Asset Tag MMPL/03/1033

Machine Make & Model Cortech & CSD1800X

Machine Serial No R-123
Machine Received From Joda
Machine Dispatch To Barra

Refurbishment Job Machine Received HMR 1599

Completion Machine Dispatch HMR

Presentation – Machine Refurbishment Job No MMPL/EXP/NOV23/CSD1800X(R-123)/22

Hydrostatic Rig Machine Refurbishment Start Date 09-11-2023

Machine Refurbishment End Date

Total Days of Refurbishment

Total Refurbishment Budget

Refurbishment In charge Dilip Gope

Refurbishment Team Members
 Work Done Statement
Structure Groups:

S.No Component Description Work Done Line Boring Status Complaints/Suggestions/Instructions

1 Frame No work No work done Checked and found frame condition good so no work done

2 Mast No work No work done Checked and found mast condition good so no work done

3 Canopy No work No work done Checked and found canopy condition good so no work done
Gear box pin 2 nos , lift cylinder pin 2 nos ,
4 Pin & Bushes new making and fitting No work done After new pin making and fitting , it works properly

5 Silencer No work No work done Found ok

6 Battery Box No work No work done Found ok

Foot clamp connector welding and cylinder

7 Foot Clamp seal change
No work done When rig testing foot clamp works properly.

8 Main Winch Guard No work No work done Checked , found ok

9 Wireline Winch Guard No work No work done Checked , found ok

10 Rotation Motor Guard No work No work done Checked , found ok

11 Radiator Shroud No work No work done Checked , found ok

12 Mud pump Chassis No work No work done Checked , found ok

13 Covers No work No work done Checked , found ok

14 Diesel Tank Cleaning and stunner change No work done No leakage found

15 Hydraulic Tank Cleaning and all filter change No work done When testing , No leakage and no heating issue found
Pin & Bushes:
Work Done Statement
S.No Component Description Work Done Part No Complaints/Suggestions/Instructions

1 Feed cylinder pin No work N/A Pin condition ok

2 Lift Cylinder Upper Pin New making N/A New pin fitting , no problem found
3 Lift Cylinder Lower Pin New making N/A New pin fitting , no problem found
4 Dump cylinder upper pin No work N/A Pin condition ok

5 Dump cylinder lower pin No work N/A Pin condition ok

6 Rod kicker upper pin No work N/A Pin condition ok

7 Rod kicker lower pin No work N/A Pin condition ok

8 Foot clamp cylinder pin No work N/A Pin condition ok

9 Reducing Gear box pin New making N/A New pin fitting , no problem found
10 4 speed gear box pin New making N/A New pin fitting , no problem found
11 Main winch pulley pin No work N/A Pin condition ok

12 Wire line winch pulley pin No work N/A Pin condition ok

Main winch rope Gide pulley
13 No work N/A Pin condition ok
pin
14 Mast pin 1 nos new making N/A New pin fitting , no problem found

15 Sliding cylinder upper pin No work N/A Pin condition ok

16 Sliding cylinder lower pin No work N/A Pin condition ok

17 Feed cylinder bush No work N/A Bush condition ok

18 Dump cylinder bushing New bush making and fitting N/A New bush fitting , no problem found

19 Wire line winch pulley bush No work N/A Bush condition ok

 Work Done Statement
Powerpack & Powertrain:

S.No Component Description Work Done Part No/Serial No Make /Model Complaints/Suggestions/Instructions

When machine testing engine condition ok no

1 Engine General service and oil service done Cummins , 6 cta
leakage , no abnormal sound found

2 Turbocharger No work N/A Turbo charger works properly

No work
3 Engine Fan N/A N/A No crack found

4 Radiator and Pad Servicing N/A N/A No leakage found and radiator works properly

5 Engine Mounting Pad N/A N/A

Gear box works properly no abnormal sound create

6 Reducing Gearbox Overhauling 11CSD4010201B Cortech
no heating issue and no leakage found

All gear shifting properly , and no abnormal sound ,

7 4 Speed Gearbox Overhauling 11CSD401030801 Cortech
no leakage and no heating issue .

