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Operational and Maintenance Manual G11 Series

     

Jalandhar 

M/s Punjab Power 
Solutions 

Shop No. 4&5, Near Bassi 
Auto Clinic 
Lamba Pind, G.T. Road , 
Bye Pass 
Jalandhar-144004 

Mr. Krishan Kumar 
Mobile: 9872288444 , 
9872788444 
[email protected] 
0181-2421550 (O) 

Jammu and 
Kashmir 

Jammu-Tawi 

M/s.Fairdeal 
Enterprises 

5, Exchange Road, 
Jammu-Tawi Pin: 180001 

Mr.D.L.Chopra 
Mr.Y.Chopra 
Mobile: 9419183626 
[email protected] 
[email protected] 
0191-2543712 (O) 
0191-2473057 (R) 
Fax: 0191-2543712(tele Fax) 

Leh - Ladakh 

M/s.National 
Engineering 

Skalzangling, Airport Road 
Opp:Post Office 
Leh - Ladakh-194 101 

Mr.Vinod Malik 
9419179110 
national.engineering.leh@gmail. 
com 
9419179110 
9560163737 

Srinagar 

M/s Asian 
Automobiles 
Engineers, 

Shop 37 Batmaloo Adda 
 Srinagar,J&K 190009 

Mr. Mazid 
Mobile No.-
09419088686,09419002317 
[email protected] 
0194-2455916 (O) 

SOUTH  REGION 

Chennai 

GREAVES COTTON 
LTD 

Wavoo Mansion, 6

th

 floor 

48 (old no.39) Rajaji Salai 
Chennai- 600001 

Tel- 91-44-25255200(O), 
25224571, Fax- 91-44-25224557 

Mr. Darshan Desai 

General Manager 

Chennai Office 

Tel-044-25224571(O) 
Mob:- 09176832881 
Tel-044- 24464955 ® 
Mob- 9176832881 
[email protected] 

Mr. K I Sahayaraj 

Manager Marketing 

Chennai Office 

Tel- 044-25251351(O) 
Tel - 044 - 26281674 
Mob-09176832884 
[email protected] 

Mr. G.V. 
Subramaniam 

Asst Manager Service 

Chennai Office 

Tel- 91-44-25255200(O) 
Mob - 09176921132 
venkatasubramanian.g@ 
greavescotton.com 

6

5

Summary of Contents for 3G11 Series

Page 1: ...MANUAL 3G11 4G11 and 6G11 Series of engines GREAVES COTTON LTD Diesel Engines Unit Chinchwad Pune 411019 India Tel 91 20 27473564 267308200 Fax 91 20 27472276 Mail ID gensetcare greavescotton com Visi...

Page 2: ...Operation and Maintenance Manual For 3G11 4G11 and 6G11 Series Engines 3G11 Series Engine 4G11 Series Engine 6G11 Series Engine...

Page 3: ...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...

Page 4: ...the D G Set is not as per the CPCB approved drawings If GOEM has his own approved design through authorized agencies and is adversely affecting performance of engine If the D G set is installed and is...

Page 5: ...r components indicating instruments Protection relays and control fuses Claim under warranty shall be summarily rejected if the defects are not notified within warranty period specified above and lodg...

Page 6: ...ons for 6G11 Series Engine 10 2 14 Dimensions and weight 3G11 Series Engine 11 2 15 Dimensions and weight 4G11 Series Engine 11 2 16 Dimensions and weight 6G11 NAx 11 2 17 Engine Lifting Instructions...

Page 7: ...3 Checking Oil Level 30 7 1 4 Changing Oil Filter with oil 31 7 2 Maintenance of Fuel System 31 7 2 1 Fuel Filter 31 7 2 2 Fuel Strainer 32 7 2 3 Fuel Injection Pump 32 7 2 4 Injector NOP Adjustment...

Page 8: ...Operational and Maintenance Manual for G11 Series Engines Modifications summary Modification No Document Number Date Details of Modifications Page No 00 141190060057 12 07 13 New Release...

Page 9: ...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...

Page 10: ...2 3 Engine Orientation of 4G11 Series Engine Fig 5 Engine Orientation 2 5 Engine Orientation of 6G11 Series Engine Fig 7 Engine Orientation 2 2 Cylinder Nomenclature Fig 4 Cylinder Nomenclature 2 4 Cy...

Page 11: ...9 Engine nomenclature system Fig 9 Engine nomenclature Example 4G11TAG1 Four cylinder turbocharged COP rating 4G11TAG2 Four cylinder turbocharged COP rating 4G11TAG3 Four cylinder turbocharged COP rat...

