SPARE PARTS CATALOGUE

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1 GREAVES COTTON LTD 4G11TAG 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 MFG Make Model Chassis Fuel Pump Assembly Injector 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 Rev Modification Date 1 00 New Release Piping for radiator, Front cover Assembly 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 ELECT. INSTR.GROUP FLYWHEEL FRONT COVER ASSEMBLY FUEL PUMP FUEL OFF SOLENOID GEAR TRAIN ASSEMBLY GEAR END CASING HOUSING FLYWHEEL Doc no Page 7

8 To be continued LUB OIL HEADER AND FILTER SHEET METAL OIL SUMP STARTER TURBO CHARGER ASSEMBLY PIPING OF CAC & RADIATOR WATER INLET PIPE WATER MANIFOLD Doc no Page 8

9 AIR CLEANER MOUNTING ARRANGEMENT Doc no Page 9

10 REF NO. LEV NO. PART NO. 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 Level Part Description Qty Remarks.1 P 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 M10 200HV FLANGED BOLT 4 M8X P SWIVEL BOLT HEX. NUT 3 M P TENSION BOLT- FABRICATED P COGGED BELT AX L HEXBOLT 1 M8X PLAIN WASHER 1 M8 200HV HEX. NUT 1 M10 Doc no Page 12

13 AIR INLET MANIFOLD Doc no Page 13

14 Ref Level 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 200HV Doc no Page 14

15 CAM SHAFT Doc no Page 15

16 Ref Level Part Description Qty Remarks CAMSHAFT ASSEMBLY IEGR GCL 1..2 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 Level Part 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 COPPER WASHER PISTON COOLING NOZZLE DOWEL 4..2 P BANJO SCREW 4 M8X26 Doc no Page 18

19 Crank Case Doc no Page 19

20 Ref Level Part Description Qty Remarks CRANK CASE ASSLY 4G11 105X CRANK CASE WITH CAM BUSH 4G11 105X CRANK CASE FINISHED MACHINED 105X CRANK CASE MACHINED STAGE 1 105X 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 STOPPER 10X11 ALUM PLUG 8 NOT SUPPLED LOOSE GRUB SCREW 1 M20X20MM LG PLUG ALU CYLINDER LINER NECK ROLLED 105 BORE 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 Level Part Description Qty Remarks CRANKSHAFT ASSLY 4G STROKE CRANKSHAFT SUB ASSLY 4G STROKE CRANKSHAFT 4G11 FINISH 133 STROKE 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 Level Part Description Qty Remarks CYLINDER HEAD ASSEMBLY CEV BS III CYLINDER HEAD SUB ASSEMBLY CEV BS III CYL. HEAD ASSLY WITH INSERTS CEV BS III CYL HEAD CEV BSIII (INDUSTRIAL) P VALVE GUIDE P INLET VALVE SEAT INSERT S/F P EXHAUST VALVE SEAT INSERT S/F 3 NOT SUPPLIED LOOSE CORE PLUG 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 8..2 P INTEGRATED ROCKER ASSEMBLY P INTEGRATED ROCKER SUPPORT P ROCKER ARM INLET P PLUG AL 8 DIA 4 x 3.5L P ROCKER ARM EXHAUST P SETTING SCREW HEX. NUT 8 M8 DIN CIRCLIP, LIGHT A 16 IS HOLLOW DOWEL 4 M11X8MM HEXBOLT 4 M8X PLAIN WASHER 8 M8 200HV P GASKET CYL HD 4G11TAG3MLS P BOLT, CYL. HEAD 16 M14X P PDC ROCKER COVER P GASKET, FOR PDC ROCKER COVER HEXBOLT 8 M8X CL COPPER WASHER 4 Doc no Page 24

25 EXHAUST MANIFOLD Doc no Page 25

26 Ref Level Part Description Qty Remarks EXHAUST MANIFOLD ASSLY CPCB II P MANIFOLD EXHAUST GASKET EXHAUST MANIFOLD STUD-M10X50L 10.9CL(CU COATED) PLAIN WASHER 8 M10 200HV HEX NUT M10 CU COATED 8 Doc no Page 26

27 ENGINE FOOT Doc no Page 27

28 REF NO. LEV NO. PART NO. 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 ELECTRICAL. INSTR.GROUP Ref Level Part Description Qty Remarks.1 P ELECT. INSTR.GROUP TO SUIT MURPHY LOPS LOP SENSORCUMSW=0-10BAR=VDO TEMP. SENSOR=120 DEG CEL=VDO 1..2 P ADAPTOR LOPS (MURPHY)&SWITCH(VDO) G-SERS HEX LOCK NUT 1 M20X1.5 X 9 MM CU.WASHER A FUSE LINK CU.WASHER PLUG FOR A/F 1/8 NPT 1 Doc no Page 29