8 Track Gearbox No work N/A N/A Works properly so no work done

Idler welding , idler shaft welding and resize ,

idler bearing change,6 roller welding and After all work of track assembly completed , track
9 Track Assembly resize , 3 roller new making , roller shaft new
11CSD3G04040 N/A
move properly , no problem found
making and roller bearing , oil seal change
N/A After changing , chuck works properly , no leakage
10 Chuck Assembly Oil seal , chuck pin , chuck spring change N/A
and no abnormal sound create
 Work Done Statement
Hydraulic Pumps, Motors & Cylinders:

S.No Component Description Work Done Part No Make /Model Complaints/Suggestions/Instructions

Due to required pressure not given , main After changing main pump working properly ,
1 Hydraulic Main Pump pump changed 12CSD40503W2 required pressure given.
2 Secondary Pump No work 12CSD4020106040 Checked and found condition ok so no workdone

3 Auxiliary Pump 1 No work 12CSD40506W1 Checked and found condition ok so no workdone

4 Auxiliary Pump 2 No work 12CSD40503W4 Checked and found condition ok so no workdone

5 Rotation Motor No work N/A Checked and found condition ok so no workdone

6 Mud Pump Drive Motor No work 11CSD4090W1-M Checked and found condition ok so no workdone

7 Main Winch Motor No work 11CSD4040W1-M Checked and found condition ok so no workdone

8 Wireline Winch Motor No work Checked and found condition ok so no workdone

9 Track Motor No work Checked and found condition ok so no workdone

After seal change feed cylinder works properly and
10 Feed Cylinder Seal change 11CSD403040 no leakage found
After seal change dump cylinder works properly and
11 Dump Cylinder Seal change 11CSD4030BW1
no leakage found
After seal change lift cylinder works properly and no
12 Lift Cylinder Seal change 11CSD404040-M-70-L leakage found
13 Jack Cylinder No work 11CSD40402040 Checked and found condition ok so no workdone
After seal change foot clamp cylinder works
14 Foot Clamp Cylinder Seal change 1112070B
properly and no leakage found
N/A After seal change sliding cylinder works properly
15 Sliding Cylinder Seal change
and no leakage found
After seal change rod kicker cylinder works properly
16 Rod Kicker Cylinder Seal change N/A and no leakage found
 Work Done Statement
Hydraulic Valve Assembly:

S.No Component Description Work Done Part No Make /Model Complaints/Suggestions/Instructions

1 8 Spool Valve No work Checked , found condition ok so no work done

2 4 Spool Valve Drilling No work Checked , found condition ok so no work done

3 4/3 Spool Valve Aux . Part No work Checked , found condition ok so no work done

4 Hold Back Valve No work Checked , found condition ok so no work done

5 Load Sensing Valve - Track No work Checked , found condition ok so no work done

6 Single Spool Valve No work Checked , found condition ok so no work done

7 Feed Pressure Valve No work Checked , found condition ok so no work done

8 Walking Valve - Track No work Checked , found condition ok so no work done

9 Rotation High – Low Valve No work Checked , found condition ok so no work done

10 Float Valve No work Checked , found condition ok so no work done

11 Main Winch Brake Valve No work Checked , found condition ok so no work done

12 Mud Pump Control Valve No work Checked , found condition ok so no work done
 Work Done Statement
Oil Coolers, Hose assemblies & Gauges:

S.No Component Description Work Done Part No Make /Model Complaints/Suggestions/Instructions

1 Hydraulic Oil Cooler No work 12CSD405W1 Cortech No crack found so only cleaning work done

N/A
2 Hydraulic Hoses 10% hose change Rajdhani After changing damage hose all hose condition ok

3 Adaptors, Fittings and 10% hose change N/A Rajdhani

After changing damage fittings , all fittings condition
Connectors ok

N/A
4 Main Pump Pressure Gauge New fitting N/A Main pump pressure gauge working properly

5 Hold Back/Push Down Drill No work N/A Micro Checked , condition ok

Pressure Gauge

6 Multi Pressure Gauge No work N/A Micro Checked , condition ok

N/A
7 Feed Pressure Gauge No work N/A Checked , condition ok

8 Rotation Speed Gauge No work N/A N/A Checked , condition ok

9 Mud Pump Pressure Gauge No work N/A N/A Checked , condition ok

 Work Done Statement
Electrical System:

S.No Component Description Work Done Part No Make /Model Complaints/Suggestions/Instructions

