GREAVES COTTON LTD. SPARE PARTS CATALOGUE. G SERIES 3G11Tx - ENGINE GREAVES COTTON LTD.
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1 GREAVES COTTON LTD. SPARE PARTS CATALOGUE G SERIES 3G11Tx - ENGINE GREAVES COTTON LTD. Diesel Engines Unit, Chinchwad, Pune , India, Tel: (91) Fax: (91) Document number. P (00) Page 1 of 62
2 GREAVES COTTON LTD WATER COOLED DIESEL ENGINE 3G11 G SERIES SPARE PARTS CATALOGUE Diesel Engines Unit Chinchwad, Pune INDIA Tel. : ( ) /65/66/67 Fax: ( ) avn@greavesmail.com Document number. P (00) Page 2 of 62
3 INTRODUCTION This spare parts Catalogue comprises the purchasable and replaceable engine parts shown on diagrams and grouped according to their belongings. On account of continuous technical development the figures and part lists are not binding. Ordering of Spare Parts : To enable us to supply correct spares please furnish following details : 1. Engine - Type (engraved on name-plate). 3G11Tx x Represent model G1, G Engine Number (engraved on name-plate and crankcase). 3. Quantity, Description, Part No., and item No. of the Spare Part(s) required. 4, Mode of dispatch you wish. 5. Your address (please specify post or railway station if necessary). Document number. P (00) Page 3 of 62
4 WATER COOLED DIESEL ENGINE Document number. P (00) Page 4 of 62
5 3G11 T Modifications summary Modification No. Document Number / Date Details of Modifications Page No 00 P New Release --- Document number. P (00) Page 5 of 62
6 Contents Sr. no Description Page number 1 Crankcase assembly 7,8 2 Crank shaft assembly 9,10 3 Camshaft assembly 11,12 4 Piston and Connecting Rod assembly 13,14 5 Cylinder Head assembly Air Intake Manifold & filter mounting arrangement 19,20 7 Air cleaner assembly 21,22 8 Exhaust manifold & exhaust system 23,24 9 Water manifold assembly 25,26 10 Oil header & filter assembly 27,28 11 Fuel pump assembly 29,32 12 Flywheel Housing & starter 33,34 13 Flywheel assembly 35,36 14 Gear end casing 37,38 15 Gear train assembly 39,40 16 Front cover & pulleys 41,42 17 Fan drive assembly 43,44 18 Alternator assembly 45,46 19 Lub. Oil Sump assembly 47,48 20 Water inlet pipe assembly 49,50 21 Engine foot 51,52 22 Radiator & radiator mounting 53,54 23 Gauges & switches Set of spare Numerical index Document number. P (00) Page 6 of 62
7 CRANKCASE ASSEMBLY Document number. P (00) Page 7 of 62
8 FIG, PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK NO CRANKCASE 1 ASSEMBLY Crank case machined 1 finished Cam bush finish 1 3 P M14 x 18 x 1.5 Main bearing cap type P Main bearing cap type x 6 mm Spring dowel pin Main bearing standard 5 7 P Washer for MB cap 8 8 P Main bearing cap bolt mm Core plug mm Core plug x 11 Stopper aluminum plug M 20 x 20 mm long. Grub screw M14 x 20 x 1.5 Cu. Washer M14 x 1.5 Hex plug M 10 x 20 mm Solid dowel pin M 10 x 28 mm Solid dowel pin Set of liners Liner & O Rings pair 1 Not illustrated O Ring (Liner) 6 20 P Cylinder liner 3 21 P Lifting eye bolt 1 Not illustrated Document number. P (00) Page 8 of 62
9 CRANKSHAFT ASSEMBLY Document number. P (00) Page 9 of 62
10 Operation and Maintenance Manual G Series 3G11T Engine FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK CRANK SHAFT Crank shaft assembly M10 x 28 mm Solid dowel pin M4 x 16 mm Spring dowel pin 2 4 P Crank shaft sleeve Thrust washer pair 2 6 P Gear crankshaft Balance weight M16 x 35 mm Hollow dowel M12 x CL Allen screw 8 Document number. P (00) Page 10 of 62
