POWER TECHNOLOGIES

ANNUAL MAINTENANCE CONTRACT (AMC)

Diesel Generator Sets – 30 kVA to 2000 kVA

POWER TECHNOLOGIES offers professional Annual Maintenance Contract (AMC) services for Diesel Generator Sets from 30 kVA to 2000 kVA, covering Cummins, Caterpillar and other leading engine makes.

Our AMC program is designed to ensure:

Reliable DG set operation
Minimum unexpected breakdowns
Maximum equipment availability
Improved fuel efficiency
Longer engine and alternator life
Reduced operating and maintenance costs
Faster breakdown response
Proper preventive maintenance records

All maintenance activities will be carried out in accordance with the applicable OEM recommendations, operating hours and actual site conditions.

1. AMC COVERAGE

Our AMC covers the following DG capacities:

DG Capacity	Service Category
30–75 kVA	Preventive & Breakdown Maintenance
82.5–140 kVA	Preventive & Breakdown Maintenance
160–200 kVA	Preventive & Breakdown Maintenance
225–380 kVA	Preventive & Breakdown Maintenance
400–500 kVA	Preventive & Breakdown Maintenance
625–750 kVA	Preventive & Breakdown Maintenance
800–1000 kVA	Preventive & Breakdown Maintenance
1010–1250 kVA	Preventive & Breakdown Maintenance
1500–2000 kVA	Preventive & Breakdown Maintenance

2. PREVENTIVE MAINTENANCE

Scheduled preventive maintenance visits will be carried out to identify potential problems before they result in equipment failure.

ENGINE INSPECTION

Complete visual inspection of DG set
Check engine oil level and condition
Check coolant level and condition
Check fuel level and fuel system
Check fuel hoses and connections
Check engine oil leakage
Check coolant leakage
Check fuel leakage
Check exhaust system
Check crankcase breather
Check air intake system
Check turbocharger and related piping
Check engine mounting
Check engine vibration
Check abnormal noise
Check engine operating temperature
Check engine oil pressure
Check engine RPM

LUBRICATION SYSTEM

Check engine oil level
Inspect oil leakage
Check oil pressure
Replace engine oil as per OEM service interval
Replace oil filter
Check oil sump and drain plug
Check oil hoses and connections

Oil and filter replacement intervals will be based on the engine manufacturer's recommended operating-hour/service schedule. For example, some Cummins generator models specify a 500-hour/1-year service interval, while other engines have different intervals.

3. FUEL SYSTEM

Inspect fuel tank
Check fuel level
Inspect fuel supply and return lines
Check fuel hoses
Check fuel leakage
Drain water/sediment from fuel system where applicable
Replace fuel filters as per OEM schedule
Check fuel filter housing
Check fuel pump
Check fuel injection system
Check fuel pressure where applicable
Check fuel contamination

4. COOLING SYSTEM

Check radiator condition
Check coolant level
Check coolant concentration
Check radiator hoses
Check hose clamps
Check radiator leakage
Check water pump leakage
Check cooling fan
Check fan belt condition and tension
Check fan pulley
Check radiator fins
Clean radiator externally
Check coolant temperature
Check expansion tank
Check coolant filter where applicable
Check and replace coolant as per OEM recommendation

Cummins maintenance guidance specifically includes inspection of coolant, radiator hoses, belts and cooling-system components as part of periodic maintenance.

5. AIR INTAKE SYSTEM

Inspect air filter
Check air filter restriction indicator
Clean/replace air filter as required
Inspect air intake hoses
Check hose clamps
Check air leakage
Inspect turbocharger
Inspect charge-air piping
Check intercooler/aftercooler system where applicable

Air-filter replacement should be based on the OEM schedule and actual restriction/operating conditions rather than applying one fixed interval to every DG model.

6. EXHAUST SYSTEM

Inspect exhaust manifold
Check exhaust flexible connection
Check exhaust pipe
Check silencer
Check exhaust supports
Check exhaust leakage
Check insulation
Check back pressure where required
Check exhaust temperature
Inspect joints, clamps and gaskets

7. BATTERY & STARTING SYSTEM

Check battery voltage
Check battery terminal condition
Clean battery terminals
Check battery electrolyte level for serviceable batteries
Check battery charging voltage
Check battery charger
Check starter motor
Check starting performance
Check battery cables
Check battery isolator
Check battery condition
Recommend replacement when battery performance is inadequate

8. ALTERNATOR INSPECTION

Check alternator output voltage
Check frequency
Check phase-to-phase voltage
Check phase-to-neutral voltage
Check current/load
Check alternator temperature
Check abnormal noise
Check vibration
Inspect terminal connections
Check winding condition where testing is required
Check insulation resistance when required
Check bearings
Check cooling fan
Check AVR
Check excitation system
Check rotating diodes where applicable

9. CONTROL PANEL / AMF PANEL

Inspection and testing of:

AMF panel
Control panel
Generator controller
Mains sensing
Generator sensing
Auto/manual operation
Start/stop operation
Emergency stop
Battery charger
Engine protection alarms
Low oil pressure protection
High coolant temperature protection
Overspeed protection
Under/over voltage
Under/over frequency
Phase failure protection
Mains failure operation
Auto changeover operation
Contactors and relays
Control wiring
Indicating lamps
Meters
Fuses/MCBs
Terminal connections

10. LOAD TEST / PERFORMANCE TEST

During scheduled maintenance, the DG set will be started and operating parameters will be checked.

Where site conditions permit:

No-load running test
Load test
Voltage measurement
Frequency measurement
Engine RPM
Oil pressure
Coolant temperature
Battery charging voltage
Load current
kW
kVA
Power factor
Engine response
Alternator performance

Load testing shall be carried out according to site requirements and available load-bank/load conditions.

