Greaves 3G11 Series User manual

OPERATION AND MAINTENANCE 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:[e-mail]
Visit us: - www.greavescotton.com

Operation and Maintenance Manual
For
3G11, 4G11 and 6G11 Series Engines
3G11 Series Engine
4G11 Series Engine
6G11 Series Engine

Operational and Maintenance Manual for G11 Series Engines
Foreword
We thank you for choosing Greaves G11 series engine for your application. G11 series engines are water-
cooled, four-stroke, multi-cylinder, direct injection compression ignition engines. The engines are designed
using modern concepts. The engines are suitable for various off-road applications. In addition to the
performance parameters the engine designers have paid special attention to ease of maintenance, ease of
assembly and disassembly, reliability and standardization.
The engines are compatible with existing emission norms and are capable of achieving the future emission
norms. The rigid construction of engine has reduced the noise and vibration to a very low level. This manual
describes the operating instruction and maintenance schedules of 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 of your engine,
reduce your running cost and reduce the down time. We would like to emphasize the use of only genuine
spare parts for the engine. Use the services of only authorized service dealer for maintenance. Use only
listed lube oils, water additives. Training facility is also available with Greaves where technicians can be
trained.
Continuous improvement may cause changes in this manual. In case the change is important, we make it a
point to inform the owners of the engine. This manual is regularly updated to include these changes. In case
of any queries, problems do not hesitate to contact our service dealer, regional office.
GREAVES COTTON LTD.
Diesel Engines Unit,
Chinchwad, Pune 411019, India,
Tel: (91) – 20 – 27473564, 267308200
Fax: (91) – 20 – 27472276
Mail-ID:[e-mail]
Visit us: - www.greavescotton.com

Operational and Maintenance Manual for G11 Series Engines
Warranty Policy
Warranty Policy for Diesel Engine
A. Warranty Policy (Diesel engines)
Greaves Cotton Ltd. warranty for the machinery is
limited to its faulty design, defective materials/
components and/or workman-ship and is valid until
a period of 15 months from the date of dispatch of
machinery from its Works/Warehouse or one year
from the date of commissioning or completion of
3500 hours of operation, whichever event shall
occur first.
OR
Greaves Cotton Ltd. warranty for the machinery is
limited to its faulty design, defective materials/
components and/or workman-ship and is valid until
a period of 24 months from the date of dispatch of
machinery from its Works/Warehouse or 18
months from the date of commissioning or
completion of 5000 hours of operation, whichever
event shall occur first provided the user of the
machinery uses recommended genuine spare
parts including “Greaves Maxtherm“ Lube Oil &
Coolant wherever applicable and use of genuine
Air Filter element and Lube Oil Filter element
purchased only from Authorized Dealers of
Greaves Cotton Ltd.
The foregoing warranty is not applicable in the
event, interalia, if:
•The machinery has been stored improperly
and not protected from adverse weather
conditions of any nature.
•Assembly of the Gen set is not carried out
as per the recommendation.
•Canopy manufactured and supplied along
with 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 in use
without approved acoustic enclosure
(canopy).
•The machinery has not been installed
strictly as per the recommendations of
Greaves Cotton Ltd. and operated in
accordance with the instructions contained
in the Greaves Cotton Ltd. operational
manual.
•The defective/improper fuel, lubricants,
coolants and any of their associated
systems are utilized
•Unauthorized person carries out repairs
and alterations.
•The maintenance of the machinery is not
strictly done as per the procedure detailed
in Greaves Cotton Ltd. operator’s
handbook/instruction manual.
•Improper tools and equipments are utilized
at any stage during erection,
commissioning and maintenance.
•During operation, the engine is improperly
shut down or happened to over speeding
or is subjected to misuse, negligence or
accident.
•Failure in any way results from use of
components / parts not manufactured or
not authorized by us for use on our engine.
•If the engine is improperly stored beyond
period of six months without recommended
long storage treatment and used without
recommended de-preservation.
•The warranty shall not apply to fair wear
and tear of the individual components or
damages due to the negligence or
improper handling by the purchaser or his
employees or agents or due to damage by
any cause beyond our control.
•The warranty does not apply to defect
arising due to default in periodic preventive
maintenance and lapse in the use of