11 CAMSHAFT ASSEMBLY Document number. P (00) Page 11 of 62
12 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK CAMSHAFT ASSLY Camshaft 3 cylinder M6 x 14 mm Solid dowel pin 1 3 P Gear camshaft M8 x 17 x 1.6 Washer M8 x 1.25 x 25 CL Hex. screw P Segment for camshaft 1 7 P Tappet 6 Document number. P (00) Page 12 of 62
13 PISTON AND CONROD ASSEMBLY Document number. P (00) Page 13 of 62
14 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK P CON ROD + PISTON 3 ASSLY. 1 P Piston + pin + circlips Single set of piston & 1 rings (Fig No - 3) 3 P Piston 1 TO BE SOLD ONLY WITH SET 1& 2 4 P Gudgeon pin - Piston 1 TO BE SOLD ONLY WITH SET 1 & A16 IS-3075 Cir clip Set of piston rings 1 7 P Con rod assly complete 1 8 P Con rod brg. top + bottom 1 9 P Locking pin 1 10 P M12 x 1.25 x 67 Con rod bolt 2 11 P Piston cooling nozzle assly. 12 P Gasket, piston cooling nozzle Piston cooling nozzle dowel Copper washer 1 15 P M8 x 26 Banjo screw Document number. P (00) Page 14 of 62
15 CYLINDER HEAD ASSEMBLY Document number. P (00) Page 15 of 62
16 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK P CYLINDER HEAD 3 ASSEMBLY 1 P Cylinder head machined mm Core plug Valve guide Inlet valve seat insert Exhaust valve seat insert 1 6 P Inlet valve 1 7 P Exhaust valve 1 8 P Valve spring outer 2 8A Set of spring 1 Not illustrated 9 P Valve spring inner 2 10 P Valve collet 4 11 P Valve stem seal 2 12 P Spring cap 2 P ROCKER ASSEMBLY 1 13 P Rocker arm support 1 14 P Rocker arm (Inlet) 1 15 P Rocker arm ( Exhaust) 1 16 P DIA 4MM x 3.5L Plug aluminum 2 17 P Set screw M8 x1 DIN 934 Nut for Rocker Arm screw A16 IS-3075 Cir clips M11 x 8 mm Hollow dowel 1 Document number. P (00) Page 16 of 62
17 CYLINDER HEAD ASSEMBLY Document number. P (00) Page 17 of 62
18 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK M8 x 1.25 x Hex screw for rocker 2 CL support Washer for rocker cover 2 bolt 23 P Gasket for rocker cover 1 24 P Rocker cover M8 x 1.25 x Bolt for rocker cover 1 CL 26 P Cu. Washer 1 27 P Gasket cylinder head 1 28 P M14 x 150 Bolts for cylinder head 4 29 P Push rod 2 Document number. P (00) Page 18 of 62
19 AIR INTAKE MANIFOLD ASSEMBLY Document number. P (00) Page 19 of 62
20 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK AIR INTAKE MANIFOLD 1 ASSLY Air Inlet manifold 1 machined 2 P Gasket air intake manifold M10X50 8.8/CL Hex bolt M10 Washer 6 Document number. P (00) Page 20 of 62
21 AIR FILTER ASSEMBLY Document number. P (00) Page 21 of 62
22 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK P AIR FILTER ASSEMBLY 1 1 P JJD Air filter dry JJ Filter 1 1A P Air filter element 1 Not illustrated 1B Restriction indicator 1 Not illustrated AIR CLEANER MTG ARRANGE DIA - 82 Hose /4 Hose clip /3X Hose clip Air intake pipe DIA 60/80 Hose 1 7 P Bracket-air filter M10X1.5X20 CL8.8 Hex screw A 10.5 (M10) Washer M10 Hex nut M8X1.25X25 CL8.8 Hex screw M8X17X1.6 Washer 2 Document number. P (00) Page 22 of 62
23 EXHAUST MANIFOLD ASSEMBLY Document number. P (00) Page 23 of 62
