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| 1 | Dismantling of existing Diesel Engine Alternator (DEA) set of following rating, including dismantling of acoustic/silent canopy, decoupling of engine and alternator, removal of the set from its foundation, disconnection and removal of control panel, fuel tank, power and control cabling, earthing leads, battery set, exhaust piping, and all associated accessories; complete with disconnection of all interconnections required for dismantling of engine components for major overhauling. The work shall include arranging all necessary tools and tackles such as toe‑bar, chain pulley block, tripod stand, crane, lifting devices, consumables, and manpower as required for safe handling, shifting, and lowering of equipment;complete as required |
| 2 | 600 KVA rating KOEL engine model KV2.5004 |
| 3 | Repairing and complete Major overhauling of the existing faulty (KOEL engine model KV2.5004) DEA set of following capacity, including replacement of worn‑out, unserviceable and defective engine components, cleaning, inspection, reassembling after replacement of required parts, testing, commissioning and ensuring satisfactory performance of the DG set, all as required and as directed by the Engineer‑in‑Charge.The scope of work includes replacement of the following parts:KOEL engine model KV2.5004 |
| 4 | Piston assembly including piston body, gudgeon pin, and associated components. |
| 5 | Piston Ring Set (compression, scraper, and oil control rings) |
| 6 | Cylinder Liner Assembly |
| 7 | Cylinder Head Gasket |
| 8 | K‑Sealant (80 ml)for gasket sealing applications |
| 9 | Inlet Valve |
| 10 | Valve Cone (Outlet) |
| 11 | Valve Seat Insert |
| 12 | Exhaust Valve Seat Insert |
| 13 | Valve Guide |
| 14 | Valve Collet |
| 15 | Injector Sleeve |
| 16 | Thrust Washer |
| 17 | Oil Seal |
| 18 | Rear & Front Seal |
| 19 | LLOP |
| 20 | Connecting Rod |
| 21 | Main Bearing Set |
| 22 | Connecting Rod Bush |
| 23 | C.R. Bearing Set |
| 24 | Lower Bearing Conrod (STD) |
| 25 | Lower Bearing Conrod |
| 26 | Push Rod |
| 27 | Bolt Conrod |
| 28 | Adjusting Screw |
| 29 | Crankshaft for above EA set |
| 30 | Fresh Water Pump |
| 31 | Lube Oil Pump |
| 32 | Labour charges for major overhauling of the KOEL engine model KV2.5004 of existing DEA set, covering complete dismantling, inspection, cleaning, replacement of defective parts (spares paid separately), reassembly, alignment, lubrication, and load testing. The scope includes inspection of lobes, journals, impeller, bearings, gears and rotors, checking clearances, ensuring proper coolant circulation and correct oil pressure,removal of connecting rod, replacement of bush, cleaning, pressing, reaming to correct size, alignment checking and correction, followed by reassembly and refixing, complete as required |
| 33 | Comprehensive B‑Check of the existing DEA set with KOEL engine model KV2.5004,including thorough inspection, servicing andreplacement of worn‑out/ unserviceable consumables, filters ,including draining of old oil, cleaning of sump, and proper disposal of used oil, coolant system, cleaning of breathers, cleaning of housing, bleeding of fuel system, checking for leakage lubrication system, belts, hoses, electrical connections, safety shutdowns, and carrying out functional testing on load to ensure satisfactory performance, complete as required and as directed by the Engineer‑in‑Charge.The following consumables/spares shall be supplied and replaced under this scope: |
| 34 | Supply and filling of KOEL Care Super Genuine Engine Oil (20 litres). |
| 35 | Supply and replacement of Fuel Pre‑Filter Assembly, including removal of old filter. |
| 36 | Supply and replacement of Lube Oil Filter Cartridge. |
| 37 | Supply and replacement of Fuel Filter Assembly (primary/secondary as applicable). |
| 38 | Supply and replacement of Air Filter Elements (inner and outer. |
| 39 | Supply and filling of coolant of approved make, including draining of old coolant, flushing of cooling system, refilling to required level, complete as required. |
| 40 | Labour charges for executing the remaining scope of major overhauling of the KOEL engine model KV2.5004 of the existing DEA set, including dismantling of the respective assemblies, replacement of defective or unserviceable parts, repair and reconditioning of the cylinder head, nozzle calibration etc., thorough cleaning, transportation, reassembly after necessary repairs, refixing in position, and load testing, complete as required. |
| 41 | Reconditioning of cylinder head, including cleaning, inspection, valve seat cutting, valve guide replacement, valve lapping, replacement of defective components, surface grinding, pressure testing as required. |
| 42 | Crankshaft grinding including cleaning, measurement of journals, ultrasonic testing, hardness checking, grinding to the required undersize, polishing, checking bearing clearances, alignment verification with main line bore, correction as necessary, dynamic balancing of crankshaft, lubrication as required at site. |
| 43 | Checking alignment of engine block main line bore, carrying out honing and line boring to restore correct bore size and alignment, including , cleaning, measurement, machining, complete as required. |
| 44 | Descaling of oil cooler, including, chemical cleaning/descaling of core, removal of sludge and deposits, flushing, drying, refixing in position, and testing for leakage, complete as required. |
| 45 | Repairing of turbocharger of the specified make and model, including dismantling, cleaning, replacement of worn‑out parts using standard repair kit, balancing, reassembling, refixing, and testing, complete as required. |
| 46 | Cleaning and descaling of radiator and after‑cooler, including dismantling, chemical descaling, removal of scale/sludge, fin cleaning, flushing, drying, refixing, and testing for proper cooling efficiency, complete as required. |
| 47 | Repairing and calibration of Fuel Injection Pump (FIP) of the specified make and model, including dismantling, cleaning, replacement of defective parts/spares, calibration on test bench, refixing, and testing, complete as required. |
| 48 | Calibration/repairing of injectors, including dismantling, cleaning, replacement of worn‑out parts, pressure setting, spray pattern testing, refixing, and testing on engine, complete as required. |
| 49 | Freight charges for transportation of engine components/assemblies from Gwalior to Delhi and back to Gwalior, including packing, loading, unloading, handling, and safe delivery, complete as required. |
