4G11T, TP, 4G11TG1,4G11TPG2 Operation and Maintenance Manual-16.03.09

GREAVES COTTON LTD.
OPERATION & MAINTENANCE MANUAL
G SERIES – 4G11T/TP,4G11TG1/TPG2 - ENGINE
GREAVES COTTON LTD.

AUXILIARY POWER DIV.
Chinchwad, Pune 411019, India,
Tel: (91) – 20 – 27473564/67308200
Fax: (91) – 20 - 27472276
Document number. 1 411 0 006 00 24 (01) Page 1 of 68

Operational and Maintenance Manual G Series – 4G11T Engine
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 dis-
assembly, reliability and standardization.
The engines are compatible with existing emission norms and are capable of achieving the
future emission norms. The rigid construction of engine has reduced the noise and vibration
to a very low level.
This manual describes the operating instruction and maintenance schedules of the engine. It
is necessary that manual needs to be read carefully before putting the engine into operation.
Good installation, clean water, air, lube oil, fuel and timely maintenance will enhance the life
of your engine, reduce your running cost and reduce the down time.
We would like to emphasize the use of only genuine spare parts for the engine. Use the
services of only authorized service dealer for maintenance. Use only listed lube oils, water
additives. Training facility is also available with Greaves where technicians can be trained.
Continuous improvement may cause changes in this manual. In case the change is important,
we make it a point to inform the owners of the engine. This manual is regularly updated to
include these changes.
In case of any queries, problems do not hesitate to contact our service dealer, regional office.
Greaves Cotton Ltd. ,

AUXILIARY POWER DIV.
Service and Spares Department
Chinchwad, Pune 411019 (INDIA)
Ph: +91 (020) 27473564 /67308200

Fax: +91 (020) 27472276

Warranty Policy (Diesel engines)
Greaves Cotton Ltd. warranty for the machinery is limited to its faulty design, defective
materials/ components and/or workman-ship and is valid until a period of 15 months from the
date of dispatch of machinery from its Works/Warehouse or one year from the date of
commissioning or completion of 3500 hours of operation, whichever event shall occur first.
OR
Greaves Cotton Ltd. warranty for the machinery is limited to its faulty design, defective
materials/ components and/or workman-ship and is valid until a period of 24 months from the
date of dispatch of machinery from its Works/Warehouse or 18 months from the date of
commissioning or completion of 5000 hours of operation, whichever event shall occur first
provided the user of the machinery uses recommended genuine spare parts including
“Greaves Maxtherm “ Lube Oil & Coolant wherever applicable and use of genuine Air Filter
element and Lube Oil Filter element purchased only from Authorized Dealers of Greaves
Cotton Ltd.
The foregoing warranty is not applicable in the event, interalia, if
• The machinery has been stored improperly and not protected from adverse
weather conditions of any nature.
• Assembly of the Genset is not carried out as per the recommendation.
• Canopy manufactured and supplied along with the DG Set is not as per the ARAI
approved drawings provided by DEU.
• If OEM has his own approved design through authorized agencies and is
adversely affecting performance of engine.
• If the DG set is installed and is in use without approved acoustic enclosure
(canopy).
• The machinery has not been installed strictly as per the recommendations of
Greaves Cotton Ltd. and operated in accordance with the instructions contained
in the Greaves Cotton Ltd. operational manual.
• The defective / improper fuel, lubricants, coolants and any of their associated
systems are utilized
• Unauthorized person carries out repairs and alterations.
• The maintenance of the machinery is not strictly done as per the procedure
detailed in Greaves Cotton Ltd. operator’s handbook/instruction manual.
• Improper tools and equipments are utilized at any stage during erection,
commissioning and maintenance.
• During operation, the engine is improperly shut down or happened to over
speeding or is subjected to misuse, negligence or accident.
• Failure in any way results from use of components / parts not manufactured or not
authorized by us for use on our engine.

TERMS OF WARRANTY
• The components having shelf life like rubber components, belts, hoses and
replacement filters / consumables which are normally maintenance spares are not
covered within the scope of this warranty.
• In cases of complaints which are proprietary bought out items, our warranty is
limited to the extent of warranty of the manufacturer to us.
• If the engine is improperly stored beyond period of six months without

recommended long storage treatment and used without recommended de-
preservation.
• All goods are supplied on the condition that under no circumstances we

undertake liability for the indirect or consequential loss or damage of any nature.
• The warranty shall not apply to fair wear and tear of the individual components or
damages due to the negligence or improper handling by the purchaser or his
employees or agents or due to damage by any cause beyond our control.
• The warranty does not apply to detect arising due to fault in periodic preventive
maintenance and lapse in the use of recommended genuine spare parts including
“Greaves Maxtherm” Lube Oil & Coolant wherever applicable and use of genuine
Air Filter element and Lube Oil Filter element and also subject to adequate
quantity of lubricating oil / coolant in respective circuits.
• In case of DG set manufactured and supplied by Greaves Cotton Ltd.,, warranty

in respect of following items will be restricted to 1000 hours of operation or 3
months, whichever shall occur first.
Main alternator
• Meters, battery charging alternator components & indicating instruments

• Protection relays and control fuses
• MCCB, ACB, contactors and accessories of the engine and the power control
panel.
• Indication lamps and batteries
• Claim under warranty shall be summarily rejected if the defects are not notified
within warranty period specified above and lodged within 3 days of the expiry of
the warranty period.
• The new or repaired part of parts will be delivered free of cost Ex-works
Chinchwad Pune. Any additional delivery cost to be borne by the purchaser.
• In respect of any warranty claim accepted by us, we shall arrange to replace or

repair relevant and respective parts free of cost to the customer. 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. shall not be responsible for replacement of the complete unit
under any circumstances. In case of any warranty claim, the responsibility of
Greaves Cotton Ltd. shall be limited to the extent of replacement or supply of
defective parts.

Modifications summary
Modification No. Document Number / Date Details of Modifications Page No

00 141100060024 New Release ---
01 141100060024 – 16.01.09

Contents
Sr. no Chapter name Page number

---- Foreword 2
---- Warranty statements 3
---- Modification summary 5
---- Contents 6
1 General 8
1.1 Safety 8
1.2 Operation Guidelines 8
1.3 Maintenance Guidelines 8
2 Engine Description 9
2.1 Engine Orientation 9
2.2 Engine Nameplate 9
2.3 Cylinder Nomenclature 9
2.4 Location of Name Plate 10
2.5 Engine nomenclature system 10
2.6 Technical data 11
2.7 Engine Illustrations 14
2.7.1 Inlet manifold side 14
2.7.2 Exhaust manifold side 15
2.7.3 Engine Dimensions and Weight 16
2.7.4 Engine Lifting Instructions 17
3 Systems 18
3.1 Lubrication System 18
3.1.1 xG11TA –Engines lubrication system 19
3.1.2 G–series lubrication system 19
3.1.3 Permissible engine inclination 20
3.1.4 G – Series lubrication system 21
3.2 Cooling Systems 22
3.2.1 G – Series Engine Cooling System 23
3.2.2 G – Series Cooling System Data 24
3.2.3 Water Specification 25
3.2.4 Coolant Additives 25
3.2.5 Filling Up Coolant On A New Installation 25
3.2.6 Topping Up Coolant In An Already Installed Engine 26
3.2.7 Draining The System 26
3.2.8 Thermostat Element Replacement 27
3.2.9 Water Pump 27
3.2.10 Cleaning Radiator /CAC 28
3.3 Fuel System 29
3.3.1 G – Series Engine Fuel System 29
3.3.2 Trapped Air Removal From The System 30
3.4 Electrical System 31
3.4.1 Starter/Alternator 31
3.4.2 Electrical Control Panel 31
3.4.3 Battery 31
4 Engine Operation 32
4.1 Standard And Typical Operating Conditions 32
4.2 Starting The Engine 33
4.2.1 Safety Instructions 33
4.2.2 First time start after installation 33
4.2.3 In case of Key start 34
4.2.4 In case of push button start 34
4.2.5 AMF operation start up 34

Sr. no Chapter name Page number

4.3 Stopping the engine 35
4.4 Safety stop 35
4.5 Running in 35
5 Service and Maintenance 36

5.1 Maintenance of Lube oil system 36
5.1.1 General 36
5.1.2 Changing Lube Oil 36
5.1.3 Checking Oil Level 37
5.1.4 Changing Oil Filter 38
5.2 Maintenance Of Fuel System 39
5.2.1 Fuel Filter 39
5.2.2 Fuel Strainer 39
5.2.3 Fuel Injection Pump 39
5.2.4 Injector NOP Adjustment 40
5.2.5 Dry Type Air Cleaner 40
5.3 Inspection and Checking of V Belt Tension 40
5.4 Checking and Adjustment of Valve Clearance 41
5.5 Flywheel Run out 41
5.6 Timing Gear 42
5.7 Maintenance Of Cooling System 42
5.8 Battery Checking Instructions 43
5.9 Electronic Governor and Actuator Fitment 44
5.10 Maintenance Schedule 45
6 Engine Preservation 50
6.1 Engine preservation during prolonged period of non-usage 50
6.2 Putting a preserved engine back into operation. 51
7 Installation Do’s and Don’ts 52
8 List of Regional Offices 53
9 Contact addresses 68

Operation and Maintenance Manual G Series – 4G11T Engine
Contact Address
1 General
1.1 Safety
Safety of your personnel, property and equipment should be the first priority during
installation, operation, maintenance of your engine and equipment.
The engine can cause harm in the following ways against which your personnel have
to guard.
Sr. No Hazard Example
1 Rotating parts Flywheel, pulleys, radiator fan
High
2 Exhaust related parts, exhaust gases, water, oil
temperature
Hot or
3 hazardous Fuel, lube oil, water, exhaust leaks or hose/pipe bursts
sprays
Electrical Alternators, starters, control panels, battery wirings

4
shocks/sparks
5. Loose objects Loose parts flying out (likelihood especially after maintenance)
Poison Additives, diesel, lube oil, exhaust gases can cause damage if
6
consumed or inhaled
• Never get near the engine while it is running wearing loose items like tie, long
chains, scarf, long loose clothes, tags with mobile phones etc.
• Display safety instruction clearly in the operating area.
• Make the operating persons aware of the safety related issues.
• Provide necessary safety equipment to the operating persons.
• Follow all applicable safety related regulations and laws.
1.2 Operation Guidelines
1. It is assumed that the reader and the user of these operating instruction is
familiar with the basic mode of operation of four stroke combustion engine and is
able to follow technical issues reasonably well. The text has been kept therefore
as short as possible for clarity and is backed by photographs and sketches.
2. Read the instructions carefully before installation of the engine or equipment.
3. In case of any doubt or difficulty, seek help from authorized service dealers.
4. Your engine needs clean air, clean fuel, clean lube oil and clean coolant.
5. Giving attention to these factors improves the life of your equipment, reduces the
running costs, and also increases the mean time between failures.
1.3 Maintenance Guidelines
1. Please read the maintenance instructions. Seek services of authorized service
dealers if needed.
2. Follow maintenance schedules.
3. Plan your maintenance.
4. Always use genuine spare parts, listed lube oil, listed additives and
unadulterated fuel from reputed agency.
5. Always use correct tools.
6. Always carry out maintenance in a clean area.
7. Follow good engineering practices during maintenance

2 Engine Description
2.1 Engine Orientation
Figure 2.1.1 Engine Orientation
2.2 Engine Nameplate
Figure 2.2.1 Engine Name Plate

2.3 Location of the Nameplate
Nameplate
Water in let pipe
Figure 2.3.1 Location Of Nameplate

2.4 Cylinder nomenclature
Figure 2.4.1 Cylinder Nomenclature
2.5 Engine nomenclature system
X G 1 1 X X X
Rating
Absent =Continuous duty
P = Prime power
Swept volume
1.1 Ltr/cyl Aspiration
NA – Naturally aspirated
T -- Turbocharged
TA -- Turbo after cooled
G series
Number of
cylinders –
2,3,4,6
Figure 2.5.1 Engine nomenclature

