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Summary of Contents for Greaves 3G11 Series
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OPERATION AND MAINTENANCE MANUAL 3G11, 4G11 and 6G11 Series of engines GREAVES COTTON LTD. Diesel Engines Unit, Chinchwad, Pune 411019, India, Tel: (91) – 20 – 27473564, 267308200 Fax: (91) – 20 – 27472276 Mail-ID:-gensetcare@greavescotton.com Visit us: - www.greavescotton.com...
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Operation and Maintenance Manual 3G11, 4G11 and 6G11 Series Engines 3G11 Series Engine 4G11 Series Engine 6G11 Series Engine...
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Operational and Maintenance Manual for G11 Series Engines Foreword We thank you for choosing Greaves G11 series engine for your application. G11 series engines are water- cooled, four-stroke, multi-cylinder, direct injection compression ignition engines. The engines are designed using modern concepts. The engines are suitable for various off-road applications. In addition to the performance parameters the engine designers have paid special attention to ease of maintenance, ease of assembly and disassembly, reliability and standardization.
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A. Warranty Policy (Diesel engines) strictly as per the recommendations of Greaves Cotton Ltd. and operated in Greaves Cotton Ltd. warranty for the machinery is accordance with the instructions contained limited to its faulty design, defective materials/ in the Greaves Cotton Ltd. operational components and/or workman-ship and is valid until manual.
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If parts are replaced, the defective part shall be property of Greaves Cotton Ltd. In any case, wherever the parts are supplied with free charges, Greaves Cotton Ltd. shall not be liable for any fitment and / or other charges. • Greaves Cotton Ltd.
Table of Contents, continued Starter / Alternator ........................ Electrical Control Panel ......................21 5.3 Battery ..........................21 5.4 Alternator ..........................Alternator regulator....................... 22 5.6 Operating conditions ......................22 5.7 Danger and cause of failure ....................23 Section 6. Engine Operation ......................6.1 Standard and Typical Operating Conditions ................
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Operational and Maintenance Manual for G11 Series Engines Modifications summary Modification Document Number Details of Modifications Page No Date 141190060057– 12.07.13 New Release...
Operational and Maintenance Manual G Series 1. GENERAL 1.1 Safety 1.2 Operation Guidelines Safety of your personnel, property and equipment should be the first priority during installation, 1. It is assumed that the reader and the user operation, maintenance of your engine and of these operating instruction is familiar equipment.
Operational and Maintenance Manual G Series 2.7 Engine Nameplate 2.9 Engine nomenclature system Fig. 9 Engine nomenclature Fig.2 Engine Name Plate Example – 2.8 Location of the Nameplate 4G11TAG1 : Four cylinder turbocharged COP rating 4G11TAG2 : Four cylinder turbocharged COP rating 4G11TAG3 : Four cylinder turbocharged COP rating 4G11 TP...
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Fuel feed pump pressure Nozzle opening pressure 250 +/-10 Lub oil circuit Lub oil grade GREAVES MAXTHERM APICF4 15W40 Lub oil sump capacity Ltrs Lub oil change period 500 hrs As per IS:1462 2005 with 5% tolerance & SFC fig. are for a well-run in Engine...
Operational and Maintenance Manual G11 Series 2.11 Engine Illustrations for 3G11 Series Engine Fig. 11 3G11 Series engine Fig. 10 3G11 Series engine Rocker cover Exhaust bellow Exhaust out Starter Exhaust bellow Engine flywheel Air filter Air cleaner Cylinder head...
Operational and Maintenance Manual G11 Series 2.12 Engine Illustrations for 4G11 Series Engine Fig. 13 4G11 Series engine Fig. 12 4G11 Series engine Flywheel Cylinder head U clamp Battery charging alternator Air filter Starter Gear end casing Oil filler cap Air intake manifold Fuel pump Flywheel housing...
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Operational and Maintenance Manual G11 Series Notes...
Operational and Maintenance Manual G11 Series 2.13 Engine Illustrations for 6G11 Series Engine Fig. 17 6G11 Series engine Fig. 16 6G11 Series engine Flywheel Cylinder head Sensor Battery charging alternator U clamp Starter Air filter Fuel filter Gear end casing Oil filler cap Air intake manifold Fuel pump...
