Format No.

:
ESS for Engine Health Check
(Frequency: As and when required)
ESN:

Site / Circle

Engine Make

Tag No.

Date of Commission:

Engine Model

Maintenance Point:

Date of Inspection:

Sr. Systems
No.

Parameters

Specifications

HRM:

Recommendation

Actual Results

Cy .No. Comp. Press.

1.
Recommended for top
Compression
2.
2
18 kg/cm for M & M, Ashok overhaul (M & M,
pressure of each
3.
Leyland engines.
Ashok Leyland
cylinder.
4.
engines)
5.
A Combustio
6.
n Chamber
Heavy or smoky blow bye orRecommended for top
oil spray through blow bye overhaul (M & M,
Blow by
vent
Ashok Leyland)
10-inch water column at
Cummins engine is
Blow by
0.221 orifice.
recommended for top
overhaul.
Hose
B

Air system Air cleaner

Exhaust
Smoky exhaust
system

Hoses

Fuel
system

Load test,
exhaust smoke

Diesel consumed
in immediate B
check to B
check.
Oil pressure

Check for surface crack &

condition

Lubricatin Oil pan

g
Oil top of
between oil
changes

Visual inspection

Replace if found
cracked or deformed.
Clear air cleaner &
replace the oil or
element if required.
Clean the silencer &
exhaust line if
required Check bellow
& joints, rectify if
required.
Replace if found
cracked / twisted /
damaged.
If found smoky
exhaust or low H.P, or
engine missing or
hunting after PM, then
calibrate FIP or
injectors.
Record in liters.

Oil pressure should not be Check oil pressure

less than 1 bar on load.
when engine reaches
to 75 to 85 0C
Clean oil pan
If drained oil found
contaminated.
Record oil topped
between two oil
changes in Liters

Sr. Systems
No.

Parameters

Specifications

Belts

Check for surface crack &

its condition

Radiator cap &

rubber gasket

Check for damage.

Radiator
Overflow hose

Check for surface crack &

its condition

Replace if found
cracked / Leak

Radiator out let

(bottom) hose

Check for surface crack &

its condition

Replace if found
cracked / Leak

Radiator inlet
Cooling upper hose

Check for surface crack &

its condition

Replace if found
cracked / Leak

By pass hose

Check for surface crack &

its condition

Replace if found
cracked / Leak

Radiator

Clogged, bend fins / tubes Clean / repair

Fan

Fan & Cowl Gap

Radiator
mounting

Check & tighten.

Replace if required

Voltmeter,
Check reasons for
Measuring Ammeter, Power abnormality, replace if
G Instrument Meter
required.
s
Water temp.
Gauge
Oil Pressure
gauge
Instrument
checking

Check calibration with

standard gauge. If required.

Actual Results

Replace if found
cracked / slipping /
damaged.
Check & replace if
required

Check for cracks &

bent. Replace if
required
Adjust if required.

Visual inspection

Recommendation

Check for
functionality, replace if
required.
Check for
functionality. Replace
if required.

RPM cum HR
meter
Oil Temp. Gauge
High water temp Manufacturer specification. Check for
switch
functionality, replace if
required.

Low oil pressure

Switch switch
checking
Solenoid

Sr. Systems
No.

Parameters

Check for
functionality, replace if
required.
Check for
Stroke length -30 mm
Operation / cable condition
Specifications

Recommendation

Actual Results

Charging
Alternator
Starter motor

Overhauling
Overhauling
Voltage of each cell is
2.20 VDC

Check & record

Voltage of each cell

Specific gravity of each

cell should be 1.23

Check & record the

Cell. No.
specific gravity of each 1.
cell
2.
3.
4.
5.
6.

Battery

Check & record battery

discharge current in
Amps.
Check & record battery
Voltage across battery
terminals. (VDC)

Battery
(During Engine
Cracking)

J Electrical
Alternator
IR values should be 5
M
Winding Resistance
should be Equal
Should be
1.0
Earthing

Should be
5.0
Should be
5.0

Cable & Bus bar

IR values should be 10
M

Cable termination
bus bar joints
ACB current
carrying
contacts / Power
contactor
contacts

Check & record IR

values for
R-E, Y-E, B-E
Check & record for
R-Y, Y-B, B-R
Check & record for
Neutral Earthing
resistance
Record Body earthing
resistance
Record AMF panel &
controller earthing
Check & record IR
values for R-Y, Y-B,
B-R, & R-E, Y-E, B-E
Check for tightness,
insulation peel of,
overheating, and
discoloration.
Check ACB current
carrying contacts for
pitting, overheating

Cell. No. Cell Voltage

1.
2.
3.
4.
5.
6.
Sp. Gr.

Performance parameters
Alternator
No Load
Parameters
Load
Parameters

Engine

Output
Voltage

Volts AC

Output
Voltage

Volts AC

Load
Current

Amps

No Load

ON Load

Engine RPM
Engine Oil
Preparation

PROBLEMS NOTICED DURING PREVENTIVE / PERIODIC MAINTENANCE:

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PROBLEM RESOLUTION:
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RECOMMENDATION:
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----------------------------(Sign. & Name of OSE)

---------------------------------(Sig. & Name of AM/SAM)

-----------------------------------(Sig. & Name of Vendor rep.)