SPARE PARTS CATALOGUE

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Diesel Engines Unit, Chinchwad, Pune- 411019, India, Tel: (91)

1 GREAVES COTTON LTD 4G11TAG23 Diesel Engine CPCB II SPARE PARTS CATALOGUE GREAVES COTTON LTD. Diesel Engines Unit, Chinchwad, Pune , India, Tel: (91) Fax: (91) Doc no Page 1

2 Parts Ordering Guidelines: Genuine Greaves Cotton Limited Parts and service facilities are available all over India. There are Greaves Cotton Limited appointed sales and service locations giving service support to the engines owned by you. Each distribution outlet is thoroughly equipped with technical data, factory trained mechanics, modern equipments and a full adequate stock of Genuine Greaves Cotton Limited Parts. For quicker and better service, your parts requirements should be ordered from your nearest Greaves Cotton Limited Distributer or Dealer. At any of the locations prompt, intelligent, courteous service is a basic trade-mark. Each is ready and eager to help in every possible way through personal contact or through the mail-at your convenience. The satisfactory ordering and receiving of parts by the purchase is greatly dependent upon the proper use of available information. In order that all avoidable errors may be eliminated, the following instructions are offered as the purchaser's guide: 1. Write your order clearly, using a soft media if possible. 2. Be sure to list the correct part number. If in doubt as to the correct part number, state the model and serial number of the engine on which the part is to be used. Part numbers are usually located in various places on the part itself. 3. When possible, arrange your purchase order in part number numerical sequence. 4. Please specify shipping instructions, if any, preferable to you. 5. State your company name and shipping address clearly. Genuine Greaves Cotton Limited means QUALITY: They re designed and engineered to fit best in your Greaves Cotton Limited. Each part is made of the highest quality and accuracy-by the top craftsman of the trade. You can be sure a Genuine Greaves Cotton Limited Part will fit better-do the job better-lessen the chances of costly breakdown. When you buy replacement parts, buy quality. Buy Genuine Greaves Cotton Limited. YOU OWN BEST...REPAIR WITH THE BEST No part of this manual may be copied, photocopied, reproduced, translated or stored in a retrieval system by any means electronic, mechanical or otherwise without prior permission in writing of Greaves Cotton Limited. Visit us at: Doc no Page 2

3 Customer Service Information This parts catalog contains parts information. Please add following information from this parts catalog. This will help you while ordering. Engine Model Engine Serial No. MFG Make Model Chassis No. Fuel Pump Assembly No. Injector No. Belt,Fan Belt,Water Fuel Flow Lub. Filter Air Cleaner Special Equipment Greaves Cotton Limited Distributor Since improvements are made from time to time the contents, in the parts catalog are subject to change without notice Doc no Page 3

4 About part indentation used in the Parts Catalogue The subject parts catalog uses parts indentation method to break sub level parts under their corresponding top assembly. By placing an order on corresponding top level assemblies / Bills of material the individual parts under that top assemblies / Bills of material can be obtained Indentation can be explained as under - Example- Level Part Number Part Name Quantity.1 P Cam Shaft 1..2 P Tappet 8..2 P Chilled Camshaft Finish P Semi-Finish Chilled Camshaft P Camshaft Chilled Casting 1..2 P Segment for Camshaft Hex screw (M8x1.25x25 Cl8.8) 6..2 P Gear, Camshaft Solid Dowel Pin M6x14mm Washer (M8x17x1.6) 6 Level '1' assembly P in above example is a top Bill of Material / Assembly. Level '2' items namely P , P , are included in P Hence these items are shifted to the right of P by one space. P is also a Bill of Material which includes parts, namely P As P is of level '2' here, these parts are of level '3'. Hence these are shifted to the right of P by one space. In above example if you order on Cam Shaft P of level '1', you will receive all the parts of level '2', '3'.& level 4. If you order on sub assembly P of level '2', you will receive all the parts of level '3' listed below this level '2' subassembly. If required, parts of level '2' & level '3' can be ordered individually. Doc no Page 4