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Operational and Maintenance Manual G11 Series 2.13.1 Engine Illustrations for 6G11 Series Engine Fig.19 6G11 Series engine Fig.18 6G11 Series engine Water Inlet Turbocharger Water manifold Exhaust out Exhaust manifold Air inlet Lub. Oil filter Cylinder head Flywheel Oil sump Flywheel housing Belts Oil header...
Operational and Maintenance Manual G11 Series 2.14 Dimensions and weight – 3G11 Series Engine For overall dimensions see the layout drawing. Engine weight - 380 kg Flywheel flange – SAE 3/11.5 2.17 Engine Lifting Instructions Fig. 20 Overall Engine Dimensions 2.15 Dimensions and weight –...
Operational and Maintenance Manual G11 Series transportation, the ropes or tackles should be positioned in such a way that they do not damage engine components like rocker cover, fuel pumps, high pressure pipes, etc. The engine should be balanced while lifting and moving. Do not keep the engine hanging on lifting tackles.
The system has a pressure-regulating valve, lube oil filter and lube oil cooler, Fig. 25 Lubrication System of 3G11 Series Engine which are housed in a lube oil header. c) Providing oil through push rod lubricates the rocker assembly. The fuel pump and turbo chargers are positively lubricated.
India suitable for Greaves engines. Greaves India Limited strongly recommends the use of SAE 15W40 Lub oil with API CH-4, CES 20071 & CES 20076 classification for all Greaves engines to get the various advantages and optimum performance from the engine. This oil has a minimum TBN of 10.5 to counteract the higher...
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India suitable for Greaves engines. Greaves India Limited strongly recommends the use of SAE 15W40 Lub oil with API CH-4, CES 20071 & CES 20076 classification for all Greaves engines to get the various advantages and optimum performance from the engine. This oil has a minimum TBN of 10.5 to counteract the higher...
3.2 Engine Cooling Systems the cooling needs of canopy enclosed genset application. 3.2.1 G11 Series Engine Cooling System Fig.30 Cooling System diagram for G11 Series Engines Fig. 29 3G11 series engine cooling system Water out to radiator Thermostat Bypass Water pump...
Dissolved Solids) 3.2.4 Coolant additive specification Fill requisite quantity of cooling water duly mixed with Greaves maxtherm specialty summer coolant / anti-freeze compounds about 20% by volume or cooling conditioner with anti-freeze, if required. 3.2.5 Filling up coolant on a new installation Fig.
Operational and Maintenance Manual G11 Series Fig. 34 Coolant Filling through Radiator cap Fig. 36 Drain Plug on Oil Cooler Header 3.2.7 Draining the system 3.2.8 Thermostat element replacement: Thermostat is provided in the cooling circuit to Note: attain the stable coolant temperature as quickly as possible.
Operational and Maintenance Manual G11 Series 3.2.9 Water pump Fig.40 Radiator charge air cooler Fig.38 Water Pump Radiator / CAC has to be cleaned every 500 hours. G11 series engine have gear driven water pump. A This frequency can vary depending on the dust weeping hole is provided on the crankcase for the condition in the area of installation, application and water to leak out.
4. FUEL SYSTEM 4.1 G11 Series engine fuel system Fig. 42 Fuel System Fig. 41 3G11 Series engine fuel system Engine must be operated with good quality diesel. Preferred quality specifications are (IS: 1460 2005) – cetane no 51, Sulfur 0.015% max, density 0.825gm/cc...
Operational and Maintenance Manual G11 Series 4.2 Trapped Air Removal from System Bleeding of delivery pump needs to be performed • Before engine operates first time. • After long period of inactivity. • If FIP or HPP loosened and there is air in the line.
Operational and Maintenance Manual G11 Series 5. ELECTRICAL SYSTEMS 5.1 Starter / Alternator Electrical system is provided with the engine including a 12 Volts starter and an alternator. Fig.47 Control Panel 5.3 Battery Fig. 45 Starter Fig.48 Battery 12 Volt / 24 Volt (optional), 88 Amp-Hr capacity battery is recommended Fig.