Operational and Maintenance Manual for G11 Series Engines
recommended spare parts including Lube
Oil & Coolant wherever applicable.
B. Terms of warranty
•The components having shelf life like
rubber components, belts, hoses and
replacement filters / consumables which
are normally maintenance spares are not
covered within the scope of this warranty.
•In cases of complaints on proprietary
bought out items, our warranty is limited to
the extent of warranty of the manufacture.
•All goods are supplied on the condition
that under no circumstances we undertake
liability for the indirect or consequential
loss or damage of any nature.
•Warranty in respect of following items will
be restricted to 1000 hours of operation or
Three months, whichever shall occur first.
•Meters, battery charging alternator
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
lodged within 3 days of the expiry of the
warranty period.
•The new or repaired part of parts will be
delivered free of cost Ex-works Chinchwad
Pune. Any additional delivery cost to be
borne by the purchaser.
•In respect of any warranty claim accepted
by us, we shall arrange to replace or repair
relevant and respective parts free of cost
to the customer. If parts are replaced, the
defective part shall be property of Greaves
Cotton Ltd. In any case, wherever the
parts are supplied with free charges,
Greaves Cotton Ltd. shall not be liable for
any fitment and / or other charges.
•Greaves Cotton Ltd. shall not be
responsible for replacement of the
complete unit under any circumstances. In
case of any warranty claim, the
responsibility of Greaves Cotton Ltd. shall
be limited to the defective parts.

Table of Contents
Page No.
Preface ....................................................................................................................................................... i
Warranty policy ........................................................................................................................................ ii
Modification summary ............................................................................................................................ iii
Table of contents..................................................................................................................................... iii
Section 1.General............................................................................................................................. 1
1.1 Safety .................................................................................................................................... 1
1.2 Operation Guidelines .............................................................................................................. 1
1.3 Maintenance Guidelines ......................................................................................................... 1
Section 2. Engine Description ......................................................................................................... 2
2.1 Engine Orientation of 3G11 Series Engine ............................................................................. 2
2.2 Cylinder Nomenclature ........................................................................................................... 2
2.3 Engine Orientation of 4G11 Series Engine ............................................................................. 2
2.4 Cylinder Nomenclature for 4G11 engine ................................................................................. 2
2.5 Engine Orientation of 6G11 Series Engine ............................................................................. 2
2.6 Cylinder Nomenclature for 6G11 engine ................................................................................. 2
2.7 Engine Nameplate .................................................................................................................. 3
2.8 Location of the Nameplate ..................................................................................................... 3
2.9 Engine nomenclature system ................................................................................................. 3
2.10 Engine Techical Specification ............................................................................................... 4
2.11 Engine Illustrations for 3G11 Series Engine .......................................................................... 6
2.12 Engine Illustrations for 4G11 Series Engine.......................................................................... 7
2.13 Engine Illustrations for 6G11 Series Engine.......................................................................... 9
2.13.1 Engine Illustrations 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 ................................................................................................... 11
2.18 Transport, packing and storage .......................................................................................... 12
2.18.1 Safety notes for transport ................................................................................................ 12
2.18.2 Transport inspection ........................................................................................................ 12
Section 3. Systems ......................................................................................................................... 13
3.1 Lubrication System .............................................................................................................. 13
3.1.1 Engines lubrication system ............................................................................................... 13
3.1.2 Permissible engine inclination ........................................................................................... 14
3.2 Engine Cooling Systems ...................................................................................................... 15
3.2.1 G11 – Series Engine Cooling System .............................................................................. 15
3.2.2 G11 – Series Cooling System Data.................................................................................. 16
3.2.3 Water Specification .......................................................................................................... 16
3.2.4 Coolant Additives Specification ......................................................................................... 16
3.2.5 Filling Up Coolant on ANew Installation ........................................................................... 16
3.2.6 Topping up Coolant In An Already Installed Engine ........................................................... 16
3.2.7 Draining the System ........................................................................................................ 17
3.2.8 Thermostat Element Replacement ................................................................................... 17
3.2.9 Water Pump..................................................................................................................... 18
3.2.10 Cleaning Radiator / CAC ................................................................................................ 18
Section 4. Fuel System .................................................................................................................. 19
4.1 G11 – Series Engine Fuel System ....................................................................................... 19
4.2 Trapped Air Removal from the System ................................................................................. 20
Section 5. Electrical Systems ........................................................................................................ 21
i