Example –
3G11 T : - Three cylinder turbocharged COP rating
3G11 TP : -Three cylinder turbocharged PRP rating
3G11 NA :-Three cylinders COP rating naturally aspirated

2.6 Technical Data
4G11T Engine Specifications for DG set application
Sr. No. Parameter 4G11 T

A) General
A1 Type 4 stroke, direct injection, compression ignition
A2 Bore(mm) 105
A3 Stroke(mm) 130
A4 No of cylinder 4
A5 Firing order 1-3-4-2
A6 Direction of rotation Anticlockwise looking at flywheel
A7 Swept volume per 1125
cylinder(cc)
A8 Total swept volume(ltr) 4.5
A9 Aspiration Turbocharged
A10 Cooling Water cooled

A11 Compression ratio 1 : 16.3
A12 Starting Electric start (12 VDC)
B) Power
B1 Rated power(kW Gross) 58.5
B2 Overload (1 hour in 12 10%
hours - ISO 3046)(kW
Gross)
B3 RPM 1500
B4 Governing Class A1- IS 10000, less than 4.5 %
C) Drives
C1 Water pump Centrifugal, gear driven
C2 Lube oil pump G-rotor, gear driven
C3 Radiator fan Belt driven, separate fan drive
C4 Alternator Belt drive
D) Systems
D1 Cooling Pressurized (7PSI) water cooled with radiator, with
thermostat (74-82ºC), pusher fan
D2 Lubrication Pressurized (3.5-4.5 bar)
Sump capacity 10 liters
Oil temperature 80 to 120 °C max

D3 Fuel Injection Inline fuel pump MICO F002AOZ626

P type injector F 002 C8Z 899 NOP 250 bar
E) Filtrations
E1 Air Filter Dry type
E2 Lube oil Filter Spin on type single element
E3 Fuel Filter Twin bowl, screwed type
F) Service Data
F1 Inlet valve tappet clearance
0.4 mm
cold
F2 Exhaust valve tappet
0.4 mm
clearance cold
F3 Bumping clearance 0.8 - 1.2 mm
F4 Crankshaft end play 0.4 mm max
F5 Cam shaft end play 0.10 to 0.35 mm
F6 Connecting-rod end play 0.4 Max.
F7 Flywheel housing face run 0.25 mm Max.
out w.r.t. crank shaft axis
F8 Flywheel housing bore run 0.10 mm Max.
out w. r. t crank shaft axis
G) Valve / Fuel injection timing
G1 Inlet valve opens 3 ° BTDC
G2 Inlet valve closes 23 ° ABDC
G3 Exhaust valve opens 33 ° BBDC
G4 Exhaust valve closes 1 ° ATDC
G5 Fuel Injection timing 15°+/-1° BTDC
Fuel injection timing need to be correctly set in order to
get good performance of the engine.
G6 Firing order 1,3,4,2
H) Bolt Torque tightening data
H1 M B Cap bolts 7-14-20Kgm (Torque in step)
H2 Cylinder head bolts 5-9-15Kgm (Torque in step)
H3 Inlet, exhaust manifold 6 kgm
H4 Connecting rod 5-9-13Kgm (Torque in step)
H5 Flywheel bolts 17Kgm
H6 Flywheel housing bolts 9.5Kgm
H7 Injector nut 5 kgm
H8 Oil Sump 2.5 kgm

H) Bolt Torque tightening data

H9 Idler Gear 6 kgm on line
H10 Pulley 17Kgm
H11 M 12 8.5Kgm
H12 M 10 7Kgm
H13 M8 2.5Kgm

2.7 Engine Illustrations

2.7.1 Inlet Manifold side
1 2
21
5
20
6
19
7
18
8
17 9
16
15
14 13 12 11 10
Figure 2.7.1.1 Inlet manifold side
1 Rocker cover 12 Belts

2 Exhaust out 13 Breather
3 Exhaust bellow 14 Alternator
4 Air inlet 15 Oil drain plug
5 Cylinder head 16 Fuel filter
6 Fuel pump 17 Fuel feed pump
7 Oil filler cap 18 Starter
8 Radiator fan 19 Stop lever
9 Water in 20 Throttle lever
10 Fan 21 Injector
11 Oil sump

2.7.2 Exhaust manifold side
Figure 2.7.2.1 Exhaust manifold side
1 Water Outlet 8 Engine foot

2 Water manifold 9 Oil pressure regulating valve
3 Exhaust manifold 10 Turbo charger
4 Lub. Oil filter 11 Gear casing
5 Flywheel 12 Oil supply to turbocharger
6 Flywheel housing 13 Air manifold
7 Oil header

2.7.3 Dimensions and weight -
For overall dimensions see the layout drawing at the end of this manual.
Engine weight - 480 kg
Flywheel flange – SAE 3
Fig 2.7.3.1 Overall Engine Dimensions

2.7.4 Engine Lifting Instructions
Lifting
Hook
Figure 2.7.4.1 Lifting Hook
Take all safety precautions while lifting and moving the engine. Only trained personnel
should handle the engine. You can consult Greaves service dealers, if necessary.
Remove water and oil from the engine before lifting. If your engine has cast iron sump
then the engine can be rested on the sump. For any other type sump, use blocks
under engine feet. Avoid jerks or abrupt resting of engine. The engine should never
be rested, stored or lifted in any other direction than upright. The engine should never
be rolled on the ground.
The engine is provided with four transportation feet even if only two feet (gear end)
are required for application. Store the spare feet, (flywheel end) carefully. Fit those
two extra feet before lifting the engine. The engine should not be rested on bell
housing for long durations.
Use only the eyebolts provided on the engine crankcase for lifting purpose. The
eyebolts are to be used for lifting engine only. Do not lift engine coupled with
alternator or entire DG set using these bolts. Ensure that, the I bolts are completely
engaged before engine is lifted.
While lifting the engine, use correct size of tackles, ropes, chains, cranes, hoists or
any other lifting or transportation device. While lifting or 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.

3 Systems
3.1 Lubrication System
3.1.1 xG11 T Engine lubrication system

G series engines use positive pressurized lubrication system. The main functions of
the lubrication system are as follows:
• Lubrication of friction related parts.

• To carry away the heat generated by friction
• To avoid corrosion
• To wash away debris created by friction wear.
a) The G series engine uses a positive displacement, G-rotor pump, which is gear
driven.
b) The system has a pressure-regulating valve, lube oil filter and lube oil cooler,
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.
The lube oil system is adequately designed to provide sufficient lubrication, oil change
period, filter element life and minimize lube oil consumption and running cost.
Rocker Assembly
R R R R
Pushrods
Fuel Pump
Return via
Tappet pocket in
T T T T
cylinder
head and
Oil to piston cooling nozzles push rod
pocket in
crankcase
Turbo
Oil to bearings
Pre. Reg. Valve

Header
Filter
Oil cooler
Pump
Lub Oil Sump Strainer Dipstick

Drain Plug
Figure 3.1.1.1 Lubrication System
Recommended Oil for G11 series engines

Company Oil brand name
Greaves Cotton Ltd Greaves Maxtherm (API CF -4- 15 W 40)

3.1.2 G–series lubrication system
Fuel pump end 10
Flywheel end
8
7
6
1
6
2
Gear end
4 5
Flow arrow
Figure 3.1.2.1 G–Series Lubrication System(Is the image correct)
1 Intermediate gear support 6 Main oil gallery

2 Nozzle gear lubrication 7 Pressure regulating valve
3 Lube oil pump 8 Lube oil filter
4 Lube oil suction strainer 9 Lube oil cooler
5 Lube oil sump 10 Push rods

Permissible Engine Inclination is 20 deg. However for continuous or intermittent

operation at an inclination contact our technical team for approval.
3.1.3 Permissible engine inclination

20°
20°
Figure 3.1.3.1 Engine Inclination

3.1.4 G–series lubrication system
Flywheel end
Manifold end
7
1 Gear end
2
6
Fuel pump end
4 5
Figure 3.1.4.1 G – Series Lubrication System
1 Piston cooling nozzle 5 Lube oil sump

2 Piston cooling nozzle gallery 6 Main bearings
3 Crank pins 7 Cam bores
4 Oil holes on crank shaft
Lube oil pump is G rotor type pump. Lube oil Pressure at various working
conditions is as below
Speed Pressure bar

Low idle speed 1.5 to 2 bar
High idle speed 5 to 6 bar
Under full load operating conditions 4 to 4.5 bar
If at any operating condition the lube oil pressure drops below 2.5 bar, then change
lube oil filter element. If the problem persists then contact authorized service agent or
dealer.

3.2 Engine Cooling Systems:
3.2.1 G series engine cooling system

G11 series engines are water-cooled engines. The water pump is gear driven. The
water is cooled by a radiator fan system. The fan is driven by a fan drive system and
is not mounted on the water pump. The water also cools lube oil in the lube oil cooler.
A thermostat (74C start to 82C full open) controls the water temperature. The
radiator has a pressure cap, which maintains the static pressure at 0.5 bar (7 psi). A
drain plug is provided to drain the system. The water system provides adequate
cooling in a simple and efficient manner to satisfy the cooling needs of canopy
enclosed genset application.
Thermostat
Bypass Water Manifold
Radiator
Water Pump
Oil Cooler Engine
Fan
Figure 3.2.1.1 Cooling System

Flywheel end 8
1 7
2
3 6
4 9
Flywheel end
5
Manifold end
Flow arrow
Figure 3.2.1.2 G – Series Cooling System
1 Water out to radiator 5 Water in from radiator

2 Thermostat 6 Oil cooler cavity
3 Bypass 7 Cylinder head
4 Water pump 8 Water manifold
9 Weeping hole

Manifold end
2 5
3
6
Flywheel end
Gear end
Fuel pump end
Flow arrow
Figure 3.2.1.3 G series Cooling System
1 Water outlet manifold 5 Bypass

2 Cylinder water cavity 6 Water pump
3 Water core 7 Water in
4 Water out
3.2.2 Cooling system data
Pump Centrifugal
Drive Engine driven gear drive
Static water pressure (radiator cap) 7 psi
Typical steady state water temp 72 – 90 ° C
Max allowable water temp 95 - 96 ° C

3.2.3 Water specifications:
pH value 6–8
Calcium/magnesium hardness 180-ppm max
Chlorides Less than 40 ppm
Sulfates Less than 100 ppm
TDS (Total Dissolved Solids) Less than 400 ppm
3.2.4 Coolant additive specification

Fill requisite quantity of cooling water duly mixed with Greaves maxtherm speciality
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
The engine is supplied with the coolant, which has to be filled up after installation.
For this refer procedure below:
1. Open the de-aeration plug.
2. Open the radiator cap.
3. Ensure all hoses are in place.
4. Prepare coolant in the specified proportion.
5. Pour coolant through the spout.
6. Water takes some time to fill up the system through the radiator tubes.
7. Wait for 20 seconds before restarting the pouring.
8. Coolant will first start coming out of the de-aeration opening.
9. Wait for the air to escape and close the plug.
10. Keep on pouring till the water is filled up in the radiator top tank. Close the cap
firmly.
Figure 3.2.5.1 Radiator Cap Figure 3.2.5.2 De-aeration Plug

3.2.6 Topping up coolant in an already installed engine
1. Never open the radiator cap of an engine that has just stopped.
2. Wait for at least 15 minutes after stopping the engine.
3. For normal top ups, it is not necessary to de-aerate the system.
4. Fill up coolant wait till the coolant level settles.
5. Confirm that the level is correct. Put the radiator cap back.
Figure 3.3.4.1 Coolant Filling through Radiator cap

Fig. 3.2.6.1 Topping up Coolant
3.2.7 Draining the system:
Note: Coolant mixture is poisonous. Store it safely.
1. The engine is provided with 3 drain plugs.