Operational and Maintenance Manual G11 Series FIP and injectors are supplied by BOSCH and 5.5 Alternator regulator (option) warranty is covered. Servicing these is a highly skilled work. This has to be done by authorized The alternating current is rectified in the alternator service agency or shop.
Operational and Maintenance Manual G11 Series • 5.7 Dangers and cause of failure Do not lay any tools on the battery. • Always disconnect the negative pole of the battery before performing work Dangers Cause of failure electrical system. Battery terminals Damage to the •...
Operational and Maintenance Manual G11 Series Typical steady state operating parameters Lube oil pressure 3.5-4.5 Lube oil pressure 2.9-4 6G11 Lube oil temperature °C 85-100 Water temperature °C 78-90 Suction depression (new air cleaner element) Suction depression (clogged air 250mm for new filter, max 550 mm cleaner element) choke limit Exhaust back pressure...
Operational and Maintenance Manual G11 Series • Confirm if all safety precautions have been taken. • Confirm that the electrical breaker is in OFF position. Note: Sudden loading of the engine from 0 to 100% of rated load is to be avoided for turbocharged and turbo after cooled engine.
Operational and Maintenance Manual G11 Series 6.3 Stopping the engine • Remove the load from the engine. • Run for 2 minutes to stabilize the temperatures. Recommended turbocharged turbo after cooled engines. • Push the stop button to stop the engine. •...
Operational and Maintenance Manual G11 Series 6.5 Running in Running on of the engine is extremely important for the engine (means what). A good running on will ensure good, long life for the engine. During the first 50 hours of running, do not load the engine suddenly and restrict the load to 80 %.
Operational and Maintenance Manual G11 Series 7. SERVICE AND MAINTENANCE 7.1 Maintenance of Lube oil system 7.1.1 General Oil change periods depend on the engine usage, application, installation and quality of fuel and lube oil. It is necessary that oil should be changed at least once in six months, if the engine use is less than specified, oil change period varies.
Operational and Maintenance Manual G11 Series 7.1.2 Changing Lube Oil Dispose used proper environmentally friendly way. 7.1.3 Checking oil level Fig. 58 Drain Plug Fig. 60 checking oil level After the specified oil change period, oil should be This preferably is done before starting the engine. changed irrespective of the oil condition.
Operational and Maintenance Manual G11 Series 7.1.4 Changing oil filter with oil 7.2 Maintenance of Fuel System Use only clean fuel, without water or particulate suspension, impurities etc. Maintain the fuel tank full reducing possibility of air and condensation entering the system. Bleeding of delivery pump must be done if •...
It is recommended that Fuel Injection pump servicing is done by BOSCH authorized service agent / personnel at authorized service center Fig. 65 Air Filter preferably through Greaves service personnel. 7.2.4 Injector NOP (nozzle opening pressure) adjustment Injector servicing needs to be done by authorized service personnel.
Crank shaft axis 0.10 mm max The water used should be clean, free from dirt or dust, floating matter, colorless, without smell. Add Greaves supplied coolant in correct proportion for efficient cooling of the system. Bad water can cause severe corrosion. These corrosion products can block cooling system and severely damage the engine.
Operational and Maintenance Manual G11 Series • Please note that while engine is supplied charged The acid in each cell should be kept in on low amperage or slow charge from authorized level with the top of the separators. Top battery maintenance / repair shop.
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Operational and Maintenance Manual G11 Series...
Operational and Maintenance Manual G11 Series 7.10 Maintenance Schedule Maintenance Schedule Particulars Check oil level in Sump Check Belt Check Fuel level in tank Check water level in radiator Check Battery condition Clean Every 500 Hrs coarse fuel filter Change air Every 500 Hrs filter Typical...
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Operational and Maintenance Manual G11 Series Maintenance Schedule Particulars Clean injector, nozzles and spray Change if necessary Cleaning up Or at least once in fuel tank a year Cleaning up Or at least once in exhaust silencer year Checking After 3500 Hrs exhaust bellows change if...