1 Meters Panel Band repairing , painting , all meters servicing N/A N/A After repairing meter panel condition ok

2 Hour Meter Replaced to new one A2C96911700 VDO Checked , new hour meter works properly

3 Battery New battery fitting with machine N/A Cummins Checked , new battery works properly

After Servicing battery cut off works properly

4 Battery Cut-Off Switch Servicing N/A N/A

After Servicing Self starter works properly

5 Self-Starter Servicing 5304291 N/A

6 Alternator Servicing 3415691 N/A After Servicing alternator works properly

After new harness fitting all function working

7 Wiring Harness New harness fitting with machine N/A N/A properly

After checking , key switch working properly so no

8 Key Switch No work N/A N/A
work done

After changing emergency switch working properly ,

9 Emergency Switch New fitment N/A N/A
no problem found
 Work Done Statement
Machine Accessories:

S.No Component Description Work Done Part No Complaints/Suggestions/Instructions

1 Lube Pump No work 12CSD401040W5 Checked , condition ok

2 Magnetic Filter Changed 12CSD401040W1 After changing , it works properly

3 Main Winch No work 11CSD4040W1 Checked , condition ok

4 Wire Line Winch No work 11CSD404250B Checked , condition ok

5 Accelerator Lever & Cable No work N/A Checked , condition ok

6 Wireline Pulley Bearing change 11CSD403010B After bearing change wire line pulley works properly

After bearing change main winch pulley works properly

7 Main Winch Pulley Bearing change N/A

Checked , condition ok
8 Expansion Bellow No work N/A

9 Mud Pump safety Valve Servicing N/A After servicing , safety valve work

After servicing , mud pump work properly

10 Mud Pump Servicing 11CSD4090W1

After servicing , safety valve work

11 Mud Pump Pressure Vessel Servicing N/A

12 Air Filter Housing No work N/A Checked , condition ok

13 Mud Mixer Motor Changed 11CSD3130W1 New motor works properly

14 Mud Mixer Only cleaning work 11CSD313010 Checked , condition ok

 Work Done Statement
General Consumables - Filters:

S.No Component Description New/Old Part No Make /Model Qty Complaints/Suggestions/Instructions

1 Engine Oil Filter New P553000 Donaldson 1 New filter condition ok and working properly

Donaldson
2 Fuel Filter New P5029055 P502913 2 New filter condition ok and working properly

3 Fuel Water Separator New P550248 Donaldson 1 New filter condition ok and working properly

4 Coolant Filter New 1 New filter condition ok and working properly

Donaldson
5 Air Filter Inner New 12CSD402020BW1 1 New filter condition ok and working properly

6 Air Filter Outer New 12CSD402020BW1 Donaldson 1 New filter condition ok and working properly

7 Hydraulic Oil Suction New 12CSD402020BW4 1 New filter condition ok and working properly
Filter

8 Hydraulic Oil Return New 12CSD402020BW2 1 New filter condition ok and working properly
Filter 1

9 Hydraulic Oil Return New 12CSD402020BW3 1 New filter condition ok and working properly
Filter 2

10 Fuel Tank Strainer New N/A 1 New filter condition ok and working properly
 Work Done Statement
General Consumables - Lubricants:

S.No Component Description Grade Qty Make Complaints/Suggestions/Instructions

1 Engine Oil 15W40 22 litre Valvoline

2 Hydraulic Oil H68 2 barrel Castrol

4 Gear Oil 80W90 30 litre Castrol

5 Coolant N/A 25 litre Castrol

 Budget Analysis

Man-hour Cost Calculation:

Description Senior Level Mid-Level Junior Level Helper/Labour

Machine Refurbishment Manhour

Engine Overhauling Manhour

Gearbox Overhauling Manhour

Hydraulic Components Overhauling Manhour

Electrical Components Overhauling Manhour

Fabrication Work Manhour

Mudpump and Drive Engine Overhauling
Manhour
Machine shop Work Manhour

Machine Testing

Machine Washing

Machine Painting

Other Miscellaneous Works

Total Man Hour

Cost/Manhour

Total Manhour Cost/Category

Total Manhour Cost

 Budget Analysis
Spare Cost Calculation:
Description Cost P.O P.O Status
Engine Spare Parts 1250
Gearbox Parts 0

Hydraulic Spare Parts 273454

Hydraulic Hose Assemblies 20000

Mud Pump and Drive Engine Parts 9513

Electrical Spare Parts 70848

Mechanical Spare Parts 20755

Electrical Accessories Parts 0

Mechanical Accessories Parts 0

Radiator and Cooler 3363

Silicon Hoses 0

Pin & Bushes 0

Fasteners 2200

Track Assembly Parts 0

Bearing 139266

Filters 34446

Lubricants 18820

Structural Steels 0

General Consumables 7500

Total Spares Cost 601415

 Budget Analysis
Repair & Development Cost Calculation:
Description Repair/Development Cost W.O No W.O Status Supplier Name

Total Cost
 Plan Vs Actual Statement
Type of Cost Cost

Man-Hour Cost

Spare Parts Cost

Repair & Development Cost

Total Cost

Type of Cost Cost Description Workdays

Allocated Cost Assigned Target Date

Actual Cost Actual Job Completion Date

Cost Deviation Workdays Deviation

Deviation Justifications
Cost Deviation Workdays Deviation
 Signature Panel

Machine Clearance By

Engine and Powertrain Clearance By

Hydraulic Components Clearance By

Electrical Components Clearance By

Fabrication Components Clearance By

Safety Interlocks Clearance By

Quality Clearance By

Refurbishment Documents Clearance By

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