist alarm
Over hoist alarm
By-pass system
3rd wrap indicator
15 LUBRICATION
15.1 Lubricate all Greasing points as per the Lubrication Chart.
15.2 Clean and water wash the equipment thoroughly.
16 Test the crane by operating all system by trail running.
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TILCRANE – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the maintenance works have been completed as per Maintenance Schedule.
2. Check the condition and anchoring points of boom and hoisting ropes.
3. Tightness of mounting bolts and nuts –random checks.
4. Start the crane and test engine for a. Oil and water leaks b. Dash board parameters
c. Function of all electrical systems and relays d. Undue vibration at couplings and propeller shafts e. Proper air filling in the air reservoirs f. Functioning of hydraulic systems g. Functioning of transmission system h. Functioning of power steering system i. Condition of Hoist rope and Boom rope j. Condition of Hook block k. Condition of tyres and wheels l. Effectiveness of Service brake / parking brake m. Performance of Safety display systems.
5. Carryout the following operation checks on the crane
A Main Hoist Hoisting
Lowering
Brakes
Limit switches
B Outriggers Extraction
Retraction
Lifting (up)
Lowering (down)
B Boom Hoist Hoisting
Lowering
Brakes
Limit switches
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TILCRANE – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
C Swing Right side
Left side
D Travel Front & Rear
Brakes
4. Carry out Road trial and check the performance of the crane
Annexure-4
TIL CRNAE – QUARTERLY MAINTENACE SCHEDLE
HOUR METER/ KM READING :
MAINTENANCE ATTENDED BY SPARE PARTS REPLACED SPARES REQUIRED TO BE REPLACED
Sl No Name Designation Sl No Description Qty Sl.No Description Qty
1 Mechanic 1 1
2 Helper 2 2
3 Helper 3 3
4 Electrician 4 4
5 5
6 6
7 7
8 8
TYRES, TUBES & FLAPS REPLACED BATTERY
Sl
No
MAKE SIZE TYRE NUMBER POSITION NUMBER SIZE QTY
1
2
3 Problem with the Equipment for want of Spares / Expertise assistance:
4
5
6
Date & Signature of the Contractor Date & Signature of the Engineer-in-charge
Annexure-4
TIL CRANE - ANNUAL MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
01 VALF/MC/15T/01 TILCRANE
Annexure-4
TIL CRANE – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Apart from the above Quarterly maintenance schedules, the
following works also to be carried out.
2 ENGINE
2.1 Change Engine oil, engine oil filter and Air cleaner oil
2.2 Change Diesel fuel filter primary and secondary
3 COOLING SYSTEM
3.1 Check the condition of the Radiator – remove, Overhaul & refit –
if required.
3.2 Check the condition of the Water Pump – remove, Overhaul &
refit – if required.
4 HYDRAULIC SYSTEM
4.1 Change Hydraulic oil, hydraulic oil filter with new
4.2 Check performance of the Hydraulic motor and Overhaul if
required
5 BOOM & DERRICKS
5.1 Check the performance of boom brake and Overhaul if required.
6 HOIST SYSTEM
6.1 Check the performance of hoist brake and Overhaul if required.
6.2 Check the condition of Sheave pulley bearings and crane hook
block bearings and replace if required.
7 SLEW SYTEM
7.1 Check the functioning of slew brake for effectiveness, overhaul
the same and refit, adjust properly and check performance.
Annexure-4
TIL CRANE – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
8 BRAKE SYSTEM
8.1 Overhaul Master cylinder, Wheel cylinders, replace worn-out
spares, refit and check for effectiveness.
8.2 Check the condition of the Pneumatic system such as Air
compressor, Reservoir, air pressure Regulator, replace / repair
the same and refit.
9 WHEEL HUBS
9.1 Overhaul all wheel hubs and repair / replace worn out spares
and refit
9.2 Check the condition of the Wheel hub bearings and replace if
required.
9.3 Check the condition of the Brake shoes, linings, springs etc, and
replace if required and adjust brakes.
10 WHEEL DISC AND TYRES
10.1 Check the condition of all tyres and rotate as per the tyres
rotation chart.
11 STEERING SYSTEM
11.1 Change steering system oil with new
11.2 Check the condition of the Power steering system and Overhaul
the system if required.
12 TORQUE CONVERTER & TRANSMISSION
12.1 Change Transmission oil with new
12.2 Change transmission oil filter / filter element with new
Annexure-4
TIL CRANE – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
13 ELECTRICAL SYSTEM
13.1 Remove Self motor and attend to Major overhauling, replace
worn out items such as bearings, Oil seals, carbon brushes etc
13.2 Remove Alternator and attend to Major overhauling, replace
worn out items such as bearings, Oil seals, carbon brushes etc
14 LUBRICATION
14.1 Lubricate all Greasing points as per the Lubrication Chart.
14.2 Water wash the equipment thoroughly.
15 PAINTING
15.1 Clean the vehicle surface thoroughly and apply putty wherever
required with minor tinkering works.
15.2 Apply two coasts of Epoxy paint with brush / spray gun of
approved shade.
15.3 LETTERING:
Load test details, Stop Board, Number Board, Vehicle FC
particulars, GOVT. OF INDIA, ISRO SDSC SHAR lettering on the
vehicles etc.
16 LOAD TEST
16.1 Conduct Load testing of the equipment to its rated capacity and
check the performance and record in the Load test format.
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER - IN - CHARGE
TILCRANE – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the maintenance works have been completed as per Maintenance Schedule.
2. Check the condition and anchoring points of boom and hoisting ropes.
3. Tightness of mounting bolts and nuts –random checks.
4. a. Oil and water leaks b. Dash board parameters c. Function of all electrical systems and relays d. Undue vibration at couplings and propeller shafts
e. Proper air filling in the air reservoirs f. Functioning of hydraulic systems g. Functioning of transmission system h. Functioning of power steering system i. Condition of Hoist rope and Boom rope j. Condition of Hook block k. Condition of tyres and wheels l. Effectiveness of Service brake / parking brake m. Performance of Safety display systems. n. Check finishing of the paint
5. Carryout the following operation checks on the crane
A Main Hoist Hoisting
Lowering
Brakes
Limit switches
B Outriggers Extraction
Retraction
Lifting (up)
Lowering (down)
B Boom Hoist Hoisting
Lowering
Brakes
Limit switches
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER - IN - CHARGE
TILCRANE – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
C Swing Right side
Left side
D Travel Front & Rear
Brakes
6. Carry out Load test of the Equipment to its rated capacity and
check the performance of the crane, whether all the parameters are within the limit.
Annexure-4
TIL CRNAE – ANNUAL MAINTENACE SCHEDLE
HOUR METER / KM READING :
MAINTENANCE ATTENDED BY SPARE PARTS REPLACED SPARES REQUIRED TO BE REPLACED
Sl No Name Designation Sl No Description Qty Sl.No Description Qty
1 Sr.Mechanic 1 1
2 Helper 2 2
3 Helper 3 3
4 Electrician 4 4
5 5
6 6
7 7
8 8
TYRES, TUBES & FLAPS REPLACED BATTERY
Sl No MAKE SIZE TYRE NUMBER POSITION NUMBER SIZE QTY
1
2
3 Problem with the Equipment for want of Spares / Expertise assistance:
4
5
6
Date & Signature of the Contractor Date & Signature of the Engineer-in-charge
Annexure-4
10t HYDRA – QUARTERLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
01 VALF/MC/10T/02 10t HYDRA
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SIGNATURE OF FACILITY-IN-CHARGE / MAINTENANCE –IN-CHARGE
ENGINEER-IN -CHARGE
10t HYDRA - QUARTERLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No : VALF/MC/10T/02
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Check and top up as required.
a. Water in the radiator.
b. Fuel in the tank c. Engine oil in the sump d. Air cleaner for cleanliness. e. Brake fluid level in Master Cylinder f. Oil level in the gear boxes & Differential g. Hydraulic oil level in the reservoir h. Transmission oil level i. Electrolyte level in the Battery & Battery Terminals
2 ENGINE
2.1 Check engine oil pressure as per the recommendation.
Change Engine oil, engine oil filter and Air cleaner oil subjected
to Engine Oil colour change, loss of Viscosity, Sediments in the
oil for 250 hours of Operation.
2.2 Check the condition of the Engine mounting bed and tighten /
replace if necessary.
2.3 Adjust the Valve Tappet Clearance to recommended value.
Check the condition of Valve door gasket, Engine cylinder head
Gasket, Water pump gaskets, Engine oil sump Gasket etc for
leaks and replace if required.
2.4 Lubricate the Fuel injection pump with engine oil.
Check the condition of Diesel fuel high pressure lines, diesel fuel
over-flow lines for leaks and tighten / replace if required.
2.5 Check diesel leaks from the tank and rectify.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SIGNATURE OF FACILITY-IN-CHARGE / MAINTENANCE –IN-CHARGE
ENGINEER-IN -CHARGE
10t HYDRA - QUARTERLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No : VALF/MC/10T/02
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
3 COOLING SYSTEM
3.1 Check the condition of Radiator Top hose, Bottom hose, Elbow
bend hoses, Hose clips etc., and replace / tighten if required.
3.2 Check the condition of the Radiator cap and replace if required.
3.3 Check the Radiator condition & performance, Radiator
mountings and repair / tighten the same.
3.4 Check the condition of the Radiator cells for leaks and repair the
same.
3.5 Check the condition and performance of the Water pump and
rectify leaks, if any
3.6 Check the condition of Fan belt and tighten / replace the same if
required.
3.7 Check the Radiator fan blade condition and its mounting bolts
for tightness and tighten if required.
3.9 Flush the Radiator water and fill with Fresh water / coolant.
3.10 Move, operate the crane for a period of 1 hour and record
the radiator water temperature.
If water temp. exceeds more than the operating temp.
of……. Same may be reported and corrective action to be
taken.
4 CLUTCH SYSTEM
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SIGNATURE OF FACILITY-IN-CHARGE / MAINTENANCE –IN-CHARGE
ENGINEER-IN -CHARGE
10t HYDRA - QUARTERLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No : VALF/MC/10T/02
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
4.1 Operate the clutch and check for smooth engagement and
disengagement of power transmission.
4.2 Check the condition of the Clutch Release Bearing and replace if
damaged.
4.3 Check the condition of the Clutch mechanical linkages and
lubricate with grease.
4.4 Check the condition of the slave cylinder and rectify leaks if any.
4.5 Adjust the clutch free play to recommended value.
5 TRANSMISSION (Mechanical Gear Box)
5.1 Check the condition and performance of the transmission
5.2 Check the performance of HIGH and LOW selectors and record
5.3 Check the oil level in the transmission and Top-up oil if
required.
5.4 Replace Oil and Oil filter subjected to 1000 hrs of operation /
loss of oil viscosity, change in oil colour, deposit of carbon,
sediments etc.,
5.5 Check for oil leakages, replace with new oil seal.
5.6 Check the tightness of the transmission top cover bolts,
inspection cover bolts, end flange bolts and Mounting bolts,
tighten to recommended torque
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SIGNATURE OF FACILITY-IN-CHARGE / MAINTENANCE –IN-CHARGE
ENGINEER-IN -CHARGE
10t HYDRA - QUARTERLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No : VALF/MC/10T/02
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
6 PROPELLER SHAFT & UNIVERSAL JOINTS
6.1 Check the condition of Propeller shaft, Shaft Flange bolts,
mounting bolts, Centre joint bearing, tighten to required torque
if necessary
6.2 Check the condition of Universal joint, UJ mounting bolts,
replace / tighten to recommended torque if required.
7 HYDRAULIC SYSTEM
7.1 Check Hydraulic oil level in the Reservoir and top-up if required.
7.2 Check the condition of the hydraulic oil for oil colour change,
sediment in the oil or 1000 hours of operation and replace.
7.3 Check condition of the Hydraulic hoses and its end fittings
replace / tighten if necessary.
7.4 Check condition of hydraulic oil filter and replace for every 1000
hrs of operation.
7.5 Check Hydraulic Pump for proper functioning
7.6 Operate the Hydraulic system lines such as Boom lift cylinder,
Hoist rope cylinder, Winch etc, rectify leaks if any
7.7 Operate the crane both Boom & Derrick for a period of 1 hour
with load / without load, record Hydraulic oil temperature.
If oil temp. exceeds more than the operating temp. of …….
Same may be reported and corrective action to be taken.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SIGNATURE OF FACILITY-IN-CHARGE / MAINTENANCE –IN-CHARGE
ENGINEER-IN -CHARGE
10t HYDRA - QUARTERLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No : VALF/MC/10T/02
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
7.8 Check the performance of Flow components such as Directional
control valve, Safety relief valve etc., rectify leaks if any
8 BOOM
8.1 Operate the boom for its maximum and lubricate with proper
grease.
8.2 Visually inspect the crane boom for pitting, dents, weld cracks,
bend, twist / distortion and any damages etc.
8.3 Check the boom hydraulic cylinder for proper functioning and
rectify leaks if any
8.4 Check the boom lift cylinder condition, replace if damaged.
8.5 Check the condition of boom telescopic cylinder for proper
functioning.
9 HOIST SYSTEM (WINCH)
9.1 Check the condition and performance of the Winch motor
(hydraulic motor) and rectify leaks if any.
9.2 Visually inspect the Winch rope for bird caging, nesting,
kincking, broken wires etc., and hoist pulleys and replace the
same, if required.
9.3 Check the winch rope anchoring points and tighten if required.
9.4 Check the rope drum and lubricate properly
9.5 Check the rope drum, winch pulleys and replace the bearings if
required
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SIGNATURE OF FACILITY-IN-CHARGE / MAINTENANCE –IN-CHARGE
ENGINEER-IN -CHARGE
10t HYDRA - QUARTERLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No : VALF/MC/10T/02
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
9.6 Check the condition of the crane hook for safety latch system,
hook throat opening, distortion etc and record the same.
9.7 Visually inspect the crane hook block and record the same.
9.8 Lubricate the hoist rope with Cardium compound.
10 BRAKE SYSTEM
10.1 Visually inspect Brake system Hydraulic hoses and its end
fittings and replace / tighten the same.
10.2 Visually inspect Brake system Pneumatic hoses and its end
fittings and replace / tighten the same.
10.3 Check the performance of the Master cylinder, Wheel cylinder
and connecting hoses and tighten / replace / repair the same.
10.4 Check the condition of the compressor V-belt and V-belt tension,
adjust tension if required.
10.5 Check the performance of the Air compressor, Regulator etc, if
any leak found, tighten / repair / replace the same.
11 WHEEL HUBS
11.1 Jack-up the wheel and check the wheel hub for shake, rectify
the same if found.
11.2 Rotate the wheel and check the condition / performance of the
wheel bearing, replace if required.
11.3 Check the wheel hubs for leaks and replace oil seals & O rings
with new.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SIGNATURE OF FACILITY-IN-CHARGE / MAINTENANCE –IN-CHARGE
ENGINEER-IN -CHARGE
10t HYDRA - QUARTERLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No : VALF/MC/10T/02
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
11.4 Check the effectiveness of Brakes and adjust if required.
11.5 Pack the wheel hub with proper grease.
12 WHEEL DISC AND TYRES
12.1 Check the condition of the wheel disc for distortion / cracks etc.,
and replace / repair the same.
12.2 Check the condition of the wheel bolts, tighten to recommended
tightening torque value. Replace wheel bolts and nuts with new
if found thread damages etc.,
Front wheel bolts tightening torque : 9-10 mkg
Rear wheel bolts tightening torque : 18-20 mkg.
12.3 Check the condition of the tyres and Replace with new subjected
to the following: tread cracks, worn out, aged tyres, side wall
cracks etc.
Note : Uneven wear of tyres to be reported and corrective action
to be taken.
12.4 Inflate the tyres to the recommended inflation pressure.
Front tyres inflation pressure : 110 psi
Rear tyres inflation pressure : 35 psi
13 STEERING SYSTEM
13.1 Check for proper functioning of Steering system for 600 on
either side,
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SIGNATURE OF FACILITY-IN-CHARGE / MAINTENANCE –IN-CHARGE
ENGINEER-IN -CHARGE
10t HYDRA - QUARTERLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No : VALF/MC/10T/02
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
13.2 Check the performance of the Power steering system, steering
system hydraulic hoses for leaks, cracks etc, tighten / replace if
required.
13.3 Check the condition and performance of the double acting
steering cylinders, replace the O rings, oil seals if hydraulic oil
leak is noticed.
14 ELECTRICAL SYSTEM
14.1 Check the specific gravity of the electrolyte in the batteries (SG-
1.2). Check the electrolyte level and top-up, if required with
distilled water. Clean the battery terminals and apply petroleum
jelly.
14.2 Check the condition and performance of Self motor and
Alternator for proper functioning, if not attend the same.
14.3 Check functioning of Head lights, tail lights, side indicators,
Parking brake light, charging circuit, battery terminals, battery
cut-off switch etc.,
15 DASH BOARD PARAMETERS
(NO LOAD / AT RATED CAPACITY)
15.1 Engine oil pressure gauge (min. 2.1 ksc)
Engine coolant temperature gauge (max. 900C)
Speed cum Hour meter Reading
Fuel gauge
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SIGNATURE OF FACILITY-IN-CHARGE / MAINTENANCE –IN-CHARGE
ENGINEER-IN -CHARGE
10t HYDRA - QUARTERLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No : VALF/MC/10T/02
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
Volt meter
Air pressure Gauge (min. 0.7 ksc)
15.2 Functioning of Safety Display System & Program system
Overload alarm
Boom warning
Over hoist alarm
16 BODY
16.4 Tighten all body and cabin bolts
16.2 Tighten driver seat mountings
16.3 Check the function of door glasses for easy sliding, door handles
& locks. Lubricate the door hinges.
16.4 Check the condition of the Glass rubber beading and change if
necessary.
17 LUBRICATION
17.1 Lubricate all Greasing points as per the Lubrication Chart.
17.2 Clean and water wash the equipment thoroughly.
17.3 Test the crane by operating all system by trail running.
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
10T HYDRA – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the maintenance works have been completed as per Maintenance Schedule.
2. Check the condition and anchoring points of boom pivot and hoisting ropes.
3. Tightness of mounting bolts and nuts –random checks.
4. Start the crane and test engine for a. Oil and water leaks b. Dash board parameters c. Function of all electrical systems and relays
d. Undue vibration at couplings and propeller shafts e. Proper air filling in the air reservoirs f. Functioning of hydraulic systems g. Functioning of transmission system h. Functioning of power steering system i. Condition of Hoist rope and Boom lift cylinder j. Condition of Hook block k. Condition of tyres and wheels l. Effectiveness of Service brake / parking brake
5. Carryout the following operation checks on the crane
A Main Hoist Hoisting
Lowering
Brakes
Limit switches
B Boom telescope Extraction
Retraction
C Boom Lifting
Lowering
Brakes
Limit switches
C Swing Right side
Left side
D Travel Front & Rear
Brakes
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
10T HYDRA – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
4. Carry out Road trial and check the performance of the crane
Annexure-4
10t HYDRA – QUARTERLY MAINTENACE SCHEDLE
HOUR METER/ KM READING :
MAINTENANCE ATTENDED BY SPARE PARTS REPLACED SPARES REQUIRED TO BE REPLACED
Sl No Name Designation Sl No Description Qty Sl.No Description Qty
1 Mechanic 1 1
2 Helper 2 2
3 Helper 3 3
4 Electrician 4 4
5 5
6 6
7 7
8 8
TYRES, TUBES & FLAPS REPLACED BATTERY
Sl No MAKE SIZE TYRE NUMBER POSITION NUMBER SIZE QTY
1
2
3 Problem with the Equipment for want of Spares / Expertise assistance:
4
5
6
Date & Signature of the Contractor Date & Signature of the Engineer-in-charge
Annexure-4
10t HYDRA - ANNUAL MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
01 VALF/MC/10T/01 10T HYDRA
Annexure-4
10t HYDRA – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Apart from the above Quarterly maintenance schedules, the
following works also to be carried out.
2 ENGINE
2.1 Change Engine oil, engine oil filter and Air cleaner oil
2.2 Change Diesel fuel filter primary and secondary
2.3 Drain diesel from tank, remove, clean, water wash properly and
refit.
3 COOLING SYSTEM
3.1 Check the condition of the Radiator – remove, Overhaul & refit –
if required.
3.2 Check the condition of the Water Pump – remove, Overhaul &
refit – if required.
4 CLUTCH SYSTEM
4.1 Check the condition and performance of the Clutch system and
Overhaul if required.
5 TRANSMISSION
5.1 Change Transmission oil with new
5.2 Change transmission oil filter / filter element with new
6 PROPELLER SHAFT & UNIVERSAL JOINTS
6.1 Check the condition of Propeller shaft, Centre joint bearing,
repair / tighten to required torque / replace if necessary
7 HYDRAULIC SYSTEM
7.1 Change Hydraulic oil, hydraulic oil filter with new
Annexure-4
10t HYDRA – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
7.2 Check performance of the Hydraulic motor and Overhaul if
required
8 BOOM
8.1 Check the performance of boom brake and Overhaul if required.
9 HOIST (WINCH) SYSTEM
9.1 Check the performance of hoist brake and Overhaul if required.
9.2 Check the condition of Sheave pulley bearings and crane hook
block bearings and replace if required.
10 BRAKE SYSTEM
10.1 Overhaul Master cylinder, Wheel cylinders, replace worn-out
spares, refit and check for effectiveness.
10.2 Check the condition of the Pneumatic system such as Air
compressor, Reservoir, air pressure Regulator, replace / repair
the same and refit.
11 WHEEL HUBS
11.1 Overhaul all wheel hubs and repair / replace worn out spares
and refit
11.2 Check the condition of the Wheel hub bearings and replace if
required.
11.3 Check the condition of the Brake shoes, linings, springs etc, and
replace if required and adjust brakes.
Annexure-4
10t HYDRA – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
12 SLEW SYTEM
12.1 Check the functioning of slew brake for effectiveness, overhaul
the same and refit, adjust properly and check performance.
13 WHEEL DISC AND TYRES
13.1 Check the condition of all tyres and rotate as per the tyres
rotation chart.
14 STEERING SYSTEM
14.1 Change steering system oil with new
14.2 Check the condition of the Power steering system and Overhaul
the system if required.
15 ELECTRICAL SYSTEM
15.1 Remove Self motor and attend to Major overhauling, replace
worn out items such as bearings, Oil seals, carbon brushes etc
15.2 Remove Alternator and attend to Major overhauling, replace
worn out items such as bearings, Oil seals, carbon brushes etc
16 LUBRICATION
16.1 Lubricate all Greasing points as per the Lubrication Chart.
16.2 Water wash the equipment thoroughly.
17 PAINTING
17.1 Clean the vehicle surface thoroughly and apply putty wherever
required with minor tinkering works.
17.2 Apply two coasts of Epoxy paint with brush / spray gun of
approved shade.
Annexure-4
10t HYDRA – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No : VALF/MC/15T/01
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
18 LETTERING:
Load test details, Stop Board, Number Board, Vehicle FC
particulars, GOVT. OF INDIA, ISRO SDSC SHAR lettering on the
vehicles etc.
19 LOAD TEST
19.1 Conduct Load testing of the equipment to its rated capacity and
check the performance and record in the Load test format.
Annexure-4
10t HYDRA – ANNAUL MAINTENACE SCHEDLE
HOUR METER/ KM READING :
MAINTENANCE ATTENDED BY SPARE PARTS REPLACED SPARES REQUIRED TO BE REPLACED
Sl No Name Designation Sl No Description Qty Sl.No Description Qty
5 Mechanic 9 9
6 Helper 10 10
7 Helper 11 11
8 Electrician 12 12
13 13
14 14
15 15
16 16
TYRES, TUBES & FLAPS REPLACED BATTERY
Sl No MAKE SIZE TYRE NUMBER POSITION NUMBER SIZE QTY
7
8
9 Problem with the Equipment for want of Spares / Expertise assistance:
10
11
12
Date & Signature of the Contractor Date & Signature of the Engineer-in-charge
Annexure-4
MAINTENANCE CHECKLIST
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No
Equip Identification No. Equipment Sl No
Equip Identification No. Equipment
1. VALF/HA/4T//01 TATA 407 EXPLOSIVES VAN 1 SPROB/HA/4T//01 TATA 407 EXPLOSIVES VAN
2. VALF/HA/4T//01 TATA 407 UPLINK VEHICLE 2 SPROB/HA/VOLVO-01/ VOLVO HAULER 400 HP
3. VALF/HA/49T/06 AMW HAULER-1 3 SPROB/HA/VOLVO-02/ VOLVO HAULER 520 HP
4. VALF/HA/49T/07 AMW HAULER-2 4 SPROB/DOLLEY/01 DOLLEY
5. VALF/HA/4T/01 DOLLEY-2 AXLE & SINGLE AXLE 5 VALF/HA/1T/01 TATA ACE (CYL TRANSPORTER)
6. VALF/HA/1T/01 TATA ACE (CYL TRANSPORTER)
7. VALF/HA/1T/01 TATA ACE (SAMPLE TRANSPORTER)
8. VALF/HA/1T/01 TATA ACE (AGNI TRANSPORTER)
9. VALF/HA/49T/03 VOLVO HAULER 400 HP
10. VALF/HA/49T/04 VOLVO HAULER 400 HP
11. VALF/HA/49T/05 VOLVO HAULER 520 HP
12. VALF/HA/49T/01 HIPPO HAULER-1 250 HP
13. VALF/HA/49T/02 HIPPO HAULER-2 250 HP
Annexure-4
TATA 407 MAINTENANCE CHECK LIST
MONTHLY MAINTENANCE SCHEDULE WORK STATION - A EQUIPMENT No : VALF/TATA 407/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1.1 Check Engine Oil level & top up if required.
1.2 Check Coolant Level in Auxillary tank & topup if required.
1.3 Check for any leakage of oil, fuel clutch fluid & coolant.
1.4 Lubricate Accelerator Linkage with oil can.
1.5 Grease all the Grease points & hinges.
1.6 Check Wheel mounting Nuts & tighten if necessary.
1.7 Check the performance of Brakes and adjust if required.
1.8 Check Electrical Gauges & Instruments for proper functioning.
1.9 Check water level in Windscreen washer & topup if necessary.
1.10 Wash & Grease the Vehicle.
1.11 Check Specific Gravity of Battery Electrolyte (Sp Gr: 1.21)
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 407 – MONTHLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Verify whether all the maintenance works have been carried out as per schedule.
2
Start the engine and check the equipment for the following.
a. Dash board parameters
b. Proper functioning of Dynamo / Alternator and self motor
c. Performance of the engine.
3 Check the tyres condition and correct inflation pressures.
4 Check the electrical systems.
5
Take the equipment for road test and check the following.
a. Clutch system
b. Function of the transmission
c. Steering
Annexure-4
d. Brakes.
QUARTERLY MAINTENANCE SCHEDULE WORK STATION - A EQUIPMENT No : VAST/TATA 407/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
Complete the Monthly Maintenance schedule.
1.1 ENGINE:
1.2 Clean Air Filter
1.3 Change Engine oil & Filter if Kms of change is run
1.4 Change Fuel Filter Element (Primary) if Kms of change is run
1.5 Check Timing Belt, adjust tension if required.
1.6 Check Alternator Belt tension & adjust
1.7 Check Injector nozzle for Opening pressure & Spray pattern
1.8 Check Engine idle speed, accelarator pedal & cable
1.9 Check Exhaust system for noise & leakages rectify if necessary
1.10 Check Exhaust Smoke level & correct
1.11 Check Engine Mountings for Looseness & damage to mountings
1.12 Check and Tighten Engine Bolts (Cylinder head cover, Oil Sump, Starter Motor, Alternator, Fuel filter)
1.13 Drain water from Fuel filters
1.14 Clean Strainer in Fuel tank
1.15 Change both fuel filters elements if Kms of run is covered
2.0 CLUTCH:
2.1 Adjust Clutch Pedal for play
3.0 GEARBOX:
3.1 Check Oil Level in Gear box & Topup if required.
3.2 Check & Tighten Mounting Bolts
3.3 Grease Propeller Shaft UJ cross & Sliding Yoke
4.0 AXLES:
4.1 Check Oil Level in Rear Axle & Topup if required.
5.0 SUSPENSION:
Annexure-4
5.1 Front & Rear spring Bush Greasing
5.2 Check Front & rear spring U Bolt Torque and tighten if necessary
5.3 Check the Condition of Shock Absorber & Bushes
5.4 Check the Condition of Front & Rear Bump Stoppers
6.0 STEERING:
6.1 Check Oil Level in Steering Gear Box & topup
6.2 Check Wheel Alignment & adjust
7.0 BRAKES:
7.1 Check Brake Fluid level & Topup
7.2 Check Parking Brake cable
7.5 Check Brake Hoses and pipes for leakage
7.6 Check Brake pedal travel & correct and adjust four wheel brakes
8.0 ELECTRICALS:
8.1 Check functioning of Electrical Gadgets
8.2 Check Electrolyte level in the Battery, topup with distilled water
9.0 WHEEL & TYRES:
9.1 Check Wheel mounting Nuts & tighten
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 407 – QUARTERLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
3 Check the tyres.
4 Check the electrical systems.
TATA 407 - HALFYEARLY MAINTENANCE SCHEDULE WORK STATION - A EQUIPMENT No : VAST/TATA 407/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
Complete the Monthly & Quarterly Maintenance schedules.
1.0 ENGINE:
1.1 Check Thermostat for correct functioning
1.2 Repl407 Air Filer Element
1.3 Change Coolant
2.0 AXLES:
2.1 Change Grease in Front & Rear Hubs and adjust bearing play
3.0 SUSPENSION:
3.1 Check the Condition of Front & Rear Leaf spring Bushes, Pins and Overhaul if required
3.2 Check the condition of Shock Absorbers
4.0 STEERING:
4.1 Check & adjust Steering wheel free play
4.2 Change oil in Steering Gear box
Annexure-4
5.0 BRAKES:
5.1 If it comes 40000 Kms of run Check the Brake application & also change WC if required.
6.0 WHEEL & TYRES:
6.1 Rotate the Tyres as per the Recommendation
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 407 – HALF YEARY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
3 Check the tyres.
4 Check the electrical systems.
TATA 407 - ANNUAL MAINTENANCE SCHEDULE WORK STATION - A EQUIPMENT No : VAST/TATA 407/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
Complete the Monthly, Quarterly and Halfyearly Maintenance schedules.
1.0 ENGINE:
1.1 Repl407 Timing Belt if it comes 80,000 kms of run
2.0 GEAR BOX:
2.1 Clean Breather on Gear Box
2.2 Change Oil in Gear box
3.0 AXLES:
3.1 Change Oil in Rear Axle
3.2 Clean Breather on Rear Axle
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 407 – ANNUAL MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Verify whether all the maintenance works have been carried out as per schedule.
2 Inspection of brake and wheel assemblies after dismantling for overhauling for repl407ment of worn out items.
3 Inspection of Self-motor, Alternator / Dynamo after dismantling for repl407ment of worn out items.
4 Verify whether all the works have been completed as per the schedule.
4.1
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
Annexure-4
AMW HAULER MONTHLY MAINTENANCE CHECK LIST
AMW HAULERS – MONTHLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 ENGINE:
1.1 Check engine oil level in the sump using dip stick and top-up if required (Specs:API CE or API CF, Viscisity: SAE - 40)
1.2 Change the Engine oil as per Hours of the Schedule
1.3
Check the engine oil for the following:
a. Coolant water mixed with oil
b. Diesel fuel mixed with Engine oil.
1.4 Check the Engine Crank case (sump) for oil leaks.tighten the mounting bolts if required
1.5 Check the condition of engine breather,clean & refit.
1.6 Check the condition of cooling system lines for leaks & tighten / replace if required.
1.7 Check radiator water coolant level in the expansion tank & top-up .
1.8 Check the condition of radiator cap & replace if required.
1.9 Check the condition of radiator top & bottom hoses and replace, if required.
1.10 Check the condition & Tension of Fan belt & replace if required.
1.11 Check for water leak at water pump. Tighten the water pump mounting bolts if required.
1.12 Lubricate the water pump with grease.
1.13 Check and tighten the cylinder head fasteners.
1.14 Check for Fuel leak at high pressure pipe line Tighten / replace H.P lines if required.
1.15 Lubricate the Fuel pump with engine oil if required.
1.16 Check the condition of Fuel filter (Primary & secondary) and replace if required.
1.17 Check the condition & functioning of Air Compressor.
Annexure-4
1.18 Check the Pneumatic system lines for leaks tighten / rectify if required.
1.19 Check for Rattling sound of silencer & Mountings & rectify
2 CLUTCH:
2.1 Lubricate the clutch shaft.
2.2 Lubricate the clutch release bearing.
2.3 Lubricate the clutch linkages.
2.4 Check and adjust clutch pedal play if required.
3 GEAR BOX / TRANSMISSION / DIFFERENTIAL
3.1 Check and top-up oil level
4 PROPELLER SHAFT:
4.1 Lubricate crosses, center joint bearings and splines.
4.2 Tighten the propeller shaft fasteners.
5 AXLES AND BRAKES:
5.1 Check and top-up rear axle oil levels.
5.2 Clean the air filter and refit.
5.3 Drain the air tank.
5.4 Clean the tyre inflation valve.
5.5 Lubricate the S cam shaft needle bearings at front and rear axle.
5.6 Check the wheel play in front wheels and adjust, if required.
5.7 Check the oil level in the reduction hubs (For Hippos only) and top-up, if required.
5.8 Check for air leaks in brake circuit and rectify, if required.
5.9 Check the condition of palm couplings and replace kit/washer, if required.
6 STEERING:
6.1 Check oil level in steering gear box and power steering system.
6.2 Tighten the steering mounting bolts.
6.3 Lubricate the tie rod ends and king pins.
7 WHEELS:
7.1 Check the condition of tyres and replace, if required.
7.2 Inflate all tyres to 6.0ksc.
7.3 Tighten all wheel nuts.
8 SUSPENSION:
8.1 Check Spring Plates Cracks for Breakings.
8.2 Check and tighten shock absorber mountings.
Annexure-4
8.3 Lubricate the shackle pins.
9 ELECTRICAL
9.1 Check the function of alternator and self motor
9.2 Check the condition of battery, clean the terminals, apply petroleum jelly and top-up electrolyte level with distilled water.
9.3 Check all electrical connections.
Check Specific Gravity with Hygrometer.
10 CABIN:
10.1 Check the condition of cabin door locks, window regulators and seats.
10.2 Check the condition of fifth wheel coupling tighten all the mountings bolts and apply grease to rubbing plate.
11 DASH BOARD PARAMETERS :
11.1 Tacho meter Gauge:
11.2 a. Use the green field for normal driving
11.3 b. Use the dark field when the engine brake is being used.
11.4 c. Never allow the engine parameters to go into the red field.
11.5 Oil Pressure Gauge:
11.6 a.While the engine is at operating temperature and at idling speed the indicator should show between (3 to 5.5 bar) or (300 to 550 kpa)
11.7 b.Stop immediately if the warning lamp lights.
11.8 Engine coolant temperature gauge:
11.9 a.Stop immediately if the warning lamp lights.
11.10
b.During normal driving the indicator should remain in Green Zone.
11.11
Fuel gauge:
11.12
a.While the warning lamp lights, it indicates that there is 7 to 10% of the fuel left in the tank.
11.13
Air pressure gauge for brakes:
11.14
a.Stop immediately if the warning lamp lights.
11.15
b.While driving the gauge should remain within the green field.
11.16
c.The upper guage (guage -1) shows the air pressure in the front brake circuit.
Annexure-4
11.17
d.The lower guage (guage -2) shows the air pressure in the rear brake circuit.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
AMW HAULERS – MONTHLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Verify whether all the maintenance works have been carried out as per schedule.
2
Start the engine and check the equipment for the following.
a. Oil, Diesel and air leaks.
b. Dash board parameters
c. Proper functioning of Dynamo / Alternator and self motor
d. Performance of the engine.
3 Check the tyres.
4 Check the electrical systems.
5 Check for any leaks in brake fluid/air lines.
6 Check the fifth wheel coupling
7 Body bolts and cabin locks.
8
Take the equipment for road test and check the following.
a. Engine and turbo charger functioning.
b. Clutch system
c. Function of the transmission
d. Steering
e. Brakes.
DATE: ENGINEER IN -CHARGE
Annexure-4
AMW – HALFYEARLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
ENGINE:
1.1 Attend to all the works mentioned in Monthly Maintenance schedule.
1.2 Check and readjust the valve tappet clearance (Inlet valve: 0.25 mm ), (Exhaust valve: 0.3 mm)
1.3 Check the tightness of Engine bed mounting bolts & tighten if required
1.4 Check the condition of Fuel injection pump mountings & tighten if required.
1.5 Change engine oil and engine oil filter, if the engine has run 100 hours after previous engine oil change.
1.6 Change the Fuel filters (Primary & Secondary) if required.
1.7 Check the air filter & clean the air filter by applying 1 kg/sq cm air pressure.
1.8 Check the condition of Air drier unit mounting bolts tighten if required.
1.9 Check the Exhaust manifold for leaks rectify / replace with manifold gaskets if required.
1.10 Check the tightness of Silencer mounting bolts tighten if required.
10.11
Inspect the condition of clutch and report.
2 TRANSMISSION:
2.1 Check for any leaks in transmission system (Differential,Gear Box) and rectify.
2.2 Tighten all gear box/ transmission mounting bolts.
2.3 Check all the Couplings & joints for tightness and tighten if requiired.
3 STEERING:
3.1 Check proper functioning of steering servo cylinder.
3.2 Check the steering tie rod end joints, cross pins and swill pins for any abnormality and ensure lock pins and dust caps are in position.
4 PNEUMATIC BRAKING SYSTEM:
4.1 Check the unloader valve setting and adjust, if required.
4.2 Check for any leak in air lines and rectify, if required
4.3 Check the proper functioning of air regulator and booster.
4.4 Check the proper functioning of pedal valve and brake chambers.
Annexure-4
4.5 Check the condition of spring brake actuator on LH & RH and adjust if required.
4.6 Lubricate the slack adjuster.
4.7 Check the air compressor,Unloader valve,Automatic Drain Valve,Graduated Hand controll valve & Spot light switch are working in good condition.
5 WHEELS AND TYRES
5.1 Check the wheel bearings for any shake and adjust wheel play.Check the Hub oil & Topup if required.
5.2 Tighten all wheel nuts. Torque: 330 +/- 30 Nm.
6 SUSPENSION
6.1 Check the condition of all spring plates and tighten, spring clamps.
6.2 Check and tighten the rear spring U bolts
7 CABIN
7.1 Check the condition of tilting mechanism
7.2 Check the drivers seat mountings and retighten, if required.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
AMW HAULERS – HALF YEARY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
3 Check the tyres.
4 Check the electrical systems.
5 Check for any leaks in brake fluid/air lines.
6 Check the fifth wheel coupling
DATE: ENGINEER IN -CHARGE
Annexure-4
AMW HAULERS - ANNUAL MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Carry out all the works mentioned in Monthly and Half yearly maintenance schedule
2 Remove the spark arrester, clean and refit.
3 Change the Primary and Secondary Air filter.
4 Change the Air dryer Desiccant.
5 Flush the radiator and fill with AMW Coolant VCS
6 Change the Fan Belt (AMW Poly V)
7 Drain the diesel tank and clean the tank and refit.
8 Change the Fuel filters.
9 Change Engine Oil: API CE or API CF, Viscisity: SAE - 40, Qty: 33 Lts & Filter.
10 Check the Engine Valve Tappet clearance and adjust. The Inlet & Exhaust Valve clearance must be 0.25 mm & 0.3 mm respectively.
11 Check the fuel injection timing with out auto timer - 22 degrees or with auto timer - 15 degrees
12 Change AMW Gear box / Transmission oil: 97315 grade,Qty: 16 lts
13 Change Front (Driven) axle Differential Oil: API GL-5, Viscosity: SAE - 140, Qty: 11.5 lts
14 Change Rear axle Differential & Hub Oil: SAEJ 2360 OR APL GL-5 OR 97312, Qty: 30 lts
15 Change Power Steering oil: ATF Oil type Dextron III or 97315 grade,
Qty: 05 lts
16 Check the wheel bearings of Inner & Outer race for Pitting or Discolorisation due to heat. Change the Bearings & Hub oil.
17 Check braking system & change the Linings if required.
18 Remove the dynamo / alternator, self motor.Overhaul and replace the worn out items and refit.
19 Overhaul Fifth Wheel Coupler
20 Change the Tilting Cabin Pump Hydraulic Oil.
21 Water wash the vehicle & Grease with AMW grease OOCS / OOCSBD
Annexure-4
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
AMW HAULERS – ANNUAL MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Verify whether all the maintenance works have been carried out as per schedule.
2 Inspection of brake and wheel assemblies after dismantling for overhauling for replacement of worn out items.
3 Inspection of self-motor, alternator / dynamo after dismantling for replacement of worn out items.
4 Completion of all the works as per schedule
5 Verify whether all the works have been completed as per the schedule.
5.1
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
DATE: ENGINEER IN -CHARGE
Annexure-4
1 & 2 AXLE DOLLEY MAINTENANCE CHECK LIST
DOLLEY HALFYEARLY MAINTENANCE SCHEDULE WORK STATION - A EQUIPMENT No : VAST/DOLLEY/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1 Check the condition of Leaf spring assembly, Shackle Pins, Bushes, Centre bolt & U Clamps amnd replace if required.
2 Check the condition of Tow Bar, Spring and connected assembly and replace if requiired.
3 Check the condition of all Bolts & Nuts and replace & retighten if required.
4 Check the condition of Fifth wheel Coupler, Spring assembly, Locking & Delocking System. Ensure the locking system is fuctioning good.
5 Open the Axle Cups and pack with Grease anf fit back, after ensuring proper condition of Bearings.
6 Tighten all Wheel Nuts.
7 Check the condition of Tyres and replace, if required. Inflate all tyres to specified pressures.
8 Check the condition of Brakes & adjust if required.
9 Water wash the trailer thoroughly & lubricate the Hinge points.
10 Check the condition of Chassis Frame & Joints.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
DOLLEY HALFYEARLY MAINTENANCE SCHEDULE WORKSTATION - A EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS
CARRIED OUT REMARKS
1 Verify whether all the maintenance works have been carried out as per schedule.
2 Inspect the Fifth wheel coupler locking system with kingpin tester.
DATE: ENGINEER IN -CHARGE
DOLLEY ANNUAL MAINTENANCE SCHEDULE WORK STATION - A EQUIPMENT No : VAST/DOLLEY/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1 Carryout all the Maintenance works mentioned in the Halfyearly Maintenance Schedule.
2 Check the condition of Axle Bearings & replace if required. Replace all wheel hubs with Grease. (Hub Servicing)
3 Overhaul the Fifth wheel coupler and Tow hook linkages.
4
Overhaul the Fifth wheel coupler should involve: - Check the Coupler with Fifth wheel King pin tester -
Inspect the Spring Assembly, Locking and Delocking system - and attend to any reconditioning works if required. - Check the King Pin for Axial Moment & Clearence with the - coupler. - Check the Bore wear & Tear - Lubricate all Mating parts. - Tighten all Mounting Bolts
Annexure-4
5
Overhauling of Tow Hook linkages should involve: - Inspect the condition of Tow hook, Spring and fasteners - Replace / reconditioning worn out components. - Lubricate the System.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
DOLLEY – ANNUAL MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS
CARRIED OUT REMARKS
1 Verify whether all the maintenance works have been carried out as per schedule.
2 Inspection of brake and wheel assemblies after dismantling for overhauling for replacement of worn out items.
3 Inspect the Fifth wheel coupler locking system with kingpin tester.
DATE: ENGINEER IN -CHARGE
Annexure-4
TATA ACE MAINTENANCE CHECK LIST
MONTHLY MAINTENANCE SCHEDULE WORK STATION - A EQUIPMENT No : VAST/TATA ACE/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Check Engine Oil level & top up if required.
1.2 Check Coolant Level in Auxillary tank & topup if required.
1.3 Check for any leakage of oil, fuel clutch fluid & coolant.
1.4 Lubricate Accelerator Linkage with oil can.
1.5 Grease all the Grease points & hinges.
1.6 Check Wheel mounting Nuts & tighten if necessary.
1.7 Check the performance of Brakes and adjust if required.
1.8 Check Electrical Gauges & Instruments for proper functioning.
1.9 Check water level in Windscreen washer & topup if necessary.
1.10 Wash & Grease the Vehicle.
1.11 Check Specific Gravity of Battery Electrolyte (Sp Gr: 1.21)
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA ACE – MONTHLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Verify whether all the maintenance works have been carried out as per schedule.
2
Start the engine and check the equipment for the following.
a. Dash board parameters
b. Proper functioning of Dynamo / Alternator and self motor
c. Performance of the engine.
3 Check the tyres condition and correct inflation pressures.
4 Check the electrical systems.
5
Take the equipment for road test and check the following.
a. Clutch system
b. Function of the transmission
c. Steering
d. Brakes.
Annexure-4
QUARTERLY MAINTENANCE SCHEDULE WORK STATION - A EQUIPMENT No : VAST/TATA ACE/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
Complete the Monthly Maintenance schedule.
1.1 ENGINE:
1.2 Clean Air Filter
1.3 Change Engine oil & Filter if Kms of change is run
1.4 Change Fuel Filter Element (Primary) if Kms of change is run
1.5 Check Timing Belt, adjust tension if required.
1.6 Check Alternator Belt tension & adjust
1.7 Check Injector nozzle for Opening pressure & Spray pattern
1.8 Check Engine idle speed, accelarator pedal & cable
1.9 Check Exhaust system for noise & leakages rectify if necessary
1.10 Check Exhaust Smoke level & correct
1.11 Check Engine Mountings for Looseness & damage to mountings
1.12 Check and Tighten Engine Bolts (Cylinder head cover, Oil Sump, Starter Motor, Alternator, Fuel filter)
1.13 Drain water from Fuel filters
1.14 Clean Strainer in Fuel tank
1.15 Change both fuel filters elements if Kms of run is covered
2.0 CLUTCH:
2.1 Adjust Clutch Pedal for play
3.0 GEARBOX:
3.1 Check Oil Level in Gear box & Topup if required.
3.2 Check & Tighten Mounting Bolts
3.3 Grease Propeller Shaft UJ cross & Sliding Yoke
4.0 AXLES:
4.1 Check Oil Level in Rear Axle & Topup if required.
5.0 SUSPENSION:
Annexure-4
5.1 Front & Rear spring Bush Greasing
5.2 Check Front & rear spring U Bolt Torque and tighten if necessary
5.3 Check the Condition of Shock Absorber & Bushes
5.4 Check the Condition of Front & Rear Bump Stoppers
6.0 STEERING:
6.1 Check Oil Level in Steering Gear Box & topup
6.2 Check Wheel Alignment & adjust
7.0 BRAKES:
7.1 Check Brake Fluid level & Topup
7.2 Check Parking Brake cable
7.5 Check Brake Hoses and pipes for leakage
7.6 Check Brake pedal travel & correct and adjust four wheel brakes
8.0 ELECTRICALS:
8.1 Check functioning of Electrical Gadgets
8.2 Check Electrolyte level in the Battery, topup with distilled water
9.0 WHEEL & TYRES:
9.1 Check Wheel mounting Nuts & tighten
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA ACE – QUARTERLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMAR
KS
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
3 Check the tyres.
4 Check the electrical systems.
Annexure-4
TATA ACE - HALFYEARLY MAINTENANCE SCHEDULE WORK STATION - A EQUIPMENT No : VAST/TATA ACE/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
Complete the Monthly & Quarterly Maintenance schedules.