5 Modification Summary Sr No. Rev No. Modification Date 1 00 New Release Water inlet pipe, piping of CAC & radiator Doc no Page 5

6 Table of Contents AIR FILTER AND MOUNTING ALTERNATOR ARRANGEMENT AIR INLATE MANIFOLD CAM SHAFT CONNECTING ROD & PISTON ASSEMBLY CRANK CASE CRANK SHAFT CYLINDER HEAD ASSEMBLY EXHAUST MANIFOLD Doc no Page 6

7 To be continued ENGINE FOOT FLYWHEEL FRONT COVER ASSEMBLY FUEL PUMP FUEL OFF SOLENOID GEAR TRAIN ASSEMBLY GEAR END CASING HOUSING FLYWHEEL LUB OIL HEADER AND FILTER Doc no Page 7

8 To be continued SHEET METAL OIL SUMP STARTER TURBO CHARGER ASSEMBLY RADIATOR ALU TTR 100KVA W/O RAD & FAN WATER INLET PIPE WATER MANIFOLD Doc no Page 8

9 AIR CLEANER MOUNTING ARRANGEMENT Doc no Page 9

10 REF LEV PART DESCRIPTION QTY. REMARKS AIR CLEANER MTG ARRANGEMENT HOSE FILTER TO TURBO HEXSCREW 4 M10X PLAIN WASHER 4 M FLANGED BOLT 2 M8X HOSECLIP / BRACKET AIR FILTER 1 Doc no Page 10

11 ALTERNATOR ARRANGEMENT Doc no Page 11

12 REF LEV PART DESCRIPTION QTY. REMARKS ALTERNATOR ARRANGEMENT ALT.W/O PULLY AUTLECK/SPR P PULLEY FOR ALTERNATOR DRIVE P BRACKET CHARGING ALT G P SPACER ALTR MTG CAST BRACKET BOLT 1 M10X PLAIN WASHER 5 M FLANGED BOLT 4 M8X P SWIVEL BOLT HEX. NUT 3 M10 DIN TENSION BOLT- FABRICATED COGGED BELT 2 AX L HEXBOLT 1 M8X PLAIN WASHER 1 M HEX. NUT 1 M10 DIN 934 Doc no Page 12

13 AIR INLET MANIFOLD Doc no Page 13

14 REF LEV PART DESCRIPTION QTY. REMARKS.1 P AIR INTAKE MANIFOLD ASSLY TA P AIR INTAKE MANIFOLD M/C 4G P GASKET, AIR INTAKE MANIFOLD HEX BOLT 8 M10X PLAIN WASHER 8 M10 Doc no Page 14

15 CAM SHAFT Doc no Page 15

16 REF LEV PART DESCRIPTION QTY. REMARKS CAMSHAFT ASSEMBLY IEGR GCL P TAPPET CAMSHAFT IEGR2 FINISH (GCL) P SEGMENT FOR CAMSHAFT FLANGED BOLT 6 M8X P GEAR, CAMSHAFT SOLID DOWEL PIN 1 M6X14MM Doc no Page 16

17 CONNECTING ROD AND PISTON Doc no Page 17

18 Ref No. Level No. Part No. Description Qty Remarks Con rod + piston assly 4..2 P CON ROD ASSLY COMPLETE P CONN.ROD & CAP ASSLY P CONNECTING ROD WITH SERRATIONS P CON.ROD BOLT M12x1.25x P BUSH CONN ROD S/END P LOCKING PIN P CON ROD BRG SET (TOP + BOTTOM ) LEON P CONN. ROD BRG. (TOP) P CONN. ROD BIG END BRG (BOTTOM) Piston +Pin + circlip + PR Set P PISTON LEON DIA TRAPEZOIDAL PISTON RING TAPERED PISTON RING-LEON OIL CONT. PISTON RING P GUDGEON PIN - PISTON CIRCLIP, LIGHT A 16 IS P GASKET, PISTON COOLING NOZZLE P PISTON COOLING NOZZLE ASSLY P TIP FOR PISTON COOLING NOZZLE P TUBE, PISTON COOLING NOZZLE P BODY PISTON COOLING NOZZLE(MS) COPPER WASHER Piston cooling nozzle dowel P BANJO SCREW M8x26 4 Doc no Page 18