11. DG SET CLEANING

Cleaning of engine exterior
Cleaning of alternator
Cleaning of radiator
Cleaning of DG enclosure
Removal of dust and oil deposits
Cleaning of control panel
Cleaning of battery area
Cleaning of ventilation openings

12. MECHANICAL CHECKS

Check engine mounting bolts
Check alternator mounting
Check coupling
Check coupling bolts
Check anti-vibration mounts
Check foundation condition
Check belt tension
Check pulleys
Check guards
Check radiator mounting
Check exhaust supports
Check fuel-pipe supports

13. BREAKDOWN MAINTENANCE

POWER TECHNOLOGIES will attend breakdown complaints during the AMC period.

Typical breakdown support includes:

Engine starting failure
Low oil pressure
High coolant temperature
Engine hunting
Overheating
Excessive smoke
Low engine RPM
DG not taking load
Voltage fluctuation
Frequency fluctuation
Battery charging problems
AMF panel faults
Starter motor problems
Fuel-system problems
Cooling-system problems
Alternator faults
AVR-related faults
Sensor-related faults

Our service team will diagnose the fault and provide recommendations for corrective action.

14. PERIODIC SERVICE PROGRAM

A typical AMC program can include:

MONTHLY / ROUTINE INSPECTION

General DG inspection
Check oil and coolant
Battery inspection
Fuel-system inspection
Cooling-system inspection
Check leakage
Check belts
Check exhaust
Check control panel
Test DG starting
Record running hours
Record operating parameters

250-HOUR / 6-MONTH SERVICE

As applicable to the engine OEM:

Engine inspection
Oil/filter service
Fuel-system inspection
Air-filter inspection
Cooling-system inspection
Battery inspection
Alternator inspection
Control-panel inspection
Electrical connection inspection
Performance testing

500-HOUR / ANNUAL SERVICE

As applicable to the engine model:

Engine oil replacement
Oil-filter replacement
Fuel-filter replacement
Air-filter replacement
Cooling-system inspection
Belt inspection
Battery testing
Alternator testing
Control-panel testing
Safety protection testing
DG performance test
Detailed service report

The exact hour-based schedule must be adjusted according to the engine model and OEM manual. Cummins itself recommends following the applicable operator's manual rather than using a universal interval.

15. DETAILED ANNUAL SERVICE

One major annual preventive service will be carried out, including applicable:

Engine oil
Oil filters
Fuel filters
Air filters
Coolant/corrosion inhibitor
Filter seals/O-rings
Belts
Hoses
Battery inspection
Cooling-system inspection
Fuel-system inspection
Alternator inspection
Control-panel inspection

Replacement of parts and consumables will be as per the AMC category and agreed commercial terms.

16. SERVICE REPORT

After every preventive-maintenance visit, POWER TECHNOLOGIES will provide a service report containing:

DG capacity
Engine make/model
DG serial number
Running hours
Date of service
Oil pressure
Coolant temperature
Battery voltage
Output voltage
Frequency
Load current
kW/kVA
Power factor
Observations
Parts replaced
Defects identified
Recommendations
Next service due

Maintaining accurate running-hour and service records is recommended by Cummins as part of effective generator maintenance.

17. AMC OPTIONS

OPTION A – NON-COMPREHENSIVE AMC

Includes:

Scheduled preventive maintenance
Inspection
Testing
Breakdown attendance
Labour/service charges
Troubleshooting
Service reports

Spares, lubricants, filters, batteries, coolant, major repairs and replacement components are charged separately.

OPTION B – COMPREHENSIVE AMC

Includes:

Scheduled preventive maintenance
Breakdown maintenance
Labour
Routine service consumables
Engine oil
Oil filters
Fuel filters
Air filters
Coolant/corrosion inhibitor where agreed
Minor repairs
Breakdown support

Major components such as engine overhaul, turbocharger, radiator, alternator winding, AVR, controller, starter motor, batteries and other major components shall be included/excluded strictly as specified in the commercial AMC agreement.

18. EXCLUSIONS

Unless specifically mentioned in the quotation, the following are normally excluded:

Major engine overhaul
Engine replacement
Alternator rewinding
Major alternator repair
Turbocharger replacement
Radiator replacement
Battery replacement
Starter motor replacement
AVR replacement
Controller replacement
AMF panel replacement
Major electrical modifications
Fuel tank replacement
Exhaust-system modification
Acoustic enclosure modification
Civil works
Crane/hydra charges
DG shifting
Transportation
Major cable work
External fuel-system work

Any excluded work will be quoted separately after inspection and customer approval.

19. EMERGENCY BREAKDOWN SUPPORT

POWER TECHNOLOGIES provides emergency technical support for AMC customers.

Our objective is to:

Minimize downtime • Identify the fault quickly • Restore DG operation safely • Provide permanent corrective action

Response time will depend on location, accessibility, site conditions, nature of breakdown and availability of required spares.

20. CUSTOMER BENEFITS

By entering into an AMC with POWER TECHNOLOGIES, customers benefit from:

✔ Preventive maintenance
✔ Reduced breakdowns
✔ Better DG reliability
✔ Improved equipment life
✔ Faster technical response
✔ Proper service records
✔ Planned maintenance expenditure
✔ Genuine/approved spare-parts support
✔ Experienced service engineers
✔ Reduced downtime

POWER TECHNOLOGIES

YOUR POWER – OUR RESPONSIBILITY

Capacity: 30 kVA to 2000 kVA

24 × 7 Emergency Breakdown Support