2. The drain plug on oil cooler header is for draining the system till cylinder head
level.
3. The drain plug on crankcase is for draining the entire engine.
4. The drain plug on the radiator is for draining the entire system.
5. Drain the coolant in a tray.
6. Dispose off the coolant safely in an environmentally friendly way.
Figure 3.2.7.1 Drain Plug on Crankcase Figure 3.2.7.2 Drain Plug On Oil Cooler Header

3.2.8 Thermostat element replacement:
Thermostat is provided in the cooling circuit to attain the stable coolant temperature
as quickly as possible. Running engine for long hours on cold coolant increases the
wear of the liners and piston. For this reason, it is wrong to run an engine without a
thermostat element. Normally the thermostat does not require any regular
maintenance. However, if sudden coolant temperature variation is observed, inspect
the thermostat element. If the element is not resting properly on its seat or if there is
any other defect in the thermostat element, it is advisable to replace it.
Thermostat Element
Figure 3.2.8.1 Drain Plug On Oil Cooler Header
3.2.9 Water pump
Figure 3.2.9.1 Water Pump
G series engine have gear driven water pump. A weeping hole is provided on the
crankcase for the water to leak out. In an unlikely event of water coming out of
weeping hole, immediately stop the engine and inform service dealer for changing of
pump seal or sealing ring.

3.2.10 Cleaning the radiator / CAC:
Radiator / CAC has to be cleaned every 500 hours. This frequency can vary
depending on the dust condition in the area of installation, application and
environment. Blowing compressed air in the direction opposite to the normal fan
airflow direction cleans radiator. Do not use water or chemicals. These can harden the
deposits into very hard cake-like formations, which are very difficult to dislodge.
Figure 3.2.10.1 Cleaning the radiator CAC

3.3 Fuel System:
3.3.1 G 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 0.825 gm/cc
G11 series engine uses inline mono-block high pressure fuel injection pump, with
multi-hole mechanical injectors. It is provided with a feed pump and double element
fuel filter.
The system is calibrated to deliver performance and meet emission norms.
Since the high pressure injection system is used on this engine, gravity flow of fuel
from fuel tank to fuel injection pump (FIP) is recommended. The fuel tank height can
be up to three meters (to be recommended by installation / service engineer), it can
also be below FIP provided suction head is up to one meter.
Figure 3.3.1.1 Fuel System

High pressure pipe
Fuel pump
Fuel Feed pump
Fuel Stop Lever

3.3.1.2 Fuel system
FIP and injectors are supplied by BOSCH and warranty is covered. Servicing these is
a highly skilled work. This has to be done by authorized service agency or shop.
3.3.2 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.
Fig 3.3.2.1Removing air from fuel line

Bleeding Process;
• Unscrew feed pump knob.
• Loosen fuel inlet banjo.
• Pump manually, till fuel comes through the screw free of air
Knob may be relocked.

3.4 Electrical system
3.4.1 Starter / Alternator -
Electrical system is provided with the engine including a 12 Volts starter and an
alternator.
Figure 3.4.1.1 Starter Figure 3.4.1.2 Alternator
3.4.2 Electrical Control Panel
Control panel has operating controls and indicators for starting, stopping and
monitoring during operation of the engine.
Engine safety unit
Starter / shutoff key
Charging alternator
Water temperature gauge
Oil pressure gauge

Figure 3.4.2.1 Control Panel
3.4.3 Battery
Fig. 3.4.3.1 Battery

12 Volt / 24 Volt (optional), 88 Amp-Hr capacity battery is recommended

4 Engine Operation
4.1 Standard and Typical Operating Conditions
Standard Operating Conditions

Sr.
Parameters Unit Value Remark
no
Ambient temperature
1 °C 25
(ISO 3046)
Relative humidity
2 % 50
(ISO 3046)
Above
3 Altitude (ISO 3046) mean sea 0
level
Ambient temperature at
Only for turbocharged and turbo
4 which deration will be °C 35
after cooled engines
applicable
Relative humidity at which Only for turbocharged and turbo
5 % 85
deration will be applicable after cooled engines
Above
Altitude at which deration Only for turbocharged and turbo
6 mean sea 500
will be applicable after cooled engines
level
Minimum temp at which
7 engine can be started °C 2
without starting aid
At 1.5 m above ground in normal
Air cleanliness for
8 mg/m3 25 industrial area or agricultural land
standard dry air cleaner
on a wind less conditions
Less
Inclination in both
9 than 1 For genset application
directions
deg
Typical steady state operating parameters

1 Lube oil pressure bar 3.5-4.5
2 Lube oil temperature °C 85-100
3 Water temperature °C 78-90
Suction depression (new mm WC
4 150
air cleaner element) Max
Suction depression
mm WC 250 mm for new filter, max 550
5 (clogged air cleaner 250
Max mm choke limit
element)
6 Exhaust back pressure mm Hg 25
7 Steady state rpm variation Total RPM 5
8 Max fuel suction lift Meter 1
9 Typical fuel temperature °C 35 - 39

4.2 Starting the Engine
4.2.1 Safety Instructions –

• The legal regulation for safety must generally be observed
• The engine may only be operated or maintained by trained staff
• Ensure sufficient ventilation in engine room
• Cleaning maintenance and repair should be done when engine is stopped and
secured.
4.2.2 First time start after installation
• Check all electrical, fuel, exhaust and other connections.
• Check that all critical fasteners are tightened (Flywheel coupling, foot mounting,
AVM bolts, crank pullet bolts, etc). Check engine alignment and mounting on
foundation.
• Engine is filled with Lube oil through the filler neck. Oil to be filled at desired level
to be checked with dipstick. Confirm that engine has adequate coolant and oil.
Oil filling neck
Fig 4.2.2.1 Lube Oil Filler Neck

• Confirm that air bubbles have been removed from fuel and coolant circuit.
• Check belt tension and make adjustments, if required.
• Confirm the battery condition.

• Confirm that all necessary safety guards are in place.
• 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. In turbo after cooled engines sudden
loading is limited to 45 to 50 % of the rated power as per ISO 8528. Never try to start
the engine on load.
• Start the engine and run on no load for 5 to 10 minutes.
• Observe abnormalities like noise, vibration, rattling brackets, leakages, etc.
• Check oil pressure. Confirm that all the meters are working.
• Confirm that every thing is OK and then slowly load the engine.
• The engine is provided with a battery-charging alternator.
• During the normal running of the engine, the charging lamp should be OFF.
If the battery-charging lamp turns ON during engine running, it is an indication that the
battery is not getting charged. Check the circuit and take corrective actions.
4.2.3 In case of Key start:

• For starting the engine turn the key from “ÓFF” to “ON” This will light up the
battery voltage gauge and the pilot lamp will light up.
• Turn the key further. Engine will rotate, when the engine picks up speed, release
the key.
Starting key
Figure 4.2.3.1 Control Panel

Note:
• Wait for 20 to 30 seconds between 2 startup attempts.
• Do not turn the key when the engine is running.
4.2.4 In case of push button start

• Press the push button. Release immediately when the engine picks up speed.
Note:
• Do not push the button when the engine is running.
• Wait for 20 to30 seconds between 2 startup attempts.
4.2.5 AMF operation start up
• In case of Auto Mains Failure (AMF) mode operation of power generation

application, the engine starts automatically when the grid power fails.
• It is extremely important to inform everybody that genset is in AMF mode.
• Access to area nearby genset should be avoided as the engine can start
automatically without notice.
• In case of maintenance, it is necessary to put the engine in non-AMF mode and
remove battery cables before starting maintenance.

4.3 Stopping the engine
• Remove the load from the engine.

• Run for 2 minutes to stabilize the temperatures. Recommended for turbocharged
and turbo after cooled engines.
• Push the stop button to stop the engine.
• The engine can also be stopped manually by turning the stop lever on the fuel
pump (Photo STOP lever on fuel pump).
Fuel stop valve
Fig. 4.3.1 Fuel Stop Valve

Turn the key to “Off” mode so that battery does not get depleted / discharged.
4.4 Safety stop
The engine will automatically stop in case of certain safety conditions like
• High water temperature
• Low lube oil pressure
Check the reason for this event before trying to restart. Do not restart, till the event is
completely explained and corrective action is taken. Never bypass safeties or try to
change their operating limits.
4.5 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 %.
After 50 hours, the engine can be loaded suddenly (Typically a sudden load of 45 %
of the rated load is allowed as per ISO 8528) and full load can be applied.
After 100 hours carry out the following actions:

• Change oil,
• Change lube oil filter cartridge,
• Change fuel filter elements,
• Change fuel filter on feed pump (Button filter or sediment bowl),
• Check belt tension and correct it, if required,
• Check tappet clearance and correct it, if required,
• Check engine for leakages and tighten the fasteners, if required
Take corrective action if abnormal noise, vibrations are observed. Now the engine is
ready for its long life.

5.0 Service and Maintenance
5.1 Maintenance of Lube oil system
5.1.1 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.
For genset applications, it is necessary that the engine be installed on level horizontal
plane area (Angle 1 deg max). For trolley mounted genset transitional angle of 12 deg
is acceptable. However, genset should never be run in an inclined position on
continuous basis.
2G11 3G11 4G11 6G11

Sump capacities 4 Liters 8 Liters 10 Liters 14.5 Liters
Engine capacities (with oil filter) 5 Liters 9 Liters 11 Liters 15.5 Liters
Oil change period First oil change after 100hr.,next oil change ref. page
no. 45, sr. no. 11
Oil filter change period Refer page no. 45, sr. no. 9
Steady state lube oil pressure 3.5 – 4.5 bar
Steady state lube oil temp 85-105°C
Lube oil consumption 0.3 % of fuel consumption
Lube oil viscosity grade recommendation
Ambient temp (Deg C) Grade of oil

-20 to + 20 SAE 10 W 30
-10 to +55 SAE 15 W 40
-5 to +45 SAE 20 W 40
5.1.2 Changing Lube Oil
Figure 5.1.2.1 Drain Plug

After the specified oil change period, oil should be changed irrespective of the oil
condition. In this period, the chemical properties of the oil are depleted. This is not
visible to naked eye or cannot be judged by experience or feel.
Start the engine and run it till it gets warmed up. When the oil temperature reaches 70
to 80 °C, stop the engine. Place a tray under the sump drain plug and open the drain
plug. Please note that the oil is hot. Drain completely. (Approximately 20 minutes).
Refit the drain plug. Remove the oil filter and drain it. Fill up the oil filter with fresh
specified oil from sealed pack and refit the oil filter. (Refer figure 5.1.4.1)
Open the oil-filling cap. Take required quantity of specified oil from a sealed package.
Pour in the filler through a funnel, after a specified quantity is if filled up, confirm oil
level by dipstick. (Refer figure 5.1.3.1) and fit the oil filler cap.
Figure 5.1.2.2. Oil Filling
Dispose off the used oil in a proper environmentally friendly way.
5.1.3 Checking oil level
Figure 5.1.3.1. Checking oil level
This preferably is done before starting the engine. If the engine is running, then stop it
and wait for 30 minutes (for an accurate measure of oil level). Routine checking can
be done in a few minutes after stopping the engine. Lube oil sump capacity is seven
liters at mean dipstick marking. Fill the oil till upper level mark without exceeding it. Do
not operate engine with oil level below lower mark.

