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 Doc no. 141100064024 Page 1
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: www.greavescotton.com Doc no. 141100064024 Page 2
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. 141100064024 Page 3
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 P21101700016 Cam Shaft 1..2 P21103250014 Tappet 8..2 P21101700024 Chilled Camshaft Finish 1...3 P21101700023 Semi-Finish Chilled Camshaft 1...4 P21101700022 Camshaft Chilled Casting 1..2 P21106730014 Segment for Camshaft 1..2 602000500825 Hex screw (M8x1.25x25 Cl8.8) 6..2 P21103710034 Gear, Camshaft 1..2 602201000614 Solid Dowel Pin M6x14mm 1..2 602150100084 Washer (M8x17x1.6) 6 Level '1' assembly P21101700016 in above example is a top Bill of Material / Assembly. Level '2' items namely P21103250014, P21101700024, are included in P21101700016. Hence these items are shifted to the right of P21101700016 by one space. P21101700024 is also a Bill of Material which includes parts, namely P21101700023. As P21101700024 is of level '2' here, these parts are of level '3'. Hence these are shifted to the right of P21101700024 by one space. In above example if you order on Cam Shaft P21101700016 of level '1', you will receive all the parts of level '2', '3'.& level 4. If you order on sub assembly P21101700024 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. 141100064024 Page 4
Modification Summary Sr Rev Modification Date 1 00 New Release 17.05.2014 2 01 Piping for radiator, Front cover Assembly 19.07.2014 Doc no. 141100064024 Page 5
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. 141100064024 Page 6
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. 141100064024 Page 7
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. 141100064024 Page 8
AIR CLEANER MOUNTING ARRANGEMENT Doc no. 141100064024 Page 9
REF NO. LEV NO. PART NO. DESCRIPTION QTY. REMARKS 141109230037 AIR CLEANER MTG ARRANGEMENT 1 1..2 141108614014 HOSE FILTER TO TURBO 1 2..2 602000501020 HEXSCREW 4 M10X20 8.8 3..2 141103400044 PLAIN WASHER 4 M10 4..2 141103510825 FLANGED BOLT 2 M8X25 8.8 5..2 604015301050 HOSECLIP 2 100-125/6 6..2 141106230015 BRACKET AIR FILTER 1 Doc no. 141100064024 Page 10
ALTERNATOR ARRANGEMENT Doc no. 141100064024 Page 11
Ref Level Part Description Qty Remarks.1 P21190790017 ALTERNATOR ARRANGEMENT 1 1..2 000767530321 ALT.W/O PULLY AUTLECK/SPR 1 2...3 P21103810034 PULLEY FOR ALTERNATOR DRIVE 1 3..2 P21106230035 BRACKET CHARGING ALT G11 1 4..2 P21103300064 SPACER ALTR MTG CAST BRACKET 1 5..2 602000101011 BOLT 1 M10X110 10.9 6..2 141103400044 PLAIN WASHER 5 M10 200HV 7..2 141103510825 FLANGED BOLT 4 M8X25 8.8 8..2 P21103510024 SWIVEL BOLT 1 9..2 602100540100 HEX. NUT 3 M10 10..2 P21103510045 TENSION BOLT- FABRICATED 1 11..2 P03450211143 COGGED BELT AX43-1143L 2 12..2 602000100885 HEXBOLT 1 M8X85-8.8 13..2 141103400034 PLAIN WASHER 1 M8 200HV 14..2 602100540100 HEX. NUT 1 M10 Doc no. 141100064024 Page 12
