Template for Comprehensive AMC of Cummins Engine for 140T B.D. Crane.
Scope of contract for Comprehensive Maintenance of Cummins Engines powering 140 tonne breakdown cranes
manufactured by Jamalpur Workshop.
1.
PREFACE:
The 140T B.D.Crane (Gottwald Type) manufactured by Jamalpur Workshop, Eastern Railway is a Disaster
Management equipment which is deployed at Accident sites for restoration of Rail traffic and saving human life and
property. Maintaining this equipment in fine fettle at all times is therefore of paramount importance.
Out of 58 nos. 140T B.D. Cranes, 57 nos. fitted with CUMMINS make Engine of four models (NT 855R4, NTA 855R
FFC, NTA 855 L BC & NTA 855 P 335), which are either maintained by Railway or through AMC with M/s Cummins
authorised dealers.
Vide letter no. 2016/M(M&P)/175/3/A/T/Codal Life dated 14.02.2017, Railway Board has advised Jamalpur
Workshop to prepare template for centralised AMC for B-Check, C-Check and D-Check of CUMMINS Make Engines.
2.
Scope of Work – Preventive Maintenance:
B- check : B- check activities at 300 hours or 6 months whichever is earlier
Activities carried out in B- Check:
S No.
Activity
1
Repeat “A” check
2
Change Engine Oil
3
Change Engine Full-Flow Oil Filter
4
Change By-Pass Filter
5
Record Oil Pressure
6
Check Throttle Linkage
7
Change Fuel Filter
8
Clean Fuel Tank Breather
9
Clean/ Change Crankcase Breather
10
Check Air Piping hump hoses
11
Check coolant inhibitor. Add coolant concentrate, if required
12
Check Belts, adjust if required
C- check : C- check activities at 1500 hours or 1 year whichever is earlier
Activities carried out in C- Check:
S No. Activity
1
Repeat “A” and “B” checks
2
Check and correct leaks if any
3
Clean Radiator externally with compressed air
4
Check Fan Hub/water pump
5
Physically check alternator and stator motor
6
Replace air filters
7
Check all rubber hoses and their respective clamps
8
Carry out valve and injector settings
9
Replace rocker cover gaskets
D – check : D- check activities at 6000 hours or 2 years whichever is earlier
Activities carried out in D- Check:
S No. Activity
1
Repeat “B” and “C” Check
2
Repairing of Air Compressor.
3
Repairing of Turbocharger.
4
Reconditioning of Injectors.
5
Repairing of Fuel Pump.
6
Repairing of Water Pump.
7
Replacement of thermostat seal and gasket.
8
Replacement of all belts and hoses.
9
Cleaning of Core after cooler.
3.
Scope of supply – Spares
Scope of supply of B- check
Sr.no Description
1
B- check kit
2
Lube of CH4 grade for replacement
3
Lube oil for top up
4
Coolant Concentrate
Scope of supply for C- check
Sr.no Description
1
B- check kit
2
Lube of CH4 grade for replacement
3
Lube oil for top up
4
Coolant Concentrate
5
Air filter set ( Inner and Outer)
6
Rocker lever gasket
Scope of supply for D- Check
Sr.no Description
1
B- check kit
2
Lube of CH4 grade for replacement
3
Lube oil for top up
4
Air filter set ( Inner and Outer)
5
Rocker lever gasket
6
Coolant Concentrate
7
Pre-mix coolant
8
Reconditioned Injector
9
Turbo charger Repair
10
Thermostat
11
Air Compressor Repair
12
Fuel Pump Repair
13
Water Pump Repair
14
Gaskets and Belts
NTA 855
Qty
1
36 ltrs
19 ltrs
5 ltrs
Qty
1
36 ltrs
19 ltrs
5 ltrs
1
3
Qty
1
36 ltrs
19 ltrs
1
3
5 ltrs
1 Pack
6
1
1
1
1
1
1
4.
Activity checklist:
Activities
Check
Clean/
Change/ Replace/
Carry out Replace
Change Engine Oil
√
Change Engine Full-Flow Oil Filter
√
B-Check
Change By-Pass Filter
√
Record Oil Pressure
√
Check Throttle Linkage (if applicable)
√
Lubricate ball joints of the throttle linkage
of Hyd. Governor (if applicable)
√
Change Fuel Filter
√
Check Air Piping hump hoses
√
Check coolant inhibitor. Add coolant
concentrate.