19 CRANK CASE Doc no Page 19

20 REF LEV PART DESCRIPTION QTY. REMARKS.1 P CRANK CASE ASSLY 4G 1..2 P CRANK CASE WITH CAM BUSH P CRANK CASE MACHINED FINISHED P CRANK CASE MACHINED STAGE P MAIN BEARING CAPS TYPE 1 S/F MAIN BEARING CAP TYPE 3 S/F P MAIN BEARING CAP BOLTS G P WASHER FOR MB CAP P CAM BUSH SEMI FINISH BRASS CAP CAP BRASS 3 NOT SUPPLIED LOOSE STOPPER 8 10X11 ALUM PLUG GRUB SCREW M20X20MM LG PLUG ALU CYLINDER LINER NECK ROLLED O RING, (LINER) MAIN BEARING G P M BRG HALF TOP SHELL P M BRG HALF BOTTOM SHELL SOLID DOWEL PIN 2 M10X20MM SOLID DOWEL PIN 2 M10X28MM HEX PLUG 1 M14X SPRING DOWEL PIN 5 4X6MM CU.WASHER 1 Doc no Page 20

21 CRANK SHAFT Doc no Page 21

22 REF LEV PART DESCRIPTION QTY. REMARKS.1 P CRANK SHAFT GA FOR 4G11TA P CRANKSHAFT ASSLY FOR 4G11TA P CRANKSHAFT FINISHED FOR 4G11TA P GEAR, CRANKSHAFT SPRING DOWEL PIN 2 M4X16MM SOLID DOWEL PIN 1 M10X28MM 5..2 P CRANKSHAFT SLEEVE THRUST WASHER PAIR P THRUST WASHER(CR.SHAFT)TOP P THRUST WASHER(C/S)BOTTOM 2 Doc no Page 22

23 CYLINDER HEAD Doc no Page 23

24 REF LEV PART DESCRIPTION QTY. REMARKS CYL HEAD ASSMBLY G A CYL HEAD SUB ASSY CYL. HEAD ASSLY WITH INSERTS P CYLINDER HEAD-MACHINED P VALVE GUIDE P INLET VALVE SEAT INSERT S/F P EXHAUST VALVE SEAT INSERT S/F 3 NOT SUPPLIED LOOSE CORE PLUG 18 25MM P INLET VALVE P EXHAUST VALVE P VALVE SPRING OUTER P VALVE SPRING INNER P SPRING CAP P VALVE COLLET P VALVE STEM SEAL P PUSH ROD P INTEGRATED ROCKER ASSEMBLY P INTEGRATED ROCKER SUPPORT P ROCKER ARM INLET P PLUG AL - 6 DIA 4 X 3.5L P ROCKER ARM EXHAUST P SETTING SCREW HEX. NUT 6 M8 DIN CIRCLIP, LIGHT A 16 IS HOLLOW DOWEL 3 M11X8MM HEXBOLT 3 M8X1.25X PLAIN WASHER 6 M P GASKET CYL HD P BOLT, CYL. HEAD 12 M14X P PDC ROCKER COVER P GASKET, FOR PDC ROCKER COVER HEXBOLT 6 M8X COPPER WASHER 3 Doc no Page 24

25 EXHAUST MANIFOLD Doc no Page 25

26 REF LEV PART DESCRIPTION QTY. REMARKS EXHAUST MANIFOLD ASSLY CPCB II P MANIFOLD EXHAUST GASKET EXHAUST MANIFOLD STUD CL(CU COATED) 8 M10X50L PLAIN WASHER 8 M HEX NUT CU COATED 8 M10 Doc no Page 26