5.1 Starter / Alternator ................................................................................................................ 21
5.2 Electrical Control Panel ........................................................................................................ 21
5.3 Battery ................................................................................................................................. 21
5.4 Alternator ............................................................................................................................. 22
5.5 Alternator regulator............................................................................................................... 22
5.6 Operating conditions ............................................................................................................ 22
5.7 Danger and cause of failure .................................................................................................. 23
Section 6. Engine Operation ........................................................................................................ 24
6.1 Standard and Typical Operating Conditions .......................................................................... 24
6.2 Starting the Engine ............................................................................................................... 25
6.2.1 Safety Instructions ............................................................................................................ 25
6.2.2 First time start after installation ........................................................................................ 25
6.2.3 In case of key start ........................................................................................................... 26
6.2.4 In case of push button start............................................................................................... 27
6.2.5 AMF operation start up...................................................................................................... 27
6.3 Stopping the engine .............................................................................................................. 27
6.4 Safety stop .......................................................................................................................... 27
6.5 Running in ............................................................................................................................ 28
Section 7. Service and Maintenance .......................................................................................... 29
7.1 Maintenance of Lube oil system .......................................................................................... 29
7.1.1 General ............................................................................................................................. 29
7.1.2 Changing Lube Oil ............................................................................................................. 30
7.1.3 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 ................................................................................................... 33
7.2.5 Dry Type Air Cleaner ......................................................................................................... 33
7.3 Inspection and Checking of V Belt Tension .......................................................................... 33
7.4 Checking and Adjustment of Valve Clearance ...................................................................... 33
7.5 Flywheel Run out ................................................................................................................. 33
7.6 Timing Gear ......................................................................................................................... 33
7.7 Maintenance of Cooling System........................................................................................... 33
7.8 Battery Checking Instructions .............................................................................................. 33
7.9 Electronic Governor and Actuator Fitment ............................................................................ 34
7.10 Maintenance Schedule ....................................................................................................... 35
Section 8. Engine Preservation ..................................................................................................... 40
8.1 Engine preservation during prolonged period of non-usage ................................................... 40
8.2 Putting a preserved engine back into operation ................................................................... 41
Section 9. Installation Do’s and Don’ts......................................................................................... 42
9.1 Do’s ..................................................................................................................................... 42
9.2 Don’ts .................................................................................................................................. 42
Section 10. GCL Regional office and dealer addresses ............................................................. 43
Section 11. Index ............................................................................................................................ 70
ii
Table of Contents, continued

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 ---

Operational and Maintenance Manual G Series
1. GENERAL
1.1 Safety
Safety of your personnel, property and equipment
should be the first priority during installation,
operation, maintenance of your engine and
equipment.
The engine can cause harm in the following ways
against which your personnel have to guard.
Sr.
No Hazard Example
1. Rotating parts
Flywheel, pulleys,
radiator fan
2. High
temperature
Exhaust related
parts, exhaust
gases, water, oil
3. Hot or
hazardous
sprays
Fuel, lube oil, water,
exhaust leaks or
hose/pipe bursts
4. Electrical
shocks/sparks Alternators, starters,
control panels,
battery wirings
5. Loose objects
Loose parts flying
out (likelihood
especially after
maintenance)
6. Poison
Additives, diesel,
lube oil, exhaust
gases can cause
damage if
consumed or
inhaled
•Never get near the engine while it is
running wearing loose items like tie, long
chains, scarf, long loose clothes, tags with
mobile phones etc.
•Display safety instruction clearly in the
operating area.
•Make the operating persons aware of the
safety related issues.
•Provide necessary 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 is familiar
with the basic mode of operation of four
stroke combustion engine and is able to
follow technical issues reasonably well.
The text has been kept therefore as short
as possible for clarity and is backed by
photographs and sketches.
2. Read the instructions carefully before
installation of the engine or equipment.
3. In case of any doubt or difficulty, seek help
from authorized service dealers.
4. Your engine needs clean air, clean fuel,
clean lube oil and clean coolant.
5. Giving attention to these factors improves
the life of your equipment, reduces the
running costs, and also increases the
mean time between failures.
1.3 Maintenance Guidelines
1. Please read the maintenance instructions.
Seek services of authorized service.
Dealers if needed.
2. Follow maintenance schedules.
3. Plan your maintenance.
4. Always use genuine spare parts, listed
lube oil, listed additives and unadulterated
fuel from reputed agency.
5. Always use correct tools.
6. Always carry out maintenance in a clean
area.
Follow good engineering practices during
maintenance.
1