AIR INLET MANIFOLD Doc no. 141100064024 Page 13
Ref Level Part Description Qty Remarks.1 P21109200027 AIR INTAKE MANIFOLD ASSLY TA 1 1..2 P21109200014 AIR INTAKE MANIFOLD M/C 4G11 1 2..2 P21108510014 GASKET, AIR INTAKE MANIFOLD 4 3..2 602000101050 HEX BOLT 8 M10X50 8.8 4..2 141103400044 PLAIN WASHER 8 M10 200HV Doc no. 141100064024 Page 14
CAM SHAFT Doc no. 141100064024 Page 15
Ref Level Part Description Qty Remarks.1 141101700027 CAMSHAFT ASSEMBLY IEGR GCL 1..2 P21103250014 TAPPET 8 1..2 141101704034 CAMSHAFT IEGR2 FINISH (GCL) 1 2..2 P21106730014 SEGMENT FOR CAMSHAFT 1 3..2 141103510825 FLANGED BOLT 6 M8X25 8.8 4..2 P21103710034 GEAR, CAMSHAFT 1 5..2 602201000614 SOLID DOWEL PIN 1 M6X14MM Doc no. 141100064024 Page 16
CONNECTING ROD AND PISTON Doc no. 141100064024 Page 17
Ref Level Part Description Qty Remarks.1 141101604039 CON ROD + PISTON ASSLY 4..2 P21101600018 CON ROD ASSLY COMPLETE 4...3 P21101500017 CONN.ROD & CAP ASSLY. 4 1...4 P21101500026 CONNECTING ROD WITH SERRATIONS 4 2...5 P21103530024 CON.ROD BOLT M12X1.25X67 8 3...4 P21104310012 BUSH CONN ROD S/END 4 4...4 P02201000414 LOCKING PIN 4 -...3 P21104306017 CON ROD BRG SET (TOP + BOTTOM ) LEON 4 5...4 P21104306014 CONN. ROD BRG. (TOP) 4 6...4 P21104306024 CONN. ROD BIG END BRG (BOTTOM) 4 -..2 141101604076 PISTON +PIN + CIRCLIP + PR SET 4 7...3 P21101600014 PISTON LEON DIA 105 4 8...3 105032111061 TRAPEZOIDAL PISTON RING 4 9...3 105032111062 TAPERED PISTON RING-LEON 4 10...3 105032111063 OIL CONT. PISTON RING 4 11...3 P05020303801 GUDGEON PIN - PISTON 4 12...3 603050100016 CIRCLIP, LIGHT A 16 IS3075 8 13..2 P21108530134 GASKET, PISTON COOLING NOZZLE 4 14..2 P21104650046 PISTON COOLING NOZZLE ASSLY 4 15..2 604920100814 COPPER WASHER 4 16..2 602201000814 PISTON COOLING NOZZLE DOWEL 4..2 P04043300826 BANJO SCREW 4 M8X26 Doc no. 141100064024 Page 18
Crank Case Doc no. 141100064024 Page 19
Ref Level Part Description Qty Remarks.1 141101104058 CRANK CASE ASSLY 4G11 105X133 1..2 141101104057 CRANK CASE WITH CAM BUSH 4G11 105X133 1...3 141101104056 CRANK CASE FINISHED MACHINED 105X133 1 1...4 141101104055 CRANK CASE MACHINED STAGE 1 105X133 1 2...4 P21101010012 MAIN BEARING CAPS TYPE 1 S/F 1 3...4 141101010032 MAIN BEARING CAP TYPE 3 S/F 4 4...4 P21103500024 MAIN BEARING CAP BOLTS G11 10 