√
Check Belts, adjust if required
√
Change Hyd. Gov. Oil (if applicable)
√
Check and correct leaks if any
Clean
Radiator
compressed air
√
externally
with
√
C-Check
Replace air filters
Check all rubber hoses
respective clamps
√
and
their
√
Carry out valve and injector settings
√
D-Check
Replace rocker cover gaskets
5.
Reconditioned
√
Check and record crankshaft and accessory
drive end play.
√
Check and record turbo charger radial and
axial clearance.
√
Repairing of Air Compressor.
Repairing of Turbocharger.
Reconditioning of Injectors.
Repairing of Fuel Pump.
Repairing of Water Pump.
Repairing of Accessory Drive.
Replacement of thermostat seal and
gasket.
Replacement of all belts and hoses.
Cleaning of Core after cooler.
√
√
√
√
√
√
√
√
√
Record Keeping:
Records are to be maintained in a log book, by Crane user, in accordance with the FORMATS for 06 monthly attention (’B’
check), yearly attention ( ’C’ check) and 2-yearly attention ( ’D’ check) given in Part-II of RDSO Report No.MP-M1-19 (Rev-00)
of Sep’2011 .
6.
Scope of Breakdown maintenance:a)
b)
c)
d)
e)
7.
Break down maintenance as and when required shall be carried out.
Visit charges per engine per person for Breakdown visit shall be applicable.
Labour charges shall be applicable for repair of assemblies.
Transportation charges shall be applicable at actuals in case assemblies are required to be transported to
workshop.
Parts required for repairing the engine shall be provided based on the list price
Service Level:
a) B- check shall be carried out in maximum of 8 hours.
b) C- check shall be carried out in maximum of 8 hours.
c) D- check will be carried out in maximum 7 days.
8.
Reporting and Restoration:
For carrying out Mandatory Maintenance (‘B’ ,‘C’ &’D’ Checks) Railway will inform CIL (DBU) Dealership in close
proximity to machine location under copy to CIL (DBU) Area office at-least three days in advance regarding the
location of the machine so that Service Engineer can be deputed as per requirement / schedule.
However in case of breakdown of Engine accessories the Service Engineer will be deputed within stipulated
hours as per table below, after receiving information by Phone Call / Fax letter etc. at CIL (DBU) Area Office or
CIL (DBU) Dealership whichever is closer to machine location. CIL (DBU) will co-ordinate and ensure that the
response from the Dealership is given on top priority.
While giving Service Calls, maximum available information with respect to the problems will be provided by
Railway’s Maintenance Personnel to enable CIL (DBU)’s Service Engineer to make arrangement with necessary
Tools and Drawings to attend and rectify the problem.
Service Levels for reporting at site against breakdown calls will be as follows:
CATEGORY
DISTANCE
LEAD TIME FOR REPORTING
A
< 50 Kms Radius
Within 8 hours
B
< 51-200 Kms Radius
Within 12 hours
C
> 201 Kms Radius
Within 24 hours
9.
CIL (Distribution Business Unit) Responsibility:a) To carry out schedule maintenance as per above mentioned scope of work.
b) Establish a system and help Railways for maintaining an Inventory of Spare Parts, Tools, Equipment, and
Consumables.
c) Deliver the spares at stores/material department of Railways,
d) Ensuring agreed Service Levels.
e) The representative deployed by Cummins for maintenance shall be equipped with all safety equipment like
safety helmets, shoes, goggles, gloves etc.
f) To inform Railways on any technological up gradation of the engine and its components.
g) To carry out performance inspection of the engines during preventive maintenance visits and advise
further course of action to be initiated by Railways if required.
10. Responsibility of Railways:
a)
Carry out daily maintenance as per Part-II of RDSO Report No.MP-M1-19 (Rev-00) of Sep’2011 and maintain
Logbook.
b) Provide compressed air / Air connection, Crane & other handling Equipment, Treated Water for topping up
as and when required.
c)
Arrange for the disposal in a safe and lawful manner of all effluent, waste products and used items resulting
from the operation and maintenance of the Installation, oil, antifreeze, filters and other consumable items.
d) Ensure engine availability for carrying out timely checks/maintenance. For B- check engine should be made
available within + or – 15 hours of 300 hours or 3 days of 6 months whichever is earlier. For C check engine
should be made available within + or – 50 hours of 1500 hours or 7 days of 1 year whichever is earlier. For D
check engine should be made available within + or – 100 hours of 6000 hours or 15 days of 2 years
whichever is earlier.
e) Transportation of the material from Stores (Railway) to the site location for carrying out scheduled
maintenance at site.
f) Provide unskilled labour as and when required for carrying out “on chassis repairs” in case of breakdown
maintenance.