24 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK EXHAUST MANIFOLD 1 ASSLY Exhaust manifold 1 2 P Gasket exhaust manifold M10 x 50 mm lg. Stud A10.5 Plain washer M10 Hex. nut 6 Document number. P (00) Page 24 of 62
25 WATER MANIFOLD ASSEMBLY Document number. P (00) Page 25 of 62
26 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK WATER MANIFOLD 1 ASSLY Water manifold machined 1 2 P Gasket water manifold M8 x 17 x 1.6 Washer M8 x 1.25 x 25 CL Hex screw P Gasket for thermostat 1 housing 6 P Thermostat housing 1 7 P Thermostat element 1 8 P Gasket for thermostat 1 cover 9 P Water outlet connection 1 10 P Thermo well M14 x 20 x 1.5 Cu. washer M14 x 1.5 Hex. plug M8 x CL Hex. screw 3 14 P DIA 31.5 Hose for bypass SS W3/ IS 4762 / 1X Hose clip 2 Document number. P (00) Page 26 of 62
27 LUB OIL HEADER AND LUB OIL FILTER Document number. P (00) Page 27 of 62
28 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK P LUB OIL HEADER & OIL 1 FILTER 1 P Oil header machined 1 2 P Relief valve assly A/16-20 x 1.5 Copper washer M14 x 1.5 Hex plug 2 5 P x 18 mm Allen Plug A22X1.5X27 Cu. washer 5 7 P M10X1mm Adaptor for pressure 1 sensor 8 P Gasket for oil cooler 2 9 P Oil cooler cartridge M8X1.25X55 8.8CL Hex bolt M8 x 17 x 1.6 Washer P M24 x 1 UNF Adaptor Lub oil filter 1 14 P Gasket for oil header 1 assembly M8 x 1.25 x 25 Hex-screw A14 X 20 Cu. washer 2 Not illustrated A25 X 30 Cu. washer 1 Not illustrated Document number. P (00) Page 28 of 62
29 FUEL PUMP WITH DRIVE Document number. P (00) Page 29 of 62
30 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK FUEL PUMP WITH 1 DRIVE Fuel pump 3G11 NA 1 2 P Gasket for fuel pump M10 x CL Stud A10.5 Washer for fuel filter 4 bracket M10 Hex. Nuts DIN P Adaptor for fuel pump 1 7 P Fuel pump gear Hex. Bolts for fuel pump 4 gear M8X17X1.6 Washer Injector MICO 3 11 P High pr. pipe set 3G11 1 engine 11A Nozzle MICO Leak off pipe Bracket for fuel filter M10 x 25 Hex. screw A10.5 Washer DB Fuel filter Fuel filter element (Pre filter) 1 Not illustrated 17A Micro filter (star type) 1 Not illustrated M12 x 1.75 x Hex. Bolts for fuel filter 2 CL. mounting Washer for fuel filter 2 mounting M14 x 1.5 x 31 lg. Banjo bolts 2 Document number. P (00) Page 30 of 62
31 FUEL PUMP WITH DRIVE Document number. P (00) Page 31 of 62
32 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK M14 x 18 x 1.5 Cu. Washer 5 22 P Pipe, FIP oil supply 1 23 P Fuel Pipe, Filter to FIP 1 24 P Feed pump pipe 1 25 P Clamp for higher pressure 1 Not illustrated 26 P Clamp for fuel flex. pipe 1 Not illustrated 27 P M10 x 22 Banjo screw Banjo bolt 2 Not illustrated Cu. washer M14 x 1.5 Hex. Plug 1 Not illustrated Document number. P (00) Page 32 of 62
33 FLYWHEEL HOUSING SAE-3 Document number. P (00) Page 33 of 62
34 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK P FLYWHEEL HOUSING 1 SAE-3 1 P Flywheel housing 1 2 P Gasket for flywheel 1 housing Oil seal M12 x Hex screw x 24 x 2.5 M S Washer ESM 12V*6M14 1 (STARTER) Stud bolts M10 DIN 934 M10 Hex nut M10 x Hex screw 1 Not illustrated Plain washer 4 Not illustrated Document number. P (00) Page 34 of 62
35 FLYWHEEL ASSEMBLY Document number. P (00) Page 35 of 62
36 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK P FLYWHEEL ASSEMBLY 1 1 P Flywheel machined SAE P Starter Ring M16 x 60 Hex. screw for flywheel x 30 x 3.0 Washer for flywheel 6 Document number. P (00) Page 36 of 62
