Greaves Engine

USER'S MANUAL GREAVES DIESEL ENGINE D3
CONTENTS
01 PREFACE, NOTES
01.1 General
U1.2 Assembly Breakdown"
01.3 Technical Status
01.4 Warranty Claims
01.5 Units System
Part 1; ENGINE DATA AND DESCRIPTION
1. 1 Engine Data
1.2 Overall Dimensions
13 Description of Engine
Part 2 : OPERATION AND POL PRODUCTS
2.1 Preparation for First -Time Operation

2.2 Engine Control
2.3 POL Specifications for Small Size Engines.
Part3 SERVICING
3. 1 : Tools and Expedients
3. 1.1 Other Additives

1 1.2
3. Trouble Tracing Table
1
3. 1.3 Servicing Schedule
1
3. 1.4 Job Sheets for Servicing
1
6
USE R'S MANUAL GRE AV ES DIESEL E NGINE D3
01 DIRECTIONS
01.1 Genera l R emarks

It is a ssumed that the reade r a nd user of th ese Operatin g Instructi ons is famili ar with t he basic
mod e of operation of a four stroke c ombustion engine and is a ble to f o llo w Techn ical Dra wi ngs
reasonably well.
T h e t e x t h a s b e e n k e p t , t h e r e f o r e , a s s hort a s p o s s i b l e f o r t h e s a k e o f c l a r i t y . T h e i n f o r m a t i o n
content is backed by photographs and sectional drawings.
01,2 As s e m b l y B re a k d o w n
1 of these Operating Instructions are broken down in the following assemblies

possible;
00 Separate Parts
01 Crankcase and Oil pan
02 Cylinder Heads
03 Crank Assembly
04 Gear Drive. Cam shaft
05 Fuel System
06 Governor
07 Lubricating system
28 Cooling System
09 Turbocharger
10 Starting System
11 Control and monitoring
1 thes e as semblies are shown in ( he engine s ectional drawings.
The figures are numbe red according to the corresponding sections and in Part 1 - acc ording to
t h e a s s e mb l i e s
Examp le:
Fig No.
Section of Operating Instructions
Assembly
Serial No
Technical Status of these Operating instructions applies to standard design al the time of going
to print. Subsequent changes can result in deviations regarding the type made available Where
differences result from idiomatic usage in German and Foreign language texts. the German text
shall govern . Any legal or other claims are thus excluded
01.4 Warranty claims
Within the scope of our conditions require that all requirements as to fuels, lubricants. Cooling
agents and servicing instructions have been duly observed and carried out
7
USER'S MANUAL GREAVES DIESEL ENGINE D-3
01.5 Measuring Units

The measuring units applied in this Operation Instructions manual are complying with the
International Unit System (Sl).
Symbol Value Unit Denomination Further units Remarks/conversions

I Length m. Meters
A Area M2 um=0.001 mm
V Volume M3
a Plane angle rad Radian * Degree 1 rad = 1 m/m=360
Minute
Second
m Mass Kg Kilogram g (Grams)
{Weight)
J Rotary mass Kgm2 Moment of inertia
J = GD2 0.25
t Time S Second min (Minute)
h (Hour)
Velocity m/s Meter per second m/min(Meter per Distance change per unit
v
Minute} of time
a Acceleration Meter per square Change of speed per unit
Second of time
Standard acceleration
Due to gravity
Gn=9.80665
n Speed 1/s Revolution per second 1/min (revolution per minute)
f Frequency Hz Hertz 1 Hz= 1/S

Vibration per second
i Angular velocity ¦ rad/s O/s (degree per Peripheral speed at
Second) radius 1
i =2 II n
u l/min applies to
I = n x u 1/s
30
F Force N. Newton 1N=1Kgm/s2=1Ws/m
1N=0.10197Kg
G Weight G = m.g
M Torque Nm Moment of a force on
lever arm
1N=0.10197Kgm
P Force of liquids bar Pa (Pascal) 1pa=1N/m2

And gases
Mm WS millimeter 1bar=10 5 pa=10n/cm2
Water gauge =1.0197Kg/cm
E Energy J joule Ws (watt second) 1J = 1 Ws = 1Nm
W Work KW/h (ki lowatt hour) 1kwh=3600 KJ

Q Quantity of heat
p Power W Watt 1W=1J/S=1 Nm/s
=1Kgm2/s
T Temperature K kelvin 'C (degrees Celsius) O c =273.15K
1C=1K(As difference
temperature of t
8
USER'S MANUAL GREAVES DIESEL ENGINE D 3
Prefixes
The units stated overleaf may be provided with prefixes expressing a decimal multiple or a decimal
part of the basic unit
Units for temperatures, angles and time (except for seconds) should be applied without a prefix
The following table is giving some prefixes with abbrevations and value.
Prefix Abbrevation Value
Mega M 105 = 1000000

Kilo K 103 = 1000
Hecto h 102 = 100
Deca da 101 = 10
DECl a 10-1 = 0.1
CertTi L 10-2 = 0 01
Mi Mi 10-3 = 0.001
Micro 10-5 = 0.000001
Equations for engine characteristic values:
1- Mean piston speed
Sxn
cm = —"— mfs 30000
2. Torque
9550x P
MD = .....................-" Nm
N
3. Mean effective pressure
1200x P
pD = .......................-" bar
N
4 Specific fuel consumption
B
b = ................... g/kvVh8431
11 : ................. %
b.
(calculated witn a lower cal. valuo ol J2 7 hJ/g)
s mm Piston stroke
n t/ mm revolutions per minute
p Kw effective power
Vh dm3 Total swept volume
B g/h fuel consumption per hour
9
1/1Part 1 ENGINE DATA AND DESCRIPTION
1.0 Views of Engine
1.1 Engine Data

1.1.1 Explanation of Model Designation
1.1.2 Cylinder Numbering
1.1.3 Construction Data
1.1.4 Adjusting Data
1.1.5 Performance Data
1.1.6 Filling Quantities
1.2 OVERALL DIMENSIONS AND WEIGHTS
1.3 DESCRIPTION OF ENGINE
1.3.0 Function of Engine
1.3.1 Cylinder Crankcase and Oil Pan
1.3.2 Cylinder Heads
1.3.3 Crank Assembly
1.3.4 Gear Drive and Camshaft
1.3.5 Fuel System
1.3.6 Lube. Oil System
1.3.7 Cooling System
1.3.8 Turbo charging System
1.3.9 Starting System
1. 3. 10 Control Pane!
1.3.11 Engine Monitoring
10
1 Engine Data and Description
1.0 Views of Engine
Fig. 1 Engine TBD 3,
1 Radiator fan 7 Injector

2 Dynamo 8 Oil filler neck
3 Sump 9 Tension roller
4 Engine foot 10 Exhaust manifold

5 Starter 11 Cyl head cover
6 Turbo charger 12 Air intake manifold
11
USER'S MANUAL GREAVES GAS ENGINE G2
Engine data and description

1.0 Views of engine
Fig 1001 Generating set, A-Side

.
1 RADIATOR
2 STARTOR
3 DYNAMO
4 TURBOCHARGER
5 AIR FILTER
6 EXHAUST OUT LET
7 FUEL FILTER
8 COVER FOR EXHAUST MANIFOLD
9 THERMOSTAT
12
1 Crankshaft 12 Crankcase ventilation
2 Camshaft 13 Injection pump
3 Camshaft bearing 14 Speed governor
4 Big-end bearing 15 Speed fine adjustment
5 Main bearing 16 Fuel pressure pipe
6 Flywheel 17 Injection pump drive
7 V-belt pulley 18 Injection pump couplin

8 Anti-vibration damper 19 Intake pipe
9 Oil pan 20 Intercooler
10 Lube oil intake pipe 21 Turbo charger
1! Oil drain plug 22 Tacho generator
13
USER'S MANUAL GREAVES GAS ENGINE D3
1. Engine data and description
1.1 Engine data
1.1.1 Type code
1.1.2 Numbering of cylinder Flywheel end
14
USER'S MANUAL GREAVES DIESEL ENGINE D3 1/5
1.1.4 Adjusting data TBD3 V6 TBD3V8 TBD3 V12
Inlet valve clearance mm 0.3 0.3 0.3

Exhaust valve clearance mm 0.5 0.5 0.5
1.1.5 Operating data All values apply to ISO standard performances – blocked (continuous net brake power)
as per DIN 6271 and/or ISO 3046/I
Intake air temperature 27° C Atmospheric pressure 1000 mbar
Relative air humidity 60%
Other operating conditions result in changes of the operating data. (Please do
also refer to test bed certificate.)
TBD3 V6 TBD3V8 TBD3 V12

Rotational speed in min*1 1500 1500 1500
Nominal speed
115 115 115
Ignition speed
Lowest idling speed 650 650 650
Pressure in bar
Compression, min. 23 23 23
Ignition pressure 150 150 150
Lube oil pressure max. 3.6 3.6 3.6
Lube oil pressure at n= 750 min-1 0.8…3 0.8..3 0.8…3
`Temperatures in °C
Cooling water, max. 85 85 8546
Exhaust gas, max.
650 650 650
Lube oil, max. (in oil pan)
120 120 120
0.6 0.6 0.6

Oil consumption, max. g/kWh
1.1.6 Filling quantities in dm 3 TBD3 V6 TBD3V8 TBD3 V12
Cooling water capacity (without radiator) 20 24 35
Lub oil capacity to top notch on

Dipstick by first filling. 22.5 29 60
Oil change capacity 16 16 52
Lub. oil filter capacity 2 3.5 3.5
15
1.2 Dimensions and Weights
Engine Engine Additional Dimension in mm

type weight weight for SAE
worthv
packing kg. A A1 B C D E F
approx.
TBD3V6 1050 kg 275 984 1284 910 366 1140 200 700
TBD3V8 1250 kg 275 1154 1454 910 366 1140 200 700
TBD3V12 2100 kg 275 1600 1850 910 366 1140 200 700
Weights (kg.)
Engine (dry, without extras)
For flexible bearing : Cooling water and oil filled in
With flywheel flange SAE 1
Subject to modification
16
1.3 Description of engine

Being thoroughly informed as to the design and function of the engine provides the
understanding which facilitates handling the engine.
Operating principle
In the reciprocating motion of the engine pistons the following procedures take place in the
individual cylinders, as is the same in any four -stroke diesel engine:
On the induction stroke, the inlet valve is opened. The engine piston speeding downwards
draws in air into the cylinder base (Fig. 5/1).
On the subsequent upward stroke, the air is compressed, causing it to heat up.
Just before top dead centre of the piston fuel is injected into the hot air by the injection pump
via the injector into the cylinder combustion chamber where it ignites and burns (Fig. 5/2).
This results in the pressure increasing in the cylinder combustion chamber speeding the
piston downwards. This is the working stroke. The connecting rod transmits the force to the
rotating crankshaft (Fig. 5/3).
The subseq uent upstroke expels the burnt gases through the open exhaust valve and the
silencer into the atmosphere (Fig. 5/4).
On the next down stroke, air is again drawn into the engine and the above procedures are
repeated.
The energy stored in the flywheel keeps the engine turning steadily.
Fig. 5
Function
17
USERS MANUAL GREAVES DIESEL ENGINE D3
1.3.01 Crankcase and oil pan
These two components form the load-bearing elements of the engine. They absorb the forces
occurring during operation in the cylinder and at the crank assembly.
In addition to the weight of the engine, the crankcase transmits to the foundation the residual
forces and the support forces caused by the torque delivered.
The crankcase accommodates the cylinder liners the crank assembly and the camshaft.
The illustrations below show more details.
Fig. 8 Crankcase
1 Crankcase
2 Cylinder liner
3 Main bearing cover
4 Main bearing shell
5 Thrust bearing for
crankshaft
5 4
Fig. 9 Oil pan
1 Oil pan
2 Dipstick
3 Oil filling neck
18
1.3.03 Crank assembly

The crank assembly is consisting of the crankshaft connecting rod, piston flywheel and torsional-vibration
Damper.
The crankshaft is provided with underslung bearing inside the crankcase.
The counter weights, bolted on the crank webs, a t ensuring the reduction in internal mass actions and therefore,
the discharge of the crankshaft bearing The masses on 6 and 8 -cylinder engines are fully conpensated .by an
Additional rotating mass (mass-balancer shaft).The flywheel serves to reduce the irregular of the crankshaft rotation.
A damper, reducing torsional vibrations , is attached to the opposite end of the crankshaft.
The crankshaft is driven via the connecting rods by the gas forces acting upon the pis tons.
Fig. 1031 Driving mechanism (Example 233 V12)

1 Small-end bushing
2 Connecting rod
3 Gudgeon pin
4 Piston
5 Piston rings
6 Vibration damper
7 Cranking disc
8 V-belt pulley
9 Crankpin
10 Main bearing journal
11 Counterweight
12 Crankshaft
13 Flywheel
19
1.3.02 Cylinder heads

1.3.02- The cylinder heads dose off the combustion chamber towards the top. Each one is attached to the
cylinder crankcase by means of four screws.
Each cylinder head contains the inlet and exhaust valves as well as the injection valve. The inlet and
exhaust valves, provided with valve-rotating appliances, a actuated by the rocker arms, mounted on the
cylinder head.
Particularly for cooling of the valve seat rings, coolant piped through cooling chambers arranged in the
cylinder head. The cooling-water overflow bores are sealed O-rings. Please refer to the following figures for
further detail
Fig. 1021 Cylinder head

1 Inlet pipe wit h integrally casted
cooling water sampling pipe
2 Pushrod
3 Rocker arm bracket with rocker arms
4 Exhaust valve
5 Injection valve
6 Exhaust pipe
7 Inlet valve
Fig. 1022 Cylinder head (section)
1 Injection valve 7 Spring plate

2 Valve springs 8 Valve turn device
3 Rocker arm (Roto cap)
4 Rocker arm bracket 9 Exhaust valve
5 Cylinder head cover 10 Valve seat ring
6 Valve clearance 11 Inlet valve
setscrew
20
1.3.04 Gear drive and camshaft
The camshaft is driven by the gear drive at damper end. i.e. by the crankshaft, from gear 1 via gear 2. An
additional gear 3, also arranged on the crankshaft, serves as a drive for lubricating-oil pump 4.
A gear is also mounted on the crankshaft at flywheel end on 6 and 8-cylinder engines. The additional
balancing shaft, provided for these number? of cylinders respectively involved, is driven by this gear.
(Example, see Figure 1032).
Fig. 1041 Gear drive

1 Crankshaft gearwheel
2 Camshaft gearwheel
3 Oil pump drive gear wheel on
crankshaft
4 Lube oil pump
21
1 Fig. 1032 Mass balance (8-cylinder engine)
2 Mass balance shaft
3 Drive gear
4 Intermediate gear
5 Crankshaft gear
6 Crankshaft
Fig. 1033 Piston

7 Gudgeon, pin
8 Piston
9 Oil scraper ring
10 Plain compression ring
11 Trapezoidal ring
12 Locking ring
13 cooling chamber for
pisto n cooling
22
The cams of the camshaft 5 driven by the gear drive actuate the inlet and exhaust valve 1 (exhaust
valve shown) via mushroom tappets 4, pushrod 3 and rocker arm 2.
Fig. 1042 Valve drive

1 Exhaust valve
2 Rocker arm
3 Pushrod
4 Mashroom tappet
5 Camshaft
23
1.3.05 Fuel system

In order to drive the engine, at every second revolution fuel is injected into the cylinder
chamber just before the piston reaches top dead centre. The fuel ignites and burns in
the compressed-heated air.
By means of the feed pump 8 the fuel is pumped from tank 1 into the injection pump 6
via filter 5. At high pressure the fuel is pumped to the injection valves 9. By means of
the injection nozzles the fuel is squirted very finely into the comb us ti on chamber.
For the purpose of cooling the injection pump 6 more fuel than required for injection is
pumped through the system by the feed pump 8. The surplus fuel is returned to the
service tank via an overflow valve at the injection pump. Any fuel spillage emerging
from the injection valves is fed back to the tank via a separate pipe.
Fig. 1051 Fuel system
1. Tank
2. Overflow pipe
3. Leak-off line
4. Injection pressure line
5- Fuel filter
6. Injection pump
7. Overflow valve
8. Feed pump
9. Injection valve
10. Fuel pre-filter
24
The balance weights are driven by the crankshaft via

gearwheels 3 and 4, the object of the balance
weights being to ensure smooth running of the
engine .
Fig. 10
Gear drive for balance weights
1 Crankshaft
2 Flywhe el
3 Crankshaft gearwheel
4 Balance weight gear
5 Balance weight
The cams 2 of the camshaft 1 driven by the gear

drive actuate the inlet and exhaust valve 5 (exhaust
valve shown) via the pushrod 3 and rocker arm 4.
Fig. 11
Controlling the valves via
the camshaft
6 Camshaft
2 Cams
3 Pushrod
4 Rocker arm
5 Inlet and exhaust valve
25
Fig. 1052 Injection pump on engine
1 Cylinder head
2 Intake pipe
3 Injection pump with governor
4 Stop linkage
5 Electric speed adjustment device
Fig. 1053 Injection pump
1 Fuel supply from filter 10 Roller tappet

2 Overflow valve (Fig.1051, pos.7) 11 Piston
3 Governor 12 Control sleeve
4 Speed adjustment lever 13 Control rod
5 Fuel supply 14 Pump cylinder
6 Fuel feed pump {see also Fig.1055) 11 Inlet drilling
7 Lubricating oil return 16 Delivery valve
8 Pipe to filter 17 Pressure connection to the injection valve
9 Camshaft for injection pump
26
Single acting Fig. 1054 Injection valve

1 Holder for injection valve
2 Delivery pipe connection
3 Edge-type filter
4 Leak-off connection
5 Compression spring
6 Nozzle holder
7 Thrust piece
8 Cap nut
9 Nozzle body
10 Nozzle needle
Fig. 1055 Fuel feed pump
1 Delivery pipe connection

2 Plunger chamber
3 Roller tappet
4 Piston rod
5 Piston spring
6 Intake valve
7 Intake connection
8 Intake chamber
9 Piston
10 Delivery valve
27
USER'S USE USERS MANUAL GREAVES DIESEL ENGINE D3
Fig. 1056 Fuel filter with filter cartridge
1 Fuel inlet pipe

2 Vent screw
3 Fuel return pipe
4 Filter head
5 Filter cartridge
28
1.3.06 Governor
The function of governor is to hold the set engine speed as constant as possible even
when there is a change in engine loading.
This governor, working by measuring centrifugal forces, is mounted on the injection pump.
Any change in load on the engine causes initially a difference between the power required
by the engine and the power momentarily produced by the engine. This difference must
be compensated for by the energy of the rotating masses (flywheel and crank assembly).
This taking or giving of energy from the rotating masses changes their rotational speed,
i.e. changes the engine speed.
The variations from the set engine speed are measured by the governor and are converted
into mechanical adjusting movements.
In the Injection pump these adjusting movements ensure that the quantity of fuel supplied
to the engine (= quantity of energy) is again adapted to the changed load on the engi ne.
As a result, the variations from the set engine speed are again finally, fully or partially
eliminated. (Depending on the speed drop setting on the governor.)
Fig. 1061 Speed governor Bosch EP / RSV
1 Fish plate 10 Adjusting pin on

2 Governor cover centrifugal pendulum
3 Lower filling limit 11 Governor housing
4 Guide lever 12 Flyweight
5 Governor lever 13 Injection pump camshaft
6 Tension lever 14 Swivel lever
7 Supplementary idling 15 Rocker
spring 16 Injection pump control rod
8 Spring retainer {adjusting movement)
9 Full load stop 17 Governor spring
29
Fig. 1062 Speed governor Bosch EP / RSUV
1 Speed adjustment device 10 Supplementary idling spring

2 Lower filling limit 11 Guide lever
3 Stop motion rods 12 Spring retainer for
4 Injection pump compensation
control (adjusting movement) 13 Maximum filling limit
5 Fish plate 14 Flyweights
6 Starting spring 15 Governor cover
7 Swivel lever 16 Governor housing
8 Tension lever 17 Drive gear wheel
9 Governor spring (speed increasing device)
18 Injection pump camshaft
30
1.3.07 Lub. oil system
To reduce the friction existing between parts in sliding contact with each other and to
carry off the heat, all bearings and the inside walls of the cylin der liners are supplied
with lubricating oil.
This oil is drawn from the oil sump 1 by the lube oil pump 2 and delivered to the oil
galleries through the oil cooler, the oil filter.
From the galleries the lube oil reaches the individual bearings on the crankshaft, the
camshaft and also lubricates the rocker arms. A further pipe supplies the injector
nozzles which inject lube oil on the inside walls of the pistons for cooling.
The oil which is slung off by the main big-end bearings lubricates the inside walls of the
cylinder liners. The oil draining off then collects in the oil pan from where it is
reintroduced into the lube oil circuit.
Fig. 1071 Schematic diagram of lub. Oil system

1 Oil pan 11 Big-end bearing
2 Lube oil pump 12 Camshaft bearing
3 Cooling oil pump 13 Injection nozzle
4 Suction pipe 14 Piston
5 Oil cooler 15 Mushroom tappet
6 Bypass pipe for oil cooler 16 Pushrod
7 Lube oil change filter 17 Rocker arm
8 Bypass valve 18 Exhaust turbocharger
9 Gallery 19 Pipe to injection pump
10 Crankshaft bearing 20 Return to oil pan
31
Dry sump lubrication
Dry sump lubrication is of advantage on engines subject to a large inclination, so that it is

impossible for the lube oil pump range to run dry. The elementary lube oil circuit is shown in Fig. 29.
In addition, a suction pump 2 incorporating three gearwheels is provided which draws off the lube oil
from the two suction spaces 3 of the oil pan 4. and returns it to the centre portion of the oil pan via
the return piping 5. From here, the engine oil pump I delivers the lube oil to the lube oil circuit of the
engine and to the cooling oil nozzl es for piston cooling.
Fig. 30
Dry sump lubrication
1 Engine oil pump

2 Three-gear suction pump
3 Suction spaces
4 Oil pan
5 Return piping
6 Cooling oil pump
7 Suction piping
Fig. 32
Engine oil pump
1 Housing
2 Drive gearwheel
3 Pump gearwheel
4 Cooling oil pump gearwheels
32
Fig. 1075 Lub. oil filter
1 Filter cartridge
2 Filter head
3 Excess pressure valve,
]]
Fig. 1076 Oil cooler

1 Oil cooler cartridge
2 Oil cooler housing
3 Cooling water pipe
33
1.3.06 Cooling system
The thermal energy generated during fuel combustion can only be partly converted into
mechanical energy.
By means of the fresh water, cooling the combustion chamber walls, part of the residual
heat is eliminated and in a heat exchanger or a finned radiator passed on to a
corresponding fluid raw water, ambient temperature). A further part of the waste heat is
absorbed by the lub oil by means of the piston cooling (turbocharged engine) and bearing
friction. In the oil cooler this heat is passed on to the fresh water.
The decision for a particular cooling system depends on the given conditions at the
place of operation. The following scheme shows diagrams for indirect cooling, fan cooling
and outer skin cooling. The coolant's direction of flow is indicated by arrows in illustrations.
Fig. 1081a Indirect cooling (diagram)
1 Thermostat 7 Cooling water pumps

2 Expansion tank for 8 Cooling water supply
Intercooler circuit cylinder bank - A
3 Expansion tank for engine circuit 9 Outer skin cooler for
4 Intercooler intercooler circuit
5 Cooling water supply 10 Outer skin cooler
cylinder bank - B for engine circuit
6 Oil cooler 11 By-pass line
12 Venting pipe
34
Fig. 1082 Heat exchanger

1 Header
2 Expansion space
3 Cooling water filler neck
4 Water level mark
5 Tube bundle
6 Cooling water outlet to engine
Fig. 1083 Fresh water pump
1 Intake bend
2 Cooling water outlet to A - bank
3 Pump housing
4 V-belt pulley
5 Ball bearings
6 Axial sealing ring
7 Impeller
8 Cooling water outlet to oil cooler (B - bank)
35
Fig. 36
Lube oil centrifuge
1 Housing
2 Housing cover
3 Rotor
4 Hollow shaft
5 Nozzle
6 Paper sleeve
7 Pressure valve
SECTION A - B
Fig. 37
Engine oil cooler
1 Cooling water inlet