1.0 ENGINE:
1.1 Check Thermostat for correct functioning
1.2 Replace Air Filer Element
1.3 Change Coolant
2.0 AXLES:
2.1 Change Grease in Front & Rear Hubs and adjust bearing play
3.0 SUSPENSION:
3.1 Check the Condition of Front & Rear Leaf spring Bushes, Pins and Overhaul if required
3.2 Check the condition of Shock Absorbers
4.0 STEERING:
4.1 Check & adjust Steering wheel free play
4.2 Change oil in Steering Gear box
5.0 BRAKES:
5.1 If it comes 40000 Kms of run Check the Brake application & also change WC if required.
6.0 WHEEL & TYRES:
6.1 Rotate the Tyres as per the Recommendation
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA ACE – HALF YEARY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMAR
KS
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
3 Check the tyres.
4 Check the electrical systems.
Annexure-4
TATA ACE - ANNUAL MAINTENANCE SCHEDULE WORK STATION - A EQUIPMENT No : VAST/TATA ACE/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
Complete the Monthly, Quarterly and Halfyearly Maintenance schedules.
1.0 ENGINE:
1.1 Replace Timing Belt if it comes 80,000 kms of run
2.0 GEAR BOX:
2.1 Clean Breather on Gear Box
2.2 Change Oil in Gear box
3.0 AXLES:
3.1 Change Oil in Rear Axle
3.2 Clean Breather on Rear Axle
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA ACE – ANNUAL MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMAR
KS
1 Verify whether all the maintenance works have been carried out as per schedule.
2 Inspection of brake and wheel assemblies after dismantling for overhauling for replacement of worn out items.
3 Inspection of Self-motor, Alternator / Dynamo after dismantling for replacement of worn out items.
4 Verify whether all the works have been completed as per the schedule.
4.1
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
Annexure-4
VOLVO HAULER MONTHLY MAINTENANCE CHECK LIST
VOLVO HAULERS – MONTHLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 ENGINE:
1.1 Check engine oil level in the sump using dip stick and top-up if required (Specs:API CE or API CF, Viscisity: SAE - 40)
1.2 Change the Engine oil as per Hours of the Schedule
1.3
Check the engine oil for the following:
a. Coolant water mixed with oil
b. Diesel fuel mixed with Engine oil.
1.4 Check the Engine Crank case (sump) for oil leaks.tighten the mounting bolts if required
1.5 Check the condition of engine breather,clean & refit.
1.6 Check the condition of cooling system lines for leaks & tighten / replace if required.
1.7 Check radiator water coolant level in the expansion tank & top-up .
1.8 Check the condition of radiator cap & replace if required.
1.9 Check the condition of radiator top & bottom hoses and replace, if required.
1.10 Check the condition & Tension of Fan belt & replace if required.
1.11 Check for water leak at water pump. Tighten the water pump mounting bolts if required.
1.12 Lubricate the water pump with grease.
1.13 Check and tighten the cylinder head fasteners.
1.14 Check for Fuel leak at high pressure pipe line Tighten / replace H.P lines if required.
1.15 Lubricate the Fuel pump with engine oil if required.
1.16 Check the condition of Fuel filter (Primary & secondary) and replace if required.
1.17 Check the condition & functioning of Air Compressor.
1.18 Check the Pneumatic system lines for leaks tighten / rectify if required.
Annexure-4
1.19 Check for Rattling sound of silencer & Mountings & rectify
2 CLUTCH:
2.1 Lubricate the clutch shaft.
2.2 Lubricate the clutch release bearing.
2.3 Lubricate the clutch linkages.
2.4 Check and adjust clutch pedal play if required.
3 GEAR BOX / TRANSMISSION / DIFFERENTIAL
3.1 Check and top-up oil level
4 PROPELLER SHAFT:
4.1 Lubricate crosses, center joint bearings and splines.
4.2 Tighten the propeller shaft fasteners.
5 AXLES AND BRAKES:
5.1 Check and top-up rear axle oil levels.
5.2 Clean the air filter and refit.
5.3 Drain the air tank.
5.4 Clean the tyre inflation valve.
5.5 Lubricate the S cam shaft needle bearings at front and rear axle.
5.6 Check the wheel play in front wheels and adjust, if required.
5.7 Check the oil level in the reduction hubs (For Hippos only) and top-up, if required.
5.8 Check for air leaks in brake circuit and rectify, if required.
5.9 Check the condition of palm couplings and replace kit/washer, if required.
6 STEERING:
6.1 Check oil level in steering gear box and power steering system.
6.2 Tighten the steering mounting bolts.
6.3 Lubricate the tie rod ends and king pins.
7 WHEELS:
7.1 Check the condition of tyres and replace, if required.
7.2 Inflate all tyres to 6.0ksc.
7.3 Tighten all wheel nuts.
8 SUSPENSION:
8.1 Check Spring Plates Cracks for Breakings.
8.2 Check and tighten shock absorber mountings.
Annexure-4
8.3 Lubricate the shackle pins.
9 ELECTRICAL
9.1 Check the function of alternator and self motor
9.2 Check the condition of battery, clean the terminals, apply petroleum jelly and top-up electrolyte level with distilled water.
9.3 Check all electrical connections.
Check Specific Gravity with Hygrometer.
10 CABIN:
10.1 Check the condition of cabin door locks, window regulators and seats.
10.2 Check the condition of fifth wheel coupling tighten all the mountings bolts and apply grease to rubbing plate.
11 DASH BOARD PARAMETERS :
11.1 Tacho meter Gauge:
11.2 a. Use the green field for normal driving
11.3 b. Use the dark field when the engine brake is being used.
11.4 c. Never allow the engine parameters to go into the red field.
11.5 Oil Pressure Gauge:
11.6 a.While the engine is at operating temperature and at idling speed the indicator should show between (3 to 5.5 bar) or (300 to 550 kpa)
11.7 b.Stop immediately if the warning lamp lights.
11.8 Engine coolant temperature gauge:
11.9 a.Stop immediately if the warning lamp lights.
11.10 b.During normal driving the indicator should remain in Green Zone.
11.11 Fuel gauge:
11.12 a.While the warning lamp lights, it indicates that there is 7 to 10% of the fuel left in the tank.
11.13 Air pressure gauge for brakes:
11.14 a.Stop immediately if the warning lamp lights.
11.15 b.While driving the gauge should remain within the green field.
11.16 c.The upper guage (guage -1) shows the air pressure in the front brake circuit.
11.17 d.The lower guage (guage -2) shows the air pressure in the rear brake circuit.
Annexure-4
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
VOLVO HAULERS – MONTHLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Verify whether all the maintenance works have been carried out as per schedule.
2
Start the engine and check the equipment for the following.
a. Oil, Diesel and air leaks.
b. Dash board parameters
c. Proper functioning of Dynamo / Alternator and self motor
d. Performance of the engine.
3 Check the tyres.
4 Check the electrical systems.
5 Check for any leaks in brake fluid/air lines.
6 Check the fifth wheel coupling
7 Body bolts and cabin locks.
8
Take the equipment for road test and check the following.
a. Engine and turbo charger functioning.
b. Clutch system
c. Function of the transmission
d. Steering
e. Brakes.
DATE: ENGINEER IN -CHARGE
VOLVO – HALFYEARLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
ENGINE:
1.1 Attend to all the works mentioned in Monthly Maintenance schedule.
1.2 Check and readjust the valve tappet clearance (Inlet valve: 0.25 mm ), (Exhaust valve: 0.3 mm)
1.3 Check the tightness of Engine bed mounting bolts & tighten if required
Annexure-4
1.4 Check the condition of Fuel injection pump mountings & tighten if required.
1.5 Change engine oil and engine oil filter, if the engine has run 100 hours after previous engine oil change.
1.6 Change the Fuel filters (Primary & Secondary) if required.
1.7 Check the air filter & clean the air filter by applying 1 kg/sq cm air pressure.
1.8 Check the condition of Air drier unit mounting bolts tighten if required.
1.9 Check the Exhaust manifold for leaks rectify / replace with manifold gaskets if required.
1.10 Check the tightness of Silencer mounting bolts tighten if required.
10.11 Inspect the condition of clutch and report.
2 TRANSMISSION:
2.1 Check for any leaks in transmission system (Differential,Gear Box) and rectify.
2.2 Tighten all gear box/ transmission mounting bolts.
2.3 Check all the Couplings & joints for tightness and tighten if requiired.
3 STEERING:
3.1 Check proper functioning of steering servo cylinder.
3.2 Check the steering tie rod end joints, cross pins and swill pins for any abnormality and ensure lock pins and dust caps are in position.
4 PNEUMATIC BRAKING SYSTEM:
4.1 Check the unloader valve setting and adjust, if required.
4.2 Check for any leak in air lines and rectify, if required
4.3 Check the proper functioning of air regulator and booster.
4.4 Check the proper functioning of pedal valve and brake chambers.
4.5 Check the condition of spring brake actuator on LH & RH and adjust if required.
4.6 Lubricate the slack adjuster.
4.7 Check the air compressor,Unloader valve,Automatic Drain Valve,Graduated Hand controll valve & Spot light switch are working in good condition.
5 WHEELS AND TYRES
5.1 Check the wheel bearings for any shake and adjust wheel play.Check the Hub oil & Topup if required.
5.2 Tighten all wheel nuts. Torque: 330 +/- 30 Nm.
Annexure-4
6 SUSPENSION
6.1 Check the condition of all spring plates and tighten, spring clamps.
6.2 Check and tighten the rear spring U bolts
7 CABIN
7.1 Check the condition of tilting mechanism
7.2 Check the drivers seat mountings and retighten, if required.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
VOLVO HAULERS – HALF YEARY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
3 Check the tyres.
4 Check the electrical systems.
5 Check for any leaks in brake fluid/air lines.
6 Check the fifth wheel coupling
DATE: ENGINEER IN -CHARGE
Annexure-4
VOLVO HAULERS - ANNUAL MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Carry out all the works mentioned in Monthly and Half yearly maintenance schedule
2 Remove the spark arrester, clean and refit.
3 Change the Primary and Secondary Air filter.
4 Change the Air dryer Desiccant.
5 Flush the radiator and fill with Volvo Coolant VCS
6 Change the Fan Belt (Volvo Poly V)
7 Drain the diesel tank and clean the tank and refit.
8 Change the Fuel filters.
9 Change Engine Oil: API CE or API CF, Viscisity: SAE - 40, Qty: 33 Lts & Filter.
10 Check the Engine Valve Tappet clearance and adjust. The Inlet & Exhaust Valve clearance must be 0.25 mm & 0.3 mm respectively.
11 Check the fuel injection timing with out auto timer - 22 degrees or with auto timer - 15 degrees
12 Change Volvo Gear box / Transmission oil: 97315 grade,Qty: 16 lts
13 Change Front (Driven) axle Differential Oil: API GL-5, Viscosity: SAE - 140, Qty: 11.5 lts
14 Change Rear axle Differential & Hub Oil: SAEJ 2360 OR APL GL-5 OR 97312, Qty: 30 lts
15 Change Power Steering oil: ATF Oil type Dextron III or 97315 grade,
Qty: 05 lts
16 Check the wheel bearings of Inner & Outer race for Pitting or Discolorisation due to heat. Change the Bearings & Hub oil.
17 Check braking system & change the Linings if required.
18 Remove the dynamo / alternator, self motor.Overhaul and replace the worn out items and refit.
19 Overhaul Fifth Wheel Coupler
20 Change the Tilting Cabin Pump Hydraulic Oil.
21 Water wash the vehicle & Grease with Volvo grease OOCS / OOCSBD
Annexure-4
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
VOLVO HAULERS – ANNUAL MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Verify whether all the maintenance works have been carried out as per schedule.
2 Inspection of brake and wheel assemblies after dismantling for overhauling for replacement of worn out items.
3 Inspection of self-motor, alternator / dynamo after dismantling for replacement of worn out items.
4 Completion of all the works as per schedule
5 Verify whether all the works have been completed as per the schedule.
5.1
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
DATE: ENGINEER IN -CHARGE
Annexure-4
HIPPO HAULER -1 MONTHLY MAINTENANCE CHECK LIST
HIPPO -1 HAULERS – MONTHLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 ENGINE:
1.1 Check engine oil level in the sump using dip stick and top-up if required (Specs:API CE or API CF, Viscisity: SAE - 40)
1.2 Change the Engine oil as per Hours of the Schedule
1.3
Check the engine oil for the following:
a. Coolant water mixed with oil
b. Diesel fuel mixed with Engine oil.
1.4 Check the Engine Crank case (sump) for oil leaks.tighten the mounting bolts if required
1.5 Check the condition of engine breather,clean & refit.
1.6 Check the condition of cooling system lines for leaks & tighten / replace if required.
1.7 Check radiator water coolant level in the expansion tank & top-up .
1.8 Check the condition of radiator cap & replace if required.
1.9 Check the condition of radiator top & bottom hoses and replace, if required.
1.10 Check the condition & Tension of Fan belt & replace if required.
1.11 Check for water leak at water pump. Tighten the water pump mounting bolts if required.
1.12 Lubricate the water pump with grease.
1.13 Check and tighten the cylinder head fasteners.
1.14 Check for Fuel leak at high pressure pipe line Tighten / replace H.P lines if required.
1.15 Lubricate the Fuel pump with engine oil if required.
1.16 Check the condition of Fuel filter (Primary & secondary) and replace if required.
1.17 Check the condition & functioning of Air Compressor.
1.18 Check the Pneumatic system lines for leaks tighten / rectify if required.
1.19 Check for Rattling sound of silencer & Mountings & rectify
2 CLUTCH:
Annexure-4
2.1 Lubricate the clutch shaft.
2.2 Lubricate the clutch release bearing.
2.3 Lubricate the clutch linkages.
2.4 Check and adjust clutch pedal play if required.
3 GEAR BOX / TRANSMISSION / DIFFERENTIAL
3.1 Check and top-up oil level
4 PROPELLER SHAFT:
4.1 Lubricate crosses, center joint bearings and splines.
4.2 Tighten the propeller shaft fasteners.
5 AXLES AND BRAKES:
5.1 Check and top-up rear axle oil levels.
5.2 Clean the air filter and refit.
5.3 Drain the air tank.
5.4 Clean the tyre inflation valve.
5.5 Lubricate the S cam shaft needle bearings at front and rear axle.
5.6 Check the wheel play in front wheels and adjust, if required.
5.7 Check the oil level in the reduction hubs (For Hippos only) and top-up, if required.
5.8 Check for air leaks in brake circuit and rectify, if required.
5.9 Check the condition of palm couplings and replace kit/washer, if required.
6 STEERING:
6.1 Check oil level in steering gear box and power steering system.
6.2 Tighten the steering mounting bolts.
6.3 Lubricate the tie rod ends and king pins.
7 WHEELS:
7.1 Check the condition of tyres and replace, if required.
7.2 Inflate all tyres to 6.0ksc.
7.3 Tighten all wheel nuts.
8 SUSPENSION:
8.1 Check Spring Plates Cracks for Breakings.
8.2 Check and tighten shock absorber mountings.
8.3 Lubricate the shackle pins.
9 ELECTRICAL
9.1 Check the function of alternator and self motor
Annexure-4
9.2 Check the condition of battery, clean the terminals, apply petroleum jelly and top-up electrolyte level with distilled water.
9.3 Check all electrical connections.
Check Specific Gravity with Hygrometer.
10 CABIN:
10.1 Check the condition of cabin door locks, window regulators and seats.
10.2 Check the condition of fifth wheel coupling tighten all the mountings bolts and apply grease to rubbing plate.
11 DASH BOARD PARAMETERS :
11.1 Tacho meter Gauge:
11.2 a. Use the green field for normal driving
11.3 b. Use the dark field when the engine brake is being used.
11.4 c. Never allow the engine parameters to go into the red field.
11.5 Oil Pressure Gauge:
11.6 a.While the engine is at operating temperature and at idling speed the indicator should show between (3 to 5.5 bar) or (300 to 550 kpa)
11.7 b.Stop immediately if the warning lamp lights.
11.8 Engine coolant temperature gauge:
11.9 a.Stop immediately if the warning lamp lights.
11.10
b.During normal driving the indicator should remain in Green Zone.
11.11
Fuel gauge:
11.12
a.While the warning lamp lights, it indicates that there is 7 to 10% of the fuel left in the tank.
11.13
Air pressure gauge for brakes:
11.14
a.Stop immediately if the warning lamp lights.
11.15
b.While driving the gauge should remain within the green field.
11.16
c.The upper guage (guage -1) shows the air pressure in the front brake circuit.
11.17
d.The lower guage (guage -2) shows the air pressure in the rear brake circuit.
Annexure-4
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
HIPPO -1 HAULERS – MONTHLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Verify whether all the maintenance works have been carried out as per schedule.
2
Start the engine and check the equipment for the following.
a. Oil, Diesel and air leaks.
b. Dash board parameters
c. Proper functioning of Dynamo / Alternator and self motor
d. Performance of the engine.
3 Check the tyres.
4 Check the electrical systems.
5 Check for any leaks in brake fluid/air lines.
6 Check the fifth wheel coupling
7 Body bolts and cabin locks.
8
Take the equipment for road test and check the following.
a. Engine and turbo charger functioning.
b. Clutch system
c. Function of the transmission
d. Steering
e. Brakes.
DATE: ENGINEER IN -CHARGE
HIPPO-1 – HALFYEARLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
ENGINE:
Annexure-4
1.1 Attend to all the works mentioned in Monthly Maintenance schedule.
1.2 Check and readjust the valve tappet clearance (Inlet valve: 0.25 mm ), (Exhaust valve: 0.3 mm)
1.3 Check the tightness of Engine bed mounting bolts & tighten if required
1.4 Check the condition of Fuel injection pump mountings & tighten if required.
1.5 Change engine oil and engine oil filter, if the engine has run 100 hours after previous engine oil change.
1.6 Change the Fuel filters (Primary & Secondary) if required.
1.7 Check the air filter & clean the air filter by applying 1 kg/sq cm air pressure.
1.8 Check the condition of Air drier unit mounting bolts tighten if required.
1.9 Check the Exhaust manifold for leaks rectify / replace with manifold gaskets if required.
1.10 Check the tightness of Silencer mounting bolts tighten if required.
10.11
Inspect the condition of clutch and report.
2 TRANSMISSION:
2.1 Check for any leaks in transmission system (Differential,Gear Box) and rectify.
2.2 Tighten all gear box/ transmission mounting bolts.
2.3 Check all the Couplings & joints for tightness and tighten if requiired.
3 STEERING:
3.1 Check proper functioning of steering servo cylinder.
3.2 Check the steering tie rod end joints, cross pins and swill pins for any abnormality and ensure lock pins and dust caps are in position.
4 PNEUMATIC BRAKING SYSTEM:
4.1 Check the unloader valve setting and adjust, if required.
4.2 Check for any leak in air lines and rectify, if required
4.3 Check the proper functioning of air regulator and booster.
4.4 Check the proper functioning of pedal valve and brake chambers.
4.5 Check the condition of spring brake actuator on LH & RH and adjust if required.
4.6 Lubricate the slack adjuster.
4.7 Check the air compressor,Unloader valve,Automatic Drain Valve,Graduated Hand controll valve & Spot light switch are working in good condition.
5 WHEELS AND TYRES
Annexure-4
5.1 Check the wheel bearings for any shake and adjust wheel play.Check the Hub oil & Topup if required.
5.2 Tighten all wheel nuts. Torque: 330 +/- 30 Nm.
6 SUSPENSION
6.1 Check the condition of all spring plates and tighten, spring clamps.
6.2 Check and tighten the rear spring U bolts
7 CABIN
7.1 Check the condition of tilting mechanism
7.2 Check the drivers seat mountings and retighten, if required.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
HIPPO-1 HAULERS – HALF YEARY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
3 Check the tyres.
4 Check the electrical systems.
5 Check for any leaks in brake fluid/air lines.
6 Check the fifth wheel coupling
DATE: ENGINEER IN -CHARGE
HIPPO-1 HAULERS - ANNUAL MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Carry out all the works mentioned in Monthly and Half yearly maintenance schedule
Annexure-4
2 Remove the spark arrester, clean and refit.
3 Change the Primary and Secondary Air filter.
4 Change the Air dryer Desiccant.
5 Flush the radiator and fill with AMW Coolant VCS
6 Change the Fan Belt (AMW Poly V)
7 Drain the diesel tank and clean the tank and refit.
8 Change the Fuel filters.
9 Change Engine Oil: API CE or API CF, Viscisity: SAE - 40, Qty: 33 Lts & Filter.
10 Check the Engine Valve Tappet clearance and adjust. The Inlet & Exhaust Valve clearance must be 0.25 mm & 0.3 mm respectively.
11 Check the fuel injection timing with out auto timer - 22 degrees or with auto timer - 15 degrees
12 Change AMW Gear box / Transmission oil: 97315 grade,Qty: 16 lts
13 Change Front (Driven) axle Differential Oil: API GL-5, Viscosity: SAE - 140, Qty: 11.5 lts
14 Change Rear axle Differential & Hub Oil: SAEJ 2360 OR APL GL-5 OR 97312, Qty: 30 lts
15 Change Power Steering oil: ATF Oil type Dextron III or 97315 grade, Qty: 05 lts
16 Check the wheel bearings of Inner & Outer race for Pitting or Discolorisation due to heat. Change the Bearings & Hub oil.
17 Check braking system & change the Linings if required.
18 Remove the dynamo / alternator, self motor.Overhaul and replace the worn out items and refit.
19 Overhaul Fifth Wheel Coupler
20 Change the Tilting Cabin Pump Hydraulic Oil.
21 Water wash the vehicle & Grease with AMW grease OOCS / OOCSBD
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
HIPPO-1 HAULERS – ANNUAL MAINTENANCE WORKSTATION - A EQUIPMENT No :
Annexure-4
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Verify whether all the maintenance works have been carried out as per schedule.
2 Inspection of brake and wheel assemblies after dismantling for overhauling for replacement of worn out items.
3 Inspection of self-motor, alternator / dynamo after dismantling for replacement of worn out items.
4 Completion of all the works as per schedule
5 Verify whether all the works have been completed as per the schedule.
5.1
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
DATE: ENGINEER IN -CHARGE
Annexure-4
HIPPO HAULER -2 MONTHLY MAINTENANCE CHECK LIST
HIPPO -2 HAULERS – MONTHLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 ENGINE:
1.1 Check engine oil level in the sump using dip stick and top-up if required (Specs:API CE or API CF, Viscisity: SAE - 40)
1.2 Change the Engine oil as per Hours of the Schedule
1.3
Check the engine oil for the following:
a. Coolant water mixed with oil
b. Diesel fuel mixed with Engine oil.
1.4 Check the Engine Crank case (sump) for oil leaks.tighten the mounting bolts if required
1.5 Check the condition of engine breather,clean & refit.
1.6 Check the condition of cooling system lines for leaks & tighten / replace if required.
1.7 Check radiator water coolant level in the expansion tank & top-up .
1.8 Check the condition of radiator cap & replace if required.
1.9 Check the condition of radiator top & bottom hoses and replace, if required.
1.10 Check the condition & Tension of Fan belt & replace if required.
1.11 Check for water leak at water pump. Tighten the water pump mounting bolts if required.
1.12 Lubricate the water pump with grease.
1.13 Check and tighten the cylinder head fasteners.
1.14 Check for Fuel leak at high pressure pipe line Tighten / replace H.P lines if required.
1.15 Lubricate the Fuel pump with engine oil if required.
1.16 Check the condition of Fuel filter (Primary & secondary) and replace if required.
1.17 Check the condition & functioning of Air Compressor.
1.18 Check the Pneumatic system lines for leaks tighten / rectify if required.
1.19 Check for Rattling sound of silencer & Mountings & rectify
2 CLUTCH:
Annexure-4
2.1 Lubricate the clutch shaft.
2.2 Lubricate the clutch release bearing.
2.3 Lubricate the clutch linkages.
2.4 Check and adjust clutch pedal play if required.
3 GEAR BOX / TRANSMISSION / DIFFERENTIAL
3.1 Check and top-up oil level
4 PROPELLER SHAFT:
4.1 Lubricate crosses, center joint bearings and splines.
4.2 Tighten the propeller shaft fasteners.
5 AXLES AND BRAKES:
5.1 Check and top-up rear axle oil levels.
5.2 Clean the air filter and refit.
5.3 Drain the air tank.
5.4 Clean the tyre inflation valve.
5.5 Lubricate the S cam shaft needle bearings at front and rear axle.
5.6 Check the wheel play in front wheels and adjust, if required.
5.7 Check the oil level in the reduction hubs (For Hippos only) and top-up, if required.
5.8 Check for air leaks in brake circuit and rectify, if required.
5.9 Check the condition of palm couplings and replace kit/washer, if required.
6 STEERING:
6.1 Check oil level in steering gear box and power steering system.
6.2 Tighten the steering mounting bolts.
6.3 Lubricate the tie rod ends and king pins.
7 WHEELS:
7.1 Check the condition of tyres and replace, if required.
7.2 Inflate all tyres to 6.0ksc.
7.3 Tighten all wheel nuts.
8 SUSPENSION:
8.1 Check Spring Plates Cracks for Breakings.
8.2 Check and tighten shock absorber mountings.
8.3 Lubricate the shackle pins.
9 ELECTRICAL
9.1 Check the function of alternator and self motor
Annexure-4
9.2 Check the condition of battery, clean the terminals, apply petroleum jelly and top-up electrolyte level with distilled water.
9.3 Check all electrical connections.
Check Specific Gravity with Hygrometer.
10 CABIN:
10.1 Check the condition of cabin door locks, window regulators and seats.
10.2 Check the condition of fifth wheel coupling tighten all the mountings bolts and apply grease to rubbing plate.
11 DASH BOARD PARAMETERS :
11.1 Tacho meter Gauge:
11.2 a. Use the green field for normal driving
11.3 b. Use the dark field when the engine brake is being used.
11.4 c. Never allow the engine parameters to go into the red field.
11.5 Oil Pressure Gauge:
11.6 a.While the engine is at operating temperature and at idling speed the indicator should show between (3 to 5.5 bar) or (300 to 550 kpa)
11.7 b.Stop immediately if the warning lamp lights.
11.8 Engine coolant temperature gauge:
11.9 a.Stop immediately if the warning lamp lights.
11.10
b.During normal driving the indicator should remain in Green Zone.
11.11
Fuel gauge:
11.12
a.While the warning lamp lights, it indicates that there is 7 to 10% of the fuel left in the tank.
11.13
Air pressure gauge for brakes:
11.14
a.Stop immediately if the warning lamp lights.
11.15
b.While driving the gauge should remain within the green field.
11.16
c.The upper guage (guage -1) shows the air pressure in the front brake circuit.
11.17
d.The lower guage (guage -2) shows the air pressure in the rear brake circuit.
Annexure-4
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
Annexure-4
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
HIPPO -2 HAULERS – MONTHLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Verify whether all the maintenance works have been carried out as per schedule.
2
Start the engine and check the equipment for the following.
a. Oil, Diesel and air leaks.
b. Dash board parameters
c. Proper functioning of Dynamo / Alternator and self motor
d. Performance of the engine.
3 Check the tyres.
4 Check the electrical systems.
5 Check for any leaks in brake fluid/air lines.
6 Check the fifth wheel coupling
7 Body bolts and cabin locks.
8
Take the equipment for road test and check the following.
a. Engine and turbo charger functioning.
b. Clutch system
c. Function of the transmission
d. Steering
e. Brakes.
DATE: ENGINEER IN -CHARGE
HIPPO-2 – HALFYEARLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
ENGINE:
1.1 Attend to all the works mentioned in Monthly Maintenance schedule.
1.2 Check and readjust the valve tappet clearance (Inlet valve: 0.25 mm ), (Exhaust valve: 0.3 mm)
1.3 Check the tightness of Engine bed mounting bolts & tighten if required
Annexure-4
1.4 Check the condition of Fuel injection pump mountings & tighten if required.
1.5 Change engine oil and engine oil filter, if the engine has run 100 hours after previous engine oil change.
1.6 Change the Fuel filters (Primary & Secondary) if required.
1.7 Check the air filter & clean the air filter by applying 1 kg/sq cm air pressure.
1.8 Check the condition of Air drier unit mounting bolts tighten if required.
1.9 Check the Exhaust manifold for leaks rectify / replace with manifold gaskets if required.
1.10 Check the tightness of Silencer mounting bolts tighten if required.
10.11
Inspect the condition of clutch and report.
2 TRANSMISSION:
2.1 Check for any leaks in transmission system (Differential,Gear Box) and rectify.
2.2 Tighten all gear box/ transmission mounting bolts.
2.3 Check all the Couplings & joints for tightness and tighten if requiired.
3 STEERING:
3.1 Check proper functioning of steering servo cylinder.
3.2 Check the steering tie rod end joints, cross pins and swill pins for any abnormality and ensure lock pins and dust caps are in position.
4 PNEUMATIC BRAKING SYSTEM:
4.1 Check the unloader valve setting and adjust, if required.
4.2 Check for any leak in air lines and rectify, if required
4.3 Check the proper functioning of air regulator and booster.
4.4 Check the proper functioning of pedal valve and brake chambers.
4.5 Check the condition of spring brake actuator on LH & RH and adjust if required.
4.6 Lubricate the slack adjuster.
4.7 Check the air compressor,Unloader valve,Automatic Drain Valve,Graduated Hand controll valve & Spot light switch are working in good condition.
5 WHEELS AND TYRES
5.1 Check the wheel bearings for any shake and adjust wheel play.Check the Hub oil & Topup if required.
5.2 Tighten all wheel nuts. Torque: 330 +/- 30 Nm.
6 SUSPENSION
Annexure-4
6.1 Check the condition of all spring plates and tighten, spring clamps.
6.2 Check and tighten the rear spring U bolts
7 CABIN
7.1 Check the condition of tilting mechanism
7.2 Check the drivers seat mountings and retighten, if required.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
HIPPO-2 HAULERS – HALF YEARY MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
3 Check the tyres.
4 Check the electrical systems.
5 Check for any leaks in brake fluid/air lines.
6 Check the fifth wheel coupling
DATE: ENGINEER IN -CHARGE
HIPPO-2 HAULERS - ANNUAL MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
1 Carry out all the works mentioned in Monthly and Half yearly maintenance schedule
2 Remove the spark arrester, clean and refit.
3 Change the Primary and Secondary Air filter.
4 Change the Air dryer Desiccant.
Annexure-4
5 Flush the radiator and fill with AMW Coolant VCS
6 Change the Fan Belt (AMW Poly V)
7 Drain the diesel tank and clean the tank and refit.
8 Change the Fuel filters.
9 Change Engine Oil: API CE or API CF, Viscisity: SAE - 40, Qty: 33 Lts & Filter.
10 Check the Engine Valve Tappet clearance and adjust. The Inlet & Exhaust Valve clearance must be 0.25 mm & 0.3 mm respectively.
11 Check the fuel injection timing with out auto timer - 22 degrees or with auto
timer - 15 degrees
12 Change AMW Gear box / Transmission oil: 97315 grade,Qty: 16 lts
13 Change Front (Driven) axle Differential Oil: API GL-5, Viscosity: SAE - 140, Qty: 11.5 lts
14 Change Rear axle Differential & Hub Oil: SAEJ 2360 OR APL GL-5 OR 97312, Qty: 30 lts
15 Change Power Steering oil: ATF Oil type Dextron III or 97315 grade, Qty: 05 lts
16 Check the wheel bearings of Inner & Outer race for Pitting or Discolorisation due to heat. Change the Bearings & Hub oil.
17 Check braking system & change the Linings if required.
18 Remove the dynamo / alternator, self motor.Overhaul and replace the worn out items and refit.
19 Overhaul Fifth Wheel Coupler
20 Change the Tilting Cabin Pump Hydraulic Oil.
21 Water wash the vehicle & Grease with AMW grease OOCS / OOCSBD
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
HIPPO-2 HAULERS – ANNUAL MAINTENANCE WORKSTATION - A EQUIPMENT No :
Sl No.
WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED
OUT REMARKS
Annexure-4
1 Verify whether all the maintenance works have been carried out as per schedule.
2 Inspection of brake and wheel assemblies after dismantling for overhauling for replacement of worn out items.
3 Inspection of self-motor, alternator / dynamo after dismantling for replacement of worn out items.
4 Completion of all the works as per schedule
5 Verify whether all the works have been completed as per the schedule.
5.1
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
DATE: ENGINEER IN -CHARGE
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
BEML HAULERS – MAINTENANCE CHECKLISTS
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
01 VALF/HA/75T/01 BEML HAULER-1 1 SPROB/1745 75 T BEML HAULER-1
02 VALF/HA/75T/02 BEML HAULER-2 2 PRT/2229 75 T BEML HAULER-2
3 PRT/7003 75 T BEML HAULER-3
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
BEML HAULER – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. ENGINE:
a. Check the engine oil level and top-up, if required b. Check the condition of radiator cap and replace, if required c. Check the coolant level in the radiator and top-up, if
required. d. Check the lubrication lines to turbo charger e. Check the radiator hoses condition and replace, if required. f. Check the lubrication and fuel lines for any leaks and
rectify. g. Check the fan belt tension and adjust, if required. h. Check the exhaust line connections and spark arrester for
any leak and rectify.
2. Check the oil level in transmission and top-up, if required.
3. Check up oil level in rear axles and in the reduction hub and top
-up, if required.
4. Check oil level in steering box /power steering system and top-
up, if required.
5. Clean the battery terminals and apply petroleum jelly. Retighten
the terminals.
6. Check the specific gravity of the battery electrolyte (SG 1.2) and
top-up the electrolyte level with the distilled water, if required.
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
BEML HAULER – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
7. Check the condition of fifth wheel coupling / tow hook
mountings and ensure the locking provisions are in condition.
8. Inflate the tyres to 6.0 ksc.
9. Carryout the electrical check-up for functioning of all systems.
10. Water wash and grease the equipment
11. Take the equipment for road test and check the performance of
the following.
a. Engine performance b. Dash board parameters c. Clutch function d. Brakes function e. Steering system f. Body systems g. For any abnormality.
Annexure-4
DATE:
ENGINEER IN -CHARGE
Page 4 of 9
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
BEML HAULER - MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the maintenance works have been carried out
2. Start the engine and check the following
a. Oil, diesel and air leaks
b. Dash board parameters
c. Proper functioning of dynamo and self motor
d. Performance of the engine
- Oil pressure
- Operating temperature
- Smooth running
- Response to throttle
- For any abnormality in sounds.
3. Check for the function of all electrical appliances
4. Check for any leaks in brake lines and drain the air tank.
5. Check the fifth wheel coupling mountings and locking
provisions.
6. Body bolts and cabin locks.
7. Take the vehicle for the road test and check the following
a. Engine and Turbo charger
Annexure-4
DATE:
ENGINEER IN -CHARGE
Page 5 of 9
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
BEML HAULER - MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
b. Clutch
c. Transmission
d. Steering
e. Brakes.
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
Page 6 of 9
BEML HAULER – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Check the engine oil level and top-up, if required.
2. Check the condition of radiator hoses and replace, if required.
3. Check the condition of fan belts and drive belts and adjust the
tension or replace, if required.
4. Check the diesel and oil leaks and rectify.
5. Check the condition of radiator water corrosion with test papers.
6. Carry out necessary preventive maintenance as per the service
due (200 hrs of engine operation) and change engine oil, engine
oil filter diesel filters and water filters.
7. Start the engine, check the performance and dash board
instruments for oil pressure, water temperature and battery
charging.
8. Check the oil levels in transmission, rear axles and reduction
hubs.
9. Check the tyre condition and replace, if required. Inflate the
tyres to 6ksc.
10. Check and retighten all wheel nuts.
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
Page 7 of 9
BEML HAULER – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
11 Check and retighten all propeller shaft joints.
12. Check for air leaks in brake circuit and rectify. Check the
condition of hoses, palm couplings and sealing washers and
replace the worn out items. Drain the air tank.
13. Check the fifth wheel coupling locks and lubricate the rubbing
plate.
14. Check the power steering and top-up oil level, if required.
15. Check the function of air horn
16 Carry out electrical check-up. Clean the battery terminals and
apply petroleum jelly. Check the specific gravity of the battery
electrolyte (SG 1.2) and top-up battery electrolyte level with
distilled water, if required.
17. Check the function of engine turbo charge and attend to
servicing, if required.
18 Check the function of engine fan hub and attend to servicing, if
required.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
BEML HAULER – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the maintenance works have been carried out.
2. Start the engine and check the equipment for the following
a. Oil, diesel and air leaks b. Dash board parameters c. Proper functioning of dynamo/alternator and self motor d. Performance of the engine.
3. Check the electrical systems.
4. Check for any leaks in the brake lines.
5. Check the fifth wheel coupling.
6. Check the body bolts and cabin locks.
7. Take the equipment for road test and check the following
performance.
a. Engine and turbo charger b. Transmission c. Steering d. Brakes.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
BEML HAULERS – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the maintenance works have been carried out as per schedule.
2. Start the engine and check the equipment for the following. a. Oil, Diesel and air leaks. b. Dash board parameters c. Proper functioning of Dynamo / Alternator and self motor d. Performance of the engine.
3. Check the tyres.
4. Check the electrical systems.
5. Check for any leaks in brake fluid/air lines.
6. Check the fifth wheel coupling
7. Body bolts and cabin locks.
8. Take the equipment for road test and check the following. a. Engine and turbo charger functioning. b. Clutch system c. Function of the transmission d. Steering e. Brakes.
9. Load test the equipment as per the procedure mentioned in Annexure 2D
Annexure-4
DATE:
ENGINEER IN -CHARGE
TRACTORS (EICHER/SAME/HMT MAKE) – MAINTENANCE CHECKLISTS
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
01 VALF/HA/15T/01 EICHER TRACTOR-1 1 PRT/2031 HMT TRACTOR
02 VALF/HA/15T/02 EICHER TRACTOR-2 2 AP26 Y 2900 SAME TRACTOR-I
03 VALF/HA/15T/03 EICHER TRACTOR-3 3 AP26 Y 2901 SAME TRACTOR-2
04 VALF/HA/15T/04 EICHER TRACTOR-4 AP26 Y 7685 SAME TRACTOR-3
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
EICHER , HMT & SAME TRACTAOR – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. ENGINE:
1.1 Check the engine oil level and top-up, if required.
1.2 Check radiator cap condition and replace if required.
1.3 Check radiator hoses and change worn out ones.
1.4 Check fuel and oil lines for any leaks and rectify, if required
1.5 Check engine mountings.
1.6 Check the air cleaner and clean.
1.7 Check the fan belt tension and adjust, I f required.
1.8 Lubricate the fuel injection pump.
1.9 Clean the exhaust pipe lines and spark arrester for any leaks
and rectify.
1.10 Lubricate the ‘OFF’ lever cable and linkages.
1.11 Start the engine and check oil pressure and functioning of
temperature gauge.
2. CLUTCH:
2.1 Check the proper functioning of clutch and adjust pedal play if
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
EICHER , HMT & SAME TRACTAOR – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
required.
3. TRANSMISSION:
3.1 Check the oil level in transmission and top-up, if required.
3.2 Check for any leaks in transmission oil lines and rectify, if
required.
3.3 Check for proper engagement of gears.
4. WHEELS:
4.1 Check all wheel disc and drum bolts and retighten. Retighten
the wheel counter weight bolts.
4.2 Check the condition of tyres and report.
4.3 Inflate the tyres. Front 2.0 ksc. Rear 3.2 ksc.
4.4 Check the rear wheels and ensure that they are not rubbing
with the side mudguards.
4.5 Check oil level in second reduction gear housing and top-up, if
required.
5 BRAKES:
5.1 Check and adjust brakes, if required.
5.2 Check brake pedal play and adjust, if required.
6. STEERING:
6.1 Check oil level in steering box and top-up, if required.
6.2 Check all steering linkages, tie rod ends and report. Retighten
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
EICHER , HMT & SAME TRACTAOR – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
all linkages, if required.
6.3 Check for presence of lock cotters and rubber boots in tie rod
ends, center shaft and swill pins.
7 ELECTRICAL:
7.1 Clean the battery terminals and apply petroleum jelly and
retighten the terminals.
7.2 Check the battery electrolyte level and specific gravity (SG
should be 1.2). Top-up the electrolyte level with distilled water, if
required.
7.3 Check the battery mountings and cover. Report.
7.4 Check the function of alternator / dynamo and self motor and
tighten the mountings, if required.
7.5 Check the function of all lights and other accessories and attend
to problems, if any.
8. BODY:
8.1 Tighten all mudguard, bonnet and cabin bolts, if required.
8.2 Tighten driver seat mountings, if required.
8.3 Tighten toe hook mountings at front and rear, if required.
8.4 Check toe-hook pin for any crack and opening and report.
9. SERVICE:
9.1 Water wash the equipment and attend to greasing of all points.
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
EICHER , HMT & SAME TRACTAOR – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
EICHER , HMT & SAME TRACTAOR
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the works have been completed as per the
schedule.
2. Take the equipment for road test and check the following.
a) Engine performance
b) Dash board parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, switches
meters etc.
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
LCG TUGGER & TRACTAOR – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Carryout all the works as per monthly schedule
2 Change engine oil and engine oil filter, if the engine has run 125
hours after previous engine oil change.
3. Clean the air cleaner and change the oil.
4. Clean the diesel tank strainer.
5. Change Pre/Micro Filter
6. Open the front hub dust cap and pack with grease and refit.
7. Check wheel bearings for any shake and adjust, if required.
8. Flush the radiator and fill with new water.
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
EICHER , HMT & SAME TRACTAOR – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Verify whether all the works have been completed as per the
schedule.
2. Take the equipment for road test and check the followings.
a) Engine performance
b) Dash board parameters
c) Function of clutch, transmission, steering and brakes
d) Functioning of electrical appliances like lights, meters ,
switches etc.
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
EICHER , HMT & SAME TRACTAOR – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in quarterly schedule.
2. Check and adjust valve tappets.
3. Change the transmission oil.
4. Carryout hub service for front wheels.
5. Open rear wheels, reduction gear box unit, and check the brake
linings and replace, if required.
6. Change the oil in reduction gear box for any water content and
dirt contamination or if the equipment has run 1000 hours after
previous oil change.
7. Remove the self-motor, dynamo / alternator over haul and refit.
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN – CHARGE
EICHER , HMT & SAME TRACTAOR – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. WHILE THE MAINTENANCE WORK UNDER PROGRESS:
1.1 Inspection of brake and wheel assemblies after dismantling for overhauling and replacement of worn out parts.
1.2 Inspection of self-motor, alternator / dynamo after dismantling for replacement of worn out parts.
2. AFTER THE COMPLETION OF MAINTENANCE WORKS:
2.1 Verify whether all the works have been completed as per the schedule.
2.2 Take the equipment for road test and check the following. a) Engine performance b) Dash board parameters c) Function of clutch, transmission, steering and brakes. d) Functioning of electrical appliances like lights, meters
switches etc.
2.3 Load testing of the equipment as per the procedure mentioned in
Annexure - 2D.
Annexure-4
FORKLIFTS – MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
01 VALF/FL/2T/01 2T FORKLIFT 01 PRT/2278 3T FORKLIFT
02 VALF/FL/3T/01 3T FORKLIFT 02 SPROB/FL/5T/01 5T FORKLIFT
03 VALF/FL/3T/02 3T FORKLIFT 03 SPROB/FL/8T/01 8T FORKLIFT
04 VALF/FL/3T/03 3T FORKLIFT 04 PRT/2279 12 FORKLIFT
05 VALF/FL/5T/01 5T FORKLIFT 05 SPROB/FL/12T/02 12T FORKLIFT
06 VALF/FL/10T/01 10T FORKLIFT
07 VALF/FL/16T/01 16T FORKLIFT
Annexure-4
5 TON FORKLIFT MAINTENANCE CHECK LIST
DIESEL FORKLIFT – MONTHLY MAINTENANCE WORKSTATION - A
EQUIPMENT No : VAST /FL/5T/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Check engine oil level in the sump using dip stick and top-up if required (Specs: 15 W 40 )
1.2 Check the engine oil, replace with new oil if required.
1.3
Check the engine oil for the following:
a. Coolant water mixed with water
b. Diesel fuel mixed with water.
c. Carbon deposit in the Engine oil.
d. Metal particles deposition in the engine oil.