5...4 P21103400054 WASHER FOR MB CAP 10 6...4 P21104320012 CAM BUSH SEMI FINISH 1 7...3 620609760024 BRASS CAP 4 8...3 620609760014 CAP BRASS 3 9...3 632413270014 STOPPER 10X11 ALUM PLUG 8 NOT SUPPLED LOOSE 10...3 102041002020 GRUB SCREW 1 M20X20MM LG -...3 623413270044 PLUG ALU. 2 11..2 141101320074 CYLINDER LINER NECK ROLLED 105 BORE 4 12..2 104932111144 O RING, (LINER) 8 -..2 141104306017 MAIN BEARING G11 5 13...3 P21104300014 M BRG HALF TOP SHELL 5 14...3 P21104300024 M BRG HALF BOTTOM SHELL 5 15..2 602201001020 SOLID DOWEL PIN 2 M10X20MM 16..2 602201001028 SOLID DOWEL PIN 2 M10X28MM 17..2 602060501415 HEX PLUG 1 M14X1.5 18..2 602201500406 SPRING DOWEL PIN 5 4X6MM 19..2 604920101420 CU.WASHER 1 Doc no. 141100064024 Page 20
CRANK SHAFT Doc no. 141100064024 Page 21
Ref Level Part Description Qty Remarks.1 141101404067 CRANKSHAFT ASSLY 4G11 133 STROKE 1..2 141101404066 CRANKSHAFT SUB ASSLY 4G11 133 STROKE 1 1...3 141101404064 CRANKSHAFT 4G11 FINISH 133 STROKE 1 2...3 P21103710014 GEAR, CRANKSHAFT 1 3...3 602201500416 SPRING DOWEL PIN 2 M4X16MM 4...3 602201001028 SOLID DOWEL PIN 1 M10X28MM 5..2 P21103300014 CRANKSHAFT SLEEVE 1..2 141103400017 THRUST WASHER PAIR 2 6...3 P21103400014 THRUST WASHER(CR.SHAFT)TOP 2 7...3 P21103400024 THRUST WASHER(C/S)BOTTOM 2 Doc no. 141100064024 Page 22
CYLINDER HEAD Doc no. 141100064024 Page 23
Ref Level Part Description Qty Remarks.1 141101800028 CYLINDER HEAD ASSEMBLY CEV BS III 4..2 141101800027 CYLINDER HEAD SUB ASSEMBLY CEV BS III 4...3 141101800026 CYL. HEAD ASSLY WITH INSERTS CEV BS III 4 1...4 141101800064 CYL HEAD CEV BSIII (INDUSTRIAL) 4 2...4 P21103320012 VALVE GUIDE 6 3...4 P21103450022 INLET VALVE SEAT INSERT S/F 3 4...4 P21103450012 EXHAUST VALVE SEAT INSERT S/F 3 NOT SUPPLIED LOOSE 5...4 602152180025 CORE PLUG 18 6...3 P21104600014 INLET VALVE 4 7...3 P21104600024 EXHAUST VALVE 4 8...3 P02403101001 VALVE SPRING OUTER 8 9...3 P02402201001 VALVE SPRING INNER 8 10...3 P21103420014 SPRING CAP 8 11...3 P21104620014 VALVE COLLET 16 12...3 P04960650121 VALVE STEM SEAL 8 13..2 P21103210014 PUSH ROD 8..2 P21106100027 INTEGRATED ROCKER ASSEMBLY 4 14...3 P21106100024 INTEGRATED ROCKER SUPPORT 4 15...3 P21106450014 ROCKER ARM INLET 4 16...3 P21103270014 PLUG AL 8 DIA 4 x 3.5L 17...3 P21106450024 ROCKER ARM EXHAUST 4 18...3 P21103580014 SETTING SCREW 8 19...3 602100540080 HEX. NUT 8 M8 DIN 934 20...3 603050100016 CIRCLIP, LIGHT A 16 IS3075 8 21..2 102201501108 HOLLOW DOWEL 4 M11X8MM 22..2 602000100840 HEXBOLT 4 M8X40 8.8 23..2 141103400034 PLAIN WASHER 8 M8 200HV 24..2 P21108540024 GASKET CYL HD 4G11TAG3MLS 4 25..2 P21103500014 BOLT, CYL. HEAD 16 M14X150 26..2 P21107960024 PDC ROCKER COVER 4 27..2 P21108530304 GASKET, FOR PDC ROCKER COVER 4 28..2 602000120860 HEXBOLT 8 M8X60 10.9CL 29..2 604920100814 COPPER WASHER 4 Doc no. 141100064024 Page 24