2 Cooling water outlet
3 Headers
4 Cooling shell
5 Tube bundle
6 Bypass valve
7 Water drain
8 Oil drain
9 Bypass line
36
Centrifugal Pump (Raw Water) Stork KGEC 11.3
Fig. 1084 Centrifugal pump (Raw water)
1 Flap valve
2 Gasket
3 Ball bearing 6303
4 Ball bearing 6203
5 Shaft
6 Oil seal
7 Mechanical seal
8 Gasket
9 Key for impeller
10 Impeller
11 Washer
12 Pump assembly KGEC 11.3
37
Fig. 1085 Thermostat
1 Cooling water inlet

2 Thermostat
3 By pass to water pump
4 To cooler
5 Thermo element
6 Valve disc
38
1.3.09 Turbo-charging
The purpose of turbo-charging the engine is to boost the output without altering the speed.
To achieve a higher output for a given capacit y, added heat must be introduced into
the operating process for each operating cycle i.e. an increased amount of fuel must be
burnt. This can only be achieved, however, when at the same time a greater weight of
air is available. This is achieved by charging the cylinders with a higher pressure.
Fig. 1091 Turbo-charging system

1 Air filter
2 Turbocharger-blower
3 Turbocharger-turbine
4 Intercooler
5 Exhaust gas
6 Charge air
7 Inlet valve
8 Exhaust pipe
9 Outlet valve
10 Coolant or cooling
air 39
Fig. 1092 Exhaust turbocharger
1 Turbine 2 Lub. oil inlet

3 Compressor 4 Intake air inlet
5 Compressor impeller 6 Axial sealing compressor side
7 Axial bearing 8 Radial bearing
9 Lub. oil connection 10 Heat shield
11 Axial sealing turbine side 12 Turbine wheel
13 Exhaust outlet 14 Exhaust inlet
15 Lub. oil return pipe
Fig. 1093 Supply lines to intercooler
1 Intercooler
2 Intake air pipe from turbocharger
3 Raw water supply
40
1.3.10 Starting system
The starter is designed to speed up the crankshaft of the engine to ignition

speed. When this speed is reached, an inflammable fuel/air mixture has been formed
inside the engine cylinders. This fuel/air mixture ignites and brings the engine into
operation.
Electric starting
The starter pinion is driven by an electric motor via a disc clutch that can axially
be shifted. By means of the meshing rod the meshing relay presses the starter
pinion in the gear rim of the flywheel and thus drives the crankshaft. Only then is
the full starter torque transmitted by the disc clutch in order to prevent the tooth
flanks from being damaged. As soon as the engine starts the disc clutch is released
via the steep-angle thread and the starter pinion is disengaged.
Fig. 1101 Electric start
1 Electrical connections
2 Starter pinion
3 Driving shaft leading to the starter pinion
4 Clutch housing
5 Steep-angle thread sleeve of the clutch
6 Meshing rod
7 Steep-angle thread
8 Clutch discs
9 Rim gear of the flywheel
41
1.3.11 Engine control and monitoring
Depending on the design the engine can be operated e.g. when starting, changing speed
or stopping it, directly or by remote c ontrol.
The engine speed can be actuated manually or by means of an electrical device. The
same is true for stopping the engine. In general the engine is started electrically. Remote
control is possible via the electrical control elements.
A pressure switc h within the oil circuit serves for monitoring the oil pressure. The cooling
water temperature is controlled by means of a temperature switch. When the limiting
values are reached this is indicated both acoustically and optically or the engine is
automatic ally being shut down by the shutdown solenoid.
In a similar way operating data like e.g. speed, oil temperature, cooling water temperature,
lub oil pressure etc. can be monitored. Operating data indicator can be mounted to the
engine or be a part of the control panel for remote control.
Fig. 1111 Control panel (examples)
1 Tachometer
2 Lub. Oil pressure
3 Ammeter
4 Water temperature
5 Lub. Oil temperature
6 Stop switch
7 Pilot lights
42
Fig. 1113 Cooling water temperature sensor
1- Cooling water sampling pipe

2-Cooling water temperature sensor
H Fig. 1113 Cooling water temperature sensor
1- Hand stopping button

2- Stopping lifting solenoid
43
STARTING THE ENGINE

(1) The Tr i -Panel can st art an engi ne in the foll ow ing w ay s. For manu al star t confi gurati ons t he
engi ne c an be star ted by pr essi ng t he STAR T but ton .
(2) T o m a n u a l l y s t a r t t h e en g i n e p r es s es t h e S T A R T b u t t o n . T h e T r i -P a n e l w i l l i n i t i a t e a
start
se q u e n c e w h i c h w i l l i n c l u d e a h e at i n g p er i o d , f u e l p um p o n , a c r an k i n g pe r i o d a n d a n o i l
m onit or del ay per iod. The st arti ng sequence status is show n on t he LC D upper wi ndow.
(3) If t he e ng in e s ta r t i s s u c ce s s ful the E N GIN E R UN ou t p ut i s a c tiva t e d. If t he s ta rt was

un s u c c e s sf u l t h e T r i - P a n e l w i l l e x p e c t t h e S T A R T b u t t o n t o b e p r e s s e d a g a i n f o r m a n ual
configurations.
(4) If the engi ne st arts independent ly the Tr i -Panel detects the condit ion and begins monitori ng.
The PR EALARM out put is act ivat ed t o give w arning of an uncontroll ed engine. Should a f at al
f a u lt c on d it i o n a r i s e , o r t h e e n gi n e i s r u n o u ts i de t h e s et op e r a t i ng va l u e s t h e T r i -Pa n e l is
unable to halt t he engine.
STOPPING THE ENGINE
(1) The Tri -Panel stops the engine by cont roll ing the fuel solenoi d.
(2) To man u all y sto p an engi n e. P r es s the S T OP b u tt on . H AL T is s ho wn on t h e L CD up pe r

wi ndow duri ng the halt phase.
(3) If t he STAR T bu tt on i s pres sed duri ng cool down th e T r i -Pan e! r et ur ns t o t he EN G I N E RU N

mode but now r equir es a pr ess of t he STOP button to stop the engi ne. A manual st art alw ays
requir es a manual stop.
(4) Act iva t in g EM ER G EN C Y S TO P sto ps t he e ngi ne i mm e di at el y. Wh en E M ER G E NC Y STO P or

the STO P butt on is act ivat ed for 10 or m ore seconds t he Tri -Panel w i ll dis play ESTO P on t he
LCD upper w i ndow . Th e E MER GEN CY STO P m us t b e deacti vated be f ore t he en gi ne rest art.
The engine can not b e res tart ed duri ng t his peri od.
(5) At t he end of H A LT th e Tr i -Pan el c he cks f or co mp le t e en gi ne re st an d co nt inu es t o c on tr a!

th e f ue l s ol e n o i d f o r 1 0 s ec o n d s a f t e r e n g in e r es t t o p r e v en t s u d d en e n gi n e re s t a r t. T h e
engine c an not be r estarted during t his period.
(6) if the fuel s olenoi d does not operate properly the Tri -Panel w i ll be unabl e t o st op the engine.
If the engine fai ls to stop, the Tri -panel wi ll act ivat e the alar m output and di splay STOP i n the
LCD upper w indow .
44
(1) The starting sequence is initiated by pressing the START button.
(2) The start sequence continues with a HEATING phase. The heating period is specified
during setup. If the engine temperature is below 30°C, the HEATER output is activated. If
the engine temperature is above 30°C, the heating phase is omitted. HEAT is shown in
the LCD upper window during the heating phase. Heat is usually set to off.
The heating period can be cut short by pressing the "START" button. There is always a
short delay between the heating and fuel pump phases.
(3) The start sequence continues by energizing the alternator via the CHARGE LAMP. The
lamp will glow indicating lack of charging current. When the engine is running and the
battery is charging the charge lamp will extinguish.
(4) The FUEL PUMP is controlled according to the PUMP type specified in setup. There is
always a short delay between fuel pump and the cranking phases.
(5) The current engine valves are checked prior to cranking. If oil pressure is detected, a
PAUSE state is entered until the oil pressure reduces below the oil pressure threshold
specified in setup. This ensures that the cranking will not occur into an already rotating
engine. PAUSE is shown on the LCD upper window for 60 seconds. A fail to START alarm
activates the ALALRM output if the condition persists.
(6) The start sequence continues with a cranking phase. The CRANK output is activated until
the engine starts or until the crank period specified in setup expires. The engine is
considered to have started when the engine speed exceeds the crank -disconnect speed.
The crank disconnects speed, or CREV, is specified in setup. CRANK is shown in the
LCD upper window during cranking.
(7) For a manual configuration if the engine does not start successfully the START button
must be released and pressed again.
(8) Regular sensor and engine condition checks are made during the startup sequence.
The displays show the current status. During the CRANK and PAUSE phases, the
displays switched off.
(9) As the engine starts the Tri-Panel enters the DELAY phase. The oil pressure in a
starting engine takes time to rise to a satisfactory level. The engine speed also takes time
to stabilize and usually overshoots the normal engine operating speed momentarily. The
DELAY phase allows time for the engine to settle before actively monitoring engine
conditions. DELAY is shown in the LCD upper window during monitor delay.
The type and time out of DELAY is specified during setup. The auto selection monitors ris ing oil
pressure and times out when the oil pressure is above the low oil pressure set point, plus
2 seconds. The maximum time out is 30 seconds. If a time is selected the Tri-Panel will s tart
monitoring the engine after the time out period.
During DELAY the engine speed is constantly monitored. If the speed overshoots the over
speed point by 25% or more a HIREV alarm occurs. The engine will be stopped. The
ALARM output will be activated. HIREV will be shown in the LCD upper window.
If an engine value is initially too low or too high its value is shown red but no alarm is raised. If
the abnormal condition is present at DELAY time out then the engine is stopped and the ALARM
output activated. The LCD upper window will show the cause of the abnormal condition.
(10) With the completion of DELAY the unit enters the ENGINE RUN phase. The ENGINE RUN
output is activated. The Tri -Panel continuously monitors the engine for abnormal conditions.
The engine RPM is shown in the LCD upper window during ENGINE RUN.
(11) The ENGINE HOURS are incremented every six minutes while engine is running. The hour
glass icon and total engine hours flashes while the engine is running and the total engine
hours are shown in the LCD lower window.
(12) Battery charging is constantly monitored for under and over voltage conditions. If an abnormal
condition is detected the PREALARM output is activated and cause of the alarm is shown in
the LCD upper window. For a low voltage the message is LVOLT. For high voltage the message
is HVOLT. Battery alarms do not stop the engine.
(13) The engine may be stopped as a result of an alarm condition or a stop signal. In any event
the engine is brought to rest by entering the HALT phase. HALT causes the FUEL supply to
be shut off. The engine is monitored for zero engine speed and zero oil pressure. HALT is
shown in the LCD upper window during the HALT phase.
If the engine stops, as it should, HALT continues to control the FUEL output for 10 seconds
after engine rest to ensure the engine does not restart. At the expiry of HALT the unit enters
STANDBY mode.
If the engine does not stop the ALARM output is activated. FSTOP is shown in the LCD
upper window. Operator intervention is required for an FSTOP condition.
(14) If the engine is stopped by an alarm both the PREALARM and ALARM output will be activated.
The cause of the alarm will be shown in the LCD upper window. The cause of the alarm must
be rectified before the Tri -Panel can be reset. Reset is achieved by pressing the STOP button
after the HALT time out phase.
Each behaves differently depending on the configuration and initial starting method.
(15) If the engine is stopped by a stop signal it will be one of two types.
• A manual stop signal from the STOP button

• An EMERGENCY STOP signal.
(16) If the engine was started by a press of the START button and the engine is stopped by a
press of the STOP button the unit will enter the HALT phase. After the halt time out, the unit
returns to STANDBY. This applies for both automatic and manual configurations.
(17) If the engine was started by a press of the manual START button and the engine is stopped
by the EMERGENCY STOP switch the unit will enter the HALT phase. After the HALT time
out the unit will enter the ESTOP mode. When t he EMERGENCY STOP is deactivated the
unit returns to STANDBY. This applies for both automatic and manual configurations.
46
ALTERNATOR WIRING
WIRING OVERVIEW
47
CLEARING ALARMS
(1) When an alar m occurs :

• Th e ca use of t he al ar m is sho wn in the L C D uppe r wi nd ow.
• Th e g auge show s the c ur re nt st at us .
• Th e P R E A L A R M o ut p u t is acti vated.
• Th e ALARM out put a c tivat ed.
• Th e engi ne is usual ly s topped.
(2) From the ala rm shown on the L CD upp er window d eter mine a nd rec tify the ca use o f the
Alarm.
(3) Wait for t he Tr i -Panel to exit the H ALT phase.
(4) Deact ivat e the EMER GE N C Y STOP s wi t ch if i t is acti vated.
(5) Press t he STO P button.
(6) The Tri -Panel w il l re tur n to STAN D BY mod e.
SPECIFICATIONS
Dimensions
• width : 280 mm
• height : 118mm
• depth : 60 mm
Power Supply
• Operating voltage 8 to 32 V DC
• Negative Earth
• Standby current 20 mA
• Operating current 570 mA
Inputs
• Transient protected
• Reverse-voltage protected
Outputs
• Protected against short -circuits
• Protected against over current
• Maximum load 500 mA
Communications
• RS485 twisted pair link (option)
Environmental conditions
• Operating 10°C to 60°C
• Storage 20°C to 70°C
• Humidity 85% RH at 50°C (non-condensing)
• Splash-proof
48
(1) The Tri-Panel incorporates many self check and system check features. They ensure that faults which
may cause engine damage or pose a safety risk are detecte d and alarms raised. The pre-alarm is the
primary warning output for this purpose. If the pre-alarm is activated the cause should be investigated
and rectified right away. The table below will be of some assistance in trouble shooting based on the
alarm conditions.
ALARM SUMMARY
NAME CONDITION REMEDY
ERROR 1:2 Tacho uncalibrated Calibrate Tacho
ERROR 1:3 System not set up Set up Tri-Panel

START Engine did not start Check engine for correct operation
FSTOP Engine will not stop Check fuel control

HIREV Engine went over speed Check governor
TACHO Tacho input not available Check alternator and engine wiring
ESTOP Emergency stop activated Deactivate emergency stop

UREV Engine was running too slowly Check governor
OREV Engine was running too fast Check g overnor

OIL Low oil pressure detected Check oil level, sensor, wiring
TEMP High temperature detected Check coolant, airflow, sensor, wiring
LVOLT Low battery charge Check battery condition, alternator
HVOLT High battery charge Check voltage regulator
HALT Engine stopping Wait for engine to stop
49
Part 2 Operation and POL products
2.0 Prevention of accidents, safety instructions
2.1 Prior to first -time operation
2.1.0 General
2.1.1 Cooling water
2.1.2 Fuel
2.1.3 Lubricating oil
2.1.4 Starting air
2.1.5 Special measures for operation
in winter
2.2 Engine control
2.2.1 Prior to starting

2.2.2 Starting engine
2.2.3 Setting speed
2.2.4 Stopping engine
2.2.5 Instructions for prolonged storage
2.2.6 Restarting after prolonged storage
2.3 POL specifications for small size engines
50
2 Operation and POL products
2.0 Prevention to accidents, safety instructions
The legal regulations for prevention of accidents (obtainable from professional associations
or specialized dealers) must generally be observed. These regulations depend on the
site, type of operation as well as the operating and auxiliary materials being used.
Special protecting measures, depending on each operation involved, are stated in the
description of work and marked with
The following prescriptions are generally valid
• For the staff:
The engine may only be operated or maintained by trained staff. Unauthorized

persons are not permitted to enter the engine room.
Wear tight-fitting clothes and ear protection during engine operation in the
engine room.
Trained staff only may be engaged for repairs or maintenance operations.
• For the engine room:
Ensure sufficient ventilation (do not cover ventilating vents).
Install first-aid boxes and appropriate fire extinguishers. Their content and
readiness for service must be checked regularly.
Combustible substances may only be stored inside the engine room if they
are needed for operation of the installation
Smoking and naked flames are prohibited inside the engine room.
• For operation and maintenance of the engine:
Start the engine only if all protecting appliances are attached and if the j
cranking device has been removed. Ensure that nobody stays within the
danger zone.
Cleaning, maintenance and repair operations should only be carried out if

the engine is stopped and secured against starting.
51
2.1 Preparation for first -time operation and for starting-up after several idle days
2.1.0 General
The following operations and checks described below are necessary for efficient operation
as well as for accident prevention. It is above all the correct functioning of crank assembly
and speed governor that is necessary for the trouble-free operation.
Clean new lines and tanks before filling with fuel, coolant and lubricating oil. After filling
please check pipes and tanks for fuel and cooling water for leakage.
Prior to first -time operation please check alignment of the engine and proper mounting
of the foundation.
Please clean engine - only then can leakages be ident ified and localized unmistakably.
If the engine was preserved, please pay attention to section 2.2.6 "Restarting after
preservation".
2.1.1 (Cooling water * )
The engine cooling system shall only be filled with treated coolant according to section
2.3 up to the lower limit in the filler neck {for filler neck see Fig. 2001) and bleeded (for
bleed plugs see Fig. 2002) Since the operating temperature of the engine is kept as
high as possible (approx. 85 ° C cooling water temperature) unsuitable cooling agents
can cause deposits and corrosion damage. Please check pipes and engine for leakages
after filling.
Fig. 2001 Filler neck Fig. 2002 Bleed plugs for cooling system
52
If a Gilkes or Steime! raw water pump (Fig. 2003) is attached to the engine the pump
housing must be filled with water through the filler tube (1)- Due to the centrifugal forces
the water forms the water ring during operation. It is necessary for the suction effect of
the pump. This is why the raw water pump has to be filled once again each time it was
drained.
Fig. 2003
Raw water pump
2.1.2 Fuel *
• Fill fuel tank with proprietary fuel complying with DIN 51601 requirements (see
section 2.3)
• Loosen banjo bolt 1 and operate hand priming pump 2 until fuel emerges free of
bubbles, tighten banjo bolt again.
Fig. 2004 Hand priming pump
1 Pressure connection
2 Hand priming pump
53
• Loosen bleed screws 3 on fuel filter, operate hand priming pump 2 until fuel
emerges free of bubbles. Continue to operate priming pump while tightening bleed
screws 3.
Note : In case of a reversible dual fuel filter the above applies to both chambers
(cock position : vertically upwards).
• Loosen overflow valve 4 on the injection pumps and operate hand priming pumps
2 until fuel emerges free of bubbles. Continue to operate priming pump while
tightening again overflow valves 4.
Fig. 2005 Dual fue l f ilter Fi g . 2 0 0 7 In j e c t i o n pu m p

3 Bl eed screw 4 O verf low val ve
2.1.3 Lubricating oil *
Do not use lub oil other than specified i n section 2.3.1. The vi scosity depends on t he
ambient temperature. The following table gives the corresponding viscosity required for
different am bient temperatures.
Brand Ambient temperature
SAE 40 constantly above 30°C

SAE 30 between 0°C and 30°C
SAE 10W constantly below 0°C
SAE 20W20 between -10°C and +10°C
Caution!
Wrong viscosi ty can r esult i n starting diff icul ti es or very low oil press ure.
54
Loosen plug 1 and fill in lub. oil up to the upper dipstick mark 2. After short engine
operation refill lub. oil up to the upper dipstick mark.
Fig. 2008 Oil filler neck
1 Plug
2 Dipstick
* Please refer to POL spec ification 6.000.0.005.4431 e, given in this operating instructions
manual.
This POL specification is being updated every year and can be obtained from Greaves
after-sales services at the beginning of each year.
2.1.4 Starting air
In case of an air-started engine fill up the starting air receiver with starting air compressor
or carbonic acid bottle (carbonic dioxide). The starting air pressure must be 30 bar.
Caution ! The starting air receiver must not be filled with

oxygen or inflammable gases due to danger of
explosion.
Open valves of the air bottle and check lines for leakage. Air leaks waste energy and
cause premature wear of the starting air compressor.
55
2.1.5 Special measures for operation in winter
• Winter engine oil

Effect in time oil change and use oil of low viscosity. See prescription 6.000.0.005.4431 of
this operating instruction .
• Winter-grade fuel
In winter, use winter-grade diesel fuel only, otherwise the fuel may cloud and block the system,
which may even occur with winter-grade fuel when frost is severe. Therefore, when only
summer -grade fuel is available or winter -grade fuel must be used in severe cold, mix it with
kerosene or normal gasoline in accordance with the table below. The admixture of gasoline,
however, is permissible for one tank charge only.
Caution : prepare the blend in the tank itself fill in gasoline first, then add diesel fuel.
Caution ! Smoking and each use of an open flame is strictly

forbidden. The blend is as easily inflammable as pure gasoline. Danger
of explosion!
Ambient temp. Summer-grade Kerosene or Winter grade diesel Kerosene or

limit down to diesel fuel % Gasoline % *) fuel % Gasoline % *)
-10°C(+14°F) 90 10 100
-14°C(+7°F ) 70 30 100
- 20°C (- 4°F) 50 50 * * ) 80 20
- 30°C (- 22°F) 50 50 * *)
For using a commercial additive, please consult your service points.
*) never use premium fuel

**) not allowable for gasoline admixture
A mixture containing filling station fuel should only be used in case of need, otherwise
difficulties may occur due to vapour bubble formation. Due to the additives the engine
output will be lower than with Diesel fuel. For that reason only the urgently needed
additives shall be added.
56
2.2 Engine control
2.2.1 Prior to starting

• Slightly open drain valve of the starting air compressor (air starting)
• Check engine stopping device for easy movement
• Switch on engine room ventilation, if available
Caution ! Remove any objects that have been put down on the engine. It is
particularly dangerous to leave anything in the crankcase saddle. It may
result in serious accident and damage.
2.2.1.1 Checking supply of POL products

In order to prevent operational failures and stoppages, it is necessary to ensure that all
POL products are available in sufficient quantities. Since the level of these products
decreases as a result of consumption, evaporation or leakages, their level should be
checked daily.
It should be ensured that use is made only of correct, clean POL products, meeting the
requirements of section 2.3
• Checking the fuel supply
Check the fuel level in the service tank and replenish if necess ary. Depending on the
size of the tank and the engine load, the service tank must be replenished several times
per day.
Caution ! When refuelling, smoking and all any naked flames are strictly
forbidden due to the explosion hazard. The same applies to the switching on
and off of electric appliances of all types.
• Open cooling water valves (raw water circuit) if attached.
• Checking the coolant level
Check coolant level in radiator 1 by opening radiator cover 2. When the engine is cold
the coolant should reac h the under mark (arrow).
When coolant is lacking, fill in coolant up to the corresponding mark.
Note : When refilling coolant at normal running temperature, let the engine run in order
to prevent sudden drop in temperature of the engine. In the event of a frequent cooling
water shortage check the cooling system for leakage. Compensate losses due to
evaporation by means of water that is free of lime. In case a considerable amount of
cooling water is filled in, check the percentage of the corrosion agent (0. 5% up to 1.5%)
and of the anti-freezing agent (at least 33%).
Fig. 2009 Cooler
1 Filler neck
2 Cooler cap
57
• Checking the lub. Oil level
Pull out dipstick 2 and wipe dry with a clean rag. Reintroduce dipstick 2 and wait for a
short time until dipstick is wet with oil. Pull out dipstick again and check lub. oil level.
Caution ! Do not keep dipstick upwards, as otherwise the oil running down would falsify
the measuring result. When the lower dipstick mark is reached, top up oil.
Fig. 2010 Oil Filter
1 Plug
2 Dipstick
Check battery
Remove plugs (Item 1) and measure density of electrolyte with hydrometer. Electrolyte
density 1.23 to 1.28 kg/I is normal. If electrolyte density is less than 1.21 kg/I recharge
the battery. The water level should be approx. 15 mm above the plate edge, if not, top
up using distilled water.
If necessary, connect battery charger to battery (positive to positive and negative to

negative) and recharge battery. The recharging current is equai to 1/10 of battery capacity
number e.g. for 145 AH - recharging c urrent is 14.5 ampere.
Caution ! Hydrogen -oxygen mixture (oxy-hydrogen gas) is released during

recharging. No naked flames, no smoking. The plugs (Item 1) must be open.
After recharging, replace plugs, clean battery terminals and grease with anti -
acid grease.
Note : Unused batteries must be recharged every 4 to 6 weeks.
Fig. 2011 Battery
1 Plugs
2 Battery terminals
58
2.2.2 Starting the engine
• Set speed governor to low engine speed
• Switch on monitoring device (in case of a key-operated switch; position 1)
• If fitted, position switch "Betrieb - Stop" (Operation - Stop) to "Betrieb" (Operation)
• Start engine by means of starter switch (In case of a key-operated switch; press
key inwards and turn it to the right as far as it will go)
• As soon as engine starts release switch. The s tarter switch automatically returns
to position "Betrieb" (Operation)
Caution ! Should the engine race (ever increasing speed) or the oil pressure does not
develop adequately, stop engine immediately and close fuel cocks.
During operation maintain key-operated switch on position 1, otherwise (position '0')

the monitoring facility will be out of circuit.
Fig. 2012 (Examples)