1.4 Check the Engine Crank case (sump) for oil leaks.tighten the mounting bolts if required (Torque: 25kg-m)
1.5 Check the condition of crank case gaskets tighten / relpace if required. (Torque: 10 kg-m)
1.6 Check the drain plug of engine crank case for metal particles deposition, clean & refit.
1.7 Check the condition of engine breather,clean & refit.
1.8 Check the functioning of engine breather replace if required.
1.9 Check the condition of engine oil filter & replace if required.
1.10 Check the condition of cooling system lines for leaks & tighten / replace if required.
1.11 Flush with water the radiator & cooling system fill with fresh water & coolant @ 50:50 mixture upto level.
1.12 Check the condition of radiator cap & replace if required.
1.13 Check the condition of expansion tank cap & replace if required.
Annexure-4
1.14 Check the condition of radiator top & bottom hoses and replace, if required.
1.15 Check the condition of Fan belt & replace if required.(Specs: )
1.16 Check tension of Fan belt & adjust if required (Allowable belt tension: 20 to 27 N or 2.0 to 2.7 kgm)
1.17 Check the condition of water pump mounting bolts tighten if required.(Torque: 3.5kg-m)
1.18 Lubricate the water pump with grease if required.
1.19 Check the Water pump for leaks rectify / replace with water pump kit if required.
1.20 Check the condition of Valve door packing (Gasket) for leaks replace / rectify if required.
1.21 Check and tighten the cylinder head Bolts. ( torque: 12kg-m)
1.22 Check and readjust the valve tappet clearance (Inlet valve: 0.25 mm ), (Exhaust valve: 0.3 mm)
1.23 Check the tightness of Engine bed mounting bolts tighten if required (Torque: 6 kg-m)
1.24 Check the condition of cylinder head & gaskets and replace if required.
1.25 Check the condition of Fuel injection pump mountings & tighten if required.
1.26 Check the tightness of Fuel high pressure pipes tighten if required (Torque 4 kg-m)
1.27 Check diesel fuel leaks in the high pressure pipes tighten / replace if required (Torque: 5 kg-m)
1.28 Lubricate the Fuel pump with engine oil.
1.29 Remove bowl filter, clean the filter refit / replace if required. (Tools : Cutting Plier)
1.3 Check the condition of Fuel filter (Primary & secondary) and replace if required.
1.31 Check the condition of Inlet manifold mounting bolts tighten if required.(Torque: 5 kg-m)
1.32 Check the Inlet manifold for leaks, rectify / replace with manifold gaskets if required.
1.33 Check the condition of Exhaust manifold mounting bolts tighten if required.(Torque: 5 kg-m)
1.34 Check the Exhaust manifold for leaks rectify / replace with manifold gaskets if required.
Annexure-4
1.35 Check the tightness of Silencer mounting bolts tighten if required.(Torque: 3.5 kg-m)
1.36 Check diesel fuel Leak off pipe, tighten bolts if required.
2 TRANSMISSION:
2.1 Check the oil (C- 4 SAE30) level in transmission and top-up, if required
2.2 Check for any leaks in transmission system (Differential,Gear Box) and rectify.
2.3 Check all the Couplings & joints for tightness and tighten if requiired.
2.4 Check for proper engagement of gears / check the proper functioning of neutral start switch.
3 STEERING
3.1 Check steering box mountings / check oil level in steering box and top-up, if required.
3.2 Check proper functioning of steering servo cylinder.
3.3 Check the steering tie rod end joints, cross pins and swill pins for any abnormality and ensure lock pins and dust caps are in position.
3.4 Check for oil seal leaks from steering cylinder & rectify if required.
3.5 Check the condition of High pressure steering hoses & replace if required.
3.6 Check and adjust steering wheel play
4 PNEUMATIC SERVICE BRAKES:
4.1 Check brake pedal free play (Max 20mm) and adjust, if required
4.2 Check the Brake oil( SAE J 1703) level in Master Cylinder and top up, if required
4.3 Check and adjust the brakes, if required.
4.4 Drain the air tank
4.5 Check for any leak in air lines and rectify, if required
4.6 Check the proper functioning of air regulator and booster.
4.7 Check the proper functioning of pedal valve and brake chambers.
4.8 Check the condition of spring brake actuator on LH & RH and adjust if required.
4.9 Check the air compressor,Unloader valve,Automatic Drain Valve,Graduated Hand controll valve & Spot light switch are working in good condition.
4.10 Ensure build - up of specified air pressure for 7 to 8 kg/sq cm.before beginning the days work.
PARKING BRAKES:
Annexure-4
4.11 Check proper functioning of Parking brake.
4.12 Check & tighten Parking brake mounting bolts.
4.13 Lubricate Parking Brake linkages.
5 WHEELS AND TYRES
5.1 Check the condition of tyres.
5.3 Tighten all wheel nuts. Driving wheel Torque: 40 to 41.5 kgm. And Steering wheel Torque: 16 to 17.5 kgm. (Wheel nut Spanner size: )
5.4 Check and adjust tyre pressure as per the specifications.
6 HYDRAULIC SYSTEM
6.1 Check the oil level in hydraulic oil (ENKLO 68) tank when tilt cylinders are in backward position and hoist cylinders are in lower position and top-up, if required.
6.2 Check for any oil leaks in hydraulic lines and hose connections & rectify, if so.
6.3 Check the proper functioning of tilt and hoist system.
6.4 Check the UJ crosses in hydraulic pump drive shaft and tighten the bolts.
6.5 Clean the hydraulic oil tank breather & refit.
6.6 Check the tilt and hoist cylinder mountings & tighten if required.
6.7 Check the condition of Hydraulic pump
7 UPRIGHT ASSEMBLY
7.1 MAST:
7.11 Check rail roller clearance & wear pattern & ensure for free rotation of guide rollers.
7.12 Check mast for alignment,looseness & smoothness of operation.
7.13 Check Mast mounting brackets & trunnions for loose bolts.
7.14 Check Hyd hoses for interference with mast.
7.2 CARRIAGE:
7.21 Check rail to roller clearance to avoid slipping.
7.22 Check Fork bar for notches / excessive wear & damage.
7.23 Check smoothness of operation.
7.3 CHAINS
7.31 Check for uniform tension in both Chains.
7.32 ubricate the Chains with Lubricants.
7.33 Check for corossion,bends & cracked links etc, rectify / replace the chain links.
7.34 Check chain mounting components for wear & damage.
Annexure-4
7.4 LIFT & TILT CYLINDERS:
7.41 Check for seal leakages & rectify if required.
7.42 Check cylinder rods for nicks & scratches.
7.43 Check cylinder racking ( uneven stroking of lift & tilt cylinders ) & rectify if found.
7.44 Check for free sliding for forks & Check the condition of fork locks & replace if required..
7.45 Lubricate the Hoist cylinder chain.
8 ELECTRICAL
8.1 Check the distilled electrolyte level in the batteries and top-up, if required with distilled water.
8.2 Clean the battery terminals and apply petroleum jelly and check the tightness of terminals.
8.3 Check the condition of battery box
8.4 Check the functioning of self-motor and dynamo/ alternator.
8.5 Check the functioning of battery charging system and adjust the regulator, if required
8.6 Check the functioning of all dash board meters & replace if not working.
8.7 Check the functioning of all lights and electrical accessories and attend to any problems, if required.
BATTERY ISOLATION SWITCH:
8.8 Check the condition of Battery Isolation switch
8.9 Tighten BIS Isolation Bolts.
REVOLVING LIGHT:
8.10 Check the condition of Revolving light Mounting plate bolts & tighten if required.
8.11 Check for proper functioning of revolving light
9 BODY
9.1 Check the tightness of counter weight mountings and retighten, if required.
9.2 Check the Condition of Rear Tow hook.
9.3 Check the drivers seat mountings and retighten, if required.
9.4 Check the Condition of Over head guard & tighten the mounting bolts if required.
9.5 Check the Condition of Wide rear view mirror & replace if required.
9.6 Tighten the Mirror mounting bolts.
10 SERVICING:
Annexure-4
10.1 Wash the equipment thoroughly and Lubricate all grease points.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Verify that works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
DIESEL FORKLIFT – QUARTERLY MAINTENANCE WORKSTATION - EQUIPMENT No :
1 WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Attend to all the works mentioned in monthly work schedule.
1.3 Check the Fuel filters (Primary & Secondary) and change if required.
1.4 Check the air filter & clean the air filter by applying 1 kg/sq cm air pressure.
1.5 Remove Oil from Oil bath air cleaner & fill with fresh engine oil.
1.6 Flush the radiator and fill with new coolant.
1.7 Check the wheel bearings for any shake and adjust wheel play./ Pack axle cups with grease and fit back.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
Annexure-4
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
DIESEL FORKLIFT – ANNUAL MAINTENANCE WORKSTATION - EQUIPMENT No :
1 WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Carryout all the works mentioned in Monthly & Quarterly schedule
1.2 Check the Engine Valve Tappet clearance and adjust if required. The Inlet & Exhaust Valve clearance must be 0.25 mm & 0.3 mm respectively.
1.3 Change engine oil and engine oil filter, if the engine has run 100 hours after previous engine oil change.
1.4 Check the fuel injection timing with out auto timer - 22 degrees or with auto timer - 15 degrees
1.5 Clean the radiator fins on every annual maintenance by flushing with water mixed rust preventive compound (K-Cool - 15 c.c/ltr)
1.6 Change the hydraulic oil replace hydraulic oil filter.Irrespective of the condition of oil,for every annual maintenance.
1.7 Change the transmission oil (C- 4 SAE30) and replace transmission oil filter.
1.8 Open all wheels and carryout hub service.
1.9 Overhaul brake system. Replace all wheels cylinder kits, MC kits. Replace brake lining, if required.
1.10 Check the condition of flow regulator, check valves and cylinder kits and replace if required.
1.11 Check the Condition of Wheel bearings & replace if required.
1.12 Check the Condition of Oil seal & replace if required.
1.13 Check the Condition of Wear sleeve & replace or repair if required.
Annexure-4
1.14 Check the Condition of Tilt Cylinders for leaks, change kits if required.
1.15 Remove the dynamo / alternator, self motor.Overhaul and replace the worn out items and refit.
1.16 Clean the diesel tank and strainer.
1.17 Remove the spark arrester, clean and refit.
1.18 Adjust the Head Light Focus
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Inspection of brake and wheel assemblies after dismantling for overhauling for replacement of worn out items.
1.1 Inspection of self-motor, alternator / dynamo after dismantling for replacement of worn out items.
2 After completion of all the works as per schedule
2.1 Verify whether all the works have been completed as per the schedule.
2.2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
Annexure-4
2 TON FORKLIFT MAINTENANCE CHECK LIST
DIESEL FORKLIFT – MONTHLY MAINTENANCE WORKSTATION - A EQUIPMENT No : VALF /FL/3T/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1.1 Check engine oil level in the sump using dip stick and top-up if required (Specs: 20 W 40 )
1.2 Check the engine oil, replace with new oil if required.
1.3
Check the engine oil for the following:
a. Coolant water mixed with water
b. Diesel fuel mixed with water.
c. Carbon deposit in the Engine oil.
d. Metal particles deposition in the engine oil.
1.4 Check the Engine Crank case (sump) for oil leaks.tighten the mounting bolts if required (Torque: 25kg-m)
1.5 a. Coolant water mixed with water
1.6 Check the drain plug of engine crank case for metal particles deposition, clean & refit.
1.7 Check the condition of engine breather,clean & refit.
1.8 Check the functioning of engine breather replace if required.
1.9 Check the condition of engine oil filter & replace if required.
1.10 Check the condition of cooling system lines for leaks & tighten / replace if required.
1.11 Flush with water the radiator & cooling system fill with fresh water & coolant @ 50:50 mixture upto level.
1.12 Check the condition of radiator cap & replace if required.
1.13 Check the condition of expansion tank cap & replace if required.
1.14 Check the condition of radiator top & bottom hoses and replace, if required.
1.15 Check the condition of Fan belt & replace if required.(Specs: )
Annexure-4
1.16 Check tension of Fan belt & adjust if required (Allowable belt tension: 20 to 27 N or 2.0 to 2.7 kgm)
1.17 Check the condition of water pump mounting bolts tighten if required.(Torque: 3.5kg-m)
1.18 Lubricate the water pump with grease if required.
1.19 Check the Water pump for leaks rectify / replace with water pump kit if required.
1.20 Check the condition of Valve door packing (Gasket) for leaks replace / rectify if required.
1.21 Check and tighten the cylinder head Bolts. ( torque: 12kg-m)
1.22 Check and readjust the valve tappet clearance (Inlet valve: 0.25 mm ), (Exhaust valve: 0.3 mm)
1.23 Check the tightness of Engine bed mounting bolts tighten if required (Torque: 6 kg-m)
1.24 Check the condition of cylinder head & gaskets and replace if required.
1.25 Check the condition of Fuel injection pump mountings & tighten if required.
1.26 Check the tightness of Fuel high pressure pipes tighten if required (Torque 4 kg-m)
1.27 Check diesel fuel leaks in the high pressure pipes tighten / replace if required (Torque: 5 kg-m)
1.28 Lubricate the Fuel pump with engine oil.
1.29 Remove bowl filter, clean the filter refit / replace if required. (Tools : Cutting Plier)
1.3 Check the condition of Fuel filter (Primary & secondary) and replace if required.
1.31 Check the condition of Inlet manifold mounting bolts tighten if required.(Torque: 5 kg-m)
1.32 Check the Inlet manifold for leaks, rectify / replace with manifold gaskets if required.
1.33 Check the condition of Exhaust manifold mounting bolts tighten if required.(Torque: 5 kg-m)
1.34 Check the Exhaust manifold for leaks rectify / replace with manifold gaskets if required.
1.35 Check the tightness of Silencer mounting bolts tighten if required.(Torque: 3.5 kg-m)
1.36 Check diesel fuel Leak off pipe, tighten bolts if required.
2 TRANSMISSION:
Annexure-4
2.1 Check the oil (C- 4 SAE30) level in transmission and top-up, if required
2.2 Check for any leaks in transmission system (Differential,Gear Box) and rectify.
2.3 Check all the Couplings & joints for tightness and tighten if requiired.
2.4 Check for proper engagement of gears / check the proper functioning of neutral start switch.
3 STEERING
3.1 Check steering box mountings / check oil level in steering box and top-up, if required.
3.2 Check proper functioning of steering servo cylinder.
3.3 Check the steering tie rod end joints, cross pins and swill pins for any abnormality and ensure lock pins and dust caps are in position.
3.4 Check for oil seal leaks from steering cylinder & rectify if required.
3.5 Check the condition of High pressure steering hoses & replace if required.
3.6 Check and adjust steering wheel play
4 SERVICE BRAKES:
4.1 Check brake pedal free play (Max 20mm) and adjust, if required
4.2 Check the Brake oil( SAE J 1703) level in Master Cylinder and top up, if required
4.3 Check and adjust the brakes, if required.
4.4 Bleed the brake system & ensure that there are no air bubbles in the Hydraulic system.
4.5 Check the condition of brake system hoses & replace if required.
PARKING BRAKES:
4.6 Check proper functioning of Parking brake.
4.7 Check & tighten Parking brake mounting bolts.
4.8 Lubricate Parking Brake linkages.
5 WHEELS AND TYRES
5.1 Check the condition of tyres.
5.3 Tighten all wheel nuts. Driving wheel Torque: 40 to 41.5 kgm. And Steering wheel Torque: 16 to 17.5 kgm. (Wheel nut Spanner size: )
5.4 Check and adjust tyre pressure as per the specifications.
6 HYDRAULIC SYSTEM
Annexure-4
6.1 Check the oil level in hydraulic oil (ENKLO 68) tank when tilt cylinders are in backward position and hoist cylinders are in lower position and top-up, if required.
6.2 Check for any oil leaks in hydraulic lines and hose connections & rectify, if so.
6.3 Check the proper functioning of tilt and hoist system.
6.4 Check the UJ crosses in hydraulic pump drive shaft and tighten the bolts.
6.5 Clean the hydraulic oil tank breather & refit.
6.6 Check the tilt and hoist cylinder mountings & tighten if required.
6.7 Check the condition of Hydraulic pump
7 UPRIGHT ASSEMBLY
7.1 MAST:
7.11 Check rail roller clearance & wear pattern & ensure for free rotation of guide rollers.
7.12 Check mast for alignment,looseness & smoothness of operation.
7.13 Check Mast mounting brackets & trunnions for loose bolts.
7.14 Check Hyd hoses for interference with mast.
7.2 CARRIAGE:
7.21 Check rail to roller clearance to avoid slipping.
7.22 Check Fork bar for notches / excessive wear & damage.
7.23 Check smoothness of operation.
7.3 CHAINS
7.31 Check for uniform tension in both Chains.
7.32 ubricate the Chains with Lubricants.
7.33 Check for corossion,bends & cracked links etc, rectify / replace the chain links.
7.34 Check chain mounting components for wear & damage.
7.4 LIFT & TILT CYLINDERS:
7.41 Check for seal leakages & rectify if required.
7.42 Check cylinder rods for nicks & scratches.
7.43 Check cylinder racking ( uneven stroking of lift & tilt cylinders ) & rectify if found.
7.44 Check for free sliding for forks & Check the condition of fork locks & replace if required..
7.45 Lubricate the Hoist cylinder chain.
Annexure-4
7.5 FORK POSITIONER:
7.51 Check for seal leakages & rectify if required.
7.52 Check cylinder rods for nicks & scratches.
7.53 Check cylinder racking ( uneven stroking of lift & tilt cylinders ) & rectify if found.
7.54 Check for free sliding for forks & Check the condition of fork locks & replace if required..
7.55 Check Hyd hoses for interference with mast.
8 ELECTRICAL
8.1 Check the distilled electrolyte level in the batteries and top-up, if required with distilled water.
8.2 Clean the battery terminals and apply petroleum jelly and check the tightness of terminals.
8.3 Check the condition of battery box
8.4 Check the functioning of self-motor and dynamo/ alternator.
8.5 Check the functioning of battery charging system and adjust the regulator, if required
8.6 Check the functioning of all dash board meters & replace if not working.
8.7 Check the functioning of all lights and electrical accessories and attend to any problems, if required.
BATTERY ISOLATION SWITCH:
8.8 Check the condition of Battery Isolation switch
8.9 Tighten BIS Isolation Bolts.
REVOLVING LIGHT:
8.10 Check the condition of Revolving light Mounting plate bolts & tighten if required.
8.11 Check for proper functioning of revolving light
9 BODY
9.1 Check the tightness of counter weight mountings and retighten, if required.
9.2 Check the Condition of Rear Tow hook.
9.3 Check the drivers seat mountings and retighten, if required.
9.4 Check the Condition of Over head guard & tighten the mounting bolts if required.
9.5 Check the Condition of Wide rear view mirror & replace if required.
9.6 Tighten the Mirror mounting bolts.
Annexure-4
10 SERVICING:
10.1 Wash the equipment thoroughly and Lubricate all grease points.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
3 TON FORKLIFT MAINTENANCE CHECK LIST
DIESEL FORKLIFT – MONTHLY MAINTENANCE WORKSTATION - A EQUIPMENT No : VALF /FL/3T/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Check engine oil level in the sump using dip stick and top-up if required (Specs: 20 W 40 )
1.2 Check the engine oil, replace with new oil if required.
1.3
Check the engine oil for the following:
a. Coolant water mixed with water
b. Diesel fuel mixed with water.
c. Carbon deposit in the Engine oil.
d. Metal particles deposition in the engine oil.
1.4 Check the Engine Crank case (sump) for oil leaks.tighten the mounting bolts if required (Torque: 25kg-m)
1.5 Check the condition of crank case gaskets tighten / relpace if required. (Torque: 10 kg-m)
Annexure-4
1.6 Check the drain plug of engine crank case for metal particles deposition, clean & refit.
1.7 Check the condition of engine breather,clean & refit.
1.8 Check the functioning of engine breather replace if required.
1.9 Check the condition of engine oil filter & replace if required.
1.10 Check the condition of cooling system lines for leaks & tighten / replace if required.
1.11 Flush with water the radiator & cooling system fill with fresh water & coolant @ 50:50 mixture upto level.
1.12 Check the condition of radiator cap & replace if required.
1.13 Check the condition of expansion tank cap & replace if required.
1.14 Check the condition of radiator top & bottom hoses and replace, if required.
1.15 Check the condition of Fan belt & replace if required.(Specs: )
1.16 Check tension of Fan belt & adjust if required (Allowable belt tension: 20 to 27 N or 2.0 to 2.7 kgm)
1.17 Check the condition of water pump mounting bolts tighten if required.(Torque: 3.5kg-m)
1.18 Lubricate the water pump with grease if required.
1.19 Check the Water pump for leaks rectify / replace with water pump kit if required.
1.20 Check the condition of Valve door packing (Gasket) for leaks replace / rectify if required.
1.21 Check and tighten the cylinder head Bolts. ( torque: 12kg-m)
1.22 Check and readjust the valve tappet clearance (Inlet valve: 0.25 mm ), (Exhaust valve: 0.3 mm)
1.23 Check the tightness of Engine bed mounting bolts tighten if required (Torque: 6 kg-m)
1.24 Check the condition of cylinder head & gaskets and replace if required.
1.25 Check the condition of Fuel injection pump mountings & tighten if required.
1.26 Check the tightness of Fuel high pressure pipes tighten if required (Torque 4 kg-m)
1.27 Check diesel fuel leaks in the high pressure pipes tighten / replace if required (Torque: 5 kg-m)
1.28 Lubricate the Fuel pump with engine oil.
1.29 Remove bowl filter, clean the filter refit / replace if required. (Tools : Cutting Plier)
1.3 Check the condition of Fuel filter (Primary & secondary) and replace if required.
1.31 Check the condition of Inlet manifold mounting bolts tighten if required.(Torque: 5 kg-m)
1.32 Check the Inlet manifold for leaks, rectify / replace with manifold gaskets if required.
1.33 Check the condition of Exhaust manifold mounting bolts tighten if required.(Torque: 5 kg-m)
Annexure-4
1.34 Check the Exhaust manifold for leaks rectify / replace with manifold gaskets if required.
1.35 Check the tightness of Silencer mounting bolts tighten if required.(Torque: 3.5 kg-m)
1.36 Check diesel fuel Leak off pipe, tighten bolts if required.
2 TRANSMISSION:
2.1 Check the oil (C- 4 SAE30) level in transmission and top-up, if required
2.2 Check for any leaks in transmission system (Differential,Gear Box) and rectify.
2.3 Check all the Couplings & joints for tightness and tighten if requiired.
2.4 Check for proper engagement of gears / check the proper functioning of neutral start switch.
3 STEERING
3.1 Check steering box mountings / check oil level in steering box and top-up, if required.
3.2 Check proper functioning of steering servo cylinder.
3.3 Check the steering tie rod end joints, cross pins and swill pins for any abnormality and ensure lock pins and dust caps are in position.
3.4 Check for oil seal leaks from steering cylinder & rectify if required.
3.5 Check the condition of High pressure steering hoses & replace if required.
3.6 Check and adjust steering wheel play
4 SERVICE BRAKES:
4.1 Check brake pedal free play (Max 20mm) and adjust, if required
4.2 Check the Brake oil( SAE J 1703) level in Master Cylinder and top up, if required
4.3 Check and adjust the brakes, if required.
4.4 Bleed the brake system & ensure that there are no air bubbles in the Hydraulic system.
4.5 Check the condition of brake system hoses & replace if required.
PARKING BRAKES:
4.6 Check proper functioning of Parking brake.
4.7 Check & tighten Parking brake mounting bolts.
4.8 Lubricate Parking Brake linkages.
5 WHEELS AND TYRES
5.1 Check the condition of tyres.
5.3 Tighten all wheel nuts. Driving wheel Torque: 40 to 41.5 kgm. And Steering wheel Torque: 16 to 17.5 kgm. (Wheel nut Spanner size: )
5.4 Check and adjust tyre pressure as per the specifications.
6 HYDRAULIC SYSTEM
Annexure-4
6.1 Check the oil level in hydraulic oil (ENKLO 68) tank when tilt cylinders are in backward position and hoist cylinders are in lower position and top-up, if required.
6.2 Check for any oil leaks in hydraulic lines and hose connections & rectify, if so.
6.3 Check the proper functioning of tilt and hoist system.
6.4 Check the UJ crosses in hydraulic pump drive shaft and tighten the bolts.
6.5 Clean the hydraulic oil tank breather & refit.
6.6 Check the tilt and hoist cylinder mountings & tighten if required.
6.7 Check the condition of Hydraulic pump
7 UPRIGHT ASSEMBLY
7.1 MAST:
7.11 Check rail roller clearance & wear pattern & ensure for free rotation of guide rollers.
7.12 Check mast for alignment,looseness & smoothness of operation.
7.13 Check Mast mounting brackets & trunnions for loose bolts.
7.14 Check Hyd hoses for interference with mast.
7.2 CARRIAGE:
7.21 Check rail to roller clearance to avoid slipping.
7.22 Check Fork bar for notches / excessive wear & damage.
7.23 Check smoothness of operation.
7.3 CHAINS
7.31 Check for uniform tension in both Chains.
7.32 ubricate the Chains with Lubricants.
7.33 Check for corossion,bends & cracked links etc, rectify / replace the chain links.
7.34 Check chain mounting components for wear & damage.
7.4 LIFT & TILT CYLINDERS:
7.41 Check for seal leakages & rectify if required.
7.42 Check cylinder rods for nicks & scratches.
7.43 Check cylinder racking ( uneven stroking of lift & tilt cylinders ) & rectify if found.
7.44 Check for free sliding for forks & Check the condition of fork locks & replace if required..
7.45 Lubricate the Hoist cylinder chain.
7.5 FORK POSITIONER:
7.51 Check for seal leakages & rectify if required.
7.52 Check cylinder rods for nicks & scratches.
7.53 Check cylinder racking ( uneven stroking of lift & tilt cylinders ) & rectify if found.
Annexure-4
7.54 Check for free sliding for forks & Check the condition of fork locks & replace if required..
7.55 Check Hyd hoses for interference with mast.
8 ELECTRICAL
8.1 Check the distilled electrolyte level in the batteries and top-up, if required with distilled water.
8.2 Clean the battery terminals and apply petroleum jelly and check the tightness of terminals.
8.3 Check the condition of battery box
8.4 Check the functioning of self-motor and dynamo/ alternator.
8.5 Check the functioning of battery charging system and adjust the regulator, if required
8.6 Check the functioning of all dash board meters & replace if not working.
8.7 Check the functioning of all lights and electrical accessories and attend to any problems, if required.
BATTERY ISOLATION SWITCH:
8.8 Check the condition of Battery Isolation switch
8.9 Tighten BIS Isolation Bolts.
REVOLVING LIGHT:
8.10 Check the condition of Revolving light Mounting plate bolts & tighten if required.
8.11 Check for proper functioning of revolving light
9 BODY
9.1 Check the tightness of counter weight mountings and retighten, if required.
9.2 Check the Condition of Rear Tow hook.
9.3 Check the drivers seat mountings and retighten, if required.
9.4 Check the Condition of Over head guard & tighten the mounting bolts if required.
9.5 Check the Condition of Wide rear view mirror & replace if required.
9.6 Tighten the Mirror mounting bolts.
10 SERVICING:
10.1 Wash the equipment thoroughly and Lubricate all grease points.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Verify that works have been completed as per schedule
Annexure-4
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
DIESEL FORKLIFT – QUARTERLY MAINTENANCE WORKSTATION - A EQUIPMENT No :
1 WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Attend to all the works mentioned in monthly work schedule.
1.3 Check the Fuel filters (Primary & Secondary) and change if required.
1.4 Check the air filter & clean the air filter by applying 1 kg/sq cm air pressure.
1.5 Remove Oil from Oil bath air cleaner & fill with fresh engine oil.
1.6 Flush the radiator and fill with new coolant.
1.7 Check the wheel bearings for any shake and adjust wheel play./ Pack axle cups with grease and fit back.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
Annexure-4
DIESEL FORKLIFT – ANNUAL MAINTENANCE WORKSTATION - A EQUIPMENT No :
1 WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Carryout all the works mentioned in Monthly & Quarterly schedule
1.2 Check the Engine Valve Tappet clearance and adjust if required. The Inlet & Exhaust Valve clearance must be 0.25 mm & 0.3 mm respectively.
1.3 Change engine oil and engine oil filter, if the engine has run 100 hours after previous engine oil change.
1.4 Check the fuel injection timing with out auto timer - 22 degrees or with auto timer - 15 degrees
1.5 Clean the radiator fins on every annual maintenance by flushing with water mixed rust preventive compound (K-Cool - 15 c.c/ltr)
1.6 Change the hydraulic oil replace hydraulic oil filter.Irrespective of the condition of oil,for every annual maintenance.
1.7 Change the transmission oil (C- 4 SAE30) and replace transmission oil filter.
1.8 Open all wheels and carryout hub service.
1.9 Overhaul brake system. Replace all wheels cylinder kits, MC kits. Replace brake lining, if required.
1.10 Check the condition of flow regulator, check valves and cylinder kits and replace if required.
1.11 Check the Condition of Wheel bearings & replace if required.
1.12 Check the Condition of Oil seal & replace if required.
1.13 Check the Condition of Wear sleeve & replace or repair if required.
1.14 Check the Condition of Tilt Cylinders for leaks, change kits if required.
1.15 Remove the dynamo / alternator, self motor.Overhaul and replace the worn out items and refit.
1.16 Clean the diesel tank and strainer.
1.17 Remove the spark arrester, clean and refit.
1.18 Adjust the Head Light Focus
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
Annexure-4
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Inspection of brake and wheel assemblies after dismantling for overhauling for replacement of worn out items.
1.1 Inspection of self-motor, alternator / dynamo after dismantling for replacement of worn out items.
2 After completion of all the works as per schedule
2.1 Verify whether all the works have been completed as per the schedule.
2.2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
Annexure-4
16 TON FORKLIFT MAINTENANCE CHECK LIST
16T FORKLIFT – MONTHLY MAINTENANCE WORKSTATION - A
EQUIPMENT No : VALF/FL/16T/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Check engine oil level and top-up (Specs:15 W 40)
1.2 Change the Engine oil & Filter as per Hours of the Maintenance schedule
1.3
Check the engine oil for the following:
a. Coolant water mixed with oil.
b. Diesel fuel mixed with Engine oil.
1.4 Check the Engine Crank case (sump) for oil leaks. Tighten the mounting bolts if required
1.5 Check the condition of engine breather,clean & refit.
1.6 Check the condition of cooling system lines for leaks & tighten / replace if required.
1.7 Check radiator water coolant level in the expansion tank & top-up .
1.8 Check the condition of radiator cap & replace if required.
1.9 Check the condition of radiator top & bottom hoses and replace, if required.
1.10 Check the condition & Tension of Fan belt & replace if required.
1.11 Check for water leak at water pump. Tighten the water pump mounting bolts if required.
1.12 Lubricate the water pump with grease.
1.13 Check the Water pump for leaks rectify / replace with water pump kit if required.
1.14 Check and tighten the cylinder head fasteners.
1.15 Check and readjust the valve tappet clearance (Inlet valve: 0.25 mm ), (Exhaust valve: 0.3 mm)
1.16 Check the condition of Engine bed mountings & replace if required.
1.17 Check the tightness of Engine bed mounting bolts tighten if required
1.18 Check the condition of Fuel injection pump mountings & tighten if required.
1.19 Check for Fuel leak at high pressure pipe line Tighten / replace H.P lines if required.
1.20 Check diesel fuel leaks in the high pressure pipes tighten / replace if required
1.21 Lubricate the Fuel pump with engine oil if required.
1.22 Remove bowl filter, clean the filter refit / replace if required.
1.23 Check the condition of Fuel filter (Primary & secondary) and replace if required.
1.24 Check the condition & functioning of Air Compressor.
1.25 Check the Pneumatic system lines for leaks tighten / rectify if required.
1.26 Check for Rattling sound of silencer & Mountings & rectify
Annexure-4
2 TRANSMISSION:
2.1 Check the oil (C- 4 SAE30) level in transmission and top-up, if required
2.2 Check for proper engagement of gears and check the proper functioning of neutral start switch.
3 STEERING
3.1 Check steering box mountings and oil level in steering box and top-up, if required.
4 BRAKES:
4.1 Check brake pedal free play (Max 20mm) and adjust, if required
4.2 Topup the Oil Level in Master Cylinder
4.3 Check and adjust the brakes, if required.
5 Pneumatic Braking system:
5.1 Drain the air tank
5.2 Ensure build - up of specified air pressure for 7 to 8 kg/sq cm.before beginning the days work.
6 WHEELS AND TYRES
6.1 Check the condition of tyres and report.
6.2 Check and adjust steering wheel play
6.3 Check and inflate tyres to the correct pressure.
7 HYDRAULIC SYSTEM
7.1 Check the oil level in hydraulic oil (ENKLO 68) tank when tilt cylinders are in backward position and hoist cylinders are in lower position and top-up, if required.
8 UPRIGHT ASSEMBLY
8.1 MAST:
8.11 Check Mast mounting brackets & trunnions for loose bolts.
8.12 Check Hyd hoses for interference with mast.
8.2 CHAINS
8.21 Check for uniform tension
8.22 check for proper lubrication.
8.3 LIFT & TILT CYLINDERS:
8.31 Check for seal leakage.
8.32 Lubricate the Hoist cylinder chain.
9 ELECTRICAL
9.1 Topup the diluted electrolyte level in the batteries and top-up, if required with distilled water.
9.2 Clean the battery terminals and apply petroleum jelly and check the tightness of terminals.
9.3 Check the functioning of self-motor and dynamo/ alternator.
9.4 Check the functioning of battery charging system and adjust the regulator, if required
Annexure-4
9.5 Check the functioning of all dash board meters and make them to work, if any of them not working.
9.6 Check the functioning of all lights and electrical accessories and attend to any problems, if required.
10 SERVICING:
10.1 Wash the equipment thoroughly and grease all the points.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
16T FORKLIFT – QUARTERLY MAINTENANCE WORKSTATION - A
EQUIPMENT No :
1 WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Attend to all the works mentioned in monthly work schedule.
1.2 Change engine oil and engine oil filter, if the engine has run 100 hours after previous engine oil change.
1.3 Check the condition of Fuel filters (Primary & Secondary) and change if required.
1.4 Check the air filter & clean the air filter by applying 1 kg/sq cm air pressure.
1.5 Clean the oil bath air cleaner with air pressure
1.6 Check the condition of Air drier unit mounting bolts tighten if required.
1.7 Check the functioning of Air drier unit replace with new kit if required.
1.8 Check the Exhaust manifold for leaks rectify / replace with manifold gaskets if required.
1.9 Check the tightness of Silencer mounting bolts tighten if required.
2 TRANSMISSION:
2.1 Check for any leaks in transmission system (Differential,Gear Box) and rectify.
Annexure-4
2.2 Check all the Couplings & joints for tightness and tighten if requiired.
3 STEERING:
3.1 Check proper functioning of steering servo cylinder.
3.2 Check the steering tie rod end joints, cross pins and swill pins for any abnormality and ensure lock pins and dust caps are in position.
4 PNEUMATIC BRAKING SYSTEM:
4.1 Check for any leak in air lines and rectify, if required
4.2 Check the proper functioning of air regulator and booster.
4.3 Check the proper functioning of pedal valve and brake chambers.
4.4 Check the condition of spring brake actuator on LH & RH and adjust if required.
4.5 Check the air compressor,Unloader valve,Automatic Drain Valve,Graduated Hand controll valve & Spot light switch are working in good condition.
5 WHEELS AND TYRES
5.1 Check the wheel bearings for any shake and adjust wheel play. Pack axle cups with grease and fit back.
5.2 Tighten all wheel nuts. Driving wheel Torque: 40 to 41.5 kgm. And Steering wheel Torque: 16 to 17.5 kgm.
6 HYDRAULIC SYSTEM
6.1 Check for any oil leaks in hydraulic lines and hose connections & rectify, if so.
6.2 Check the proper functioning of tilt and hoist system.
6.3 Clean the hydraulic oil tank breather.
6.4 Check the tilt and hoist cylinder mountings.
7 MAST
7.1 Check rail roller clearance & wear pattern & ensure for free rotation of guide rollers.
7.2 Check mast for alignment,looseness & smoothness of operation.
8 CARRIAGE
8.1 Check Fork bar for notches / excessive wear & damage.
8.2 Check for smoothness of operation.
9 LIFT & TILT CYLINDERS
9.1 Check cylinder rods for nicks & scratches.
9.2 Check cylinder racking ( uneven stroking of lift & tilt cylinders ).
9.3 Check for free sliding for forks & proper functioning of fork locks.
10 BODY
10.1 Check the drivers seat mountings and retighten, if required.
Annexure-4
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
16T FORKLIFT – ANNUAL MAINTENANCE WORKSTATION - A
EQUIPMENT No :
1 WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Carryout all the works mentioned in Monthly & Quarterly Maintenance schedule
1.2 Check the Engine Valve Tappet clearance and adjust. The Inlet & Exhaust Valve clearance must be 0.25 mm & 0.3 mm respectively.
1.3 Check the fuel injection timing with out auto timer - 22 degrees or with auto timer - 15 degrees
1.4 Clean the radiator fins on every annual maintenance by flushing with water mixed rust preventive compound (K-Cool - 15 c.c/ltr)
1.5 Change the hydraulic oil replace the hydraulic oil filter.Irrespective of the condition of oil,for every annual maintenance.
1.6 Change the transmission oil (C- 4 SAE30) and replace transmission oil filter.
1.7 All wheels hub service.
1.8 Overhaul brake system. Replace all wheels cylinder kits, MC kits. Replace brake lining, if required.
1.9 Check the condition of regulator, check valves and cylinder kits and replace if required.
1.10 Remove the dynamo / alternator, self motor.Overhaul and replace the worn out items and refit.
Annexure-4
1.11 Clean the diesel tank and strainer.
1.12 Flush the radiator and fill with new coolant.
1.13 Remove the spark arrester, clean and refit.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Inspection of brake and wheel assemblies after dismantling for overhauling for replacement of worn out items.
2 Inspection of self-motor, alternator / dynamo after dismantling for replacement of worn out items.
3 After completion of all the works as per schedule
4 Verify whether all the works have been completed as per the schedule.
4.1
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of Transmission, Steering and Brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
10 TON FORKLIFT MAINTENANCE CHECK LIST
DIESEL FORKLIFT – MONTHLY MAINTENANCE WORKSTATION -A EQUIPMENT No : VALF/FL/10T/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Check engine oil level in the sump using dip stick and top-up if required (Specs: 20 W 40 ),(Qty: Min , Max )
1.2 Check the viscosity of the engine oil, replace with new oil if required.
1.3
Check the engine oil for the following:
a. Coolant water mixed with water
b. Diesel fuel mixed with water.
c. Carbon deposit in the Engine oil.
Annexure-4
d. Metal particles deposition in the engine oil.
1.4 Check the Engine Crank case (sump) for oil leaks.tighten the mounting bolts if required
1.5 Check the condition of crank case gaskets tighten / relpace if required.(Torque: N-m)
1.6 Check the drain plug of engine crank case for metal particles deposition, clean & refit.(Tank Capacity: )
1.7 Check the condition of engine breather,clean & refit.
1.8 Check the functioning of engine breather replace if required.
1.9 Check the condition of engine oil filter & replace if required.(Part no: )
1.10 Check the condition of cooling system lines for leaks & tighten / replace if required.
1.11 Flush with water the radiator & cooling system fill with fresh water & coolant @ 50:50 mixture upto level.
1.12 Check radiator water coolant level in the expansion & top-up if required.( specs: Ratio : )
1.13 Check the condition of radiator cap & replace if required.
1.14 Check the radiator water coolant level in the Exhaust tank & top-up if required.
1.15 Check the condition of expansion tank cap & replace if required.
1.16 Check the condition of radiator top & bottom hoses and replace, if required.
1.17 Check the condition of Fan belt (Belt no: ),(Qty: ) & replace if required.
1.18 Check tension of Fan belt & adjust if required (Allowable belt tension: kgm)
1.19 Check the condition of water pump mounting bolts tighten if required.(Torque: N-m)
1.2 Lubricate the water pump with grease if required.
1.21 Check the Water pump for leaks rectify / replace with water pump kit if required.
1.22 Check and tighten the cylinder head fasteners. ( torque: Nm)
1.23 Check and readjust the valve tappet clearance (Inlet valve: 0.25 mm ), (Exhaust valve: 0.3 mm)
1.24 Check the condition of Engine bed mountings & replace if required. (Front ; rear )
Annexure-4
1.25 Check the tightness of Engine bed mounting bolts tighten if required (Torque: N-m)
1.26 Check & tighten of Cam shaft mounting bolts (Torque: N-m)
1.27 Check the condition of cylinder head & gaskets and replace if required.
1.28 Check the condition of Fuel injection pump mountings & tighten if required.
1.29 Check the tightness of Fuel high pressure pipes tighten if required (Torque N-m)
1.3 Check diesel fuel leaks in the high pressure pipes tighten / replace if required (Torque: N-m)
1.31 Lubricate the Fuel pump with engine oil if required.
1.32 Remove bowl filter, clean the filter refit / replace if required.
1.33 Check the condition of Fuel filter (Primary & secondary) and replace if required.( Capacity: ),(Part no: ).
1.34 Check the condition & functioning of Air Compressor.
1.35 Check the Pneumatic system lines for leaks tighten / rectify if required.
1.36 Check the condition of Self locking type palm couplings & rubber seals and replace if required.
1.37 Check the condition of Air drier unit mounting bolts tighten if required.(Torque: N-m)
1.38 Check the functioning of Air drier unit replace with new kit if required.
1.39 Check the condition of Inlet manifold mounting bolts tighten if required.(Torque: N-m)
1.4 Check the Inlet manifold for leaks rectify / replace with manifold gaskets if required.
1.41 Check the condition of Exhaust manifold mounting bolts tighten if required.(Torque: N-m)
1.42 Check the Exhaust manifold for leaks rectify / replace with manifold gaskets if required.
1.43 Check the tightness of Silencer mounting bolts tighten if required.(Torque: N-m)
2 TRANSMISSION:
2.1 Check the oil (C- 4 SAE30) level in transmission and top-up, if required
2.2 Check for any leaks in transmission system (Differential,Gear Box) and rectify.
2.3 Check all the Couplings & joints for tightness and tighten if requiired.
Annexure-4
2.4 Check for proper engagement of gears and check the proper functioning of neutral start switch.
3 STEERING
3.1 Check steering box mountings and oil level in steering box and top-up, if required.
3.2 Check proper functioning of steering servo cylinder.
3.3 Check the steering tie rod end joints, cross pins and swill pins for any abnormality and ensure lock pins and dust caps are in position.
4 BRAKES:
4.1 Check brake pedal free play (Max 20mm) and adjust, if required
4.2 Check the oil( SAE J 1703) level in Master Cylinder and top up, if required
4.3 Check and adjust the brakes, if required.
5 Pneumatic Braking system:
5.1 Drain the air tank
5.2 Check for any leak in air lines and rectify, if required
5.3 Check the proper functioning of air regulator and booster.
5.4 Check the proper functioning of pedal valve and brake chambers.
5.5 Check the condition of spring brake actuator on LH & RH and adjust if required.
5.6 Check the air compressor,Unloader valve,Automatic Drain Valve,Graduated Hand controll valve & Spot light switch are working in good condition.
5.7 Ensure build - up of specified air pressure for 7 to 8 kg/sq cm.before beginning the days work.
6 WHEELS AND TYRES
6.1 Check the condition of tyres and report.
6.2 Check and adjust steering wheel play
6.3 Tighten all wheel nuts. Driving wheel Torque: 40 to 41.5 kgm. And Steering wheel Torque: 16 to 17.5 kgm.
6.4 Check and adjust tyre pressure as per the specifications.
7 HYDRAULIC SYSTEM
7.1 Check the oil level in hydraulic oil (ENKLO 68) tank when tilt cylinders are in backward position and hoist cylinders are in lower position and top-up, if required.
7.2 Check for any oil leaks in hydraulic lines and hose connections & rectify, if so.
Annexure-4
7.3 Check the proper functioning of tilt and hoist system.
7.4 Check the UJ crosses in hydraulic pump drive shaft and report.
7.5 Clean the hydraulic oil tank breather.
7.6 Check the tilt and hoist cylinder mountings.
8 UPRIGHT ASSEMBLY
8.1 MAST:
8.11 Check rail roller clearance & wear pattern & ensure for free rotation of guide rollers.
8.12 Check mast for alignment,looseness & smoothness of operation.
8.13 Check Mast mounting brackets & trunnions for loose bolts.
8.14 Check Hyd hoses for interference with mast.
8.2 CARRIAGE:
8.21 Check rail to roller clearance
8.22 Check Fork bar for notches / excessive wear & damage.
8.23 Check smoothness of operation.
8.3 CHAINS
8.31 Check for uniform tension
8.32 check for proper lubrication.
8.33 Check for corossion,bends & cracked links etc.
8.34 Check chain mounting components for wear & damage.
8.4 LIFT & TILT CYLINDERS:
8.41 Check for seal leakage.
8.42 Check cylinder rods for nicks & scratches.
8.43 Check cylinder racking ( uneven stroking of lift & tilt cylinders ).
8.44 Check for free sliding for forks & proper functioning of fork locks.
8.45 Lubricate the Hoist cylinder chain.
9 ELECTRICAL
9.1 Check the distilled electrolyte level in the batteries and top-up, if required with distilled water.
9.2 Clean the battery terminals and apply petroleum jelly and check the tightness of terminals.
9.3 Check the condition of battery box
9.4 Check the functioning of self-motor and dynamo/ alternator.
9.5 Check the functioning of battery charging system and adjust the regulator, if required
Annexure-4
9.6 Check the functioning of all dash board meters and make them to work, if any of them not working.
9.7 Check the functioning of all lights and electrical accessories and attend to any problems, if required.
10 BODY
10.1 Check the tightness of counter weight mountings and retighten, if required.
10.2 Check the drivers seat mountings and retighten, if required.
11 SERVICING:
11.1 Wash the equipment thoroughly and grease all the points.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
DIESEL FORKLIFT – QUARTERLY MAINTENANCE WORKSTATION - EQUIPMENT No :
1 WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Attend to all the works mentioned in monthly work schedule.
1.2 Change engine oil and engine oil filter, if the engine has run 100 hours after previous engine oil change.
1.3 Check the Fuel filters (Primary & Secondary) and change if required.
1.4 Check the air filter & clean the air filter by applying 1 kg/sq cm air pressure.
Annexure-4
1.5 Check the oil bath air cleaner for every Quarterly maintenance.
1.6 Flush the radiator and fill with new coolant.
1.7 Check the wheel bearings for any shake and adjust wheel play. Pack axle cups with grease and fit back.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
DIESEL FORKLIFT – ANNUAL MAINTENANCE WORKSTATION - EQUIPMENT No :
1 WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Carryout all the works mentioned in Monthly & Quarterly schedule
1.2 Check the Engine Valve Tappet clearance and adjust if required. The Inlet & Exhaust Valve clearance must be 0.25 mm & 0.3 mm respectively.
1.3 Check the fuel injection timing with out auto timer - 22 degrees or with auto timer - 15 degrees
1.4 Clean the radiator fins on every annual maintenance by flushing with water mixed rust preventive compound (K-Cool - 15 c.c/ltr)
1.5 Change the hydraulic oil replace hydraulic oil filter.Irrespective of the condition of oil,for every annual maintenance.