Remove dipstick and wipe it. Re-insert the dipstick till it rests on the collar. Remove
the dipstick and observe the oil level. If the level is between low mark and high mark,
oil level is ok. If level is below low oil level mark, fill up oil at least to between low and
high oil marks. If the oil level is above high-level mark, then drain the oil and bring the
level back to high level. More oil in the sump than required is not only a waste; in
extreme cases it is injurious for the engine.
5.1.4 Changing oil filter with oil
Figure 5.1.4.1 Changing oil filter
• This operation is done preferably a few hours after the oil is changed.
• G series engines use spin-on type oil filters
• Clean up the lube oil filter area on the engine.
• Remove the oil filter cartridge.
• A commercially available strap type tool can be used to remove and re-fit the oil
filter cartridge. The cartridge has oil in it and has to be stored carefully to avoid
spillage.
• Take a new genuine oil filter cartridge. Fill up fresh specified oil from sealed
package into the oil filter cartridge. Fit it using the strap tool.
Note:
Never try to clean up a cartridge and re-use. This causes severe injury to the engine.

5.2 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
• Engine operates first time,
• If it is idle for long time,
• If High Pressure Pipe lines are loosened,
• If air is trapped in the system between fuel tank and feeds pump connecting
flexible pipe.
5.2.1 Fuel filter
To protect the FIP and Injectors, fuel filter is provided before FIP. If the filter element
is contaminated then it need to be replaced. For changing fuel filter cartridge
• Close the fuel cock.

• Loosen the filter cartridge with strap wrench.
• Coat the seal of the new filter cartridge with fuel.
• Screw the filter cartridge in filter head down to the seal, then tighten by ½ turn.
• Bleed the fuel filter.
Figure 5.2.1.1 Fuel Filter

Similarly you can change filter element if required from fuel filter.
5.2.2 Fuel strainer

Fuel feed pump is mounted on FIP. It has fuel strainer, which needs cleaning
periodically. Remove banjo bolt below feed pump at the inlet. Unplug screw to take
out the strainer. Clean the strainer with diesel and refit the assembly.
5.2.3 Fuel Injection Pump

It is recommended that Fuel Injection pump servicing is done by BOSCH authorized
service agent / personnel at authorized service center preferably through Greaves
service personnel.

5.2.4 Injector NOP (nozzle opening pressure) adjustment

Injector servicing needs to be done by authorized service personnel. Hence this
needs to be brought to the authorized service station for servicing and setting.
Figure 5.2.4.1 Nozzle Testing (Description of nozzle testing)
5.2.5 Dry Type Air Cleaner
The element in the air cleaner needs to be replaced or serviced, when maximum
allowable restriction has been reached. Remove the filter element gently. It is
recommended to replace the filter element once used. But only in exceptional cases
the filter element is to be blown out in longitudinal direction and then inside.
Reassemble the element after careful inspection and confirmation for reuse.
Figure 5.2.5.1 Air Filter Figure 5.2.5.2 Air Filter Element
5.3 Inspection and checking of V belt tension
Ensure that the belt tension is correct by pressing it by finger or thumb as shown.
Deflection needs to be 5 to 8 mm. It can be adjusted at the alternator adjustor as
shown below. Operate the engine with new belt for five to ten minutes and then adjust
the belt tension.
Tension adjuster
Figure 5.3.1 Inspection and Checking of V Belt Tension

5.4 Checking and Adjustment of Valve clearance
Adjust the valve clearance when engine is in cold condition. Adjust the clearance with
piston at top dead center and ensure that both valves are closed. Clearance is 0.4
mm. for both inlet and exhaust valves.
Figure 5.4.1 Checking and adjustment of Valve Clearance
5.5 Flywheel Run out
Flywheel run out on face to be maintained as 0.2 mm.

Flywheel coupling mounting bore run out wrt. Crank shaft axis 0.10 mm max
Figure 5.5.1 Flywheel Runouts

5.6 Timing Gear
Except water pump and oil pump gear, all other gears in the gear train has timing
markings, which need to be aligned to get correct fuel injection and valve timing. FIP
gear has kidney slots and it is mounted on coupling flange on FIP shaft with four bolts.
The finer adjustment of injection timing can be made by loosening these bolts and
turning FIP shaft as required in any desired direction.
Idler gear matching with crank gear, match idler gear ‘0’ and matching with crank gear
‘0’.
Locate cam gear in dowel & ensure matching of mark ‘1’ mark on cam gear matching
with ‘1-1’ marking of idler gear.
FIP gear
Water pump gear
Cam shaft gear

Idle gear
Crankshaft gear Oil pump gear
Figure 5.6.1 Timing Gear
5.7 Maintenance of cooling system
The engine cooling system contains gear driven water pump, cooling passages on the
engine and cylinder head, water manifold, thermostat, radiator, fan and lube oil cooler
(which is cooled by engine water)
The water used should be clean, free from dirt or dust, floating matter, colourless,
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.
Hard water can completely chock up the cooling system with scale formation, salts,
sulfates and other compounds. This can cause engine seizure. Never use
concentrated acidic compounds or soda lime to clean up the cooling system.

5.8 Battery Checking Instructions
The battery is of lead acid type. After 150 hours of running it should receive the
attention as follows:
1. Brush the dirt from the battery.
2. Remove the vent plugs.
3. Check the level of Acid.
• The acid in each cell should be kept in level with the top of the separators. Top up,
if necessary, with distilled water. Do not allow distilled water to come in contact
with metal, use only the glass or earthenware container and funnel.
• Do not bring a naked light bulb near when plugs are removed or when the battery
is on charge as the gas given off by the acid is highly inflammable.
• The charge of the battery can be checked with hydrometer which shows specific
gravity of the electrolyte. This varies with the state of the charge. Check the
specific gravity of the acid with a hydrometer. When charged the specific gravity
should be as follows:
A B C
At climates below 80ºF At climates between 80ºF and At climates over 100ºF
(27ºC) specific gravity 100OF (27ºC-38OC) specific (38ºC) specific gravity
corrected to (60ºF) (16ºC) gravity corrected to (60ºF) (16ºC) corrected to (60ºF) (16ºC)
1.28-1.30 1.25-1.27 1.22-1.24
When the hydrometer is as low as 1.25 for “A”, “1.20” for B and “1.18” for “C” the
battery must be charged as soon as possible, either by the engine or from an
independent source.
• Clean the vent plugs and free their air passages.

• Ensure that the terminals are free from corrosion. If corrosion has taken place, the
terminal should be disconnected from the battery and the corrosion scraped off.
Wipe with a rag moistened with weak ammonia or bicarbonate of soda solution.
The terminal should be bolted tightly on the terminal posts and coated with
petroleum jelly (no grease).
Please note that while engine is supplied charged on low amperage or slow charge
from authorized battery maintenance / repair shop. Time required for initial battery
charging is approximately 48 Hrs. Always use battery full charged while
commissioning of engine.
Some assorted maintenance jobs
• Starter and alternator brushes to be replaced, if worn out sufficiently.

• To clean exhaust, silencer and piping for soot.
• Fuel tank to be drained to remove sediments or cleaned at regular intervals.
• Check and tighten fasteners, if required at regular intervals.

5.9 Electronic Governor and actuator fitment
Engine speed is sensed by magnetic pickup sensor. This sensor is used by electronic
control unit to give signal to rotary actuator to control speed regulating lever of fuel
injection unit to control the speed of engine at 1500 rpm for 50Hz Genset.
Magnetic pickup
Actuator
Lever
Fig 5.9.1 Actuator

5.10 Maintenance Schedule
Maintenance Schedule
1000 hours
1500 hours
3000 hours
3500 hours
500 hours
Sr.
Particulars
no
Others
hours
10000
Daily
Check oil level
1 **
in Sump
Check Belt
2 **
tension
Check Fuel
3 **
level in tank
Check water
4 level in **
radiator
Check Battery
5 **
condition
Clean coarse Every 500
6 ** ** ** ** ** ** **
fuel filter Hrs
Change air Every 500
7 ** ** ** ** ** **
filter element Hrs
Change filter
8 on the feed ** ** ** ** **
pump
Typical
Change oil
9 ** ** ** ** ** ** change
filter cartridge
periods are
Change fuel maximum
10 ** ** ** ** ** ** periods.
filter cartridge
Depending
11 Changing oil ** ** ** ** ** ** on the local
conditions,
these may
have to be
shortened.
Set up your
own
Cleaning up
12 ** ** ** maintenance
radiator fins frequency
with
experience,
Based on
site
conditions
First re-set
Checking up
valve
valve
clearance
13 clearance and ** ** ** ** ** **
after
set if
60hours of
necessary
running.
Tightening up
Check
14 external ** **
regularly
fasteners

1000 hours
1500 hours
3000 hours
3500 hours
500 hours
Sr.
Particulars
no
Others
hours
10000
Daily
Clean injector,
nozzles and
** **
15 spray Change
if necessary
Or at least
Cleaning up
16 ** ** once in a
fuel tank
year
Cleaning up Or at least
17 exhaust ** once in a
silencer year
Checking
exhaust
After 3500
18 bellows and **
Hrs
change if
necessary
Checking
valve and
insert
19 **
condition,
change if
necessary
To be done
Calibrating by Bosch
20 **
fuel pump authorized
dealer
Changing
valve stem
If leakage is
21 seals if **
observed
leakage
observed
Changing gear Whenever
end and the oil
22 **
flywheel end leakage is
oil seals observed
Changing
23 thermostat **
element
Changing
24 cylinder head **
gaskets
Changing air /
exhaust /
water
25 manifold / **
thermostat
housing
gaskets
Checking
sensors and
26 **
change if
necessary

1000 hours
1500 hours
3000 hours
3500 hours
500 hours
Sr.
Particulars
no
Others
hours
10000
Daily
Overhauling
27 starter and **
alternator
Checking and
change AV
28 **
mountings if
necessary
Replace
radiator cap
31 **
with rubber
ring
All hoses and
32 **
hose clips
Changing
33 main bearings **
if required
Changing
conod big end Major
34 and small end ** overhaul
bearings if should be
required carried out
Changing set at 10000
35 of gaskets and ** hours or 7
O rings years
Changing whichever is
36 water pump if ** earlier.
required Carry out all
Changing activities of
valves, valve top overhaul
guides and also.
37 ** Except
valve seat
inserts if rubber parts
required and gaskets
Changing high if metal
38 pressure ** parts can be
pipes reusable
Changing then need
39 injectors if ** not be
required replaced
Changing based on
40 liners if ** condition of
required the parts.
Changing
piston
assembly if
41 **
required
Checking and
changing con
42 rod small end **
bush if
required

1000 hours
1500 hours
3000 hours
3500 hours
500 hours
Sr.
Particulars
no
Others
hours
10000
Daily
To be
Changing fuel
procured
pump
43 ** from Bosch
elements if
authorized
required
dealer
Checking all
critical
45 fasteners and **
replace if
necessary
Checking fan
46 drive **
assembly
Add coolant Every 500
47 ** ** ** ** ** **
additive hrs
Replace
48 cooling water **
and additive
49 Change belt **
Check engine
50 protection ** ** **
system
Note :-
This schedule is applicable only when Greaves Maxtherm oil and coolant are used

Notes
Never re-use following items
• Cylinder head gasket,
• Copper washers,
• O-rings,
• Valve stem seals,
• Oil seals,
Top and major overhaul depends on the type of loading, quality of installation, quality
and regularity of maintenance, etc., the above mentioned intervals are typical periods.
Users should keep a close watch on their engine installation to see the signs of
service requirement. It is also advisable to get the engine overhauled in lean
operation period or ahead of a heavy season of running.