11. Exclusion:
a) Any failures arising out of operational faults, failures due to wrong grade of fuel, accidents due to external
factors, damage or excess wear to the maintained equipment or parts resulting from unusual or special
operating environments, such as airborne contaminants or corrosive atmosphere.
b) Replacement / reworking of Exhaust Silencer, Exhaust Piping & Battery replacement. Major overhauling of
Engine and any repairs/ replacement of Cylinder Block, Crankshaft, Camshaft, Cylinder Heads, Liners,
Pistons and Piston Rings.
c) Replacement of sub-assemblies with new which are beyond economical repair (BER). In Such Cases, new
assembly shall be provided at applicable price from price list. If, assembly price is not available in price list
then a separate quote shall be given for the same.
d) Any failure occurring due to engine being un-available for carrying out schedule/preventive maintenance
shall be considered out of scope and beyond warranty.
12. Warranty:
Warranty is not applicable on filters and rubber components of B and C checks as these are consumables.
For new part supply or repair warranty of 30 months shall be applicable from date of repair or new part supply
against bad workmanship.
13. Duration:
Contract duration shall be for 36 months from LOA Date / Agreement date.
14. Validity:
120 days from date of issue of offer.
15. Termination:
Either party, with 60 days’ advance notice may terminate the contract with a written communication.
16. Force Majeure:
CIL (DBU) is not liable in whatsoever manner in the event of any delay in performance of any of its obligations
under this agreement due to conditions constituting force majeure which shall include but not be limited to
strike, lock-outs, breakdown of communication etc.
17. Extension:The extension can be provided for maximum of 6 months beyond contract with an escalation of 9% on last year
value and there after fresh renewal agreement to be entered.
18. Penalty:
Time Period for Completion of D Check of one engine is maximum 7 days from the date of handing over engine
or else penalty of Rs 1500/- per day of delay to be deducted from the bill of contractor subject to maximum 10%
of total D Check Value for that particular engine
If the engine fails within the warranty period and if the firm does not attend the defects within 24 Hrs from the
time of receiving mail/fax/ telephonic message, a penalty of Rs 1500/- per day per engine will be deducted from
the bill.
Note:
VAT and Service tax as applicable shall be levied extra on parts and labour respectively as per prevailing
government norms. Should tax rates change during currency of contract, new tax rates as per state/central
government shall be applicable.
Invoices shall be made for the jobs carried out during the given period.
For break down maintenance, freight shall be applicable on all sub-assemblies that are carried to workshop for
repair
Visit charges are for per person per day and per engine basis. One day shall be of 8 hours.
Payments will be made within 30 days of submitting invoices along with necessary documentation.
19. General Terms and Conditions:
a) CIL (DBU), its Delivery Partners or their authorized representative will carry out the schedule checks, any
work on the engine as per the contract terms.
b) The contract will be for preventive maintenance checks and breakdown requirements for Cummins Diesel
Engines for 24 months from the date of issue of letter of acceptance by Railway.
c)
After completion of the job/visit CIL (DBU)’s Authorized Dealer’s representative will prepare service report
or submit Preventive maintenance Check sheet. Designated Railway official will acknowledge the service
report as proof of service rendered.
d) Whenever the repairs / overhaul is not possible at site, the sub-assemblies / engine will be dismantled and
taken to Dealer / CIL (DBU) workshop and will be fitted back after due repairs. However, Railways may
assist but shall not be bound to provide labor & lifting and transportation arrangement for engine/heavy
equipment which shall be CIL’s responsibility.
e)
Railway may provide special tools as such heavy-duty torque wrenches, sockets etc., only if available.
Service Engineer however will carry all tools required for repairing works on site.
f)
G.C.C. will be applicable for all other terms not covered under the above terms and conditions.
Dy CME (Crane)
E.Rly/JMP
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