Annexure-4
1.6 Change the transmission oil (C- 4 SAE30) and replace transmission oil filter.
1.7 Open all wheels and carryout hub service.
1.8 Overhaul brake system. Replace all wheels cylinder kits, MC kits. Replace brake lining, if required.
1.9 Check the condition of regulator, check valves and cylinder kits and replace if required.
1.10 Remove the dynamo / alternator, self motor.Overhaul and replace the worn out items and refit.
1.11 Clean the diesel tank and strainer.
1.12 Remove the spark arrester, clean and refit.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Inspection of brake and wheel assemblies after dismantling for overhauling for replacement of worn out items.
1.1 Inspection of self-motor, alternator / dynamo after dismantling for replacement of worn out items.
2 After completion of all the works as per schedule
2.1 Verify whether all the works have been completed as per the schedule.
2.2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
8 TON FORKLIFT MAINTENANCE CHECK LIST
DIESEL FORKLIFT – MONTHLY MAINTENANCE WORKSTATION EQUIPMENT No : VAST /FL/5T/01
Annexure-4
- A
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Check engine oil level in the sump using dip stick and top-up if required (Specs: 15 W 40 )
1.2 Check the engine oil, replace with new oil if required.
1.3
Check the engine oil for the following:
a. Coolant water mixed with water
b. Diesel fuel mixed with water.
c. Carbon deposit in the Engine oil.
d. Metal particles deposition in the engine oil.
1.4 Check the Engine Crank case (sump) for oil leaks.tighten the mounting bolts if required (Torque: 25kg-m)
1.5 Check the condition of crank case gaskets tighten / relpace if required. (Torque: 10 kg-m)
1.6 Check the drain plug of engine crank case for metal particles deposition, clean & refit.
1.7 Check the condition of engine breather,clean & refit.
1.8 Check the functioning of engine breather replace if required.
1.9 Check the condition of engine oil filter & replace if required.
1.10 Check the condition of cooling system lines for leaks & tighten / replace if required.
1.11 Flush with water the radiator & cooling system fill with fresh water & coolant @ 50:50 mixture upto level.
1.12 Check the condition of radiator cap & replace if required.
1.13 Check the condition of expansion tank cap & replace if required.
1.14 Check the condition of radiator top & bottom hoses and replace, if required.
1.15 Check the condition of Fan belt & replace if required.(Specs: )
1.16 Check tension of Fan belt & adjust if required (Allowable belt tension: 20 to 27 N or 2.0 to 2.7 kgm)
1.17 Check the condition of water pump mounting bolts tighten if required.(Torque: 3.5kg-m)
1.18 Lubricate the water pump with grease if required.
1.19 Check the Water pump for leaks rectify / replace with water pump kit if required.
Annexure-4
1.20 Check the condition of Valve door packing (Gasket) for leaks replace / rectify if required.
1.21 Check and tighten the cylinder head Bolts. ( torque: 12kg-m)
1.22 Check and readjust the valve tappet clearance (Inlet valve: 0.25 mm ), (Exhaust valve: 0.3 mm)
1.23 Check the tightness of Engine bed mounting bolts tighten if required (Torque: 6 kg-m)
1.24 Check the condition of cylinder head & gaskets and replace if required.
1.25 Check the condition of Fuel injection pump mountings & tighten if required.
1.26 Check the tightness of Fuel high pressure pipes tighten if required (Torque 4 kg-m)
1.27 Check diesel fuel leaks in the high pressure pipes tighten / replace if required (Torque: 5 kg-m)
1.28 Lubricate the Fuel pump with engine oil.
1.29 Remove bowl filter, clean the filter refit / replace if required. (Tools : Cutting Plier)
1.3 Check the condition of Fuel filter (Primary & secondary) and replace if required.
1.31 Check the condition of Inlet manifold mounting bolts tighten if required.(Torque: 5 kg-m)
1.32 Check the Inlet manifold for leaks, rectify / replace with manifold gaskets if required.
1.33 Check the condition of Exhaust manifold mounting bolts tighten if required.(Torque: 5 kg-m)
1.34 Check the Exhaust manifold for leaks rectify / replace with manifold gaskets if required.
1.35 Check the tightness of Silencer mounting bolts tighten if required.(Torque: 3.5 kg-m)
1.36 Check diesel fuel Leak off pipe, tighten bolts if required.
2 TRANSMISSION:
2.1 Check the oil (C- 4 SAE30) level in transmission and top-up, if required
2.2 Check for any leaks in transmission system (Differential,Gear Box) and rectify.
2.3 Check all the Couplings & joints for tightness and tighten if requiired.
2.4 Check for proper engagement of gears / check the proper functioning of neutral start switch.
Annexure-4
3 STEERING
3.1 Check steering box mountings / check oil level in steering box and top-up, if required.
3.2 Check proper functioning of steering servo cylinder.
3.3 Check the steering tie rod end joints, cross pins and swill pins for any abnormality and ensure lock pins and dust caps are in position.
3.4 Check for oil seal leaks from steering cylinder & rectify if required.
3.5 Check the condition of High pressure steering hoses & replace if required.
3.6 Check and adjust steering wheel play
4 PNEUMATIC SERVICE BRAKES:
4.1 Check brake pedal free play (Max 20mm) and adjust, if required
4.2 Check the Brake oil( SAE J 1703) level in Master Cylinder and top up, if required
4.3 Check and adjust the brakes, if required.
4.4 Drain the air tank
4.5 Check for any leak in air lines and rectify, if required
4.6 Check the proper functioning of air regulator and booster.
4.7 Check the proper functioning of pedal valve and brake chambers.
4.8 Check the condition of spring brake actuator on LH & RH and adjust if required.
4.9 Check the air compressor,Unloader valve,Automatic Drain Valve,Graduated Hand controll valve & Spot light switch are working in good condition.
4.10 Ensure build - up of specified air pressure for 7 to 8 kg/sq cm.before beginning the days work.
PARKING BRAKES:
4.11 Check proper functioning of Parking brake.
4.12 Check & tighten Parking brake mounting bolts.
4.13 Lubricate Parking Brake linkages.
5 WHEELS AND TYRES
5.1 Check the condition of tyres.
5.3 Tighten all wheel nuts. Driving wheel Torque: 40 to 41.5 kgm. And Steering wheel Torque: 16 to 17.5 kgm. (Wheel nut Spanner size: )
5.4 Check and adjust tyre pressure as per the specifications.
6 HYDRAULIC SYSTEM
Annexure-4
6.1 Check the oil level in hydraulic oil (ENKLO 68) tank when tilt cylinders are in backward position and hoist cylinders are in lower position and top-up, if required.
6.2 Check for any oil leaks in hydraulic lines and hose connections & rectify, if so.
6.3 Check the proper functioning of tilt and hoist system.
6.4 Check the UJ crosses in hydraulic pump drive shaft and tighten the bolts.
6.5 Clean the hydraulic oil tank breather & refit.
6.6 Check the tilt and hoist cylinder mountings & tighten if required.
6.7 Check the condition of Hydraulic pump
7 UPRIGHT ASSEMBLY
7.1 MAST:
7.11 Check rail roller clearance & wear pattern & ensure for free rotation of guide rollers.
7.12 Check mast for alignment,looseness & smoothness of operation.
7.13 Check Mast mounting brackets & trunnions for loose bolts.
7.14 Check Hyd hoses for interference with mast.
7.2 CARRIAGE:
7.21 Check rail to roller clearance to avoid slipping.
7.22 Check Fork bar for notches / excessive wear & damage.
7.23 Check smoothness of operation.
7.3 CHAINS
7.31 Check for uniform tension in both Chains.
7.32 ubricate the Chains with Lubricants.
7.33 Check for corossion,bends & cracked links etc, rectify / replace the chain links.
7.34 Check chain mounting components for wear & damage.
7.4 LIFT & TILT CYLINDERS:
7.41 Check for seal leakages & rectify if required.
7.42 Check cylinder rods for nicks & scratches.
7.43 Check cylinder racking ( uneven stroking of lift & tilt cylinders ) & rectify if found.
7.44 Check for free sliding for forks & Check the condition of fork locks & replace if required..
7.45 Lubricate the Hoist cylinder chain.
8 ELECTRICAL
Annexure-4
8.1 Check the distilled electrolyte level in the batteries and top-up, if required with distilled water.
8.2 Clean the battery terminals and apply petroleum jelly and check the tightness of terminals.
8.3 Check the condition of battery box
8.4 Check the functioning of self-motor and dynamo/ alternator.
8.5 Check the functioning of battery charging system and adjust the regulator, if required
8.6 Check the functioning of all dash board meters & replace if not working.
8.7 Check the functioning of all lights and electrical accessories and attend to any problems, if required.
BATTERY ISOLATION SWITCH:
8.8 Check the condition of Battery Isolation switch
8.9 Tighten BIS Isolation Bolts.
REVOLVING LIGHT:
8.10 Check the condition of Revolving light Mounting plate bolts & tighten if required.
8.11 Check for proper functioning of revolving light
9 BODY
9.1 Check the tightness of counter weight mountings and retighten, if required.
9.2 Check the Condition of Rear Tow hook.
9.3 Check the drivers seat mountings and retighten, if required.
9.4 Check the Condition of Over head guard & tighten the mounting bolts if required.
9.5 Check the Condition of Wide rear view mirror & replace if required.
9.6 Tighten the Mirror mounting bolts.
10 SERVICING:
10.1 Wash the equipment thoroughly and Lubricate all grease points.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Verify that works have been completed as per schedule
2 Take the equipment for road test and check the followings.
Annexure-4
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
DIESEL FORKLIFT – QUARTERLY MAINTENANCE WORKSTATION - EQUIPMENT No :
1 WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Attend to all the works mentioned in monthly work schedule.
1.3 Check the Fuel filters (Primary & Secondary) and change if required.
1.4 Check the air filter & clean the air filter by applying 1 kg/sq cm air pressure.
1.5 Remove Oil from Oil bath air cleaner & fill with fresh engine oil.
1.6 Flush the radiator and fill with new coolant.
1.7 Check the wheel bearings for any shake and adjust wheel play./ Pack axle cups with grease and fit back.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
Annexure-4
DIESEL FORKLIFT – ANNUAL MAINTENANCE WORKSTATION - EQUIPMENT No :
1 WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Carryout all the works mentioned in Monthly & Quarterly schedule
1.2 Check the Engine Valve Tappet clearance and adjust if required. The Inlet & Exhaust Valve clearance must be 0.25 mm & 0.3 mm respectively.
1.3 Change engine oil and engine oil filter, if the engine has run 100 hours after previous engine oil change.
1.4 Check the fuel injection timing with out auto timer - 22 degrees or with auto timer - 15 degrees
1.5 Clean the radiator fins on every annual maintenance by flushing with water mixed rust preventive compound (K-Cool - 15 c.c/ltr)
1.6 Change the hydraulic oil replace hydraulic oil filter.Irrespective of the condition of oil,for every annual maintenance.
1.7 Change the transmission oil (C- 4 SAE30) and replace transmission oil filter.
1.8 Open all wheels and carryout hub service.
1.9 Overhaul brake system. Replace all wheels cylinder kits, MC kits. Replace brake lining, if required.
1.10 Check the condition of flow regulator, check valves and cylinder kits and replace if required.
1.11 Check the Condition of Wheel bearings & replace if required.
1.12 Check the Condition of Oil seal & replace if required.
1.13 Check the Condition of Wear sleeve & replace or repair if required.
1.14 Check the Condition of Tilt Cylinders for leaks, change kits if required.
1.15 Remove the dynamo / alternator, self motor.Overhaul and replace the worn out items and refit.
1.16 Clean the diesel tank and strainer.
1.17 Remove the spark arrester, clean and refit.
1.18 Adjust the Head Light Focus
Annexure-4
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Inspection of brake and wheel assemblies after dismantling for overhauling for replacement of worn out items.
1.1 Inspection of self-motor, alternator / dynamo after dismantling for replacement of worn out items.
2 After completion of all the works as per schedule
2.1 Verify whether all the works have been completed as per the schedule.
2.2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
Annexure-4
12 TON FORKLIFT MAINTENANCE CHECK LIST
DIESEL FORKLIFT – MONTHLY MAINTENANCE WORKSTATION - A
EQUIPMENT No : VAST /FL/5T/01
S.NO WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Check engine oil level in the sump using dip stick and top-up if required (Specs: 15 W 40 )
1.2 Check the engine oil, replace with new oil if required.
1.3
Check the engine oil for the following:
a. Coolant water mixed with water
b. Diesel fuel mixed with water.
c. Carbon deposit in the Engine oil.
d. Metal particles deposition in the engine oil.
1.4 Check the Engine Crank case (sump) for oil leaks.tighten the mounting bolts if required (Torque: 25kg-m)
1.5 Check the condition of crank case gaskets tighten / relpace if required. (Torque: 10 kg-m)
1.6 Check the drain plug of engine crank case for metal particles deposition, clean & refit.
1.7 Check the condition of engine breather,clean & refit.
1.8 Check the functioning of engine breather replace if required.
1.9 Check the condition of engine oil filter & replace if required.
1.10 Check the condition of cooling system lines for leaks & tighten / replace if required.
1.11 Flush with water the radiator & cooling system fill with fresh water & coolant @ 50:50 mixture upto level.
1.12 Check the condition of radiator cap & replace if required.
1.13 Check the condition of expansion tank cap & replace if required.
1.14 Check the condition of radiator top & bottom hoses and replace, if required.
1.15 Check the condition of Fan belt & replace if required.(Specs: )
1.16 Check tension of Fan belt & adjust if required (Allowable belt tension: 20 to 27 N or 2.0 to 2.7 kgm)
Annexure-4
1.17 Check the condition of water pump mounting bolts tighten if required.(Torque: 3.5kg-m)
1.18 Lubricate the water pump with grease if required.
1.19 Check the Water pump for leaks rectify / replace with water pump kit if required.
1.20 Check the condition of Valve door packing (Gasket) for leaks replace / rectify if required.
1.21 Check and tighten the cylinder head Bolts. ( torque: 12kg-m)
1.22 Check and readjust the valve tappet clearance (Inlet valve: 0.25 mm ), (Exhaust valve: 0.3 mm)
1.23 Check the tightness of Engine bed mounting bolts tighten if required (Torque: 6 kg-m)
1.24 Check the condition of cylinder head & gaskets and replace if required.
1.25 Check the condition of Fuel injection pump mountings & tighten if required.
1.26 Check the tightness of Fuel high pressure pipes tighten if required (Torque 4 kg-m)
1.27 Check diesel fuel leaks in the high pressure pipes tighten / replace if required (Torque: 5 kg-m)
1.28 Lubricate the Fuel pump with engine oil.
1.29 Remove bowl filter, clean the filter refit / replace if required. (Tools : Cutting Plier)
1.3 Check the condition of Fuel filter (Primary & secondary) and replace if required.
1.31 Check the condition of Inlet manifold mounting bolts tighten if required.(Torque: 5 kg-m)
1.32 Check the Inlet manifold for leaks, rectify / replace with manifold gaskets if required.
1.33 Check the condition of Exhaust manifold mounting bolts tighten if required.(Torque: 5 kg-m)
1.34 Check the Exhaust manifold for leaks rectify / replace with manifold gaskets if required.
1.35 Check the tightness of Silencer mounting bolts tighten if required.(Torque: 3.5 kg-m)
1.36 Check diesel fuel Leak off pipe, tighten bolts if required.
2 TRANSMISSION:
2.1 Check the oil (C- 4 SAE30) level in transmission and top-up, if required
Annexure-4
2.2 Check for any leaks in transmission system (Differential,Gear Box) and rectify.
2.3 Check all the Couplings & joints for tightness and tighten if requiired.
2.4 Check for proper engagement of gears / check the proper functioning of neutral start switch.
3 STEERING
3.1 Check steering box mountings / check oil level in steering box and top-up, if required.
3.2 Check proper functioning of steering servo cylinder.
3.3 Check the steering tie rod end joints, cross pins and swill pins for any abnormality and ensure lock pins and dust caps are in position.
3.4 Check for oil seal leaks from steering cylinder & rectify if required.
3.5 Check the condition of High pressure steering hoses & replace if required.
3.6 Check and adjust steering wheel play
4 PNEUMATIC SERVICE BRAKES:
4.1 Check brake pedal free play (Max 20mm) and adjust, if required
4.2 Check the Brake oil( SAE J 1703) level in Master Cylinder and top up, if required
4.3 Check and adjust the brakes, if required.
4.4 Drain the air tank
4.5 Check for any leak in air lines and rectify, if required
4.6 Check the proper functioning of air regulator and booster.
4.7 Check the proper functioning of pedal valve and brake chambers.
4.8 Check the condition of spring brake actuator on LH & RH and adjust if required.
4.9 Check the air compressor,Unloader valve,Automatic Drain Valve,Graduated Hand controll valve & Spot light switch are working in good condition.
4.10 Ensure build - up of specified air pressure for 7 to 8 kg/sq cm.before beginning the days work.
PARKING BRAKES:
4.11 Check proper functioning of Parking brake.
4.12 Check & tighten Parking brake mounting bolts.
4.13 Lubricate Parking Brake linkages.
5 WHEELS AND TYRES
5.1 Check the condition of tyres.
Annexure-4
5.3 Tighten all wheel nuts. Driving wheel Torque: 40 to 41.5 kgm. And Steering wheel Torque: 16 to 17.5 kgm. (Wheel nut Spanner size: )
5.4 Check and adjust tyre pressure as per the specifications.
6 HYDRAULIC SYSTEM
6.1 Check the oil level in hydraulic oil (ENKLO 68) tank when tilt cylinders are in backward position and hoist cylinders are in lower position and top-up, if required.
6.2 Check for any oil leaks in hydraulic lines and hose connections & rectify, if so.
6.3 Check the proper functioning of tilt and hoist system.
6.4 Check the UJ crosses in hydraulic pump drive shaft and tighten the bolts.
6.5 Clean the hydraulic oil tank breather & refit.
6.6 Check the tilt and hoist cylinder mountings & tighten if required.
6.7 Check the condition of Hydraulic pump
7 UPRIGHT ASSEMBLY
7.1 MAST:
7.11 Check rail roller clearance & wear pattern & ensure for free rotation of guide rollers.
7.12 Check mast for alignment,looseness & smoothness of operation.
7.13 Check Mast mounting brackets & trunnions for loose bolts.
7.14 Check Hyd hoses for interference with mast.
7.2 CARRIAGE:
7.21 Check rail to roller clearance to avoid slipping.
7.22 Check Fork bar for notches / excessive wear & damage.
7.23 Check smoothness of operation.
7.3 CHAINS
7.31 Check for uniform tension in both Chains.
7.32 ubricate the Chains with Lubricants.
7.33 Check for corossion,bends & cracked links etc, rectify / replace the chain links.
7.34 Check chain mounting components for wear & damage.
7.4 LIFT & TILT CYLINDERS:
7.41 Check for seal leakages & rectify if required.
7.42 Check cylinder rods for nicks & scratches.
7.43 Check cylinder racking ( uneven stroking of lift & tilt cylinders ) & rectify if found.
Annexure-4
7.44 Check for free sliding for forks & Check the condition of fork locks & replace if required..
7.45 Lubricate the Hoist cylinder chain.
8 ELECTRICAL
8.1 Check the distilled electrolyte level in the batteries and top-up, if required with distilled water.
8.2 Clean the battery terminals and apply petroleum jelly and check the tightness of terminals.
8.3 Check the condition of battery box
8.4 Check the functioning of self-motor and dynamo/ alternator.
8.5 Check the functioning of battery charging system and adjust the regulator, if required
8.6 Check the functioning of all dash board meters & replace if not working.
8.7 Check the functioning of all lights and electrical accessories and attend to any problems, if required.
BATTERY ISOLATION SWITCH:
8.8 Check the condition of Battery Isolation switch
8.9 Tighten BIS Isolation Bolts.
REVOLVING LIGHT:
8.10 Check the condition of Revolving light Mounting plate bolts & tighten if required.
8.11 Check for proper functioning of revolving light
9 BODY
9.1 Check the tightness of counter weight mountings and retighten, if required.
9.2 Check the Condition of Rear Tow hook.
9.3 Check the drivers seat mountings and retighten, if required.
9.4 Check the Condition of Over head guard & tighten the mounting bolts if required.
9.5 Check the Condition of Wide rear view mirror & replace if required.
9.6 Tighten the Mirror mounting bolts.
10 SERVICING:
10.1 Wash the equipment thoroughly and Lubricate all grease points.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
Annexure-4
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Verify that works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
DIESEL FORKLIFT – QUARTERLY MAINTENANCE WORKSTATION - EQUIPMENT No :
1 WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Attend to all the works mentioned in monthly work schedule.
1.3 Check the Fuel filters (Primary & Secondary) and change if required.
1.4 Check the air filter & clean the air filter by applying 1 kg/sq cm air pressure.
1.5 Remove Oil from Oil bath air cleaner & fill with fresh engine oil.
1.6 Flush the radiator and fill with new coolant.
1.7 Check the wheel bearings for any shake and adjust wheel play./ Pack axle cups with grease and fit back.
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Verify whether all the works have been completed as per schedule
2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
Annexure-4
DATE: ENGINEER IN -CHARGE
DIESEL FORKLIFT – ANNUAL MAINTENANCE WORKSTATION - EQUIPMENT No :
1 WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT
REMARKS
1.1 Carryout all the works mentioned in Monthly & Quarterly schedule
1.2 Check the Engine Valve Tappet clearance and adjust if required. The Inlet & Exhaust Valve clearance must be 0.25 mm & 0.3 mm respectively.
1.3 Change engine oil and engine oil filter, if the engine has run 100 hours after previous engine oil change.
1.4 Check the fuel injection timing with out auto timer - 22 degrees or with auto timer - 15 degrees
1.5 Clean the radiator fins on every annual maintenance by flushing with water mixed rust preventive compound (K-Cool - 15 c.c/ltr)
1.6 Change the hydraulic oil replace hydraulic oil filter.Irrespective of the condition of oil,for every annual maintenance.
1.7 Change the transmission oil (C- 4 SAE30) and replace transmission oil filter.
1.8 Open all wheels and carryout hub service.
1.9 Overhaul brake system. Replace all wheels cylinder kits, MC kits. Replace brake lining, if required.
1.10 Check the condition of flow regulator, check valves and cylinder kits and replace if required.
1.11 Check the Condition of Wheel bearings & replace if required.
1.12 Check the Condition of Oil seal & replace if required.
1.13 Check the Condition of Wear sleeve & replace or repair if required.
1.14 Check the Condition of Tilt Cylinders for leaks, change kits if required.
1.15 Remove the dynamo / alternator, self motor.Overhaul and replace the worn out items and refit.
Annexure-4
1.16 Clean the diesel tank and strainer.
1.17 Remove the spark arrester, clean and refit.
1.18 Adjust the Head Light Focus
SUPERVISOR OF THE CONTRACTOR WITH DATE: SR TECHNICIAN TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED-OUT BY ENGINEER IN-CHARGE
1 Inspection of brake and wheel assemblies after dismantling for overhauling for replacement of worn out items.
1.1 Inspection of self-motor, alternator / dynamo after dismantling for replacement of worn out items.
2 After completion of all the works as per schedule
2.1 Verify whether all the works have been completed as per the schedule.
2.2
Take the equipment for road test and check the followings.
a) Engine performance
b) Dashboard parameters
c) Function of clutch, transmission, steering and brakes.
d) Functioning of electrical appliances like lights, meters, switches etc.
e) Function of hydraulic system.
DATE: ENGINEER IN -CHARGE
Annexure-4
Annexure-4
GOLDHOFER TRAILER – QUARTERLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
34 VALF/HT/200T/01 GOLDHOFER TRAIELR (THREE MODULES)
18 ATN 6027 GOLDHOFER TRAILER (SINGLE MODULE)
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
GOLDHOFER TRAILER - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Check the hydraulic oil level in the gooseneck
2. Check the hydraulic hose connections in between modules and
gooseneck for leaks and rectify, if any
3. Check the condition of air brake connections for leaks and
rectify, if any.
4. Check the condition of air and hydraulic hoses and replace, if
required.
5. Check for oil leaks below the trailer bottom and rectify, if
required.
6. Check the condition of pressure gauges and connecting capillary
tubes and replace, if required.
7. Check the condition of steering linkages and retighten.
8. Check the tightness of module connecting bolts, lock bolts of
pins and retighten.
9. Water wash/ clean the trailer thoroughly.
10. Check the presence of hub caps for all wheel hubs.
11. Check the condition of tyres and replace worn out ones.
12. Inflate all tyres to 8ksc.
13. Check the tightness of all wheel nuts.
14. Check the oil level and diesel level in the power pack and top-up,
if required.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
GOLDHOFER TRAILER - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
15. Clean the power pack battery terminals and top-up the
electrolyte level with distilled water. Retighten the terminals.
16. Tighten the power pack bed bolts and mounting bolts.
17. Check the condition of power pack V belts and replace, if
required.
18. Check for oil and diesel leaks in power pack and rectify, if
required.
19. Check the condition of props and presence of locking pins with
chain.
20. Check the presence of earth chain.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
GOLDHOFER TRAILER - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
21. Start the power pack and check a. Performance of engine and condition of spark arrester for
clean exhaust. b. Unlock the fifth wheel locks, raise the goose neck and check
the condition of king pin and apply new grease to the rubbing plate.
c. Lower the gooseneck, lock the fifth wheel and adjust the
wedge piece. d. Check the function of leveling system and adjust the
platform level to 1165 + or – 50mm e. Check the function of manual steering and adjust the wheel
alignment. f. Check the function of hydraulic props provided below the
gooseneck. g. Check the operation of the trailer parking and service brakes
and parking brake operating valves.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
GOLDHOFER TRAILER – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all maintenance works have been carried out as
per the schedule.
2. Check the hydraulic hose connections in between modules and
gooseneck for leaks.
3. Check the brake connections for air leaks.
4. Tighten the steering linkages.
5. Start the power pack and check a. Performance of the power pack engine b. For any oil and diesel leaks c. Function of leveling system d. Function of manual steering e. Function of hydraulic props f. Wheel alignment.
Annexure-4
GOLDHOFER TRAILER – ANNUAL MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
34 VALF/HT/200T/01 GOLDHOFER TRAIELR (THREE MODULES)
18 ATN 6027 GOLDHOFER TRAILER (SINGLE MODULE)
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
GOLDHOFER TRAILER – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Carry out the works mentioned in the quarterly maintenance
schedule.
2. Change engine oil and fuel filter for power pack.
3. Change diesel filter for power pack.
4. Check the function of tilt warning device separately.
5. Check the hydraulic oil for contamination of water and dirt and
change, if required. Also change the filter element.
6. Remove all wheel drums and clean the brake parts. Carry out
hub servicing for all wheels.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
GOLDHFOER TRAILER – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the maintenance works have been carried out
as per schedule.
2. Check the hydraulic hose connections in between modules and
gooseneck for leaks.
3. Check the brake connections for air leaks.
4. Tightness of steering linkages – random check.
5. Start the power pack engine and check
a. Performance of power pack engine. b. For any oil and diesel leak c. Function of leveling system d. Function of manual steering e. Function of hydraulic props f. Wheel alignment
6. Check the function of tilt warning device
7. Load test the trailer as per the procedure mentioned in
Annexure 2D
Annexure-4
COMETTO TRAILER – QUARTERLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Equip Identification No. Equipment Equip Identification No. Equipment
VALF/HT/70T/02 COMETTO TRAILER (SINGLE MODULE)
COMETTO TRAILER (SINGLE MODULE)
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
COMETTO TRAILER - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Check the hydraulic oil level in the gooseneck
2. Check the hydraulic hose connections in between modules and
gooseneck for leaks and rectify, if any
3. Check the condition of air brake connections for leaks and
rectify, if any.
4. Check the condition of air and hydraulic hoses and replace, if
required.
5. Check for oil leaks below the trailer bottom and rectify, if
required.
6. Check the condition of pressure gauges and connecting capillary
tubes and replace, if required.
7. Check the condition of steering linkages and retighten.
8. Check the tightness of module connecting bolts, lock bolts of
pins and retighten.
9. Water wash/ clean the trailer thoroughly.
10. Check the presence of hub caps for all wheel hubs.
11. Check the condition of tyres and replace worn out ones.
12. Inflate all tyres to 8ksc.
13. Check the tightness of all wheel nuts.
14. Check the oil level and diesel level in the power pack and top-up,
if required.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
COMETTO TRAILER - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
15. Clean the power pack battery terminals and top-up the
electrolyte level with distilled water. Retighten the terminals.
16. Tighten the power pack bed bolts and mounting bolts.
17. Check the condition of power pack V belts and replace, if
required.
18. Check for oil and diesel leaks in power pack and rectify, if
required.
19. Check the condition of props and presence of locking pins with
chain.
20. Check the presence of earth chain.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
COMETTO TRAILER - QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
21. Start the power pack and check a. Performance of engine and condition of spark arrester for
clean exhaust. b. Unlock the fifth wheel locks, raise the goose neck and check
the condition of king pin and apply new grease to the rubbing plate.
c. Lower the gooseneck, lock the fifth wheel and adjust the
wedge piece. d. Check the function of leveling system and adjust the
platform level to 1165 + or – 50mm e. Check the function of manual steering and adjust the wheel
alignment. f. Check the function of hydraulic props provided below the
gooseneck. g. Check the operation of the trailer parking and service brakes
and parking brake operating valves.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
COMETTO TRAILER – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all maintenance works have been carried out as
per the schedule.
2. Check the hydraulic hose connections in between modules and
gooseneck for leaks.
3. Check the brake connections for air leaks.
4. Tighten the steering linkages.
5. Start the power pack and check a. Performance of the power pack engine b. For any oil and diesel leaks c. Function of leveling system d. Function of manual steering e. Function of hydraulic props f. Wheel alignment.
Annexure-4
COMETTO TRAILER – ANNUAL MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
VALF/HT/70T/01 COMETTO TRAIELR (SINGLE MODULE)
COMETTO TRAILER (SINGLE MODULE)
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
COMETTO TRAILER – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Carry out the works mentioned in the quarterly maintenance
schedule.
2. Change engine oil and fuel filter for power pack.
3. Change diesel filter for power pack.
4. Check the function of tilt warning device separately.
5. Check the hydraulic oil for contamination of water and dirt and
change, if required. Also change the filter element.
6. Remove all wheel drums and clean the brake parts. Carry out
hub servicing for all wheels.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
COMETTO TRAILER – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the maintenance works have been carried out
as per schedule.
2. Check the hydraulic hose connections in between modules and
gooseneck for leaks.
3. Check the brake connections for air leaks.
4. Tightness of steering linkages – random check.
5. Start the power pack engine and check
a. Performance of power pack engine. b. For any oil and diesel leak c. Function of leveling system d. Function of manual steering e. Function of hydraulic props f. Wheel alignment
6. Check the function of tilt warning device
7. Load test the trailer as per the procedure mentioned in
Annexure
Annexure − 4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
BATTERY OPERATED TRUCKS – CHECKLISTS
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
1. VALF/BOT/4W-2T/01 BATTERY OPERATED TRUCK 1 SPROB/DOT/2T/01 DIESEL OPERATED TRUCK
2. VALF/BOT/3W-2T/02 BATTERY OPERATED TRUCK 2 SPROB/DOT/2T/02 DIESEL OPERATED TRUCK
3. VALF/BOT/3W-2T/03 BATTERY OPERATED TRUCK 3 SPROB/DOT/2T/03 DIESEL OPERATED TRUCK
4. VALF/BOT/4W-2T/04 BATTERY OPERATED TRUCK 4 SPROB/DOT/2T/04 DIESEL OPERATED TRUCK
5. VALF/BOT/4W-2T/05 BATTERY OPERATED TRUCK 5 SPROB/DOT/2T/05 DIESEL OPERATED TRUCK
6. VALF/BOT/4W-2T/06 BATTERY OPERATED TRUCK
7. VALF/BOT/4W-2T/07 BATTERY OPERATED TRUCK
8. VALF/BOT/4W-2T/08 BATTERY OPERATED TRUCK
9. VALF/BOT/4W-2T/09 BATTERY OPERATED TRUCK
10. VALF/BOT/4W-2T/10 BATTERY OPERATED TRUCK
11. VALF/BOT/4W-2T/11 BATTERY OPERATED TRUCK
12. VALF/BOT/4W-2T/12 BATTERY OPERATED TRUCK
13. VALF/BOT/4W-2T/13 BATTERY OPERATED TRUCK
14. VALF/BOT/4W-2T/14 BATTERY OPERATED TRUCK
15. VALF/BOT/4W-2T/15 BATTERY OPERATED TRUCK
16. VALF/BOT/4W-2T/16 BATTERY OPERATED TRUCK
17. VALF/BOT/4W-2T/17 BATTERY OPERATED TRUCK
18. VALF/BOT/4W-2T/18 BATTERY OPERATED TRUCK
19. VALF/BOT/4W-2T/19 BATTERY OPERATED TRUCK
20. VALF/BOT/4W-2T/20 BATTERY OPERATED TRUCK
21. VALF/BOT/4W-2T/21 BATTERY OPERATED TRUCK
22. VALF/BOT/4W-2T/22 BATTERY OPERATED TRUCK
23. VALF/BOT/4W-2T/23 BATTERY OPERATED TRUCK
24. VALF/BOT/4W-2T/24 BATTERY OPERATED TRUCK
25. VALF/BOT/4W-2T/25 BATTERY OPERATED TRUCK
26. VALF/BOT/4W-2T/26 BATTERY OPERATED TRUCK
Annexure − 4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
27. VALF/BOT/4W-2T/27 BATTERY OPERATED TRUCK
BATTERY OPERATED TRUCK – MONTHLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Check the battery voltage.
2. Check the specific gravity of the electrolyte – should be 1.2
3. Check the electrolyte level in the battery and top-up with
distilled water, if required. Clean the battery terminals and
battery top surface.
4. Check all controls such as lights, horn, brakes, accelerator
pedal, battery socket and plug.
5. Inspect the tyres – Remove stones or metal swarf (filings,
turnings, grindings) etc.
Annexure − 4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
BATTERY OPERATED TRUCK – MONTHLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
6. Motor maintenance:
a. Carbon brush is free in its holder.
b. Carbon brushes are contacting correctly.
c. The pig tails are secured in the carbon and not frayed
d. The length of the brush is not less than 22mm. If less,
replace
e. The commutator segments are smooth and clean, free of
grease.
f. The solder in the commutator neck is perfect and not soft.
7. Put battery on equalizing charge.
8. Check all wheel nuts and bolts and tighten, if required.
9. Inspect the battery terminals.
10. Check transmission unit gear box.
11. Grease the equipment.
12. Examine the control panel. See that all the connections and
contacts are clean and make firm contact. All frayed wire should
be replaced.
13. Clean and lubricate with grease the moving mechanical parts:
Check the condition of chain and align the chain drive in three
wheel units. Ensure that lubricant does not come in contact
with the electrical system.
Annexure − 4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
BATTERY OPERATED TRUCK – MONTHLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
14. Check oil level in gear box and brake cylinder and top-up, if
required.
15. Check the condition of seats and platform. Attend to the
problems, if any thing is noticed.
16. Check hand and foot brake mechanism and adjust, if necessary.
17. Check all bolts and nuts.
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
BATTERY OPERATED TRUCK – MONTHLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the works have been carried out as per
schedule.
2. Check the battery condition for cleanliness and electrolyte level –
random checks.
Annexure − 4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
3. Take the equipment for road test and check the performance of a. Normal functioning of motor and control switches and
contacts. b. Gear box. c. Steering performance d. Function of electrical appliances e. Brakes.
BATTERY OPERATED TRUCK – QUARTERLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Carry out the all maintenance works as per monthly schedule.
2. Check the condition of transmission oil. If it is contaminated
with dirt or water, replace the transmission oil.
3. Open wheels, check brake system replace linkages and kits,
repack wheel hubs with new grease and fit. Overhaul the brake
system. Replace the MC kit, WC kit, and brake linings, if
required.
Annexure − 4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
BATTERY OPERATED TRUCKS–QUARTERLY MAINTENANCE
WORKSTATION - A
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the works have been carried out as per
schedule.
2. Check the battery condition for cleanliness and electrolyte level –
random checks.
3. Take the equipment for road test and check the performance of f. Normal functioning of motor and control switches and
contacts. g. Gear box. h. Steering performance i. Function of electrical appliances j. Brakes.
Annexure − 4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
BATTERY OPERATED TRUCK – ANNUAL MAINTENANCE
WORKSTATION - A
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Carry out the all maintenance works as per Monthly and Half
yearly schedule.
2. Drain, Flush and refill transmission gear unit
3. Repack Motor Bearings
4. Repack all Axle Hubs
5. Drain Flush and refill Hydraulic tank
Annexure − 4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
BATTERY OPERATED TRUCKSS– ANNUAL MAINTENANCE
WORKSTATION - A
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the works have been carried out as per
schedule.
2. Check the battery condition for cleanliness and electrolyte level –
random checks.
3.
Take the equipment for road test and check the performance of k. Normal functioning of motor and control switches and
contacts. l. Gear box. m. Steering performance n. Function of electrical appliances o. Brakes.
Annexure-4
Annexure-4
Annexure-4
MAINTENANCE CHECKLIST
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No
Equip Identification No. Equipment Sl No Equip Identification No. Equipment
1 AP26 T 2240 TATA 807 SAFETY VAN-1 1 SPROB/HA/0.8T/01 TATA ACE (CYLINDER TRANSPORTER)
AP26 X 7114 TATA 709 SAFETY VAN-1
2 AP26 W 9868 TATA 709 INDUSTRIAL MINI TRUCK
3 AP26 T 791 TATA 1210 E PLATFORM TRUCK
4 AP26 X 7113 CYLINDER TRANSPORTER
5 AP26 X 7116 AGNI TRANSPORTER
6 AP26 X 4189 SAMPLE TRANSPORTER
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 807 SAFETY VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Carry out all maintenance works as per monthly service
schedule
2. ENGINE:
2.1 Check for engine oil due and change engine oil and oil filter
cartridge.
2.2 Change fuel filter element –Fuel tank.
2.3 Change fuel filter elements.
2.4 Clean breather and check hoses for leaks. Replace, if required.
2.5 Clean air filter element. Replace, if red band appears on service
indicator.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 807 SAFETY VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
3 Tighten all fasteners:
Front grill- Oil Sump- Oil and fuel lines – Fuel filter mountings –
Exhaust manifold and pipe – Air filter – Engine and clutch
housing – Radiator mountings – Accelerator Cable – Radiator
hoses – Propeller Shaft fittings – U bolts and Nuts of springs –
Joints of Pitman arm – All steering links – Brake rods – Upper
ball joints of fish bone – Mountings of lower and upper links –
Steering gear box and mounting bracket – Vacuum and
hydraulic line connections – Head lamp mountings – Cabin and
body mountings – Anti roll bar mountings – Vacuum servo unit –
Master cylinder mountings – Slave cylinder mountings – Rear
anchor plate mountings – Front disc brake mountings – Fuel
tank strap fittings – Front suspension rubber mounting nut.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 807 SAFETY VAN – QUARTELY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the works have been completed as per schedule.
2. Take the vehicle for road test and check the following a. Engine performance b. Dash board parameters c. Function of clutch, transmission, steering and brakes d. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 807 SAFETY VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Carry out all maintenance works as per quarterly service
schedule
2. ENGINE:
2.1 Check timing belt, adjust tension, if required replace.
3. AXLES & GEARBOX.
3.1 Check for oil change due for rear axle and gearbox. Change, if
required.
4. STEERING:
4.1 Check wheel alignment and adjust, if necessary.
5 BRAKES:
5.1 Check front brake pads and rear brake linings. Replace, if
required.
6. ELECTRICAL:
6.1 Apply graphite grease on starter motor pinion bushing.
6.2 Grease the wiper motor linkages.
6.3 Check head light focusing and readjust, if required.
6.4 Check for the continuity/shot circuit of glow plugs. Replace, if
required.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 807 SAFETY VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the works have been completed as per schedule.
2. Take the vehicle for road test and check the following e. Engine performance f. Dash board parameters g. Function of clutch, transmission, steering and brakes
h. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 807 SAFTY VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Carry out all maintenance works as per half yearly service
schedule
2. ENGINE:
2.1 Check injection nozzle for opening pressure and spray
characteristics.
2.2 Change coolant in cooling system.
2.3 Replace timing belt.
3 AXLES:
3.1 Change grease in wheel hubs and adjust the bearing play.
4. SUSPENSION AND STEERING:
4.1 Check and adjust steering wheel pre play.
4.2 Replace oil in steering gear box.
4.3 Check the condition of rubber bushes in the following and
replace, if required.
a. Top wish bone b. Lower Link c. Anti roll bar d. Rear Links e. Pan hard rod.
5. BRAKES:
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 807 SAFTY VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.1 Overhaul the following brake components and change brake
fluid in the system.
Tandem master cylinder – Front caliper –Rear wheel cylinders –
Clutch master cylinder and slave cylinder
5.2 Overhaul the vacuum booster and change the felt and
polyurethane filters along with the rubber bellow.
6. ELECTRICAL :
6.1 Over haul the wiper motor, self-motor and alternator and replace
the worn out items.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 807 SAFETY VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. While work is in progress, inspect the dismantled items for over hauling for arranging replacement.
2 Ensure that all the works have been completed as per schedule.
3 Take the vehicle for road test and check the following a. Engine performance b. Dash board parameters c. Function of clutch, transmission, steering and brakes d. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 SAFTY VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. ENGINE:
1.1 Check oil level and top-up, if required
1.2 Check coolant level in the radiator and top-up, if required.
1.3 Check for leakage of coolant and rectify.
1.4 Check the condition of radiator cap and replace, if required.
1.5 Check the condition of radiator hoses and replace the worn out
ones.
1.6 Check fuel and lubricating oil lines for leaks and rectify. Remove
the FI pump bowl filter, clean and refit. Remove air lock in fuel
line.
1.7 Check the engine mountings.
1.8 Check the air cleaner and clean, if required.
1.9 Check fan belt tension and adjust, if required. (Max deflection
10-15mm on longer span)
1.10 Lubricate the fuel pump.
1.11 Lubricate the accelerator linkages.
1.12 Check the exhaust pipe lines and spark arrester for leaks and
correct, if required.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 SAFTY VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1.13 Start the engine and check oil pressure, temperature and
dashboard parameters for functioning..
2. CLUTCH:
2.1 Check proper functioning of clutch and adjust.
2.2 Adjust the clutch pedal play, if required.
2.3 Lubricate the clutch linkages with oilcan.
2.4
3. TRANSMISSION:
3.1 Check oil level in the transmission and top-up, if required.
3.2 Check for any leaks in the transmission oil lines and rectify.
3.3 Check for proper engagement of gears.
4. REAR AXLE:
4.1 Check oil level in the differential housing and top-up, if required.
4.2 Check and tighten differential cover mounting bolts, axle shaft
cover bolts and tighten, if required.
5. WHEELS:
5.1 Check the condition of tyres. Replace, if required.
5.2 Check all wheel discs bolts and tighten, if required
5.3 Inflate the tyres Front 5.0 ksc Rear 5.5 ksc.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 SAFTY VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.4 Check and ensure that the rear wheels are not rubbing with
springs.
6. SPRINGS:
6.1 Check all springs visually for any breakage of leaves, missing of
fasteners and dislocation of leaves etc. Rectify, if required.
6.2 Check shock absorber mountings and shock absorbers for
leakage.
7 BRAKES:
7.1 Check and adjust brake pedal play, if required.
7.2 Check and brakes, if required.
7.3 Drain the air tank.
7.4 Lubricate the brake linkages.
7.5 Check the condition of brake line rubber components (like boots,
pipes etc.) and replace, if required.
8 STEERING:
8.1 Lubricate the steering linkages with oil
8.2 Check oil in power steering hydraulic tank and top-up, if
required. Check hydraulic piping connections for leaks and
rectify, if any.
8.3 Check and tighten steering linkages. Check for the presence of
cotter pins and rubber boots in tie rod end nuts and kingpin
lock bolts.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 SAFTY VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
9. PROPELLER SHAFTS.
9.1 Check the condition of center joint mountings, bearings and
presence of rubber boots.
9.2 Check all propeller shaft crosses for any shake and presence of
grease.
10. ELECTRICAL:
10.1 Clean the battery terminals and apply petroleum jelly and
tighten terminals.
10.2 Check battery electrolyte level and specific gravity. The specific
gravity should be 1.2. Top-up electrolyte level with distilled
water, if required.
10.3 Check battery-box condition. Clean/repair and fit, if required.
10.4 Check for the functioning of dynamo/alternator and self motor
and tighten the mountings.
10.5 Check the function of electrical appliances and condition of
fittings and replace the worn out items. Attend to problems, if
necessary.
11 BODY:
11.1 Tighten all body and cabin bolts.
11.2 Tighten driver seat mountings.
11.3 Check the function of door glasses for easy sliding. Lubricate the
door hinges.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 SAFTY VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
12. SERVICE:
12.1 Water wash the vehicle and grease all nipples.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 709 SAFETY VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following e. Engine performance f. Dash board parameters g. Function of clutch, transmission, steering and brakes h. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 SAFETY VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in monthly schedule
2. ENGINE:
2.1 Lubricate with oil can control to fuel injection pump and
exhaust brake linkage ball joints.
2.2 Check and tighten, if necessary the following
a. Injector pressure lines b. Leak off fuel banjo bolts
c. Heat exchanger bolts d. Oil sump screws e. Oil pressure transducer at engine block f. Exhaust manifold mounting bolts g. Fly wheel housing mounting bolts h. Turbo charger mounting fasteners i. Clutch housing mounting bolts.
2.3 Check and tighten, if necessary the following
a. Push rod chamber cover b. Cylinder head cover c. Radiator Fuel tank brackets d. Fuel filter mounting bolts e. Air duct hose f. Engine mounting hose g. Engine breather rubber hose clamp.
2.4 Check air intake piping hoses and clamps. Replace the damaged
hoses.
2.5 Check service indicator. Change primary filter, if red band is in
raised position.
3. CLUTCH AND TRANSMISSION:
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 SAFETY VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
3.1 Remove grease cup for lubricating clutch release bearing.
Repack 3/4th full with grease and tighten by a few turns
3.2 Lubricate with oil can clutch linkages and felt pad of clutch
release bearing sleeve.
4. STEERING AND SUSPENSION:
4.1 Check and tighten, if necessary
a. U bolts of front and rear springs b. Nuts of spring pin wedge bolts
c. Anti roll bar bracket mounting bolts d. Spare wheel carrier. e. Shock absorber mountings
4.2 Check and tighten, if necessary
a. Pitman arm b. Drag link rod c. Tie rod d. Steering gear box mounting bracket bolts and nuts e. Steering gear box mounting bolts
4.3 Check the steering wheel pre play. Adjust, if required.
5. BRAKES:
5.1 Check and if necessary tighten air tank mountings and air line
clamps.