Page 12: ...spirated Naturally Aspirated Turbo Charged Turbo Charged Turbo Charged Turbo Charged Turbo Charged Turbo Charged Charged after cooled Charged after cooled Charged after cooled Charged after cooled Cha...

Page 13: ...ow 4 Air filter 5 Cylinder head 6 Fuel pump 7 Oil filler cap 8 Blow by pipe 9 Oil sump 10 Engine foot 11 Flywheel housing 12 Fuel filter 13 Starter 14 Fan 15 Lifting hook 16 Fuel pipe Fig 11 3G11 Seri...

Page 14: ...nator 3 Starter 4 Oil filler cap 5 Fuel pump 6 Fuel feed pump 7 High pressure pipe 8 Engine foot 9 Water in 10 Water out 11 Fan 12 Air filter bracket 13 Stop lever Fig 13 4G11 Series engine 1 Flywheel...

Page 15: ...Operational and Maintenance Manual G11 Series Notes 7...

Page 16: ...el pump 7 Fuel feed pump 8 High pressure pipe 9 Engine foot 10 Water out 11 Water inlet manifold 12 Air filter bracket 13 Stop lever 14 Throttle lever 15 Air inlet pipe Fig 17 6G11 Series engine 1 Fly...

Page 17: ...xhaust out 3 Air inlet 4 Cylinder head 5 Oil sump 6 Belts 7 Breather 8 Alternator 9 Oil drain plug 10 Centrifugal Filter 11 Lifting bracket Fig 19 6G11 Series engine 1 Water Inlet 2 Water manifold 3 E...

Page 18: ...e layout drawing Engine weight 650 kg Flywheel flange SAE1 14 2 17 Engine Lifting Instructions Fig 22 Lifting Hook for 3G11 Engine Take all safety precautions while lifting and moving the engine Only...

Page 19: ...nents 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 2 18 Transport packing and storage 2...

Page 20: ...1 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...

Page 21: ...ecommends the use of SAE 15W40 Lub oil with API CH 4 CES 20071 CES 20076 classification for all Greaves engines to get the various advantages and optimum performance from the engine This oil has a min...

Page 22: ...ecommends the use of SAE 15W40 Lub oil with API CH 4 CES 20071 CES 20076 classification for all Greaves engines to get the various advantages and optimum performance from the engine This oil has a min...

Page 23: ...an drive system and is not mounted on the water pump The water also cools lube oil in the lube oil cooler A thermostat 74 C start to 82 C full open controls the water temperature The radiator has a pr...

Page 24: ...p 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 thr...

Page 25: ...ly friendly way Fig 35 Drain Plug on Crankcase Fig 36 Drain Plug on Oil Cooler Header 3 2 8 Thermostat element replacement Thermostat is provided in the cooling circuit to attain the stable coolant te...

Page 26: ...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 har...

Page 27: ...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 f...

Page 28: ...o 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 44 Removing air from fuel line Bleeding Process Unscrew feed pu...

Page 29: ...Volts starter and an alternator Fig 45 Starter Fig 46 Alternator 5 2 Electrical Control Panel Control panel has operating controls and indicators for starting stopping and monitoring during operation...

Page 30: ...rnating current is rectified in the alternator regulator fig and constantly regulated to approx 14 2 14 5 v Fig 51 Alternator regulator Connections on the alternator regulator 2 x yellow alternator co...

Page 31: ...ry before performing work on the electrical system Do not mix up the plus and minus poles of the battery Connect the plus cable first and the minus cable afterwards when installing the battery Disconn...

Page 32: ...Operational and Maintenance Manual G11 Series 6 ENGINE OPERATION 6 1 Standard and Typical Operating Conditions 24...

Page 33: ...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 shou...

Page 34: ...he 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 w...

Page 35: ...tically without notice In case of maintenance it is necessary to put the engine in non AMF mode and remove battery cables before starting maintenance 6 3 Stopping the engine Remove the load from the e...

Page 36: ...y 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...

Page 37: ...For trolley mounted gen set transitional angle of 12 deg is acceptable However gen set should never be run in an inclined position on continuous basis oil change period First oil change after 60hr ne...

Page 38: ...el by dipstick Refer figure 5 1 3 1 and fit the oil filler cap Fig 59 Oil Filling Dispose off the used oil in a proper environmentally friendly way 7 1 3 Checking oil level Fig 60 checking oil level T...

Page 39: ...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 Blee...