Switch and control board
Engine start with flame starting system
• Turn key-operated switch to position I
• Draw out push-pull switch up to first notch (Preheating of the flame glow plug)
• When the corresponding temperature (pilot lamp flashes up) has been reached
draw out push-pull switch as far as possible (starting position)
• When engine- starts press push-pull switch inwards to stop limit.
59
2.2.2.2 Emergency start with Hansa quick starter
1. Remove cylinder head cover from the cylinder with

which the quick starter is connected.
2. Crank the engine until both valves are closed (push

rods can be easily turned, ignition top dead
centre). Continue cranking until the starting mark
"S" on the V -be!t pulley (Fig. 2013) and the mark
on the indicator coincide. Remove cranking bar
and replace cylinder head cover.
3. In order to open ihe starting valve of the cylinder

head loosen lock nut 1 and unscrew threaded Fig. 2013
spindle 2 as far as it will go (Fig. 2014).
4. Switch on monitoring device (in case of key -

operated switch : position 1) and position injection
pump control rod to complete filling.
5. Remove cap 3, loosen valve seat of the main valve

by means of tightening the nut 5, back off nut 5
again.
Note : cap 3 blocks the main valve, tighten cap

again only after, starting the engine.
Fig. 2014
6. Check whether cap screw 6 is tightened (hand-
tight only).
7. Loosen screw 7, place ignition film strip (max,

length 1,5 m) over the film strip fork 8. Rescrew
and tighten screw 7 again.
8. Strike (storm proof) match and throw it through

bore 9 into the pressure container. Close apert ure
9 by means of lever 10. The engine starts due to
the developing pressure.
Caution ! Keep away from the safety valve 11 as

there is danger of accident due to gases emerging
under high pressure
9. Once the engine has started, close starting valve

on the cylinder head (main valve spindle 2) and
tighten lock nut 1.
Dismantle Hansa quick starter and oil all threads

and conical items.
Fig. 2015
60
2.2.3 Speed Adjustment
After cold start of the engine wait a few minutes until running the engine at full load and
speed; increase speed and load gradually.
Manual speed adjustment device (Fig. 2016)
Loosen lock nut 1 and operate handwheel 2 until the required speed is attained. Tighten
lock nut 1 again.
Electrical speed adjustment (Fig. 2017)
Operate speed switch unti! the required speed is attained. The highest and lowest
adjustable speed is blocked by means of limit switches.
Fig. 2016 Manual speed adjustment device Fig. 2017

1 Lock nut switch for speed adjustment Switch for speed adjustment
2 Hand wheel
Checking operating values

Checking the operating values is an important preventive measure with regard to the
reliability of the engine. By means of periodical controls, malfunctions can be recognized
in time, thus avoiding damages. The test report gives the normal operating values read
off in order to be able to determine gradual changes by comparing them with previous
test results over a long period of time.
Data to be controlled and indications as to possible sources of error are mentioned
below:
Lub. oil pressure (Pressure gauge 2)
Possible reasons for an inadequate lub. oi! pressure :
• Lub. oil too hot (oil cooler or cooling system clogged, engine overloaded)
• Oil control valve 3 seizes
• Lub. oil filter clogged
• Lub. oi) too thin (wrong viscosity, oil change)
• Pressure gauge faulty
• Too high bearing claeranco on driving mechanism
Possible reasons for a too high lub. oil pressure :
• Lub. oil (still) too cold
• Oil control valve 3 seizes
• Lub. oi! too thick (wrong viscosity, oil change)
• Pressure gauge faulty
61
Cooling water temperature (thermometer 1)
Possible reasons for high cooling water temperat ure

Engine overloaded
Cooling water level too low
V-belt for water pump drive is broken or loos e
Cooler clogged
Thermostat faulty
Possible reasons for low cooling water temperature:
Thermostat faulty
Fig. 2018 Control board Fig. 2019 Lub oil filter
1 Cooling water temperature 3 Oil pressure valve

2 Lubricating oil pressure
2.2.4 Stopping the engine
In order to prevent heat from being retained in the cylinder liners and cylinder heads,
avoid stopping the engine at full load. Allow the engine to run at low speed and output
for approx. 5 minutes before stopping it.
1. Shut down engine by pressing stop push-button on monitoring panel.
2. Switch off monitoring appliances by means of ignition-lock key on switch position .
3. The engine can also be stopped manually (Fig. 2020) using the solenoid.
4. If the engine be stopped for a long time, close the fuel cocks.
Fig. 2020 Manual stopping device
62
2.2.5 Engine preservation
If the engine is taken out of service for a longer period, it must be preserved in order to
prevent corrosion damage. This also applies if the engine is put into service later than 3
months after delivery. See Job Sheet No. 3.3.003 for preservation instructions.
2.2.6 Engine operation after preservation
The anti -corrosion agents used for preservation influence the way the engine runs and
therefore have to be removed prior to operation. Clean engine and remove protecting
grease from the blank parts, e.g. control rod.
Remove covers and blank flanges from intake and exhaust pipe.
Fill engine cooling system with clean cooling water without admixture (section 2.1.1)
Empty fuel filter and fuel tank (see also Job Sheet No. 3.2.053), fill in fuel (section
2.1.3) followed by bleeding of the fuel tank.
Clean air-filter (job sheets 3.2.002 D), Drain lub oil filter (see Job Sheet 3.2.025) and fill
in lub. oil (section 2.1.3).
Carry out the operations and checks described in section 2.2.1 and start engine (section
2.2.2). For about 15 minutes, let the engine run at low speed and output, then stop it
and drain off water. Fill in cooling water in accordance with section 2.1.1.
63
USERS MANUAL GREAVES DIESEL ENGINE D3 2/14
G R E A V E S POL-Specification small-size engines Oct 97 1.000.0.0054401

----------------------------------- ------------------------------------------------------------------- ---------------- --- ----------------------------------
Lubricating oil grades B= API-CF-4 Explanations

GENERAL
Fuel Distrillates as per DIN 51601 IMDF as per MDF as per Normal and heavy- duty operation in vehicles
BS 2869 class A1 OR A2 BS 2869 BS 2869 installations and generating sets
ASTM-D 975 No. 1 D and/or 2D __________ Class B 1 Class B 2
Sulphur contents in % by weight to 0.5 to-1 to-1. 5 CHPM/ heat pumps
Application in combined heat and power modules
Emergency CHPM
Type of application GENERAL power heat GENERAL EMERGENCY POWER Supply
supply pumps
------------------------------------ ------------------------ -------------- ---------------------------------------------------- Operation in emergency generating sets
TBD B B B In case of operating periods less than 20h/ month
turbo charged
please consults our factory.

B B B Oil change every 6 months at least
Engine type
Lubricating oil grade
---------------------------------------------------------------------------------------------------------- (See overleaf)
Oil change interval 250 250 250 250 or ace. 125 125
in operating hours to analysis
Lubricating - oil viscosity
The class of lubricating oil viscosity depends on the prevailing ambient temperature
Ambient temperature Class of viscosity
Above 30° C SAE 40
0 - 30º C SAE 30
below 0ºC SAE 10W
- 10ºC to 10º C 20W- 20
Special regulations, enclosed to the operating instructions manual, may be valid for engines with manual starting appliances Multi-grade oils
are only provided for use in automotive engines Only Multi-grade oils. Perfectly meeting the requirements of specifications MIL- L-21O4C/D
and API-CD to CD+ may be used. Multi- grades oils are not permissible, when using MDF fuels
Lubricating oil change Limiting values for analysis mm max

7
Viscosity at 100° mm /s(cSt) DIN 51562
The lubricating - oil level must regularly be checked and completed up to SAE 20W 20 7.0 11.0
the top dipstick mark SAE 30 9.5 14.0
In cases of operation involving a mostly constant engine load (e.g. CHPM) SAE 40 11.0 17 0
the oil change interval may be extended, if the optimum oil-change interval Flashpoint ºC 200 ISO2719
has been determined by a series of used- oil analyses. Oil companies and Fuel contents % by vol. 6
technical institutions may be asked to carry out these analyses or Greaves solid foreign matters
against reimbursement of the costs involved The lubricating oil must be (Heaptane) % by weight 1.5(2)" DIN51365
changed, in any case, if the results of the used- oil analysis are exceeding Water contents % by weight 0.2 ISO3733
one or several limiting values stated in the opposite table Base number (TBN) % 50% of value when new AST M664
____________________________________________________________________________1) The values in brackets are permissible in exceptional cases only._________________
Cooling water Admixture, initial and subsequent dosage of the anticorrosion agent as well as regular
Clean water with the lowest possible lime contents should be used as a concentration checks should be performed according to the instructions of the
Cooling water within the limiting values mentioned below for analysis. The respective manufacturer.
analysis values may be 10% higher or lower than the liming values An Caution No chemical anticorrosion agents should be used for internally
anticorrosion agent approved by Greaves . must be added to the cooling galvanized piping
water
Water quantity mm max Anticorrosion agents min | max
PH value 7 9 Only water of Chemical anticorrosion agents may also acc to the
Contents of chlonde IONS Mg/1 100 this qualit y should be used with water from desalinization
Contents of sulfate ions Mg/1 100 and vaporizations. Instalations (not valid
instruction of the
Total contents of anions Mg/1 150 . fo r T BD3) manufacturer
When using antifreeze should be mi xed involved
Total (german) hardness dGH 3 12 with One of the ___________________________________________________________________
(gernan) cart nate hardness dKGH 3 additives
when using chemical mentioned Antifreeze/frost protection down to 2Oº
anticorrosion agents overleaf c. An antifreeze concentration of at least 33% 5QO/o
Total German hardness dGh. 0 12 33% should be complied with during the
Who le ye ar t o p re ve nt co rro si on
Damage
Caution Replace antifreeze every 2 years and chemical anticorrosion agents every year.
Water quality is to be determined by consulting the water-works or Warranty claims concerning damage caused by POL-products can only
using Greaves test kit case 6 088 801.6020 4 When in doubt, have be met. if above regulations are carefully observed and adhered to
the water analyzed in chemical laboratory See next page for cooling-water additives
Never use non-analyzed water'
64
NALFLEET 9-111 ENGINE COOLING

SYSTEM TREATMENT
Benefits Protects all metals in engine cooling Reduces maintenance time and
systems including copper, copper costs.
alloys, lead solder and aluminium
from corrosive attack. Liquid form for simple application add
directly to the engine radiator or
Protects against liner pitting and cooling system.
cavitation-erosion.
Treated water does not cause
Water pump lubricant. dermatitis or other skin conditions.
Keeps engines free from heat Does not affect nonmetallic materials
absorbing sludge and mineral scale in engine cooling systems and rubber
deposits -prevents over heating. gaskets or hose.
Extends antifreeze life
Principal Uses Nalfleet 9-111 functions as a It is approved for use in an engine

protective film forming corrosion cooling system circulating as the
inhibitor and scale suppresant. It is heating medium for generator
effective in hot and in cold fresh producing fresh water for drinking
water and is fully compatible with and culinary purposes, provided the
glycol/water mixtures. It also contains recommended dosage rates are
an anti-incrustant to prevent adhered to.
deposition on hot surfaces and keep
waterways in radiators clear.
General Nalfleet 9-111 has the following Odor : None

Description typical characteristics. Color : Dark Solubility in Water
blue Soluble in small proportions.
Feeding Nalfleet 9-111 may be fed directly Empty and fresh the cooling system
from drums but because of the thoroughly before commencing as
alkalinity of the neat product plastic much old rust as possible. If the
taps should be used for dispensing. system is exceptionally rusty it is
advisable to repeat this procedure
Nalfleet 9-111 should be added after after the first week or two of
the circulation of the cooling water treatment.
system.
Dosage The concentration of Nalfleet 9-111 Nalfleet 9-111 should be added fresh
in the cooling water should be in the after every 'B' check.
proportion of 1 part Nalfleet 9-111 in
125 parts cooling water by volume {8
liters/tonne).
Storage & Nalfleet 9-111 may cause irritation to Keep away from heat, sparks and
Handling skin and eyes Avoid contact with skin open flames. Keep drums closed
and eyes or cloths. Prolonged or when not in use. In case of contact,
repeated breathing of vapor should wash skin with soap and water, for
be avoided This chemical is to be eyes immediately flush with large
used with adequate ventilation. Do amounts of water for at least 15
not take internally. minutes and get medical attention.
Remove contaminated clothing and
wash before reuse.
65
All POL- products mentioned below are meeting our requirements according to the manufacturers portion all the products appearing as suitable ones. This is why other POL - products which are data
even if some engine oils do not comply with classificatio ns as per API and or Mil in certain not stated here, may be used provided that they meet our requirements Each manufacturer cases
In view of t h e l a r g e num be r oil p rodu cts, i t i s im poss i ble f or us t o men is s ol ely r esp onsible for the co nst ant qual it y of his PO L - products at t h e i nternational l evel
FIRM B Engine oil API CF-4 Antifreeze Chemical anticorrosion agent
Supplier Denomination
Agip Agip Antifreeze Plus
Aral Aral- Kuhlerfrostschutz
Avia Avia FROSTSCHUTZ
bavwa Fricifir
c
M
mx
BP BP Anti-Frost c/5
Castrol Castrol RX-SUPER PLUS 15W/40 Castrol Antl-Free?c Pern Pretty Filter >C
Chevron'' naifloc Om
CalMn Naftlesl
Deutzpr Glysantin Forte Cooianl Condrtione* m
0m KG
Coolant Flush
g
m
EH
<fl
GlaceK m
r
m
Esso Esso Kuhlerfrostsohutz z
D
I
m
Fina Fina Termidor P 100
Fuchs Fncofm
IND Mobjl IND-MOBIL DELVAC SUPER 1300i I5W- 40 Frostschutz 500
Motur MOTUL HP4D 15W40
BHG Fricofin
Snell GlycosheH
Texaco Texaco Frostschytz
Total Total Frostfree
veedol Veedol Antifreeze
Winte shall Kuhle'schutz
• SHIM>()!<•
66
LUBRICATION FOR GREAVES ENGINES
LUBRICATING OIL CHANGE PERIODS ARE RECOMMENDED FOR

GUIDANCE. THESE PERIODS CAN BE ALTERED DEPENDING UPON THE
WORKING CONDITIONS, ENVIRONMENT, QUALITY OF LUB. OIL AND
MAINTENANCE OF THE ENGINE. THE LIFE OF LUB. OIL AND FUEL
FILTER ELEMENTS DEPENDS ON THE QUALITY OF LUB. OIL AND
DIESEL USED RESPECTIVELY.
REGULAR OIL CHANGE AND GOOD PREVENTIVE MAINTENANCE

GIVE THE ENGINE LONG LIFE AND SMOOTH WORKING.
RECOMMENDED LUB. OILS
i) API - CF4 OR EUIVALENT

ii) CASTROL RX-SUPER PLUS 15W-40
iii) IND-MOBIL DELVAC SUPER 1300 15W-40
iv) elf PERFORMANCE 3D 15W-40
v) IOCL SERVO PREMIUM CI4 15W-40
67
USER'S MANUAL GREAVES DIESELENGINE D3
Part 3 Servicing
3.1 Tools and expedients

3.1.1 Other additives
3.1.2 Trouble tracing table
3.1.3 Servicing schedule
3.1.4 Job sheets for servicing
68
3. Servicing
Unavoidable pollution of the environment which can enter the engine through the POL
products (air, fuel, lubricating oil, grease and coolant) as well as other loads in operation
can endanger satisfactory operation of the engine. Servicing has the task of preventing
these dangers and responsible servicing enhances the safe reliable operation and life of
the engine, thus saving costs.
3.1 Tools and expendients for servicing
The following tools and expedients are required for carrying out the servicing tasks.
1. Set of tools 6.000.0.018.500.7

Servicing set
2. Set of tools 6.000.0.018.501.7

Servicing set
3. Set of tools 6.232.0.018.009.7

Supplementary kit
4. Set of tools 6.234.0.018.003.7

Servicing set
69
1. Set of tools
Servicing set
Order No. 6.000.0.018.500.7
Item Qty. Description Part No.
1 1 Tool case 6.085.610.2001.3

2 1 Wrench 10 x 12 DIN 3110 6.086.417.0101.2
3 1 Wrenc h 13 x 17 DIN 3110 6.086.417.0131.7
4 1 Wrench 14 x 15 DIN 3110 6.086.417.0141.5
5 1 Wrench 19 x 22 DIN 3110 6.086.417.0192.2
6 1 Socket insert 13 x 12.5 DIN 3124 6.086.424.0013.2
13 1 Cross handle A 12,5 x DIN 3122 6.086.445.0112.2
14 1 Extension B 12.5 x 125 DIN 3123 6.086.445.1120.2
15 1 Screwdriver A 0,8 x 5,5 x 125 6.086.460.5000.9
DIN 5265
16 1 Set of feeler gauges 0,2-0,45 6.086.104.0004.0
17 1 Square spanner, spanner opening 3,5 6.086.422.2000.1
70
2. Set of tools
Servicing set Order No.
6.000.0.018.501.7
Item Qty. Description Part No.
1 1 Tool case 6.085.610.2001.4

2 1 Wrench 10 x 12 DIN 3110 6.086.417.0101.2
3 1 Wrench 13 x 17 DIN 3110 6.086.417.0131.7
4 1 Wrench 14 x 15 DIN 3110 6.086.417.0141.5
5 1 Wrench 19 x 22 DIN 3110 6.086.417.0192.2
6 1 Wrench 24 x 27 DIN 3110 6.086.417.0242.7
9 1 Sock et insert 17 x 12.5 DIN 3124 6.086.424.0017.2
14 1 Cross handle A 12,5 DIN 3122 6.086.445.0112.1
15 1 Extension B 12.5 x 125 DIN 3123 6.086.445.1120.2
16 1 Extension B 12.5 x 250 DIN 3123 6.086.445.1120.1
17 1 Universal joint C 12.5 DIN 3123 6.086.445.2120.1
18 1 Head of ratchet 12. 5/0 - 400 Nm 6.086.440.9000.1
19 1 Pipe handle 6.086.440.9002.2
20 1 Torque wrench 0-210 Nm 6.086.440.1021.1
21 1 Extension lever 0-420 Nm 6.086.440.9002.5
22 1 Screwdriver A 0.8 x 5.5 DIN 5265 6.086.460.5000.9
23 1 Set of feeler gauges 0.05 1 mm 6.086.104.0001.0
24 1 Square spanner, spanner opening 3.25 6.086.422.2000.1
71
Special tool set, item number 6.232.0.018.009.7
Item Description Part No.
1 Tool box C 1613/01 6.085.610.2001.6

2 Screwdriver A1 x 7 x 150 6.086.460.5001.0
3 Screwdriver 2 DIN 5262 6.086.461.1002.1
4 Plier C 19 DIN 5256 (for piston 6.086.009.0000.2
pin retaining ring)
5 Piston ring pliers 110 - 150 RD 6.087.105.1000.3
6 Testing device CH 1612/4 (to check 6.088.801.2031.4
the cylinder liner set back and upper
distance of piston)
7 Dial guage A 10 DIN 878 (to 6.086.001.0002.1
testing device CH 1612/4)
8 Overflow pipe CH 1612/6 6.088.801.4010.7
(to check injection timing)
9 Overflow cup 1774/21.2 (to 6.088.801.4010.8
overflow pipe CH 1612/6)
10 Screwdriver insert SW 8, square 6.086.425.0008.1
12.5 (for fastening bolt of injection
pump)
11 Socket wrench insert CH 1983.1/6 6.088.801.4011.0
21 x 24 (for pressure pipe
connection on injection pump)
72
Set of tools - Servicing set 6.234.0.018.003.7

Tool case 6.085.610.2003.5
Hydrometer 6.0759.80.0.0001
Cooling water test kit 6.088.801.6020.4
Strap wrench for disposable filter 6.086.442.1000.1
Square spanner for Zinc protection 6.086.423.0001.4
73
3.1.2 Fault-Tracing Table

The fault-tracing table lists faults in engine operation with a description of how they may occur
and their causes. The potential causes are given in the order in which the true cause is likely to be
localized with the least effort.
The sections given under "Remedy" contain information on how to remedy the fault. The
cause; of deviations in lube oil pressure, lube oil temperature and coolant temperature as well
as information on how to remedy them are given in Job Sheets 3.1.4.2 and 3.1.4.3.
causes
Engine does not turn When
Engine running irregularly
Abnormal exhaust gas

Engine does not achieve
Or stop after a few ignite
Engine stop operating

specified out put /speed
Engine does not ignite
Engine overheating
Engine over speed

Engine knocking
Water in lub oil.

colorings
started
No control current
Battery discharged
Insufficient fuel
Monitoring system has workshop

tripped
Engine too cold
Turbocharger defective workshop
Starting system defective workshop
Oil cooler leaking workshop
Governor defective or workshop

governor linkage sticking
Defect at crank assembly workshop
Cylinder line in crankcase workshop

leaking
74
3.1.3 Servicing schedule

The following table shows the servicing tasks, subdivided according to servicing intervals. The servicing
work has to be carried out at the latest as soon as the operating hours, indicated in the columns on the
left page, have been reached.
The servicing tasks must be repeated according to the given number of operating hours.
for the first time on Checking exhaust back pressure 3.2.033

commissioning
only once after Engine oil change 3.2.001
50 operating hours Checking V-belt drive 3.2.003
Replace engine oil filter cartridges 3.2.025
for continuous operation for emergency & stand
by
daily 250h 1000 h 2000 h Servicing tasks No. of operation.
to be repeated every X Job Sheet
•Engine oil change 3.2.001 monthly 1 year
Checking coolant level prior to starting engine and 2years
3.1.4.2
X
checking coolant temperature during operation
X Checking oil level and oil pressure 3.1.4.3
X Check battery 3.1.-1.4
X Checking maintenance indicator on the air filter 3.1.4.5
X X Replace exhaust gas filter (after visual check) 3.2.002A
Replace dry-type air filter clement 3.2.002B X
X (Note maintenance indicator)
X Clean after cooler & heat exchanger 3.2.003 X
X Checking any resetting valve clearance 3.2.028 X

X Checking exhaust back pressure 3.2.033 X
Renew sparking plugs @250 Hrs 3.2.052 X
X Checking monitoring 3.2.059 X
X Lubricating the bearings (generator type T1) 3.:2.060 X
* Tightening torques of main screw connections 3.3.001
according to in Nm
requirements Engine preservation 3.3.003
** Cleaning heat exchanger & After cooler. 3.3.007
Cleaning exhaust-gas heat exchanger 3.3.008
Checking control unit for ignition point and 3.3.009
ignition
coils as well as cleaning impulse solenoids
• Determine service life of lubricating oil according to POL
products specification 6.000.0.005.4432 e of this operating instruction.
**Caution: Cylinder-head screws, bearing cover and connecting-rod

bolts should never be retightened
· In case of higher cooling-water temperature, check heat pieces

visually and clean, if necessary.
· Monitor H 2S, CH4, H 2O, Content in gas line
75
3.1.3.1 Overhauls
The reliability of the engine is affected over long periods by wear and corrosion. In order to avoid
engine failures, we suggest to carry out the overhauls indicated in the following table. The first
overhaul operations must be performed after 10.OOO operating hours or, if not reacted, after 2
years. The work sequence is described in the Workshop Manual, which can be obtained n our
Spare Parts Department.
Inspection Operating hours
Checking bearing clearance on turbocharger 5 000h