5.2 Check free movement of plunger in dual brake valve.
5.3 Check for proper functioning of exhaust brake, free movement of
plunger of exhaust brake valve, mounting bolts for loosening
and slackness in linkage.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 SAFETY VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.4 Lubricate with oil can brake chamber fork pin, linkages of foot
brake , ball joints of exhaust brake linkages – hand and foot
brake linkages.
5.5 Checks for travel of brake chamber push rod/ brake lining wear
and clearance with brake drum. Adjust service brakes, if
necessary
5.6 Check brake torque plate (carrier plate) mounting bolts and
tighten, if necessary.
5.7 Check for the brake lining wear by observing indicator and
report.
6. ELECTRICALS:
6.1 Check mountings of alternator and self motor and tighten, if
required.
6.2 Check head lamp focusing and adjust, if required.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 709 SAFETY VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following
i. Engine performance j. Dash board parameters k. Function of clutch, transmission, steering and brakes l. Function of electrical system.
Annexure-4
DATE:
ENGINEER IN -CHARGE
TATA 709 SAFETY VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in quarterly schedule
2. ENGINE:
2.1 Check for engine oil due and change oil in the engine sump
while the engine is hot. Change oil filter.
2.2 Check coolant concentration.
2.3 Change two fuel filters and O rings. Bleed the system.
3. GEARBOX:
3.1 Change in oil in gearbox while hot.
3.2 Check and tighten, if necessary gearbox mountings, propeller
shaft coupling flange bolts and center joint bearing support
brackets
4 AXLES:
4.1 Check crown wheel thrust pad and adjust, if necessary.
4.2 Check and tighten, if necessary, carrier and rear cover mounting
nuts. Also tighten axle shaft cover mounting bolts.
4.3 Remove front hub cap, fill 3/4th full with wheel bearing grease
and refit.
4.4 Check wheel alignment and adjust, if necessary.
5. STEERING AND SUSPENSION:
5.1 Check mountings of spare wheel carrier and tighten, if
necessary.
5.2 Check shock absorber and replace, if necessary.
Annexure-4
DATE:
ENGINEER IN -CHARGE
TATA 709 SAFETY VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.3 Check the condition of shock absorber rubber bushes and
replace, if necessary.
6. BRAKES:
6.1 Check air brake rubber hoses / air pipes for damages / leaks
and replace, if required.
6.2 Check the condition of gaiter in different brake valves, exhaust
flap in dual brake valve, exhaust check diaphragm in valve,
nylon breather tube and clips of spring brake actuator. Replace,
if found damaged / deteriorated.
6.3 Check mounting bolts of brake chambers, different valve
mountings, air tank mountings, air cylinder mounting, master
cylinder mountings, air line clamps hydraulic pipes and tighten,
if necessary.
7. ELECTRICALS:
7.1 Check the mountings of alternator / self motor and tighten, if
necessary.
7.2 Lubricate the pinion bush of self motor and wiper motor
linkages.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 709 SAFETY VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following m. Engine performance n. Dash board parameters o. Function of clutch, transmission, steering and brakes p. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 SAFETY VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in half yearly schedule
2. ENGINE:
2.1 Remove the fuel tank, clean and refit. Check the condition of
strainer and replace, if required.
2.2 Remove and clean the spark arrester and refit.
2.3 Check the end play of turbo charger shaft and radial clearance
between turbine wheel and housing.
2.4 Check fan hub and drive belt tensioner bearing.
2.5 Check valve clearance and adjust, if required.
2.6 Check the condition of vibration damper and report.
2.7 Remove the injectors, check and reset the pressure (if required
only)
3. CLUTCH AND GEARBOX:
3.1 Clean gearbox breather.
3.2 Overhaul clutch master and slave cylinder with new kits.
3.3 Replace differential oil.
3.4 Remove front wheel and rear wheel hubs, dismantle and clean
bearing and other components. Replace damaged / worn out
parts. Repack with fresh wheel bearing grease and refit. Adjust
wheel hub play.
4. STEERING AND SUSPENSION;
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 SAFETY VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
4.1 Change oil in power steering system. Replace filter and cartridge.
4.2 Dismantle front and rear springs. Clean and inspect leaves.
Check and replace bushes if necessary. Apply graphite grease on
leaves and reassemble.
5. BRAKES:
5.1 Overhaul the pneumatic aggregates of the brake system with
replacement of new kits.
5.2 Remove brake drums, inspect the brake linings, brake drums
etc. Rectify for defects.
5.3 Remove the air filter element, clean and refit.
6. ELECTRICALS:
6.1 Overhaul the self motor and alternator and refit.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 709 SAFETY VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. While work is in progress, inspect the dismantled items for over hauling for arranging replacement.
2 Ensure that all the works have been completed as per schedule.
3 Take the vehicle for road test and check the following q. Engine performance r. Dash board parameters s. Function of clutch, transmission, steering and brakes t. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. ENGINE:
1.1 Check oil level and top-up, if required
1.2 Check coolant level in the radiator and top-up, if required.
1.3 Check for leakage of coolant and rectify.
1.4 Check the condition of radiator cap and replace, if required.
1.5 Check the condition of radiator hoses and replace the worn out
ones.
1.6 Check fuel and lubricating oil lines for leaks and rectify. Remove
the FI pump bowl filter, clean and refit. Remove air lock in fuel
line.
1.7 Check the engine mountings.
1.8 Check the air cleaner and clean, if required.
1.9 Check fan belt tension and adjust, if required. (Max deflection
10-15mm on longer span)
1.10 Lubricate the fuel pump.
1.11 Lubricate the accelerator linkages.
1.12 Check the exhaust pipe lines and spark arrester for leaks and
correct, if required.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1.13 Start the engine and check oil pressure, temperature and
dashboard parameters for functioning..
2. CLUTCH:
2.1 Check proper functioning of clutch and adjust.
2.2 Adjust the clutch pedal play, if required.
2.3 Lubricate the clutch linkages with oilcan.
2.4
3. TRANSMISSION:
3.1 Check oil level in the transmission and top-up, if required.
3.2 Check for any leaks in the transmission oil lines and rectify.
3.3 Check for proper engagement of gears.
4. REAR AXLE:
4.1 Check oil level in the differential housing and top-up, if required.
4.2 Check and tighten differential cover mounting bolts, axle shaft
cover bolts and tighten, if required.
5. WHEELS:
5.1 Check the condition of tyres. Replace, if required.
5.2 Check all wheel discs bolts and tighten, if required
5.3 Inflate the tyres Front 5.0 ksc Rear 5.5 ksc.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.4 Check and ensure that the rear wheels are not rubbing with
springs.
6. SPRINGS:
6.1 Check all springs visually for any breakage of leaves, missing of
fasteners and dislocation of leaves etc. Rectify, if required.
6.2 Check shock absorber mountings and shock absorbers for
leakage.
7 BRAKES:
7.1 Check and adjust brake pedal play, if required.
7.2 Check and brakes, if required.
7.3 Drain the air tank.
7.4 Lubricate the brake linkages.
7.5 Check the condition of brake line rubber components (like boots,
pipes etc.) and replace, if required.
8 STEERING:
8.1 Lubricate the steering linkages with oil
8.2 Check oil in power steering hydraulic tank and top-up, if
required. Check hydraulic piping connections for leaks and
rectify, if any.
8.3 Check and tighten steering linkages. Check for the presence of
cotter pins and rubber boots in tie rod end nuts and kingpin
lock bolts.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
9. PROPELLER SHAFTS.
9.1 Check the condition of center joint mountings, bearings and
presence of rubber boots.
9.2 Check all propeller shaft crosses for any shake and presence of
grease.
10. ELECTRICAL:
10.1 Clean the battery terminals and apply petroleum jelly and
tighten terminals.
10.2 Check battery electrolyte level and specific gravity. The specific
gravity should be 1.2. Top-up electrolyte level with distilled
water, if required.
10.3 Check battery-box condition. Clean/repair and fit, if required.
10.4 Check for the functioning of dynamo/alternator and self motor
and tighten the mountings.
10.5 Check the function of electrical appliances and condition of
fittings and replace the worn out items. Attend to problems, if
necessary.
11 BODY:
11.1 Tighten all body and cabin bolts.
11.2 Tighten driver seat mountings.
11.3 Check the function of door glasses for easy sliding. Lubricate the
door hinges.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
12. SERVICE:
12.1 Water wash the vehicle and grease all nipples.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following u. Engine performance v. Dash board parameters w. Function of clutch, transmission, steering and brakes x. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 INDUSTRAL MINI TRUCK – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in monthly schedule
2. ENGINE:
2.1 Lubricate with oil can control to fuel injection pump and
exhaust brake linkage ball joints.
2.2 Check and tighten, if necessary the following
j. Injector pressure lines
k. Leak off fuel banjo bolts l. Heat exchanger bolts m. Oil sump screws n. Oil pressure transducer at engine block o. Exhaust manifold mounting bolts p. Fly wheel housing mounting bolts q. Turbo charger mounting fasteners r. Clutch housing mounting bolts.
2.3 Check and tighten, if necessary the following
h. Push rod chamber cover i. Cylinder head cover j. Radiator Fuel tank brackets k. Fuel filter mounting bolts l. Air duct hose m. Engine mounting hose n. Engine breather rubber hose clamp.
2.4 Check air intake piping hoses and clamps. Replace the damaged
hoses.
2.5 Check service indicator. Change primary filter, if red band is in
raised position.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 INDUSTRAL MINI TRUCK – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
3. CLUTCH AND TRANSMISSION:
3.1 Remove grease cup for lubricating clutch release bearing.
Repack 3/4th full with grease and tighten by a few turns
3.2 Lubricate with oil can clutch linkages and felt pad of clutch
release bearing sleeve.
4. STEERING AND SUSPENSION:
4.1 Check and tighten, if necessary
f. U bolts of front and rear springs g. Nuts of spring pin wedge bolts h. Anti roll bar bracket mounting bolts i. Spare wheel carrier. j. Shock absorber mountings
4.2 Check and tighten, if necessary
f. Pitman arm g. Drag link rod h. Tie rod i. Steering gear box mounting bracket bolts and nuts j. Steering gear box mounting bolts
4.3 Check the steering wheel pre play. Adjust, if required.
5. BRAKES:
5.1 Check and if necessary tighten air tank mountings and air line
clamps.
5.2 Check free movement of plunger in dual brake valve.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 INDUSTRAL MINI TRUCK – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.3 Check for proper functioning of exhaust brake, free movement of
plunger of exhaust brake valve, mounting bolts for loosening
and slackness in linkage.
5.4 Lubricate with oil can brake chamber fork pin, linkages of foot
brake , ball joints of exhaust brake linkages – hand and foot
brake linkages.
5.5 Checks for travel of brake chamber push rod/ brake lining wear
and clearance with brake drum. Adjust service brakes, if
necessary
5.6 Check brake torque plate (carrier plate) mounting bolts and
tighten, if necessary.
5.7 Check for the brake lining wear by observing indicator and
report.
6. ELECTRICALS:
6.1 Check mountings of alternator and self motor and tighten, if
required.
6.2 Check head lamp focusing and adjust, if required.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following
y. Engine performance z. Dash board parameters aa. Function of clutch, transmission, steering and brakes bb. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in quarterly schedule
2. ENGINE:
2.1 Check for engine oil due and change oil in the engine sump
while the engine is hot. Change oil filter.
2.2 Check coolant concentration.
2.3 Change two fuel filters and O rings. Bleed the system.
3. GEARBOX:
3.1 Change in oil in gearbox while hot.
3.2 Check and tighten, if necessary gearbox mountings, propeller
shaft coupling flange bolts and center joint bearing support
brackets
4 AXLES:
4.1 Check crown wheel thrust pad and adjust, if necessary.
4.2 Check and tighten, if necessary, carrier and rear cover mounting
nuts. Also tighten axle shaft cover mounting bolts.
4.3 Remove front hub cap, fill 3/4th full with wheel bearing grease
and refit.
4.4 Check wheel alignment and adjust, if necessary.
5. STEERING AND SUSPENSION:
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.1 Check mountings of spare wheel carrier and tighten, if
necessary.
5.2 Check shock absorber and replace, if necessary.
5.3 Check the condition of shock absorber rubber bushes and
replace, if necessary.
6. BRAKES:
6.1 Check air brake rubber hoses / air pipes for damages / leaks
and replace, if required.
6.2 Check the condition of gaiter in different brake valves, exhaust
flap in dual brake valve, exhaust check diaphragm in valve,
nylon breather tube and clips of spring brake actuator. Replace,
if found damaged / deteriorated.
6.3 Check mounting bolts of brake chambers, different valve
mountings, air tank mountings, air cylinder mounting, master
cylinder mountings, air line clamps hydraulic pipes and tighten,
if necessary.
7. ELECTRICALS:
7.1 Check the mountings of alternator / self motor and tighten, if
necessary.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
7.2 Lubricate the pinion bush of self motor and wiper motor
linkages.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following cc. Engine performance dd. Dash board parameters ee. Function of clutch, transmission, steering and brakes ff. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in half yearly schedule
2. ENGINE:
2.1 Remove the fuel tank, clean and refit. Check the condition of
strainer and replace, if required.
2.2 Remove and clean the spark arrester and refit.
2.3 Check the end play of turbo charger shaft and radial clearance
between turbine wheel and housing.
2.4 Check fan hub and drive belt tensioner bearing.
2.5 Check valve clearance and adjust, if required.
2.6 Check the condition of vibration damper and report.
2.7 Remove the injectors, check and reset the pressure (if required
only)
3. CLUTCH AND GEARBOX:
3.1 Clean gearbox breather.
3.2 Overhaul clutch master and slave cylinder with new kits.
3.3 Replace differential oil.
3.4 Remove front wheel and rear wheel hubs, dismantle and clean
bearing and other components. Replace damaged / worn out
parts. Repack with fresh wheel bearing grease and refit. Adjust
wheel hub play.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
4 STEERING AND SUSPENSION;
4.1 Change oil in power steering system. Replace filter and cartridge.
4.2 Dismantle front and rear springs. Clean and inspect leaves.
Check and replace bushes if necessary. Apply graphite grease on
leaves and reassemble.
5. BRAKES:
5.1 Overhaul the pneumatic aggregates of the brake system with
replacement of new kits.
5.2 Remove brake drums, inspect the brake linings, brake drums
etc. Rectify for defects.
5.3 Remove the air filter element, clean and refit.
6. ELECTRICALS:
6.1 Overhaul the self motor and alternator and refit.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 709 INDUSTRIAL MINI TRUCK – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. While work is in progress, inspect the dismantled items for over hauling for arranging replacement.
2 Ensure that all the works have been completed as per schedule.
3 Take the vehicle for road test and check the following gg. Engine performance hh. Dash board parameters ii. Function of clutch, transmission, steering and brakes jj. Function of electrical system.
Annexure-4
DATE:
ENGINEER IN -CHARGE
TATA 1210E PLATFORM TRUCK – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. ENGINE:
1.1 Check oil level and top-up, if required
1.2 Check coolant level in the radiator and top-up, if required.
1.3 Check for leakage of coolant and rectify.
1.4 Check the condition of radiator cap and replace, if required.
1.5 Check the condition of radiator hoses and replace the worn out
ones.
1.6 Check fuel and lubricating oil lines for leaks and rectify. Remove
the FI pump bowl filter, clean and refit. Remove air lock in fuel
line.
1.7 Check the engine mountings.
1.8 Check the air cleaner and clean, if required.
1.9 Check fan belt tension and adjust, if required. (Max deflection
10-15mm on longer span)
1.10 Lubricate the fuel pump.
1.11 Lubricate the accelerator linkages.
1.12 Check the exhaust pipe lines and spark arrester for leaks and
correct, if required.
1.13 Start the engine and check oil pressure, temperature and
dashboard parameters for functioning..
2. CLUTCH:
Annexure-4
DATE:
ENGINEER IN -CHARGE
TATA 1210E PLATFORM TRUCK – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
2.1 Check proper functioning of clutch and adjust.
2.2 Adjust the clutch pedal play, if required.
2.3 Lubricate the clutch linkages with oilcan.
2.4
3. TRANSMISSION:
3.1 Check oil level in the transmission and top-up, if required.
3.2 Check for any leaks in the transmission oil lines and rectify.
3.3 Check for proper engagement of gears.
4. REAR AXLE:
4.1 Check oil level in the differential housing and top-up, if required.
4.2 Check and tighten differential cover mounting bolts, axle shaft
cover bolts and tighten, if required.
5. WHEELS:
5.1 Check the condition of tyres. Replace, if required.
5.2 Check all wheel discs bolts and tighten, if required
5.3 Inflate the tyres Front 5.0 ksc Rear 5.5 ksc.
5.4 Check and ensure that the rear wheels are not rubbing with
springs.
6. SPRINGS:
6.1 Check all springs visually for any breakage of leaves, missing of
fasteners and dislocation of leaves etc. Rectify, if required.
Annexure-4
DATE:
ENGINEER IN -CHARGE
TATA 1210E PLATFORM TRUCK – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
6.2 Check shock absorber mountings and shock absorbers for
leakage.
7 BRAKES:
7.1 Check and adjust brake pedal play, if required.
7.2 Check and brakes, if required.
7.3 Drain the air tank.
7.4 Lubricate the brake linkages.
7.5 Check the condition of brake line rubber components (like boots,
pipes etc.) and replace, if required.
8 STEERING:
8.1 Lubricate the steering linkages with oil
8.2 Check oil in power steering hydraulic tank and top-up, if
required. Check hydraulic piping connections for leaks and
rectify, if any.
8.3 Check and tighten steering linkages. Check for the presence of
cotter pins and rubber boots in tie rod end nuts and kingpin
lock bolts.
9. PROPELLER SHAFTS.
9.1 Check the condition of center joint mountings, bearings and
presence of rubber boots.
9.2 Check all propeller shaft crosses for any shake and presence of
grease.
Annexure-4
DATE:
ENGINEER IN -CHARGE
TATA 1210E PLATFORM TRUCK – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
10. ELECTRICAL:
10.1 Clean the battery terminals and apply petroleum jelly and
tighten terminals.
10.2 Check battery electrolyte level and specific gravity. The specific
gravity should be 1.2. Top-up electrolyte level with distilled
water, if required.
10.3 Check battery-box condition. Clean/repair and fit, if required.
10.4 Check for the functioning of dynamo/alternator and self motor
and tighten the mountings.
10.5 Check the function of electrical appliances and condition of
fittings and replace the worn out items. Attend to problems, if
necessary.
11 BODY:
11.1 Tighten all body and cabin bolts.
11.2 Tighten driver seat mountings.
11.3 Check the function of door glasses for easy sliding. Lubricate the
door hinges.
12. SERVICE:
12.1 Water wash the vehicle and grease all nipples.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 1210E PLTFORM TRUCK – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following kk. Engine performance ll. Dash board parameters mm. Function of clutch, transmission, steering and brakes nn. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1210E PLATFORM TRUCK– QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in monthly schedule
2. ENGINE:
2.1 Lubricate with oil can control to fuel injection pump and
exhaust brake linkage ball joints.
2.2 Check and tighten, if necessary the following
s. Injector pressure lines t. Leak off fuel banjo bolts u. Heat exchanger bolts v. Oil sump screws w. Oil pressure transducer at engine block x. Exhaust manifold mounting bolts y. Fly wheel housing mounting bolts z. Turbo charger mounting fasteners aa. Clutch housing mounting bolts.
2.3 Check and tighten, if necessary the following
o. Push rod chamber cover p. Cylinder head cover q. Radiator Fuel tank brackets r. Fuel filter mounting bolts s. Air duct hose t. Engine mounting hose u. Engine breather rubber hose clamp.
2.4 Check air intake piping hoses and clamps. Replace the damaged
hoses.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1210E PLATFORM TRUCK– QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
2.5 Check service indicator. Change primary filter, if red band is in
raised position.
3. CLUTCH AND TRANSMISSION:
3.1 Remove grease cup for lubricating clutch release bearing.
Repack 3/4th full with grease and tighten by a few turns
3.2 Lubricate with oil can clutch linkages and felt pad of clutch
release bearing sleeve.
4. STEERING AND SUSPENSION:
4.1 Check and tighten, if necessary
k. U bolts of front and rear springs l. Nuts of spring pin wedge bolts m. Anti roll bar bracket mounting bolts n. Spare wheel carrier. o. Shock absorber mountings
4.2 Check and tighten, if necessary
k. Pitman arm l. Drag link rod m. Tie rod n. Steering gear box mounting bracket bolts and nuts o. Steering gear box mounting bolts
4.3 Check the steering wheel pre play. Adjust, if required.
5. BRAKES:
5.1 Check and if necessary tighten air tank mountings and air line
clamps.
5.2 Check free movement of plunger in dual brake valve.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1210E PLATFORM TRUCK– QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.3 Check for proper functioning of exhaust brake, free movement of
plunger of exhaust brake valve, mounting bolts for loosening
and slackness in linkage.
5.4 Lubricate with oil can brake chamber fork pin, linkages of foot
brake , ball joints of exhaust brake linkages – hand and foot
brake linkages.
5.5 Checks for travel of brake chamber push rod/ brake lining wear
and clearance with brake drum. Adjust service brakes, if
necessary
5.6 Check brake torque plate (carrier plate) mounting bolts and
tighten, if necessary.
5.7 Check for the brake lining wear by observing indicator and
report.
6. ELECTRICALS:
6.1 Check mountings of alternator and self motor and tighten, if
required.
6.2 Check head lamp focusing and adjust, if required.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 1210E PLATFORM TRUCK – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following
oo. Engine performance pp. Dash board parameters qq. Function of clutch, transmission, steering and brakes rr. Function of electrical system.
Annexure-4
DATE:
ENGINEER IN -CHARGE
TATA 1210E PLATFORM TRUCK – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in quarterly schedule
2. ENGINE:
2.1 Check for engine oil due and change oil in the engine sump
while the engine is hot. Change oil filter.
2.2 Check coolant concentration.
2.3 Change two fuel filters and O rings. Bleed the system.
3. GEARBOX:
3.1 Change in oil in gearbox while hot.
3.2 Check and tighten, if necessary gearbox mountings, propeller
shaft coupling flange bolts and center joint bearing support
brackets
4 AXLES:
4.1 Check crown wheel thrust pad and adjust, if necessary.
4.2 Check and tighten, if necessary, carrier and rear cover mounting
nuts. Also tighten axle shaft cover mounting bolts.
4.3 Remove front hub cap, fill 3/4th full with wheel bearing grease
and refit.
4.4 Check wheel alignment and adjust, if necessary.
5. STEERING AND SUSPENSION:
5.1 Check mountings of spare wheel carrier and tighten, if
necessary.
5.2 Check shock absorber and replace, if necessary.
Annexure-4
DATE:
ENGINEER IN -CHARGE
TATA 1210E PLATFORM TRUCK – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.3 Check the condition of shock absorber rubber bushes and
replace, if necessary.
6. BRAKES:
6.1 Check air brake rubber hoses / air pipes for damages / leaks
and replace, if required.
6.2 Check the condition of gaiter in different brake valves, exhaust
flap in dual brake valve, exhaust check diaphragm in valve,
nylon breather tube and clips of spring brake actuator. Replace,
if found damaged / deteriorated.
6.3 Check mounting bolts of brake chambers, different valve
mountings, air tank mountings, air cylinder mounting, master
cylinder mountings, air line clamps hydraulic pipes and tighten,
if necessary.
7. ELECTRICALS:
7.1 Check the mountings of alternator / self motor and tighten, if
necessary.
7.2 Lubricate the pinion bush of self motor and wiper motor
linkages.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 1210E PLATFORM TRUCK – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following ss. Engine performance tt. Dash board parameters uu. Function of clutch, transmission, steering and brakes vv. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1210E PLATFORM TRUCK – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in half yearly schedule
2. ENGINE:
2.1 Remove the fuel tank, clean and refit. Check the condition of
strainer and replace, if required.
2.2 Remove and clean the spark arrester and refit.
2.3 Check the end play of turbo charger shaft and radial clearance
between turbine wheel and housing.
2.4 Check fan hub and drive belt tensioner bearing.
2.5 Check valve clearance and adjust, if required.
2.6 Check the condition of vibration damper and report.
2.7 Remove the injectors, check and reset the pressure (if required
only)
3. CLUTCH AND GEARBOX:
3.1 Clean gearbox breather.
3.2 Overhaul clutch master and slave cylinder with new kits.
3.3 Replace differential oil.
3.4 Remove front wheel and rear wheel hubs, dismantle and clean
bearing and other components. Replace damaged / worn out
parts. Repack with fresh wheel bearing grease and refit. Adjust
wheel hub play.
4 STEERING AND SUSPENSION;
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1210E PLATFORM TRUCK – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
4.1 Change oil in power steering system. Replace filter and cartridge.
4.2 Dismantle front and rear springs. Clean and inspect leaves.
Check and replace bushes if necessary. Apply graphite grease on
leaves and reassemble.
5. BRAKES:
5.1 Overhaul the pneumatic aggregates of the brake system with
replacement of new kits.
5.2 Remove brake drums, inspect the brake linings, brake drums
etc. Rectify for defects.
5.3 Remove the air filter element, clean and refit.
6. ELECTRICALS:
6.1 Overhaul the self motor and alternator and refit.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 1210E PLATFORM TRUCK – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. While work is in progress, inspect the dismantled items for over hauling for arranging replacement.
2 Ensure that all the works have been completed as per schedule.
3 Take the vehicle for road test and check the following ww. Engine performance xx. Dash board parameters yy. Function of clutch, transmission, steering and brakes zz. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA ACE – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Carry out all maintenance works as per monthly service
schedule
2. ENGINE:
2.1 Check for engine oil due and change engine oil and oil filter
cartridge.
2.2 Change fuel filter element –Fuel tank.
2.3 Change fuel filter elements.
2.4 Clean breather and check hoses for leaks. Replace, if required.
2.5 Clean air filter element. Replace, if red band appears on service
indicator.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA ACE – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
3 Tighten all fasteners:
Front grill- Oil Sump- Oil and fuel lines – Fuel filter mountings –
Exhaust manifold and pipe – Air filter – Engine and clutch
housing – Radiator mountings – Accelerator Cable – Radiator
hoses – Propeller Shaft fittings – U bolts and Nuts of springs –
Joints of Pitman arm – All steering links – Brake rods – Upper
ball joints of fish bone – Mountings of lower and upper links –
Steering gear box and mounting bracket – Vacuum and
hydraulic line connections – Head lamp mountings – Cabin and
body mountings – Anti roll bar mountings – Vacuum servo unit –
Master cylinder mountings – Slave cylinder mountings – Rear
anchor plate mountings – Front disc brake mountings – Fuel
tank strap fittings – Front suspension rubber mounting nut.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA ACE – QUARTELY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the works have been completed as per schedule.
2. Take the vehicle for road test and check the following i. Engine performance j. Dash board parameters k. Function of clutch, transmission, steering and brakes l. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA ACE – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Carry out all maintenance works as per quarterly service
schedule
2. ENGINE:
2.1 Check timing belt, adjust tension, if required replace.
3. AXLES & GEARBOX.
3.1 Check for oil change due for rear axle and gearbox. Change, if
required.
4. STEERING:
4.1 Check wheel alignment and adjust, if necessary.
5 BRAKES:
5.1 Check front brake pads and rear brake linings. Replace, if
required.
6. ELECTRICAL:
6.1 Apply graphite grease on starter motor pinion bushing.
6.2 Grease the wiper motor linkages.
6.3 Check head light focusing and readjust, if required.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA ACE – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
6.4 Check for the continuity/shot circuit of glow plugs. Replace, if
required.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA ACE – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the works have been completed as per schedule.
2. Take the vehicle for road test and check the following m. Engine performance n. Dash board parameters o. Function of clutch, transmission, steering and brakes
p. Function of electrical system.
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA ACE – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Carry out all maintenance works as per half yearly service
schedule
2. ENGINE:
2.1 Check injection nozzle for opening pressure and spray
characteristics.
2.2 Change coolant in cooling system.
2.3 Replace timing belt.
3 AXLES:
3.1 Change grease in wheel hubs and adjust the bearing play.
4. SUSPENSION AND STEERING:
4.1 Check and adjust steering wheel pre play.
4.2 Replace oil in steering gear box.
4.3 Check the condition of rubber bushes in the following and
replace, if required.
f. Top wish bone g. Lower Link h. Anti roll bar i. Rear Links j. Pan hard rod.
5. BRAKES:
Annexure-4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA ACE – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.1 Overhaul the following brake components and change brake
fluid in the system.
Tandem master cylinder – Front caliper –Rear wheel cylinders –
Clutch master cylinder and slave cylinder
5.2 Overhaul the vacuum booster and change the felt and
polyurethane filters along with the rubber bellow.
6. ELECTRICAL :
6.1 Over haul the wiper motor, self-motor and alternator and replace
the worn out items.
Annexure-4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA ACE – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. While work is in progress, inspect the dismantled items for over hauling for arranging replacement.
2 Ensure that all the works have been completed as per schedule.
3 Take the vehicle for road test and check the following aaa. Engine performance bbb. Dash board parameters ccc. Function of clutch, transmission, steering and brakes ddd. Function of electrical system.
Annexure -4
MAINTENANCE CHECKLIST
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No
Equip Identification No. Equipment Sl No Equip Identification No. Equipment
1 VALF/HA/5T/01 TATA 1613 EXPLOSIVES VAN 1 AP26U2673 TATA 207 MINI EXPLOSIVE VAN
2 VALF/HA/4T/01 TATA 407 MINI EXPLOSIVES VAN 2 SPROB/HA/5T/01 TATA 1613 EXPLOSIVES VAN
3 VALF/HA/4T/02 TATA 407 UPLINK VEHICLE 3 VALF/HA/4T/01 TATA 407 MINI EXPLOSIVES VAN
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 207 MINI EXPLOSIVE VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Carry out all maintenance works as per monthly service
schedule
2. ENGINE:
2.1 Check for engine oil due and change engine oil and oil filter
cartridge.
2.2 Change fuel filter element –Fuel tank.
2.3 Change fuel filter elements.
2.4 Clean breather and check hoses for leaks. Replace, if required.
2.5 Clean air filter element. Replace, if red band appears on service
indicator.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 207 MINI EXPLOSIVE VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
3 Tighten all fasteners:
Front grill- Oil Sump- Oil and fuel lines – Fuel filter mountings –
Exhaust manifold and pipe – Air filter – Engine and clutch
housing – Radiator mountings – Accelerator Cable – Radiator
hoses – Propeller Shaft fittings – U bolts and Nuts of springs –
Joints of Pitman arm – All steering links – Brake rods – Upper
ball joints of fish bone – Mountings of lower and upper links –
Steering gear box and mounting bracket – Vacuum and
hydraulic line connections – Head lamp mountings – Cabin and
body mountings – Anti roll bar mountings – Vacuum servo unit –
Master cylinder mountings – Slave cylinder mountings – Rear
anchor plate mountings – Front disc brake mountings – Fuel
tank strap fittings – Front suspension rubber mounting nut.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 207 MINI EXPLOSIVE VAN – QUARTELY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the works have been completed as per schedule.
2. Take the vehicle for road test and check the following a. Engine performance b. Dash board parameters c. Function of clutch, transmission, steering and brakes d. Function of electrical system.
Annexure -4
TATA MOBILE 207 MINI EXPLOSIVE VAN – HALF YEARLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
12 AP26U2673 TATA 207 MINI EXPLOSIVE VAN
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 207 MINI EXPLOSIVE VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Carry out all maintenance works as per quarterly service
schedule
2. ENGINE:
2.1 Check timing belt, adjust tension, if required replace.
3. AXLES & GEARBOX.
3.1 Check for oil change due for rear axle and gearbox. Change, if
required.
4. STEERING:
4.1 Check wheel alignment and adjust, if necessary.
5 BRAKES:
5.1 Check front brake pads and rear brake linings. Replace, if
required.
6. ELECTRICAL:
6.1 Apply graphite grease on starter motor pinion bushing.
6.2 Grease the wiper motor linkages.
6.3 Check head light focusing and readjust, if required.
6.4 Check for the continuity/shot circuit of glow plugs. Replace, if
required.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 207 MINI EXPLOSIVE VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the works have been completed as per schedule.
2. Take the vehicle for road test and check the following e. Engine performance f. Dash board parameters g. Function of clutch, transmission, steering and brakes
h. Function of electrical system.
Annexure -4
TATA MOBILE 207 MINI EXPLOSIVE VAN – ANNUAL MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
12 AP26U2673 TATA 207 MINI EXPLOSIVE VAN
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 207 MINI EXPLOSIVE VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Carry out all maintenance works as per half yearly service
schedule
2. ENGINE:
2.1 Check injection nozzle for opening pressure and spray
characteristics.
2.2 Change coolant in cooling system.
2.3 Replace timing belt.
3 AXLES:
3.1 Change grease in wheel hubs and adjust the bearing play.
4. SUSPENSION AND STEERING:
4.1 Check and adjust steering wheel pre play.
4.2 Replace oil in steering gear box.
4.3 Check the condition of rubber bushes in the following and
replace, if required.
a. Top wish bone b. Lower Link c. Anti roll bar d. Rear Links e. Pan hard rod.
5. BRAKES:
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 207 MINI EXPLOSIVE VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.1 Overhaul the following brake components and change brake
fluid in the system.
Tandem master cylinder – Front caliper –Rear wheel cylinders –
Clutch master cylinder and slave cylinder
5.2 Overhaul the vacuum booster and change the felt and
polyurethane filters along with the rubber bellow.
6. ELECTRICAL :
6.1 Over haul the wiper motor, self-motor and alternator and replace
the worn out items.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 207 MINI EXPLOSIVE VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. While work is in progress, inspect the dismantled items for over hauling for arranging replacement.
2 Ensure that all the works have been completed as per schedule.
3 Take the vehicle for road test and check the following a. Engine performance b. Dash board parameters c. Function of clutch, transmission, steering and brakes d. Function of electrical system.
Annexure -4
TATA 1613 EXPLOSIVE VAN – MONTHLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
1 AP26 X 1954 TATA 1613 EXPLOSIVES VAN
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1613 EXPLOSIVE VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. ENGINE:
1.1 Check oil level and top-up, if required
1.2 Check coolant level in the radiator and top-up, if required.
1.3 Check for leakage of coolant and rectify.
1.4 Check the condition of radiator cap and replace, if required.
1.5 Check the condition of radiator hoses and replace the worn out
ones.
1.6 Check fuel and lubricating oil lines for leaks and rectify. Remove
the FI pump bowl filter, clean and refit. Remove air lock in fuel
line.
1.7 Check the engine mountings.
1.8 Check the air cleaner and clean, if required.
1.9 Check fan belt tension and adjust, if required. (Max deflection
10-15mm on longer span)
1.10 Lubricate the fuel pump.
1.11 Lubricate the accelerator linkages.
1.12 Check the exhaust pipe lines and spark arrester for leaks and
correct, if required.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1613 EXPLOSIVE VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1.13 Start the engine and check oil pressure, temperature and
dashboard parameters for functioning..
2. CLUTCH:
2.1 Check proper functioning of clutch and adjust.
2.2 Adjust the clutch pedal play, if required.
2.3 Lubricate the clutch linkages with oilcan.
2.4
3. TRANSMISSION:
3.1 Check oil level in the transmission and top-up, if required.
3.2 Check for any leaks in the transmission oil lines and rectify.
3.3 Check for proper engagement of gears.
4. REAR AXLE:
4.1 Check oil level in the differential housing and top-up, if required.
4.2 Check and tighten differential cover mounting bolts, axle shaft
cover bolts and tighten, if required.
5. WHEELS:
5.1 Check the condition of tyres. Replace, if required.
5.2 Check all wheel discs bolts and tighten, if required
5.3 Inflate the tyres Front 5.0 ksc Rear 5.5 ksc.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1613 EXPLOSIVE VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.4 Check and ensure that the rear wheels are not rubbing with
springs.
6. SPRINGS:
6.1 Check all springs visually for any breakage of leaves, missing of
fasteners and dislocation of leaves etc. Rectify, if required.
6.2 Check shock absorber mountings and shock absorbers for
leakage.
7 BRAKES:
7.1 Check and adjust brake pedal play, if required.
7.2 Check and brakes, if required.
7.3 Drain the air tank.
7.4 Lubricate the brake linkages.
7.5 Check the condition of brake line rubber components (like boots,
pipes etc.) and replace, if required.
8 STEERING:
8.1 Lubricate the steering linkages with oil
8.2 Check oil in power steering hydraulic tank and top-up, if
required. Check hydraulic piping connections for leaks and
rectify, if any.
8.3 Check and tighten steering linkages. Check for the presence of
cotter pins and rubber boots in tie rod end nuts and kingpin
lock bolts.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1613 EXPLOSIVE VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
9. PROPELLER SHAFTS.
9.1 Check the condition of center joint mountings, bearings and
presence of rubber boots.
9.2 Check all propeller shaft crosses for any shake and presence of
grease.
10. ELECTRICAL:
10.1 Clean the battery terminals and apply petroleum jelly and
tighten terminals.
10.2 Check battery electrolyte level and specific gravity. The specific
gravity should be 1.2. Top-up electrolyte level with distilled
water, if required.
10.3 Check battery-box condition. Clean/repair and fit, if required.
10.4 Check for the functioning of dynamo/alternator and self motor
and tighten the mountings.
10.5 Check the function of electrical appliances and condition of
fittings and replace the worn out items. Attend to problems, if
necessary.
11 BODY:
11.1 Tighten all body and cabin bolts.
11.2 Tighten driver seat mountings.
11.3 Check the function of door glasses for easy sliding. Lubricate the
door hinges.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1613 EXPLOSIVE VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
12. SERVICE:
12.1 Water wash the vehicle and grease all nipples.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 1613 EXPLOSIVE VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following e. Engine performance f. Dash board parameters g. Function of clutch, transmission, steering and brakes h. Function of electrical system.
Annexure -4
TATA 1613 EXPLOSIVE VAN – QUARTERLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
13 AP26U7150 TATA 1613 EXPLOSIVE VAN
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1613 EXPLOSIVE VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in monthly schedule
2. ENGINE:
2.1 Lubricate with oil can control to fuel injection pump and
exhaust brake linkage ball joints.
2.2 Check and tighten, if necessary the following
a. Injector pressure lines
b. Leak off fuel banjo bolts c. Heat exchanger bolts d. Oil sump screws e. Oil pressure transducer at engine block f. Exhaust manifold mounting bolts g. Fly wheel housing mounting bolts h. Turbo charger mounting fasteners i. Clutch housing mounting bolts.
2.3 Check and tighten, if necessary the following
a. Push rod chamber cover b. Cylinder head cover c. Radiator Fuel tank brackets d. Fuel filter mounting bolts e. Air duct hose f. Engine mounting hose g. Engine breather rubber hose clamp.
2.4 Check air intake piping hoses and clamps. Replace the damaged
hoses.
2.5 Check service indicator. Change primary filter, if red band is in
raised position.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1613 EXPLOSIVE VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
3. CLUTCH AND TRANSMISSION:
3.1 Remove grease cup for lubricating clutch release bearing.
Repack 3/4th full with grease and tighten by a few turns
3.2 Lubricate with oil can clutch linkages and felt pad of clutch
release bearing sleeve.
4. STEERING AND SUSPENSION:
4.1 Check and tighten, if necessary
a. U bolts of front and rear springs b. Nuts of spring pin wedge bolts c. Anti roll bar bracket mounting bolts d. Spare wheel carrier. e. Shock absorber mountings
4.2 Check and tighten, if necessary
a. Pitman arm b. Drag link rod c. Tie rod d. Steering gear box mounting bracket bolts and nuts e. Steering gear box mounting bolts
4.3 Check the steering wheel pre play. Adjust, if required.
5. BRAKES:
5.1 Check and if necessary tighten air tank mountings and air line
clamps.
5.2 Check free movement of plunger in dual brake valve.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1613 EXPLOSIVE VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.3 Check for proper functioning of exhaust brake, free movement of
plunger of exhaust brake valve, mounting bolts for loosening
and slackness in linkage.
5.4 Lubricate with oil can brake chamber fork pin, linkages of foot
brake , ball joints of exhaust brake linkages – hand and foot
brake linkages.
5.5 Checks for travel of brake chamber push rod/ brake lining wear
and clearance with brake drum. Adjust service brakes, if
necessary
5.6 Check brake torque plate (carrier plate) mounting bolts and
tighten, if necessary.
5.7 Check for the brake lining wear by observing indicator and
report.
6. ELECTRICALS:
6.1 Check mountings of alternator and self motor and tighten, if
required.
6.2 Check head lamp focusing and adjust, if required.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 1613 EXPLOSIVE VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following
i. Engine performance j. Dash board parameters k. Function of clutch, transmission, steering and brakes l. Function of electrical system.
Annexure -4
TATA 1613 EXPLOSIVE VAN – HALF YEARLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
13 AP26U7150 TATA 1613 EXPLOSIVE VAN
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1613 EXPLOSIVE VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in quarterly schedule
2. ENGINE:
2.1 Check for engine oil due and change oil in the engine sump
while the engine is hot. Change oil filter.
2.2 Check coolant concentration.
2.3 Change two fuel filters and O rings. Bleed the system.
3. GEARBOX:
3.1 Change in oil in gearbox while hot.
3.2 Check and tighten, if necessary gearbox mountings, propeller
shaft coupling flange bolts and center joint bearing support
brackets
4 AXLES:
4.1 Check crown wheel thrust pad and adjust, if necessary.
4.2 Check and tighten, if necessary, carrier and rear cover mounting
nuts. Also tighten axle shaft cover mounting bolts.
4.3 Remove front hub cap, fill 3/4th full with wheel bearing grease
and refit.
4.4 Check wheel alignment and adjust, if necessary.
5. STEERING AND SUSPENSION:
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1613 EXPLOSIVE VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.1 Check mountings of spare wheel carrier and tighten, if
necessary.
5.2 Check shock absorber and replace, if necessary.
5.3 Check the condition of shock absorber rubber bushes and
replace, if necessary.
6. BRAKES:
6.1 Check air brake rubber hoses / air pipes for damages / leaks
and replace, if required.
6.2 Check the condition of gaiter in different brake valves, exhaust
flap in dual brake valve, exhaust check diaphragm in valve,
nylon breather tube and clips of spring brake actuator. Replace,
if found damaged / deteriorated.
6.3 Check mounting bolts of brake chambers, different valve
mountings, air tank mountings, air cylinder mounting, master
cylinder mountings, air line clamps hydraulic pipes and tighten,
if necessary.
7. ELECTRICALS:
7.1 Check the mountings of alternator / self motor and tighten, if
necessary.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1613 EXPLOSIVE VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
7.2 Lubricate the pinion bush of self motor and wiper motor
linkages.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 1613 EXPLOSIVE VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following m. Engine performance n. Dash board parameters o. Function of clutch, transmission, steering and brakes p. Function of electrical system.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1613 EXPLOSIVE VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in half yearly schedule
2. ENGINE:
2.1 Remove the fuel tank, clean and refit. Check the condition of
strainer and replace, if required.
2.2 Remove and clean the spark arrester and refit.
2.3 Check the end play of turbo charger shaft and radial clearance
between turbine wheel and housing.
2.4 Check fan hub and drive belt tensioner bearing.
2.5 Check valve clearance and adjust, if required.
2.6 Check the condition of vibration damper and report.
2.7 Remove the injectors, check and reset the pressure (if required
only)
3. CLUTCH AND GEARBOX:
3.1 Clean gearbox breather.
3.2 Overhaul clutch master and slave cylinder with new kits.
3.3 Replace differential oil.
3.4 Remove front wheel and rear wheel hubs, dismantle and clean
bearing and other components. Replace damaged / worn out
parts. Repack with fresh wheel bearing grease and refit. Adjust
wheel hub play.
4. STEERING AND SUSPENSION;
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 1613 EXPLOSIVE VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
4.1 Change oil in power steering system. Replace filter and cartridge.
4.2 Dismantle front and rear springs. Clean and inspect leaves.
Check and replace bushes if necessary. Apply graphite grease on
leaves and reassemble.
5. BRAKES:
5.1 Overhaul the pneumatic aggregates of the brake system with
replacement of new kits.
5.2 Remove brake drums, inspect the brake linings, brake drums
etc. Rectify for defects.
5.3 Remove the air filter element, clean and refit.
6. ELECTRICALS:
6.1 Overhaul the self motor and alternator and refit.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 1613 EXPLOSIVE VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. While work is in progress, inspect the dismantled items for over hauling for arranging replacement.
2 Ensure that all the works have been completed as per schedule.
3 Take the vehicle for road test and check the following q. Engine performance r. Dash board parameters s. Function of clutch, transmission, steering and brakes t. Function of electrical system.
Annexure -4
TATA 407 EXPLOSIVE VAN – MONTHLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
1 AP26 X 1954 TATA 1613 EXPLOSIVES VAN
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 EXPLOSIVE VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. ENGINE:
1.1 Check oil level and top-up, if required
1.2 Check coolant level in the radiator and top-up, if required.
1.3 Check for leakage of coolant and rectify.
1.4 Check the condition of radiator cap and replace, if required.
1.5 Check the condition of radiator hoses and replace the worn out
ones.
1.6 Check fuel and lubricating oil lines for leaks and rectify. Remove
the FI pump bowl filter, clean and refit. Remove air lock in fuel
line.
1.7 Check the engine mountings.
1.8 Check the air cleaner and clean, if required.
1.9 Check fan belt tension and adjust, if required. (Max deflection
10-15mm on longer span)
1.10 Lubricate the fuel pump.
1.11 Lubricate the accelerator linkages.
1.12 Check the exhaust pipe lines and spark arrester for leaks and
correct, if required.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 EXPLOSIVE VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1.13 Start the engine and check oil pressure, temperature and
dashboard parameters for functioning..
2. CLUTCH:
2.1 Check proper functioning of clutch and adjust.
2.2 Adjust the clutch pedal play, if required.
2.3 Lubricate the clutch linkages with oilcan.
2.4
3. TRANSMISSION:
3.1 Check oil level in the transmission and top-up, if required.
3.2 Check for any leaks in the transmission oil lines and rectify.
3.3 Check for proper engagement of gears.
4. REAR AXLE:
4.1 Check oil level in the differential housing and top-up, if required.
4.2 Check and tighten differential cover mounting bolts, axle shaft
cover bolts and tighten, if required.