27 ENGINE FOOT Doc no Page 27

28 REF LEV PART DESCRIPTION QTY. REMARKS ENGINE BEARERS FOR BASE ENGINE HOLLOW DOWEL 4 M16X35MM 2..2 P ENGINE FOOT (GEAR END) HEXBOLT 6 M12X50 8.8/C PLAIN WASHER 6 M P LIFITNG I-BOLT 2 M HAMER DRIVESCREW NO2=3/16 4 Doc no Page 28

29 FLYWHEEL Doc no Page 29

30 Ref No. Level No. Part No. Description Qty Remarks.1 P FLYWHEEL ASSLY 1..2 P FLYWHEEL WITH RING GEAR-SAE P FLYWHEEL - SAE P STARTER RING HEX SCREW M16X PLAIN WASHER M16 200HV 6 Doc no Page 30

31 FRONT COVER Doc no Page 31

32 REF LEV PART DESCRIPTION QTY. REMARKS FRONT COVER ASSEMBLY (113.4PCD PULLEY) P FRONT WALL COVER FLANGED BOLT 15 M8X HEXBOLT 11 M8X OILSEAL CRANK PULLEY PASVN ALLEN SCREW 4 M16X P PLASTIC SPOUT ASM P PLASTIC SPOUT WITH PLATE P PLASTIC CAP FOR SPOUT P PIPE PLASTIC SPOUT FLANGED BOLT 5 M8X CLIP FOR CONDUIT ASSEMBLY FAN DRIVE 3 SPACER P FAN DRIVE BRACKET MACHINED HEX SCREW 4 M10X PLAIN WASHER 4 M P SPACER BETWEEN BEARINGS PLASTIC SPACER G HEXBOLT 6 M8X PLAIN WASHER 6 M CIRCLIP 35 MM EXTERNAL P KNOB FOR FAN DRIVE SPACER FOR FAN BRACKET BALL BEARING 2 SKF RS FAN PULLEY WITH BLANKING PLATE PLAIN WASHER 22 M HEXBOLT 2 M8X PLAIN WASHER TIMING POINTER SOLID DOWEL PIN 1 M5X12MM HEX SCREW 1 M6X PLAIN WASHER 1 M6 Doc no Page 32

33 FUEL PUMP Doc no Page 33

34 REF LEV PART DESCRIPTION QTY. REMARKS FIP + DRIVE 100 KVA 4G11TA23 CPCBII FIP for 100 KVA CPCB II BOSCH NO F002A3Z P GASKET, FIP STUD 4 M10X P ADAPTOR FOR FIP DRIVE P GEAR, FUEL PUMP FLANGED BOLT 4 M8X RING WASHER 4 D/ P BRACKET - FUEL FILTER HEXSCREW 2 M10X PLAIN WASHER 2 M DB FILTER MICO HEX PLUG 1 M14X HEXSCREW- 2 M10X PLAIN WASHER M12 200HV BANJO SCREW 4 M14X1.5X31LG CU.WASHER INJECTOR ASSEMBLY F002C8Z HIGH PRESSURE PIPE SET CPCB II 4G LEAK OFF PLASTIC 4G11 STD P PIPE, FIP OIL SUPPLY P PLASTIC PIPE FUEL FLTER P PLASTIC PIPE FUEL FILTER P BANJO SCREW 1 M10X HEX. NUT 4 M10 DIN BANJO BOLT 1 DIN CU.WASHER PLAIN WASHER 4 M8 Doc no Page 34

35 FUEL OFF SOLENOID VALVE REF LEV PART DESCRIPTION QTY. REMARKS 1.1 P FUEL OFF SOLENOID WITH FINE SPEED ADJUSTMENT 1 12VDC Doc no Page 35

