Asset Tag MMPL/03/1036

Machine Make & Model Cortech , CSD-1800X

Machine Serial No R-127
Machine Received From Joda
Machine Dispatch To

Refurbishment Job Machine Received HMR N/A

Completion Machine Dispatch HMR

Presentation – Machine Refurbishment Job No MMPL/EXP/NOV23/CSD1800X(R-127)/21

Hydrostatic Rig Machine Refurbishment Start Date 08-11-2023
Machine Refurbishment End Date

Total Days of Refurbishment

Total Refurbishment Budget

Refurbishment In charge RANJIT KR VISWAKARMA

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 After physically checked we found good condition so no work.

Feed cylinder guide plate welding work

2 Mast done
No work done We found feed cylinder guide plate has cracked

3 Canopy No work No work done We found canopy condition good

We found lift cylinder upper pin, foot clamp cylinder pin, gear box pin , Wire line
4 Pin & Bushes Some pin is new making No work done
pulley pin , mast pin damaged.

5 Silencer welding work done as crack found No work done After welding work silencer found ok
No work
6 Battery Box No work done We found canopy condition good

7 Foot Clamp Cleaning and seal change No work done After seal change we found there is no leakage on foot clamp

8 Main Winch Guard New making and fitting No work done New making and fitment

No work We found wire line winch guard condition good

9 Wireline Winch Guard No work done

10 Rotation Motor Guard New making and fitting No work done New making and fitting

11 Radiator Shroud No work No work done We found radiator shroud condition good

12 Mud pump Chassis No work No work done We found mud pump chassis condition good

13 Covers Cleaning work done No work done We found Cover condition good

14 Diesel Tank Washing work done No work done We found diesel tank condition good , there is no crack

15 Hydraulic Tank Washing and seal change No work done After seal change we found there is no problem at hyd tank
Pin & Bushes:
Work Done Statement
S. No Component Description Work Done Part No Complaints/Suggestions/Instructions

1 Feed cylinder pin No work 11CSD40313 We found feed cylinder old pin condition good

2 Lift Cylinder Upper Pin New pin making 11CSD40405 After new pin fitting we found there is no problem

3 Lift Cylinder Lower Pin No work 11CSD40421 We found pin condition good
No work We found pin condition good
4 Dump cylinder upper pin 11CSD40333

5 No work 11CSD40333 We found pin condition good

Dump cylinder lower pin

6 Rod kicker upper pin No work 11CSD40307 We found pin condition good

7 Rod kicker lower pin No work 11CSD40307 We found pin condition good
After new pin fitting we found there is no problem
8 Foot clamp cylinder pin New pin making 111202

9 New pin making 11CSD3031006 After new pin fitting we found there is no problem
Reducing Gear box pin
After new pin fitting we found there is no problem
10 4 speed gear box pin New pin making 11CSD3031013

11 Main winch pulley pin No work 11CSD4030106 We found pin condition good

12 New pin making 11CSD3030105 After new pin fitting we found there is no problem
Wire line winch pulley pin
Main winch rope Gide pulley After new pin fitting we found there is no problem
13 New pin making 11CSD4A030107
pin
After new pin fitting we found there is no problem
14 Mast pin New pin making 11CSD40315

15 Sliding cylinder upper pin No work 11CSD4031620B We found pin condition good

16 Sliding cylinder lower pin No work 11CSD4031620B We found pin condition good

17 Feed cylinder bush No work N/A We found pin condition good

18 Dump cylinder bushing No work N/A We found pin condition good

After new bush fitting we found there is no problem
19 Wire line winch pulley bush New bush making N/A
 Work Done Statement
Powerpack & Powertrain:

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

1 Engine Only general service work 78512742 Cummins , 6CTA After general service engine condition ok

33500358
2 Turbocharger No work Cummins We found turbo charger condition good

No work N/A
3 Engine Fan Cummins We found engine fan condition good

Radiator general service work done and N/A After machine testing we found there is no leakage
4 Radiator and Pad mounting pad change
N/A
and no crack at radiator

N/A
5 Engine Mounting Pad No work N/A We found engine mounting pad condition good