Replacing exhaust- gas filter (probe end) after at the X
latest or earlier depending on the blackening degree 10 000 h
(visual check) Replacing exhaust- gas filter (pump X
end) after at the latest or earlier depending on the X
blackening degree (visual check) Replacing exhaust- X
gas pump X
Carry out measurement of harmful constituents * X
Overhauling cylinder heads Cleaning combustion X
chamber Checking cylinder liners Cleaning oil cooler X
Checking rocker arms and rocker-arm bracket X
Cleaning and checking cooling-water regulator X
Replacing cooling-water hose* and expansion joints X
Cleaning and checking gas-pressure regulator, gas X
solenoid valve and mixing valve Checking ignition unit X
* Replacing starter wearing parts * Checking X
exhaust installation for wear
Partial overhaul
Replacing pistons Replacing cylinder liners Cleaning 20 000 h
and checking oil relief valves Replacing crankshaft X
seals, checking axial clearance Checking big-end X
bearings, replace connecting rod bushes, if necessary X
Exchanging anti -vibration dampers (Holset) X
Basic overhaul
Measuring crankshaft (grind, if necessary) 40 000 h
Replacing main and connecting-rod bearings X
Overhauling starter (Bosch) Checking gear drive X
Checking control unit, replacing wearing parts X
Replacing oil pump X
X
• The harmful constituents should be measured with electronic measuring appliances by MWM-
staff only. It is recommended to measure the harmful constituents after the first 5000 h
and/or to have the O2 - regulating unit checked and measured by the TOV and to replace
defective parts, if necessary.
The above-mentioned operating-hour 4ntervals are average values and valid for standard operating
conditions and appropriate maintenance in accordance with the descriptions. These are standard
values without warranty obligations. Deteriorating operating conditions are caused by
• frequent starting
• long operating periods at zero load
• extremely rapid and frequent load charges
• frequent operation at overload
The execution of the repairs (maintenance and overhauls) requires skill and special knowledge.
Should you have no skilled staff at your disposal, our Af ter-Sales Service Department will be
pleased to give you information about maintenance contracts involving various work scopes.
76
3.1.4 Job Sheets for Servicing
For a better survey, the jobs are subdivided and described on Job Sheets.
When carrying out these jobs a good knowledge of the various functions of the engine
and how they interact is necessary.
Information to this extent is provided in part 1 and part 2 of these Operating Instructions.
The Job Sheets describing the jobs are numbered.
The individual Job Sheets contain the following information:
• Description of job involved and Sheet No.
• Servicing interval
• Remarks on tools, fixtures and expedients required
• Information on any spare parts required
• General servicing directions
• Step-by -step description of servicing procedures
• Figures illu strating the text
• Important items in these figures are numbered
• Necessary reference relating to further Job Sheets
The object of the Job Sheets is to facilitate preparations and for implementing actual
servicing tasks.
77
TBD3
If the engine is used for standby or emergency service, corrosion

may occur due to condensation of water. In order to prevent
this and to test the operational readiness of the engine, a trial
run should be performed once in a month.
Starting the engine
1. Check the supply of POL products (Section 2.2.1.1)
2. Open the cooling water cocks and, if fitted, switch on

pump sets.
3. Open the fuel supply.
4. Switch on monitoring system {for key -operated switch :

position 1 fig. 1) and set speed governor to low speed.
5. If fitted, set switch 1 "Betrieb - Stop" (Operation - Stop)

to "Betrieb" (Operation) and start engine by means of the
u starting switch (for key - operated switch : press key
inwards and turn clockwise as far as possible)
Caution : if the engine races out of control (engine speed

continues to rise) or if no oil pressure is built up, switch
off the engine immediately and close the fuel supply.
During operation, keep key -operated switch in position

1, Position O means that the monitoring system is out of
operation.
1. Running the engine
Just after starting, run the engine at 1/3 load only. After
approximately 10 minutes it can be run at 3/4 load and after a
further 5 minutes at full load (nominal output). When the engine
has reached normal running temperature, check the operating
values (section 2.2.3.1). Before stopping the engine, let it run
for another approx. 10 minutes at 1/3 load.
2. Stopping the engine
Press manual stopping device (Fig. 3) in stop- direction until

flywheel stands still or set instrument panel lever to "Stop" (item
1 or 2). If fresh water pump units are fitted, they should run for
a few more minutes after stopping in order to prevent the buildup
of heat at the cylinder liners and cylinder heads.
Close fuel and cooling water cocks and switch of f monitoring

svstem.
78
Engine type Job Sheet No
Date first time after
GREAVES Job Sheet
5.97 TBD3 3 14 1
after and every Page of

Trial run 1 I 1 page
month
need thoroughly
prior to beginning
Necessary tools Necessary materials and auxiliaries Spare Table No.
If the engine is used for standby or emergency service, corrosion

m a y o c c u r d u e to co n d e n s a t ion w a t e r . I n o r d er t o p r e v e n t th is
and to test the operational readiness of the engine, a t r i a l run
s h o ul d b e p e r f o r m e d o n c e a m o n t h
S t a r ti n g a n d m o n i t o r i n g o f e n g i n e
1 Check the supply of POL products (Section 2 . 2 . 1 . 1 )

2 Op e n th e c o ol i n g wa t e r cocks and, i f fi tted, s witch on
pump sets.
Engine Protection Unit
3 Open the fuel supply.
4 T o s t a r t t h e e n g i n e s w i t c h O N t h e c o n t r o l s u p p ly k e y
switch. Press the bypass button and start the engine from
s ta r t p u s h b u t t o n . T h e b y p a s s b u t t o n m a y b e r e l e a s e d
when the e ngine ac hieves oil p res sur e.
Ca u tio n : n' the en g in e rac es o ui o f con tr ol (e ng i ne

speed continues to rise) or if no oil pressure is built up,
s wi t c h o f f t h e e n g i n e i m m e d i a t e l y a n d c l o s e t h e f u e l
supply
D u r in g o p e r a t i o n , k e e p k e y -op e r a te d s w i t ch i n p o si t i o n
1, P ositio n O mea ns t hat the mo nitoring s ys tem is o ut
of operation
1. Ru n n i n g t h e e n g i n e
1-RPM Meter Ju s t a f t e r s t a r t i n g , ru n t h e e ng i n e a t 1 / 3 lo a d o n ly A ft e r
2- L O Pre Gauge app rox ima tel y 10 mi nut es it c an be r un at 3/4 loa d and a fte r a
3-W T Gauge fu rt he r 5 m i nu te s a t fu ll lo a d (n om i na l o ut pu t) Wh en th e engine
4-Ammeter has reac hed nor mal runn ing temp eratur e, chec k the ope rating
5 - L O T Gauge (optional) v a l u e s ( s e c t i o n 2 . 2 . 3 1 ) Be f o r e s t o p p in g t h e e n g i n e , l e t i t r u n
6- Stop push button for another approx 10 minutes at 1 / 3 loa d
7-Warning Lamp
2. Stopping the engine
T h e e n g i n e i s s t o p p e d f r o m t h e s t o p p u s h b u t t o n o n th e
Instrument panel by putting the switch in OFF position
E rig i n e Protection
De s c r ip t i o n
Th e e n g i n e m o u n t e d s w i t c h e s c o n s i s t o f l o w l u b o i l p r e s s u r e
switch (operating at 1 5 t C 0 5 bar f a l l i n g pressure), high water
t e m p e r a t u r e s w i t c h ( o p e r a t i n g a t 9 6 De g C ) 2 D e g C r i s in g
te mp er a tu re ) t h at st o ps th e engine if either of the conditions are
a c h ie v e d T h e c o n d it i o n a n n u n c i a t e d b y a h o o t e r a n d d i s p l a y e d
by re sp ect ive DC la mp
For gen er at or s et s up pl ied wit h c ontro l pa ne l by GDE U th e e ngine
pr o te c t io n c om e s in teg ral with pa ne l c on tr ol w ith c ir cu it. I f fr es h
wa te r pu m p u nit s a re fi t te d th e y s h o u ld r u n f or a f e w mo re min u t e s
aft er st op ping in or der to p rev en t t he bu il du p o f h ea t a t t he cy li nde r
liners an d cylinde r heads.
Clo se fu el a nd c oo li ng w ater c oc ks and sw it ch off monitoring
sys te m.
79
Engine type Job sheet No.
Job Sheet
Date First time
after TBD3 3.1.4.4
after and every Page of
Checking the battery 1 1 page
daily
read thoroughly
prior to beginning
Necessary tool* Necessary materials and auxiliaries Spares Table No
Hydrometer 6.0759.80.0.0001 Distilled water

Cloth Anti-acid grease Bosch No. 5 700 102 005
When the engine is not operating, the battery supplies current to

consumers and delivers the high power required for starting. The
capacity of the battery deteriorates during long periods of non-
operation or as the result of excessive loading. For these reasons the
battery must be checked at the intervals indicated in the servicing
schedule.
Caution: The charging gases are explosive. Do not, in

any case, manipulate naked flame, produce sparks or
smoke in the vicinity of the batteries.
Wear protecting glasses when working on batteries
being connected to the charger.
Allow frozen batteries to thaw before charging.
Checking battery and recharging it, if necessary

1. Wipe battery using a humid cloth. Remove corrosion marks
and rinse the poles using a solution composed of water and
natron and coat with acid-resisting grease. Check, whether
connecting terminals are tightened.
2. Unscrew battery-cell caps (item 1) and measure electrolyte
density of the battery using a hydrometer (item 2).
Electrolyte density: 1.23 to 1.28 kg/I normal
Electrolyte density below 1.2 1 kg/I recharge.
Reference temperature 20°C.
3. Unscrew all battery-cell caps (item 1) and fill up, if necessary
with distilled-water to approx. 15 mm above plate edge.
4. If the battery has to be recharged, disconnect battery cables
(beginning with negative pole) and connect battery charger.
Positive to positive pole and negative to negati ve pole.
Switch charger on and recharge battery.
The charging current represents 1 / 1 0 th of the numerical value of
the battery capacity, e. g. 143 Ah = charging current of 14.3 A. The
battery is charged when the acid density and charging voltage do
not ris e any more within 2 hours.
5. Switch off and disconnect charger. Close all battery-cell caps
and connect battery cables (beginning with positive pole).
Note:
Recharge stopped batteries every 4 to 6 weeks.
80
Job Sheet No.
Date first time after after and every Engine type
GREAVES Job Sheet 3.2,002 D
06.86 TBD3
Page
Checking dry air filter for dirt (Visual check on read thoroughly prior
to beginning 1
Necessary tools maintenance indicator)
Necessary materials and auxiliaries Spare Table No.
Set of tools Cleaning agent 79 -

Compressed air
Gaskets
In dry-type air filter, the intake air is directed through a paper

filter insert retaining the dirt particles. The filter gets clogged as
a result of the dirt particles accumulated inside the filter insert,
thus increasing the vacuum downstream of the filter. This
vacuum is measured inside maintenance sensor. In case of
excessive vacuum i.e. a contaminated dry-type air filter, the
maintenance sensor incorporated in the switchboard switches a
signal lamp on. It is now time to perform maintenance operations
or after one year at the latest. Filter element 3 must be replaced
to make the engine ready for operation again.
In order to increase the service life of the filter element a pre-
filter is installed in front of the filter. It retains the coarser
particles of dirt of the intake air.
Caution! Operations may be performed on the air filter
only if the engine is stopped. "Risk of accidents"
Check dust collector 1 mounted on Pre-filters clean
pre-filter
Check dust quantity in dust collector 1. When the mark 2 is
reached, empty dust collector 1 and carry out the following
operations :
1. Loosen clamping screw 3 and remove pre-filter
2. Clean air intake openings 4 and dust discharge slot of
the dust collector 1 by means of a piece of wire.
3. Clean all parts with a detergent solution and dry them.
4. Reassemble in reverse sequence. Pay attention to seal
Check maintenance indicator, renew dry air filter elem ent
Check sight glass 6 of the maintenance indicator while the
engine is out of operation. If the red mark continues to be seen,
carry out the following operations :
1. Remove nut 7, cover 8 and renew filter element 9.
2. Reassemble in reverse sequence. Pay attention to seal
10.
Cleaning the dry-type filter element (only in exceptional
cases)
1. Remove filter element as described under "Renewing
filter element".
2. With the clean room closed the filter element is to be
blown out in longitudinal direction of the folds a n d
afterwards from inside.
Note : The filter elements can also be washed out with
detergent 053 or P 3 RST (Messrs. Henkel). We advice
however, not to do so for reasons of safety. Beating the
filter element is not recommended either.
3. Reassemble in reverse sequence.
Note : Afler having cleaned the filter element 5 times,
or every 2 years, at the latest, the filter element has to
be renewed.
81
Job Sheet No.
Job Sheet 3.2.003
GREAVES 5.85 60 h 500 h TBD3
read thoroughly prior Page of
Checking V -belt drive/Lubricating raw water pump 1
to beginning 1 page
Necessary tools Necessary materials and auxiliaries Sparc Table No.
Tool set Lithium saponified grease 57 -

Cranking bar 59 -
Grease gun 65 -
67 -
69 -
89 -
The V-belt drives on the opposite end of the main P.T.O. are
used to drive the raw water pump (Fig. 1, Item 1), fresh water
pump (Fig. 1, Item 2) and alternator (Fig. 1, Item 3)
The V-belt tension is correct when the V-belt can be pressed

in 1 to 2 cm with the thumb (Fig. 1 arrows). Otherwise (he V-belt
must be readjusted.
Checking and resetting V-belt tension
1. Remove V-belt guard
2. Check V-belt tension (Fig. 1, arrows) if required :
3. Loosen screws 4 on tensioning roller bracket or alternator
4. Regulate tension by moving the tensioning roller or

alternator accordingly
5. Tighten screws 4
Observe tightening torques of the screw connections (Job sheet
3.3.001)
Caution !
Tensioning the V-belt excessively aggravates wear just as much

as slack V-belts.
As soon as cracks or other signs of wear are noticed the V-belt

must be changed. For checking the V-belt all over, crank the
engine.
Lubricating the raw water pump
Fill the grease nipples (Fig. 2 or 3, arrows) with lithium saponified

grease (multi -purpose grease) by means of a grease gun.
82
Date first time after after and every Engine type Job Sheet No.
GREAVES Job Sheet TBD3
4.38 500 h 500 h 3.2.005
Checking zinc protective coating read thoroughly prior Page of
to beginning 1 1 page
Square wrench 11 mm : 14 mm 1 Sealing ring 6.0492.01.5.4249 63 75

Fresh water containers 2 Sealing rings 6.0492.06.5.0331
* Zinc paint 6.1489.01.0.8044
* Zine paint 6.1489.01.0.8054
* Quantity as required
Due to the aggressive substances contained in the cooling water, (he cooling water passages are exposed to corrosion.
To avoid destruction of the walls, plugs with a zinc protective coating are provided in the cooling water and raw water
circuits. Since the zinc protective coating (base metal) will decompose with time, it must be checked at the intervals
given in the servicing schedule.
Removing and fitting zinc protective coating
1. Close the raw water inlet and return cock.

2. Drain water from engine (drain cocks are identified by item 1 in the illustration, also not forgetting to drain the
other side of the engine)
3. Remove plugs with zinc protective coating (identified by arrows in the illustrations) and check condition. If
heavily decomposed, renew.
4. Refit plugs with new sealing rings
5. Close drain cocks
6. Open raw water cocks, open cock under funnel (Item 3) and fill raw water pump. Then reclose cock under
funnel.
7. Bleed system at plugs (identified Item 2 in illustrations)
83
Job Sheet
GREAVES 1.86 60 h 500 h D3
TBD3
3.2-025
Replacing engine oil filter cartridges read thoroughly prior Page of

Tool set Filter cartridge 6.0541.29.7.0048 = 6 Cyl. 47 -

Oil pan Filter cartridge 6.0541.29.7.0039 = 8 + 1 2 Cyl.
For reversible filter : or (in case of a reversible duplex filter): 2 filter
Cock wrench SW 17 cartridges 6.0541.18.8.0008
Within the lub. oil circuit, the oil filter is installed in such a way
that all particles of dirt are kept away from the bearings. These
particles clog the filter. As a result the oil pressure decreases.
Therefore, the filter cartidges have to be replaced from time to
time.
If a reversible duplex fuel filter is mounted, the filter cartridges

can be replaced while the engine is in operation, provided that
the corresponding filter chamber has been switched off (see
Fig. 3) During normal operation, both filters must be in operation.
Replacing filter cartridges
1. Loosen filter cartridge 1 with strap wrench and unscrew

it.
2. Clean seal seat and oil seat of new filter cartridge

slightly.
3. Fill the new filter element/s with fresh oil up to full and
quickly tighten it to the filter head. (Some amount of oil
may fall down)
4. Screw filter cartridge until seal contacts, then tighten

manually. Do not use tools!
5. Check filter for leakage with engine running.
Cock position 1 : left filter closed

Cock position 2 : Both filters open
Cock position 3 : right filter closed
84
Date first time after Engine type Job Sheet No.
Job Sheet
GREAVES 1.86 after and every D3
3.2.028A
TBD3
read thoroughly prior Spare Table No.
1000 h
to beginning Page
Checking and readjusting valve clearnce (6 cylinder engine)
1
Necessary materials and auxiliaries
Necessary tools
Set of tools 19 21
Turning rod
Inlet and exhaust valves can only reliably close tightly if there
is a certain clearance set between camshaft and valve stem
inside the valve-drive unit. Valves which do not close tightly may
cause the valve seat and valve plate to burn off. On the other
hand, excessive valve clearance would cause considerable wear.
Maintaining the valve clearance of the correct setting increases
service life and engine reliability.
Checking and adjusting of valve clearance (on cold engine)
1. Screw out bolts 1 on all cylinder heads and remove

cylinder head covers.
2. Crank engine in direction of rotation until valve 2 close
in cylinder A1; then, crank crankshft further by approx.
half a turn, this position corresponding to ignition TDC.
3. Check valve clearance between rocker arms and valve
stem end with corresponding feeler gauge.
Valve clearance for : Inlet valve 2 Exhaust valve 3
naturally-aspirated engine 0.2 mm 0.3 mm

turbocharge d engine 0.3 mm 0.5 mm
The feeler g auge should be inserte d wit h a c ert ain

amount of force. In case of deviation the valve clearance
Checking and/or setting sequence (ingnition TOC) must be readjusted.
Loosen locking nut 4 and setting screw 5. Screw in
setting nut by screw driver until (he feeler gauge begins
to clamp. Tighten locking nut and check valve cleara nce
Flyweel end as above.
Checking and/or adjusting sequence :
Beginning of the second
The checking and adjusting of the valve clearance is
effected as per the ignition sequence, starting with
cylinder A 1 as described in section 2.
After having checked and/or adjusted the valve clearance
on cylinder A1, the engine is to be checked further,
progressively, in firing order and direction of rotation for
additional checks as follows:
Ignition TDC A1 B2 A3 B1 A2 B3
see also figure 2
Beginning of the second 6. Fix cylinder-head covers, taking care of gaskets.

Beginning of the first
Crankshaft rotaion Crankshaft rotaion
85
Engine type Job Sheet No.
GREAVES Job Sheet
Date first time after
D3
1.86 TBD3 3.2.028B
Checking readjusting valve clearance (8 + 12 cylinder- engine) to beginning 1 1 pages
Set of 19
tools 21
fuming rod
Inlet and exhaust valves can only be reliably closed tightly if

there is a certain clearance set between camshaft and valve
stem inside the valve-drive unit. Valves which do not close tightly
may cause the valve seat and valve plate to bum off. On the
other hand, excessive valve clearance would cause considerable
wear,. Maintaining the valve clearance of the correct setting
increases service life and engine reliability.
Checking and adjusting of valve clearance (on cold engine)
1. Screw out bolts 1 on all cyl inder heads and remove
cylinder head covers.
2. Crank engine in direction of rotation until cylinder A1
reaches ignition TDC. Cylinder A1 is placed on ignition
TDC when valves A4 on 8 -cylinder engines or A6 on
12-cylinder engines are overlapping, i.e. when exhaust
valve 3 closes and inlet valve 2 begins to open (Load-
change TDC)
3. Check valve clearance between rocker arms and valve
stem end with corresponding feeler gauge.
Valve clearance for : Inlet valve 2 Exhaust valve 3
Checking and/or setting sequence (ignition TDC) 8 naturally-aspirated engine 0.2 mm 0.3 mm
Cylinder Fly wee I end 0.3 mm
turbocharged engine 0.5 mm
first
The feeler gauge should be inserted with a certain
amount of force. In case of deviation the valve clearance
must be readjusted.
4. Loosen locking nut 4 and setting screw 5. Screw in setting
nut by screw driver until the feeler gauge begins to clamp.
Tighten locking nut and check valve clearance as above.
5. Checking and/or adjusting sequence :
The checking and adjusting of the valve clearance is
effected as per the ignition sequence, starting with
cylinder A 1 as described in section 2. After having
Beginning of the -Beginning of the second checked and/or adjusted the valve clearance on cylinder
Crankshaft rotation Crankshaft rotation A1, the engine is to be checked further, progressively,
12 Cylinder in firing order and direction of rotation for additional
checks as follows:
Ignition TDC A1 B2 A3 B1 A4 B3 A2 B4
Valve over A4 B3 A2 B4 A1 82 A3 B1
lapping
8 - Cylinder engine
see also figure 2
Ignition A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1
TDC
Valve over A6 A2 A2 B4 A4 B1 A1 B5 A5 B3 A3 B6
lapping
12 - Cylinder engine see also fig. 2
6. Fix cylinder-head covers, taking care of gaskets.
86
Job Sheet No.
Date first time after and every Engine type
GREAVES Job Sheet 3.2.053
5.85 2000h T8D3
read thoroughly Page of
Renewing fuel finer cartridges of fuel fitter element
prior to beginning 1 2 Page
Set of tools Fuel filter Fig. 1 29 -

Filter cartridge 6.0541.18.8.0004
Fuel fitter Fig. 4
Filler element 6.0541.14.0.0003
For single-stage filter 1 each
For duplex filter 2 each
In order to protect the fuel injection pumps and injectors, a fuel filter
is incorporated in the fuel system upstream of the pumps and
injectors. A contaminated filter element reduces the flow of fuel and
must therefore be replaced after the above-mentioned operating
hours .
If a reversible fuel filter is provided, the filter cartridges may also

be renewed while the engine is running.
Caution!
Only when the fil ter elements are ch an ge d m us t th e
corresponding filters be shut down. During normal operation
leave both filter in circuit! Fitter switching diagram, see figure 5.
Renewing fuel filter cartridge (Filter Fig. 1}
1. Close fuel cocks

2. Loosen filter cartridge 1 with strap wrench and remove it.
3. Coat seal of the new filter cartridge with fuel.
4. Screw filter cartridge into filter h ead down to the real, then
tighten by 1/2 a turn. Do not use tools.
5. Bleed the fuel filter (see last paragraph)
Renewing the fuel filter element (Filter Fig. 2....4)
1. Close fuel cocks.

2. Unscrew wing screws, item 2, and take down cover item
3, taking care of gasket
3. Slacken centre screws, item 4, and take down cover, item 5.
4. Take filter elements, item 6, out of filter housing and clean
inside of filter housing.
5. Insert new filter elements into housing and reattach cover
in the reverse sequence, taking care of gaskets.
6. Vent fuel titter (see last paragraph)
Right - hand Both filters Left-hand

filter in operation fitter
in operation in operation
5
87
GREAVES Job Sheet Date 5.85 first time after alter and every
Engine type Job Sheet No.
2000H 3-2053
Renewing fuel filter cartridges of fuel filter element. TBD3
Page of
read thoroughly prior 2 I 2 pages
6a beginning
Necessary tools Necessary materials and auxiliaries Spare Tab » c No-
Set of tools Fuel fitter Fig. 1 29 - _

Filter cartridge 6.0541.18.8.0004
Fuel! filter Fig. 4
Fitter element 6.0541.14.0.0003
For single -stage litter 1 each
For duplex filter 2 each
Cleaning fuel pre filter (fig. 6)
1. Close fuel cocks
2. Loosen knurled nut 7 and put strap aside- Remove sight-

glass 8 and filter element 9.
3. Clean a(l parts with fuel, use a soft brush in order to

remove strong dirt.
4. Reassemble in reverse sequence. For bleeding open fuet

cocks, loosen banjo bolt 10 and operate hand fuel pump
until fuel emerges free of bubbles. Continue pumping
while tightening banjo bolt again.
Bleeding the fuel fitter
1. Open bleeding screws 11 and operate hand fuel pump

until fuel emerges free of bubbles. Continue pumping
while tightening bleeding screws 11 again.
2. Check filter for leakage during operation.
88
Job Sheet after and every Engine type Job Sheet No.
GREAVES Date first time after
2000 h D3 3.2.055
1.86 TBD3
read Page of
Checking monitoring and engine stopping device. thoroughly prioi to
1 1 page
beginning
Necessary tools Spare Table No.
Heatable container Molybdenum sulfide spray 41 - ...

