Service Initiatives

Preventive Maintenance 61 Point Checklist

In each Preventive Maintenance visit, KOEL CARE Service Engineer will thoroughly check the Genset which includes 61 check points specifically designed for your Genset.

Although there are numerous benefits, we are listing some of the main benefits underneath:

  • It increases productivity of engine as engine run in its maximum capacity
  • Decreased operating cost, as there will be very low breakdown of engine
  • Less risk factor, because the engine is being regularly checked, there is less risk to breaking down without notice
  • Increases the engine life

Please find below 61 Check Points which our KOEL CARE Service Engineer will check at each Preventive Maintenance visit.

DG Check Sheet

Sr.No

Check Points

Action Taken

Air Intake System

1A.

Air Cleaner (Primary/outer Element) Dry type

Found OK      Red band appearing on Vacuum Indicator Replaced


1000 hrs./ 1 year  / Vacuum Indicator shows red band whichever occurs first.


( First replacement   / second replacement / third replacement.)

1B.

Air Cleaner (Safety Element) Dry type

Found OK        Replaced on third primary element change        


Replaced on 2 years

1C.

Restriction / Vacuum indicator operation

Found OK         Not OK                           Replaced the indicator

1D.

Air cleaner housing cap

Found OK         Not OK                           Replaced

1E.

Evacuator valve

Found OK         Damaged   Not available   Replaced

2

Hose

Found OK         Cracks found                  Replaced

3

Hose clamp

Found OK         Tightened the clamp      Replaced the clamp

4

CAC/Intercooler fins

Found OK         Found chocked              Cleaned with blower

Lubrication System

5

Lube oil level

Found OK       Top up the oil     Replaced oil                                    Note: oil change period ( whichever occur first )                                         Super oil  (500 Hrs. / 6months)  ,Premium oil (500 hrs. or 1 Year)

CPCB II engines -Only premium Oil Used.

CRDI- 300 hrs/ 1Year.

Power Car Genset -300 Hrs/ 6 months

6

Oil leakage

Found No leakage      Rectified the leakage

7

Lube oil filter

Found OK       Replaced

Note: Filter change period is every 500 hrs. or 6 months or every oil change

8

Centrifuge Service

Service done        Service not done

Every scheduled PM, Service Centrifuge assembly, if provided.

Cooling System

9

Coolant level

Found OK      Top up the coolant Replaced Glass tube

10

Coolant pH testing

Found OK (value between 7 to 9)   Replaced the coolant

11

Coolant Leakage

Found No leakage      Rectified the leakage

12

Fan belt

Found OK      Adjusted the belt   Belt cracked/worn out                              Replaced      ( Replace the belt at 1000 hrs. or 1 year )

13

Water pump weep hole and coolant leakage

Found OK         Replaced water pump

(Don’t close weep hole )

14

Radiator Pressure Cap (Rubber gasket and Spring)

Found OK     Replaced the cap

15

Radiator Fin

Found OK     Cleaned with blower

16

Radiator Hose

Found OK     Replaced the hose

17

Radiator Hose clamps

Found OK     Tightened the clamp     Replaced the clamp

18

DG ventilation

Found OK     Changes recommended to customer

19

Coolant residual voltage 0.10 volt

Found OK     Not OK, recommended for flushing and replacement of coolant.

20

Radiator core earthing

Earthing Found OK     Earthing Found not OK     Earthing Done    

Fuel System

21

Fuel Level

Found OK     Educated the customer

22

Fuel Filter

Found OK       Replaced the fuel filter elements

23

Water Separator

Drained the water       Not drained the water Found Body damage

24

Fuel leakage

Found No leakage      Rectified the leakage

25

Fuel Pipe

Found OK                   Replaced the pipe   Crack on pipes.

26

Adulterated Fuel

Found Fuel OK, Clean.                       Found Dirty fuel                                                  Found fuel mixing with other fuel        Educated Customer on Adulterated fuel   

27

Fuel Tank

Found OK           Fuel tank dirty                      Cleaned the fuel tank & breather    Sediments and water drained. Recommended cleaning.

28

Button filter/Feed Pump strainer

Found OK                   Cleaned

Engine Exhaust System

29

Turbocharger Hose

Found OK         Crack on hose   Replaced hose  

30

Turbocharger oil supply pipe

Found OK         Tightened the connections      Replaced the pipe

31

Turbocharger oil out let pipe

Found OK         Replaced the joint         Replaced the pipe

32

Turbocharger

Found OK         Not OK, recommended for repair

Engine Electrical System

33*

Battery Specific Gravity

_____________

34

Battery Electrolyte level

Found OK          Top up with distilled water

35

Battery Terminal connections

Found OK          Tightened and applied Petroleum jelly

36

Battery Vent Hole

Found OK          Cleaned

37*

A)Battery voltage, DG OFF condition without Battery charger

B) Battery voltage, DG OFF condition with Battery charger

C) Battery voltage, DG ON condition without Battery charger

A) __________v

B) __________v

C) __________v

38

Charging Alternator

Found OK       Not OK, recommended for repair          Replaced

39

Functioning of Safety Sensors

Found OK        Replaced  

40

Emergency stop switch

Found OK        Replaced

41

Wiring Harness connection

Found OK        Tightened the connections

42

Controller Unit

Found OK        Tightened the connections      Replaced

Display Blank

43

Battery Charger Available

YES / NO

44

For Costal area - space heater used

YES / NO

45

For High Moisture area - heater used

YES / NO

AC Alternator& AMF Panel

46

Earthing connection

Found OK (earthing resistance)            Rectified the earthing

47

AMF Functioning (Auto/Manual Mode)

Working OK in Auto & Manual mode    Rectified the Auto function

48

Load balancing in all 3 phase

Found OK        Recommended for load balancing

Canopy

49

Exhaust Fan

Found OK       Repaired / Replaced

50

Canopy cleanliness

Cleaned Found Material kept inside canopy

51

KOEL Branding sticker on canopy

Sticker present on canopy   Put sticker on canopy     Sticker not available

52

KOEL CARE Toll Free no

Stick KOEL CARE branding sticker along with help desk number on canopy

Sticker not available  Freelancer Sticker available

Controller

53

Connection

Found OK       Tightened the connections

Educated Customer on routine maintenance to be carried out

54

Cleaning/Change of Air Cleaner (Dry / Oil Bath); Restriction Indicator operation

YES / NO

55

Lube Oil & Oil Filter Change

YES / NO

56

Fuel / Filter Element Change

YES / NO

57

Cleaning of Radiator Cooling fins

YES / NO

58

Cleaning of Liner & Cylinder Head Fins in case of Air Cooled Engine

YES / NO

59

Belt Tension Check

YES / NO

60

Hose Conditions

YES / NO

61

Genset Starting, Stopping, Emergency stop

YES / NO

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