11CSD4010201B After bearing and oil seal change there is no

6 Reducing Gearbox Cleaning , Bearing and oil seal change Cortech
leakage and no abnormal sound found

11CSD401030801 After testing we found all gear shifted properly and

7 4 Speed Gearbox Only cleaning work done Cortech
no abnormal sound create and no leakage

8 Track Gearbox No work N/A Cortech After testing track gearbox works properly

9 Track Assembly Bearing of idler changed 11CSD3G04040 Cortech After bearing change idler works properly

10 Chuck Assembly Cleaning , seal and spring washer changed N/A Cortech After seal change chuck works properly
 Work Done Statement

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

After testing there is no problem , required pressure
1 Hydraulic Main Pump No work 12CSD40503W2 given.
2 Secondary Pump No work 12CSD4020106040 After testing there is no problem
After testing there is no problem
3 Auxiliary Pump 1 No work 12CSD40506W1

4 Auxiliary Pump 2 No work 12CSD40503W4 After testing there is no problem

5 Rotation Motor Seal change N/A After seal change rotation motor works properly
INI
6 Mud Pump Drive Motor No work 11CSD4090W1-M Y1D9MO274 After testing there is no problem

7 Main Winch Motor No work 11CSD4040W1-M After testing there is no problem

8 Wireline Winch Motor No work N/A After testing there is no problem

N/A
9 Track Motor No work After testing there is no problem
After seal change Feed cylinder works properly` and
10 Feed Cylinder Seal change 11CSD403040 Cortech no leakage found on it
After seal change there is no leakage on dump
11 Dump Cylinder Seal change 11CSD4030BW1 Cortech
cylinder and it works properly
After seal change there is no leakage on lift cylinder
12 Lift Cylinder Seal change 11CSD404040-M-70-L Cortech and it works properly
After checking we found jack cylinder condition
13 Jack Cylinder No work 11CSD40402040 Cortech
good
After seal change there is no leakage on Foot clamp
14 Foot Clamp Cylinder Seal change 1112070B Cortech
cylinder and it works properly
After seal change there is no leakage on sliding
15 Sliding Cylinder Seal change N/A Cortech
cylinder and it works properly
After seal change there is no leakage on rod kicker
16 Rod Kicker Cylinder Seal change N/A Cortech
cylinder and it works properly
 Work Done Statement
Hydraulic Valve Assembly:

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

1 8 Spool Valve Repairing N/A N/A After repairing 8 spool control valve condition good

2 4 Spool Valve Drilling Changed N/A N/A After changed the valve, it working properly

3 4/3 Spool Valve Aux.Part No work N/A N/A We found 4/3 spool valve condition ok

4 Hold Back Valve Changed After changed the valve, it working properly

5 Load Sensing Valve - Track

6 Single Spool Valve No work We found single spool valve condition good

7 Feed Pressure Valve No work We found feed pressure valve condition good

No work
8 Walking Valve - Track We found walking valve condition good

9 Rotation High – Low Valve No work We found rotation high-low valve condition good

10 Float Valve No work We found float valve condition good

11 Main Winch Brake Valve No work We found main winch brake valve condition good

12 Mud Pump Control Valve No work We found main pump control valve condition good
 Work Done Statement
Oil Coolers, Hose assemblies & Gauges:

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

After checking we found hyd oil cooler condition

1 Hydraulic Oil Cooler No work 12CSD405W1 Cortech good

2 Hydraulic Hoses Changed N/A Rajdhani After new hose fitting there are no leakage found

3 Adaptors, Fittings and Changed N/A Rajdhani

After new adapter fittings there are no leakage
Connectors found

After checking we found main pump pressure gauge

4 Main Pump Pressure Gauge No work N/A Micro
condition good

5 Hold Back/Push Down Drill No work N/A Wika

After checking we found hold back pressure gauge
Pressure Gauge condition good

After checking we found multi pressure gauge

6 Multi Pressure Gauge No work N/A N/A condition good

After checking we found feed pressure gauge

7 Feed Pressure Gauge No work N/A Wika condition good

After checking we found rotation speed gauge

8 Rotation Speed Gauge No work N/A N/A
condition good

After checking we found mud pump pressure gauge

9 Mud Pump Pressure Gauge No work N/A Zoom
condition good
 Work Done Statement
Electrical System:

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

1 Meters Panel Servicing N/A N/A After servicing all meters are working properly

N/A
2 Hour Meter No work N/A After checking hours meter condition good

After new battery fitting no problem found , it

3 Battery Changed N/A Exide
working properly

After checking battery cut off switch working

4 Battery Cut-Off Switch No work N/A N/A
properly

5 Self-Starter Servicing N/A N/A After general service self working properly

After general service alternator working properly

6 Alternator Servicing N/A N/A

7 Wiring Harness Changed N/A N/A After new harness fitting , no problem found

8 Key Switch No work N/A N/A After checking key switch is working properly

N/A After checking emergency switch is working

9 Emergency Switch No work N/A
properly
 Work Done Statement
Machine Accessories:

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

1 Lube Pump Changed 12CSD401040W5 After change the lube pump ,it working properly

2 Magnetic Filter No work 12CSD401040W1 After checking we found magnetic filter condition good

3 Main Winch Bearing and oil seal changed 11CSD4040W1 After full servicing main winch working properly, no problem

After full servicing wire line winch working properly there

4 Wire Line Winch Bearing change 11CSD404250B
are no problem

5 Accelerator Lever & Cable New fitment N/A After new accelerator lever fitment ,no problem found

6 Wireline Pulley Bearing change 11CSD403010B After new bearing fitting wire line pulley working properly
After new bearing fitting main winch pulley working
7 Main Winch Pulley Bearing change N/A properly

8 Expansion Bellow No work N/A After checking we found expansion bellow condition good

9 Mud Pump safety Valve Servicing N/A After Servicing mud pump safety valve working properly

After full servicing mud pump working properly , there are no

10 Mud Pump Servicing 11CSD4090W1
leakage
After checking we found mud pump pressure vessel condition
11 Mud Pump Pressure Vessel No work N/A
good
After cleaning work air filter housing condition good, no crack
12 Air Filter Housing Cleaning N/A
found
After change the mud mixture motor , mud mixture working
13 Mud Mixer Motor Changed 11CSD3130W1
properly, no problem found

14 Mud Mixer Cleaning 11CSD313010 After checking we found mud mixture condition good
 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 01 After new filter fitting , there are no problem found ,working properly

P502905 After new filter fitting , there are no problem found ,working properly
2 Fuel Filter New
P502913
Donaldson 02

After new filter fitting , there are no problem found ,working properly
3 Fuel Water Separator New P550248 Donaldson 01

Donaldson After new filter fitting , there are no problem found ,working properly
4 Coolant Filter New P552075 01

After new filter fitting , there are no problem found ,working properly
5 Air Filter Inner New 12CSD402020BW1 Donaldson 01

After new filter fitting , there are no problem found ,working properly
6 Air Filter Outer New 12CSD402020BW1 Donaldson 01

7 Hydraulic Oil Suction New 12CSD402020BW4 Lemin 01

After new filter fitting , there are no problem found ,working properly
Filter

8 Hydraulic Oil Return New 12CSD402020BW2 Lemin 01

After new filter fitting , there are no problem found ,working properly
Filter 1

9 Hydraulic Oil Return New 12CSD402020BW3 Lemin 01 After new filter fitting , there are no problem found ,working properly
Filter 2

After new filter fitting , there are no problem found ,working properly
10 Fuel Tank Strainer New 01
 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 H 68 2 Barrel CASTROL

4 Gear Oil 80W90 30 Litre MOBIL

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

Gearbox Parts

Hydraulic Spare Parts

Hydraulic Hose Assemblies

Mud Pump and Drive Engine Parts

Electrical Spare Parts

Mechanical Spare Parts

Electrical Accessories Parts

Mechanical Accessories Parts

Radiator and Cooler

Silicon Hoses

Pin & Bushes

Fasteners

Track Assembly Parts

Bearing

Filters

Lubricants

Structural Steels

General Consumables

Total Spares Cost

 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
 Digital Pictured
Machine Received Condition Machine Dispatch Condition
 Digital Pictured
Machine Received Condition Machine Dispatch Condition
 Signature Panel
After final testing we found there is no engine problem ,no electrical fault ,no hydraulic leakages all hose and
cylinder are in good condition, all hydraulic functions are working properly , gear box working properly and have
no leakages , Track motor , Chain and roller are in good condition , no crack and damages in this machine.

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