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Operational and Maintenance Manual G11 Series Maintenance Schedule Particulars Changing air / exhaust / water manifold / thermostat housing gaskets Checking sensors and change if necessary Overhauling starter and alternator Checking and changing AV mounts if required Replace Major overhaul radiator cap with should be rubber ring...
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Operational and Maintenance Manual G11 Series Maintenance Schedule Particulars Changing injectors if required Changing liners if required Changing piston assembly if required Checking and changing Con rod small end bush if required To be Changing fuel pump procured from elements if required Bosch authorized dealer...
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Operational and Maintenance Manual G11 Series...
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Operational and Maintenance Manual G11 Series Note : 1. This schedule is applicable only when Greaves Maxtherm oil and coolant are used 2. # - For initial starting only Notes: Never re-use following items • Cylinder head gasket, • Copper washers, •...
10. After this point do not rotate the engine. 11. Remove belts and store separately. If the period between engine dispatch from 12. The battery should be disconnected. Greaves and the installation is more than six Ensure electrolyte level. Charge months or if a engine is to be non operational for battery at regular intervals.
Operational and Maintenance Manual G11 Series Recommended preservatives Lube oil and fuel Manufacturer Rust preventive Cooling system circuit Bharat Sherol B Bharat Rustol Bharat Preserve oil 30 Bharat Petroleum emulsion with water (1: 20 ratio) Servo Cut S 20% Servo preserves 30. Indian Oil Corporation Servo RP 125 Emulsion with water...
4. Check fire hazard possibility near fuel, oil storage. 5. Plan release direction of the exhaust. 6. Judge engine size properly. Seek help from Greaves service dealers or area offices for this purpose. 7. Provide adequate safety measures around installation area.
Operational and Maintenance Manual G11 Series 10. GCL REGIONAL OFFICE AND DEALER ADDRESSES Location Name Address Tele. / Fax & e-mail GREAVES COTTON Western Region Office Tel. 91-20-27473564(O) LIMITED, PUNE Corporate Park II, Fax- . 91-20-27472276 / 27474567 Floor , Sion Tromby Road,...
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Operational and Maintenance Manual G11 Series Pune, M K Services 6/15 Chintamani Industrial Mr.Madhusudan Kashilekar Ahmednagar Estate, Sinhagad rd, Mob - 9822043604 Nashik, Wadgaon bk, Pune 411041 Cell -9372007424 Solapur, A'bad Tel/Fax - 020 - 24393688 Aurangabad, M.K.Services 303, Labh Chambers Mr.Vinod Apshinde 9372007438 Jalgaon, Station Road, Aurangabad-...
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Operational and Maintenance Manual G11 Series Baroda Jay Mech. 15, Sunrise Complex, opp. Tejash Athavia Panchmahal, Mob- 99779388488 Jay Ambe School, Near Anand jaymech@rediffmail.com Darbar Chokdi, Manjalpur Vadodara Surat Ajay Enterprises 1/660, Bundar Street, behind Ajay Athavia Kim, Civil Court, Nanpura, Mob- 9825861456 Hazira, aenterprise@rediffmail.com...
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Korba 9301723312 Raipur-492099 Ambikapur, ssdiesels@gmail.com Bhilai Tel Fax- 0771-2572782/83 Rajnandgaon Chattisgad state NORTH REGION Delhi M/s GREAVES Exp. Building Annexe,9-10 Tel.:91-11-23730554 COTTON LIMITED Bahadur Shah Zafar Marg (8 ines) P.B.No.7024, New Delhi- /23317039 110002 FAX.:91-1123359782 / 23357739 Mr. Rajiv Tel. 011-23359783...
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Operational and Maintenance Manual G11 Series Mr. Manish Trivedi Mob. 09654101304 Manager Service NR Tel.011-23318037(O) Delhi manish.trivedi@greavescotton. Mr. Kapil Saini Mob. 09891442407 Delhi Asst. Manager-Sales kapil.saini@greavescotton.com Mr. P.S. Guleria Mob- 09871816336 ps.guleria@greavescotton.com Asst. Manager-Service Delhi Lucknow Office no. 208, Iind floor 0522-2202900 Shalimar Square 126/31 B N Road, Lal Bagh...