EXHAUST MANIFOLD Doc no. 141100064024 Page 25
Ref Level Part Description Qty Remarks.1 141109314037 EXHAUST MANIFOLD ASSLY CPCB II 1 1..2 P21109310014 MANIFOLD EXHAUST 1 2..2 141108530524 GASKET EXHAUST MANIFOLD 4 3..2 102011071050 STUD-M10X50L 10.9CL(CU COATED) 8 4..2 141103400044 PLAIN WASHER 8 M10 200HV 5..2 602100700100 HEX NUT M10 CU COATED 8 Doc no. 141100064024 Page 26
ENGINE FOOT Doc no. 141100064024 Page 27
REF NO. LEV NO. PART NO. DESCRIPTION QTY. REMARKS.1 141106014027 ENGINE BEARERS FOR BASE ENGINE 1 1..2 102201501635 HOLLOW DOWEL 4 M16X35MM 2..2 P21106010014 ENGINE FOOT (GEAR END) 2 3..2 602000101250 HEXBOLT 6 M12X50 8.8/C 4..2 141103400054 PLAIN WASHER 6 M12 5..2 P21103510034 LIFITNG I-BOLT 2 M14 -..2 000090010401 HAMER DRIVESCREW NO2=3/16 4 Doc no. 141100064024 Page 28
ELECTRICAL. INSTR.GROUP Ref Level Part Description Qty Remarks.1 P21190210328 ELECT. INSTR.GROUP TO SUIT MURPHY LOPS 1..2 100007761195 LOP SENSORCUMSW=0-10BAR=VDO1.5 1..2 100007761193 TEMP. SENSOR=120 DEG CEL=VDO 1..2 P21103550396 ADAPTOR LOPS (MURPHY)&SWITCH(VDO) G-SERS 1..2 102100502015 HEX LOCK NUT 1 M20X1.5 X 9 MM..2 604920101014 CU.WASHER 3..2 100007761194 35A FUSE LINK 1..2 604920101420 CU.WASHER 1..2 141103550274 PLUG FOR A/F 1/8 NPT 1 Doc no. 141100064024 Page 29
FLYWHEEL Doc no. 141100064024 Page 30
Ref Level Part Description Qty Remarks.1 P21101450017 FLYWHEEL ASSLY 1..2 P21101450015 FLYWHEEL WITH RING GEAR-SAE 3 1 1...3 P21101450014 FLYWHEEL - SAE3 1 2...3 P21103750014 STARTER RING 1 3..2 602000521660 HEX SCREW 6 M16X60-10.9 4..2 141103400074 PLAIN WASHER M16 200HV 6 Doc no. 141100064024 Page 31
FRONT COVER Doc no. 141100064024 Page 32
Ref Level Part Description Qty Remarks.1 141107804057 FRONT COVER ASSEMBLY 1 1..2 P21107800024 FRONT WALL COVER 1 2..2 141103510825 FLANGED BOLT M8X1.25X25 8.8 15 3..2 602000100860 HEXBOLT=M8X1.25X60 8.8CL 11 4..2 104960650100 OILSEAL 78-100-12 1 5..2 141103810304 CRANK PULLEY 3G PCD 113.4 1 6..2 602007041660 ALLEN SCREW M16X60-12.9 4 -..2 P21107870027 PLASTIC SPOUT ASM 1 7...3 P21107870064 PLASTIC SPOUT WITH PLATE 1 8...3 P21107870074 PLASTIC CAP FOR SPOUT 1 9...3 P21108610374 PIPE PLASTIC SPOUT 1 2...3 141103510825 FLANGED BOLT M8X1.25X25 8.8 5 10...3 001700531019 CLIP FOR CONDUIT 1 11..2 141103400034 PLAIN WASHER M8 200HV 13 12..2 602000100855 HEXBOLT=M8X1.25X55 8.8CL 2 13..2 141106504054 TIMING POINTER 1 14..2 602201000512 SOLID DOWEL PIN M5X12MM 1 15..2 602000500610 HEX SCREW M6X10 8.8 CL 1 16..2 141103400084 PLAIN WASHER M6 200HV 1 -..2 141107354036 FAN DRIVE ASSEMBLY 3G WITH ONE ALU. SPAC 1 17...3 P21106230084 FAN PULLEY BKT 70MM OFFSET 1 18...3 P21103300114 SPACER BETWEEN BEARINGS. 