5. WHEELS:
5.1 Check the condition of tyres. Replace, if required.
5.2 Check all wheel discs bolts and tighten, if required
5.3 Inflate the tyres Front 5.0 ksc Rear 5.5 ksc.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 EXPLOSIVE VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.4 Check and ensure that the rear wheels are not rubbing with
springs.
6. SPRINGS:
6.1 Check all springs visually for any breakage of leaves, missing of
fasteners and dislocation of leaves etc. Rectify, if required.
6.2 Check shock absorber mountings and shock absorbers for
leakage.
7 BRAKES:
7.1 Check and adjust brake pedal play, if required.
7.2 Check and brakes, if required.
7.3 Drain the air tank.
7.4 Lubricate the brake linkages.
7.5 Check the condition of brake line rubber components (like boots,
pipes etc.) and replace, if required.
8 STEERING:
8.1 Lubricate the steering linkages with oil
8.2 Check oil in power steering hydraulic tank and top-up, if
required. Check hydraulic piping connections for leaks and
rectify, if any.
8.3 Check and tighten steering linkages. Check for the presence of
cotter pins and rubber boots in tie rod end nuts and kingpin
lock bolts.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 EXPLOSIVE VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
9. PROPELLER SHAFTS.
9.1 Check the condition of center joint mountings, bearings and
presence of rubber boots.
9.2 Check all propeller shaft crosses for any shake and presence of
grease.
10. ELECTRICAL:
10.1 Clean the battery terminals and apply petroleum jelly and
tighten terminals.
10.2 Check battery electrolyte level and specific gravity. The specific
gravity should be 1.2. Top-up electrolyte level with distilled
water, if required.
10.3 Check battery-box condition. Clean/repair and fit, if required.
10.4 Check for the functioning of dynamo/alternator and self motor
and tighten the mountings.
10.5 Check the function of electrical appliances and condition of
fittings and replace the worn out items. Attend to problems, if
necessary.
11 BODY:
11.1 Tighten all body and cabin bolts.
11.2 Tighten driver seat mountings.
11.3 Check the function of door glasses for easy sliding. Lubricate the
door hinges.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 EXPLOSIVE VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
12. SERVICE:
12.1 Water wash the vehicle and grease all nipples.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 407 EXPLOSIVE VAN – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following u. Engine performance v. Dash board parameters w. Function of clutch, transmission, steering and brakes x. Function of electrical system.
Annexure -4
TATA 407 EXPLOSIVE VAN – QUARTERLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
13 AP26U7150 TATA 1613 EXPLOSIVE VAN
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 EXPLOSIVE VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in monthly schedule
2. ENGINE:
2.1 Lubricate with oil can control to fuel injection pump and
exhaust brake linkage ball joints.
2.2 Check and tighten, if necessary the following
j. Injector pressure lines
k. Leak off fuel banjo bolts l. Heat exchanger bolts m. Oil sump screws n. Oil pressure transducer at engine block o. Exhaust manifold mounting bolts p. Fly wheel housing mounting bolts q. Turbo charger mounting fasteners r. Clutch housing mounting bolts.
2.3 Check and tighten, if necessary the following
h. Push rod chamber cover i. Cylinder head cover j. Radiator Fuel tank brackets k. Fuel filter mounting bolts l. Air duct hose m. Engine mounting hose n. Engine breather rubber hose clamp.
2.4 Check air intake piping hoses and clamps. Replace the damaged
hoses.
2.5 Check service indicator. Change primary filter, if red band is in
raised position.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 EXPLOSIVE VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
3. CLUTCH AND TRANSMISSION:
3.1 Remove grease cup for lubricating clutch release bearing.
Repack 3/4th full with grease and tighten by a few turns
3.2 Lubricate with oil can clutch linkages and felt pad of clutch
release bearing sleeve.
4. STEERING AND SUSPENSION:
4.1 Check and tighten, if necessary
f. U bolts of front and rear springs g. Nuts of spring pin wedge bolts h. Anti roll bar bracket mounting bolts i. Spare wheel carrier. j. Shock absorber mountings
4.2 Check and tighten, if necessary
f. Pitman arm g. Drag link rod h. Tie rod i. Steering gear box mounting bracket bolts and nuts j. Steering gear box mounting bolts
4.3 Check the steering wheel pre play. Adjust, if required.
5. BRAKES:
5.1 Check and if necessary tighten air tank mountings and air line
clamps.
5.2 Check free movement of plunger in dual brake valve.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 EXPLOSIVE VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.3 Check for proper functioning of exhaust brake, free movement of
plunger of exhaust brake valve, mounting bolts for loosening
and slackness in linkage.
5.4 Lubricate with oil can brake chamber fork pin, linkages of foot
brake , ball joints of exhaust brake linkages – hand and foot
brake linkages.
5.5 Checks for travel of brake chamber push rod/ brake lining wear
and clearance with brake drum. Adjust service brakes, if
necessary
5.6 Check brake torque plate (carrier plate) mounting bolts and
tighten, if necessary.
5.7 Check for the brake lining wear by observing indicator and
report.
6. ELECTRICALS:
6.1 Check mountings of alternator and self motor and tighten, if
required.
6.2 Check head lamp focusing and adjust, if required.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 407 EXPLOSIVE VAN – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following
y. Engine performance z. Dash board parameters aa. Function of clutch, transmission, steering and brakes bb. Function of electrical system.
Annexure -4
TATA 407 EXPLOSIVE VAN – HALF YEARLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
1 AP26TT0511 TATA 407 MINI EXPLOSIVES VAN 1 AP26U7150 TATA 1613 EXPLOSIVE VAN
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 EXPLOSIVE VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in quarterly schedule
2. ENGINE:
2.1 Check for engine oil due and change oil in the engine sump
while the engine is hot. Change oil filter.
2.2 Check coolant concentration.
2.3 Change two fuel filters and O rings. Bleed the system.
3. GEARBOX:
3.1 Change in oil in gearbox while hot.
3.2 Check and tighten, if necessary gearbox mountings, propeller
shaft coupling flange bolts and center joint bearing support
brackets
4 AXLES:
4.1 Check crown wheel thrust pad and adjust, if necessary.
4.2 Check and tighten, if necessary, carrier and rear cover mounting
nuts. Also tighten axle shaft cover mounting bolts.
4.3 Remove front hub cap, fill 3/4th full with wheel bearing grease
and refit.
4.4 Check wheel alignment and adjust, if necessary.
5. STEERING AND SUSPENSION:
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 EXPLOSIVE VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.1 Check mountings of spare wheel carrier and tighten, if
necessary.
5.2 Check shock absorber and replace, if necessary.
5.3 Check the condition of shock absorber rubber bushes and
replace, if necessary.
6. BRAKES:
6.1 Check air brake rubber hoses / air pipes for damages / leaks
and replace, if required.
6.2 Check the condition of gaiter in different brake valves, exhaust
flap in dual brake valve, exhaust check diaphragm in valve,
nylon breather tube and clips of spring brake actuator. Replace,
if found damaged / deteriorated.
6.3 Check mounting bolts of brake chambers, different valve
mountings, air tank mountings, air cylinder mounting, master
cylinder mountings, air line clamps hydraulic pipes and tighten,
if necessary.
7. ELECTRICALS:
7.1 Check the mountings of alternator / self motor and tighten, if
necessary.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 EXPLOSIVE VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
7.2 Lubricate the pinion bush of self motor and wiper motor
linkages.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 407 EXPLOSIVE VAN – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following cc. Engine performance dd. Dash board parameters ee. Function of clutch, transmission, steering and brakes ff. Function of electrical system.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 EXPLOSIVE VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in half yearly schedule
2. ENGINE:
2.1 Remove the fuel tank, clean and refit. Check the condition of
strainer and replace, if required.
2.2 Remove and clean the spark arrester and refit.
2.3 Check the end play of turbo charger shaft and radial clearance
between turbine wheel and housing.
2.4 Check fan hub and drive belt tensioner bearing.
2.5 Check valve clearance and adjust, if required.
2.6 Check the condition of vibration damper and report.
2.7 Remove the injectors, check and reset the pressure (if required
only)
3. CLUTCH AND GEARBOX:
3.1 Clean gearbox breather.
3.2 Overhaul clutch master and slave cylinder with new kits.
3.3 Replace differential oil.
3.4 Remove front wheel and rear wheel hubs, dismantle and clean
bearing and other components. Replace damaged / worn out
parts. Repack with fresh wheel bearing grease and refit. Adjust
wheel hub play.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 EXPLOSIVE VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
4 STEERING AND SUSPENSION;
4.1 Change oil in power steering system. Replace filter and cartridge.
4.2 Dismantle front and rear springs. Clean and inspect leaves.
Check and replace bushes if necessary. Apply graphite grease on
leaves and reassemble.
5. BRAKES:
5.1 Overhaul the pneumatic aggregates of the brake system with
replacement of new kits.
5.2 Remove brake drums, inspect the brake linings, brake drums
etc. Rectify for defects.
5.3 Remove the air filter element, clean and refit.
6. ELECTRICALS:
6.1 Overhaul the self motor and alternator and refit.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 407 EXPLOSIVE VAN – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. While work is in progress, inspect the dismantled items for over hauling for arranging replacement.
2 Ensure that all the works have been completed as per schedule.
3 Take the vehicle for road test and check the following gg. Engine performance hh. Dash board parameters ii. Function of clutch, transmission, steering and brakes jj. Function of electrical system.
Annexure -4
TATA 407 UPLINK VEHICLE – MONTHLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
1 TATA 407 UPLINK VEHICLE
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 UPLINK VEHICLE – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. ENGINE:
1.1 Check oil level and top-up, if required
1.2 Check coolant level in the radiator and top-up, if required.
1.3 Check for leakage of coolant and rectify.
1.4 Check the condition of radiator cap and replace, if required.
1.5 Check the condition of radiator hoses and replace the worn out
ones.
1.6 Check fuel and lubricating oil lines for leaks and rectify. Remove
the FI pump bowl filter, clean and refit. Remove air lock in fuel
line.
1.7 Check the engine mountings.
1.8 Check the air cleaner and clean, if required.
1.9 Check fan belt tension and adjust, if required. (Max deflection
10-15mm on longer span)
1.10 Lubricate the fuel pump.
1.11 Lubricate the accelerator linkages.
1.12 Check the exhaust pipe lines and spark arrester for leaks and
correct, if required.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 UPLINK VEHICLE – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1.13 Start the engine and check oil pressure, temperature and
dashboard parameters for functioning..
2. CLUTCH:
2.1 Check proper functioning of clutch and adjust.
2.2 Adjust the clutch pedal play, if required.
2.3 Lubricate the clutch linkages with oilcan.
2.4
3. TRANSMISSION:
3.1 Check oil level in the transmission and top-up, if required.
3.2 Check for any leaks in the transmission oil lines and rectify.
3.3 Check for proper engagement of gears.
4. REAR AXLE:
4.1 Check oil level in the differential housing and top-up, if required.
4.2 Check and tighten differential cover mounting bolts, axle shaft
cover bolts and tighten, if required.
5. WHEELS:
5.1 Check the condition of tyres. Replace, if required.
5.2 Check all wheel discs bolts and tighten, if required
5.3 Inflate the tyres Front 5.0 ksc Rear 5.5 ksc.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 UPLINK VEHICLE – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.4 Check and ensure that the rear wheels are not rubbing with
springs.
6. SPRINGS:
6.1 Check all springs visually for any breakage of leaves, missing of
fasteners and dislocation of leaves etc. Rectify, if required.
6.2 Check shock absorber mountings and shock absorbers for
leakage.
7 BRAKES:
7.1 Check and adjust brake pedal play, if required.
7.2 Check and brakes, if required.
7.3 Drain the air tank.
7.4 Lubricate the brake linkages.
7.5 Check the condition of brake line rubber components (like boots,
pipes etc.) and replace, if required.
8 STEERING:
8.1 Lubricate the steering linkages with oil
8.2 Check oil in power steering hydraulic tank and top-up, if
required. Check hydraulic piping connections for leaks and
rectify, if any.
8.3 Check and tighten steering linkages. Check for the presence of
cotter pins and rubber boots in tie rod end nuts and kingpin
lock bolts.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 UPLINK VEHICLE – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
9. PROPELLER SHAFTS.
9.1 Check the condition of center joint mountings, bearings and
presence of rubber boots.
9.2 Check all propeller shaft crosses for any shake and presence of
grease.
10. ELECTRICAL:
10.1 Clean the battery terminals and apply petroleum jelly and
tighten terminals.
10.2 Check battery electrolyte level and specific gravity. The specific
gravity should be 1.2. Top-up electrolyte level with distilled
water, if required.
10.3 Check battery-box condition. Clean/repair and fit, if required.
10.4 Check for the functioning of dynamo/alternator and self motor
and tighten the mountings.
10.5 Check the function of electrical appliances and condition of
fittings and replace the worn out items. Attend to problems, if
necessary.
11 BODY:
11.1 Tighten all body and cabin bolts.
11.2 Tighten driver seat mountings.
11.3 Check the function of door glasses for easy sliding. Lubricate the
door hinges.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 UPLINK VEHICLE – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
12. SERVICE:
12.1 Water wash the vehicle and grease all nipples.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 407 UPLINK VEHICLE – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following kk. Engine performance ll. Dash board parameters mm. Function of clutch, transmission, steering and brakes nn. Function of electrical system.
Annexure -4
TATA 407 UPLINK VEHICLE – QUARTERLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 UPLINK VEHICLE – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in monthly schedule
2. ENGINE:
2.1 Lubricate with oil can control to fuel injection pump and
exhaust brake linkage ball joints.
2.2 Check and tighten, if necessary the following
s. Injector pressure lines
t. Leak off fuel banjo bolts u. Heat exchanger bolts v. Oil sump screws w. Oil pressure transducer at engine block x. Exhaust manifold mounting bolts y. Fly wheel housing mounting bolts z. Turbo charger mounting fasteners aa. Clutch housing mounting bolts.
2.3 Check and tighten, if necessary the following
o. Push rod chamber cover p. Cylinder head cover q. Radiator Fuel tank brackets r. Fuel filter mounting bolts s. Air duct hose t. Engine mounting hose u. Engine breather rubber hose clamp.
2.4 Check air intake piping hoses and clamps. Replace the damaged
hoses.
2.5 Check service indicator. Change primary filter, if red band is in
raised position.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 UPLINK VEHICLE – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
3. CLUTCH AND TRANSMISSION:
3.1 Remove grease cup for lubricating clutch release bearing.
Repack 3/4th full with grease and tighten by a few turns
3.2 Lubricate with oil can clutch linkages and felt pad of clutch
release bearing sleeve.
4. STEERING AND SUSPENSION:
4.1 Check and tighten, if necessary
k. U bolts of front and rear springs l. Nuts of spring pin wedge bolts m. Anti roll bar bracket mounting bolts n. Spare wheel carrier. o. Shock absorber mountings
4.2 Check and tighten, if necessary
k. Pitman arm l. Drag link rod m. Tie rod n. Steering gear box mounting bracket bolts and nuts o. Steering gear box mounting bolts
4.3 Check the steering wheel pre play. Adjust, if required.
5. BRAKES:
5.1 Check and if necessary tighten air tank mountings and air line
clamps.
5.2 Check free movement of plunger in dual brake valve.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 UPLINK VEHICLE – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.3 Check for proper functioning of exhaust brake, free movement of
plunger of exhaust brake valve, mounting bolts for loosening
and slackness in linkage.
5.4 Lubricate with oil can brake chamber fork pin, linkages of foot
brake , ball joints of exhaust brake linkages – hand and foot
brake linkages.
5.5 Checks for travel of brake chamber push rod/ brake lining wear
and clearance with brake drum. Adjust service brakes, if
necessary
5.6 Check brake torque plate (carrier plate) mounting bolts and
tighten, if necessary.
5.7 Check for the brake lining wear by observing indicator and
report.
6. ELECTRICALS:
6.1 Check mountings of alternator and self motor and tighten, if
required.
6.2 Check head lamp focusing and adjust, if required.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 407 UPLINK VEHICLE – QUARTERLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following
oo. Engine performance pp. Dash board parameters qq. Function of clutch, transmission, steering and brakes rr. Function of electrical system.
Annexure -4
TATA 407 UPLINK VEHICLE – HALF YEARLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
1 TATA 407 UPLINK VEHICLE 1
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 UPLINK VEHICLE – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in quarterly schedule
2. ENGINE:
2.1 Check for engine oil due and change oil in the engine sump
while the engine is hot. Change oil filter.
2.2 Check coolant concentration.
2.3 Change two fuel filters and O rings. Bleed the system.
3. GEARBOX:
3.1 Change in oil in gearbox while hot.
3.2 Check and tighten, if necessary gearbox mountings, propeller
shaft coupling flange bolts and center joint bearing support
brackets
4 AXLES:
4.1 Check crown wheel thrust pad and adjust, if necessary.
4.2 Check and tighten, if necessary, carrier and rear cover mounting
nuts. Also tighten axle shaft cover mounting bolts.
4.3 Remove front hub cap, fill 3/4th full with wheel bearing grease
and refit.
4.4 Check wheel alignment and adjust, if necessary.
5. STEERING AND SUSPENSION:
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 UPLINK VEHICLE – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
5.1 Check mountings of spare wheel carrier and tighten, if
necessary.
5.2 Check shock absorber and replace, if necessary.
5.3 Check the condition of shock absorber rubber bushes and
replace, if necessary.
6. BRAKES:
6.1 Check air brake rubber hoses / air pipes for damages / leaks
and replace, if required.
6.2 Check the condition of gaiter in different brake valves, exhaust
flap in dual brake valve, exhaust check diaphragm in valve,
nylon breather tube and clips of spring brake actuator. Replace,
if found damaged / deteriorated.
6.3 Check mounting bolts of brake chambers, different valve
mountings, air tank mountings, air cylinder mounting, master
cylinder mountings, air line clamps hydraulic pipes and tighten,
if necessary.
7. ELECTRICALS:
7.1 Check the mountings of alternator / self motor and tighten, if
necessary.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 UPLINK VEHICLE – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
7.2 Lubricate the pinion bush of self motor and wiper motor
linkages.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 407 UPLINK VEHICLE – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1 Ensure that all the works have been completed as per schedule.
2 Take the vehicle for road test and check the following ss. Engine performance tt. Dash board parameters uu. Function of clutch, transmission, steering and brakes vv. Function of electrical system.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 UPLINK VEHICLE – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Attend to all the works mentioned in half yearly schedule
2. ENGINE:
2.1 Remove the fuel tank, clean and refit. Check the condition of
strainer and replace, if required.
2.2 Remove and clean the spark arrester and refit.
2.3 Check the end play of turbo charger shaft and radial clearance
between turbine wheel and housing.
2.4 Check fan hub and drive belt tensioner bearing.
2.5 Check valve clearance and adjust, if required.
2.6 Check the condition of vibration damper and report.
2.7 Remove the injectors, check and reset the pressure (if required
only)
3. CLUTCH AND GEARBOX:
3.1 Clean gearbox breather.
3.2 Overhaul clutch master and slave cylinder with new kits.
3.3 Replace differential oil.
3.4 Remove front wheel and rear wheel hubs, dismantle and clean
bearing and other components. Replace damaged / worn out
parts. Repack with fresh wheel bearing grease and refit. Adjust
wheel hub play.
Annexure -4
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
TATA 407 UPLINK VEHICLE – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
4 STEERING AND SUSPENSION;
4.1 Change oil in power steering system. Replace filter and cartridge.
4.2 Dismantle front and rear springs. Clean and inspect leaves.
Check and replace bushes if necessary. Apply graphite grease on
leaves and reassemble.
5. BRAKES:
5.1 Overhaul the pneumatic aggregates of the brake system with
replacement of new kits.
5.2 Remove brake drums, inspect the brake linings, brake drums
etc. Rectify for defects.
5.3 Remove the air filter element, clean and refit.
6. ELECTRICALS:
6.1 Overhaul the self motor and alternator and refit.
Annexure -4
DATE:
ENGINEER IN -CHARGE
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
TATA 407 UPLINK VEHICLE – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. While work is in progress, inspect the dismantled items for over hauling for arranging replacement.
2 Ensure that all the works have been completed as per schedule.
3 Take the vehicle for road test and check the following ww. Engine performance xx. Dash board parameters yy. Function of clutch, transmission, steering and brakes zz. Function of electrical system.
Annexure -4
DATE:
ENGINEER IN -CHARGE
EICHER TRACTOR AND HMT TRACTOR – QUARTERLY MAINTENANCE SCHEDULE
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
VAST/HA/15T/01 EICHER TRACTOR –I AAN 5576 EICHER TRACTOR
VAST /HA/15T/02 EICHER TRACTOR-II PRT/2031 HMT TRACTOR
EICHER TRACTOR & TRACTAOR – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
DIESEL FORKLIFT – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
EICHER TRACTOR & TRACTAOR – MONTHLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
Annexure -4
DATE:
ENGINEER IN -CHARGE
DIESEL FORKLIFT – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
DATE:
SUPERVISOR OF THE CONTRACTOR
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
DATE:
ENGINEER IN -CHARGE
Annexure-4
FULL TRAILERS
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No
Equip Identification No. Equipment
1. VALF/MC/AST/10T/01 10T AIR SUSPENSION TRAILER 1. SXC 1601 APPLE TRAILER-1
2. VALF/FT/AFT/15T/01 15T AIR SUSPENSION TRAILER 2. SXC-1801 APPLE TRAILER-2
3. VALF/AST/18T/01 18T AIR SUSPENSION TRAILER 3. SXC -2201 APPLE TRAILER-3
4. VALF/FT/4T/01 4T FLAT BED FULL TRAILER 4. SXC-2301 APPLE TRAILER-4
5. VALF/FT/5T/01 5T FLAT BED FULL TRAILER 5. SXC-2501 APPLE TRAILER-5
6. VALF/FT/8T/01 8T FLAT BED FULL TRAILER 6. SXC-2601 APPLE TRAILER-6
7. VALF/FT/10T/01 10T FLAT BED FULL TRAILER 7. SXC-3001 APPLE TRAILER-7
8. VALF/FT/10T/02 10T FLAT BED FULL TRAILER 8. SXC-3101 APPLE TRAILER-8
9. VALF/LT/10T/01 10T WELL BED TRAILER 9. SXC-3201 APPLE TRAILER-9
10. VALF/LT/10T/02 10T WELL BED TRAILER 10. SXC-3301 APPLE TRAILER-10
11. VALF/FT/15T/01 15T FLAT BED FULL TRAILER 11. SXC-4202 LOW BED TRAILER
12. VALF/FT/15T/02 15T FLAT BED FULL TRAILER 12. SXC-4302 LOW BED TRAILER
13. VALF/FT/30T/01 30T DEAD WEIGHT TRANSPORTER 13. SXC-4402 LOW BED TRAILER
14. VALF/ST/30T/01 30T FLAT BED SEMI TRAILER 14. SXC-4802 LOW BED TRAILER
15. VALF/ST/PSO/01 PSO TRANSTILT 15. SXC-4005 AP BIN TRAILER
16. VALF/ST/CT/01 CRYO TRANSTILT 16. SXC -4105 AP BIN TRAILER
17. VALF/ST/CT/02 CRYO TRANSTILT C25 17. AP BIN TRAILER
18. VALF/ST/L40/01 L-40 TRANSTILT 18. AP BIN TRAILER
19. VALF/ST/L110/01 L110 TRANSTILT 19. SXC 4615 BOWL TRAILER
20. VALF/ST/PSO-XL/01 PSOM-XL TRANSTILT 20. SXC 2115 BOWL TRAILER-1
21. VALF/HAT/N2-2X2/01 12T SEMI TRAILER-1 21. SXC-2915 BOWL TRAILER-2
22. VALF/HAT/N2-2X2/02 12T SEMI TRAILER-2 22. SXC 3215 BOWL TRAILER-3
23. LSSF/ST/LH-2/45CM/01 LIQUID HYDROGEN TANKER-I
23. SXC 2820 LOW BED TRAILER(20T)
24. LSSF/ST/LH-2/45CM/02 LIQUID HYDROGEN TANKER-2
24. SXC 4725 PSO-XL TRIALER-I
25. LSST/ST/OXY/45CM/02 15KL LIQUID OXYGEN TANKER-1 25. PSO-XL TRAILER-2
26. LSSF/ST/LH-1/40KL/01 40KL LIQUID HYDROGEN TANKER-1 26. SXC 4825 WELL BED TRAILER
27. LSSF/ST/LHE-1/40KL/01 40 KL LIQUID HELIUM TANKER-I 20T BOWL TRILER
28. VALF/FT/1T/01 ADITYA MOTOR TRANSPORTER
Annexure-4 FULL TRAILERS
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No Equip Identification No. Equipment
29. VALF/AT/1T/01 AGNI MOTOR TRAILER-1
30. VALF/AT/1T/02 AGNI MOTOR TRAILER-2
31. VALF/JT/1T/01 JEEP TRAILER-1
32. VALF/JT/1T/02 JEEP TRAILER-2
33. VALF/FT/RH200/2T/01 RH 200 TRANSPORTER
34. VALF/FT/RH560/3T/01 RH 560 TRANSPORTER-1
35. VALF/FT/RH560/6T/01 RH 560 TRANSPORTER-2
36. LSSF/FT/N2-8CM/01 NITROGEN TANKER ( 8CM)
37. LSSF/FT/N2-10T/01 10T N2 MODULE TRAILER-1
38. LSSF/FT/N2-10T/02 10T N2 MODULE TRALIER II
39. LSSF/FT/N2-10T/03 10T N2 MODULE TRAILER-III
40. LSSF/FT/N2-10T/04 10 N2 MODULE TRAILER-IV
41. CTF/N2-2X2/01 12T SEMI TRAILER-1
42. BS/N2-2X2/02 12T SEMI TRAILER-II
43. CTF/03 12T SEMI TRAILER-III
44. CTF/04 12T SEMI TRAILER-IV
45. LSSF/FT/DMW-1.5KL/0.1 DM WATER TANKER
46. LSSF/FT/DMW-1.5KL/0.2 DM WATER TANKER-II
47. LSSF/FT/5KL/02 DM WATER TANKER-III
48. LSSF/ST/DMW-10KL/01 15T DM WATER TANKER-IV
49. LSSF/FT/EF-7KL/01 EFFLUENT TANKER-I
50. LSSF/FT/N2-1X2/01 N2 MODULE -I
51. LSSF/FT/N2-1X2/02 N2 MODULE -II
52. LPSC/FT/SITVC-5KL/01 SITVC TANKER-I
53. LPSC/FT/SITVC-5KL/02 SITVC TANKER-2
54. LSSF/FT/MON3.5KL/01 PROPELLANT TRANSFER UNIT-I
55. LSSF/FT/MON3.5KL/02 PROPELLANT TRANSFER UNIT-II
56. LSSF/FT/N2-0.5 X 2/01 N2 MODULE TRAILER-I
57. LSSF/ST/N2/2X2/01 12T NITROGEN TANKER-I
58. LSSF/ST/N2/2X2/02 12T NITROGEN TANKER-II
59. LSSF/ST/N2/0.5X4/01 NITROGEN TANKER-I
60. LSSF/ST/HE-2X2/01 12T HELIUM MODULE-I
61. LSSF/ST/HE-2X2/02 12T HELIUM MODULE -II
62. LSSF/ST/HE-1X4/01 12T HELIUM MODULE-III
63. LSSF/ST/30KL/E-5003/01 IMT TANKER-I(NEW)N2O4
64. LSSF/ST/30KL/02 IMT TANKER-2 N2O4
65. LSSF/ST/30KL/E-4003/01 IMT TANKER-I NEW UH-25
66. LSSF/ST/30KL/02 IMT TANKER-2 UH25
67. LSSF/BS/UH-25/01 RT TANKER-1 UH-25
68. LSSF/BS/UH-25/02 RT TANKER -2 UH-25
69. LSSF/BS/N204/01 RT TANKER-I N2O4
70. LSSF/BS/N2O4/02 RT TANKER-2 N2O4
Annexure-4
SEMI TRAILERS
WORK STATION – A (Equipment Ref. As per Annexure – 1)
WORK STATION – B (Equipment Ref. As per Annexure – 1)
Sl No Equip Identification No. Equipment Sl No
Equip Identification No. Equipment
1. VALF/MC/AST/10T/01 10T AIR SUSPENSION TRAILER
2. VALF/FT/AFT/15T/01 15T AIR SUSPENSION TRAILER
3. VALF/AST/18T/01 18T AIR SUSPENSION TRAILER
4. VALF/ST/30T/01 30T FLAT BED SEMI TRAILER
5. VALF/ST/PSO/01 PSO TRANSTILT
6. VALF/ST/CT/01 CRYO TRANSTILT
7. VALF/ST/CT/02 CRYO TRANSTILT C25
8. VALF/ST/L40/01 L-40 TRANSTILT
9. VALF/ST/L110/01 L110 TRANSTILT
10. VALF/ST/PSO-XL/01 PSOM-XL TRANSTILT
11. VALF/HAT/N2-2X2/01 12T SEMI TRAILER-1
12. VALF/HAT/N2-2X2/02 12T SEMI TRAILER-2
13. LSSF/ST/LH-2/45CM/01 LIQUID HYDROGEN TANKER-I
14. LSSF/ST/LH-2/45CM/02 LIQUID HYDROGEN TANKER-2
15. LSST/ST/OXY/45CM/02 15KL LIQUID OXYGEN TANKER-1
16. LSSF/ST/LH-1/40KL/01 40KL LIQUID HYDROGEN TANKER-1
17. LSSF/ST/LHE-1/40KL/01 40 KL LIQUID HELIUM TANKER-I
18. LSSF/ST/N2-8CM/01 NITROGEN TANKER (8CM)
19. CTF/N2-2 X 2 /01 12T SEMI TRAILER
20. BS/N2-2 X 2/02 12T SEMI TRAILER-II
21. CTF/03 12T SEMI TRAILER-III
22. CTF/04 12T SEMI TRAILER-IV
23. LSSF/ST/DMW 10 KL/01 15T DM WATER TANKER IV
24. LSSF/ST/N2/2 X 2 /01 12T NITROGEN TANKER-I
25. LSSF/ST/N2/2 X 2/02 12T NITROGEN TANKER-II
26. LSSF/ST/N2/0.5 X 4 /01 NITROGEN TANKER-I
27. LSSF/ST/HE-2 X 2/01 12T HELIUM MODULE-I
28. LSSF/ST/HE-2X2/02 12T HELIUM MODULE-II
29. LSSF/ST/HE-1 X 4/01 12T HELIUM MODULE –III
30. LSSF/ST/30KL/E-5003/01 IMT TANKER-I(NEW) N2O4
31. LSSF/ST/30KL/02 IMT TANKER-2 N2O4
32. LSSF/ST/30KL/E-4003 IMT TANKER -1 (NEW) UH-25
33. LSSF/ST/30KL/02 IMT TANKER-2 UH-25
34. LSSF/BS/UH-25/01 RT TANKER-I UH-25
35. LSSF/BS/UH-25/02 RT TANKER-2 UH-25
36. LSSF/BS/N2O4/01 RT TANKER-1 N2O4
37. LSSF/BS/N2O4/02 RT TANKER-2 N2O4
Annexure-4
FULL TRAILERS – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Check the condition of leaf spring assembly, shackle pins,
bushes, center bolt and U clamps and replace, if required
2. Check the condition of tow bar, spring and connected assembly
and replace, if required.
3. Check the condition of all bolts and nuts and replace and
retighten, if required.
4. Open the axle cups and pack with grease and fit back after
ensuring proper condition of bearings.
5. Check the condition of turn table, retighten the mountings and
lubricate.
6. Tighten all wheels and bolts.
7. Check the condition of tyres and replace, if required. Inflate all
tyres to specified pressures.
Tyre Size Ply Rate Air Pressure
7.50X15 16PR 8.0 ksc.
11.00X20 16PR 6.0 ksc.
10.00X20 16PR 6.0 ksc
9.00X20 14PR 5.5 ksc.
7.00X12 12PR 6.0 ksc.
7.50X20 12PR 5.5 ksc
6.00X16 8PR 2.0 ksc.
4.00X8 8PR 2.0 ksc.
7.50X20 12PR 5.0 ksc.
8.25X20 12PR 5.5 ksc.
6.50X10 10PR 5.0 ksd.
8. Check the condition of brakes and adjust, if required.
Annexure-4 FULL TRAILERS – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
9. Water wash the trailer thoroughly & Lubricate all grease nipples
and hinge points.
10 Check the condition of chassis frame, platform, presence of
earth chain and hooking points, red reflectors and report.
Annexure-4
DATE:
ENGINEER IN -CHARGE
Page 6 of 12
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
FULL TRAILERS – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify all the works have been completed as per schedule.
2. Presence of all fasteners and random checking of their tightness.
3. Conduct the road performance trial and check for the following.
a) Function of brakes
b) Function of suspension
c) Function of turn table
d) Wheels for wobbling
e) Heating of brake drums
f) General performance of the trailer and the hauler during the
movement.
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
Page 7 of 12
FULL TRAILERS – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Carryout all the maintenance works mentioned in the half yearly
maintenance schedule.
2. Check the condition of axle bearings and replace, if required.
Repack all wheels with grease. (Hub Servicing)
3. Overhaul the turntable and tow hook linkages.
3.1 Overhauling of turn table should involve
- Dismantling of turntable - Inspection of rubbing plates, kingpin, in mountings, pin
fasteners, pin bush and attend to any reconditioning works, if required.
- Lubricating the all mating parts. - Re-assembly & checking the function.
3.2 Overhauling of tow hook linkages should involve
- Dismantling of tow hook and steering connecting ball ends. - Inspection of the condition of tow hook, spring, track rod
ends, track tods and fasteners. - Replacing / reconditioning worn out components. - Re-assembly and lubrication.
4. Load testing as per the procedure given in the Annexure – 2D
(Other than tankers)
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
Page 8 of 12
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
FULL TRAILERS – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. WHILE MAINTENANCE WORK IS UNDER PROGRESS:
1.1 Inspect the condition of wheel bearings and hubs after
dismantling for overhaul for replacement of worn out items.
2. AFTER COMPLETION OF ALL MAINTENANCE WOARKS:
2.1 Verify whether all the works have been completed as per
schedule.
2.2 Presence of all fasteners and random checking of their
tightness.
2.3 Load testing of the trailer (Other than tankers)
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
Page 9 of 12
SEMI TRAILERS – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Check the condition of spring assemblies, shackle pins, bushes, center bolt and U clamps, earth chain and replace, if required.
2. Check the condition of kingpin and rubbing plate and lubricate.
3. Check the condition of all bolts and nuts and replace, if required. Check the condition of body mounting clamps tighten / replace, if required.
4. Check the condition of tyres and replace, if required. Inflate all tyres to the specified pressure.
Tyre Size Ply Rating Air Pressure
11.00x20 16 PR 6.0ksc.
10.00x20 16 PR 6.0ksc
9.00x20 14 PR 5.5ksc
7.50x20 12PR 5.0ksc
5 Check the air brake system for any leaks and proper functioning of valves etc. Adjust brakes, if required. Check the function of parking brakes.
6. Check the condition of props / jacks and tighten the mountings, if required.
7. Tighten all wheel bolts and nuts.
8. Water wash the trailer and lubricate all grease nipples.
Annexure-4
DATE:
ENGINEER IN -CHARGE
Page 10 of 12
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
SEMI TRAILERS – HALF YEARLY MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Verify whether all the works have been completed as per
schedule
2. Presence of all fasteners and random checking of their tightness
3. Servicing and greasing. Works should involve
- Water washing the trailr
- Removal of greasy/ oily spots on the platform chassis
- Removal of water by blowing with air
- Greasing the brake linkages and suspension hinges.
4. Conduct the road performance trial and check for the following
- Function of brakes
- Function of suspension
- Function of Turntable /fifth wheel coupling
- Wheels for any wobbling
- Heating of brake drums
- General performance of the trailer during movement.
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
Page 11 of 12
SEMI TRAILERS – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. Carryout all the works mentioned in half yearly maintenance
schedule
2. Check the condition of axle bearings and replace, if required.
Repack all wheels with grease
Annexure-4
DATE:
SR TECHNICIAN
TECH. ASST
ENGINEER IN -CHARGE
Page 12 of 12
CHECKS TO BE CARRIED OUT BY ENGINEER IN - CHARGE
SEMI TRAILERS – ANNUAL MAINTENANCE
WORKSTATION -
EQUIPMENT No :
Sl No. WORKS TO BE CARRIED OUT OBSERVATION WORKS CARRIED OUT REMARKS
1. WHILE MAINTENANCE WORK UNDER PROGRES
1.1 Inspect the condition of wheel bearings and hubs after dismantling for overhauling for replacement of worn out items
1.2 Inspect the turn table pin and table parts for any damages
2. AFTER COMPLETION OF ALL THE MAINTENANCE WORKS
2.1 Verify whether all the works have been completed as per schedule.
2.2 Presence of all fasteners and random checking of their tightness
2.3 Load testing as per the procedure mentioned in Annexure –2D (other than tankrers)
ANNEXURE-5
LOAD TEST REPORTS OF
EQUIPMENT
Annexure-5
15t Mobile Crane Page No:
LOAD TEST REPORT OF 15t MOBILE CRANE
1. Equipment Details:
1.1 15t capacity Mobile Crane VALF/MC/15T/01 WORK STATION- A
1.2 Capacity 15t at 3.5m operating radius
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 15t Capacity Mobile crane as per the daily checklist 3. Procedure for Load Testing:
Description With no load With load Remarks
Power Plant
Power Plant fitted with ALU 412 Ashok Leyland water cooled engine with Spark Arrestor fitted
to engine exhaust. Dash board parameters :
Engine oil pressure (1.0-5.5ksc)
Volt meter (24V)
Fuel gauge
Engine coolant temperature (750-900C)
Transmission shift lever
Swing control lever
Rear steer control switch
Main hoist control lever
Boom lift control lever
Transmission range selector switch
Outrigger selector panel
Outrigger extension / retraction switch
Park brake control switch
360 degree swing lock control
Load moment indicating (LMI) control panel
Differential lock switch
Annexure-5
15t Mobile Crane Page No:
Description With no load With load Remarks
Boom System: Boom system provided with 3 section telescopic full power boom extending from 9.4m to 22.9m. Telescoping is mechanically synchronized with single lever control. Telescopic sections slide on adjustable and replaceable lower friction wear pads. The boom provided with boom angle, boom radius indicator, boom length indicator, max. permissible load indicator, overload warning indicator, limit switch etc.,
Function:
Boom up (-30 to 760)
Boom down (760 to -30)
Boom Telescope extraction (22.9m)
Boom Telescope retraction (9.4m)
Hoist System The Hoist System provided with power up and power lowering , automatic brakes for hoist system, 16mm dia, 137 m long non-rotating rope of suitable capacity , overload warning for hoist system, load indicator etc.,
Function :
Hoist up
Hoist down
Hoist brake
Slew System 360 degree slew system provided with spring applied hydraulically release brake and slew lock.
Function :
Clock wise ( 2 RPM)
Anti-clock wise( 2 RPM)
Slew system brake
Annexure-5
15t Mobile Crane Page No:
Description With no load With load Remarks
Outrigger System: The out rigger system is provided with hydraulic operated independent horizontal and vertical movements. The controls of outriggers provided at operator’s cab, level indicator at operator’s cabin and also provided with failsafe lock for safety.
Function :
Front outriggers
Front left outrigger extraction
Front left outrigger retraction
Front right outrigger extraction
Front right outrigger retraction
Rear outriggers
Rear left outrigger extraction
Rear left outrigger retraction
Rear right outrigger extraction
Rear right outrigger retraction
Transmission:: Transmission is
engine mounted multi speed power shift of 6Forward / 6 Reverse speeds.
Function :
Transmission range selector switch (HI / LOW)
Forward
Reverse
Steering The steering system
provided with 4 main steering modes – front only, rear only, crab and coordinated steering
Function :
Axle differential lock
Four wheel steering
Front wheel steering
Rear wheel steering
Four wheel steering
Crabbing
Brakes The crane provided with foot operated service brake and parking brake which acts as failsafe brake.
Annexure-5
15t Mobile Crane Page No:
Description With no load With load Remarks
Function :
Service brake of the crane
Parking brake of the crane
Hydraulic System: The Hydraulic system is provided with 2 main pumps & steering pumps driven by engine through PTO. The hydraulic system can be operated by precision 4 way double acting pilot operated control valve, permits simultaneous control of multiple crane functions by 2 individual valve banks. The capacity of the hydraulic reservoir is 341lts, oil cooled with temp control, full flow return type filter with by-pass protection, service indicator, oil level indicator for reservoir and replaceable type filter cartridge.
Function :
Condition of hydraulic hoses (leaks etc)
Functioning of hydraulic pumps
Maintenance Details:
Type of maintenance scheduled Monthly, quarterly, Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
LOAD TEST REPORT OF VOLVO & HIPPO HAULERS 1. Equipment details:
1.1
HIPPO Hauler – 1 VALF/HA/70t/01
WORK STATION-A
HIPPO Hauler – 2 VALF/HA/70T/02
VOLVO Hauler -1 VALF/HA/70T/03
VOLVO Hauler -2 VALF/HA/70T/04
VOLVO Hauler -3 VALF/HA/70T/05
VOLVO Hauler 520 HP AP 26 Y 7685 WORK STATION-B
VOLVO Hauler 400 HP AP 26 TB 5085
1.2 Capacity 86t GCW
1.3 Load Test Venue
1.4 Date
2. Pre-Checks: Daily Checks for Hauler and Hydraulic suspension Goldhofer trailer / Cometto trailer as per the Daily Checklists shall be carried out. 3. No load performance of Hauler & Trailer:
Sl No Item Status
01 Connect the Hauler and Trailer – adjust the steering wedge play (Tighten fully with hand and loosen 1/4th turn).
02 Start the Hauler engine and pressurize the trailer and hauler lines and ensure release of parking/ fail-safe brakes.
03 Start Hydraulic suspension trailer’s Hydraulic power pack
and adjust the trailer platform level to 1165mm± 10mm at all four corners.
04 Check Wheel alignment of trailer and readjust if required.
05 Check Performance of Hauler and trailer in no load condition.
4. Dead Weight / Tools & Materials Required
Sl No Item Qty Status
1. Concrete block – 55t Dead weight 1 No
2. Four legged Handling slings for the above blocks
1 No
3. Crane facility for loading the block 1 No
4. Felt pieces As required
5. Steel Rule 1 No.
6. 15m tape 1 No.
Annexure-5
5. Procedure for Load testing:
Sl No Item Status
01 Take the hauler and trailer to the facility where the concrete blocks and EOT crane facility are available for loading of concrete blocks.
02 Spread the felt pieces on the trailer to have even seating of the concrete blocks.
03 Load the concrete blocks by using the EOT crane/ mobile crane at a distance of 3.5m from rear end of the trailer as per the Loading Scheme:
04 Check for any abnormality and leaks at hydraulic pipe lines, hoses and couplings in loaded condition
05 Check the performance of the hauler and trailer under loaded condition and record the parameters
6. Performance of the Hauler & Trailer
Sl No
Description Observations
No load With load
1. Engine: Eng Oil Pressure - Idling (between 1.0 and 3.0 bar) Eng Oil Pressure at Operating speed (between 3.0 and 5.5 bar) Radiator coolant Temp Maximum (Indicator should be in green zone) Charging System :
Should show charging Deflection of pointer on +ve side
2. Clutch - Engagement & disengagement - For any slip
3. Transmission - Engagement & Disengagement of
gears. - For any slip - For any abnormality
4. Steering (Hauler & Trailer) - Function of steering on both sides. - For any other abnormality
5. Brakes ( Hauler & Trailer) Service Brakes
Annexure-5
Sl No
Description Observations
No load With load
- Function of brakes on all wheels. - Effectiveness of brakes Parking Brakes - Effectiveness of brakes
6. Gradient: - Performance of the Equipment
7. For any leaks in hose connections
8. Function of fifth wheel coupling
7. Maintenance Details: Hauler maintenance Details::
Type of maintenance scheduled Monthly, half yearly & Annual
Maintenance last attended
Next maintenance due
Hydraulic Suspension Trailer::
Type of maintenance scheduled Quarterly & Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
Annexure-5
AMW Haulers load test Report
AMW HAULER – 1 & 2 LOAD TEST REPORT 1. Equipment details:
1.1 AMW HAULER - 1 VALF/HA/49T/06
WORK STATION-A AMW HAULER - 1 VALF/HA/49T/07
1.2 Capacity 49t GCW
1.3 Load Test Venue
1.4 Date
2. Pre-Checks: Daily Checks for AMW Haulers and Hydraulic suspension Goldhofer trailer / Cometto trailer as per the Daily Checklists shall be carried out. 3. No load performance of Hauler & Trailer:
Sl No Item Status
01 Connect the Hauler and Trailer – adjust the steering wedge play (Tighten fully with hand and loosen 1/4th turn).
02 Start the Hauler engine and pressurize the trailer and hauler lines and ensure release of parking/ fail-safe brakes.
03
Start Hydraulic suspension trailer’s Hydraulic power pack
and adjust the trailer platform level to 1165mm± 10mm at all four corners.
04 Check Wheel alignment of trailer and readjust if required.
05 Check Performance of Hauler and trailer in no load condition.
4. Dead Weight / Tools & Materials Required
Sl No Item Qty Status
1. Concrete block – 15.5 & 5T Dead weight Each 1 No
2. Four legged Handling slings for the above blocks
1 No
3. Crane facility for loading the block 1 No
4. Felt pieces As required
5. Steel Rule 1 No.
6. 15m tape 1 No.
Annexure-5
AMW Haulers load test Report
5. Procedure for load testing:
Sl No Item Status
01 Take the hauler and trailer to the facility where the concrete blocks and EOT crane facility are available for loading of concrete blocks.
02 Spread the felt pieces on the trailer to have even seating of the concrete blocks.
03 Load the concrete blocks by using the EOT crane/ mobile crane at a distance of 3.5m from rear end of the trailer as per the Loading Scheme: VALF/MHS/T&E/HA/49T
04 Check for any abnormality and leaks at hydraulic pipe lines, hoses and couplings in loaded condition
05 Check the performance of the hauler and trailer under loaded condition and record the parameters
6. Performance of the Hauler & Trailer
Sl No
Description Observations
No load With load
1. Engine:
Eng Oil Pressure - Idling (between 1.0 and 3.0 bar) Eng Oil Pressure at Operating speed (between 3.0 and 5.5 bar) Radiator coolant Temp Maximum (Indicator should be in green zone) Charging System : Should show charging Deflection of pointer on +ve side
2. Clutch
- Engagement & disengagement - For any slip
3. Transmission - Engagement & Disengagement of
gears. - For any slip - For any abnormality
4. Steering (Hauler & Trailer) - Function of steering on both sides. - For any other abnormality
5. Brakes ( Hauler & Trailer) Service Brakes
- Function of brakes on all wheels.