Thermometer (up to 100 °C) or 89 - ...
Tool set Wrench SW 27 Lithium saponified grease
Lub. oil
In order to avoid damages resulting from the malfunction of

lubrication or cooling, monitoring devices are mounted on the
engine. In case of an excessive cooling water temperature or a
too low oil pressure, warning devices (pilot lamp, siren) are
switched on or the engine is shut down via the shutdown
solenoid.
Checking and lubricating manual shutdown device Press
shutdown button 1 in direction of arrow and release again. The
shutdown device automatically returns to starting position. If
this is not the case, check rods for smooth working. Lubricate
joints 2 and tie rod 3 of the solenoid with molybdenum sulfide
or oil.
Checking oil pressure monitoring device Mole : if a timing
relay is installed the reactions of the monitoring device may delay
for 15 sec. (maximum). Switch on monitoring devic e (in case of
key-operated switch : pos. 1) and put switch "Operation - Stop"
to "Operation". The pilot lamp "oil pressure" flashes up and the
siren sounds. Operate switch "Siren off" and the siren is shut
off.
If the pilot lamp does not light up, check fuses 4 in the
instrument panel or change the bulb. If this is of no use, short
circuit connection 5 on the oil pressure switch on - it it is a
unipolar connection - ground them. If the pilot lamp lights up,
renew oil pressure switch. If not, check cable con nection. After
checking, switch off monitoring device.
Checking cooling water monitoring device
Switch on monitoring device (in case of key - operated switch :
pos. *) and position switch "Operation-Stop" to "Operation".
Short-circuit connection on temperature sensor or - if it is a
unipolar connection - ground it. Pilot lamp "cooling water
temperature" lights up, siren sounds. If this is not the case,
renew fuses 4 in the instrument panel or change the bulb. If
still not illuminating, check cable connections .
Drain off cooling water (drain cocks 7), pinch off cable
connections on temperature sensor 6 and dismantle temperature
sensor. Repinch temperature sensor, suspend in a water bath
and heat it. At approx. 95°C pilot lamp must light up and siren
sound. If this is not the case, renew temperature sensor.
Checking shutdown solenoid

Short-circuit connection on oil pressure switch or temperature
sensor 6. The shutdown solenoid is in "Stop" position. If this is
not the case, operate switch "Engine - Stop". If the shutdown
solenoid passes to position "Stop", check cable connection. If
this is of no use, renew shutdown solenoid.
89
GREAVES Job Sheet 3.2.057
5.85 2000 n TBD3
Cleaning the intercooler. read thoroughly prior Page of
Container, size at least Approx, 20 dm3 Henkel neutralizing agent P3 -croni 77 - ...
500 mm x 200 mm x 200 mm Approx, 20 dm3 Henkel detergent solution P3T-
Tool set 1166
Hexagon socket wrench SW 6 (Messrs. Henkel, 4000 Dusseldorf)
The intercooler serves for cooling the air coming from the
turbocharger, whereby the weight of the air inside the cylinder
is further increased. As a precondition the walls of the cooling
lubes must be free of dirt and deposits.
At the same time, the flow resistance of the air is increased

due to deposits on the air end of the cooling tubes and thus
the amount of turbo charging air diminished.
Cleaning the intercooler
1. Drain engine cooling water.
2. Remove fresh water pipes 2.
3. Loosen hose clamps 3, unscrew bolts 4 and remove inlet
pipes 8 and elbow 7
4. Remove raw water connections 5.
5. Unscrew bolts 6 and mounting bolts on intercooler frame
(Fig. 2,arrow), lift off intercooler.
6. Remove the air circulation 11
Note : The cooling fins on the air end are very delicate.
Cover flange surface with a board or the like.
7. Unscrew mounting bolts 9, remove head pieces 10.
8. Place the nest of tubes into a container with detergent
solution P3T - 1166, Henkel (concentration as per
information of the manufacturer). Foaming of the solution
characterizes the reaction. When the reaction is
completed, i.e. after 15 minutes at the latest, take the
nest of tubes off the detergent and clean the cooling
fins with a duct cleaner. The nest of tubes is then
washed out with clean water and put into a
neutralizing
agent consisting of P3-Croni (Henkel) for approx.
10
minutes. Finally, wash out the nest of tubes
thoroughly
with water.
Check the soldered connection of the nest of tubes and, if
necessary, resolder.
Reassemble in reverse sequence.
Renew gaskets.
90
Job Sheet No.
Job Sheet 3.2.060
GREAVES 5.85 2000 h TBD3
read thoroughly prior Page
to beginning 1
as required 89 - ...
Ball bearing grease Ft 1 v 34 (Messrs. Bosch)
A charging alternator is required for supplying power to the

electric loads on the engine, such as starter, indicator and
operating systems. Since the battery has a limited capacity, it
is recharged by the charging alternator which is driven by the
engine through a V-belt.
The rotor of the charging alternator has ball bearings at both

ends. These bearings must be lubricated at the intervals given
in the servicing schedule.
Lubricating bearings
Screw in the grease cups 2 turn. If the grease cups have already
been screwed in as far as they will go, unscrew and re-pack
with ball bearings grease.
Screw in Stauffer boxes until you strike an obstacle, then screw

in by two further rotations.
Caution!
91
GREAVES Job Sheet D3
06.86 3-3.001
TBD3
Tightening torques of main screw connections in Nm
to beginning 1 3 pages
* Tightening torque specification for cylinder head bolts:
Lubricate screw thread and contact surface (do not use
Molykote). Tighten the bolts crosswise to 20 Nm, and then
tighten further in three stages (100 Nm, 200 Nm, 400 Nm)
• With washer ? with lock washer.
92
Job Sheet Date first time after after and every Job Sheet No.
GREAVES
6.86 Engine type 3.3.001
Tightening torques of main screw Page of
connections in Nm TBD3
2 3 pages
Necessary tools Spare Table No.
* 60° (1 hexagon)
93
first time after after and every Job Sheet No.
Job Sheet
GREAVES Date 3.3.001
Tightening torques of main screw 6.86 Engine type Page of
connections in Nm D3 3 | 3 pages
TBD3 Spare Table No.
Necessary tools
Set of tools
94
Job Sheet No.
GREAVES Job Sheet 3.3.003 A
5.85 TBD3
read thoroughly prior Page 1 of 2
Anti-corrosion treatment for engines not yet installed to beginning
Necessary tools Necessary materials and auxiliaries
Spare Table No.
Protective grease e.g. Messrs, Fuchs KG; Antikorit-MV
Set of tools Anti-corrosion oil for lubricating oil system,
e.g. Messrs. Fina; Rusan 20 W 20
Spray gun Anti-corrosion oil for fuel system, e.g.
Tilt (waterproof) Messrs. Castrol : Rustillo DWX 32
Anti-corrosion agent cooling water, e.g.
Messrs. Khubier-Chemie : Puriton 4110
Talcum powder
In case of engine not installed and commissioned within a period

of 3 months, an anti -corrosion treatment is lo be carried out to
prevent corrosion.
Anti-corrosion treatment of the engine
1. Mark position of the flywheel or of the crankshaft flange.
There might be first beginnings on the cylinder liners in
the height of the piston rings, therefore the position of
the piston should be changed after each anti-corrosion
treatment.
2. Fill fuel mixture consisting of 9 parts Diesel fuel and 1
part anti-corrosion oil in fuel filter.
3. Wash and/or rinse out of sump and additional devices
with own oil filling with Diesel fuel. Screw -in oi l
discharging screw No. 1 and tighten it.
4. Fill anti -corrosion oil in the engine (inlet connection 2)
and/or spray it in the additional devices.
5. In case of engines equipped with a hand pump, pump
the 'filed in anti -corrosion oil through the engine by
means of a hand pump and race the crankshaft by hand
so that all bearings and liners are slightly wet.
In case of engines not equipped with a hand pump, the
anti -corrosion oil has to be passed through the oil system
by means of the mounted lubricating oil pump, in the
following manner.
Remove blind flange on intake - and exhaust pipe. If
the starter is mounted and a battery is available, turn
the crankshaft by the starter.
Attention: Ignition of the engine is allowed, but only
with minima! speed until the oil pressure is built up. If
the engine is not equipped with a starter, race the
crankshaft serveral times by truning. In case of super-
charged engines the turbine wheel must be raced several
times by hand.
6. Remove cylinder head cover 3, spray in valve springs
and rocker arms with anti -corrosion oil, install cylinder
head cover.
7 Remove injection nozzles 4 and bring the corresponding
piston to BDC. Spray anti-corrosion oil in the combustion
rooms through the opening on the cylinder head. Re
install injection nozzles.
8. In case of engi/ies equipped with a compressed air start,
remove starling star and starting line on the cylinder
head. Spray in starting star and openings of the starting
line in the cylinder head with anti-corrosion oil. Reinstall
removed parts .
9. Unscrew oil discharging screw 1 and drain anti -corrosion
oil. Tighten oil dischrging screws 1. The fuel mixture can
remain in the system.
10. Fill cooling water mixture consisting of 20 parts cooling
water and 1 part anti -corrosion agent in the engine and
circulate the cooling water mixture in the engine by a
separate pump. Then drain the cooling water mixture
and let the draining cocks 5 opened.
11. The intake and exhaust openings are to be closed so
that external weather influences are kept away from the
engine inside.
95
Job Sheet No.
GREAVES Job Sheet 3.3.003 A
5.85 TBD3
read thoroughly prior Page of page

Anti-corrosion treatment for engines not yet installed to beginning 1 2
Protective grease e.g. Messrs, Fuchs KG;
Set of tools Antikorit-MV
Spray gun Anti-corrosion oil for lubricating oil system,
Tilt (waterproof) e.g. Messrs. Fina; Rusan 20 W 20 Anti-
corrosion oil for fuel system, e.g. Messrs.
Castrol : Rustillo DWX 32 Anti-corrosion
agent cooling water, e.g. Messrs. Khubier-
Chemie : Purrton 4110 Talcum powder.
Representing the outer parts of engine
1. Degrease all bright outer parts of engine and clean with

fuel,
2. Coat the bright items, e.g. linkage 6 with protecting

grease.
3. Dust all rubber items (hoses, anti -vibration mounting

pads) with talcum powder.
4. Check paintwork for damage and, if necessary repair
5. If possible locate engine in storage area, spray with

preserving oil (spray gun) and cover with tarpaulin.
6. Note date of preservation and fix message "do not turn

crankshaft" at a prominent point on the engine.
96
Job Sheet No.
GREAVES Job Sheet 3.3.003 B
5.85 TBD3
Treating the installed engines against corrosion for lengthy standstill periods to beginning 1 2 pages
Protective grease e.g. Messrs, Fuchs KG; Antikorit -MV
eg. Messrs. Fina; Rusan 20 W 20
Spray gun Anti- corrosion oil for fuel system, e.g.
Tilt (waterproof) Messrs. Castrol: Rustilk) DWX 32
Messrs. Khubier-Chemie : Puriton 4110
Talcum powder
If the engine is kept out of operation for a fairly long period of

time, an appropriate treatment against corrosion should be done.
Treating the engine against corrosion
1. Drain engine oil (drain plugs 1), then screw in and

tighten drain plugs again.
2. Unscrew, drain and reattach oil-filter cartridge 2.

Tightening procedure for filter cartridge : screw in filter
cartridge until gasket touches slightly, then, tighten,
turning by approx. half a turn manually and using no
tool.
3. Fill engine with anticorrosion oil (filling neck 3).
4. Drain cooling water (drain cock 5) and fill engine with

mixture composed of 20 parts of cooling water and 1
part of anticorrosion agent. Vent at venting screws 6
and fill in with mixture through filling neck up to lower
mark.
5. Drain fuel out of tank, make a mixture composed of 9
parts of fuel and 1 part of anticorros ion oil and fill it into
tank.
6. Start engine, wait until oil pressure gauge indicates

pressure and then, increase speed to approx. 2/3 of
nominal speed. Allow engine to run for about 15 minutes
without load.
7. Stop engine
8. Remove air filter.
9. If the engine is equipped with Nova starting appliances,

close starting air receiver, remove starting-air line up
stream of main valve and fill approx. 0.25 dm 3 o f
anticorrosion oil into starting line. Connect starting line
again.
10. Crank engine using starting appliances while holding stop

lever 4 on stop position. Spray anticorrosion oil into open
air-intake pipes, using a spraying gun, during the starting
process.
11. Attach air filter.
12. Drain anticorrosion agent out of fuel tank, oil pan and
cooling system.
13. The intake and exhaust line being already laid must be
closed so as to keep external atmospheric influences
away from the engine interior.
97
GREAVES Job Sheet
5.85 TBD3 3.3.003 B
read thoroughly prior Page 2 of 2
Treating the installed engines against corrosion for lengthy standstill periods to beginning
Protective grease e.g. Messrs, Fucfis KG; Antikorit -MV

Spray gun e.g. Messrs. Fina; Rusan 20 W 20
Anti-corrosion oil for fuel system, e.g.
Tilt (waterproof) Messrs- Castrol : Rustillo DWX 32
Messrs. Khubier -Chemie : Puriton 4110
Talcum powder.
Preserving the outer parts
1. Coat all bright items, e.g. control linkages (Fig. 4} with

protecting grease.
2. Dust all rubber items (hoses, anti -vibration mounting

pads) with talcum powder.
3. Check paintwork for damage and, if necessary, repair.
4. Locate engine in storage area, spray with preserving oil

(spray gun) and cover with tarpaulin.
5. Note date of preservation and fix message "do not turn

crankshaft" at a prominent point on the engine.
Caution! Repeat preservation after at least 3 months
98
Job Sheet first time after after and every Engine type Job Sheet No.
GREAVES Date
TBD3
9.84 3.3.007 A
Cleaning fresh water recooler (indirect read thoroughly prior
Page or
cooling) to beginning
1 2 pages
1 O-rings 6.0493.10.4.1405
2 O-rings 6.0493.10.4.1655 63 -
Tool set 1 O-ring 6.0493.10.5.0803
Brush 1 Sealing ring 6.0492.01.0.1418
Stud, min. 100 mm long, M 8 1 Sealing ring 6.0492.01.0.0814
1 Sealing ring 6.232. 0.850.004.4
Wevolic 2 Sealing compound 6 0153.70.1.0205
Fuel 6.0153.70.1.0205
For the protection of the engine, the cooling system is divided

into a raw water circuit and a fresh water circuit. The fresh
water absorbs the heat given off by the engine and passes it
on to the raw water in the heat exchanger. Efficient exchange
of heat is only ensured when the walls of the tube bundle in
the heat exchanger are free of dirt and scale.
Removing and cleaning the tube bundle
1. Close the raw water cocks.

2. Drain cooling water at drain cocks (Fig. 1, item 1 for
fresh water, item 2 for raw water). Collect the fresh water
for reuse.
3. Remove fuel filter (Fig. 2) with mounting bracket and
place on engine.
Caution!
Do not kink the hoses!
4. Remove raw water connections (Fig. 1, item 4) and fresh
water return (Fig. 3, item 1)
5. Remove flange connector for fresh water return (Fig. 3
arrow)
6. Unscrew bolts mounting headers (Fig. 1, item 3) and
adjusting screw (Fig. 1 item 5), Remove headers.
7. Withdraw tube bundle (Fi g. 4) from shell and clean in
fuel with brush. Check the solder joints on the jacket
(Fig. 4, arrows) and re-solder if necessary.
8. Clean the remaining parts in fuel. Check the supply lines
for fouling and clean if necessary.
9. Remove gasket {Fig. 5, arrow) on flange connector for
fresh water return, clean seat and apply new gasket with
sealing compound (bond only the end face).
10. Renew all the other seals, applying grease to the O-rings.
99
GREAVES Job Sheet D3
9.84 TBD3
3.3.007 A

Cleaning fresh water recooler (indirect cooling) to beginning 2 2 pages
Tool set 4 O-rings 6.0493.10.4.1405

2 O-rings 6.0493.10.4.1655 63 -
Brush 1 O-ring 6.0493.10.5.0803
Stud, min. 100 mm long, M 8 1 Sealing ring 6.0492.01.0.1418
1 Sealing ring 6.232.0.850.004.4
Wevolic 2 Sealing c ompound 6.0153.70.1.0205
Fuel
11. Screw in the stud M8 x 100 (or longer) into the adjusting
tapping of the tube bundle and mount the header on
the tube bundle (Fig. 6)
12. Unscrew stud and fit adjusting screw.
13. Coat sealing surface (Fig. 7, arrow) of the header with

sealing compound, place tube bundle in shell (Fig. 7)
and screw in the mounting bolts loosely.
Note :
The sealing compound is necessary for heat insulating

purposes, since greatly differing temperatures arise in
the shell and header.
14. Coat the sealing surface of the second header with

sealing compound and fit header.
15. Fit flange connector, ensuring proper location of gasket.

If required, realign tube bundle by turning the header
(Fig. 7)
16. Tighten the headers.
17. Refit fuel filter, raw water and fresh water connections.
18. Filter the fresh water through a cloth and refill, bleed
by means of the bleeder plugs (Fig. 9, Pos. 1) and top
up fresh water up to the bottom mark (Fig. 8).
100
first time after after and every Engine type Job Sheet No.
Job Sheet Date
GREAVES 5.85 TBD3
3.3.007 B
Cleaning fresh water re cooler (indirect cooling) read thoroughly prior Page of
Set of tools 1 set of gaskets 6.234.0.013.005.7 63 -

Brush (Nylon) Fuel
Round iron 150 mm long, 5 mm
Rubber arch
The cooling system of the engine is divided into a raw water

circuit and a fresh water circuit. The fresh water absorbs the
heat given off by the engine and passes it on to the raw water
in the heat exchanger. Efficient exchange of heat is only ensured
when the walls of the tube bundle in the heat exchanger are
free of dirt and scale.
Removing and cleaning the tube bundle
1. Close the raw water cocks.

2. Drain cooling water at drain cocks (Fig. 1 for fresh water,
Item 2 for raw water). Collect the fresh water for reuse.
3. Remove fuel filter (Fig. 2) with mounting bracket and
place on engine.
Caution!
Do not kink the hoses!
4. Remove raw -water connections (item 3)

5. Unscrew fastening screws (Item 4) from both head
pieces (Item 5) and take down head pieces.
6. Insert 2 rods irons (5mm dia.) on left-hand and right
hand side of the tube nest (bracket)
7. Extract tube nest from its seat by knocking gently (mallet)
and lift it off the housing at rod irons.
8. Clean tube nest in fuel, using a nylon brush (inside the
tubes), then rinse with pure water. Check soldering joints
of jacket (Item 6) and re solder, if necessary. Clean head
pieces and screws in fuel as well.
9. Check cooling-water lines for contamination and clean,
if necessary.
NOTE :
Replace all seals and O-rings. Coat O-rings with grease.

Pay attention to proper attachment when mounting tube
nest (Item 9)
10. Assemble in reverse sequence.
11. Filter fresh water through cloth and fill up again; vent at
venting screws (Item 7) and top up with fresh water up
to bottom mark (Item 8)
12. Open the raw water cocks. Fill the raw water pump.
101
CODE NO. : 1.233.0.006.026.4 (01) 04/08
In view of continuous improvements the specifications are subject to change without notice.
GREAVES COTTON LTD
WATER COOLED
DIESEL ENGINE
TBD3 V12 SERIES
SPARE PARTS CATALOGUE
Diesel Engines Unit

Chinchwad, Pune- 411 019. INDIA
Tel. : (091-020) 27473564 /65/66/67
Fax: (091-020) 27472276
e-mail : [email protected]
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).
2. 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).
3
GREAVES COTTON LTD
WATER COOLED DIESEL ENGINE
TBD3 V12
INDEX
Sr. No. Description Page No.
1 Crankcase 7,8,9,10
2 Flywheel Housing 11
3 Front wall 12,13
4 Crankshaft Assembly 14
5 Piston and Connecting Rod 15,16
6 Camshaft 17
7 Valve with Actuation Mechanism 18
8 Cylinder Head with Cover 19,20
9 Fuel Pump & governor 21,22
10 FUEL FILTER & WATER SEPARATOR 23,24
11 Fuel Pump Drive 25
12 Fuel Injector with over flow 26
13 High Pressure, Fuel Injector Pipes and Overflow 27,28
14 Fine Speed Adjusting Device 29
15 Fuel on Solenoid Shutdown Device 30
16 Lub. Oil Sump 31
17 Gear Type Lub. Oil Pump with Suction Pipe 32
18 Lub. Oil Filter 33
19 Oil Cooler Assembly 34,35

20 Cooling Water Pipes 36
21 Centrifugal Water Pump {Fresh Water) 37

22 Circulation Cooling 38,39
23 Radiator and Radiator Mounting Bracket 40

24 Fan drive 41,42
25 Tension Roller for Fan & Water pump 43
26 Air Intake Manifold 44,45
5
Sr. No. Description Page No.
27 Exhaust Pipe 46
28 ASSEMBLY OF SUPERCHARGER GROUP 47,48
29 Air Filter (Dry Type) 49
30 TURBOCHARGER PIPING HE COOLED ENGINE 50,51,52
31 CIRCULATION HE COOLING 53,54
32 CENTRIFUGAL ASSEMBLY 55
33 EXHAUST OUTLET 56
34 Turbocharger Assembly 57
35 CASING FOR TURBINE 58
36 Exhaust Silencer 59
37 Engine Foot 60
38 Battery Charging Alternator and Starter Motor 61
39 Gauges and Switches 62
40 Instrument Panel and Engine Protection Unit standard 63,64
40 Instrument panel std. EPU with electronic governor 65,66,67
41 Instrument panel and pricol engine protection unit with solenoid 68,69
42 Instrument panel pricol EPU with ele. governor 70,71,72
43 Set of gaskets 73,74
44 Set of ‘O’ Rings set of flexible pipes 75
45 Set of hoses 76
46 Set of hose clip 77
47 Cylinder head de carbonsing & overhauling kit 78
48 Top overhauling kit for cylinder 79
49 Servicing Kit for Lub cooler / Centrifuge 80
50 Overhauling kit for HE 81
6
CRANKCASE
Fig. Part no Special Data Description Qty for Qty for TBD
No. TBD 3V 12 3V12 Non Remarks
Emission Emission
1 123301100067 Crank Case, Compl 1 1
Consist of fig. No. 3 -
33
3 623203100014 Dowel Pin 7 7
4 623203100024 Dowel Pin 7 7
5 623203300224 Bush FIP Locating 1 1
6 602000181856 BM18X 165 DIN 931m Hexagon Screw 28 28
12.9
7 623404320022 Cam Bearing Bush 2 2
9 602150611851 Washer 28 28
10 623404320012 Cam Bearing Bush 5 5
12 620513270014 ? 10 mm Plug Aluminum 8 8
13 632413270024 ? 14 mm Plug Aluminum 4 4
14 620609760024 ? 25 mm DIN 443 - Cap 6 6