1 19...3 141103300124 PLASTIC SPACER G11 1 20...3 602000100850 HEX BOLT M8X1.25X50 8.8/CL 6 11...3 141103400034 PLAIN WASHER M8 200HV 6 21...3 603050100035 CIRCLIP 35 MM EXTERNAL 1 22...3 P21106230074 KNOB FOR FAN DRIVE 1 23...3 602100540100 HEX. NUT M10 DIN 934M-10 4 24...3 141103400044 PLAIN WASHER M10 200HV 4 25...3 602011081025 STUD BOLT M10X25-10.9 CL 4 26...3 141103300184 SPACER FOR FAN BRACKET 1 27...3 603200746207 BALL BEARING SKF 6207-2RS1 2 28...3 141103810196 FAN PULLEY WITH BLANKING PLATE 1 29...3 141103306014 6G11 FAN DRIVE SPACER 1 Doc no. 141100064024 Page 33
FUEL PUMP Doc no. 141100064024 Page 34
Ref Level Part Description Qty Remarks.1 141107254217 FIP DRIVE 125 KVA BOSCH NO E040297900 1 1..2 105200240237 FIP A5000 BOSCH NO E040297900 125KVA 1 2..2 P21108530174 GASKET, FIP 1 3..2 602012021030 STUD 4 M 10 x30 8.8 4..2 141104110024 ADAPTOR FIP DRIVE 1 5..2 141103710024 GEAR FUEL PUMP A5000 1 6..2 141103510825 FLANGED BOLT 4 M8X25 8.8 7..2 602150610841 RING WASHER D/234 4 8..2 P21106370035 BRACKET - FUEL FILTER 1 9..2 602000501025 HEXSCREW 2 M10X25 8.8 10..2 141103400044 PLAIN WASHER 2 M10 200HV 11..2 001200240183 DB FILTER MICO 028 1 12..2 602060501415 HEX PLUG 1 M14X1.5 13..2 602000501035 HEXSCREW- 2 M10X35-8.8 14..2 141103400044 PLAIN WASHER 2 M10 200HV 15..2 604043200008 BANJO SCREW 2 M14X31LG. 16..2 604920101420 CU.WASHER 4 15..2 604043200008 BANJO SCREW 2 M14X31LG. 16..2 604920101420 CU.WASHER 4 17..2 105302000062 INJECTOR MICO E 0801662 00 00 4 18..2 141109064037 HIGH PRESSURE PIPE SET CPCB II 4G11 1 -...3 141109063045 HIGH PRESSURE PIPE(6X1.8X575 MM) 4 19..2 141109394054 LEAK OFF PLASTIC 4G11 STD 1 20..2 P21109010055 PIPE, FIP OIL SUPPLY 1 21..2 P21109390125 PLASTIC PIPE FUEL FLTER 1 22..2 P21109390115 PLASTIC PIPE FUEL FILTER 1 23..2 P04043301022 BANJO SCREW 1 M10x22 24..2 602100540100 HEX. NUT 4 M10 -..2 604043200004 BANJO BOLT (DIN-7623) 1 25..2 604920101014 CU.WASHER 8 26..2 141103400034 PLAIN WASHER 4 M8 200HV 16..2 604920101420 CU.WASHER 1 -..2 141104110014 DISTANCE PIECE 1 Doc no. 141100064024 Page 35
FUEL OFF SOLENOID VALVE Ref Level Part Description Qty Remarks 1.1 P21100780017 FUEL OFF SOL.12VDC WITH FINE 1 Doc no. 141100064024 Page 36
GEAR TRAIN ASSEMBLY Doc no. 141100064024 Page 37