Annexure-5
AMW Haulers load test Report
Sl No
Description Observations
No load With load
- Effectiveness of brakes Parking Brakes
- Effectiveness of brakes
6. Gradient: - Performance of the Equipment
7. For any leaks in hose connections
8. Function of fifth wheel coupling
7. Maintenance Details: Hauler maintenance Details::
Type of maintenance scheduled Monthly, half yearly & Annual
Maintenance last attended
Next maintenance due
Hydraulic Suspension Trailer::
Type of maintenance scheduled Quarterly & Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
AMW Haulers load test Report
Annexure-5
BEML Haulers Load test Report
BEML HAULR LOAD TEST REPORT
1. Equipment Details:
1.1
70T BEML HAULER - 1 VALF/HA/70T/01 70T BEML HAULER - 2 VALF/HA/70T/01 70T BEML HAULER - 1 SPROB/1745
70T BEML HAULER – 2 PRT/2229
70T BEML HAULER – 3 PRT/7003
1.2 Capacity 86t GCW
1.3 Load Test Venue
1.4 Date
2. Pre-Checks: Daily Checks for BEML Hauler and 30t Flat Bed trailer as per the Daily Checklists shall be carried out.
3. Procedure: The BEML Tractor is load tested for Payload of 30t as per
the procedure given below.
Sl No. Description Status
1 Carry out the pre test checks to the hauler and trailer as per daily check lists.
2 Connect the trailer to the BEML Hauler
3 Take the hauler and trailer for a trial to check the hauler for no load performance.
4 If no load performance is satisfactory, load the trailer with two 30t payload as per the loading scheme: VALF/MHS/T&E/HA/70T.
5 Lash the loads to the trailer platform.
6 Take the hauler and trailer for road trial and check for the parameters given in the performance table 5 and record.
4. Load Details:
Sl No Item Description Qty Remarks
1 30t Flat bed Full Trailer 1 No
2 15t Dead Weights 2 nos
3. 15m Measuring tape 1 No
4. Chalk Pieces 05 nos
Annexure-5
BEML Haulers Load test Report
5. Performance of BEML Haulers:
Sl No Description Observations
No load With load
1. Engine: Lub Oil Pressure - Engine idling (1.0ksc – 2.0 ksc) Lub Oil Pressure – Engine full speed ( 3.0 ksc – 4.0 ksc ) Radiator water temperature Maximum (850C) Charging System : Should show charging By deflection of pointer on +ve side
2. Clutch
- Engagement & disengagement - For any slip
3. Transmission - Engagement & Disengagement
of gears. - For any slip - For any abnormality
4. Rear Axle : For any abnormal sound and over heating of wheel hubs.
5. Wheels : Check rubbing of wheels of wheels against any body surface and wheel shake
6. Steering (Hauler & Trailer) - Function of steering on both
sides. - For any other abnormality
7. Brakes ( Hauler & Trailer) Service Brakes - Function of brakes on all
wheels. - Effectiveness of brakes Parking Brakes - Effectiveness of brakes
8. Gradient:
- Performance of the Equipment
Annexure-5
BEML Haulers Load test Report
6. Maintenance Details:
BEML Hauler::
Type of maintenance scheduled Monthly, half yearly & Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
BEML Haulers Load test Report
Annexure-5
Tractor Page No:
LOAD TESTING OF TRACTORS 1. Equipment Details:
1.1 HMT TRACTOR PRT/2031 WORK STATION-B
1.2 Capacity 13t GCW
1.3 Load Test Venue
1.4 Date
2. Materials & Equipment Required for Load Testing:
S.NO Item Qty Status
01 5t Concrete blocks 1 Nos.
02 MST Wheels 2 nos
03 10t Flat bed full trailer 1 No
04 15m Measuring Tape 1 No.
05 Chalk-piece As required
3. Procedure:
Sl No. Description Status
01 Connect the trailer to Eicher tractor
02 Load the trailer with 8t Concrete blocks as per the scheme: SPROB/MHS/T&E/HA/13T
03 Take the Tractor and trailer for road trial and check the performance and record in table 4
4. Performance of Hauler:
Sl No Description Observations
No load With load
1. Engine: Lub Oil Pressure –Engine idling (Should be in Green Zone) Lub Oil Pressure – Engine full speed (Should be in Green Zone ) Temp Maximum (850 Celsius) Charging System : Should show charging By deflection of pointer on +ve side
2. Clutch - Engagement & disengagement - For any slip
3. Transmission - Engagement & Disengagement of
gears. - For any slip - For any abnormality
4. Steering
Annexure-5
Tractor Page No:
Sl No Description Observations
No load With load
- Function of steering on both sides. - For any other abnormality
5. Brakes Service Brakes - Function of brakes on all wheels. - Effectiveness of brakes Parking Brakes - Effectiveness of brakes
6. Gradient: - Performance of the Equipment
5. Maintenance Details:
Type of maintenance scheduled
Monthly, Quarterly, Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
Tractor Page No:
Annexure-5
Tractor Page No:
LOAD TESTING OF TRACTORS 1. Equipment Details:
1.1
Eicher Tractor-1 VALF/HA/15T/01 Eicher Tractor-2 VALF/HA/15T/02 Eicher Tractor-3 VALF/HA/15T/03 Eicher Tractor-4 VALF/HA/15T/04 SAME Tractor – 1 AP 26 Y 2900
SAME Tractor – 1 AP 26 Y 2901
SAME Tractor – 1 AP 26 AC 2503
1.2 Capacity 15t GCW
1.3 Load Test Venue
1.4 Date
2. Materials & Equipment Required for Load Testing:
S.NO Item Qty Status
01 5t Concrete blocks 2 Nos.
02 10t Flat bed Full trailer 1 No
04 15m Measuring Tape 1 No.
05 Chalk-piece As required
3. Procedure:
Sl No. Description Status
01 Connect the 10t Flat Bed full trailer to Eicher tractor
02 Load the trailer with 2 Nos. of 5t Concrete blocks as per the scheme: VALF/MHS/T&E/HA/15T
03 Take the Tractor and trailer for road trial and check the performance and record in table 4
4. Performance of Hauler:
Sl No Description Observations
No load With load
1. Engine: Lub Oil Pressure –Engine idling (Should be in Green Zone) Lub Oil Pressure – Engine full speed (Should be in Green Zone ) Temp Maximum (850 Celsius) Charging System : Should show charging By deflection of pointer on +ve side
2. Clutch - Engagement & disengagement - For any slip
3. Transmission
Annexure-5
Tractor Page No:
Sl No Description Observations
No load With load
- Engagement & Disengagement of gears.
- For any slip - For any abnormality
4. Steering - Function of steering on both sides. - For any other abnormality
5. Brakes Service Brakes - Function of brakes on all wheels. - Effectiveness of brakes Parking Brakes - Effectiveness of brakes
6. Gradient: - Performance of the Equipment
5. Maintenance Details:
Type of maintenance scheduled
Monthly, Quarterly, Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
Tractor Page No:
Annexure -5
2t Forklift Load test report Page No:
2t CAPACITY FORKLIFT LOAD TEST REPORT
1. Equipment Details:
1.1 2T Godrej Forklift VALF/FL/2T/01 WORK STATION- A
1.2 Capacity 2t at 500mm Load centre
1.3 Load Test venue
1.4 Date
2. Pre-Checks: Daily Checks for 2t forklift as per the Daily Checklists shall be
carried out. 3. Materials Required for Load Testing
Sl No Item Qty Status
1. 2 t cement block 1 no
2. Measuring Tape 15m 1 No
3. Chalk pieces / scriber As required
4. Procedure:
Sl No Description Status
1. Arrange to keep the dummy 2t dummy weight on a level ground.
2. Support the load on forks at 500mm load center as per the Load test scheme no. VALF/MHS/T&E/SCHEME/2T/01
3. Lift the load slowly from the ground and check the fork lift for performance in loaded condition
4. Keep the load in the lift condition for 3 minutes and mark the position of guide way with chalk
5. Slowly bring down the load to the ground in mast back condition.
VI Performance of the Forklift:
Sl No Description Observations
No load With load
01 Engine: Lub Oil Pressure – Engine idling (1.0 ksc - 1.5 ksc) Lub Oil Pressure – Engine full speed (3.0 ksc - 4.0 ksc) Radiator water temperature Maximum (850 Celsius) Charging System :
Should show charging By deflection of pointer on +ve side
Annexure -5
2t Forklift Load test report Page No:
Sl No Description Observations
No load With load
02 Mast Lifting & Lowering: Functioning of Mast lifting and lowering Observe for any leaks in hoses during operations.
03 Mast Tilting:
Functioning of Mast tilting Forward and Backward. Observe for any leaks during operation
04
Transmission - Engagement & Disengagement of
gears. - For any slip - For any abnormality
05 Steering
- Function of steering on both sides. - For any other abnormality
06 Brakes Service Brakes - Function of brakes on all wheels. - Effectiveness of brakes Parking Brakes - Effectiveness of brakes
07 Gradient: - Performance of the Equipment
VII Maintenance Details:
Type of maintenance scheduled Monthly, quarterly, Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure -5
2t Forklift Load test report Page No:
Annexure-5
3t Forklift Load test report Page No:
3t CAPACITY FORKLIFT LOAD TEST REPORT 1. Equipment details:
1.1
3T Godrej Forklift – 1 VALF/FL/3T/01
WORK STATION – A 3T Godrej Forklift – 2 VALF/FL/3T/02
3T Godrej Forklift – 3 VALF/FL/3T/03
3T Godrej Forklift PRT/2278 WORK STATION – B
1.2 Capacity 3t at 500mm Load centre
1.3 Load Test venue
1.4 Date
2. Pre-Checks: Daily Checks 3t Forklift as per the Daily Checklists shall be carried out. 3. Materials Required for Load Testing
Sl No Item Qty Status
1. 2t cement block 1 no
2. 1t cement block 1 no
3. Measuring Tape 15m 1 No
4. Chalk pieces / scriber As required
4. Procedure:
Sl No Description Status
1. Arrange to keep the dummy 3t weight on a level ground.
2. Support the load on forks at 500mm load center as per the drawing Scheme. VALF/MHS/T&E/FL/3T
3. Lift the load slowly from the ground and check the fork lift for performance in loaded condition
4. Keep the load in the lift condition for 3 minutes and mark the position of guide way with chalk
5. Slowly bring down the load to the ground in mast back condition.
VI Performance of the Forklift:
Sl No Description Observations
No load With load
01 Engine: Lub Oil Pressure – Engine idling (1.0 ksc - 1.5 ksc) Lub Oil Pressure – Engine full speed (3.0 ksc - 4.0 ksc) Radiator water temperature Maximum (850 Celsius)
Annexure-5
3t Forklift Load test report Page No:
Sl No Description Observations
No load With load
Charging System :
Should show charging By deflection of pointer on +ve side
02 Mast Lifting & Lowering:
Functioning of Mast lifting and lowering Observe for any leaks in hoses during operations.
03 Mast Tilting:
Functioning of Mast tilting Forward and Backward. Observe for any leaks during operation
04
Transmission - Engagement & Disengagement of
gears. - For any slip - For any abnormality
05 Steering - Function of steering on both sides. - For any other abnormality
06 Brakes Service Brakes - Function of brakes on all wheels. - Effectiveness of brakes Parking Brakes - Effectiveness of brakes
07 Gradient: - Performance of the Equipment
VII Maintenance Details:
Type of maintenance scheduled Monthly, quarterly, Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
3t Forklift Load test report Page No:
Annexure-5
5t Forklift Load test report Page No:
5t CAPACITY FORKLIFT LOAD TEST REPORT
1. Equipment details:
1.1 5t Godrej Forklift VALF/FL/5T/01 WORK STATION – A
5t Godrej Forklift SPROB/FL/5T/01 WORK STATION – B
1.2 Capacity 5t at 600mm Load Centre
1.3 Load Test Venue
1.4 Date
2. Pre-Checks: Daily Checks for Hauler and Hydraulic suspension Goldhofer trailer / Cometto trailer as per the Daily Checklists shall be carried out. 3. Materials Required for Load Testing
Sl No Item Qty Status
1. 5t Cement Block 1 no
2. Measuring Tape 15m 1 No
3. Chalk pieces / scriber As required
4. Procedure:
Sl No Description Status
1. Arrange to keep the dummy 5t dummy weight on a level ground.
2. Support the load on forks at 600mm load center as per the loading scheme. VALF/MHS/T&E/FL/5T
3. Lift the load slowly from the ground and check the fork lift for performance in loaded condition
4. Keep the load in the lift condition for 3 minutes and mark the position of guide way with chalk
5. Slowly bring down the load to the ground in mast back condition.
5. Performance of the Forklift:
Sl No Description Observations
No load With load
01 Engine: Lub Oil Pressure – Engine idling (1.0ksc - 1.5ksc) Lub Oil Pressure – Engine full speed (3.0ksc-4.0ksc) Radiator water temperature Maximum (850 Celsius) Charging System : Should show charging
Annexure-5
5t Forklift Load test report Page No:
Sl No Description Observations
No load With load
By deflection of pointer on +ve side
02 Mast Lifting & Lowering: Functioning of Mast lifting and lowering Observe for any leaks in hoses during operations.
03 Mast Tilting: Functioning of Mast tilting Forward and Backward. Observe for any leaks during operation
04
Transmission
- Engagement & Disengagement of gears.
- For any slip - For any abnormality
05 Steering
- Function of steering on both sides. - For any other abnormality
06 Brakes Service Brakes
- Function of brakes on all wheels. - Effectiveness of brakes Parking Brakes
- Effectiveness of brakes
07 Gradient: - Performance of the Equipment
6. Maintenance Details:
Type of maintenance scheduled Monthly, quarterly, Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
5t Forklift Load test report Page No:
Annexure-5
8t Forklift Load test report Page No:
8t CAPACITY FORKLIFT LOAD TEST REPORT
1. Equipment details:
1.1 8t Godrej Forklift SPROB/FL/8T/01 WORK STATION – B
1.2 Capacity 8t at 600mm Load Centre
1.3 Load Test Venue
1.4 Date
2. Pre-Checks: Daily Checks for 8t Forklift as per the Daily Checklists shall be
carried out. 3. Materials Required for Load Testing
Sl No Item Qty Status
1. 5t Cement Block 1 nos
2. MST wheels 2 nos
3. Measuring Tape 15m 1 No
4. Chalk pieces / scriber As required
4. Procedure:
Sl No Description Status
1. Arrange to keep the dummy 8t dummy weight on a level ground.
2. Support the load on forks at 900mm load center as per the loading scheme. SPROB/MHS/T&E/FL/8T
3. Lift the load slowly from the ground and check the fork lift for performance in loaded condition
4. Keep the load in the lift condition for 3 minutes and mark the position of guide way with chalk
5. Slowly bring down the load to the ground in mast back condition.
5. Performance of the Forklift:
Sl No Description Observations
No load With load
01 Engine:
Lub Oil Pressure – Engine idling (1.0ksc - 1.5ksc) Lub Oil Pressure – Engine full speed (3.0ksc-4.0ksc) Radiator water temperature Maximum (850 Celsius) Charging System :
Should show charging By deflection of pointer on +ve side
Annexure-5
8t Forklift Load test report Page No:
Sl No Description Observations
No load With load
02 Mast Lifting & Lowering:
Functioning of Mast lifting and lowering Observe for any leaks in hoses during operations.
03 Mast Tilting:
Functioning of Mast tilting Forward and Backward. Observe for any leaks during operation
04
Transmission - Engagement & Disengagement of
gears. - For any slip - For any abnormality
05 Steering
- Function of steering on both sides. - For any other abnormality
06 Brakes
Service Brakes
- Function of brakes on all wheels. - Effectiveness of brakes Parking Brakes
- Effectiveness of brakes
07 Gradient:
- Performance of the Equipment
6. Maintenance Details:
Type of maintenance scheduled Monthly, quarterly, Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
8t Forklift Load test report Page No:
Annexure-5
10t Forklift Load test report Page No:
10t CAPACITY FORKLIFT LOAD TEST REPORT
1. Equipment details:
1.1 10t Godrej Forklift VALF/FL/10T/01 WORK STATION – A
1.2 Capacity 10t at 900mm Load Centre
1.3 Load Test Venue
1.4 Date
2. Pre-Checks: Daily Checks for Hauler and Hydraulic suspension Goldhofer
trailer / Cometto trailer as per the Daily Checklists shall be carried out. 3. Materials Required for Load Testing
Sl No Item Qty Status
1. 5t Cement Block 2 nos
2. Measuring Tape 15m 1 No
3. Chalk pieces / scriber As required
4. Procedure:
Sl No Description Status
1. Arrange to keep the dummy 10t dummy weight on a level ground.
2. Support the load on forks at 900mm load center as per the scheme. VALF/MHS/T&E/FL/10T
3. Lift the load slowly from the ground and check the fork lift for performance in loaded condition
4. Keep the load in the lift condition for 3 minutes and mark the position of guide way with chalk
5. Slowly bring down the load to the ground in mast back condition.
5. Performance of the Forklift:
Sl No Description Observations
No load With load
01 Engine: Lub Oil Pressure – Engine idling (1.0ksc - 1.5ksc) Lub Oil Pressure – Engine full speed (3.0ksc-4.0ksc) Radiator water temperature Maximum (850 Celsius) Charging System :
Should show charging By deflection of pointer on +ve side
Annexure-5
10t Forklift Load test report Page No:
Sl No Description Observations
No load With load
02 Mast Lifting & Lowering: Functioning of Mast lifting and lowering Observe for any leaks in hoses during operations.
03 Mast Tilting:
Functioning of Mast tilting Forward and Backward. Observe for any leaks during operation
04
Transmission - Engagement & Disengagement of
gears. - For any slip - For any abnormality
05 Steering - Function of steering on both sides. - For any other abnormality
06 Brakes Service Brakes - Function of brakes on all wheels. - Effectiveness of brakes Parking Brakes - Effectiveness of brakes
07 Gradient: - Performance of the Equipment
6. Maintenance Details:
Type of maintenance scheduled Monthly, quarterly, Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
10t Forklift Load test report Page No:
Annexure-5
12t Forklift Load test report Page No:
12t CAPACITY FORKLIFT LOAD TEST REPORT
1. Equipment details:
1.1 12t Godrej Forklift PRT/2279
WORK STATION – B 12t Godrej Forklift SPROB/FL/12T/02
1.2 Capacity 12t at 1200mm Load Centre
1.3 Load Test Venue
1.4 Date
2. Pre-Checks: Daily Checks for 8t Forklift as per the Daily Checklists shall be carried out. 3. Materials Required for Load Testing
Sl No Item Qty Status
1. 5t Cement Block 2 nos
2. 2t Dead weight 1 nos
3. Measuring Tape 15m 1 No
4. Chalk pieces / scriber As required
4. Procedure:
Sl No Description Status
1. Arrange to keep the dummy 12t dummy weight on a level ground.
2. Support the load on forks at 900mm load center as per the loading scheme. SPROB/MHS/T&E/FL/12T
3. Lift the load slowly from the ground and check the fork lift for performance in loaded condition
4. Keep the load in the lift condition for 3 minutes and mark the position of guide way with chalk
5. Slowly bring down the load to the ground in mast back condition.
5. Performance of the Forklift:
Sl No Description Observations
No load With load
01 Engine:
Lub Oil Pressure – Engine idling (1.0ksc - 1.5ksc) Lub Oil Pressure – Engine full speed (3.0ksc-4.0ksc) Radiator water temperature Maximum (850 Celsius) Charging System : Should show charging By deflection of pointer on +ve side
Annexure-5
12t Forklift Load test report Page No:
Sl No Description Observations
No load With load
02 Mast Lifting & Lowering:
Functioning of Mast lifting and lowering Observe for any leaks in hoses during operations.
03 Mast Tilting:
Functioning of Mast tilting Forward and Backward. Observe for any leaks during operation
04
Transmission
- Engagement & Disengagement of gears.
- For any slip - For any abnormality
05 Steering
- Function of steering on both sides. - For any other abnormality
06 Brakes Service Brakes
- Function of brakes on all wheels. - Effectiveness of brakes Parking Brakes
- Effectiveness of brakes
07 Gradient:
- Performance of the Equipment
6. Maintenance Details:
Type of maintenance scheduled Monthly, quarterly, Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
12t Forklift Load test report Page No:
Annexure-5
16t Forklift Load test report Page No:
16t CAPACITY FORKLIFT LOAD TEST REPORT
1. Equipment details:
1.1 16t VOLTAS Forklift VALF/FL/16T/01 WORK STATION-A
1.2 Capacity 16t at 1200 Load Centre
1.3 Load Test Venue
1.4 Date
2. Pre-Checks: Daily Checks for 16t forklift as per the Daily Checklists shall be carried out. 3. Materials Required for Load Testing
Sl No Item Qty Status
1. 5t Cement Block 3 nos
2. 1 dead weight 1 no
3. Measuring Tape 15m 1 No
4. Chalk pieces / scriber As required
4. Procedure:
Sl No Description Status
1. Arrange to keep the dummy 16t dummy weight on a level ground.
2. Support the load on forks at 1200mm load center as per the scheme. VALF/MHS/T&E/FL/16T
3. Lift the load slowly from the ground and check the fork lift for performance in loaded condition
4. Keep the load in the lift condition for 3 minutes and mark the position of guide way with chalk
5. Slowly bring down the load to the ground in mast back condition.
5. Performance of the Forklift:
Sl No Description Observations
No load With load
01 Engine: Lub Oil Pressure – Engine idling (1.0ksc - 1.5ksc) Lub Oil Pressure – Engine full speed (3.0ksc-4.0ksc) Radiator water temperature Maximum (850 Celsius) Charging System : Should show charging By deflection of pointer on +ve side
Annexure-5
16t Forklift Load test report Page No:
Sl No Description Observations
No load With load
02 Mast Lifting & Lowering: Functioning of Mast lifting and lowering Observe for any leaks in hoses during operations.
03 Mast Tilting: Functioning of Mast tilting Forward and Backward. Observe for any leaks during operation
04
Transmission
- Engagement & Disengagement of gears.
- For any slip - For any abnormality
05 Steering
- Function of steering on both sides. - For any other abnormality
06 Brakes Service Brakes
- Function of brakes on all wheels. - Effectiveness of brakes Parking Brakes
- Effectiveness of brakes
07 Gradient: - Performance of the Equipment
6. Maintenance Details:
Type of maintenance scheduled Monthly, quarterly, Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
16t Forklift Load test report Page No:
Annexure-5
HYDRAULIC SUSPENSION TRAILER LOAD TEST REPORT PAGE NO
LOAD TESTING OF HYDRAULIC SUSPENSION TRAILERS (GOLDHOFER/COMETTO TRAILER)
I. Equipment Details:
1.1 GOLDHOFER TRAILER-1 VALF/HT/65T/01
WORK STATION- A GOLDHOFER TRAILER-2 VALF/HT/65T/01
GOLDHOFER TRAILER-3 VALF/HT/65T/01
COMETTO TRAILER-1 VALF/HT/70T/01
COMETTO TRAILER-1 SPROB/HT/70T/01 WORK STATION-B
1.2 Capacity 65t/70T Payload
1.3 Load Test venue
1.4 Date
II. Pre-Checks of trailer: Check the 15t Flat Bed Air suspension trailer and Hauler as per the daily checklist III. No load performance of Hauler & Trailer:
Sl No Item Status
01 Connect the Hauler and Trailer – adjust the steering wedge play (Tighten fully with hand and loosen 1/4th turn)
02 Start the Hauler engine and pressurize the trailer and hauler lines and ensure release of parking/ fail-safe brakes
03 Start the power pack and adjust the trailer platform
level at four corners to the operating level 1165mm± 10mm
04 Check the alignment of trailer wheels and readjust if required.
05 In no load condition, take the hauler and trailer for a road trial, check the performance
IV. Materials Required
Sl No Item Qty Status
1. Dead Weight Concrete block
15t block -4no 5ton – 1 block
Total: 55.0t
2. Four legged Handling sling for the above blocks (80t)
1 No
3. Crane facility for loading the block 1 No
4. Felt pieces As required
5. Steel Rule 1 No.
6. 15m tape 1 No.
7. Square Steel plates 4 nos
Annexure-5
HYDRAULIC SUSPENSION TRAILER LOAD TEST REPORT PAGE NO
Sl No Item Qty Status
8. permanent marker 1 no
V. Procedure:
Sl No Item Status
01 Take the hauler and trailer to the facility where the concrete blocks and EOT crane facility are available for loading of concrete blocks (weight = 55t)
02 Spread the felt pieces on the trailer to have even seating of the concrete blocks.
03 Load the concrete blocks by using the EOT crane / Crane / Forklift as per the scheme: VALF/MHS/T&E/HT/70T
04 Park the trailer on level ground and note down the heights of the trailer on four corners of the platform.
04 Check for any abnormality and leaks at pipe lines, hoses and couplings in loaded condition
05 If no abnormality is observed check the performance of the hauler and trailer under loaded condition and record.
VI. Heights of the trailer platform:
S.No Description Initial level Final Level
Remarks
1 55 t loaded on single module GH trailer, level shall be checked from top edge of the platform to ground
FR FR
2 FL FL
3 RR RR
4 RL RL
NOTE: FR – FRONT RIGHT FL: FRONT LEFT; RR – REAR RIGHT; RL – REAR LEFT VII. Line Pressure checks are made as Follows:
S.No
Description Unladen Laden Remarks
1
Pressure Gauge Readings (bar)
FR FR
2 FL FL
3 RR RR
4 RL RL
Annexure-5
HYDRAULIC SUSPENSION TRAILER LOAD TEST REPORT PAGE NO
VIII. General Observations:
S.No Description Unladen Laden Remarks
1 Lifting & Lowering of gooseneck
2 Lifting & Lowering of Rear Left side of trailer
3 Lifting & Lowering of Rear Right side of trailer
4 RH Steering of the trailer at standstill condition
5 LH Steering of the trailer at standstill condition
6 RH Steering of the trailer in normal movement
7 LH Steering of the trailer in normal movement
IX. Performance of the Hauler & Trailer
Sl No Description Observations
No load With load
1. Engine Parameters: Eng Oil Pressure - Idling (between 1.0 and 3.0 bar) Eng Oil Pressure at Operating speed (between 3.0 and 5.5 bar) Radiator coolant Temp Maximum (Indicator needle should be in green zone)
2. Charging System : Should show charging Deflection of pointer to +ve side
3. Clutch - Engagement & disengagement
4. Transmission - Engagement & Disengagement of
gears. - For any abnormal noise
5. Steering (Hauler & Trailer) - Function of steering on both sides. - For any other abnormal noise
Annexure-5
HYDRAULIC SUSPENSION TRAILER LOAD TEST REPORT PAGE NO
Sl No Description Observations
No load With load
6. Brakes ( Hauler & Trailer) Service Brakes - Function of brakes on all wheels. - Effectiveness of brakes Parking Brakes - Effectiveness of brakes
7. Climbing Gradient: (1 in 10) - Performance of the Equipment
8. For any leaks at hose connections
9. Function of 5th wheel coupling
Engagement
Disengagement
X. Maintenance Details: Hauler::
Type of maintenance scheduled Monthly, half yearly & Annual
Maintenance last attended
Next maintenance due
GOLD HOFER/COMETTO Trailer::
Type of maintenance scheduled Quarterly & Annual
Maintenance last attended
Next maintenance due
Certified that the above Equipment are cleared for operation Date: Engineer, MHS Engineer, QRG
Annexure-5
HYDRAULIC SUSPENSION TRAILER LOAD TEST REPORT PAGE NO
Annexure-5
15t Pneumatic suspension trailer Page No:
15T AIR SUSPENSION TRAILER - LOAD TEST REPORT
1. Equipment Details:
1.1 15t Air Suspension Trailer VALF/AST/15T/01 WORK STATION- A
1.2 Capacity 15t Payload
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 15t Flat Bed Air suspension trailer as per the daily checklist 3. Procedure for Load Testing:
Sl No Description Status
01 Park the trailer on a level ground.
02 Take the initial measurements for measuring the deflection under no load condition as shown in the sketch
03 Keep a 15t (5t concrete blocks – 3 nos) load at the center of the trailer platform as per the loading scheme: VALF/MHS/T&E/AST/15T
04 Take the measurements under loaded condition
06 Permissible Deflection (Wheel base /325) 5150/325= 14.71mm
07 Record the Deflection
08 Whether the deflection is with in the limits?
09 Previous year deflection
10 Raise all four landing legs
Take the trailer for road test in loaded condition and test the performance of the trailer for the following. - Free rotation of wheels without any binding and
wobbling - Function of Turn table for free operation on both
left and right directions. - Function of tow bar & spring. - Effectiveness of brakes. Suspension System: - The suspension control valve should exhaust the
air in the bellows when wheel happen to climb a heap.
- The suspension Control valve should admit air into bellows when the wheels fall into road pit.
- For any abnormality
Annexure-5
15t Pneumatic suspension trailer Page No:
4. Maintenance Details:
Type of maintenance scheduled Half yearly / Annual
Maintenance last attended
Next Maintenance Due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
15t Pneumatic suspension trailer Page No:
Annexure-5
10T AIR SUSPENSION TRAILER Page No:
LOAD TEST REPORT OF 10T AIR SUSPENSION TRAILER
1. Equipment Details:
1.1 10t Air Suspension Trailer VALF/AST/10T/01 WORK STATION- A
1.2 Capacity 10t Payload
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 10t Flat Bed Air suspension trailer and Hauler as per the daily checklist 3. Procedure for Load Testing:
Sl No.
Description Status
1. Connect the hauler and check for no load performance (The hauler to be used)
2. If no load performance is satisfactory, keep the trailer for loading.
3. Take the measurements of the trailer platform as per the details given in the sketch in no load condition for calculating the deflection
4. Load 10t (5T concrete blocks – 2 nos) so that the load is equally shared on the trailer platform as per the scheme: VALF/MHS/T&E/AST/10T.
5. Take the measurements of the trailer platform as per the details given in the sketch in loaded condition for calculating deflection
6. Calculate the deflection as per the procedure given in the sketch and record.
7. Take the hauler and trailer for road trial and check the performance of the trailer for the items mentioned in the sketch and record.
8. After the road trial, remove the load. Take measurements of the trailer platform again as per the details given in the sketch compare with the measurements taken to verify that there is no permanent set
9. Check the trailer platform and parts physically that no permanent deformation has taken place.
4. TRAILER OPERATIONAL CHECKS:
Sl No
SYSTEM
Status
No Load With Load (10.0T)
1. DEFLECTION CALCULATION
2. CLH = Height of the platform at ( C) on
left side
Annexure-5
10T AIR SUSPENSION TRAILER Page No:
Sl No
SYSTEM
Status
No Load With Load (10.0T)
CRH = Height of the platform at ( C) on
right side
3. Net Deflection Measured at C =
4. Permissible deflection at C
5. Whether the deflection is within limits
6. OPERATIONAL TESTS:
7. Function of fifth wheel for free
operation on both left and right
directions.
8. Free rotation of wheels without any
binding and wobbling
9. Effectiveness of brakes
10. Functioning of air bellows, height
control valve, and kingpin.
11. Suspension System
- The height of the platform in laden
condition + deflection of trailer
under load = 1100 ± 25mm
- The suspension control valve should
exhaust the air in the bellows when
wheels happen to climb a heap.
- The suspension control valve should
admit air into bellows when the
wheels fall into road pit.
12. Any abnormality
13. Noticing of any permanent set after
removal of load
14. REMARKS IF ANY:
Annexure-5
10T AIR SUSPENSION TRAILER Page No:
VI Maintenance Details:
Type of maintenance scheduled Monthly, quarterly, Annual
Maintenance last attended
Next Maintenance Due
Load test results are found Satisfactory.
Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
10T AIR SUSPENSION TRAILER Page No:
Annexure-5
18t Pneumatic suspension trailer Page No:
18T AIR SUSPENSION TRAILER - LOAD TEST REPORT I. EQUIPMENT DETAILS:
1.1 18t Air Suspension Trailer VALF/FT/18T/01 WORK STATION- A
1.2 Capacity 18t Payload
1.3 Load Test venue
1.4 Date
II. Pre-Checks of trailer: Check the 18t Flat Bed Air suspension trailer and Hauler as per the daily checklist III Procedure for Load Testing:
Sl No Description Status
01 Park the trailer on a level ground.
02 Take the initial measurements for measuring the deflection under no load condition as shown in the sketch
03 Keep a 18t (3 Concrete blocks & 2 MST wheels) load at the center of the trailer platform as per the loading scheme: VALF/MHS/T&E/AST/18T
04 Take the measurements under loaded condition
05 Permissible Deflection (Wheel base /325) 11850/325= 36.46mm
06 Measured Deflection
07 Whether the deflection is with in the limits?
08 Previous Year measured Deflection
09 Raise all four landing legs
Take the trailer for road test in loaded condition and test the performance of the trailer for the following. - Free rotation of wheels without any binding and
wobbling - Function of Turn table for free operation on both left
and right directions. - Function of tow bar & spring. - Effectiveness of brakes. Suspension System: - The suspension control valve should exhaust the air
in the bellows when wheel happen to climb a heap. - The suspension Control valve should admit air into
bellows when the wheels fall into road pit. - For any abnormality
V Maintenance Details:
Type of maintenance scheduled Half yearly / Annual
Maintenance last attended
Next Maintenance Due
Certified that the above Equipment is cleared for operation Date: Engineer, MH Engineer, QRG
Annexure-5
18t Pneumatic suspension trailer Page No:
Annexure-5
10T FLATBED TRAILER Page No:
LOAD TEST REPORT OF 10T FLAT BED TRAILER
1. Equipment Details:
1.1 10t Flat Bed Full Trailer VALF/FT/10T/01 WORK STATION- A
1.2 Capacity 10t Payload
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 10t Flat Bed Full Trailer and Hauler as per the daily checklist 3. No load Performance of the trailer:
S.No Description Status
1. Connect the hauler and check the trailer - Function of turntable for free operation on both Left & right directions. - Free rotation of wheels without any binding and wobbling - Action of toe bar spring and anchoring points - For any abnormality
4. Material required for Load testing:
Sl.No Item Qty Status
6.1 5t Concrete blocks 2 nos
6.2 Steel rule 1 no
6.3 MS plate 4 nos
6.4 Measuring tape 1no
6.5 Chalk piece or scriber A.R
6.6 Nylon thread required length
5.Procedure:
Sl No.
Description Status
7.1 Park the trailer on a level ground.
7.2 Take the initial measurements for measuring the deflection under no load condition as shown in the sketch.
7.3 Keep 5 ton blocks- 2 nos load at the centre of the trailer platform.
7.4 Take the measurements under loaded condition.
7.5 Calculate the Deflection as per the procedure as per the procedure given in the sketch & Record.
7.6 Total Deflection measured
7.7 Permissible deflection (Wheel Base / 325)
Annexure-5
10T FLATBED TRAILER Page No:
Sl
No.
Description Status
6950/325 = 21.385 mm
7.8 Whether the deflection is within the limits?
7.9 Previous year deflection measured in mm
8.0 After measuring the deflection, remove the load and take the measurements again and compare with the initial measurements taken to verify that there is no permanent set.
8.1 Place the load again in the same position
8.2 Take the trailer for the road test in loaded condition and test the performance of the trailer for the following.
- Function of turntable for free operation on both left & right directions.
- Free rotation of wheels without any binding and wobbling.
- Action of the Toe bar spring & anchoring points. - For any abnormality.
VI Maintenance Details:
Type of maintenance scheduled Monthly, quarterly, Annual
Maintenance last attended
Next Maintenance Due
Load test results are found Satisfactory. Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
10T FLATBED TRAILER Page No:
Annexure-5
8T FLATBED TRAILER Page No:
LOAD TEST REPORT OF 8T FLAT BED TRAILER
1. Equipment Details:
1.1 8t Flat Bed Full Trailer VALF/FT/8T/01 WORK STATION- A
1.2 Capacity 8t Payload
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 8t Flat Bed Full Trailer and Hauler as per the daily checklist
3. No load Performance of the trailer:
Sl No.
Description Status
1. Connect the hauler and check the trailer - Function of turntable for free operation on both Left & right directions. - Free rotation of wheels without any binding and wobbling - Action of toe bar spring and anchoring points - For any abnormality
4. Material required for Load testing:
Sl.No Item Qty Status
1. 5t Concrete block & MST Wheels 1 no & 2 nos
2. Steel rule 1 no
3. MS plate 150mmX 150mm 4 nos
4. Measuring tape 1no
5. Chalk piece or scriber A.R
5.Procedure:
S.No Description Status
1 Park the trailer on a level ground.
2 Take the initial measurements for measuring the deflection under no load condition as shown in the sketch.
3 Keep 5 ton blocks- 1 no and MST wheels 02 nos load at the centre of the trailer platform as per the Load test scheme
4 Take the measurements under loaded condition.
5 Calculate the Deflection as per the procedure as per the procedure given in the sketch & Record.
6 Total Deflection measured
7 Permissible deflection (Wheel Base / 325) 1600/325 = 4.90 mm
Annexure-5
8T FLATBED TRAILER Page No:
S.No Description Status
8 Whether the deflection is within the limits?
9 Previous year deflection measured in mm
10 After measuring the deflection, remove the load and take the measurements again and compare with the initial measurements taken to verify that there is no permanent set.
11 Place the load again in the same position
12 Take the trailer for the road test in loaded condition and test the performance of the trailer for the following.
- Function of turntable for free operation on both left & right directions.
- Free rotation of wheels without any binding and wobbling.
- Action of the Toe bar spring & anchoring points. - For any abnormality.
Maintenance Details:
Type of maintenance scheduled Half yearly / Annual
Maintenance last attended
Next Maintenance Due
Certified that the above Equipment is cleared for operation Date: Contract Supervisor Engineer, MHS
Annexure-5
8T FLATBED TRAILER Page No:
Annexure-5
20T BOWL TRAILER Page No:
LOAD TEST REPORT OF 20t BOWL TRAILER
1. Equipment Details:
1.1 Low Bed Trailer WORK STATION- B
1.2 Capacity 20t PAYLOAD
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 20t capacity Bowl Trailer and Hauler as per the daily checklist
3. No load Performance of the trailer:
Sl No.
Description Status
1. Connect the hauler and check the trailer - Function of turntable for free operation on both Left & right directions. - Free rotation of wheels without any binding and wobbling - Action of toe bar spring and anchoring points - For any abnormality
4. Material required for Load testing:
Sl.No Item Qty Status
1. 5t Concrete blocks 4 nos
2. Steel rule 1 no
3. MS plate 150mmX 150mm 4 nos
4. Measuring tape 1no
5. Chalk piece or scriber A.R
5. Procedure:
S.No Description Status
1 Park the trailer on a level ground.
2 Take the initial measurements for measuring the deflection under no load condition as shown in the sketch.
3 Keep 5t block- 4 nos and load at the centre of the trailer platform as per the Load test scheme: SPROB/MHS/T&E/FT/20T
4 Take the measurements under loaded condition.
5 Calculate the Deflection as per the procedure as per the procedure given in the sketch & Record.
6 Total Deflection measured
7 Permissible deflection (Wheel Base / 325)
8 Whether the deflection is within the limits?
Annexure-5
20T BOWL TRAILER Page No:
S.No Description Status
9 Previous year deflection measured in mm
10 After measuring the deflection, remove the load and take the measurements again and compare with the initial measurements taken to verify that there is no permanent set.
11 Place the load again in the same position
12 Take the trailer for the road test in loaded condition and test the performance of the trailer for the following.
- Function of turntable for free operation on both left & right directions.
- Free rotation of wheels without any binding and wobbling.
- Action of the Toe bar spring & anchoring points. - For any abnormality.
Maintenance Details:
Type of maintenance scheduled Half yearly / Annual
Maintenance last attended
Next Maintenance Due
Certified that the above Equipment is cleared for operation Date: Contract Supervisor Engineer, MHS
Annexure-5
20T BOWL TRAILER Page No:
Annexure-5
15t Flat bed trailer Load test report Page No:
LOAD TEST REPORT FOR 15 TON FLAT BED TRAILER
1. Equipment Details:
1.1 15t Air Suspension Trailer VALF/FT/15T/01 WORK STATION- A
1.2 Capacity 15t Payload
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 15t Flat Bed Air suspension trailer and Hauler as per the daily checklist 3. No load Performance of the trailer:
Sl No Description Status
01 Connect the hauler and check the trailer
- Function of Turn Table for free operation on both left and right directions.
- Free rotation of wheels without any binding and wobbling
- Action of toe bar spring and anchoring points - For any abnormality
4. Materials Required for Load Testing
Sl No Item Qty Status
01 5t Concrete block 3 Nos.
02 Steel rule 1 No
03 Ms Plates 4 Nos.
04 Measuring tape 1 No
05 Chalk piece or scriber A.R
06 Nylon thread required length
5. Procedure:
Sl No Description Status
01 Park the trailer on a level ground.
02 Take the initial measurements for measuring the deflection under no load condition as shown in the sketch
03 Keep a 5t block-3nos load at the center of the trailer platform as per the load test scheme
04 Take the measurements under loaded condition
05 Calculate the deflection as per the procedure given in the sketch and record.
Annexure-5
15t Flat bed trailer Load test report Page No:
Sl No Description Status
06 Total Deflection measured
07 Permissible Deflection (Wheel base /325) 5950/325= 18.3 mm
08 Whether the deflection is with in the limits?
09 Previous year deflection measured (mm)
10 After measuring of deflection, remove the load moment and take the measurements again and compare with the initial measurements taken to verify that there is no permanent set .
11 Place the load again in the same position
12 Take the trailer for road test in loaded condition and test the performance of the trailer for the following. - Function of turntable for free operation on
both left and right directions. - Free rotation of wheels without any binding
and wobbling - Action of toe bar spring and anchoring points - For any abnormality
6. Maintenance Details:
Type of maintenance schedule Half yearly & Annual
Maintenance last attended
Next maintenance due
Load test results are found Satisfactory.
Date: Contractor’s Supervisor Engineer-in-charge
Annexure-5
15t Flat bed trailer Load test report Page No:
Annexure-5
AP BIN TRAILER Page No:
LOAD TEST REPORT OF AP BIN TRAILERS
1. Equipment Details:
1.1
AP BIN Trailer SXC 4005
WORK STATION- B AP BIN Trailer SXC 4105
AP BIN Trailer
AP BIN Trailer
1.2 Capacity 5t Payload
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 5t capacity AP bin Full Trailer and Hauler as per the daily checklist 3. No load Performance of the trailer:
Sl
No. Description Status
1. Connect the hauler and check the trailer
- Function of turntable for free operation on both Left & right directions. - Free rotation of wheels without any binding and wobbling - Action of toe bar spring and anchoring points - For any abnormality
4. Material required for Load testing:
Sl.No Item Qty Status
1. 5t Concrete block 1 no
2. Steel rule 1 no
3. MS plate 150mmX 150mm 4 nos
4. Measuring tape 1no
5. Chalk piece or scriber A.R
5.Procedure:
S.No Description Status
1 Park the trailer on a level ground.
2 Take the initial measurements for measuring the deflection under no load condition as shown in the sketch.
3 Keep 5ton block- 1 no and load at the centre of the trailer platform as per the Load test scheme: SPROB/MHS/T&E/FBT/5T
4 Take the measurements under loaded condition.
5 Calculate the Deflection as per the procedure as per the procedure given in the sketch & Record.
6 Total Deflection measured
Annexure-5
AP BIN TRAILER Page No:
S.No Description Status
7 Permissible deflection (Wheel Base / 325)
8 Whether the deflection is within the limits?
9 Previous year deflection measured in mm
10 After measuring the deflection, remove the load and take the measurements again and compare with the initial measurements taken to verify that there is no permanent set.
11 Place the load again in the same position
12 Take the trailer for the road test in loaded condition and test the performance of the trailer for the following.
- Function of turntable for free operation on both left & right directions.
- Free rotation of wheels without any binding and wobbling.
- Action of the Toe bar spring & anchoring points. - For any abnormality.
Maintenance Details:
Type of maintenance scheduled Half yearly / Annual
Maintenance last attended
Next Maintenance Due
Certified that the above Equipment is cleared for operation Date: Contract Supervisor Engineer, MHS
Annexure-5
AP BIN TRAILER Page No:
Annexure-5
APPLE FULL TRAILER Page No:
LOAD TEST REPORT OF APPLE TRAILERS
1. Equipment Details:
1.1 APPLE Trailer – 8 SXC 3101
WORK STATION- B APPLE Trailer – 10 SXC 3301
1.2 Capacity 1t Payload
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 1t capacity Apple Full Trailer and Hauler as per the daily checklist 3. No load Performance of the trailer:
Sl No.
Description Status
1. Connect the hauler and check the trailer - Function of turntable for free operation on both Left & right directions. - Free rotation of wheels without any binding and wobbling - Action of toe bar spring and anchoring points - For any abnormality
4. Material required for Load testing:
Sl.No Item Qty Status
1. 1t Concrete block 1 no
2. Steel rule 1 no
3. MS plate 150mmX 150mm 4 nos
4. Measuring tape 1no
5. Chalk piece or scriber A.R
5.Procedure:
S.No Description Status
1 Park the trailer on a level ground.
2 Take the initial measurements for measuring the deflection under no load condition as shown in the sketch.
3 Keep 1ton block- 1 no and load at the centre of the trailer platform as per the Load test scheme: SPROB/MHS/T&E/FBT-1/1T
4 Take the measurements under loaded condition.
5 Calculate the Deflection as per the procedure as per the procedure given in the sketch & Record.
6 Total Deflection measured
7 Permissible deflection (Wheel Base / 325)
Annexure-5
APPLE FULL TRAILER Page No:
S.No Description Status
1000/325 = 3.07 mm
8 Whether the deflection is within the limits?
9 Previous year deflection measured in mm
10 After measuring the deflection, remove the load and take the measurements again and compare with the initial measurements taken to verify that there is no permanent set.
11 Place the load again in the same position
12 Take the trailer for the road test in loaded condition and test the performance of the trailer for the following.
- Function of turntable for free operation on both left & right directions.
- Free rotation of wheels without any binding and wobbling.
- Action of the Toe bar spring & anchoring points. - For any abnormality.