6CRMO17
15 123304650015 Nozzle for cooling oil 12 12
17 602000100845 M8X45DIN931 -8.8 Hexagon screw 12 12
19 602160310080 B8DIN 137 Spring washer 12 12
22 623203300144 Sleeve 24 24
23 623403300114 Sleeve 24 24
25 620609760014 30DIN443-XCRM017 Brass Cap on Main 6 6
Lub oil Gallery
27 602060501215 AM12X1.5DIN7604.5.8 Screw Plug 1 1
28 604920101218 A12X18DIN7603 -Cu Copper washer 1 1
7
CRANKCASE
No. TBD 3V 12 3V12 Non Remarks
Emission Emission
29 604920101014 Washer 1 1
30 60206050 0815 M8X16DIN933 -8.8 Hexagon Screw 1 1
31 623203400084 Thrust washer - Steel 2 2
32 623203400074 Thrust washer - 2 2
Bronze
33 623203400122 0.060" o/w (1.5mm) Thrust washer 2 2
(Repair stage)
34 602032100612 AM6X12DIN963 -5.8 Countersunk screw 4 4
35 602201500408 4X8 DIN 1481 Clamping Sleeve 7 7
43 602201001024 10m 6X24 DIN 7 Straight pin 4 4
45 602100540080 M8 DIN934m - 10 Hexagon Nut 1 1
46 602011010811 M8X110DIN939-5.8 Stud 4 4
47 623207880524 Cover Plate 1 1
49 623208530154 Shaped gasket 1 1
50 602000500820 M8X20 DIN933-8.8 Hexagon Screw 8 8
51 602160100080 B 8 DIN 127 Spring Washer 9 9
52 602032100815 AM8X15 DIN 963 - 5.8 Countersunk Screw 1 1
for Cover plate
63 604931301401 14X3 'O' Ring 24 24
64 623406370114 Bracket 1 1
65 602000502040 M20X40 DIN 933m-8.8 Hexagon screw 1 1
66 602150120210 21 DIN125-V2A Washer 1 1
70 623204300017 Main Bearing Pair 7 7
complete
123204300017 Main Bearing Pair - 7 7
Alternative to above
123204300117 Main Bearing Pair - 7 7
72 123301320024 Cylinder liner 12 12
73 604931314202 142X4, 5 DIN 3770 'O' Ring 24 24
8
CRANKCASE
Fig. Part no Special Data Description Qty for Qty for TBD Remarks
No. TBD 3V 12 3V12 Non
Emission Emission
101 623284300037 Main Bearing Pair - 7 7
Repair Stage - 1
123484300137 Main Bearing Pair - Repair 7 7
Stage - 1 (Alternative to
above)
102 623284300057 Main Bearing Pair - Repair 7 7
Stage - 2
above)
Stage - 3
above)
Stage - 4
above)
9
FRONT WALL COVER
Fig. No. Part no Special Data Description Qty for Qty for
TBD TBD 3V12 Remarks
3V 12 Non
Emission
Emission
1 123207800166 Front wall cover, 1 1
complete. With fig. No.
1A 123207800164 Front Wall Cover without 1 1
Oil seal
2 604960650901 Oil seal 1 1
3 623208530094 Shaped gasket 1 1
4 602000100860 M8 × 60 DIN-931 -8.8 Hexagon screw 7 7
5 602000100870 M8 × 70 DIN-931- 8.8 Hexagon screw 1 1
7 602000110813 M8 ×130 DIN-931-8.8 Hexagon bolt 1 1
8 602000111013 M10×130DIN-931- 8.8 Hexagon bolt for Fan 2 2
Drive
9 602000500820 M8 × 20DIN-933 -8.8 Hexagon screw 5 5
10 602160310080 B8 DIN-137 Spring washer 7 7
11 602160100100 Spring washer 2 2
12 602011010811 M8 X 110 Stud 4 4
13 602100540080 M8 Hex. Nut suitable for 4 4
above stud
14 602160100080 M8 Spring washer 4 4
15 * 602000110815 M8 X 150 Hexagon Screw for 2 2
Centrifuge Mounting
16 * 602000500825 M8 X 25 Hexagon Screw for 2 2
Centrifuge Mounting
17 623207870214 cover 1 1
20 602160100080 Spring washer 12 12
21 623206500494 Bracket 1 1
22 602000100895 M8 × 95 DIN-931 - 8.8 Hexagon screw 3 3
* Not Illustrated
10
FRONT WALL COVER
Fig. No. Part no Special Data Description Qty for Qty for TBD
TBD 3V12 Non Remarks
3V 12 Emission
Emission
27 623209760034 Cover 1 1
29 604931041243 "O" ring 1 1
30 630507870124 Cover 1 1
31 604931040423 "O" ring 1 1
32 602032100815 Countersunk screw 1 1
34 * 123209423207 Venting Valve Assembly 1 1

consisting Fig No. 35 - 39
35 123409420615 Vent pipe 1 1
36 604931000204 'O' Ring 1 1
37 604021002415 Pipe clip 1 1
38 602000500612 M6x12 DIN 931-8.8 Hexagon Screw for pipe 1 1

clip
39 602160100060 Spring washer for pipe clip 1 1
40 602100540060 M6 DIN-934m - 10 Hexagon Nut for pipe clip 1 1

62 602007011216 M12 160 DIN-912- Allen screw 2 2
10.9
63 602150611251 Washer 4 4
64 602100540120 M12 DIN-934m - 10 Hexagon Nut 2 2
* Not Illustrated
11
FLYWHEEL HOUSING
TBD 3V 12 3V12 Non Remarks
Emission Emission
1 123207010384 Flywheel Housing 1 1

SAE – 1 with oil seal
2 123207010380 Flywheel Housing 1 1
SAE – 1 with out oil seal
3 604960651332 Oil Seal Flywheel side 1 1
4 623208530094 Shaped Gasket 1 1
5 602000100885 M8 × 85 DIN-931 - Hex. Screw 5 5

8.8CL
6 602160310080 B8 × DIN-137 Spring Washer 5 5
7 602001001665 M16 × 1.5 × 65 DIN- Hex. Screw 1 1

960- M-8G
8 602000100845 M8 × 45 DIN-931 – 8G Hex. Screw 2 2
9 602160310160 B16 DIN-137 Spring Washer 1 1
12 602000101260 M12 × 60 DIN-913m - Hex. Screw 8 8

8G
13 602007011216 M12×60 DIN-912 - 10K Allen Screw 2 2
14 602150100170 Plain washer (Starter 3 3

Mounting)
15 602160100160 Spring Washer (Starter 3 3
Mounting)
16 602000501640 M16 X 40 – 10.9 CL Hex Bolt (Starter 3 3
Mounting)
12
CRANK SHAFT
Fig. Part no Special Data Description Qty for Qty for Remarks
No. TBD 3V12 TBD 3V12
Emission Non
Emission
1 123301400066 Crankshaft, compl. consist 1 1
of Fig No. 2-8
2 623413270014 Plug 12 12
3 623203710014 Crank Gear 1 1
4 P23303710014 Front Gear Wheel (Lub oil 1 1

Pump Driving)
5 123206700014 Balance weight 6 6
6 602000121690 M16X90 DIN912-10.9 Allen screw 12 12
7 602201500614 6X14 DIN 1481 Spring dowel 1 1

9 623203400064 Crankshaft ring 1 1
10 602001016401 BM 16X1X1.5X75 Hex screw 8 8
DIN96
14 123201450815 Flywheel (For Sm 130 PE) 1 1
16 123203750054 Starter ring 1 1

17 623203810344 (5 GROOVED) Crankshaft pulley - for 1 1
Radiator cooled engine
and HE cooled Marine
engine
20 623207030164 Vibration damper 1 1
21 623204110174 Cranking Ring 2 2

30 602001014401 BM 14X1.5X75 DIN Allen screw 10 10
96
32 623203810144 3Grooved V - Belt pulley - for HE 1 1
Cooled non Marine engine
34 632113400014 Washer 12 12
13
PISTON AND CONNECTING ROD
No. TBD 3V12 3V12 Non
Emission Emission
1A 123301600016 Piston assembly (Non- 12
Emission) consisting of
1A E23301600016 Piston assembly 12 -
(Emission) consisting of
Bare Piston + G Pin + Cir
clips
1 123301600014 Piston bare (Non - 12 Not Supplied in
Emission) spare
1 E23301600014 Piston bare ( Emission) 12 -
2A 623400190077 Piston Ring set consisting 12 12
of three rings
2B 123400190077 Piston Ring set consisting 12 12

of three rings - Alternative
to above
5 605020305001 Gudgeon Pin 12 12
6 603050200050 Cir clip ( Lock ring) 12 12
7A 123301500017 Connecting rod assembly 12 12
consisting of Con .Rod +
Bush + Con rod Bolts as
given at Fig No.8 -10
7 123301500016 Connecting rod - Bare 12 12
(With out bush )
8 123304310014 Con Rod Bush 12 12
9 623203530014 M 16 X 1.5X73 Con rod Bolts 24 24
10.9
10 602201500420 M 4X20 DIN Clamping Sleeve or 12 12
1481 Spring dowel
14
PISTON AND CONNECTING ROD
Emission Emission
11 623204306107 91.942- 91.964 mm Connecting rod 12 12

Bearing Top +
Bottom - Std size
11 123204306107 91.942- 91.964 mm Connecting rod 12 12

Bearing Top +
Bottom - Std size –
12 623284306027 91.692 - 91.714 mm Connecting rod 12 12
Bearing Top +
Bottom -Repair
Stage - 1
13 623284306047 91/442 - 91.464 mm Connecting rod 12 12
Bearing Top +
Bottom - Repair
14 623284306067 91.192 - 91.214 mm stage -2
Connecting rod 12 12
Bearing Top +
Bottom – Repair
15 623284326087 90.942 - 90.964 mm stage -3
Connecting rod
Bearing Top + 12 12
Bottom -Repair
Stage -4
15
CAM SHAFT
No. TBD 3V12 3V12 Non Remarks
Emission Emission
1 123301700063 Cam shaft 1 1
2 123203710096 Cam gear assly. 1 1

Consisting Fig. No. 3-6,
22-23
3 602007001030 M10X30 DIN912- Allen screw 5 5
10.9
4 602160100080 Spring washer 10 10
5 602201500614 Dowel 1 1
20 623404320022 Cam Bearing bush 2 2

21 623404320012 Cam Bearing bush 5 5
22 623203710214 Gear Driving FIP gear 1 1
23 623203710294 Cam Gear 1 1
26 623203440014 Coupling Ring 1 1

27 623206730014 Segment 1 1
28 602000500820 M8X20 DIN-933- Hex. screw 2 2
8.8
16
VALVE WITH ACTUATING MECHANISM
No. TBD 3V12 3V12 Non Remarks
Emission Emission
1 623406100017 Support of rocker arm. 12 12

compl. consist of fig.
1A 123406100016 No. 2-6 Arm Bracket
Rocker 24 24
consisting of Fig No. 2 - 5
2 623406100014 Bracket Rocker Arm 24 24
3 623406450014 Rocker Arm Lever - Bare 24 24
4 623403400034 Washer 24 24
5 603050100022 22X1,2 DIN 471 Locking ring 24 24
6 623203580024 Setting screw 24 24
7 602100540100 M10 DIN 934 m-10 Hexagon nut 24 24
9 123409420315 Guard tube 24 24
10 604920102227 A22X27DIN7903- Copper washer 24 24

Cu
11 602000121065 M10X65 DIN931- Hexagon screw 36 36
10.9
12 602160100100 Washer 36 36
15 623203210034 Push Rod 24 24
16 623403250014 Mushroom-shaped tappet 24 24
17
CYLINDER HEAD WITH COVER
Emission Emission
1 E23301800017 Cylinder Head Complete consist 12 -

of Fig No. 2 to 27 expect fig No.
21 i.e. brass cap
1 123301800017 Cylinder Head Complete consist - 12
of Fig No. 2 to 27 expect fig No.
21 i.e. brass cap
2 123301800015 Cylinder Head Bare consisting 12 -
of Valve guides, Injector Sleeve
fitment and with Aluminum Plug
2 623401803055 Cylinder Head Bare consisting - 12
of Valve guides, Injector Sleeve
fitment and with Aluminum Plug
4 E23403510034 Injector Stud 24
4 623403510034 Injector Stud 24
5 623404600064 Valve (Inlet) 12 12
6 P23304600014 Valve ( Exhaust) 12 12
9. 603262001703 Roto cap 24 24
10 623403420014 Spring Cap 24 24
11 623404620014 Valve Collets 48 48
12 602403701220 Valve Spring (Outer) 24 24
13 602402701130 Valve Spring (Inner) 24 24
17 623403400174 Ring 12 12
19 623403300044 Injector Sleeve 12 12
20 623403600014 Grooved Nut 12 12
21 620609760014 Brass Cap 24 24
18
CYLINDER HEAD WITH COVER
Emission Emission
22 632413270014 10mm Dia X 11mm in L Aluminum Plug 12 12

23 604931301001 O' ring Viton (Valve Guide) 36 36
24 123403450042 Valve Seat Insert (inlet) 12 12
25 123403450032 Valve Seat Insert (Exhaust) 12 12
26 623403329014 Valve Guide with out 'O' 24 24
ring
623403329016 Valve guide with '0' ring
27 604931302404 24X5.5 MM Injector 'OT ring 12 12
30 623407960034 Cylinder Head Cover 12 12
31 623408530084 Cyl. Head cover Gasket 12 12
32 602000100855 M8X1.25X55 8.8CL Hexagon Screw 12 12
33 604920100814 A8X 14 DIN -7603 - Cu Copper Washer 12 12
36 623408550054 Cylinder Head Gasket 12 12
37 604931300902 9.0X4.5 MM O' Ring Viton 48 48
39 604931301802 18.0X5.0 MM O' Ring Viton 48 48
40 623403500044 M18X 180L - 10.9 CL Cylinder Head Bolt 48 48
41 623403400214 27.0 Dia Disc Washer 24 24
42 623403400224 17.5 Dia Disc Washer 24 24
43 623403300124 Copper Sleeve or Bush 24 24
44 623403300134 Copper Sleeve or Bush 24 24

19
FUEL PUMP DRIVE
Emission Emission
1 123207110036 Injection pump drive 1 1

compl. consist of fig.
No. 2-12
2 623207110064 Housing 1 1
3 123203000124 Shaft 1 1
4 603200406206 6206 DIN-625 Ball bearing 1 1
5 603200406011 6011 DIN-625 Ball bearing 1 1
6 603050200090 90 × 3 DIN-472 Circlip 1 1

7 604960103040 B30 × 52 × 12 DIN- Oil seal 1 1
6503 - B1 Fg
8 602352006010 6× 10DIN-6888 Key 1 1
9 623203710204 Gear wheel 1 1
11 602201500624 6×24DIN-1481 Spring dowel 1 1
12 602007041035 M10×35DIN-912 - 10.9 Allen screw 5 5
13 604931040803 O-ring 1 1
24 623200330027 Coupling Assly. 1 1
Consisting of Fig. No.
25, 27
25 12320 0330026 Disc Coupling Sub- 1 1
Assembly
27 6232030100 35 Shaft 1 1
20
FUEL PUMP AND GOVERNOR
No. TBD 3V12 Non
3V12 Emission
Emission
1 623407253266 PE-12 P12DA520/5RS Fuel injection 1 1
428-1 RSUV 300-900 Pump (BOSCH)
POA 320-1 FP/KD22 Type -S1000 With
P10 BOSCH Assly RSUV Governor
Part No. 0 401 870 and feed Pump.
091. 0440008008
1 123407253266 Fujikura - PE - 12 Fuel Injection Pump 1 1
Complete with RSUV
Governor and Feed
Pump - alternative to
above
12 605202030027 Feed pump 1 1
13 623409010205 Pipe 1 1
14 623206500294 Bracket 1 1
15 631349770014 Pipe clip half 1 1
16 632449770124 Pipe clip half 1 1
19 602100540060 M6 DIN934m - 10 Hexagon Nut 1 1
20 602160100060 B6 DIN 127 Spring Washer 4 4
21 600099775194 Pipe clip 1 1
23 602000500815 M8X15 DIN933-8.8 Hexagon screw 2 2
24 602160100080 B 8 DIN 127 Spring washer 2 2
25 604043200004 A 4 DIN 7623 Banjo screw 1 1
26 604920101014 A10X14 DIN7603 -Cu Copper washer 2 2
29 604043200006 A 6 DIN 7623 Banjo screw 2 2
30 604042300080 Adaptor 1 1
31 604920101218 A12X18 DIN7603-Cu Copper washer 4 4
32 604920101420 A14X20 DIN7603-Cu Copper washer 12 12
33 123499390075 Cu. Drain Pipe 1 1
21
FUEL FILTER & WATER SEPARATOR
Fig. Part no Special Data Description Qty Qty for TBD Remarks
No. forTBD 3V12 Non
3V12 Emission
Emission
25 123207400447 Fuel Pre-Filter 1 1
Assembly
26 106900000033 'O' ring 1 1
27 105413100062 Filter Element 1 1
28 001200243950 Water Separator 1 1
29 100099390374 500 mm Long Flexible Pipe 1 1
30 604043200008 Banjo Bolt 4 4
31 604920101418 Copper washer 8 8
32 001200240183 Fuel filter ass y.. Compl. 1 1
Consisting of fig. 33-40
33 001200240911 Fuel element (felt type) 1 1
34 001200240912 Fuel element (paper 1 1
type)
35 606903780602 Console or Cover 1 1
36 001200240901 'O' ring 2 2
37 602000100895 M8X95 DIN931-8.8CL Hexagon screw 2 2
38 604920100814 A8 X 14 DIN 7603 - Cu Copper was her 2 2
39 602060501415 AM14 X1.5 DIN 7604 Screw Plug 1 1
40 104532960001 Overflow Valve 1 1
41 604920101418 Copper washer 11 11
42 604043200008 Banjo Screw 2 2
22
FUEL FILTER & WATER SEPARATOR
Emission Emission
43 123206230314 Bracket for Fuel Filter 1 1
44 620799730055 Drip Tray 1 1
For HE
CL
46 602150100105 Plain washer 1 1 Cooled
engine &
47 602160100100 M10 Spring washer 3 3 Higher RPM
48 602100540100 M10 Hexagon Nut 1 1 RC cooled
Engines
49 623203300464 Bush 2 2
*602060501415 Plug on tray 1 1
*604920101418 Copper washer 1 1
50 602160100080 M8 Spring washer 2 2
51 602000500820 M8 X 20 - 8.8 CL Hexagon screw for 3 3
filter mounting
52 602160100080 bracketwashers for
Spring 3 3
above Hex. Screws. For new RC
53 602000101045 M10 X 45 DIN-931-8.8 Hex Screw for 3 3 engines
Filter mounting @1500 RPM
54 602150100105 Plain washer 3 3
55 602160100100 Spring washer 2 2
56 602100540100 M10 Hex. Nut 2 2
57 *100099392095 Junction Injection 1 1
overflow Pipe –
Combined
58 *623209390304 450 MM Long Flexible Pipe – Hand 1 1
priming pump to Fuel
lift Pump
59 *123209390124 840 MM Long Flexible Pipe – Feed 1 1
Pump to Fuel filter
60 *623209390324 580 MM Long Flexible Pipe – Fuel 1 1
Filter to FIP
61 *100099390744 1500 MM Long Flexible Fuel Pipe 2 2
* Not Illustrated
23
FUEL INJECTOR WITH OVER FLOW
Fig. No. Part no Special Data Description Qty for Qty for TBD Remarks
TBD 3V 12 3V12 Non
Emission Emission
E05302000050 F002C7Z121 Injector assembly 12 -

Complete- Emission
1 105302000001 K. B. EL-9053/13 Injector assembly - 12
(0 432 291 569) +DLLA - 142SV Complete – Non Emission
3118720
2 623406530034 Bracket 12 12
3 602100540080 M8 DIN-934m - 10 Hexagon nut 24 24
4 602150100084 A-8-4 DIN-125 - St Washer 24 24
5 623408550044 Sealing ring 12 -
5 604920690092 20 X 9.5 X 2 MM Seal Washer or Sealing 12
ring
6 604931040203 20 × 3 DIN-3770 "O" Ring 12 12
7 105300100056 Nozzle-four hole –for non - 12

emission as well as for
higher RPM
7 105302000004 with 5 Holes DLL Nozzle-four holes 12 -
(12270158) A14251188
8 1234093900 44 Injector overflow pipe 2 12
metallic
9 604920100610 Copper washer 24 24
10 604043350613 Banjo Screw 12 12
11 623203308024 Bush 12 12
12 100099392095 Fuel pipe – over flow 1 1
24
HIGH PRESSURE FUEL INJECTOR PIPES AND OVERFLOW
Fig. No. Part no Special Data Description Qty for Qty for
TBD 3V 12 TBD 3V12 Remarks
Emission Non
1 E23209061105 Cyl. A1 Fuel pressure pipe 1 1
7 E23209061165 Cyl. B1 Fuel pressure pipe 1 1
14 606907241109 Pipe clip 2 2
15 606907241108 Pipe clip 2 2
16 606907241107 Pipe clip 6 6
19 623209060285 Fuel pressure pipe 1 1
20 623209060295 Fuel pressure pipe 1 1
21 623203500074 Banjo screw 1 1
22 623206500294 Bracket 1 1
23 604021001015 Pipe clip 1 1
24 602000500612 M6X12-DIN933-8.8 Hexagon screw 1 1
25
HIGH PRESSURE FUEL INJECTOR PIPES AND OVERFLOW
Emission Emission
25 123206500254 Bracket 1 1
26 1052001000 05 Hand pump, compl. 1 1
27 602000500630 M6X30DIN933-8.8 Hexagon screw 2 2
29 632109390304 Flexible pipe 1 1
30 604043200008 A8 DIN7623 Banjo screw 6 6
31 604920101418 A14X18DIN7603 - Copper washer 8 8

CuC
41 602100540060 M6DIN934m-10 Hexagon nut 1 1
42 602160100060 B6DIN127 Spring washer 1 1
43 602000500815 M8X16 DIN 933-8.8 Hexagon screw 2 2

46* 123309050127 Set of high pr. pipes As reqd. As reqd.
* Not Illustrated
26
FINE SPEED ADJUSTING DEVICE
Emission Emission
1 623207220216 Fine Speed adjusting 1 1
device compl. consist of
Fig. No. 2-10
2 623206320014 Bracket 1 1
3 623206400084 Lever 1 1
4 623203300164 Bush 1 1
5 630503400104 Washer 1 1

9 623203120015 Threaded spindle 1 1

10 612613020634 Hand wheel 1 1
13 623206500384 Bracket 1 1

16 6232032001 54 Threaded rod 1 1
17 602701011010 AS10LIDIN71802 Angular joint 1 1
19 602701010010 AS10DIN71802 Angular Joint 1 1
27
FINE SPEED ADJUSTING DEVICE
Emission Emission
20 602101000006 M6LI DIN934m-10 Hexagon nut 1 1
23 623206500244 Bracket 1 1
24 632403300234 Bush 2 2
25 602000500625 M6X25 DIN933-8.8 Hexagon screw 2 2
28
FUEL ON SOLENOID SHUT DOWN DEVICE
TBD 3V 12 3V12 Non
Emission Emission
1 607120170004 Lifting magnet 1 1
2 623406340145 Bracket solenoid 1 1
mounting
2A 623406340215 Bracket solenoid 1 1
mounting
3 623206410094 Lever 1 1
6 623406340094 Bracket 1 1
10 602000500835 M8X35DIN933-8.8 Hexagon screw 2 2
12 602150100084 A8,4DIN125-St Washer 4 4
17 *623406340075 Bracket 1 1
19 602160100060 B6DIN127 Spring washer 9 9
20 602700100816 G8X16DIN7152-5S Yoke end 1 1
25 623203200214 Threaded rod 1 1
26 602701011010 AS10DIN71802 Angular joint 1 1
27 602701010010 AS10LinksDIN71802 Angular joint 1 1
29 602101000006 M6LIDIN931m-10 Hexagon nut 1 1
30 623403300184 Bush 1 1
31 623406500144 Bracket 1 1
32 632143300124 Bush 2 2
34 602421902130 Tension spring 1 1
35 *623203300634 Bush 1 1
¨ Not Illustrated 29
· For ‘Prime’ power Genset application engine solenoid is optional
LUB. OIL SUMP
Emission Emission
1 623201153165 Oil sump - Aluminum 1 1
2 123203520134 AM18X1,5DIN7604 Screw plug 2 2
3 604920101824 A18X24DIN7603 -Cu Copper washer 2 2
4 123208530094 Gasket 2 2
5 123207430055 Oil filler neck 1 1
6 602012020820 M8X20 DIN8 53-8.8 Stud 3 3
7 602100540080 M8 DIN 934-8.8 Hexagon nut 3 3
8 602160310080 B8 D IN 137 Belevi washer 45 45
9 123203290095 Dip stick 1 1
12 623207870164 Cover 1 1
14 604931041404 "O" Ring 1 1
15 123208530146 Segmented gasket 1 1

17 602060502215 AM122X1.5 DIN 7604 Screw Plug for sump 1 1
18 604920102227 A22X27 DIN 7603 - Cu Copper washer 1 1
19 000207371009 Filler Cap 1 1