Ref Level Part Description Qty Remarks.1 P21103710018 GEAR TRAIN ASSEMBLY GA 1 1..2 P21103000024 IDLER SHAFT 1 2..2 P21103710026 IDLER GEAR+BUSH ASSLY 1 3...3 P21103710024 GEAR, IDLER 1 4...4 P21104320024 IDLER BEARING 1 5..2 P21106500014 IDLER PLATE 1 6..2 602000101060 HEX BOLT 3 M10X60 8.8 7..2 141103400044 PLAIN WASHER M10 200HV 3 8..2 P21107310017 W / P with o ring & gear 1 9...3 104932117704 O ring water pump dia. ( small) 1 10...3 104932119204 O ring water pump flange 1 11..2 141103510825 FLANGED BOLT 6 M8X25 8.8 12..2 P21107300017 LUB OIL PUMP ASSLY 1 13...3 104932117802 O RING (OIL PUMP) 1 14..2 141109010035 LUB OIL STRAINER 1 15..2 P21108530224 GASKET, OIL STRAINER 1 16..2 P21104650025 NOZZLE,GEAR LUBRICATION 1 17..2 604920100814 COPPER WASHER 4 Doc no. 141100064024 Page 38
GEAR END CASING Doc no. 141100064024 Page 39
Ref Level Part Description Qty Remarks.1 P21107800017 GEAR END CASING GA 1..2 P21107800016 GEAR END CASING SUB-ASSLY. 1 1...3 P21107880014 GEAR END CASING 1 2...3 P21103550014 SLEEVE FOR WATER CONNECTION 1 3..2 P21108530034 GASKET, GEAR END HSG 1 4..2 141103510825 FLANGED BOLT 8 M8X25 8.8 5..2 602201001020 SOLID DOWEL PIN 2 M10X20MM Doc no. 141100064024 Page 40
HOUSING FLYWHEEL Doc no. 141100064024 Page 41
Ref Level Part Description Qty Remarks.1 P21107010017 HOUSING FLYWHEEL-SAE 3 ASSY.GA 1 1..2 P21107010014 FLYWHEEL HOUSING SAE-3 1 2..2 602000501240 HEX.SCREW 8 M12X40 8.8 3..2 141103400054 PLAIN WASHER 8 M12 200HV 4..2 104960650160 OILSEAL 130-160-12 1 5..2 P21108530114 GASKET, FLYWHEEL HSG 1 6..2 141103400044 PLAIN WASHER 3 M10 200HV 7..2 602012021030 STUD 3 M 10X30 8.8 8..2 602100540100 HEX. NUT M10 DIN 934 3 M-10 9..2 141103550064 PLUG MPU - 5/8" - 18 UNF 2 Doc no. 141100064024 Page 42
LUB OIL HEADER Doc no. 141100064024 Page 43
Ref Level Part Description Qty Remarks.1 P21109400017 LUB OIL HEADER & OIL FILTER GA 1..2 P21109400016 OIL COOLER & HEADER ASSEMBLY 1 1...3 P21107520014 OIL HEADER MACHINED 1 2...3 P21108520014 GASKET OIL COOLER OVAL 2 3...3 P21109400015 OIL COOLER CARTRIDGE 1 4...3 602000100855 HEXBOLT 4 M8X55 8.8 5...3 141103400034 PLAIN WASHER 4 M8 200HV 6...3 P06962970002 RELIEF VALVE ASSLY 1 7...4 P06962970001 RELIEF VALVE BODY 1 8...4 P21102401504 RELIEF VALVE SPRING G11 1 9...4 P03250100001 STEEL BALL 1 DIA 17MM 10...4 P21103420024 RELIEF VALVE CAP 1 11...3 602060501415 HEX PLUG M14X1.5 2 12...3 604920101620 COPPER WASHER 1 A/16-20X1.5 13...3 141103510825 FLANGED BOLT 10 M8X25 8.8 14...3 604920101420 CU.WASHER 2 15...3 604920102227 CU.WASHER 1 A22X1.5X27 16...3 604920102530 CU-WASHER 1 17...3 P02041002018 ALLEN PLUG 2 M20X18 MM 18...3 P04041110001 ADAPTOR M24X1"UNF 1 19..2 605411880008 LUB OIL FILTER(232V12) 1 20..2 P21108530054 GASKET BETWEEN HEADER AND CRANKCASE 1 Doc no. 141100064024 Page 44