30 FLYWHEEL Doc no Page 30

31 Ref Level Part Description Qty Remarks.1 P FLYWHEEL ASSLY 1..2 P FLYWHEEL WITH RING GEAR-SAE P FLYWHEEL - SAE P STARTER RING HEX SCREW 6 M16X PLAIN WASHER M16 200HV 6 Doc no Page 31

32 FRONT COVER Doc no Page 32

33 Ref Level Part Description Qty Remarks FRONT COVER ASSEMBLY P FRONT WALL COVER FLANGED BOLT M8X1.25X HEXBOLT=M8X1.25X60 8.8CL OILSEAL CRANK PULLEY 3G PCD ALLEN SCREW M16X P PLASTIC SPOUT ASM P PLASTIC SPOUT WITH PLATE P PLASTIC CAP FOR SPOUT P PIPE PLASTIC SPOUT FLANGED BOLT M8X1.25X CLIP FOR CONDUIT PLAIN WASHER M8 200HV HEXBOLT=M8X1.25X55 8.8CL TIMING POINTER SOLID DOWEL PIN M5X12MM HEX SCREW M6X CL PLAIN WASHER M6 200HV FAN DRIVE ASSEMBLY 3G WITH ONE ALU. SPAC P FAN PULLEY BKT 70MM OFFSET P SPACER BETWEEN BEARINGS PLASTIC SPACER G HEX BOLT M8X1.25X50 8.8/CL PLAIN WASHER M8 200HV CIRCLIP 35 MM EXTERNAL P KNOB FOR FAN DRIVE HEX. NUT M10 DIN 934M PLAIN WASHER M10 200HV STUD BOLT M10X CL SPACER FOR FAN BRACKET BALL BEARING SKF RS FAN PULLEY WITH BLANKING PLATE G11 FAN DRIVE SPACER 1 Doc no Page 33

34 FUEL PUMP Doc no Page 34

35 Ref Level Part Description Qty Remarks FIP DRIVE 125 KVA BOSCH NO E FIP A5000 BOSCH NO E KVA P GASKET, FIP STUD 4 M 10 x ADAPTOR FIP DRIVE GEAR FUEL PUMP A FLANGED BOLT 4 M8X RING WASHER D/ P BRACKET - FUEL FILTER HEXSCREW 2 M10X PLAIN WASHER 2 M10 200HV DB FILTER MICO HEX PLUG 1 M14X HEXSCREW- 2 M10X PLAIN WASHER 2 M10 200HV BANJO SCREW 2 M14X31LG CU.WASHER BANJO SCREW 2 M14X31LG CU.WASHER INJECTOR MICO E HIGH PRESSURE PIPE SET CPCB II 4G HIGH PRESSURE PIPE(6X1.8X575 MM) 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 M BANJO BOLT (DIN-7623) CU.WASHER PLAIN WASHER 4 M8 200HV CU.WASHER DISTANCE PIECE 1 Doc no Page 35

36 FUEL OFF SOLENOID VALVE Ref Level Part Description Qty Remarks 1.1 P FUEL OFF SOL.12VDC WITH FINE 1 Doc no Page 36

37 GEAR TRAIN ASSEMBLY Doc no Page 37

38 Ref Level Part 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 3 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 38

39 GEAR END CASING Doc no Page 39

40 Ref Level 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 P GASKET, GEAR END HSG FLANGED BOLT 8 M8X SOLID DOWEL PIN 2 M10X20MM Doc no Page 40

41 HOUSING FLYWHEEL Doc no Page 41

42 Ref Level Part Description Qty Remarks.1 P HOUSING FLYWHEEL-SAE 3 ASSY.GA P FLYWHEEL HOUSING SAE HEX.SCREW 8 M12X PLAIN WASHER 8 M12 200HV OILSEAL P GASKET, FLYWHEEL HSG PLAIN WASHER 3 M10 200HV STUD 3 M 10X HEX. NUT M10 DIN M PLUG MPU - 5/8" - 18 UNF 2 Doc no Page 42

43 LUB OIL HEADER Doc no Page 43

44 Ref Level Part Description Qty Remarks.1 P LUB OIL HEADER & OIL FILTER GA 1..2 P OIL COOLER & HEADER ASSEMBLY P OIL HEADER MACHINED P GASKET OIL COOLER OVAL P OIL COOLER CARTRIDGE HEXBOLT 4 M8X PLAIN WASHER 4 M8 200HV 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 M14X COPPER WASHER 1 A/16-20X FLANGED BOLT 10 M8X CU.WASHER CU.WASHER 1 A22X1.5X 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 44