Maintenance Details:
Type of maintenance scheduled Half yearly / Annual
Maintenance last attended
Next Maintenance Due
Certified that the above Equipment is cleared for operation Date: Contract Supervisor Engineer, MHS
Annexure-5
APPLE FULL TRAILER Page No:
APPLE FULL TRAILER Page No:
LOAD TEST REPORT OF APPLE TRAILERS
1. Equipment Details:
1.1
APPLE Trailer – 1 1SXC 1601
WORK STATION- B
APPLE Trailer – 2 SXC 1801
APPLE Trailer – 3 SXC 2201
APPLE Trailer – 4 SXC 2301
APPLE Trailer – 5 SXC 2501
APPLE Trailer – 6 SXC 2601
APPLE Trailer – 7 SXC 3001
APPLE Trailer – 9 SXC 3201
1.2 Capacity 1t Payload
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 1t capacity Apple Full Trailer and Hauler as per the daily checklist 3. No load Performance of the trailer:
Sl
No. Description Status
1. Connect the hauler and check the trailer - Function of turntable for free operation on both Left & right directions. - Free rotation of wheels without any binding and wobbling - Action of toe bar spring and anchoring points - For any abnormality
4. Material required for Load testing:
Sl.No Item Qty Status
1. 1t Concrete block 1 no
2. Steel rule 1 no
3. MS plate 150mmX 150mm 4 nos
4. Measuring tape 1no
5. Chalk piece or scriber A.R
5.Procedure:
S.No Description Status
1 Park the trailer on a level ground.
2 Take the initial measurements for measuring the deflection under no load condition as shown in the sketch.
3 Keep 1ton block- 1 no and load at the centre of the trailer platform as per the Load test scheme:
SPROB/MHS/T&E/FT/1T
4 Take the measurements under loaded condition.
APPLE FULL TRAILER Page No:
S.No Description Status
5 Calculate the Deflection as per the procedure as per the procedure given in the sketch & Record.
6 Total Deflection measured
7 Permissible deflection (Wheel Base / 325) 800/325 = 2.46 mm
8 Whether the deflection is within the limits?
9 Previous year deflection measured in mm
10 After measuring the deflection, remove the load and take the measurements again and compare with the initial measurements taken to verify that there is no permanent set.
11 Place the load again in the same position
12 Take the trailer for the road test in loaded condition and test the performance of the trailer for the following.
- Function of turntable for free operation on both left & right directions.
- Free rotation of wheels without any binding and wobbling.
- Action of the Toe bar spring & anchoring points. - For any abnormality.
Maintenance Details:
Type of maintenance scheduled Half yearly / Annual
Maintenance last attended
Next Maintenance Due
Certified that the above Equipment is cleared for operation Date: Contract Supervisor Engineer, MHS
APPLE FULL TRAILER Page No:
Annexure-5
BOWL TRAILER Page No:
LOAD TEST REPORT OF BOWL TRAILERS
1. Equipment Details:
1.1 BOWL Trailer SXC 4615
WORK STATION- B BOWL Trailer – 1 SXC 2115
BOWL Trailer – 2 SXC 2915
BOWL Trailer – 3 SXC 3215
1.2 Capacity 20t GCW
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 15t capacity Bowl Full Trailer and Hauler as per the daily checklist 3. No load Performance of the trailer:
Sl No.
Description Status
1. Connect the hauler and check the trailer - Function of turntable for free operation on both Left & right directions. - Free rotation of wheels without any binding and wobbling - Action of toe bar spring and anchoring points - For any abnormality
4. Material required for Load testing:
Sl.No Item Qty Status
1. 1t Concrete block 1 no
2. Steel rule 1 no
3. MS plate 150mmX 150mm 4 nos
4. Measuring tape 1no
5. Chalk piece or scriber A.R
5.Procedure:
S.No Description Status
1 Park the trailer on a level ground.
2 Take the initial measurements for measuring the deflection under no load condition as shown in the sketch.
3 Keep 5ton block- 3 nos and load at the centre of the trailer platform as per the Load test scheme:
SPROB/MHS/T&E/FBT/15T
4 Take the measurements under loaded condition.
5 Calculate the Deflection as per the procedure as per the procedure given in the sketch & Record.
Annexure-5
BOWL TRAILER Page No:
S.No Description Status
6 Total Deflection measured
7 Permissible deflection (Wheel Base / 325)
8 Whether the deflection is within the limits?
9 Previous year deflection measured in mm
10 After measuring the deflection, remove the load and take the measurements again and compare with the initial measurements taken to verify that there is no permanent set.
11 Place the load again in the same position
12 Take the trailer for the road test in loaded condition and test the performance of the trailer for the following.
- Function of turntable for free operation on both left & right directions.
- Free rotation of wheels without any binding and wobbling.
- Action of the Toe bar spring & anchoring points. - For any abnormality.
Maintenance Details:
Type of maintenance scheduled Half yearly / Annual
Maintenance last attended
Next Maintenance Due
Certified that the above Equipment is cleared for operation Date: Contract Supervisor Engineer, MHS
Annexure-5
BOWL TRAILER Page No:
Annexure-5
LOW BED TRAILER Page No:
LOAD TEST REPORT OF LOW BED TRAILERS
1. Equipment Details:
1.1
Low Bed Trailer SXC 4202
WORK STATION- B Low Bed Trailer SXC 4302
Low Bed Trailer SXC 4402
Low Bed Trailer SXC 4802
1.2 Capacity 2t PAYLOAD
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 2t capacity Low bed Trailer and Hauler as per the daily checklist 3. No load Performance of the trailer:
Sl
No. Description Status
1. Connect the hauler and check the trailer
- Function of turntable for free operation on both Left & right directions. - Free rotation of wheels without any binding and wobbling - Action of toe bar spring and anchoring points - For any abnormality
4. Material required for Load testing:
Sl.No Item Qty Status
1. 2t Concrete block 1 nos
2. Steel rule 1 no
3. MS plate 150mmX 150mm 4 nos
4. Measuring tape 1no
5. Chalk piece or scriber A.R
5. Procedure:
S.No Description Status
1 Park the trailer on a level ground.
2 Take the initial measurements for measuring the deflection under no load condition as shown in the sketch.
3 Keep 2t block- 1 nos and load at the centre of the trailer platform as per the Load test scheme: SPROB/MHS/T&E/FBT/2T
4 Take the measurements under loaded condition.
5 Calculate the Deflection as per the procedure as per the procedure given in the sketch & Record.
6 Total Deflection measured
Annexure-5
LOW BED TRAILER Page No:
S.No Description Status
7 Permissible deflection (Wheel Base / 325)
8 Whether the deflection is within the limits?
9 Previous year deflection measured in mm
10 After measuring the deflection, remove the load and take the measurements again and compare with the initial measurements taken to verify that there is no permanent set.
11 Place the load again in the same position
12 Take the trailer for the road test in loaded condition and test the performance of the trailer for the following.
- Function of turntable for free operation on both left & right directions.
- Free rotation of wheels without any binding and wobbling.
- Action of the Toe bar spring & anchoring points. - For any abnormality.
Maintenance Details:
Type of maintenance scheduled Half yearly / Annual
Maintenance last attended
Next Maintenance Due
Certified that the above Equipment is cleared for operation Date: Contract Supervisor Engineer, MHS
Annexure-5
LOW BED TRAILER Page No:
Annexure-5
AP BIN TRAILER Page No:
LOAD TEST REPORT OF LOW BED TRAILERS
1. Equipment Details:
1.1 Low Bed Trailer SXC 2820 WORK STATION- B
1.2 Capacity 20t PAYLOAD
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 20t capacity Low bed Trailer and Hauler as per the daily checklist 3. No load Performance of the trailer:
Sl No.
Description Status
1. Connect the hauler and check the trailer - Function of turntable for free operation on both Left & right directions. - Free rotation of wheels without any binding and wobbling - Action of toe bar spring and anchoring points - For any abnormality
4. Material required for Load testing:
Sl.No Item Qty Status
1. 5t Concrete blocks 4 nos
2. Steel rule 1 no
3. MS plate 150mmX 150mm 4 nos
4. Measuring tape 1no
5. Chalk piece or scriber A.R
5. Procedure:
S.No Description Status
1 Park the trailer on a level ground.
2 Take the initial measurements for measuring the deflection under no load condition as shown in the sketch.
3 Keep 5t block- 4 nos and load at the centre of the trailer platform as per the Load test scheme:
SPROB/MHS/T&E/FBT/20T
4 Take the measurements under loaded condition.
5 Calculate the Deflection as per the procedure as per the procedure given in the sketch & Record.
6 Total Deflection measured
7 Permissible deflection (Wheel Base / 325)
8 Whether the deflection is within the limits?
Annexure-5
AP BIN TRAILER Page No:
S.No Description Status
9 Previous year deflection measured in mm
10 After measuring the deflection, remove the load and take the measurements again and compare with the initial measurements taken to verify that there is no permanent set.
11 Place the load again in the same position
12 Take the trailer for the road test in loaded condition and test the performance of the trailer for the following.
- Function of turntable for free operation on both left & right directions.
- Free rotation of wheels without any binding and wobbling.
- Action of the Toe bar spring & anchoring points. - For any abnormality.
Maintenance Details:
Type of maintenance scheduled Half yearly / Annual
Maintenance last attended
Next Maintenance Due
Certified that the above Equipment is cleared for operation Date: Contract Supervisor Engineer, MHS
Annexure-5
AP BIN TRAILER Page No:
Annexure-5
PS0 XL TRAILER Page No:
LOAD TEST REPORT OF PS0 XL TRAILER
1. Equipment Details:
1.1 WELL BED TRAILER SXC 4825 WORK STATION- B
1.2 Capacity 25t Payload
1.3 Load Test venue
1.4 Date
2. Pre-Checks of trailer: Check the 25t capacity Well Bed trailer and Hauler as per the daily checklist 3. No load Performance of the trailer:
Sl No.
Description Status
1. Connect the hauler and check the trailer - Function of turntable for free operation on both Left & right directions. - Free rotation of wheels without any binding and wobbling - Action of toe bar spring and anchoring points - For any abnormality
4. Material required for Load testing:
Sl.No Item Qty Status
1. 5t Concrete blocks 5 nos
2. Steel rule 1 no
3. MS plate 150mmX 150mm 4 nos
4. Measuring tape 1no
5. Chalk piece or scriber A.R
5. Procedure:
S.No Description Status
1 Park the trailer on a level ground.
2 Take the initial measurements for measuring the deflection under no load condition as shown in the sketch.
3 Keep 5t blocks- 5 no and load at the centre of the trailer platform as per the Load test scheme: SPROB/MHS/T&E/WBT/25T
4 Take the measurements under loaded condition.
5 Calculate the Deflection as per the procedure as per the procedure given in the sketch & Record.
6 Total Deflection measured
7 Permissible deflection (Wheel Base / 325)
Annexure-5
PS0 XL TRAILER Page No:
S.No Description Status
8 Whether the deflection is within the limits?
9 Previous year deflection measured in mm
10 After measuring the deflection, remove the load and take the measurements again and compare with the initial measurements taken to verify that there is no permanent set.
11 Place the load again in the same position
12 Take the trailer for the road test in loaded condition and test the performance of the trailer for the following.
- Function of turntable for free operation on both left & right directions.
- Free rotation of wheels without any binding and wobbling.
- Action of the Toe bar spring & anchoring points. - For any abnormality.
Maintenance Details:
Type of maintenance scheduled Half yearly / Annual
Maintenance last attended
Next Maintenance Due
Certified that the above Equipment is cleared for operation Date: Contract Supervisor Engineer, MHS
Annexure-5
PS0 XL TRAILER Page No:
Page 1 of 11
Annexure-6
LIST OF MINOR BREAKDOWN / REPAIR WORKS
ENGINE, CLUTCH, STEERING, BRAKES AND GENERAL VEHICLE SYSTEMS
SL No.
Type of break down / Repair activities
1. Fan belt replacement
2. Replacement of radiator hoses
3. Removing and changing of radiator assembly
4. Diesel and oil pipes changing
5. Minor radiator repairs
6. Removal and fitment of Water pump assembly
7. Changing of water pump kit
8. Removal and fitment of FIP injectors
9. Removal and fitment of FI Pump Assembly
10. Removing and changing of cylinder head and changing of head gasket
11. Removing and refitting exhaust pipes for repairs
12. Removing and refitting of clutch units and changing of clutch plates
13. Replacement of Propeller Shaft Universal Joint crosses
14. Replacement of Propeller Shaft Center Joint bearing
15. Replacing of unloader valve kit
16. Replacing of check valve kit
17. Replacing of tyre inflator kit
18. Replacing of brake chamber diaphragm
19. Replacing palm coupling / kit
20. Replacing foot pedal valve kit
21. Replacing of Speedo meter / hour meter cable
22. Replacing of Master Cylinder Kit and bleeding
23. Replacing of Wheel Cylinder kits and bleeding
24. Removing of diesel tank, cleaning, repairing and fitment
HYDRAULIC SYSTEM
SL No.
Type of break down / Repair activities
1. Replacing of hoses and connected fittings and filters
2. Removing and refitting of hydraulic drive pump assembly
3. Replacing of hydraulic pump kits
4. Removing and refitting of control valve assembly
5. Replacing of control valve service kits
6. Replacing of check valve assembly
7. Replacing of check valve kit
8. Removing of hoist cylinder, changing of kit and refitting to the equipment
9. Removing of tilt cylinder, changing of kit and refitting to the equipment
10. Removing and replacing of steering cylinder
11. Replacing of steering repair kit
12. Removing and cleaning of transmission oil strainer and refitting
Page 2 of 11
ELECTRICAL SYSTEM
SL No.
Type of break down / Repair activities
1. Replacing of Battery
2. Soldering of battery clamps & terminals
3. Battery pole replacement
4. Replacing of ignition switch and other switches
5. Removal and fitment of Head light assemblies
7. Removing and refitting of generator / alternator
8. Adjusting regulator settings
9. Replacing of regulator assembly
10. Removal and fitment of horn assemblies
11. Attending to the repairs of horn and tuning
12. Attending to self motor problems and overhauling
13. Attending to dynamo / alternator problems and overhauling
14. Fixing of extra light fittings as per requirement
15. Adjusting head light focus
16. Reconditioning of self motor solenoid switches
OTHER ELECTRICAL SYSTEM
SL No.
Type of break down / Repair activities
1. Mixing of battery acid, making the new dry battery ready for charging and charging
2. Reconditioning of self motor and dynamo / alternator armatures with new winding and commutator setting
3. Providing new insulation tape to filed coils of self motor and dynamo / alternator, varnishing and fitting back.
Page 3 of 11
Annexure-7
LIST OF EQPT FOR PAINTING OF MATERIAL HANDLING EQUIPMENT
WORKSTATION – A & B
Sl.NO EQUIPMENT NAME & EQUIPMENT NUMBER
1. 2T GODREJ FORKLIFT VALF/FL/2T/01
2. 3T GODREJ FORKLIFT-1 VALF/FL/3T/01
3. 3T GODREJ FORKLIFT-2 VALF/FL/3T/02
4. 3T GODREJ FORKLIFT-3 VALF/FL/3T/03
5. 5T GODREJ FORKLIFT VALF/FL/5T/01
6. 10T GODREJ FORKLIFT VALF/FL/10T/01
7. 16T VOLTAS FORKLFIT VALF/FL/16T/01
8. EICHER TRACTOR-1 VALF/HA/15T/01
9. EICHER TRACTOR-2 VALF/HA/15T/02
10. EICHER TRACTOR-3 VALF/HA/15T/03
11. EICHER TRACTOR-4 VALF/HA/15T/04
12. ASHOK LEYLAND HIPPO HAULER 1/13, VALF/HA/49T/01
13. ASHOK LEYLAND HIPPO HAULER ¼ VALF/HA/49T/02
14. VOLVO HAULER -1 VALF/HA/49T/03
15. VOLVO HAULER -2 VALF/HA/49T/04
16. VOLVO HAULER -3 VALF/HA/49T/05
17. AMW HAULER - 1 VALF/HA/49T/06
18. AMW HAULER – 2 VALF/HA/49T/07
19. TATA PRIMA HAULER VALF/HA/49T/08
20. 70T BEML HAULER – 1 VALF/HA/70T/01
21. 70T BEML HAULER – 2 VALF/HA/70T/02
22. TATA ACE CYLINDER TRANSPORTER AP 26 X 7113
23. TATA ACE AGNI MOTOR TRANSPORTER AP 26 X 7116
24. TATA ACESAMPLE PROPELLANT TRANSPORTER , AP 26 TT 4189
25. TATA 407 MINI EXPLOSIVE VAN AP26 TT 0510
26. TATA UPLINK VEHICLE
27. TATA 807 SAFETY VAN, AP26 T 2240
28. TATA 709 SAFETY VAN, AP26 X 7114
29. TATA 709 EXINDUSTIAL MINI TRUCK, AP26 W 9868
30. TATA 1210 E PLATFORM TRUCK AP26 T 791
31. TATA 1613 EXPLOSIVE VAN AP26 X 1954
32. 10T HYDRA PICK ‘N’ CARRY CRANE VALF/MC/10T/01
33. 15T TYRE MOUNTED TIL CRANE VALF/MC/15T/01
34. 10T AIR SUSPENSION TRAILER VALF/ST/AST/10T/01
35. 15T AIR SUSPENSION TRAILER VALF/FT/AFT/15T/01
36. 18T AIR SUSPENSION TRAILER VALF/AST/18T/01
37. GOLDHOFER TRAILER-2 VALF/HT/65T/02
38. GOLDHOFER TRAILER-3 VALF/HT/65T/03
39. COMETTO TRAILER-1 VALF/HT/70T/01
Page 4 of 11
Sl.NO EQUIPMENT NAME & EQUIPMENT NUMBER
40. 4T FLAT BED FULL TRAIER VALF/FT/4T/01
41. 5T FLAT BED FULL TRAILER VALF/FT/5T/01
42. 8T FLAT BED FULL TRAILER VALF/FT/8T/01
43. 10T FLAT BED FULL TRAILER-1 VALF/FT/10T/01
44. 10T FLAT BED FULL TRAILER-2 VALF/FT/10T/02
45. 10T WELL BED TRAILER-1 VALF/LT/10T/01
46. 10T WELL BED TRAILER-2 VALF/LT/10T/02
47. 15T FLAT BED FULL TRAILER-1 VALF/FT/15T/01
48. 15T FLAT BED FULL TRAILER-2 VALF/FT/15T/02
49. 30T DEAD WEIGHT TRANSPORTER VALF/FT/30T/01
50. 30T FLAT BED SEMI TRAILER VALF/ST/30T/01
51. PS0 TRANSTILT VALF/ST/PS0/01
52. CRYO TRANSTILT VALF/ST/CT/01
53. CRYO TRANSTILT C25 VALF/ST/CT/02
54. L40 TRANSTILT VALF/ST/L40/01
55. L110 TRANSTILT VALF/ST/L110/01
56. PS0M – XL TRANSTILT VALF/ST/PS0-XL/01
57. 12T SEMI TRAILER – 1 VALF/HAT/N2-2X2/01
58. 12T SEMI TRAILER – 2 VALF/HAT/N2-2X2/02
59. LIQUID HYDROGEN TANKER-I LSSF/ST/LH-2/45CM/01
60. LIQUID HYDROGEN TANKER-II LSSF/ST/LH-2/45CM/02
61. LIQUID OXYGEN TANKER LSSF/ST/OXY/45CM/01
62. 15 KL LIQUID HYDROGEN TANKER-I LSSF/ST/LH-1/15KL/01
63. 40 KL LIQUID HYDROGEN TANKER-I LSSF/ST/LH-1/40KL/01
64. 40 KL LIQUID HELIUM TANKER-I LSSF/ST/LHE-1/40KL/01
65. ADITHYA MOTOR TRANSPORTER VALF/FT/1T/01
66. AGNI MOTOR TRAILER-1 VALF/AT/1T/01
67. AGNI MOTOR TRAILER-2 VALF/AT/1T/02
68. JEEP TRAILER-1 VALF/JT/1T/01
69. JEEP TRAILER-2 VALF/JT/1T/02
70. RH 200 TRANSPORTER VALF/FT/RH200/2T/01
71. RH 560 TRANSPORTER-2 VALF/FT/RH560/3T/01
72. RH 560 TRANSPORTER-1 VALF/FT/RH560/6T/01
73. NITROGEN TANKER (8CM) LSSF/FT/N2-8CM/01
74. 10T N2 MODULE TRAILER-I LSSF/FT/N2-10T/01
75. 10T N2 MODULE TRAILER-II LSSF/FT/N2-10T/02
76. 10T N2 MODULE TRAILER-III LSSF/FT/N2-10T/03
77. 10T N2 MODULE TRAILER-IV LSSF/FT/N2-10T/04
78. 12T SEMI TRAILER – I,CTF/N2-2X2/01
79. 12T SEMI TRAILER – II, BS/N2-2X2/02
80. 12T SEMI TRAILER – III, CTF/03
81. 12T SEMI TRAILER – IV, CTF/04
82. DM WATER TANKER – I LSSF/FT/DMW-1.5KL/0.1
83. DM WATER TANKER - II LSSF/FT/DMW-5KL/0.2
Page 5 of 11
Sl.NO EQUIPMENT NAME & EQUIPMENT NUMBER
84. DM WATER TANKER - III LSSF/FT/5KL/02
85. 15T DM WATER TANKER – IV LSSF/ST/DMW-10KL/01
86. EFFLUENT TANKER – I LSSF/FT/EF-7KL/01
87. N2 MODULE – I LSSF/FT/N2-1X2/01
88. N2 MODULE – II LSSF/FT/N2-1X2/02
89. SITVC TANKER - 1 LPSC/FT/SITVC-5KL/01
90. SITVC TANKER -2 LPSC/FT/SITVC-5KL/02
91. PROPELLANT TRANSFER UNIT – I LSSF/FT/MON-3.5KL/01
92. PROPELLANT TRANSFER UNIT – II LSSF/FT/MMH-3.5KL/02
93. N2 MODULE TRAILER – I LSSF/FT/N2-0.5X2/01
94. 12T NITROGEN TANKER – I LSSF/ST/N2/2X2/01
95. 12T NITROGEN TANKER - II LSSF/ST/N2/2X2/02
96. NITROGEN TANKER – I LSSF/ST/N2/0.5X4/01
97. 12T HELIUM MODULE-I LSSF/ST/HE-2x2/01
98. 12T HELIUM MODULE-II LSSF/ST/HE-2x2/02
99. 12T HELIUM MODULE-III LSSF/ST/HE-1x4/01
100. IMT TANKER-1(New) N2O4 LSSF/ST/30KL/E-5003/01
101. IMT TANKER -2 N2O4 LSSF/ST/30KL/02
102. IMT TANKER -1(New) UH25 LSSF/ST/30KL/E-4003/01
103. IMT TANKER -2 UH25 LSSF/ST/30KL/02
104. RT TANKER -1 UH-25 LSSF/BS/UH-25/01
105. RT TANKER -2 UH-25 LSSF/BS/UH-25/02
106. RT TANKER -1 N2O4 LSSF/BS/N2O4/01
107. RT TANKER -2 N2O4 LSSF/BS/N2O4/02
108. MOBILE MOTR AIR SUSPENSION SEMI TRAILER
109. PS2/GS2 STAGE TRANSPORTATION TRAILER
110. BATTERY OPERATED TRUCK-1 VALF/BOT/2T/01
111. BATTERY OPERATED TRUCK-2 VALF/BOT/2T/02
112. BATTERY OPERATED TRUCK-3 VALF/BOT/2T/03
113. BATTERY OPERATED TRUCK-4 VALF/BOT/2T/04
114. BATTERY OPERATED TRUCK-5 VALF/BOT/2T/05
115. BATTERY OPERATED TRUCK-6 VALF/BOT/2T/06
116. BATTERY OPERATED TRUCK-7 VALF/BOT/2T/07
117. BATTERY OPERATED TRUCK-8 VALF/BOT/2T/08
118. BATTERY OPERATED TRUCK-9 VALF/BOT/2T/09
119. BATTERY OPERATED TRUCK-10 VALF/BOT/2T/10
120. BATTERY OPERATED TRUCK-11 VALF/BOT/2T/11
121. BATTERY OPERATED TRUCK-12 VALF/BOT/2T/12
122. BATTERY OPERATED TRUCK-13 VALF/BOT/2T/13
123. BATTERY OPERATED TRUCK-14 VALF/BOT/2T/14
124. BATTERY OPERATED TRUCK-15 VALF/BOT/2T/15
125. BATTERY OPERATED TRUCK-16 VALF/BOT/2T/16
126. BATTERY OPERATED TRUCK-17 VALF/BOT/2T/17
127. BATTERY OPERATED TRUCK-18 VALF/BOT/2T/18
Page 6 of 11
Sl.NO EQUIPMENT NAME & EQUIPMENT NUMBER
128. BATTERY OPERATED TRUCK-19 VALF/BOT/2T/19
129. BATTERY OPERATED TRUCK-20 VALF/BOT/2T/20
130. BATTERY OPERATED TRUCK-21 VALF/BOT/2T/21
131. BATTERY OPERATED TRUCK-22 VALF/BOT/2T/22
132. BATTERY OPERATED TRUCK-23 VALF/BOT/2T/23
133. BATTERY OPERATED TRUCK-24 VALF/BOT/2T/24
134. BATTERY OPERATED TRUCK-25 VALF/BOT/2T/25
135. BATTERY OPERATED TRUCK-26 VALF/BOT/2T/26
136. BATTERY OPERATED TRUCK-27 VALF/BOT/2T/27
137. BATTERY OPERATED TRUCK-28 VALF/BOT/2T/28
138. BATTERY OPERATED TRUCK-29 VALF/BOT/2T/29
139. DOLLEY – 1 (2 AXLES) VALF/DL/20T/01
140. DOLLEY – 2 (2 AXLES) VALF/DL/20T/02
141. DOLLEY – 3 (2 AXLES) VALF/DL/20T/03
142. DOLLEY – 4 (SINGLE AXLE) VALF/DL/10T/01
143. HMT TRACTOR, PRT/2031
144. SAME TRACTOR-1, AP 26 Y 2900
145. SAME TRACTOR-2, AP 26 Y 2901
146. SAME TRACTOR-3, AP 26 AC 2503
147. VOLVO HAULER 520 HP AP 26 Y 7685
148. VOLVO HAULER 400 HP
149. 70T BEML HAULER-1, SPROB/1745
150. 70T BEML HAULER-2, PRT/2229
151. 70T BEML HAULER-3, PRT/7003
152. 3T GODREJ FORKLIFT, PRT/2278
153. 5T GODREJ FORKLIFT SPROB/FL/5T/01
154. 8T GODREJ FORKLIFT
155. 12T GODREJ FORKLIFT-1 PRT/2279
156. 12T GODREJ FORKLIFT-2 SPROB/FL/12T/02
157. TATA 207, AP 26 Y 7152
158. TATAACE CYLINDER TRANSPORTER AP26X7113
159. TATA 407 EXPLOSIVES VAN-2 AP 26 X 7614
160. TATA 1613 EXPLOSIVES VAN-1 AP 26 U 7150
161. COMETTO TRAILER-1
162. COMETTO TRAILER-2
163. APPLE TRAILER-1, SXC 1601
164. APPLE TRAILER-2, SXC 1801
165. APPLE TRAILER-3 SXC 2201
166. APPLE TRAILER-4, SXC 2301
167. APPLE TRAILER-5, SXC 2501
168. APPLE TRAILER-6, SXC 2601
169. APPLE TRAILER-7, SXC 3001
170. APPLE TRAILER-8, SXC 3101
171. APPLE TRAILER-9, SXC 3201
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Sl.NO EQUIPMENT NAME & EQUIPMENT NUMBER
172. APPLE TRAILER-10, SXC 3301
173. DIESEL OPERATED TRUCK-1 SPROB/DOT/2T/01
174. DIESEL OPERATED TRUCK-2 SPROB/DOT/2T/02
175. DIESEL OPERATED TRUCK-3 SPROB/DOT/2T/03
176. DIESEL OPERATED TRUCK-4 SPROB/DOT/2T/04
177. DIESEL OPERATED TRUCK-5 SPROB/DOT/2T/05
178. LOW BED TRAILER, SXC 4202
179. LOW BED TRAILER, SXC 4302
180. LOW BED TRAILER, SXC 4402
181. LOW BED TRAILER, SXC 4802
182. AP BIN TRAILER, SXC 4005
183. AP BIN TRAILER, SXC 4105
184. AP BIN TRAILER
185. AP BIN TRAILER
186. BOWL TRAILER, SXC 4615
187. BOWL TRAILER-1, SXC 2115
188. BOWL TRAILER-2, SXC 2915
189. BOWL TRAILER-3, SXC 3215
190. LOW BED TRAILER (20T), SXC 2820
191. PS0-XL TRAILER – 1, SXC 4725
192. PS0-XL TRAILER – 2
193. WELLBED TRAILER, SXC 4825
194. 20T BOWL TRAILER
195. PS0-XL TRAILER
Page 8 of 11
Annexure-8
CONFIRMATION / COMPLIANCE STATEMENT
Sl No
Description of terms and conditions
Compliance Reasons for deviation
Yes No
If No, explain the reason (if space is not sufficient separate sheet may be
enclosed)
1 SCOPE OF WORK: Maintenance & Operation/Driving of material Handling equipment once in a year, attending to Minor & Major breakdown maintenance & Operational support as per the points 1.1 to 1.3 of tender document (Annexure-1).
2 Work Stations: Number of Work Stations, Place of work & its location as per the point 2.1 to 2.3 of tender document (Annexure-1).
3 Equipment to be Maintained: List of vehicles / equipment to be maintained, type of Maintenance as per Annexure 3, 4, 5 & 6 as per points 3.1 to 3.5 of tender document (Annexure-1).
4 Operation / Driving works: Vehicles / equipment to be operated in and around SDSC SHAR, Sriharikota in general & outside as and when required & as per the points 4.1 to 4.9 of tender document (Annexure-1).
5 Periodic maintenance schedule book for each equipment / vehicle as per the Annexure 4 as per points 4.5 of tender document (Annexure-1).
6 Submission of rates for scheduled periodic maintenance of equipment / vehicle listed in the Annexure-2 as per the tender document (Annexure-1).
7 Tyre & Wheel Change as per point 3.7 of tender document (Annexure-1).
8 Quotation of rate for Replacement / re-fitment of ages tyres as per point 3.7.2 of tender document (Annexure-1).
9 Tyres and tubes will be supplied by Department as per point 3.7.3 of tender document (Annexure-1).
10 Essential expertise of Maintenance staff as per point 3.8 of tender document (Annexure-1).
11 Addition or deletion of equipment / vehicles during the contract period as per point 3.9 of tender document (Annexure-1).
12 Arranging additional manpower for completion of maintenance of vehicles / equipment with no extra payment as per point 3.11 of tender document (Annexure-1).
13 Load Testing: Acceptance for load testing of Equipment / Vehicles after annual maintenance as per the terms mentioned in the point 3.12 of tender document (Annexure-1)
14 Acceptance for Load testing of equipment as per point 3.12.4 of tender document (Annexure-1)
15 Working Hours: General working timings, public holidays as per points 5.1 to 5.2 of tender document (Annexure-1).
16 Working on public holidays, beyond normal working hours on working days as and when work demands as per points 5.3 to 5.5 of tender document (Annexure-1).
17 Duration of Contract: Period of contract will be Two years as per Point 6.1 of tender document (Annexure-1).
Page 9 of 11
Sl No
Description of terms and conditions
Compliance Reasons for deviation
Yes No
If No, explain the reason (if space is not sufficient separate sheet may be
enclosed)
18 Acceptance of contract for 3rd year as per the point 6.2 of tender document (Annexure-1).
19 Department’s right to terminate contract at any time as per the point 6.3 & 6.4 of tender document (Annexure-1).
20 Manpower deployment: Qualification and experience of Contractor’s staff as per point 7.1 to 7.3 of tender document (Annexure-1).
21 Minimum work force and penalty for absenteeism as per point 7.4 of tender document (Annexure-1).
22 Work Routines: Scrutinize of Maintenance schedules, responsibility of filling up schedules check lists in prescribed format as per 8.1 to 8.3 of tender document (Annexure-1).
23 Attending to Minor breakdown maintenance to vehicles / equipment with no extra cost as per 9.1 of tender document (Annexure-1).
24 Major breakdown maintenance: Acceptance of providing additional manpower for attending to major breakdown maintenance as per Point 9.2.1 of tender document (Annexure-1).
25 Acceptance of attending to Major Breakdown maintenance in side & outside SDSC SHAR & Machining works as per Point 9.2.2, 9.2.3 & 9.2.4 respectively of tender document (Annexure-1).
26 Acceptance for providing additional manpower for operational support works as per points 9.3.1 to 9.3.4 of tender document (Annexure-1).
27 Acceptance for Painting of Equipment as per the point 10.1 to 10.15 of tender document (Annexure-1).
28 Acceptance for bringing set of Tools and minimum quantity of consumable as per the point 11.1 to 11.3 of tender document (Annexure-1).
29 Spare parts / Lubricants: Procurement of spare parts, lubricants & components as per points 12.1 to 12.4 of tender document (Annexure-1).
30 Transportation & Accommodation: Transportation and accommodation arrangements for contractor’s staff as per points 13.1 to 13.2 of tender document (Annexure-1).
31 Entry Pass arrangement: Furnishing authentic proof of his staff and Acceptance of points 14.1 to 14.4 of tender document (Annexure-1).
32 Settlement of bills & Payment: Acceptance of Payment terms, Income tax deductions as per the points 15.1 to 15.3 of tender document (Annexure-1).
33 Acceptance of terms as per point 15.4 of tender document (Annexure-1)
34 Penalty clause: Acceptance of penalty as per the points 16.1 to 16.4 of tender document (Annexure-1).
35 Contractor’s Site visit as per the Point 18.2 of tender document (Annexure-1).
36 Acceptance of offer validity period of SIX months as per the point 18.3 of tender document (Annexure-1).
37 Acceptance for issue of individual letter of appointments to contractor’s staff as per point 18.4 of tender document (Annexure-1).
Page 10 of 11
Sl No
Description of terms and conditions
Compliance Reasons for deviation
Yes No
If No, explain the reason (if space is not sufficient separate sheet may be
enclosed)
38 Acceptance of disbursement of monthly salaries through Nationalized Bank as per the point 18.5 of tender document (Annexure-1).
39 Acceptance for ensuring contract staff wearing safety gadgets as per points 18.6 to 18.8 as per tender document (Annexure-1).
40 Acceptance for submitting proof of EPF remittance as per point 18.11 of tender document (Annexure-1).
41 Acceptance for no liability of department as per point 18.14 to 18.15 as per tender document (Annexure-1).
42 Acceptance for mobilization of contractor’s team within 15 days from the date of receipt of firm purchase order as per point 18.17 of tender document (Annexure-1).
43 Acceptance for disbursement of salaries to Contractor’s staff on or before 7th of every succeeding month as per of tender document (Annexure-1).
44 Acceptance for ensuring various acts and amendments as per point 18.18 to 18.37 of tender document (Annexure-1).
45 Acceptance for maintaining records and documents as per labour laws as per point 23.6 of tender document (Annexure-1).
46 Acceptance for department’s rights to withhold the bills as per point 18.24 of tender document (Annexure-1).
47 Age limit: Acceptance for deploying manpower as per the age restrictions mentioned in the point 19 of tender document (Annexure-1).
48 Taxes & Duties: Acceptance of terms as per 20 of tender document (Annexure-1)
49 Security Deposit: Acceptance of security deposit terms as per the point 21.1 & 21.2 of tender document (Annexure-1).
50 Legal terms & conditions: Acceptance of terms as per point no. 23.1 to 23.16 of tender document (Annexure-1)
51 Safety & security: Acceptance of terms as per point no. 24.1 to 24.10 of tender document (Annexure-1)
52 Joint & several Liabilities: Acceptance of terms as per point no. 25 of tender document (Annexure-1)
53 Severability: Acceptance of terms as per point no. 26 of tender document (Annexure-1)
54 Immunity from liability: Acceptance of terms as per point no. 27 of tender document (Annexure-1)
55 Intellectual property: Acceptance of terms as per point no. 28 of tender document (Annexure-1)
56 Down time compensation: Acceptance of terms as per point no. 29.1 & 29.2 of tender document (Annexure-1)
57 Joint & several Liabilities: Acceptance of terms as per point no. 25 of tender document (Annexure-1)
Page 11 of 11
Sl No
Description of terms and conditions
Compliance Reasons for deviation
Yes No
If No, explain the reason (if space is not sufficient separate sheet may be
enclosed)
58 Termination & short closing of contract Acceptance of terms as per point no. 30.1 to 30.6 of tender document (Annexure-1)
59 Parallel / Adhoc work package order Acceptance of terms as per point no. 31 of tender document (Annexure-1)
60 Volume of work: Acceptance of terms as per point no. 32 of tender document (Annexure-1)
61 Force majeure clause: Acceptance of terms as per point no. 33 of tender document (Annexure-1)
62 Applicable law, jurisdiction and arbitration: Acceptance of terms as per point no. 34.1 & 34.2 of tender document (Annexure-1)
63 Price Variation Per Year : Acceptance for Price variation clause per year, as per point 35 of tender document (Annexure-1).
64 Arbitration: Acceptance of Arbitration terms as per point 36 of tender document (Annexure-1).
65 Submission of Confirmation / Compliance statement along with Techno Commercial bid (part-1) as per the point 38.2.1 of tender document. (Annexure-1).
66 Submission of Quotation Format-1, 2 & 3 along with Price bid (part-2) as per the point 38.2.2 of tender document (Annexure-1).
67 Acceptance of receipt of Annexure-1, 2, 3, 4, 5, 6 & 7
68 Pre qualification criteria Minimum three years of Work Experience & terms as per point 39.1. (a) of tender document (Annexure-1)
69 Service certificates from previous organizations: Submission of clean chit/service certificates where he worked previously as per point no. 39.1. b
70 Annual Turnover: Annual Turnover of minimum 50 lakhs and terms as per 39.1. c.1 (b) of tender document (Annexure-1).
71 Acceptance of terms as per point 39.1 d & e of tender document (Annexure-1)
S a t i sh Dhawan Spac e Cen t e r SHAR S a t i sh Dhawan Spac e Cen t e r SHAR S a t i sh Dhawan Spac e Cen t e r SHAR S a t i sh Dhawan Spac e Cen t e r SHAR
Welcome, Materials Master (isro)31 August 2017,
17:16:08 IST
MAIN VIEW HELP
Preview For STANDARD TERMS AND CONDITIONS
Page Destination: Tender Header Format Type : Normal
. :
GOVERNMENT OF INDIA
DEPARTMENT OF SPACE
SATISH DHAWAN SPACE CENTRE
PURCHASE DIVISION
Tele No.08623-225023/225174/225127 Fax No.08623-225170/22-5028 e-Mail ID : [email protected], [email protected], [email protected]
STANDARD TERMS & CONDITIONS
1.OFFERS SHALL BE SENT ONLINE ONLY USING STANDARD DIGITAL SIGNATURE CERTIFICATE OF CLASS III WITH ENCRYPTION / DECRYPTION. THE TENDERS AUTHORISED ONLINE ON OR BEFORE THE OPEN AUTHORISATION DATE AND TIME ONLY WILL BE CONSIDERED AS VALID TENDERS EVEN THOUGH THE BIDS ARE SUBMITTED ONLINE.
2.THE TENDERER MUST AUTHORISE BID OPENING WITHIN THE TIME STIPULATED IN THE SCHEDULE BY SDSC SHAR. OTHERWISE THE ONLINE BID SUBMITTED WILL NOT BE CONSIDERED FOR EVALUATION. PHYSICAL COPY WILL NOT BE CONSIDERED EVEN THOUGH IT IS RECEIVED BEFORE THE BID SUBMISSION DATE. In case of two-part tenders, parties shall submit their offers as follows:-
1) Part-I – Techno-commercial Bid (No price details shall be mentioned in this bid and shall not upload the details of price along with the techno-commercial bid) 2) Part-II – Price Bid
In view of Two Part Tender, the Offers submitted contrary to above instructions will be summarily rejected. 3.In case, the tenderer is not interested to participate in the tender, the tenderer shall submit regret letter giving reasons, failing which future enquiries will not be sent. 4.Offer Validity: The validity of the offers / tenders should be 90 days (in case of single part tender) and 120 days (in case two part
tender) from the date of opening of the tenders. Tenders with offer validity less than the period mentioned above, will not be considered for evaluation. 5.GST - GST and/or other duties/levies legally leviable and intended to be claimed should be distinctly shown separately in the tender. GST details are given below
GSTIN: 37AAAGS1366J1Z1 LEGAL NAME : SATISH DHAWAN SPACE CENTRE SHAR VALIDITY FROM:29/08/2017
TYPE OF REGISTRATION:REGULAR 6.Customs Duty - SDSC-SHAR is eligible for 100% Customs Duty exemption as per Notification No. 050/2017 539 (b) Dt: 30.06.2017.
This may be taken into account while quoting for import items, if any. In case tenderers offering items considering customs duty exemption, they should also indicate the bill of materials and price, separately, with Customs Duty component and terms and conditions thereto. 8.Advance Payment - Wherever advance payment is requested, Bank Guarantee from any Nationalized Bank/Scheduled Bank should be
furnished. In case of advance payments, if the party is not supplying the material within the delivery schedule, interest will be levied as per the Prime Lending Rate of RBI plus 2% penal interest. Interest will be loaded for advance payments/stage payments as per the prime lending rate of RBI and will be added to the landed cost for comparison purpose. In case of different milestone payments submitted by the parties, a standard and transparent methodology like NPV will be adopted for evaluating the offers.
9.Liquidated Damages - In all cases, delivery schedule indicated in the Purchase Order/Contract is the essence of the contract and if the party fails to deliver the material within the delivery schedule, Liquidated Damages will be levied @ 0.5% per week or part thereof subject to a maximum of 10% of total order value. 10.Performance Bank Guarantee - Performance Bank Guarantee for 10% of the order value should be furnished in the form of Bank
Guarantee from nationalized/scheduled bank or by Demand Draft valid till warranty period plus sixty days as claim period.
Page 1 of 3
11.Security Deposit – Security Deposit for 10% of the order value is mandatory, if the ordered value is Rs.5.00 lakhs and above. Party shall furnish the Security Deposit in the form of Bank Guarantee from nationalized/scheduled bank or by Demand Draft valid till
completion of the contract period plus sixty days towards claim period for faithful execution of the contract. 12.BANK GUARANTEE FOR FIM: Supplier has to submit Bank guarantee for equal value of Free Issue of Materials (FIM) issued by the Department from Nationalised / Scheduled Bank valid till receipt and acceptance of supply and satisfactory accounting of FIM plus sixty days as claim period.
13.The delivery period mentioned in the tender enquiry, IF ANY, is with the stipulation that no credit will be given for earlier deliveries and offers with delivery beyond the period will be treated as unresponsive. 14.The Department will have the option to consider more than one source of supply and final orders will be given accordingly.
15.The bidders should note that conditional discounts would not have edge in the evaluation process of tenders. 16.Non-acceptance of any conditions wherever called for related to Guarantee/ Warranty, Performance Bank Guarantee, Security Deposit, Liquidated damages are liable for disqualification. 17.Wherever installation/ commissioning involved, the guarantee/warrantee period shall reckon only from the date of installation and
commissioning. 18.Purchase/Price Preference will be extended to the MSMEs under the Public Procurement Policy for MSMEs formulated under the Micro, Small and Medium Enterprises Development Act, 2006 and instructions issued by Government of India from time to time. Vendors who would like to avail the benefit of MSME should clearly mention the same and submit all the documentary evidences to substantiate their claim along with tender itself.
19.The drawings, specifications, end use etc., given by the Centre/Unit along with the tender enquiry are confidential and shall not be disclosed to any third party. 20.SPECIAL CONDITIONS FOR SUBMITTING QUOTATIONS IN FOREIGN CURRENCY BY THE INDIAN AGENTS
The Tenderer should submit the following documents/information while quoting:- a)Foreign Principal's proforma invoice/quote indicating the commission payable to the Indian Agent and nature of after sales service to be rendered by the Indian Agent. b)Copy of Agency agreement with the Foreign Principal and the Indian Agent, precise relationship between them and their mutual
interest in the business. c)Registration and item empanelment of the Indian Agent. d)Agency Commission will be paid only Indian Currency.
e)Compliance of the tax laws by the Indian Agent. 21. High Sea Sales- Against High Sea Sale transactions: a.Offers shall be on all inclusive basis including delivery upto Sriharikota at the risk and cost of the supplier. Customs Clearance is the responsibility of the supplier and at his cost and risk.
b.100% payment will be made within 30 days after receipt and acceptance of the items at our site. c. GST as applicable d.Customs Duty Exemption Certificate and other relevant documents required for Customs clearance will be provided.
e.High Sea Sales Agreement furnished by the supplier in accordance with the terms and conditions of our purchase order will be signed and issued by SDSC-SHAR. 22.The following information/ documents are to be submitted wherever applicable.
1.Product Literature 2.Core banking account number of SBI, RTGS Details 3.PAN No. in quotation and invoices
4.GST Registration details. 5.In case of MSME, registration details / documents from Competent Authority. 23.EXCLUSION OF TENDERS
The following tenders shall be summarily rejected from the procurement process a.Tenders received from vendors who have not qualified in terms of their registration. b.Tenders received against publishing of a limited tender in the CPP portal.
c.Tenders of vendors who have been removed from the vendor list or banned/debarred from having business dealings. d.Unsolicited tenders from vendors. e.The tenders which materially depart from the requirements specified in the tender document or which contain false information.
f.The tenders which are not accompanied by the prescribed Earnest Money Deposit. g.The tenders of vendors who have not agreed to furnish Security Deposit, Performance Bank Guarantee and Liquidated Damages. h.The validity of the tenders is shorter than the period specified in the tender enquiry.
i.The tenders received from vendors or their agents or anyone acting on their behalf, who have promised or given to any official of the Centre/Unit/Department, a gratification in any form, or anything of value, so as to unduly influence the procurement process. j.The tenders received from vendors, who, in the opinion of the Centre/Unit, have a conflict of interest materially affecting fair competition.
Page 2 of 3
k.The tenders received from Indian agents on behalf of their foreign Principals/OEMs (in cases where the Principals/OEMs also submit their tenders simultaneously for the same item/product in the same tender).
l.In case two or more tenders are received from an Indian agent on behalf of more than one foreign Principal/OEM, in the same tender for the same item/product. m.If a firm quotes ‘NIL’ charges / consideration, the bid shall be treated as un-responsive and will not be considered.
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