SHEET METAL OIL SUMP Doc no. 141100064024 Page 45
Ref Level Part Description Qty Remarks.1 141101150017 4G11 SHEETMETAL OIL SUMP ASSLY 1 1..2 141101150015 SHEETMETAL OIL SUMP 4G11 1 2..2 602060501815 HEX HD PLUG 1 M18X1.5X17 3..2 604920101824 CU.WASHER (1.5MM) 1 4..2 602000500815 HEX SCREW 26 M8X16 8.8 5..2 141103400034 PLAIN WASHER 26 M8 200HV 6..2 P21103290054 DIPSTICK FOR 4G11 SHEETMETAL SUMP 1 Doc no. 141100064024 Page 46
STARTER Ref Level Part Description Qty Remarks 1.1 000707530229 STARTER 12V*6M14*26935113A 1 Doc no. 141100064024 Page 47
TURBO CHARGER Doc no. 141100064024 Page 48
Ref Level Part Description Qty Remarks.1 141106034227 TURBO & ATTACHMENTS FOR 125 KVA CPCBII 1 1..2 P05292000081 TURBO TR 59 2.471N-6.11 4G11TAG3 1 2..2 141108530544 GASKET BETWEEN EXHAUST MANIFD & TURBO S 1 3..2 102011070834 STUD-M8X34 LONG (ST.STEEL) 4 4..2 141103400034 PLAIN WASHER 4 M8 200HV 5..2 602100540081 HEXNUT COPR.PLATED M8 10G 4 -..2 P21108510024 GASKET, AIR INTAKE MANIFOLD END SIDE 1 6..2 141103510825 FLANGED BOLT 4 M8X25 8.8 3..2 102011070834 STUD-M8X34 LONG (ST.STEEL) 4 7..2 P21108530384 GASKET FOR TR65 TURBO 92 PCD 1 8..2 141109014035 TURBO OIL DRAIN PIPE (4G11TAG3) 1 9..2 604920101824 CU.WASHER (1.5MM) 1 10..2 P21109010105 TURBO OIL INLET PIPE SIDE OPEN 1 11..2 604920101420 CU.WASHER 1 12..2 P21108530184 GASKET, T/C OIL SUPPLY 1 13..2 141108530514 GASKET TURBO DRAIN 1 6..2 141103510825 FLANGED BOLT 4 M8X25 8.8 4..2 141103400034 PLAIN WASHER 4 M8 200HV 5..2 602100540081 HEXNUT COPR.PLATED M8 10G 4 6..2 141103400034 PLAIN WASHER 4 M8 200HV 14..2 P21103550084 ADAPT. TURBO IN 1 M18,M22 15..2 P21103550074 ADAPT. TURBO IN 1 M14,M16 16..2 P21103550034 ADAPTOR T/C OIL DRAIN 1 17..2 604022110070 SS V BAND 70DIA 3 SEGMENT 1 18..2 141109210054 EXHAUST ELBOW MACH. 125kVA 1 Doc no. 141100064024 Page 49
PIPING OF CAC & RADIATOR Doc no. 141100064024 Page 50
Ref Level Part Description Qty Remarks.1 141109424617 PIPING FOR 125 KVA ENGINE WITH YOUNG RAD 1 1..2 141109424605 CAC OUTLET PIPE 125 KVA YOUNG RADIATOR 1 2..2 141106374415 SUPPORT BRACKET FOR RADIATOR 125 KVA 1 3..2 141109210034 ADAPTOR PIPE-COMP.TO CAC INLET FINISH 1 4..2 141109426034 PIPE WATER (THERMO-RAD) 1 5..2 141108610314 HOSE THERMO - RAD 6G11 1 6..2 141109424595 CAC INLET PIPE 125 KVA YOUNG RADIATOR 1 7..2 141108616034 HOSE WATER OUTLET THERMO SIDE 1 8..2 141108616024 HOSE 100IDX100 L 3 9..2 P21109770014 U CLAMP FOR ENGINE INLET PIPE 2 10..2 141109776014 U CLAMP DIA 105 2 11..2 141103400034 PLAIN WASHER M8 200HV 8 12..2 602100540080 HEX. NUT M8 DIN 934 8 13..2 