Operational and Maintenance Manual G Series
2.ENGINE DESCRIPTION
2.1 Engine Orientation of 3G11 Series Engine
Fig. 1 Engine Orientation
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
2.4Cylinder Nomenclature for 4G11 engine
Fig.6 Cylinder Nomenclature
2.6 Cylinder Nomenclature for 6G11 engine
Fig. 8 Cylinder Nomenclature
2

Operational and Maintenance Manual G Series
2.7 Engine Nameplate
Fig.2 Engine Name Plate
2.8 Location of the Nameplate
Fig.3 Location of Nameplate
2.9 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 rating
4G11 TP : Four cylinder turbocharged PRP rating
4G11 NA : Four cylinders COP rating naturally
aspirated 4G11Tx -
x-Represents model G1 – 4G11T , G2 – 4G11T
3

Sr.No Parameter Unit
1Engine Model - 3G11NAG1 3G11NAG2 3G11TG4 3G11TG1 3G11TG2 3G11TG3 4G11TG1 4G11TG2 4G11TAG1 4G11TW1 4G11TAG2 4G11TAG3 6G11TAG1 6G11TAG2 6G11TAG3 6G11TAG4
2Genset kVA Rating Prime - 25 30 35 40 45 50 62.5 75 82.5 82.5 100 125 140 160 180 200
3Alternator efficiency (%) 86.9 88.9 88.35 88.7 89 88.5 90.85 90.9 90.5 90.5 90.6 92.5 92.3 92.5 92.9 93.1
4kWe 20 24 28 32 36 40 50 60 66 66 80 100 112 128 144 160
5kWm rated net 23.01 27.00 31.69 36.08 40.45 45.20 55.0 66.0 72.9 72.9 88.3 108.1 121.3 138.4 155.0 171.9
6kWm rated gross 24.3 28.0 33.1 38.2 43.4 47 61.0 69.1 77.2 77.2 93.4 114.0 127.2 144.5 163.0 178.8
7Rated speed RPM 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500
8Bore X Stroke mm 105x130 105x130 105x130 105x130 105x130 105x130 105x130 105x130 105x130 105x130 105x130 105x130 105x130 105x130 105x130 105x130
9Engine Configuration - Inline Inline Inline Inline Inline Inline Inline Inline Inline Inline Inline Inline Inline Inline Inline Inline
10 Working principle - 4-Stroke 4-Stroke 4-Stroke 4-Stroke 4-Stroke 4-Stroke 4-Stroke 4-Stroke 4-Stroke 4-Stroke 4-Stroke 4-Stroke 4-Stroke 4-Stroke 4-Stroke 4-Stroke
11 No. of cylinders - 3 333334444444 6 6 6
12 Total swept Volume Ltr 3.375 3.375 3.375 3.375 3.375 3.375 4.5 4.5 4.5 4.5 4.5 4.5 6.75 6.75 6.75 6.75
13 BMEP (At rated Power) Bar 5.76 6.64 5.88 6.79 7.71 8.35 10.84 12.28 13.72 13.72 16.60 20.26 15.07 17.1 19.3 21.19
14 Combustion type: DI / IDI - DI DI DI DI DI DI DI DI DI DI DI DI DI DI DI DI
15 Cooling - Water Cooled Water Cooled Water Cooled Water Cooled Water Cooled Water Cooled Water Cooled Water Cooled Water Cooled Water Cooled Water Cooled Water Cooled Water Cooled Water Cooled Water Cooled Water Cooled
16 Compression ratio - 18 18 16.2 16.2 16.2 16.2 16.2 16.2 16.2 16.2 16.2 16.2 16.2 16.2 16.2 16.2
17 No. of valves / cyl. - 2 222222222222 2 2 2
18
Aspiration
-