36 GEAR TRAIN ASSEMBLY Doc no Page 36

37 Ref No. Level No. Part No. Description Qty Remarks.1 P GEAR TRAIN ASSEMBLY GA P IDLER SHAFT P IDLER GEAR+BUSH ASSLY P GEAR, IDLER P IDLER BEARING P IDLER PLATE HEX BOLT M10X PLAIN WASHER M10 200HV P W / P with o ring & gear O ring water pump dia. ( small) O ring water pump flange FLANGED BOLT 6 M8X P LUB OIL PUMP ASSLY O RING (OIL PUMP) LUB OIL STRAINER P GASKET, OIL STRAINER P NOZZLE,GEAR LUBRICATION COPPER WASHER 4 Doc no Page 37

38 GEAR END CASING Doc no Page 38

39 REF LEV PART DESCRIPTION QTY. REMARKS.1 P GEAR END CASING GA 1..2 P GEAR END CASING SUB-ASSLY P GEAR END CASING P SLEEVE FOR WATER CONNECTION 3..2 P GASKET, GEAR END HOUSING FLANGED BOLT SOLID DOWEL PIN 2 1 M8X M10X20MM Doc no Page 39

40 HOUSING FLYWHEEL Doc no Page 40

41 REF LEV PART DESCRIPTION QTY. REMARKS.1 P FLYWHEEL HOUSING ASSY. 1 SAE P FLYWHEEL HOUSING 1 SAE HEX SCREW 8 M12X PLAIN WASHER 8 M OILSEAL P GASKET, FLYWHEEL HSG PLAIN WASHER 3 M STUD 3 M10x HEX NUT 3 M PLUG MAGNETIC PICKUP UNIT 2 5/8"- 18UNF Doc no Page 41

42 LUB OIL HEADER Doc no Page 42

43 REF LEV PART DESCRIPTION QTY. REMARKS.1 P LUB OIL HEADER & OIL FILTER GA P OIL COOLER & HEADER ASSEMBLY P OIL HEADER MACHINED P GASKET OIL COOLER OVAL P OIL COOLER CARTRIDGE HEXBOLT 4 M8X55 8.8CL PLAIN WASHER 4 M P RELIEF VALVE ASSLY P RELIEF VALVE BODY P RELIEF VALVE SPRING G P STEEL BALL 1 DIA 17MM P RELIEF VALVE CAP HEX PLUG 2 M14X COPPER WASHER 1 A/16-20X FLANGED BOLT 10 M8X CU.WASHER 2 A22X1.5X CU.WASHER CU-WASHER P ALLEN PLUG 2 M20X18 MM P ADAPTOR M24X1"UNF LUB OIL FILTER(232V12) P GASKET BETWEEN HEADER AND CRANKCASE 1 Doc no Page 43

44 SHEET METAL OIL SUMP Doc no Page 44

45 REF LEV PART DESCRIPTION QTY. REMARKS G11 SHEETMETAL OIL SUMP ASSLY SHEETMETAL OIL SUMP 4G HEX HD PLUG 1 M18X CU.WASHER 1 1.5MM HEX SCREW 26 M8X PLAIN WASHER 26 M P DIPSTICK FOR 4G11 SHEETMETAL SUMP 1 Doc no Page 45

STARTER REF LEV PART DESCRIPTION QTY. REMARKS 1.

46 STARTER REF LEV PART DESCRIPTION QTY. REMARKS STARTER 12V*6M14* A 1 Doc no Page 46

47 TURBO CHARGER Doc no Page 47

48 Ref No. Level No. Part No. Description Qty Remarks TURBOCHARGER ATTACHMENT 100 KVA P TURBO TR N G11TAG P GASKET, EXHAUST MANIFOLD STUD-M8X34 LONG (ST.STEEL) PLAIN WASHER M8 200HV HEXNUT COPR.PLATED M8 10G P GASKET, AIR INTAKE MANIFOLD END SIDE FLANGED BOLT M8X1.25X STUD-M8X34 LONG (ST.STEEL) P GASKET TURBO OUT & EXH P TURBO OIL DRAIN PIPE SIDE OPEN CU.WASHER (1.5MM) P TURBO OIL INLET PIPE SIDE OPEN CU.WASHER P GASKET, T/C OIL SUPPLY P GASKET, T/C OIL DRAIN FLANGED BOLT M8X1.25X HEXNUT COPR.PLATED M8 10G PLAIN WASHER M8 200HV P HOSE DIA 50x55L P ADAPT. TURBO IN M18,M P ADAPT. TURBO IN M14,M P ADAPTOR T/C OIL DRAIN EXHAUST ELBOW MACH. 125kVA 1 Doc no Page 48