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Operational and Maintenance Manual G11 Series Mr. R.P.Singh Faridabad, M/s.Power( Service) B-488, IInd Floor, Nehru Syndicater pss_fbd@sify.com Palwal Ground Opp.Punjab Mobile:9312215510 national Bank, N.I.T. 0129-2421298 (O) Faridabad-121001 0129-2413356(O) FAX: 0129-2411898 Mr.D.K.Sharma M/s.R.S. Powertronix 305,310, Triveni Complex Mobile: 9312268885 E-10-12, Jawahar Park, rspowertronix@yahoo.co.in Laxmi Nagar, Vikas Marg, Delhi-110 092...
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Operational and Maintenance Manual G11 Series WESTERN DEALERS G.S.Enterprises Mumbai 24,Nagdevi Cross Lane, 3rd Mr. Shabbir/Abhijit Central Area floor Mob-9820038788 Boiser, Tardeo) Mumbai- 400003 Tel- 022 -28935025 ® Tel- 022- 23722303(O) Tel-022- 23451686(O) Fax-23453804 Kolhapur, Deltran Diesel 2094-A, Vikram Nagar, Ravindra Balgunde Karad, Sangli Market Yard, Kolhapur-...
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Operational and Maintenance Manual G11 Series Goa, UPA Engg Sales & 1) House No-557, Dande Vado Tel- 0832-2863532 (O) Tel- 0832-2863533 (O) Sindudurg Services Chinchinim, Salcete, Goa- Fax- 0832-2863534 403715 TeleFax- 0832-2513685 (Vasco) Tel -0832-2514512(Vasco) 2) Pai Building, Mundvel, upaengg@gmail.com Behind Uma Petrol Pump, Vasco-Da-Gama, Goa-403802 Ravi Rashmi...
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Operational and Maintenance Manual G11 Series MVR Diesel “MVR House”, Plot No.105, Mr.M. V.R.Mohan Gandhidham, Electromech Mob- 9825274076 Bhuj, Sector – 1/A, Engineers 9428749072 Naliya Gandhidham- 3700201 9825274076 Branch off- Rajkot, mvrdiesel@yahoo.co.in 303 Ronak Complx Jamnagar, Near Bombay Hotel Morbi Tel-02836-329883 Gondal road Rajkot Tel fax-02836-226719...
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Operational and Maintenance Manual G11 Series NORTH REGION Delhi M/s GREAVES Exp. Building Annexe,9-10 Tel.:91-11-23730554 COTTON LIMITED Bahadur Shah Zafar Marg (8 ines) /23317039 P.B.No.7024, New Delhi- FAX.:91-11-23359782/ 110002 23357739 Mr. Rajiv Tel. 011-23359783 Kulshreshta Mobile- 9654141301 Delhi Regional Manager rajeev.kul@greavescotton.com...
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Operational and Maintenance Manual G11 Series NORTH DEALERS Ghaziabad M/s. Ambika Power 211/6 Rajendra Nagar Mr. S.K.Sharma Bulandsher, point Ind.Area, Opp:Dass Mobile No: 09212077086, Meerut Factory,P.O. Mohan 09810282482 Noida, Hapur, Nagar,G.T Road, Mr.Rajeev Goswami Shahibabad, Ghaziabad-201007 Mobile No:09810545055, 09212679484 app_rg40@yahoo.co.in & ambika.powerpoint@gmail.com Tel-0231-2651095 Tel-0231-2537931 (R)
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Operational and Maintenance Manual G11 Series Mr.K.K.Katarya M/s.Supertech Zila Hotel Compound, Opp: supertech@supertechmail.com Engineers & Co. Sophia Market Court Road, Mob-09927045957, Saharanpur-247001 09927045958 0132-2725957 (O) 0132-2645564 (R) FAX: 0132-2711149 Panipat, Mr. Teja Kamboj M/s. Kamboj Power Plot No.-331,Sec 25 Narnaul & Hissar Mobile: 9416508275 Generator Service Phase-II, GT Road,...
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