6.0 Engine Preservation
6.1 Engine preservation during prolonged period of non-usage
If the period between engine dispatch from Greaves and the installation is more than
six months or if a engine is to be non operational for more than twelve months, the
engine has to be preserved to avoid damage due to corrosion, dust, and other factors.
Preferably a preserved engine should be covered in plastic sheet and stored in cool
dry, shaded place.
Following instructions are to be followed for engine preservation:

1. Run the engine with clean fuel at rated speed at no load for about 10 minutes.
This warms up the engine and the lube oil is circulated all over inside the engine.
2. Stop the engine and immediately drain the oil. Fill up the engine with one of the
preservative oils to the low level mark on dipstick. Choose preservative oil from
the list given below.
3. Run the engine at rated speed with no load for 5 minutes.
4. Make a clean solution of preservative oil and diesel (1: 5 ratio) and connect the
mixture to the fuel pump inlet by gravity feed.
5. Drain the coolant from cooling system. Rinse the system thoroughly with clean
water. Fill the cooling system with mixture of water and any of the coolant
additives listed - in the requisite ratio.
6. Crank the engine and run it at rated speed with no load for half a minute. Stop
the engine.
7. Remove air cleaner, fuel filter and lube oil filter, pack them separately.
8. Drain preservative oil from sump and refit the drain plug. Drain water-
preservative mixture from cooling circuit. Treat all unpainted open surfaces with
rust preventive coats.
9. Seal all openings with caps, plastic sheets or waterproof paper. Seal the dipstick
with the tape.
10. After this point do not rotate the engine.
11. Remove belts and store separately.
12. The battery should be disconnected. Ensure electrolyte level. Charge the battery
at regular intervals.
13. Put a mark on the engine indicating date of preservation.
14. Periodically inspect the engine for corrosion, effects of humidity and dirt.
15. The above procedure has to be repeated after every 12 months.
Recommended preservatives
Lube oil and fuel

Manufacturer Rust preventive Cooling system
circuit
Bharat Sherol B
Bharat Rustol Bharat Preserve oil
Bharat Petroleum emulsion with water
152 30
(1: 20 ratio)
Servo Cut S 20% Servo preserves 30.
Indian Oil Corporation Servo RP 125
Emulsion with water Servo Run-N oil 30
Koolkit 40.5% emulsion
Hindustan Petroleum Rustop 274 Auto run T 120
with water
Veedol Amulkut 4
Veedol Veedol Rustop IT Emulsion with water Veedol 30/40
1:15

6.2 Putting a preserved engine back into operation.(check numbering)
1. Remove all seals. Clean up the engine. Remove rust preventive coat.
2. Fit air cleaner, fuel filter, Lube oil filter, and belts. Use new filter elements. Apply
correct tension to the belts.
3. If rubber components (Hoses, belts, etc) are cracked or brittle, replace them.
4. Fill up correct grade oil up to the high level mark on dipstick.
5. Fill up coolant. Remove trapped air.
6. Connect supply of clean fuel. Remove trapped air.
7. Fit a charged battery. Check the electrical connections.
8. Run the engine at rated speed at no load for 5 minutes. Observe and look for any
irregular noise, vibration, etc. If some irregular behavior is observed take
corrective actions or call authorized service dealer.
9. Start the engine and put it into service.

7.0 Installation Do’s and Don’ts
7.1 Do’s
1. Install the engine on horizontal, hard area. This area should be properly
ventilated. It should have access to maintenance areas.
2. All the mounting structure should properly rest on the ground.
3. Check with civil engineers and architects before mounting the engine on slabs,
beams, raised structures, above ground floor, etc.
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.
7.2 Don’ts
1. Never install the engine on inclined surface.

2. Remember that a good installation reduces running cost, maintenance cost,
provides reliable and safe service.

8.0 GCL regional office and Dealer Addresses
Location Name & address Contact person Tele. / Fax Area covered
New Delhi & Around
Ghaziabad M/s. Ambika Power Mr.S.K.Sharma 0120- Ghaziabad,

point Mobile No: 9810282482 2941465 (O) Bulandsher, Meerut
211/6 Rajendra Nagar Mr.R.Goswami 0120- Noida, Hapur,
Ind.Area, Opp: Dass 3097069 (O)
Factory Mobile No.9810545055 Shahibabad, Agra,
0120- Mathura
P.O.Mohan Nagar, app_rg21@yahoo.com 2632688(R)
Ghaziabad-201007
Faridabad M/s. Patiala Agencies Mr. S. Pajni 0129- Faridabad, Palwal

Shop No.8, Saluja Mobile: 9810184759 2411299 (O)
Shopping Complex pajni@yahoo.co.uk 0129-
Flyover Neelam 2428848(O)
Chowk, Faridabad- 0129-
121001 2227442 (R)
M/s. Power Service Mr.R.P.Singh 0129- Faridabad, Palwal

Syndicate Mobile: 9312215510 2413356 (O)
B-488, IInd Floor, pss_fbd@sify.com 0129-
Nehru Ground 3953923(O)
Behind Punjab 0129-
National Bank, 5045406 (R)
Faridabad-121001 Tel.Fax:0129-
2421298
New Delhi M/s. R. S. Mr.D.K.Sharma 011-2465081 Delhi, Ghaziabad

Powertronics Mobile: 9312268885 (O) Meerut,
305, Triveni Complex 011- Bulandshahar
E-10-12, Jawahar 30966448 (O) Noida, Modinagar
Park Tel.Fax:011-
Laxmi Nagar, Vikas 22572969 (R)
Marg, Delhi-110 092
M/s. Delhi Power Mr.J.K.Verma 011- Delhi (N.C.T.)

Service & Co. Mobile: 9811225115 26360314 (O)
F-12, Vishwakarma Mobile: 9312503906 011-
Col., Lalkuan 55676265(R)
jkv_dpsc@yahoo.co.in
Mehrauli-Badarpur
Road, New Delhi-
110044
M/s. Radiant Power Mr. Ansar Ali 011- Delhi (N.C.T.)

Engineers Mobile: 9810621361 25777570 (O)
WZ-B-93, Tanwar 011-
Market 22136158(R)
Naraina, Ring Road
New Delhi-110 028
Gurgaon M/s. Power Service Mr.R.P.Singh 0124- Gurgaon, Rewari,

Syndicate (Gurgaon) Mobile: 9312215510 2200916 (O) Bhiwani.
Village: Islampur, pss_fbd@sify.com 0129-
Near Bus stand 5045406(R)
Gurgaon-Sohna Road,
Gurgaon
Moradabad M/s. Bharat Machinery Mr.Vinay Rawal 0591- Moradabad, Rampur

& Auto Service Mr.Madan Rawal 2313786 (O) Bijnor,

Station Road, Mobile: 9837026470 0591- UdhamsinghNagar
Moradabad-244001 manju@mickyonline.com 2310379 (O)
0591-
2491948(R)
0591-
2491565(F)
Saharanpur M/s. Supertech Mr.K.K.Katarya 0132- Saharanpur

Engineers & Co. supertech@supertechmai.com 2725957 (O) Haridwar, Karnal
Zila Hotel Compound, Mobile -9897780600 0132- Yamuna Nagar
Opp: Sophia Market 2645908 (R)
Dehradun
Court Road, 0132-
Saharanpur-247001 2645564 (R)
FAX: 0132-
2711149
Panipat M/s. Kamboj Power Mr.Teja Kamboj 0180- Panipat.

Generator Service Mobile: 9896375295 5002825
Jai Mata Market. Near Mobile: 9812075295
Malik Hospital,
Gohana Road,
Panipat
Uttar Pradesh
Varanasi M/s. Tumen Diesels Mr.Suman Jaiswal 0542- Varanasi, Balpur

D/381/1, 2nd Floor, Mobile: 9839043988 2412878 (O) Gazipur, Bhadhohi
Hauz Katora, tumenvns@sify.com 0542-
Godowlia 2419088 (O)
Varanasi-221001 FAX: 0542-
2419087
M/s. Accurate Mr.D.K.Gupta 0542- Varanasi, Balpur

Engineers Mobile: 9839042726 2359346 (O) Gazipur, Bhadhohi
Children's Academy accurateengg@satyam.net.in 0542-
Campus,B-21/196 2451365 (O)
SBI Building,, 0542-
Kamachha, Varanasi- 2322463 (R)
221004 FAX: 0542-
2454238
Kanpur M/s. Diesel Sales and Mr.S. Banerjee 0512- Kanpur, Unnao,
Service Mobile: 9839102386 2611229 (O) Etawah
783/5, W1 Block, 0512- Mainpuri, Mahoba,
Saket Nagar, Kanpur 2608029 (R) Jalon
Hamirpur
M/s. Hi-Tech Diesels Mr .S.N.Ahmed 0512- Kanpur, Kannouj

123/426, Fazal Ganj, Mobile: 9415050740 2234185 (O) Fatehpur, Jhansi
Factory Area hightech10@sify.com 0512- Orai, Farukhabad
Opp: Panama Factory, 2505303 (R)
Kanpur-208012 Fax:0512-
2234732

Lucknow M/s. Frontline Mr.Vinod Sehgal 0522- Lucknow, Faizabad

Technocrats (P) Ltd. vrsehgal@sancharnet.in 2346292 (O) Bareilly, Sitapur,
326, 3rd Floor, Sahara Mobile: 9415028353 0522- Allahabad,
Shopping Centre 2343705 (O) Gonda, Balrampur
Faizabad Road, Indira 0522-
Nagar, Lucknow 2329970 (R)
FAX: 0522-
2338573
0522-
22344995
M/s. Diesel Power Mr.B.S.Rawat 0522- Lucknow, Hardoi,

Service Mobile: 9839014522 2349320 (O) Barabanki,
B-101 Sahara Trade genpowersolution@yahoo.com 0522- Baharainch,
Centre, Faizabad 2349659 (O) Sultanpur.
Road 0522-
Lucknow-226016 2701162 (R)
Gorakhpur M/s. Raman Trading Mr.Raman Sawhney 0551- Gorakhpur, Basti

Corporation Mobile: 94152110339 2335287 (O) Deoria, Maharajgarh
A-5, Ramnagar r_t_c@sancharnet.in 0551- Padravna
Colony 2200832 (R)
Mohaddipur, Fax:0551-
Gorakhpur-273008 2331547
Bareilly M/s. Diesel Engineers Mr.Rajeev Kakkar 0581- Bareilly,

88 T.J. Market, Opp: Mobile: 9837089269 2577779 (O) Nainital, Pillbhit
Hind Talkies dieselengineer_bg1@rediff.com 0581- Shajahanpur
Bareilly-243001 2428003 (O)
0581-
2424487 (R)
FAX: 0581-
2478003
Rajasthan
Abu road M/s. Power Mr.R.K.Panchal 02952- Abu Road

Engineering Mobile - 94141 56707 221266 (O) Sirohi Road
25,Sanjog Complex, kkpanchal75@yahoo.com Fax:02974-
Kelwa Chaupati, 220550(pp)
Kelwa Dist
Rajsmand , Pin 313
334
Udaipur M/s. Crossland Earth Mr. B. B. Sharma 0294- Udaipur, Banswara

Movers Pvt. Ltd. Mobile: 9414165554 2526543 (O)
4-B Circle View Mr. Vipin Henry 0294-
Apartments 2527854 (O)
Mobile: 9414165854
Sukhadia Circle, 0294-
Udaipur shal@crossland.biz 2418174(R)
Fax:0294-
2521863
Kota M/s. Crossland Earth Mr.S.Metha 0744- Kota, Bundi

Movers Pvt.Ltd. Mobile: 9414074995 2503020 (O)
A31, Ballabh Nagar, Mr.S.Acharya FAX: 0744-
Kota 2360275
Mobile: 9414188020

Chittorgarh M/s.Kay-Pee Mr.P.S.Wasal 01472- Chittorgarh, Kankroli

Enterprise Mobile: 9829043350 247840 (O) Bhilwara
3-A 1st Floor, Main powersolution1@yahoo.co.in 0294-
Road, 2481592(R)
Pratap Nagar,
Opp:Panna Hotel,
Chittorgarh
Ajmer M/s.Manish Industrial Mr.R.C.Jain 0145- Ajmer, Makrana,