Page 40: ...ing and setting Fig 64 Nozzle Testing Description of nozzle testing 7 2 5 Dry Type Air Cleaner The element in the air cleaner needs to be replaced or serviced when maximum allowable restriction has be...

Page 41: ...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 Fig 70 Engine gear train 7 7 Maintenance o...

Page 42: ...ine 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 fr...

Page 43: ...Operational and Maintenance Manual G11 Series 35...

Page 44: ...lean coarse fuel filter Every 500 Hrs 7 Change air filter Every 500 Hrs 8 Change oil filter cartridge Typical change periods are maximum periods Depending on the local conditions these may have to be...

Page 45: ...nce in a year 16 Cleaning up exhaust silencer Or at least once in a year 17 Checking exhaust bellows and change if necessar After 3500 Hrs 18 Checking valve and insert condition change if 19 Calibrati...

Page 46: ...cap with rubber ring Major overhaul should be carried out at 10000 hours or 7 years whichever is earlier Carry out all activities of top overhaul also Except rubber parts and gaskets if metal parts c...

Page 47: ...on assembly if required 39 Checking and changing Con rod small end bush if required 40 Changing fuel pump elements if required To be procured from Bosch authorized dealer 41 Checking all critical fast...

Page 48: ...Operational and Maintenance Manual G11 Series 40...

Page 49: ...hers 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 typica...

Page 50: ...s 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 wi...

Page 51: ...nto 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 t...

Page 52: ...itects 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 s...

Page 53: ...20465952 manish kulkarni greavescotton com Mr M B Kulkarni Service Manager Chembur Office Tel 022 25264711 O Tel 022 28406702 Fax 022 25262622 Mob 9820605381 mb kulkarni greavescotton com Mr Rishikesh...

Page 54: ...OPAL Sandeep Singh Assistant Manager Service Greaves Cotton Ltd BG 1 WR D3 404 Danish Nagar Hoshangabad Road Bhopal 462026 sr singh greavesctton com M 9425603620 NAGPUR Mr Atul Meshram Assitant Manage...

Page 55: ...l 022 27606868 O Tel 022 27606969 O Tel 022 25360643 27602663 response dieselenginerepairs co in Nagpur Akola Amravati Vardha Buldhana Buldhana Nagpur Motors Machineries Subhash Road Nagpur 440018 Mr...

Page 56: ...arketing Pvt Ltd 301 302 Topaz Arked Opp The Imperial Palace Dr Yagnik Road Rajkot 360001 Mr Joseph Rozario Mob 9824222660 cristline rozariogroup com joseph rozariogroup com Tel 0281 2464105 O Tel fax...

Page 57: ...nchyat Near Govt High School Ranjhi Mr Chandra Prakash Sharma Mob 9589196753 Mob 9669445401 Shiv Kumar karanagencies gmail com Raipur Bilaspur Korba Ambikapur Bhilai Rajnandgaon Chattisgad state S S D...

Page 58: ...greavescotto com Mr Atul Aluwalia Dy Genral Manager Chandigarh Mob 0951325885 atul aluwalia greavescotton com Jaipur Mr Mayank Agarwal Asst Manager Sales Jaipur Mob 09460727237 mayank agarwal greaves...

Page 59: ...raina Ring Road New Delhi 110 028 Mr Ansar Ali Mobile 9810621361 radiantpower sify com 011 25777570 O 011 65070489 R M s Power Service Syndicate Gurgaon 596 3 Prem Nagar Sec 12A Near Telephone Exchang...

Page 60: ...Ltd 326 A B 3rd floor Sahara Shopping Centre Faizabad Road Indira Nagar Lucknow 226016 Mr Vinod Sehgal Mobile 9415028353 ftpl sancharnet in 0522 2346292 O 0522 2343705 Tele Fax 0522 2329970 R M s Shri...

Page 61: ...prises com M s Modern Power Engineers Ganga Shahar Road Bikaner M 09982370108 mpejpr rediffmail com Chandigarh M s Power Tech Engineers 760 Ind Area Phase II Ram Darbar Chandigarh 160002 Mr Parshottam...

Page 62: ...el 079 26585709 O Tel 079 65411073 Mob 9825147873 Fax 079 26587783 s barmanray greavescotton com Mr S Banerjee Sr Manager Marketing Kolkata Office Tel 033 40120926 O Mob 9674164481 s banerjee greavesc...

Page 63: ...cotton com Mr S Barpujari Asst Manager Service Guwahati office Mob 9864155225 s borpujari greavescotton com EAST DEALERS WEST BENGAL Kolkatta Stotex Corporation 33 1 N S Road Marshall House 6th Floor...