45 SHEET METAL OIL SUMP Doc no Page 45

46 Ref Level Part Description Qty Remarks G11 SHEETMETAL OIL SUMP ASSLY SHEETMETAL OIL SUMP 4G HEX HD PLUG 1 M18X1.5X CU.WASHER (1.5MM) HEX SCREW 26 M8X PLAIN WASHER 26 M8 200HV 6..2 P DIPSTICK FOR 4G11 SHEETMETAL SUMP 1 Doc no Page 46

47 STARTER Ref Level Part Description Qty Remarks STARTER 12V*6M14* A 1 Doc no Page 47

48 TURBO CHARGER Doc no Page 48

49 Ref Level Part Description Qty Remarks TURBO & ATTACHMENTS FOR 125 KVA CPCBII P TURBO TR N G11TAG GASKET BETWEEN EXHAUST MANIFD & TURBO S STUD-M8X34 LONG (ST.STEEL) PLAIN WASHER 4 M8 200HV HEXNUT COPR.PLATED M8 10G P GASKET, AIR INTAKE MANIFOLD END SIDE FLANGED BOLT 4 M8X STUD-M8X34 LONG (ST.STEEL) P GASKET FOR TR65 TURBO 92 PCD TURBO OIL DRAIN PIPE (4G11TAG3) CU.WASHER (1.5MM) P TURBO OIL INLET PIPE SIDE OPEN CU.WASHER P GASKET, T/C OIL SUPPLY GASKET TURBO DRAIN FLANGED BOLT 4 M8X PLAIN WASHER 4 M8 200HV HEXNUT COPR.PLATED M8 10G PLAIN WASHER 4 M8 200HV P ADAPT. TURBO IN 1 M18,M P ADAPT. TURBO IN 1 M14,M P ADAPTOR T/C OIL DRAIN SS V BAND 70DIA 3 SEGMENT EXHAUST ELBOW MACH. 125kVA 1 Doc no Page 49

50 PIPING OF CAC & RADIATOR Doc no Page 50

51 Ref Level Part Description Qty Remarks PIPING FOR 125 KVA ENGINE WITH YOUNG RAD CAC OUTLET PIPE 125 KVA YOUNG RADIATOR SUPPORT BRACKET FOR RADIATOR 125 KVA ADAPTOR PIPE-COMP.TO CAC INLET FINISH PIPE WATER (THERMO-RAD) HOSE THERMO - RAD 6G CAC INLET PIPE 125 KVA YOUNG RADIATOR HOSE WATER OUTLET THERMO SIDE HOSE 100IDX100 L P U CLAMP FOR ENGINE INLET PIPE U CLAMP DIA PLAIN WASHER M8 200HV HEX. NUT M8 DIN SUPPORT BRACKET FOR AIR INLET BEND SLEEVE FOR TURBO COMP OUTLET HOSE 63.5IDX65 L T BOLT CLAMP TB HOSE CLIP40-60(2X)9THK T BOLT CLAMP TB T BOLT CLAMP TB HOSE RAD - C/CASE IN PIPE 6G PLAIN WASHER M12 200HV HEX. NUT M12 DIN 934M HEXSCREW=M8X1.25X20 8.8CL PLAIN WASHER M8 200HV A V MOUNTING-AVDO/4030/A WATER INLET PIPE 125 KVA YOUNG RADIATOR CAPSCREW=M8X1.25X RING WASHER D/ FLANGED BOLT M8X1.25X HEXSCREW=M10X1.5X25 8.8CL HEXSCREW=M8X1.25X20 8.8CL PLAIN WASHER M8 200HV PLAIN WASHER M10 200HV 1 Doc no Page 51

52 Ref Level Part Description Qty Remarks HOSECLIP 60-80/3X STUD-M8X34 LONG (ST.STEEL) PLAIN WASHER M8 200HV HEX. NUT M8 DIN Doc no Page 52

53 WATER INLET PIPE Doc no Page 53

54 Ref Level Part Description Qty Remarks WATER INLET CONNECTION ASSEMBLY HOSE-WATER INLET CONNECTION HOSE WATER INLET CONNECTION PIPE WATER INLET CONNECTION HOSE CLIP 25-40/1X HEXSCREW=M8X1.25X20 8.8CL PLAIN WASHER M8 200HV 2 Doc no Page 54

55 WATER INLET MANIFOLD Doc no Page 55

56 Ref Level Part Description Qty Remarks WATER MANIFOLD PLASTIC 4G WATER MANIFOLD PLASTIC 4G WATER MANIFOLD ASSLY PLASTIC 4G 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/ IS 4762/ 1X 2 Doc no Page 56

57 Index SR NO DESCRIPTION A PAGE NO. 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 WATER INLET PIPING ASSEMBLY WATER INLET MANIFOLD 53 Doc no Page 57

SPARE PARTS CATALOGUE

GREAVES COTTON LTD 4G11TAG23 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