20 604922500051 'O' ring 1 1
23 602160310080 B8 D IN 137 Belevi washer 4 4
30
GEAR TYPE LUB. OIL PUMP WITH SUCTION PIPE
Emission Emission
1 123407300076 Gear type oil pump 1 1
(Supplied as assly.)
3 604931302202 "O" Ring 1 1
10 123409010075 Lubricating oil pipe 1 1
14 604931060353 35 X 3 MM "O" Ring 1 1
16 123306500045 Bracket 1 1
21 623209770104 Pipe clip 1 1
25 623409010715 Oil pipe 1 1
26 60200 0100850 M8 × 50 DIN-931 - 8.8 Hexagon screw 2 2
27 604931301401 "O" Ring 2 2
31
LUBRICATING OIL FILTER
Emission Emission
1 605411880008 Disposable filler 2 2
element
2 123307400016 Filter head Consists of 1 1
fig. no. 10-15
3 604931060243 O-ring 3 3
4 602000121065 M10×65DIN-931 –10.9 Hexagon Screw 3 3
5 602000111050 M10×105DIN-931 -8.8 Hexagon Bolt 1 1
6 602160100100 B10×DIN -137 Spring Washer 4 4
10 104041110002 Adapter 2 2
11 606902971202 Relief valve body 1 1
12 603251000170 Steel ball 1 1
13 606902053121 Spring 1 1
14 604920103036 Copper Washer 1 1
15 606904550104 Cap nut 1 1
32
OIL COOLER ASSEMBLY
Emission Emission
1 1232094002 27 Oil Cooler complete 1 1
consisting of fig. No. 2-43
2 6232094001 65 Nest of tubes 2 2
3 6232097200 74 Cover Plate 2 2
4 604015210503 Tighten strip 6 6
5 604015200001 Hose clamp strip 6 6
6 604931308001 'O' ring 8 8
8 602041000620 Threaded pin 2 2
9 602100540060 M6 DIN-934 M-10 Hexagon nut 2 2
10 623208610044 Packing Washer 2 2
11 604931310101 Round cord ring 4 4
12 6232094102 65 Oil cooler jacket 1 1
13 6232094201 55 Guard pipe For by pass 1 1
pipe
14 604931302001 'O' ring 2 2
15 602160100080 B-8 DIN 127 Spring Washer, 12 12
16 602000500825 M8 x 25 DIN-933-86 Hexagon Screw 12 12
18 604520480014 Cm 14 x 15 Keg. Exhaust valve 1 1
DIN-71401
19 604920101418 Copper Washer 3 3
33
OIL COOLER ASSEMBLY
Emission Emission
20 602060501415 AM18 X 1.5 DIN-1418 Screw Plug 3 3
21 604920101824 A18 X 24 DIN 7603-Cu Copper washer 1 1
22 602060501815 AM18 X 1.5 DIN-7604 Screw Plug 1 1
23 603251100024 DIN-5401 Steel Ball 1 1
24 602401302500 Pressure ring 1 1
25 602001501024 10 X 24 DIN 1481 Clamping sleeve 1 1
26 604920600262 Washer 1 1
27 623203520024 Screw plug 1 1
28 604021032020 Pipe clip 1 1
29 602160100060 B-6 DIN - 127 Spring Washer 1 1
30 602000500610 M6 X 10 DIN - 933-8G Hexagon screw 1 1
31 602160100100 Spring Washer 5 5
32 602000501020 M10 X 20 DIN 933 Hexagon Screw 1 1
35 602000501025 M10X25 DIN 933 Hexagon Screw 4 4
40 123207520064 Lub. oil cooler cover 1 1
41 123207520054 Lub. oil cooler cover 1 1
43 123209410065 Oil Cooler Jacket 1 1
44 123300190647 Lub oil cooler Repair kit As As
consisting of following Required Required
spares
4 604015210503 Tighting strip 4 4
5 604015200001 Hose Clamp strip 4 4
6 604931308001 'O' Ring 8 8
10 623208610044 Packing washer 2 2
11 604931310101 Round cord ring 4 4
14 604931302001 'O' Ring 2 2
34
CENTRIFUGAL ASSEMBLY
TBD 3V 12 3V12 Non Remark
Emission Emission s
1 623209520224 Elbow 1 1
2 123208530234 Gasket - Lub oil 1 1
Centrifuge
3 602000501030 M10 X 30 Screw 5 5
4 602160100100 B 10 Spring washer 5 5

5 604931041003 100 X 3 MM 'O' ring NBR 1 1
6 602000110815 M8 X 150- 8.8 CL Hexagon bolt 2 2
7 602000500825 M8 X 25 - 8.8 CL Hexagon Screw 2 2
8 602160100080 B- 8 Spring washer 5 5
9 604920101824 1.5 MM Copper Washer 1 1
10 623206500424 Fish plate 1 1
11 602000500815 M8 X 15- 8.8 CL Hexagon Screw 1 1
12 604021011012 Pipe clip 1 1
13 602033000512 Cheese head screw 1 1
14 602100500050 M5 Hex Nut 1 1
15 602160100050 B- 8 Spring washer 1 1
16 12340 7400517 Centrifuge assembly 1 1
17 123209011665 Pipe Lub oil supply to 1 1
Centrifuge
18 604043200008 M14 X 1.5 X 31L Banjo screw 2 2
20 604920101418 M14X18X1.5 Copper washer 4 4
21 106908740006 Paper Insert 1 1
22 * 123500190737 Centrifuge overhauling kit As required As required

* NOT ILLUSTRATED
35
CENTRIFUGAL PUMP
Emission Emission
1 123407310037 Centrifugal Pump Compl. 1 1
with 3 groove pulley
1 623407310087 Centrifugal Pump Compl. 1 1
with 2 groove pulley for
HE cooled
2 * 623407310074 Fresh Water Pump 1 1
Housing
3 * 1234040000 14 Impeller 1 1
4 * 623403000064 Shaft 1 1
5 * 604961550001 Mechanical Seal 1 1
6 * 623403400074 Ring - Heat Treated 1 1
7 *104961500005 Ceramic Ring 1 1
8 * 602151842251 52 X 42 X 2.5 MM Washer 1 1
9 * 623203300254 Bush Heat Treated 1 1
10 603200736304 6304 RS-C3 DIN 625 Ball Bearing 2 2
11 * 603050510520 52 X 2 MM Circlip Intl. 1 1
12 * 602101701611 M 16 X 1.5 MLD Grip Locknut 1 1
13 623203810524 1:1.34 Ratio Fresh Water Pulley 1 1
3 Grove
13 623203810474 1:1.34 Ratio Fresh Water Pulley – 1 1
2 Groove
14 * 604931051014 101 X 4.5 MM 'O' ring NBR 1 1
15 *623409520094 Elbow Water Pump 1 1
16 602160310060 B6 DIN 137 Beveled Washer 5 5
17 602000500620 M6 X 20 DIN 933 - 8.8 Hexagon Bolt 3 3
18 602000100680 M6 X 80 DIN931 – 8.8 Hexagon Screw 2 2
19 602000100840 M8 ×40 DIN-931 - 8.8 Hexagon Screw 2 2
20 602000110816 M8 ×160 DIN-931- 8.8 Hexagon Bolt 2 2
21 602160100080 B8 × DIN-127 Spring Washer 4 4
22 **123400190527 Water pump repair kit con. As reqd. As reqd
of 4,5,10,11,12,&14
** Not Illustrated 36
* NOT SUPPLIED LOOSE
FAN DRIVE
Emission Emission
1 123207350537 Fan Drive 1 1
2 123207880054 Plate 1 1
3 123203100074 Bearing Journal 1 1

4 603200756207 6207-Z-C3DIN625 Ball Bearing 2 2
5 623209500734 Round Flange 1 1
6 623203300654 Bush 1 1
7 602000132013 M20x 130 DIN 931- Hexagon Bolt 1 1
10.9
8 602100540200 M20XIN934 Hexagon Nut 1 1
9 602000500625 M6x 25 DIN 933-8.8 Hexagon Screw 3 3
10 123203400064 Disc 1 1
11 623203400044 Ring 2 2
12 603050100035 35x1.5 DIN 471 Circlip 1 1

13 602160100060 B6-DIN127 Spring Washer 3 3
14 123203810294 V-Belt Pulley 1 1
15 623203300324 Bush Mounting 4 4
16 602000111018 M10x 180 DIN 931-8.8 Hexagon Bolt 4 4
17 602100540100 M10DIN934 Hexagon Nut 2 2
18 602160100100 B10DIN127 Spring Washer 4 4
37
FAN DRIVE
Emission Emission
19 123204010624 Fan 1 1
20 623204110264 Intermediate Flange 1 1
21 623204110024 Intermediate Flange 2 2

24 602152160050 Cover 1 1
25A 602000500870 M8 X 70 DIN 933 – 8.8 Hexagon Screw 6 6
26 *602011001060 M10 X 60 DIN-939-5.8 Stud 2 2
* Not Illustrated
38
TENSION ROLLER FOR FAN AND WATER PUMP
Emission Emission
1 623203400174 Ring 1 1
2 623203400314 Disc 1 1
3 602000121275 M12x75 D IN 931 - Hexagon Screw -For 3 1 1

12. 9 Groove
3 602000121260 M12 X 60 DIN -931 Hexagon Screw -For 2 1 1
-12 . 9 C L Groove
4 602160100120 B1 2D I N1 2 7 Spring Washer 1 1
5 602360102206 Clamping element 1 1
6 602160100140 B1 4D I N1 2 7 Spring Washer 1 1
7 602000101460 M14x60 D I N 931 - Hexagon screw 1 1

8. 8
8 623203810604 Pulley (3 groove) 1 1
8 623203810084 Pulley (2 groove) 1
9 603200746204 6204- 2 RS - C3 DIN Ball bearing 2 2

625
10 623203300344 Bush for 3 Groove Pulley 1 1
11 623203300354 Bush for 2 Groove Pulley 1 1
12 623206400094 Lever 1 1
13 623203410086 Consist of Fig. No. Tension Roller 1 1

1-4 an d 8- 12 Assembly ( 3 Groove)
13 123203410016 Consist of Fig. No. Tension Roller 1 1
1-4 an d 8- 12 Assembly ( 2 Groove)
39
COOLING WATER PIPES
Emission Emission
2 123209121495 Cooling water pipe 1 1
4 604010104255 42 x5Px 55 DIN 73411 Piece of tube 2 2
6 604931302001 'O' Ring 2 2
7 602000501225 M12x25DIN933-8.8 Hexagon screw 4 4
8 602000501025 M10x25DIN933-8.8 Hexagon screw 6 6
9 604911005615 Gasket 2 2
12 602160100100 Spring washer 10 10
15 604911004015 40 DIN 71511 -Itoe Gasket 1 1
16 602000501025 M1 0x25 DIN 933-8.8 Hexagon screw 2 2
18 604015360380 Hose clip 4 4
21 602000501020 M 10x20 DIN 933-8.8 Hexagon screw 1 1
22 602160100100 B10-DIN-127 Spring washer 7 7
23 602160100120 B12xDIN127 Spring washer 4 4
40
CIRCULATION COOLING – RC COOLED ENGINE
Emission Emission
1 123200521486 Radiator for Continuous 1 1
rated Genset Engine
1 123200520926 Radiator for ‘P’ rated 1 1
Genset engine
2 605250100010 Thermostat 2 2
4 604931040534 NBR 53 X 4 'O' Ring 2 2
5 603460211676 A X 66 V-Belt 3 3
7 623208610304 Hose 4 4
9 602000501040 M10x40DIN933 Hex screw 4 4
15 623209120065 Cooling water pipe (Pipe 1 1

between thermostat)
16 123209420715 By – Pass pipe 1 1
17 123209424345 Cooling water pipe – 1 1
Radiator to Water Pump
20 604015360380 Hose Clip 16 16
21 623208610514 Hose Piece 2 2
22 604015300850 Hose Clip 4 4
23 623208610254 Hose 3 3
24 620708610104 Hose piece 2 2
41
CIRCULATION COOLING HE
Emission Emission
1 623409520035 Elbow - Bend compl 2 2
with fig. no. 2
2 602011001030 M10 × 30 DIN-939- 5.8 Stud bolt 4 4
3 602160310100 B10 DIN-137 Lock washer 8 8
4 602100540100 M10 DIN-934 m-10 Hexagon nut 8 8
6 604911005015 50 DIN-71511 Gasket 4 4
7 123309420305 50mm Dia X 166 L Pipe between elbow to 2 2
Thermostat
8 605250100010 Thermostat 2 2
9 123309420385 40mm Dia Pipe between 1 1
Thermostat + By-pass
10 623208610304 50 Dia X 55 L Hose Pipe 4 4
11 604015360380 40-60(2X)/9THK Hose Clip 14 14

12 6232086102 54 40mm Dia X 60 L Hose 3 3
14 123309420375 Pipe from HE to water 1 1
Pump
15 623208610384 60mm Dia X 90 L Hose for above pipe 1 1
(HE side)
16 604015300650 60 - 80 / 3X Hose Clip 2 2
17 623208610514 80mm Dia X 70 L Hose for above pipe 1 1

(Water Pump side)
18 604015300850 Hose Clip 2 2
19 123207500147 Heat Exchanger 1 1
Complete - Marine
20 604010900700 7 MM ID X 650 MM L Nylon tube for HE 1 1
42
Emission Emission
21 623406220014 Holder or Bracket for 1 1
HE and After Cooler
22 623406220024 Holder or Bracket for 1 1
HE and After Cooler
21A 623409710014 Plate 1 1
22A 623406520104 Intermediate Plate 2 2
23 602000111018 M10X1.5X180 - 8.8CL Hex. Bolt 2 2
24 602011031018 M10 X 180 - 8.8 CL Stud 2 2

25 602000121065 M10X1.5X65 - 10.9 CL Hex. Bolt 2 2
26 6021005401 00 M10 DIN 934m - 10 Hex Nut 2 2
27 602160100100 M -10 Spring Washer 6 6
28 606500100007 Anti Vibration Mounting 4 4
29 602011000815 M8 X 16 - 5.8 CL Stud 4 4
30 103460211016 Cogged Belt AX - 40 2 2
30A 602160100080 B- 8 Spring Washer 4 4
31 602100540080 M8 DIN 934m - 10 Hexagon Nut 4 4
32 123409520056 Inlet pipe to After cooler 1 1
33 123408530024 Gasket 2 2
34 123309420395 Pipe between After 1 1

cooler to HE
43
Emission Emission
35 604931000504 NBR 50 X 4 'O' ring 2 2
36 123209422735 Raw Water Outlet pipe 1 1
from HE
37 602000501225 M12X1.75X25 8.8C Hexagon Screw 4 4
38 602160100120 M12 Spring Washer 4 4
39 602000501645 M16X2.0X45 CL8.8 Hexagon Screw 8 8
40 602101500016 M16X2 - 8/CL Nylock Nut 8 8

41 602160100160 M16 Spring Washer 8 8
42 123209500344 Round Flange 2 2

43 123300190837 Overhauling kit for HE 1 1
consisting of following
parts. (Not illustrated_
44 *604931041405 'O' ring for HE element 4 4
45 *604931050803 'O' ring for Flange 3 3

socket
46 *604931041655 'O' ring for Housing 4 4
47 *604931040354 'O' ring for HE cap 1 1
48 *604920100814 A8 X 14 DIN 7603 Cu Copper Washer 1 1
49 *604920154249 A42X49-DIN7603 Cu-01 Copper Washer 1 1
50 *604920102227 A22X 27 DIN 7603 -Cu Copper Washer 2 2
51 *604920101418 A14X18 DIN 7603 -Cu Copper Washer 2 2
* NOT ILLUSTRATED 44
RADIATOR & MOUNTING BRACKET
Emission Emission
1 123206372815 Bracket - Radiator top 1 1
2 6020001008 45 M8x45DIN 931-8.8 Hexagon Screw 2 2
4 602000501025 M1 0x25 DIN 933-8.8 Hexagon Screw 1 1
5 602150100105 10.5 DIN 125 St Washer 9 9
7 602100540100 M10DIN934 Hexagon Nut 1 1

8 001260733735 A.V. Mounting 2 2
18 123209950445 Fan Guard 1 1

19 623203300234 Bush 4 4
21 602150100084 8.4 DIN 125St Washer 4 4

22 602100540100 M10 DIN 934 Hexagon Nut 4 4
23 602000501020 M1 0x20 DIN 933-8.8 Hexagon Screw 8 8
45
EXHAUST MANIFOLD
Emission Emission
1 123209302566 Exhaust manifold 2 2
2 123209302576 Exhaust manifold 2 2
5 123203510224 M8x22 (SS – 304) Stud 6 6 *
6 123203510264 M10x31 - SS Stud 12 12
7 123408520024 Oval gasket 12 12

9 602007051015 M10x115DIN 912.9 Allen screw 24 24
(01139985) X5NiCrTi2615
10 623403400494 Washer 16 16
11 123406520015 Flanged bellow 2 2
12 602101920800 M8DIN934m-10-C2A Hexagon nut 12 12
13 123408530354 Square gasket 2 2
14 123408530344 Shaped gasket 2 2
16 602101921000 Hexagon nut 20 20
17 123408530364 Gasket 4 4
19 123309310136 Exhaust elbow 'A' Bank 1 1
20 123309310146 Exhaust elbow 'B' Bank 1 1
21 623203400714 Washer 8 8
27 123203510264 M10x 30 DI Stud 8 8
N939NI
31 123203302124 Sleeve 24 24
46
AIR INTAKE MANIFOLD
Emission Emission
1 623409200364 Intake manifold 2 2
2 623408530064 Gasket 12 12
5 602160310100 B10DIN137 Beveled Washer 36 36
6 602060420012 R 1/2" DIN 910-5.8 Screw plug 6 6
7 604920102227 A22x27DIN7603-Cu Copper washer 6 6
12 604911005015 50DIN 71511 Gasket 4 4
14 602160310100 B10DIN137 Beveled Washer 8 8

17 602150100105 A10.5DIN125 -St Washer 12 12
19 623408510034 Square gasket 4 4
20 623409520044 Elbow 2 2
21 604010106065 60 x5Px 65 DIN 73411 Hose piece 1 1
23 604015120072 Hose clip 3 3
24 623409500274 Oval flange 2 2
25 602060501415 AM 14x1.5 DIN 7604- Screw plug 2 2
26 604920101418 A14x18DIN7603-Cu Copper washer 2 2
47
EXHAUST OUTLET ELBOW
Emission Emission
1 123409310016 Exh. elbow 2 2
2 602060420012 G1/2DIN910 Screw plug 2 2

3 604920102227 A22 x 27 DIN 7603-Cu Copper washer 2 2
4 623208500104 Round gasket 2 2
5 123203510264 M10x 30 DIN 939-10.9 Stud 10 10
6 602101921000 M10 DIN 70615.8 A3B Hexagon nut 10 10
7 602150100105 A10.5 DIN 125-St Washer 10 10
8 123299330565 125NW x152L Flexible Exhaust Bellow 2 2
- Stainless steel
9 100099500894 Round flange 2 2
10 604910121250 Gasket 2 2
11 602000501645 M16 X 2.0 X 45 - 8.8 Hexagon Screw 16 16
CL
12 602160100160 Spring Washer 16 16
13 602100540160 Hexagon Nut 16 16
48
COVER FOR EXHAUST MANIFOLD
Emission Emission
1 123409340035 Exh. Manifold cover 1 1
1 623409340165 Exh. Manifold cover 1 1

2 623406370104 Bracket 8 8
3 623406370144 Bracket 8 8
4 602000500820 M8x20DIN 933-8.8 Hexagon screw 16 16
5 602160100080 B8 DIN 127 Spring washer 16 16
6 602150100064 A 6,4 DIN 125-St Washer 16 16
7 602000500612 M6x 12 DIN 933-8.8 Hexagon screw 8 8
9 602000500610 M6x 10 DIN 933-8.8 Hexagon screw 8 8

10 123409340035 Exhaust Manifold cover 1 1
49
Emission Emission
1 105292000069 S3B/91H36AJS/14CF6 Turbocharger Assembly 2 2
complete for 1500 RPM
other than Gneset as
well as for higher RPM
engines.
2 *106972100014 T/c repair kit for above As Reqd. As Reqd
T/c
1 105292000073 J92 Turbocharger Assembly 2 2

complete for 1500 RPM
2 *106907210008 T/c repair kit for above As Reqd. As Reqd
T/c
* Not Illustrated
50
Emission Emission
10 123309010085 'A' Bank Lub oil drain pipe from 1 1
Turbocharger
13 123309010095 'B' Bank Lub oil drain pipe from 1 1
Turbocharger
14 604931302403 'O' Ring 2 2
15 602000500820 M8 x 20 DIN 933-8.8 Hexagon screw 9 9
16 602160100080 Spring washer 17 17
17 123408520054 Oval gasket 2 2
19 602000500825 M8 x 25 DIN933– 8.8 Hexagon screw 4 4
20 602160100080 Spring washer 10 10
25 604043930120 OL12 DIN2353-St Screw Connection 1 1
26 604043913121 KL12DIN2352-St Screw connection 2 2
27 123409010275 Lubrication oil pipe 2 2
29 623409010474 'A' Bank L.O. Supply pipe to T/c 1 1
30 623409010484 'B' Bank L.O. Supply pipe to T/c 1 1
32 123408520044 Oval gasket 2 2
34 602007000825 M8x 25 DIN 912-10.9 Allen screw 4 4
37 623409740204 Fastening plate 2 2
39 623408613014 Hose piece 2 2
40 604015310701 Hose clip 4 4
41 123208612084 Humped Hose piece 4 4
42 604015310901 Hose clip 8 8
51
Emission Emission
45 * 602000121055 M1 0x55 DIN 931-10.9 Hexagon screw 2 2
46 602000500815 M8x16 DIN 933-8.8 Hexagon screw 8 8
50 * 602150100105 A10,5DIN125-St Washer 24 24
51 602160310100 B10DIN137 Beveled washer 24 24
52 * 632593300074 Bush 4 4
53 123309420065 ‘A’ Bank Pipe from T/c to A/c 1 1
54 123309420075 ‘B’ Bank Pipe from T/c to A/c 1 1
55 123309420035 ‘A’ Bank Pipe from A/c to Intake 1 1
Manifold
57 623403500074 Vent plug 2 2
59 604920102227 A22x27DIN7603 - Cu Copper washer 2 2
60 123206373207 Pipe Clip set 4 4
63 604021072215 Pipe clip 2 2
64 602100540080 M8DIN934m -10 Hexagon nut 13 13
66 623406500134 Bracket 1 1
67 623403300084 Sleeve 1 1
70 602007001025 M1 0x25DIN 912-10.9 Allen screw 1 1
72 123309420045 ‘B’ Bank Pipe from A/c to Intake 1 1
Manifold
* Not Illustrated 52
Emission Emission
1 105292000069 S3B/91H36AJS/1.4CF6 Turbocharger Complete 2 2
1 105292000073 J 92 Turbocharger Complete 2 2

– Alternative to above
10 123309010085 'A' Bank Lub oil drain pipe from 1 1
Turbocharger
13 123309010095 'B' Bank Lub oil drain pipe from 1 1
Turbocharger
14 604931302403 'O' Ring 2 2
15 602000500820 M8 x 20 DIN 933-8.8 Hexagon screw 9 9
16 602160100080 Spring washer 9 9
17 123408520064 Oval gasket 2 2
19 602000500825 M8 x 25 DIN933– 8.8 Hexagon screw 4 4
20 602160100080 Spring washer 10 10
25 604043930120 OL12 DIN2353-St Screw Connection 1 1
26 604043913121 KL12DIN2352-St Screw connection 2 2
29 623409010474 'A' Bank L.O. Supply pipe to T/c 1 1
30 623409010484 'B' Bank L.O. Supply pipe to T/c 1 1
32 123408520044 Oval gasket 2 2
35 123409210024 Elbow for 'A' bank 1 1
36 123409210034 Elbow for 'B' bank 1 1
39 623408613014 Hose piece 2 2
40 604015310701 Hose clip 4 4
41 123208612084 Humped Hose piece 4 4
42 604015310901 Hose clip 8 8
53
Emission Emission
43 623409422585 Pipe – Turbocharger to 2 2
After cooler
45 623409210034 Elbow – Turbocharger 2 2
side
46 623408510024 Square gasket 2 2
47 602000500830 M8X30 DIN933.8.8 Hexagon screw 8 8

50 623407520055 Housing 1 1
51 123307520065 Housing, with fig.No. 52 1 1
52 602011001025 M10X25 DIN939.5.5 Stud bolt 8 8
53 623408510014 Square gasket 2 2
56 602007000890 M8X90 DIN912.10.9 Allen screw 2 2
57 602060501215 AM12X1.5 Screw plug 1 1
DIN7604.5.8
59 602060501415 AM14X1.5 Screw plug 1 1
DIN7604.5.8
60 604020101418 A14X18 DIN7603.Cu Copper washer 1 1
61 602160310100 B 10 DIN 137 Beveled washer 24 24
62 602100540100 M10 DIN934m.10 Hexagon nut 24 24

63 602150100105 A10,5 DIN1125.St Washer 24 24
65 604021071215 Pipe clip 2 2
54
Emission Emission
67 604071072216 Pipe clip 1 1
71 602011001020 M10X20 DIN939.5.8 Stud bolt 2 2