37 GEAR END CASING Document number. P (00) Page 37 of 62
38 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK P GEAR END CASING 1 1 P Gear end casing M8 x 17 x 1.6 Washer M8 x 1.25 x 25 CL Hex. Screw P Sleeve for water connection M10 x 20 mm Solid dowel 2 6 P Gasket gear end casing 1 Document number. P (00) Page 38 of 62
39 GEAR TRAIN ASSEMBLY Document number. P (00) Page 39 of 62
40 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK GEAR TRAIN 1 ASSEMBLY Water pump assembly O Ring O Ring M8 x 1.5 x CL Hex screw M8 x 17 x 1.6 Washer 6 6 P Gasket for oil strainer M6 x 10mm - 8.8CL Hex screw M6 Washer 1 9 P Oil Suction strainer Lub oil pump assembly O ring for lub oil pump 1 12 P Idler gear + bush assly P Idler shaft 1 14 P Idler plate M10 x CL Hex screw M6 Plain Washer 3 17 P Nozzle for gear lubrication 1 18 P M8 x 26 Banjo screw Copper washer 4 20 P Gear lub. oil pump 1 Not illustrated Document number. P (00) Page 40 of 62
41 FRONT COVER ASSEMBLY Document number. P (00) Page 41 of 62
42 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK P FRONT COVER 1 ASSEMBLY 1 P Gasket for front cover 1 2 P Front cover M8X1.25X25 CL8.8 Hex screw M8 Washer M8X1.25X60 8.8CL Hex. screw 11 6 P Gasket for fuel pump 1 cover(spout) 7 P Plate for breather (spout) Perforated Sheet 1 9 P Oil filler cover 1 10 P Sealing Ring for oil filler 1 cover 11 P Oil filler cap 1 12 P Blow by pipe Clip for conduit 1 Not illustrated Oil seal gear end 1 15 P Crank shaft pulley M16 x Allen screw for crank 4 pulley M5X12MM Solid dowel pin 1 18 P Pointer M6 x 10 Hex screw M6 Washer 1 Document number. P (00) Page 42 of 62
43 FAN DRIVE ASSEMBLY Document number. P (00) Page 43 of 62
44 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK P FAN DRIVE ASSEMBLY 1 21 P Fan drive bracket 1 machined M10 x 30 DIN Hex. Screw M10 Washer Bearings for fan drive 2 bracket 25 P Spacer Ring Circlip internal Circlip external 1 28 P Pulley for fan drive 1 29 P Spacer for fan drive 1 assembly M8 x CL Hex. bolt 6 Not illustrated M8 Washer 6 Not illustrated Document number. P (00) Page 44 of 62
45 ALTERNATOR ARRANGEMENT Document number. P (00) Page 45 of 62
46 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK P ALTERNATOR 1 ARRANGEMENT Alternator 1 2 P Pulley for Alternator 1 3 P Bracket for charging alt. 1 4 P Spacer for altr mtg bracket M10 x 110 DIA CL Hex. Screw A 10.5 Washer M10 Hex. Nut M8 Washer M8 x 1.25 x25 Hex. Screw 4 10 P Tension bolt M8 x 1.25 x 85 Hex. Screw 1 12 P Swivel bolt 1 13 P A X L Cogged belt 2 Document number. P (00) Page 46 of 62
47 LUB OIL SUMP ASSEMBLY Document number. P (00) Page 47 of 62
48 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK OIL SUMP ASSEMBLY Lub oil sump machined M18 x 1.5 Hex. plug M18 x 22 x 1.5 Cu washer 1 4 P Gasket for lub oil sump Washer for lub oil sump M8 x 1.25 x 25 Hex. screw 22 CL8.8 7 P Dipstick x 3 G11 O ring 1 Document number. P (00) Page 48 of 62
49 WATER INLET PIPE ASSEMBLY Document number. P (00) Page 49 of 62
50 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK WATER INLET PIPE 1 ASSEMBLY Water inlet pipe M8 Washer M8 Hex. Nut 3 4 P Gasket for water inlet pipe M8 x 1.25 x CL Stud 3 Document number. P (00) Page 50 of 62