Naturally
Naturally
Turbo
Turbo
Turbo
Turbo
Turbo
Turbo
Turbo
Charged after
Turbo
Charged after
Turbo
Charged after
Turbo
Charged after
Turbo
Charged after
Turbo Charged
Turbo Charged
Turbo Charged after
2.10 Engine Technical Specification - Genset Application 50Hz ( CPCB Stage I)
Details
18
Aspiration
-
Naturally
Aspirated
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
Charged after
cooled
Turbo Charged
after cooled
Turbo Charged
after cooled
Turbo Charged after
cooled
19 Governing type - Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical Mechanical
20 Governing - A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1 A1
21 Direction of rotation (From
flywheel side) -Anti clockwise Anti clockwise Anti clockwise Anti clockwise Anti clockwise Anti clockwise Anti clockwise Anti clockwise Anti clockwise Anti clockwise Anti clockwise Anti clockwise Anti clockwise Anti clockwise Anti clockwise Anti clockwise
22 SFC at rated power * gm/kW.h 230 230 225 225 225 223 217 217 208 208 206 199.8 202 202 202 202
23 SFC at 75 % power * gm/kW.h 221 221 231 231 231 222 220 220 208 208 204 196.6 200 200 200 200
24 SFC at 50 % power * gm/kW.h 235 235 235 235 235 230 231 231 220 220 211 199.1 206 206 206 206
25 Weight (Dry) kg 380 380 390 390 390 390 465 465 485 485 485 485 650 650 650 650
26 Flywheel housing/Flywheel - SAE 3/11.5" SAE 3/11.5" SAE 3/11.5" SAE 3/11.5" SAE 3/11.5" SAE 3/11.5" SAE 3/11.5" SAE 3/11.5" SAE 3/11.5" SAE 3/11.5" SAE 3/11.5" SAE 3/11.5" SAE 1/14" SAE 1/14" SAE 1/14" SAE 1/14"
27 Emission compliance -
Components
28 FIP type -
29 Injector -
30 Water pump -
31 Lub oil pump -
32 Cylinder head -
33 Crank shaft -
34 Fan drive -
35 Lub oil cooler - NA NA
36 Air Cleaner -
37 Engine Starting System -
38 Lub oil filter -
Centrifugal - Gear driven
G rotor - Gear driven
Unit cylinder head
Forged - induction hardened
Independent fan drive arrangement Vee belt
P type
Mechanical
Compliant to CPCB Stage I, Upgradable to CPCB Stage II
Plate type water cooled
Dry Type
12/24V DC
Single element - spin on type
39 Fuel filter -
Fuel circuit
40 Fuel to be used -
41 Fuel filteration micron
42 Max suction lift by feed
pump meter
43 Fuel feed pump pressure Bar
44 Nozzle opening pressure Bar
Lub oil circuit -
45 Lub oil grade -
46 Lub oil sump capacity Ltrs 6 6 8 8 8 8 10 10 10 10 10 10 17 17 17 17
47 Lub oil change period Hrs 500 hrs
IS-1460 2005 cetane 51 S 0.015% Density 0.825
Twin element- coarse + fineSingle element
GREAVES MAXTHERM APICF4 15W40
10
1
1.5
250 +/-10
4
As per IS:1462 2005 with 5% tolerance & SFC fig. are for a well-run in Engine