Corporation Mobile: 9414007508 2624706 (O) Kishangarh
Madan Kirpa 275/6 0145- Nagour, Beawari
Laxmi Chowk Ajmer- 2624708 (O)
305001 0145-
2423958 (R)
FAX: 0145-
2420747(pp)
Jaipur M/s.Pink City Engg. & Mr. M. L. Gupta 0141- Jaipur, Savai
Trading Co. Mr. Ashish Gupta 2304491 (O) Madhopur
Shop No.5, petco@pinkcity.com 0141-
Chowdhary Complex 2304179 (O)
Mobile: 9414076591
Hazi Colony Corner, 0141-
Jhotwara Road 0141-3304179 2304429 (R)
Jaipur-302016 FAX: 0141-
2304179
Jodhpur M/s.Super Nova Mr. Pradeep Bhandari 0291- Jodhpur, Barmer

Engineers Mobile: 9414128666 2617965 (O) Jaisalmer, Pali
11, Gulab Singh 0291-
Building, Chopasani 2431007 (O)
Road 0291-
Jodhpur-342003 2548733 (R)
0291-
2441733(O)
FAX: 0291-
435082
Rajsamand M/s.Kay-Pee Mr.P.S.Wasal 02952- Rajsamand

Enterprise Mobile: 9829043350 224332 (O)
Opp: Octroi Naka
No.5, N.H. 8
Udaipur-Ajmer
Highway, Rajsamand
Power Engineering, Mr.K.K.Panchal 02952- Rajsamand,

Near Maharaja Guest Mobile: 94114156707 221266(O)
House 02952-
NH-8, Sewli, 221964 (pp)
Rajsamand
Punjab Haryana & Chandigarh
Chandigarh M/s.Power Tech Mr.Parshottam Singh 0172- Ropar, Chandigarh

Engineers Mobile: 9814087082 2656559 (O) Ambala, Fathehgarh
195 Ind.Area, Phase- parshot_singh@yahoo.co.in 0172- Patiala, Himachal
II 2225455 (R) Pradesh
Ram Darbar,
Chandigarh-160002

Amritsar M/s.K.C.Engineers Mr. J. S. Grewal 0183- Amritsar, Batala

1st Floor, Street No.4, Mobile: 9814022388 2531457 (O) Gurdaspur
Kot-Atma Singh Mr. Santokh Singh 0183-291942
Near Chowk Hussain (O)
kcengineers@sify.co.in
Pura, Amritsar 0161-
2454927(R)
Ludhiana M/s.K.C.Engineers Mr. Santokh Singh 0161- Ludhiana, Khanna,

6, B-XXII Ist Floor, Mobile: 9814064174 2534374 (O) Muktsar
Link Road Opp: Rishi Mr. J. S. Grewal 0161- Sangrur, Moga,
Dhaba 2493292 (R) Ferozpur,Faridkot,
Mobile: 9814022388
Campa Cola Chowk, 0161- Barnala
Ludhiana-3 2547022
Jalandhar M/s.Sharma Mr. Neeraj Sharma 0181- Jalandhar,Phagwara

Engineering Works Mobie: 9815090839 2290839 (O) Kapurthala,Pathankot
S-18, Shop No.7, 0181-
Opp: UCO Bank 5083148 (O)
Near Post Office, 0181-
Industrial Area, 2292124 (R)
Jalandhar FAX: 0181-
2290839
Jammu & Kashmir
Jammu M/s.Fairdeal Mr. D. L. Chopra 0191- Jammu, Nagrota,

Enterprises Mr. Y. Chopra 2543712 (O) Udhampur, Akhnoor,
5, Exchange Road, Mobile: 9419183626 0191- Rajori.
Jammu-Tawi 2473057 (R)
Fax: 0191-
2543712
Srinagar M/s.Marshal Traders Mr. Firdous Karim 0194- Srinagar, Kupwara

Magrmal Bagh, Mobile: 9419013045 2471362 (O)
Church Lane marshal_genset@rediffmail.com 0194-
Srinagar-190001 2437744 (R)
Leh M/s.Rakshak Mr. Ravinder Kothidhar 01982- Leh, Ladakh.

Enerprises 251658(O)
Changla Shopping
Complex
Shop No.14,
Skalzangling Air Port
Road
Leh - Ladakh-194 101
East Region
Kolkatta Stotex Corporation Mr. Prakash Jain Tel- 033- Kolkatta,

33/1, N.S. Road, Mobile: 9831027938 23283222(O)
Marshall stotexcoporation@hotmail.com Tel-23293558
House, 6th Floor, (R)
Shop No. 636 Kolkatta Tel- 033-
700 001. 30960846(O)
Tel- 033-
22207119 (O)
Fax: 033-
30227119
Tel: 033 -
23293558 (R)

Unitrade International Mr. Ramesh Jain Tel- 033- Kolkatta,

2B, Grant Lane, Room Mob: 9830041204 22114598 (O)
no-52 Mobile- 9830215112 Tel- 033-
Kolkatta- 700 012 22114904 (O)
unitrade1980@hotmail.com
Tel033-
dhanu_1953@yahoo.co.in 24462471 ®
Fax : 033-
22114904
Fax : 033-
22114904
ESDEE Electromill Mr. C. R. Sikdar Tel- 033- Marine West Bengal

Pvt.Ltd. Tel-033- 32749425 24711731 (O)
350 N.S.C. Bose esdeecal@vsnl.net Tel- 033-
Road 24710225 (O)
Kolkatta 700 047 Tel-033-
24625439 ®
Fax- 033-
24116799
Associated Engg. Mr. S.Sarkar Tel-033- Howrah, Burdwan,

Services Mobile- 9831031136 26580201 ® Midnapore
103/1, Shibpur Road Mr. P.K.Baul Tel-033- Purulia, Durgapur
Howrah- 711102 26788820 (O)
Mobile- 9831031135
Fax- 033-
aes_kol@sify.com 26783040
Siliguri Modern Commercial Mr. Kazal Sarkar Tel-0353- Siliguri North Bengal
Corp. Mobile- 94340007238 2542208, (O)
Kapil Centre, Sevoke mccslg@satyam.net.in Tel- 0353-
Road, 2547108 (O)
mccslg@sancharnet.in
Siliguri - 1 Tel- 0353-
2596881 ®
Jharkhand
Jamshedpur Agro Engg. & Eqpt. Mr. Amit K. Hazra Tel- 0657- Jamshedpur
Co. Mobile - 9431110799 2424569 (O)
Q Road, Bistupur, agroengg@satyammail.com Tel- 0657-
Jamshedpur 831 001 2425170 (O)
Tel- 0657-
2226525 (R)
Fax: 0657-
2425170
Unique Suppliers & Mr. Pradeep Kumar / Mr. Nair Jharkhand Telecom
Services Mobile- 9835381135
Iqbal Mansion, Purulia ussjsr@hotmail.com
Road
Mango . Jamshedpur
831 012
Ranchi Utility Services Mr. M. J. Kale/ Mr. Ghanekar Tel- 0651- Ranchi
340-B, Road No. 4-B, Mobile - 9431114407 / 9431127874 2241756 (O)
Ashok Nagar, utilityservices@yahoo.com Tel- 0651-
2240325 ®
Ranchi 834 002 mjkale@yahoo.com
Fax: 0651-
2241756

Bihar
Patna Taeez engineering co Mr. Aziz Tel-0612- Bihar

11, sashi complex Mobile - 9431078965 2236494 ®
Exhibition road, Patna taeez@sify.com Tel- 0612-
2237028 (O)
K.K.Enterprises Mr. Kundan Kumar Tel- 0612- Telcom Patna

H-18, Hotel Windsor Mobile - 9835004333 2206016 (O)
Complex
Ground Floor,
Exhibition Road
Patna
Elemech Services Mr. B.N.Singh Tel. 0612- Bihar

Bipin Bihari Complex Mobile - 9431014295 2367457®
Room No- 105, 1st Tel- 0612-
floor 3095873(O)
Kankarbagh, Patna-
800020
Assam
Guwahati Mechwell Engineers Mr. S. K. Bhattacharjee Tel-0361- Guwahati &

Kamakhya Umananda Mobile - 9864027457 / 9435111988 2513724 (O) Williamson Tea
Bhawan mecwelengineers@sify.com Tel-0361-
Opp. S.B.I, Near Over 2516375 (O)
Bridge Tel-0361-
A.T.Road, Guwahati- 2477265 ®
781001 Fax- 0361-
2516375
Podder & Podder Mr. Vivek Podder/ Mr. S.K. Mitra Tel- 0361- Guwahati
Swastik Bhavan, Mobile - 9435071298 2344060(O) Meghalaya ,
G.S.Road Mob- Nagaland & Telecom
Mobile - 9864083849
Dispur, Nr. Over 9435071295
podder_2004@yahoo.co.in
Bridge
Silchar 788 001
Popular Diesels (ASR- Mr. K.J.Thampan Tel-0361- Assam

Service) Mobile - 9435118773 2450714 ®
Tezpur Ruthy Diesel Sales & Mr. Rupak Sharma Tel-0361- Tezpur- North Bank
Services Mobile - 9864097076 2460037
Kumargaon, Cotton ruthymess2003@sify.com Tel-0361-
Road 2450881
Tezpur, Sonitpur,
Assam

Dibrugarh Delta Power Sales & Mr. N.G.Saha/ Mr. Pankaj Tel-0373- Dibrugarh Sibsagar.
Services Mobile - 9435032982 2328576 (O)
Mancutta Road, Nr. Tel- 0373-
Over Bridge 2321824 ®
Dibrugarh -786001 Tel- 0373-
2324974
Fax- 0373-
2323218
Power Mech Services Mr. Pranab Sharma Tel-0373- Assam

(ASR Service) Mobile - 9435131800 2311506
Silchar Podder & Podder Mr. Vivek Podder Tel- 03842- Silchar , Tripura
1st floor,Vijayshree Mobile - 9435071298 268780(O) Mizoram, Manipur
complex vivek_podder@yahoo.co.uk Tel-03842-
Trunk Road, Silchar- 268027(O)
788001 Tel- 03842-
268027 ®`
Tinsukia Industrial Trade Mr. Pradeep Kasera Tel-0374- Tinsukia

&Agency Mobile - 9435037606 2338390 (O)
Makum Road,Jamuna itagencies@sancharnet.in Tel-0374-
Bhawan, 2855475 (R)
Tinsukia 786125 Fax : 0374-
2336289
Modi Diesels Mr. Binod Modi Tel- 0374- Tinsukhia &

Makuma Mobile - 9435035194 2330125 Dibrugarh
Road,Tinsukia-786125 modil@sancharnet.in Tel-0374-
2340294
Tel - 0374-
2341909 ®
Jorhat Joyshree Motor Parts Mr. Shyam Agarwal Tel.0376- Arunachal,Jorhat

& Accessories Mobile - 9864021115 / 9435011999 2320381 (O)
A.T.Road, Chowk carriers_indialimited@hotmail.com Tel- 0376-
Bazar Jorhat - 785001 2324185 ®
Orissa
Bhubaneshwar Unique Supplier and Mr. Pradip Kumar Tel-0674- Orissa

Services, Mobile - 9437082076 2575324 (O)
Pushpa Market, ussbbsr2@hotmail.com Tel-0674-
Jharpara, 6 Cuttak 2575319 (O)
Road, Tel- 0674-
Bhubaneshwar 751 2575229 (R)
006
Barbil Unique Supplier and Mr. S.Ravi Mob- Rourkela/ Barbil.