49 RADIATOR ALU TTR 100KVA W/O RAD & FAN Doc no Page 49

50 Ref No. Level No. Part No. Description Qty Remarks PIPING OF CAC & RADIATOR 100 KVA CPCB II PIPE CAC IN KLIPCO SS W3/ IS 4762 / 2X HOSECLIP /4X P HOSE DIA 76 X 100 L PIPE CAC OUT HOSE THERMO TO RADIATOR HOSE WATER INLET CONNECTION` HOSECLIP 60-80/3X Klipco SS W3/ IS 4762 / SS V BAND 70DIA 3 SEGMENT 1 Doc no Page 50

51 WATER INLET PIPE Doc no Page 51

52 REF LEV PART DESCRIPTION QTY. REMARKS WATER INLET PIPE ASLY TA 100 KVA CPCB II WATER INLET PIPE P GASKET, WATER INLET PIPE HEX. NUT M8 DIN PLAIN WASHER M8 200HV STUD=M8X1.25X25MM 8.8/CL 3 Doc no Page 52

53 WATER INLET MANIFOLD Doc no Page 53

54 REF LEV PART DESCRIPTION QTY. REMARKS WATER MANIFOLD PLASTIC 4G WATER MANIFOLD PLASTIC 4G11 1 WATER MANIFOLD ASSLY PLASTIC G P THERMOSTAT ELEMENT HEX PLUG 1 M14X CU.WASHER SPL.CU.WASHER FLANGED BOLT 8 M8X P HOSE DIA31.5 W/BYPASS G KLIPCO SS W3// 1X 2 IS 4762 Index Doc no Page 54

55 SR NO DESCRIPTION A PAGE 1 AIR FILTER MOUNTING ASSEMBLY 11 2 ALTERNATOR ASSEMBLY 13 3 AIR INLET MANIFOLD ASSEMBLY 15 4 ANTI VIBRATING MOUNT 53 C 3 CAMSHAFT ASSEMBLY 17 4 CONNECTING ROD & PISTON ASSEMBLY 19 5 CRANK CASE 21 6 CRANK SHAFT ASSEMBLY 23 7 CYLINDER HEAD ASSEMBLY 25 E 8 EXHAUST MANIFOLD ASSEMBLY 27 9 ENGINE FOOT ASSEMBLY 29 F FLYWHEEL ASSEMBLY FRONT COVER ASSEMBLY FUEL PUMP ASSEMBLY FUEL-OFF SOLENOID ASSEMBLY 37 G 13 GEAR TRAIN ASSEMBLY GEAR END CASING ASSEMBLY HOUSING ASSEMBLY 42 L 16 LUB OIL HEADER ASSEMBLY 44 S 17 SHEET METAL OIL SUMP STARTER 48 T 19 TURBO CHARGER ASSEMBLY 49 W 20 RADIATOR ALU TTR 100KVA W/O RAD & FAN WATER INLET PIPING ASSEMBLY WATER INLET MANIFOLD 55 Doc no Page 55

SPARE PARTS CATALOGUE

GREAVES COTTON LTD 4G11TAG Diesel Engine CPCB II SPARE PARTS CATALOGUE GREAVES COTTON LTD. Diesel Engines Unit, Chinchwad, Pune- 411019, India, Tel: (91) 20 67308200 Fax: (91) 20 27472276 E-mail: gensetcare@greavescotton.com