Operational and Maintenance Manual G11 Series
2.11 Engine Illustrations for 3G11 Series
Engine
Fig. 10 3G11 Series engine
1. Rocker cover
2. Exhaust out
3. Exhaust bellow
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 Series engine
1. Exhaust bellow
2. Starter
3. Engine flywheel
4. Air cleaner
5. High pressure fuel line
6. Water outlet to Radiator/
Heat Exchanger
7. Feed pump
8. Alternator
5

Operational and Maintenance Manual G11 Series
2.12 Engine Illustrations for 4G11 Series
Engine
Fig. 12 4G11 Series engine
1. Cylinder head
2. Battery charging alternator
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
2.
U clamp
3.
Air filter
4.
Gear end casing
5.
Air intake manifold
6.
Flywheel housing
7.
Lub. oil filter
8.
Oil sump
9.
Exhaust out let
10.
Exhaust bend
11.
Fuel Filter
6

Operational and Maintenance Manual G11 Series
Notes
7

Operational and Maintenance Manual G11 Series
2.13 Engine Illustrations for 6G11 Series
Engine
Fig. 16 6G11 Series engine
1.
Cylinder head
2.
Battery charging alternator
3.
Starter
4.
Fuel filter
5.
Oil filler cap
6.
Fuel 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. Flywheel
2. Sensor
3. U clamp
4. Air filter
5. Gear end casing
6. Air intake manifold
7. Flywheel housing
8. Lub. oil filter
9. Oil sump
10. Exhaust out let
11. Exhaust manifold
12. Exhaust bend
13. Crank case
14. Radiator Hose
8

Operational and Maintenance Manual G11 Series
2.13.1 Engine Illustrations for 6G11 Series
Engine
Fig.18 6G11 Series engine
1. Turbocharger
2. Exhaust 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.
Exhaust manifold
4. Lub. Oil filter
5.
Flywheel
6.
Flywheel housing
7. Oil header
8.
Engine foot
9.
Air Cleaner
10. Turbo charger
11.
Exhaust outlet
9

Operational and Maintenance Manual G11 Series
2.14 Dimensions and weight – 3G11 Series
Engine
For overall dimensions see the layout drawing.
Engine weight - 380 kg
Flywheel flange – SAE 3/11.5
Fig. 20 Overall Engine Dimensions
2.15 Dimensions and weight – 4G11 Series
Engine
For overall dimensions see the layout drawing.
Engine weight - 465 kg
Flywheel flange – SAE 3/11.5
Fig. 21 Overall Engine Dimensions
2.16 Dimensions and weight – 6G11NA
For overall dimensions see the 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 trained personnel should
handle the engine. You can consult Greaves
service dealers, if necessary.
Remove water and oil from the engine before
lifting. If your engine has cast iron sump then the
engine can be rested on the sump. For any other
type sump, use blocks under engine feet.
Avoid jerks or abrupt resting of engine. The
engine should never be rested, stored or lifted in
any other direction than upright. The engine
should never be rolled on the ground.
10

Operational and Maintenance Manual G11 Series
Fig. 23 Lifting Hook for 4G11 Engine
The engine is provided with four transportation
feet even if only two feet (gear end) are required
for application. Store the spare feet, (flywheel
end) carefully. Fit those two extra feet before
lifting the engine. The engine should not be
rested on bell housing for long durations.
Use only the eyebolts provided on the engine
crankcase for lifting purpose. The eyebolts are to
be used for lifting engine only. Do not lift engine
coupled with alternator or entire DG set using
these bolts. Ensure that, the
I bolts are
completely engaged before engine is lifted.
Fig. 24 Lifting Hook for 6G Engine
While lifting the engine, use
correct size of
tackles, ropes, chains, cranes, hoists or any other
lifting or transportation device. While lifting or
transportation, the ropes or tackles should be
positioned in such a way that they do not damage
engine components 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
2.18.1 Safety notes for transport
CAUTION!
Damage due to improper transport!
Significant damage to property and injuries to
persons can occur in the case of improper
transport.
Therefore:
•Proceed carefully when unloading the
packages and on delivery and internal
transport and observe the signs and
notices on the packing.
•Only use the attachment points provided.
•Do not remove packing until just before the
installation.
2.18.2 Transport inspection
Check the delivery immediately on receipt for
completeness and transport damage.
If externally detectable transport damage is found,
proceed as follows:
•Do not accept the delivery, or only with
reservation.
•Record the extent of transport damage in
the transport documents or on the delivery
note of the forwarding agent.
•Start complaints procedure.
NOTE!
•Claim any damage as soon as it is
detected.
•Compensation claims can only be
submitted within
•The applicable complaints periods.
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Operational and Maintenance Manual G11 Series
3. SYSTEMS
3.1 Lubrication System
3.1.1 G11 Engine Lub. System
G11 series engines use positive pressurized
lubrication system. The main functions of the
lubrication system are as follows:
•Lubrication of friction related parts.
•To carry away the heat generated by
friction
•To avoid corrosion
•To wash away debris created by friction
wear.
a) The G11 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) Providing oil through push rod lubricates
the rocker assembly. The fuel pump and
turbo chargers are positively lubricated.
The lube oil system is adequately designed to
provide sufficient lubrication, oil change period,
filter element life and minimize lube oil
consumption and running cost.
Fig. 25 Lubrication System of 3G11 Series Engine
Fig. 26 Lubrication System of 4G11 Series Engine
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