141106374425 SUPPORT BRACKET FOR AIR INLET BEND 125 1 14..2 141103304014 SLEEVE FOR TURBO COMP OUTLET 1 15..2 141108616014 HOSE 63.5IDX65 L 1 16..2 104015150104 T BOLT CLAMP TB104 6 17..2 604015360380 HOSE CLIP40-60(2X)9THK. 3 18..2 104015150034 T BOLT CLAMP TB34 1 19..2 104015150054 T BOLT CLAMP TB54 2 20..2 141108610324 HOSE RAD - C/CASE IN PIPE 6G11 1 21..2 141103400054 PLAIN WASHER M12 200HV 4 22..2 602100540120 HEX. NUT M12 DIN 934M-10 4 -..2 602000500820 HEXSCREW=M8X1.25X20 8.8CL 2 11..2 141103400034 PLAIN WASHER M8 200HV 2 -..2 606500110005 A V MOUNTING-AVDO/4030/A 4 23..2 141109424615 WATER INLET PIPE 125 KVA YOUNG RADIATOR 1 -..2 602007040825 CAPSCREW=M8X1.25X25 12.9 2 -..2 602150610841 RING WASHER D/234 2 24..2 141103510825 FLANGED BOLT M8X1.25X25 8.8 1 25..2 602000501025 HEXSCREW=M10X1.5X25 8.8CL 1 -..2 602000500820 HEXSCREW=M8X1.25X20 8.8CL 2 11..2 141103400034 PLAIN WASHER M8 200HV 3 -..2 141103400044 PLAIN WASHER M10 200HV 1 Doc no. 141100064024 Page 51
Ref Level Part Description Qty Remarks 26..2 604015300650 HOSECLIP 60-80/3X 2 27..2 102011070834 STUD-M8X34 LONG (ST.STEEL) 3 11..2 141103400034 PLAIN WASHER M8 200HV 3 12..2 602100540080 HEX. NUT M8 DIN 934 3 Doc no. 141100064024 Page 52
WATER INLET PIPE Doc no. 141100064024 Page 53
Ref Level Part Description Qty Remarks.1 141109424127 WATER INLET CONNECTION ASSEMBLY 1 1..2 141108614114 HOSE-WATER INLET CONNECTION 1 -..2 141108614124 HOSE WATER INLET CONNECTION 1 2..2 141109424335 PIPE WATER INLET CONNECTION 1 3..2 604015300220 HOSE CLIP 25-40/1X 4 -..2 602000500820 HEXSCREW=M8X1.25X20 8.8CL 2 -..2 141103400034 PLAIN WASHER M8 200HV 2 Doc no. 141100064024 Page 54
WATER INLET MANIFOLD Doc no. 141100064024 Page 55
Ref Level Part Description Qty Remarks.1 141109100028 WATER MANIFOLD PLASTIC 4G11 1..2 141109100026 WATER MANIFOLD PLASTIC 4G11 1 1...3 141109104007 WATER MANIFOLD ASSLY PLASTIC 4G11 1 2...3 P05250100002 THERMOSTAT ELEMENT 1 3...3 602060501415 HEX PLUG 1 M14X1.5 4...3 604920101420 CU.WASHER 3 5...3 141103400024 SPL.CU.WASHER 1 6..2 141103510825 FLANGED BOLT 8 M8X25 8.8 7..2 P21108610024 HOSE DIA31.5 W/BYPASS G11 1 8..2 104015150040 KLIPCO SS W3/ IS 4762/ 1X 2 Doc no. 141100064024 Page 56
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 31 10 FRONT COVER ASSEMBLY 33 11 FUEL PUMP ASSEMBLY 35 12 FUEL-OFF SOLENOID ASSEMBLY 37 G 13 GEAR TRAIN ASSEMBLY 38 14 GEAR END CASING ASSEMBLY 40 15 HOUSING ASSEMBLY 42 L 16 LUB OIL HEADER ASSEMBLY 44 S 17 SHEET METAL OIL SUMP 46 18 STARTER 48 T 19 TURBO CHARGER ASSEMBLY 49 W 20 WATER INLET PIPING ASSEMBLY 51 21 WATER INLET MANIFOLD 53 Doc no. 141100064024 Page 57