Page 64: ...ia Mechwell Engineers Kamakhya Umananda Bhawan Opp Axis bank first floor A T Road Guwahati 781001 Mr pakaj S K Bhattacharjee Mob 9435199451 9435111988 mecwelengineers yahoo com Tel 0361 2513724 O Tel...

Page 65: ...Saket Plaza Jamal Road Patna 800 001 Mr Y Rathore Manoj Krishna 9334129421 9835418332 services royal10 gmail com Ph 0612 3261762 Fax 0612 2299233 K K Enterprises shop 114 first floor narayan plaza Exh...

Page 66: ...hilekar Mob 9822043604 Cell 9372007424 Tel Fax 020 24393688 Aurangabad Jalgaon Marathwada Dhule M K Services 303 Labh Chambers Station Road Aurangabad 431005 Nashik 422008 Mr Vinod Apshinde 9372007438...

Page 67: ...Athavia Mob 99779388488 jaymech rediffmail com Surat Kim Hazira Bharuch Ajay Enterprises 1 660 Bundar Street behind Civil Court Nanpura Surat 395001 Ajay Athavia Mob 9825861456 aenterprise rediffmail...

Page 68: ...rma Mob 9425054857 RAJESH Mob 9425059587 U B SHARMA ubsharma indore gmail com Tel 0731 2595407 R Telfax 0731 4090021 Bhopal Sagar Harda Mandideep Jabalpur Hoshangabad Karan Agencies 204 Dynamic Centre...

Page 69: ...1 23318037 O manish trivedi greavescotton com Mr Kapil Saini Asst Manager Sales Delhi Mob 09891442407 kapil saini greavescotton com Mr P S Guleria Asst Manager Service Delhi Mob 09871816336 ps guleria...

Page 70: ...510 0129 2421298 O 0129 2413356 O FAX 0129 2411898 M s R S Powertronix 305 310 Triveni Complex E 10 12 Jawahar Park Laxmi Nagar Vikas Marg Delhi 110 092 Mr D K Sharma Mobile 9312268885 rspowertronix y...

Page 71: ...9839043988 tumen_vs sify com 0542 2412878 O 0542 2419088 tele fax Kanpur Lucknow Faizabad Rai Bareilly Sitapur Allahabad Gonda Balrampur M s Diesel Sales and Service 783 5 W1 Block Saket Nagar Kanpur...

Page 72: ...4491 O 0141 2304179 O 0141 2304429 R Fax 0141 2304179 M S Modern Power Engineers G 8 B Amber Tower S C Road Jaipur 302016 Mr Deepak Sharma Mob 09414055633 09314873633 response indiagensets com deepak...

Page 73: ...k 9419179110 national engineering leh gmail com 9419179110 9560163737 Srinagar M s Asian Automobiles Engineers Shop 37 Batmaloo Adda Srinagar J K 190009 Mr Mazid Mobile No 09419088686 09419002317 asia...

Page 74: ...48 6 2 47 A C Guards P o Box No 9 Hyderabad 500004 Tel 040 23314025 O Tel 040 23316446 O Tel 040 23390544 O Tel 040 23318557 O ks thampan greavescotton com Mr Mathavan Asst Manager Service Hyderabad O...

Page 75: ...V Ganesh Mob 9443258608 Mob 9894054141 Email genservice airtelmail in genservice_madurai yahoo co in Tel 0452 4354141 O Mob 09442200298 Tel 0452 2383336 Fx Tel 0452 4354156 Tirunelveli Gen Service an...

Page 76: ...Srinivas Rao 09849306447 Mr M Gurrayya 09849458509 Email poweron2007 gmail com 040 27541057 O 040 66203318 Tel Fax 040 23530535 09290711456 Vizag D S Enterprises C 5 Classic complex Prakasaraopet Dab...

Page 77: ...6884 O 0484 2367994 O 0484 2367995 Fx 0484 2389020 Kottayam Unique Diesels P Ltd Sree Krishna Complex 12 1016 M L Road Kottayam 686001 Mr Baburaj 09961425002 0481 2300333 O Calicut Electro Diesels 4 6...

Page 78: ...35 1 st Floor 2nd Cross Journalist Colony Bangalore 560 002 Mr Umkanth 9448289870 Email akashuk eth net Tel 080 41513733 O Tel 080 41513734 O Tel 080 41513735 O Fax 080 26704737 Tel Res 080 23481987...

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