Services, Mobile - 9437214501 9437214501
398/1059 ,Post Barbil,
Keonjhar

Andman and Nicobar
Port Blair Dweep Engineering Mr. R. N. Pande Tel - 03192- Andaman and
Works Mobile - 9332956267 230406 ® Nicobar Islands.
P.B. No. 662, Tel-03192-
Near Hindi Medium 243180 (O)
School, P.O Tel-03192-
Haddo,Port Blair 238326
Southern Region
Tamilnadu
Chennai Industrial Diesel Mr. Bijoy Pillai Tel-044- Chennai,

Engineers, 53, Vada Mobile - 98410 98110 23742722 (O) Kanchipuram,
Agaram Street, Off: Tel-044- Tiruvallur, Villupuram,
Nelson Manickam info@idengineers.com Tiruvonnamalai
23743735 (O)
road, Choolaimedu, districts Villupuram,
Chennai 600 094 Tel -044- Vellore
23613149
(Residence)
Fax-044-
23741762
Trichy Ideal Agro Services, Mr. John Britto Tel-0431- Trichy, Thanjavur,
49-F Madurai road, Mobile - 9345100771, 9344089995 2415930 (O) Pudukottai,
Cantonment, Trichy Tel-0431- Nagapattinam,
620 001 autoled@yahoo.com Thiruvarur,
2414934 (O)
Perambalur districts
Tel-0431-
2418786 (Fx)
Tel-0431-
2482908
(Residence)
Madurai Gen Service and Mr. V. Ganesh Tel- 0452- Madurai, Dindigul,
Controls, 7, Gayathri Mobile -9443258608 2380603 (O) Virudhunagar,
street, Duraisamy Tel- 0452- Ramnad, Sivagangai
nagar, By pass road, Mobile -9894054141 2385113 & Karur districts
Madurai 625 010 genservice@airtelbroadband.in, (Residence)
Tel- 0452-
2383336 (Fx)
Tel-0452-
4354141 (O)
Tirunelveli Gen Service and Mr. Surender Tirunelveli

Controls 119,Bharati Mobile - 9443258609 Kanyakumari
Nagar, Tuticorin district
Perumalpuram, Near
Saratucker college,
Tirunelveli 627 007
Salem Mach Diesels 1/124A Mr. N. Satish Kumar Tel-0427- Salem, Dharmapuri,
N.V.Complex, Mobile - 9443042739 2274566 Krishnagiri &
Kondalampatti (TFx) Namakkal districts
Bypass, Salem 636 machdiesels@sancharnet.in
010

Coimbatore Power Techs R. K. Mr. C. V. Ramakrishnan Tel-0422- Coimbatore, Erode &

Building, 2108 Trichy Mobile - 9443225992 2599255 Nilgiris districts
Road, Singanallur, (TFx) 0422-
Coimbatore 641 005 Mr. C. S. Selvarajan 2599256
Mobile -94430 64207 Mob:
powertechs@vsnl.com 9244402606
Pondichery Phoenix Engineers, Mr. S. Jeyasingh Tel-0413- Pondichery, Karaikal

286, Point Care Mobile -9443253054 2354384 area of Pondy &
Street, phoenixengrs@yahoo.co.in, (TFx) Cuddalore dist of
Ulandaikeerapalayam, Tamil Nadu
Mudialarpet,
Pondichery - 609 004
Andhra Pradesh
Hyderabad Raju & Sastry G3 Mr. Raju 040- Hyderabad,

Arun Apartments, Red Mobile 9849120730 23390796 (F) Warangal,
hills, Opp. Cancer 040- Nalaconda,
Hospital, Hyderabad Mr.U.G.K.Sastry 23307717 (O) Patancheru, Karim
500 004 Mobile. 9849120720 040- Nagar, Pasha
raju-sastry@indiatimes.com, 23372118 (O) Mailaram,
ugksastry@gmail.com, 040- Rangareddy (except
24066709 Jeedi Metla & Bala
(Residence) Nagar)
040-
24043688
(Residence)
Secundrabad P. S. Engineers 5-2- Mr. Subba Rao 040- Bala Nagar, Gandhi
414, Flat No.103, Mobile 98480 53318 27533664 (O) Nagar, Jeedi Metla,
Dacha Mansion, 040- Medak dist (except
Hyder basti, Mr. Ravi Varma Raju 27533644 Patancheru) &,
Secunderabad 500 Mobile 98482 36942 (TFx) 040- Adilabad,
003 psengineers@yahoo.co.in 55203318 (O) Nizamabad,
040- Mehboob nagar,
23530535 ® Kurnool districts
Vizag D.S. Enterprises Mr. D. R. Raju 0891- Vishakapatnam, East

C-5 Classic complex, Mobile 9848199465 2705258 (O) Godavari, Srikakulam
Prakasaraopet, Daba 0891- & Vizianagaram
Mr. Varma 2705217 (O) Districts & Yanam
Gardens, Vizag 530
020 Mobile 9346768113 0891- territory
centerprisesvsp@ yahoo.co.in, 2540216
mrk_varma@yahoo.com (TFx) 0891-
2553778 ®
0891-
2792653
(Residence)
Vijayawada Sree Guru Mr.CH.Kottaiah 0866- Vijyawada, Krishna,

Raghavendra Mobile 9848113083 2493874 (O) Khammam,
Agencies, 38-4-5 0866- Prakasam, West
Montessori College Mr.Srinivasa Rao 2494983 Godavari & Guntur
Street, Bunder Road, Mobile 94493 55839 (TFx) 0866- Districts
Vijayawada 520 010 Mr. Sambashiva Rao 2494983
(Residence)
Mobile 9966943806
coast_guru@rediffmail.com,
Nellore Coramandel Agro & Mr.Manimaran 0861- Nellore, Chittoor,

Marine Agency 23/897 Mobile 9440275343 2349184 (O) Anantapur &
Wahabpet, Near 0861- Cudappah districts
Madras Bus stand, Mr. Vengadesan 5529184
Nellore 524 003 Mobile 9440045642 (Residence)
cama_gcl_mlr@yahoo.co.in,

Kerala
Cochin Judeson Engineering Mr. Prem Kumar 0484- Cochin Taluk

Sales & Service, Mobile 9447035721 2317625 (excluding Vypeen
Krishna Krupa, 2nd (TFx) 0484- Island), Alleppey
Floor, Ravipuram judeson@satyam.net.in 2318625 (O)
Road, Ernakulam, 0484-
Kochi 682 016 2314001
Trivandrum Judeson Engineering Mr. Jyothi Kumar 0471- Trivandrum Dist

Sales & Service, TC Mobile 9447162754 2740367
76/905, Sujalayam (TFx)
Anayara, Trivandrum - Mr. Johnson
695029 Mobile 9447185726
judeson@satyam.net.in
Quilon Judeson Engineering Mr. Donnel Fernandez - Quilon &

Sales & Service, Bibin 9447252942 Pathanamthitta
Villa, 81/Divya Nagar, districts
Pattathanam west, judeson@satyam.net.in
Near Vimala Hrudaya
School, Kollam
UTL Judeson Engineering judeson@satyam.net.in 0489- Complete Union

Sales & Service, 6263299 (O) Territory of
Rajdhani, Near Indira Lakshadweep
Gandhi Hospital,
Kavaratti, UTL
Kottayam Unique Diesels (P) Mr. Regi James 0481- Idukki & Kottayam
Ltd., Sree Krishna Mobile 9447036688, 2300333 (O) dist
Complex, 12/1016,
M.L. Road, Kottayam - Mr. Vinodkumar
686001 Mobile 9447040592
Calicut Electro Diesels Mr. Mohan Goray 0495- Kannur, Calicut,

"Bhaskara" 17/308, Mobile 9447725740, 2721275 (O) Wyanad, Malappuram
Near Sree 0495- & Kasaragod Districts
Kanteswara Temple, Mr.Amarnath Goray, 2720095
Calicut 673 001. Mobile 9447698222 (Residence)
electrodiesels@asianetindia.com 0495-
2725740
(TFx)
Palakkad Electro Diesels Mr.Subramaniam 0491- Palakkad Dist

Dibba Tourist Home Mobile 944752205, 2531425 (O)
V. H. Road, Near Mr.Amarnath Goray,
Veterinary Hospital,
Room No.103 Mobile 9447698222
electrodiesels@asianetindia.com
Karnataka
Bangalore Trans Diesel Mr. Ravish Tel :080 - North Part of B'lore,
Engineers, No.110/4- Mobile 9448115513/ 9900911022 22242624 (O) Tumkur, Hassan,
1,M.Krishnappa Tel :080 - Chikmagalur,
Layout, Opp. Cross Mr. Ashok C 22272839 (O) Chitradurga, Kolar &
Indian Oil Petrol Bunk, Mobile 9448115688 / 9900911011 Fax: 080 - Shimoga districts
(Lalbagh Traders), transdiesel@rediffmail.com, 22240478
Lalbagh Road, Tel: 080 -
Bangalore, 560 027 23405953
(Residence)
Mangalore Trans Diesel Mr. Loknath Tel :0824- Mangalore & Karwar
Engineers, No. 8, Mobile 9900549320 2448811 (O) districts
Masco Plaza Maidan,
4th Cross Road,
Mangalore - 575 001

Hubli Trans Diesel Mr. Farooq 9448377262 Tel: 0836- Hubli-Dharwad,

Engineers, No. 101, 2236262 (O) Belgum, Bagalkot
HIG Block -11, Akshay
Park, Gokul Road,
Hubli 580 030
Bangalore Supreme Diesel Mr. Umkanth Tel: 080- Southern Part of

Service & Mobile 9448289870 51513733 B'lore Dist. Hosur
Consultancy, 35, 1st (O) Tel: 080-
Floor, 2nd Cross, akashuk@eth.net 51513734
Journalist Colony, (O) Tel: 080-
Bangalore 560 002 51513735
(O) Fax: 080-
26704737
Tel: 080 -
23481987
(Residence)
Mysore Supreme Diesel Mr. Ambrish Tel: 0821 - Mysore, Mandya &
Service & 2519546 (O) Kodagu Dist.
Consultancy, No. 357,
14th Main, 3rd Cross,
Saraswathi Puram,
Mysore 570 009
Gulbarga Supreme Diesel Gangadhar C.M. Gulbarga, Raichur,

Service & Mobile 9448289873 Bidar & Koppal Dist.
Consultancy, Plot No.
11/2, House No.
132/A, NGOS Colony,
Jevargi Road,
Gulbarga
Western Region
Gujarat
Ahmedabad Ravi Rashmi T.V.Ravindranathan Tel-079- Ahmedabad

Energymech Ltd. Mob- 9824009411 26562868(O) Mehasana
1st floor, Avani ravirashmigroup@yahoo.co.in Tel-079- Kheda
Complex 26561046(O)
Behind Navarangpura Tel-079-
Police Station 27456251®
Navarangpura, Fax- 079-
Ahmedabad- 380009 26565024
Vadodara Shreenath Engineers Manoj Shah Tel-0265- Baroda, Panchmahal

201, Sapan flats, Mob- 9825064081 2327053(O)
Behind Mother's shreenathengineersbaroda@indiatimes.com Tel-0265-
School 2339647(O)
Harinagar, Water
Tank Road
Gotri Road, Vadodara-
390021
Surat Ajay Enterprises Ajay Athavia Tel- 0261- Surat, Kim, Hazaria
1/660, Bundar Street Mob- 9825861456 2471217
behind Civil Court, aenterprise@rediffmail.com Tel- 0261-
Nanpura 2475361
Surat- 395001

Deev Engineers Mr. Varghese Tel-0261- Surat, Sachin

Shop No- 33, National Mobile - 9825114985 5552298(O)
Plaza mt_varghese@indiatimes.com Tel- 0260-
Shopping Complex, 3090285®
Surat, Navsari road Fax-0260-
Surat- 394210 2426997
Vapi Deev Engineers Mr. Varghese Tel- 0260- Vapi, Valsad

Plot no- C-1/23, LIC Mobile - 9825114985 2431620(O)
Sector mt_varghese@indiatimes.com Tel- 0260-
Nr. Padam plastics, 2436464(O)
GIDC Tel-0260-
Silvassa Road, Vapi- 2426997(Fax)
360001
Rajkot Cristline Marketing Pvt Mr. Joseph Rozario Tel-0281- Rajkot, Amreli
Ltd. Mobile - 9824222660 2464105(O) Surendranagar
1st floor, Sameer cristline_3c@icenet.co.in Tel-0281- Bhavnagar,
Building 2463110 ® Porbander
Dr. Yagnik Road Fax -0281- Morvi
Rajkot- 360001 2468456
Gandhidham MVR Diesel Mr.M. V.R.Mohan Tel-02836- Gandhidham, Bhuj,