51 ENGINE BEARERS ASSEMBLY Document number. P (00) Page 51 of 62
52 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK P ENGINE BEARERS 1 1 P Engine foot (flywheel end) 2 2 P Engine foot (Gear end) M12 x 1.75 x 50 Hex. screw x 24 x 2.5 M S Washer M16 x 35 mm Hollow dowel 4 Document number. P (00) Page 52 of 62
53 RADIATOR ASSEMBLY Document number. P (00) Page 53 of 62
54 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK P RADIATOR BRACKET 1 ASSLY. 1 P Bracket radiator M8 x 1.25 x 25 Hex. Screw M8 x 17 x 1.6 Washer A2T / 4030B A V Mounting M10 x 16.5 Stud M10 x 1.5 x 20 Hex. Screw A10.5 Washer M16 x 1.5 Hex. Nut 4 P RADIATOR- 4G11 ASSEMBLY 9 P Radiator - G11 NA 1 10 P ID50 Hose radiator inlet 1 11 P DIA 50 Hose 1 12 P Fan (Fabricated) - 20" SS W3/ IS 4762 / Hose clip 4 2X A2T/4030B A V Mounting 4 1 Document number. P (00) Page 54 of 62
55 TURBOCHARGER ATTACHMENT Document number. P (00) Page 55 of 62
56 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK TURBOCHARGER 1 ATTACHMENTS 1 P HOLSET HX25- Turbocharger 1 TD04HL Gasket, exhaust manifold M8X34 LONG Stud - (ST.STEEL) M8 Washer M8 Hex. Nut CU. Washer Adapt. turbo Pipe, turbo oil supply 1 9 P Gasket, t/c oil drain Adaptor turbocharger M6 x 1.25 x15 Hex. Screw Washer Exhaust elbow Gasket 1 15 P DIA 55x50L Hose SS W3/ IS 4762 / 2X Hose clip SS W3/ IS 4762 / 2X Hose clip 1 18 P Elbow inlet manifold 1 19 P Gasket air intake manifold M8 x 1.25 x25 Hex. Screw M8 x 17 x 1.6 Washer Pipe turbo drain M18 x 22 Adaptor Copper washer Document number. P (00) Page 56 of 62
57 ELECTRIC INSTRUMENT Document number. P (00) Page 57 of 62
58 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK P ELECT.INSTR.+GAUGES= 1 KRB101EPU 1 P INSTR.PANEL CUM 1 BKT.= KRB EPU Kg/Sqcm,M10X1 LOP SWITCH 1 THD /-2DegCel WATER TEMP.SWITCH BAR+SENSOR ELE PRESS GAUGE Kg/cm2,ø52 12V,PRESS.GAUGE, PRESSURE 1 TRANSDUCER 7 P M10X1mm= ADAPTOR=LOP 1 SW/SENSOR ( deg.cel) 12V,TEMP.GAUGE SENSOR-FOR ETG 1 ELECT. 24V AMMETER 1 11 P F/OFF SOL.+ EPU (KRB101) 12 P FUEL OFF SOL.12VDC WITH FINE 13 P EPU+WIRING=KRB 202=STD ENGINE PROTECTION UNIT- KRB P EWD WITH KRB 202 EPU Document number. P (00) Page 58 of 62
59 SET OF SPARE Document number. P (00) Page 59 of 62
60 FIG, NO PART NUMBER SPECIAL DATA DESCRIPTION QTY REMARK SET OF SPARE Set of gasket Set of O Ring Set of hoses Set of cyl. head valves Set of fan drive belts 1 6 P High pr. pipe set 3G11 engine 1 Document number. P (00) Page 60 of 62
61 CODE NO FIG NO PAGE NO A A B A NUMERICAL INDEX PART No. TO PAGE No. AND FIG CODE NO FIG NO PAGE NO Document number. P (00) Page 61 of 62
62 CODE NO FIG NO PAGE NO NUMERICAL INDEX PART No. TO PAGE No. AND FIG CODE NO FIG NO PAGE NO Document number. P (00) Page 62 of 62
63 CODE NO FIG NO PAGE NO P P P P P P P P P P P P P P P P P P P P P P P P NUMERICAL INDEX PART No. TO PAGE No. AND FIG CODE NO FIG NO PAGE NO P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P Document number. P (00) Page 63 of 62
64 CODE NO FIG NO PAGE NO P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P NUMERICAL INDEX PART No. TO PAGE No. AND FIG CODE NO FIG NO PAGE NO P P P P P P P A 22 P P P P P P P P Document number. P (00) Page 64 of 62
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