Electromech Mobile - 9825274076 309883 Naliya
Engineers Tel-02836-
G-3, Ground Floor, 367645
Silver Arc, Tel-02836-
Plot no- 57, Sec-8 367646
Gandhidham-
3700201
Mumbai G.S.Enterprises Mr. Shabbir/Abhijit Tel- 022 - Mumbai, Central Area

24,Nagdevi Cross Mobile -9820038788 28935025 ® Boiser, Tardeo
Lane, 3rd floor gsenteprises@rediffmail.com Tel- 022-
Mumbai- 400003 23722303(O)
Tel-022-
23451686(O)
Fax-
23453804
Kolhapur Deltran Diesel Mr.H.V.Bhasker Rao Tel-0231- Kolhapur, Karad,

2094-A, Vikram Mobile - 9422213750 2652326 Sangli and Ratnagiri
Nagar, Satish- Tel-0231-
Market Yard, 2651095
Mobile 9422046240
Kolhapur- 416005 Tel-0231-
deltrandiesels@gmail.com, 2537931
Fax- 0231-
2654072
Pune M K Services Mr. Madhusudan Tel - 020 - Pune, Ahmednagar

8,Managalam Mobile - 9822043604 25433046
Chambers, Mr. N P Malshe Tel - 020 -
Paud Road,Opp.Jog 65223499
Mobile - 9422319061
Hospital, Tel - 020 -
mkservices@vsnl.net, 25446595®
Kothrud Pune 411029
M.N. Patankar Tel -020 -
Mobile 9372007430 25462477®
Fax - 020 –
24331375

Aurangabad M.K.Services Mr. Venkatesh Tel- 0240- Aurangabad,

303, Labh Chambers Mobile - 9823040962 5621885 Jalgaon,Marathwada
Station Road, venkys74@yahoo.com
Aurangabad- 431005 Mr. Sunil
Mobile - 9422319062
Mr. Rajesh
Mobile - 9422213552
Nashik M.K.Services Mr. Sanjay Hire Tel-0253- Nashik, Igatpuri

6, Shanthai, C.H.S Mobile - 9422319065 2413756 (O) Sangamner.
Tagore Nagar
Opp Ambedkar Nagar
Nashik- 422066
Nagpur Nagpur Motors & Mr. Mohan Nabira Tel.0712- Nagpur, Akola,
Machineries Mobile - 9422102309 2726307 (O) Amravati
Subhash Road, Tel-0712- Vardha, Buldhana.
Nagpur- 440018 2726306 (O)
Tel- 0712-
2231187 ®
Chandrapur Abhay Enterprises Mr. Abhay Mamidwar Tel. 07172- Chandrapur

C/O Geetesh Mob - 9822566049 255336
Automobile, geetauto@nagpur.dot.net.in Tel.07172-
Nagpur Road,Bapat 271289®
Nagar Fax-07172-
P.B.No-119, 250630
Chandrapur- 442401
Thane Geekay Engg Mr. S.N. Gokhale Tel-022- Thane, Bhiwandi.

Services Mob- 9820133409 27606868 (O)
W/354, T.T.C Area. Mr. Kelkar Tel-022-
Thane Belapur Road 27606969 (O)
Mob- 9821134078
Opp Anthony Garrage Tel-022-
geekayengg@vsnl.com 25360643®
MIDC, Rebale, Thane-
400701 Tel-022-
25404444(O)
Fax-022-
55903650
Mumbai International Mr. Ambrish Jondhale Tel-022- Mumbai

Operations Mob- 9820605379 22886550
National Insurance Fax-022-
Building , ground 22882102
Floor,59, Dr VB
Gandhi Marg, Mumbai
400001
Madhya Pradesh
Indore Katare Power Mr. Umesh Sharma Tel- 0731- Indore, Khargaon,
Industries Mob- 9425013455 5090021(O) Sendhwa, Ratlam,
114 Dey's Tower, Mob- 9425059587 Tel- 0731- Devas
19/2, 2595407(R) Ujjain.
Manorama Gunj, Fax - 0731-
Malvade Apt. 5090021
Palasia Indore-
452001

Bhopal Karan Agencies Mr. S.K.Sinha Tel- 0755- Bhopal, Sagar,

210, Dynamic Centre, Mob- 9425004664 2555584(O) Harda,
Plot no- 241/242 Mob- 9425003691 Tel- 0755- Mandideep, Jabalpur,
Zone.1, Maha Rana 2571822(O) Hoshingabad.
karanag@hotmail.com
Pratap Nagar Tel- 0755-
Bhopal- 462011 2417028 ®
Fax- 0755-
2555584
Jabalpur Karan Agencies (Br. Mr. Shailendra Sinha Tel- 0761- Jabalpur
Off) Mob- 9425009220 2424496
B-8, Ratan Nagar,
Jabalpur (M.P)
Gwalior Katare Power Mr. Rakesh Sharma Tel- 0751- Gwalior, Jhansi
Industries Mob- 9301120688 2448452(O) Satna, Reeva
A -37, Purshottam katareelctro@sify.com Tel-0751-
Vihar 5040117 (R)
Mr. Ajay Sharma
Gola Ka Mandir, Bhind Fax- 0751-
Road Mob- 9301118886 2366452
Gwalior- 474006
Raipur S S Diesels Mr.S P Varvandkar Tel- 0771- Raipur,Bilaspur,Korba

Tatyapara,Kanaklipara Mob- 9893123313 22530512(O) Ambikapur,Bhilai
Road, shashiv@mantrafreenet.com Tel-0771- Rajnandgaon
Raipur 492001(C.G) 2255340(O)
Tel- 0771-
2254382®
Fax- 0771-
22530512
Goa
Goa UPA Engg Sales & Mr. U.G.Pai Angale Tel- 0832- Goa, Sindudurg,
Services Mob: 9822103819 2863532 (O) Vasco
House No-557, Dande upa@sancharnet.co Tel- 0831-
Vado 2863533 (O)
upa@sancharnet.in
Chinchinim, Salcete, Fax- 0832-
Goa- 403715 2863534
UPA Engg Sales & Tel- 0832-
Services 2863532 (O)
Pai Building, Mundvel, Tel-0831-
Behind Uma Petrol 2863533 (O)
Pump Fax- 0832-
Vasco-Da-Gama, 2863534®
Goa-403802 2514512 /
2513685

9.0 Contact addresses
GREAVES COTTON LTD.
Engine Sales Division

‘Industry Manor’, Appasaheb Marathe Marg,
Prabhadevi, Mumbai – 400 025
Phone: 91-22-24223747, 24365510(O), 24377730

Fax No: 91-22-24379555/
Regional and Branch Offices:
‘Industry Manor’, 91-22-

Appasaheb Marathe Marg, 91-22-24223747/
Bombay 24379555/
Prabhadevi, Mumbai – 400 025 91-22-24365510
91-22-24377730
Thappar House, 25 Brabourne Road,

Calcutta 91-33-22421459/ 91-33-22424325
Calcutta 700 001
Express Building - Annexe. 9-10, 91-11-23359782
New Delhi Bahadurshah Zafar Marg, New Delhi 110 91-11-23730554
002 91-11-23357739
‘Wavoo Mansion’, 6th floor,

Madras Rajaji Salai, Chennai – 600 001 91-44-25255200 91-44-25224557
Branch Offices
Jaidarshan, Ashram Road, 91-79-
Ahmedabad 91-79-26587783
Navrangpura, Ahmedabad 380 009. 26581856
16/3 Ali Asker road, 91-80-
Bangalore 91-80-22253472
Bangalore 560052 22262062
91-484-
39/6636, M. G. Road Ernakulam, 2359272 /
Cochin 91-484-2359589
Cochin 682 015 91-484-
2359661
6-2-47 A.C.Guards, P. O. Box No-9, 91-40-

Hyderabad 23314025 / 91- 91-4023318557
Hyderabad 500 004 40-23316446
New Narendra Kuttir (Raj Niketan), 91-651-
Ranchi 1st Floor, circular Road, Ranchi 834 2562069 / 91- 91-651-2562027
001 651-2562651

4G11T, TP, 4G11TG1,4G11TPG2 Operation and Maintenance Manual-16.03.09

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

4G11T, TP, 4G11TG1,4G11TPG2 Operation and Maintenance Manual-16.03.09

Uploaded by

Copyright:

Available Formats

GREAVES COTTON LTD.

OPERATION & MAINTENANCE MANUAL

G SERIES – 4G11T/TP,4G11TG1/TPG2 - ENGINE

GREAVES COTTON LTD.

Document number. 1 411 0 006 00 24 (01) Page 1 of 68

Greaves Cotton Ltd. ,

Ph: +91 (020) 27473564 /67308200

Document number. 1 411 0 006 00 24 (01) Page 2 of 68

Warranty Policy (Diesel engines)

The foregoing warranty is not applicable in the event, interalia, if

Document number. 1 411 0 006 00 24 (01) Page 3 of 68

• If the engine is improperly stored beyond period of six months without

• All goods are supplied on the condition that under no circumstances we

• In case of DG set manufactured and supplied by Greaves Cotton Ltd.,, warranty

• Meters, battery charging alternator components & indicating instruments

• In respect of any warranty claim accepted by us, we shall arrange to replace or

Document number. 1 411 0 006 00 24 (01) Page 4 of 68

Modification No. Document Number / Date Details of Modifications Page No

Document number. 1 411 0 006 00 24 (01) Page 5 of 68

Sr. no Chapter name Page number

Document number. 1 411 0 006 00 24 (01) Page 6 of 68

Sr. no Chapter name Page number

5 Service and Maintenance 36

7 Installation Do’s and Don’ts 52

8 List of Regional Offices 53

Document number. 1 411 0 006 00 24 (01) Page 7 of 68

Sr. No Hazard Example

1 Rotating parts Flywheel, pulleys, radiator fan

Electrical Alternators, starters, control panels, battery wirings

Document number. 1 411 0 006 00 24 (01) Page 8 of 68

2.1 Engine Orientation

Figure 2.1.1 Engine Orientation

2.2 Engine Nameplate

Figure 2.2.1 Engine Name Plate

Water in let pipe

Figure 2.3.1 Location Of Nameplate

Document number. 1 411 0 006 00 24 (01) Page 9 of 68

2.4 Cylinder nomenclature

Figure 2.4.1 Cylinder Nomenclature

2.5 Engine nomenclature system

Figure 2.5.1 Engine nomenclature

Document number. 1 411 0 006 00 24 (01) Page 10 of 68

2.6 Technical Data

4G11T Engine Specifications for DG set application

Sr. No. Parameter 4G11 T

A10 Cooling Water cooled

Document number. 1 411 0 006 00 24 (01) Page 11 of 68

D3 Fuel Injection Inline fuel pump MICO F002AOZ626

Document number. 1 411 0 006 00 24 (01) Page 12 of 68

H) Bolt Torque tightening data

Document number. 1 411 0 006 00 24 (01) Page 13 of 68

2.7 Engine Illustrations

Figure 2.7.1.1 Inlet manifold side

1 Rocker cover 12 Belts

Document number. 1 411 0 006 00 24 (01) Page 14 of 68

2.7.2 Exhaust manifold side

Figure 2.7.2.1 Exhaust manifold side

1 Water Outlet 8 Engine foot

Document number. 1 411 0 006 00 24 (01) Page 15 of 68

2.7.3 Dimensions and weight -

Engine weight - 480 kg

Flywheel flange – SAE 3

Fig 2.7.3.1 Overall Engine Dimensions