73 632593300074 Bush 2 2
74 623409010545 'B' Bank Lubricating oil pipe 1 1
75 623406500134 Bracket 1 1
76 623403300084 Sleeve 1 1
80 604920101218 A12X18 DIN7603.Cu Copper washer 1 1
81 602150611251 Washer 4 4
82 602100540120 M12 DIN934m.10 Hexagon nut 2 2
83 632403400364 Washer 2 2
84 602101500010 M1XDIN985.8 Lock nut 2 2
85 602007011216 M 12X160 DIN912.10.9 Allen screw 2 2
55
AFTER COOLER
Emission Emission
2 623409450044 Blower air cooler, 1 1
compl.,
10 606901290363 Gasket 2 2
11 602160542080 Securing washer 20 20
12 602007000836 M8X35 DIN912 Allen screw 20 20
13 602060551215 M12X1,5 DIN7604 Screw plug 2 2
14 604920101215 A12X15,5 DIN7603 Copper washer 2 2
56
Emission Emission
1 105413100099 Air filter Assembly for 1
Non DG set engine
1 105413100114 Air filter Assembly for 1
DG set engine
3 123409200030 Air intake Junction 1 1
4 123408610094 86 I/D x 45L Hose 2 2
5 604015310801 80x100 Hose clip 4 4
6 123408610104 200 I/D x 150L Hose 1 1

7 604015342101 210- 230 Hose clip 2 2
8 123406230135 SAE 1 HOUSING Bracket 1 1

8a 123406230155 SAE 0 HOUSING Bracket 1 1
9 123406500144 Plate 1 1
10 123406500154 Plate 1 1
11 606500100001 A V Mounting 4 4
12 632503400024 Disc 4 4
13 602150100084 Plain washer 6 6
14 602160100080 B8 Spring washer 6 6
15 602100540080 M8 Hex. nut 6 6
57
Emission Emission
16 602000501025 M10x 25 Hex screw 6 6
17 602150100105 A-10.5 Plain washer 2 2
18 602160100100 B10 Spring washer 6 6
19 602100540100 M10 Hex nut 2 2
20 105760100002 Vacuum indicator 1 1
21 105950200131 Sticker 1 1
22 105413100102 Air Filter Element - Outer 1 1
23 105413100103 Air Filter Element - Inner 1 1
58
CASING FOR TURBINE
Emission Emission
1 623409860045 Cladding 2 2
2 602101020630 M6X30 DIN939-8.8 Stud 4 4
3 623203300244 Bush 4 4
4 620703300034 Bush 4 4
5 602011000615 M6X16 DIN939-5.8 Stud 4 4

6 602100540060 M6 DIN934m - 10 Hexagon nut 8 8
7 602000500612 M6X12 DIN933-8,8 Hexagon screw 4 4
8 602150100064 A6,4 DIN 125-St Washer 12 12

9 623409740084 Plate 4 4
59
Charging Alternator and Starter Motor
Emission Emission
1 105710100117 Battery charging 1 1
alternator 28 V, 27A
2 132406500024 Lever 1 1
3 602100540120 M12 DIN-934 Hexagon Nut 2 2
5 602150100130 A13 DIN - 125 - St. Plain washer 2 2
6 602000501025 M10×25 DIN-933-8.8 Hexagon screw 1 1
8 602000111212 M12 × 120 DIN-931 - Hexagon Bolt 2 2
9 123206300444 Bracket 1 1
10 123206300454 Bracket 1 1
11 602000501030 M10×30 DIN-933-8.8 Hexagon screw 1 1
12 123203300194 Bush 1 1
13 602100540100 M10 DIN-934 Hexagon nut 1 1
14 602000101245 M12 ×45 DIN-931 -8.8 Hexagon screw 1 1
15 123203810394 V-belt pulley 1 1
16 602000501045 M10×45 DIN-931 -8.8 Hexagon screw 1 1
17 602150100105 10.5 DIN-125- St Plain washer 2 2

18 123209860015 V belt guard 1 1
19 103460211143 A45 V belt (cogged) 1 1
20 105720520016 24 Volt-7.5 KW Starter Motor with 1 1
flange for SAE-1
21 *602007041640 M16 X 40 Allen screw 1 1
22 *602160100160 B 16 Spring washer 3 3
* Not illustrated 60
GAUGES AND SWITCHES
Emission Emission
1 105685000620 Water temp. gauge 1 1
2 105612412501 Lub. oil pressure gauge 1 1
3 600099395045 Flex. pipe 1 1
4 630899280065 Pressure gauge pipe 1 1
5 123403550014 Adaptor 1 1
5 123503550014 Adaptor Alternative to 1 1
above
6 604920101014 Copper washer 2 2
7 604043200004 A4 DIN-7623 Banjo screw 1 1

8 001700530031 Ammeter 1 1
9 105782010018 Lub. oil pressure switch 1 1
10 105685090027 Water temp. switch 2 1
11 604920101218 Copper washer 1 1
61
SILENCER
Emission Emission
1 100099320275 Exh. Silencer for non 2
canopised DG set as
well as for higher RPM
engines
2 604910121250 Gasket for above silencer 4
1 100099320656 Exhaust Silencer – 1
Residential for Emission
compiled canopised DG
set
2 604910121500 Gasket for above silencer 4
3 123409310114 EX.JUNCTION - 1
WHISPOWER GW 500
4 100099500894 Round Flange 4 2
5 602000501645 M16X40 DIN933-8.8 Hex. screw 32 32
6 602100540160 M16X DIN 934 Hex. nut 32 32

7 123299330565 Expansion Bellow 2 2
62
ENGINE BEARERS
Emission Emission
1 623206010294 Engine foot 3 3
2 602000501235 M12×35 DIN-933 - 8.8 Hexagon screw 16 16
4 602201500624 6×24DIN-1481 Spring dowel 4 4
5 623206010304 Engine foot 1 1
6 602000501290 M12 X 90 DIN-933-8.8 Hexagon screw 4 4
CL
63
INSTRUMENT PANEL AND ENGINE PROTECTION UNIT - STANDARD
+
Emission Emission
1 100099800996 Instrument panel 1 1
2 105950200128 Front Panel 1 1
3 104980100004 Rubber grommet 5 5
4 107460100008 Micro push button 1 1
5 001700530098 Fuse 1 1
6 000090014228 2BA×5/8"lg Screw 2 2
7 602160100040 B4DIN-127 Spring washer 2 2
8 000090012002 2BA Hexagon Nut 2 2
9 107677190070 Charging lamp 1 1
10 623203300234 Bush 2 2
11 6020001008 30 M8×30 Hexagon screw 2 2
13 606500100210 Ant vibration mounting 7 7
14 602100500040 M4 DIN - 934 Hexagon Nut 14 14
17 123299810045 Bracket Instrument 1 1
Panel
17A *123406370215 Bracket Instrument 1 1
Panel
18 000207585031 Engine Protection Unit 1 1
19 123299800507 D.C. Junction Box 1 1

20 000127585017 24V DC,2N0+2NC OEN Relay 2 2
21 J23490770067 Cable Harness 1 1

assembly
21A 123490770066 Cable Harness 1 1
* Not Illustrated
64
INSTRUMENT PANEL AND ENGINE PROTECTION UNIT - STANDARD
+
Emission Emission
22 105652020109 Hour cum RPM meter 1 1
23 103010154001 Flex Tacho-cable 1.5mtr 1 1
24 123207870044 Tacho cover 1 1
25 623203550125 Adaptor+ sintered bush 1 1
26 602100101815 M18 x 1.5 Hex Lock nut 1 1
27 623203000194 Shaft for Sensor drive 1 1
28 605654850002 Driver Tachometer 1 1
29 *604931040423 'O' ring 1 1
30 *123208520044 Gasket – Tacho-drive 1 1
31 *623203440014 Clutch ring 1 1
32 *602000500825 M8x25 Hex screw 3 3
33 *602100540080 M8 DIN 934m-10 Hexagon Nut 3 3
34 *604021011820 Pipe Clip 11 11
35 *623209820294 Angle Plate 3 3
36 *623209820034 Angle Plate 3 3
37 *602000500620 M6 X 20 - 8.8 CL Hex screw 6 6
38 *602160100060 B6 DIN -127 Spring Washer 6 6
39 *602100540060 M6 DIN 934 Hex. Lock Nut 6 6
40 *123206372034 Bracket 1 1
41 *602000100860 M8 X 1.25 X 60 Hexagon Bolt 2 2
42 *602000100865 M8 X 65 - Hexagon Bolt 2 2
43 *602000501220 M12 X 1.75 X 20 Hexagon Screw 2 2
44 *602160100080 B8 Spring Washer 2 2
45 *632403400364 24 Dia Washer 2 2
46 *602000500815 M8 X 15 DIN 934 Hexagon Screw 1 1
** ABOVE IS STD SCOPE OF SUPPLY FOR CONT. RATING GEN. ENGINE AS WELL AS HIGHER RPM TBD 3 V12
INSTRUMENT PANEL, STANDARD E.P.U. WITH ELECTRONIC GOVERNOR
TBD 3V 12 3V12 Non
Emission Emission
1 106902090005 ACTUATOR ADC 225 S 1 1
106902090057 ACTUATOR (PED) 1 1
ALTERNATOR TO ABOVE
2 106902090002 ELE CNTRL UNIT ESD 5221 1 1
106902090058 ELE. CNTRL UNIT (PED) – 1 1
ALTERNATIVE TO ABOVE
3 105652190001 MAG.PICK-UP-GAC-MSP6721 1 1
100007760793 MAG PICK UP PED – 1 1
ALTERNATIVE TO ABOVE
4 602700550081 PSF-8-M6X1 SWIVEL JOINT 1 1
5 602700550082 PSFL-8-M6X1 SWIVEL JOINT 1 1
5A 123203200284 THREADED ROD 1 1
6 602100540060 M6 DIN 934M-10 HEX. NUT 8 8
7 602101000006 M6 L.H. CL/8 HEX.NUT 1 1
8 *602000500625 M6X1.25X25 8.8CL HEXSCREW 2 2
9 602150100064 M6 WASHER 10 10
10 602160100060 M-6 SPRING WASHER 7 7
11 123306373165 BRACKET-ELC GOV. 1 1
D3V12
12 602000500825 M8X1.25X25 CL8.8 HEXSCREW 4 4
13 *602100540080 M8 DIN 934M-10 HEX. NUT 4 4
14 *602150100084 M8X17X1.6 WASHER 9 9
15 602160100080 B-8 SPRING WASHER 10 10
16 *602000500820 M8X1.25X20 8.8CL HEXSCREW 5 5
17 123490770067 Cable Harness Assy. 1 1
17A *123490770066 C-HARNSS(D/TD/TBD)V12 1 1
18 *105685090027 WATER TEMP SWITCH 96 1 1
DEG.
19 *1057820100 18 PR-CONTL -SWTCH-1.5/2.2 1 1
20 *604920101418 M14X18X1.5 CU.WASHER 11 11
TBD 3V 12 3V12 Non
Emission Emission
21 602000500815 M8X16 8.8/CL HEX SCREW 1 1

22 *604021011820 PIPE-CLIP 8 8
23 *623206500294 FISH PLATE 2 2
24 *602000500615 M6X1.X16 HEXSCREW 6 6
8.8/CL
25 *602000500620 M6X20 8.8/CL HEX SCREW 1 1
26 *602000501015 M10X15L 8.8 HEX SCREW. 1 1
CL
27 *602160100100 SPRING WASHER M -10 1 1
28 *623209820024 ANGLE PLATE 3 3
29 100099800996 INSTPANEL+ACCESSORYS 1 1
30 123299810045 HOLDER FOR INST. PANEL 1 1
31 123406370215 BRACKET-INSTRUMENT 1 1
PANEL
32 606500100210 A V MOUNTG -AVD/1515A 14 14
33 602100540040 M4 D934 CL/10 HEX NUT 14 14
34 602160100040 M4 SINGLCOIL SPRINGWASHER 14 14
35 000090014228 2BA 3/4"LG SCREW CHS HD 4 4

36 *000090012002 2BA NUT ST/HEX 4 4
37 *001700530098 FUSE BOX WITH 2FUSES=35A 2 2
38 105950200128 INSTRUMENT PANEL PLATE 1 1

39 001700530031 AMMETER 1 1
40 000137760084 L.INDCTR HOLDER(RED) J/10 1 1

41 000137760082 BULB24V1.5W/TBLR/SP/THRD 1 1
TBD 3V 12 3V12 Non
Emission Emission
42 *105685000620 1380MM L W.T.GAUGE 1 1
Capillary.
43 105612412501 PRESSURE GAUGE. 1 1
44 *600099395045 M12X1.5X600 L FLEX.TUBE= 1 1
45 *630899280065 PRESSURE GUAGE 1 1
PIPE(BRAZ)
46 *604043200004 (DIN-7623) BANJO BOLT 1 1
47 *604920101014 CU.WASHER 4 4
48 105652020109 HOUR CUM RPM METER 1 1
49 103010154001 1.5MTR FLEX TACHOCABLE 1 1
50 123207870044 TACHO COVER 1 1
51 623203550125 ADAPTOR+SINTERED BUSH 1 1
52 602100101815 M18 X 1.5 HEX LOCK NUT 1 1
53 623203000194 SHAFT FOR SENSOR DRIVE 1 1
54 605654850002 DRIVER TACHOMETER 1 1
55 604931040423 'O' RING 1 1
56 *123208520044 GASKET - TACHODRIVE 1 1
57 *623203440014 CLUTCH RING 1 1
58 *J23490770067 CABLE HARNESS ASSLY 1 1
58A 123490770066 CABLE HARNESS 1 1
59 000127585017 24V DC, RELAY OEN 1 1
2N0+2NC
60 *000207760380 2.5SQ5.2IDMM LUG7010 RDTY 10 10
61 000207585031 24V EPU,FUEL-ON SOLONAID 1 1
62 *123290773077 ENGINE WIRING DIAGRAM 1 1
63 *123299800507 JUNCTION BOX DC 1 1
64 *001200530786 30A/12WAYS TERMNL STRIP 1 1
* Not Illustrated
68
INSTRUMENT PANEL AND PRICOL ENGINE PROTECTION UNIT WITH SOLENOID
Emission Emission
1 100077600018 Instrument panel Assembly 1 1
and Pricol EPU with
Standard wiring
2 100007760776 Engine Monitor - ECK 401 1 1
3 *100090770277 Engine wiring diagram with
Picol EPU and solenoid
4 *123290776837 Engine wiring diagram with 1 1
Picol EPU and solenoid
5 000090014228 2BA 5/8"LG Screw CHS HD 4 4
6 000127585019 Socket + 3CLP + SCRW 2 2
for Relay
7 001200530786 30A / 12WAYS Terminal Strip 1 1
8 123299800507 DC Junction Box 1 1
9 000127585017 Relay OEN 24V with 2 NO 2 2
and 2 NC
10 *000207761304 3.5. Mtr Length 12 Core Control Cable of 3.5 3.5
1.5 Sqmm
11 123406370575 Bracket - Pricol EPU + 1 1
Instrument Panel
12 60200050 1020 M10 X 20 - 8.8 Cl Hexagon Screw 2 2
13 602160100100 B-10 Spring Washer 2 2
14 606500110304 Anti Vibration Mounting 4 4
15 602100540060 M6 DIN 934m-10 Hexagon Nut 4 4
16 602160100060 M6 Spring washer 4 4
16A 602150100064 B-6 Plain Washer 4 4
17 J23490770868 Cable Harness assembly 1 1
consisting of Fig No. 18 -
27 Not illustrated
18 *123206372034 Bracket 1 1
19 *123206372044 Bracket 1 1
* Not Illustrated
69
INSTRUMENT PANEL AND PRICOL ENGINE PROTECTION UNIT WITH SOLENOID
Fig. No. Part no Special Data Description Qty for Qty for Remarks
TBD 3V 12 TBD 3V12
Emission Non
20 *123490770867 TBDV12 Pricol Cable Harness 1 1
21 *602000500820 M8 X 1.25 X 20 - 8.8CL Hex Screw 5 5
22 *602000500825 M 8 X 1.25 X 25 - 8.8CL Hex Screw 5 5
23 *602100540080 M8 DIN 934M-10 Hex Nut 7 7

24 *602160100080 B-8 Spring washer 7 7
25 *602160100100 M-10 Spring Washer 2 2
26 *604021091820 Pipe Clips 11 11
27 *623206370324 Holder 2 2
28 *001700530098 Fuse Box with 2 Fuses 1 1
of 35 Amps
29 *000207760380 2.5 Sqmm X 2.0mm ID Lug 7010 RDTY 10 10
30 *1057820100 18 Low oil Pressure switch 1 1
31 *105652190001 Magnetic Pick up 1 1
32 *100007760793 Magnetic Pick up - 1 1

* Not Illustrated
70
INSTRUMENT PANEL, PRICOL E.P.U. WITH ELECTRONIC GOVERNOR
TBD 3V 12 3V12 Non
Emission Emission
1 123307230017 Electronic Governor (GAC) 1 1
complete consisting of
Parts from Sl. No. 2 to 19
1 100007230017 Electronic Governor (PED) 1 1
complete - Alternative to
above consisting of Parts
from Sl. No. 2 to 19
2 106902090005 Actuator ADC 225 S 1 1
2 106902090057 Actuator (PED) - 1 1
3 105652190001 Magnetic Pick up (GAC) 1 1
MSP 6721
3 100007760793 Magnetic Pick up (PED) - 1 1
4 106902090002 Electronic Control Unit 1 1
ESD 5221 (GAC)
4 106902090058 Electronic Control Unit 1 1
(PED) - Alternative to
above
9 *123306373165 Bracket for Electronic 1 1
Governor
10 602000500820 M8 x 1.25x20 - 8.8CL Hex Screw 3 3
11 602160100080 B-8 Spring Washer 3 3
12 602700550081 PSFL-8-M6 X 1 PSF Swivel Joint 1 1
13 602700550082 PSFL-8-M6 X 1 PSF Swivel Joint 2 2
17 602100540060 M6 DIN 934M-10 Hex Nut 2 2
18 602101000006 M6 L.H. CL/8 Hex Nut 1 1
19 602000500830 M8X 1.25 X 30 - 8.8C Hex Screw 2 2
INSTRUMENT PANEL AND PRICOL ENGINE PROTECTION UNIT WITH GOVERNOR
TBD 3V 12 3V12 Non
Emission Emission
20 602160100080 B-8 Spring Washer 2 2
21 602100540060 M6 DIN 934M-10 Hex Nut 2 2
22 * 602000500820 M8X1.25X20 - 8.8CL Hex Screw 1 1
23 * 602160100080 B-8 Spring Washer 2 2
24 123203200284 Threaded Rod 1 1
25 100007760776 Engine Monitor - ECK 401 1 1
26 *100090770437 Engine wiring diagram with 1 1
Picol EPU and Ele.
Governor For AMF / PRCP
sets)
26A *100090770787 Engine wiring diagram with 1 1
Picol EPU and Ele.
Governor For SRCP sets
27 123290777037 Cable Harness Assembly 1 1
consisting of Sl No.28 - 32
28 000127585019 Socket + 3CLP + SCRW 2 2
for Relay
29 100099800917 DC Junction Box 1 1
30 001200530786 30A / 12WAYS Terminal Strip 2 2
31 000090014228 2BA 5/8"LG Screw CHS HD 8 8
32 000127585017 Relay - OEN 24 V with NO 2 2
& 2 NC
33 * 000207761304 12 Core - 1.5SQMM Control Cable 3.3 3.3
34 123206373794 Bracket for Pricol EPU + 1 1
Instrument Panel
35 123406370575 Bracket for Pricol EPU + 1 1
Instrument Panel -
36 * 602000500820 M8 X 1.25 X 20 - Hex Screw 3 3
8.8CL
37 * 602160100080 B8 Spring Washer 3 3
* Not Illustrated
72
INSTRUMENT PANEL AND PRICOL ENGINE PROTECTION UNIT WITH GOVERNOR
TBD 3V 12 3V12 Non
Emission Emission
38 606500110584 Anti Vibration Mounts 4 4
39 602100540060 M6 DIN 934M-10 Hex Nut 4 4
40 602160100060 B-6 Spring Washer 4 4
40A * 602150100064 B-6 Plain Washer 2 2
41 001700530098 Fuse Box with 2 Fuses 1 1
of 35 Amps
42 * 000207760380 2.5SQ5.2IDMM Lug 7010 RDTY 15 15
43 * 001700530096 Fuse Box with 2 Fuses 1 1
of 5 Amps
44 *J00090770988 Cable Harness 1 1
Assembly consisting of
Sl. No. 39 - 49
45 *123490770867 Cable Harness Bare 1 1
suitable for Pricol EPU
with Electronic
46 * 602000500620 M6 X 20 - 8.8 CL Governor
Hex Screw 2 2
47 * 602000500820 M8X1.25 X 20 - 8.8 CL Hex Screw 2 2
48 * 602000500825 M8 X 25 - 8.8 CL Hex Screw 2 2
49 * 602000501220 M12 X 1.75 X 20 -.8CL Hex Screw 2 2
50 * 602100540080 M8 DIN 934M-10 Hex Nut 4 4
51 * 602160100060 M6 Spring Washer 2 2
52 * 602160100080 B8 Spring Washer 4 4
53 * 602160100120 M-12 Spring Washer 2 2
54 * 604021011820 Pipe Clip 15 15
55 000207760585 Rubber Grommet 3 3
56 * 1057820100 18 Low Oil Pressure Switch 1 1
** ABOVE IS STD SCOPE OF SUPPLY FOR PRP RATING GEN SET ENGINE OF TBD 3 V12
* Not Illustrated
73
SET OF SPARES
SET OF GASKET
Fig. Part No. Description Qty. for Qty. for Remarks
No. Special Data TBD3V 12 TBD3V12
Emission Non Emission
1233001908 57 Set of Gaskets for TBD3V 12 FOR 1 1
RC Cooled Engine - Consisting of
following parts
1 623208530154 Shaped Gasket for Gear End Plate 1 1
2 623408530094 Shaped Gasket for Fly wheel 1 1
3 623208530094 Shaped Gasket - Gear End cover 1 1
5 123208520094 Gasket for Filler Neck 2 2
6 123208530146 Shaped gasket for sump 1 1
7 604911005615 Gasket for pipe from Water Pump to 2 2

L.O. cooler
Crankcase 'A' bank side
9 123408530354 Square Gasket 2 2
10 123408530344 Square Gasket 2 2
11 123408530364 Gasket 4 4
12 604911005015 Gasket 4 4
13 623408510034 Square gasket 4 4
14 623208500104 Round Gasket 2 2

15 604910121250 Gasket 2 2
16 623208520064 Oval Gasket 2 2
17 123408520044 Oval Gasket 2 2
18 604910121500 Gasket for Silencer 4 4
19 *123208520044 Gasket – Tacho-drive 1 1
** ROCKER COVER, INTAKE AND EXHAUST MANIFOLD GASKETS, CYLINDER HEAD GASKETS
HAVE NOT COVERED IN ABOVE SET. FOR THESE GASKETS PLEASE REFER CYLINDER
OVERHAULING KIT GIVEN ON PAGE NO. 81
74
SET OF SPARES
SET OF GASKET
Fig. Part No. Description Qty. for Qty. for Remarks
No. Special Data TBD3V 12 TBD3V12
1233001908 67 Set of Gaskets for TBD3V 12 FOR 1 1
HE Cooled Engine - Consisting of
following parts
1 623208530154 Shaped Gasket for Gear End Plate 1 1
2 623408530094 Shaped Gasket for Fly wheel 1 1
3 623208530094 Shaped Gasket - Gear End cover 1 1
5 123208520094 Gasket for Filler Neck 2 2
6 123208530146 Shaped gasket for sump 1 1

L.O. cooler
Crankcase 'A' bank side
9 123408530354 Square Gasket 2 2
10 123408530344 Square Gasket 2 2
11 123408530364 Gasket 4 4
12 604911005015 Gasket 4 4
13 623408510034 Square gasket 4 4
14 623208500104 Round Gasket 2 2

15 604910121250 Gasket 2 2
16 623208520064 Oval Gasket 2 2
17 123408520044 Oval Gasket 2 2
18 604910121500 Gasket for Silencer 4 4
19 123208520044 Gasket – Tacho-drive 1 1

20 604911005015 Gasket 4 4
21 123408530024 Gasket 2 2
22 623408510024 Square gasket 2 2
23 623408510014 Square gasket 2 2
24 606901290363 Gasket 2 2
** ROCKER COVER, INTAKE AND EXHAUST MANIFOLD GASKETS, CYLINDER HEAD GASKETS
HAVE NOT COVERED IN ABOVE SET. FOR THESE GASKETS PLEASE REFER CYLINDER
OVERHAULING KIT GIVEN ON PAGE NO. 81
75
SET OF SPARES
SET OF 'O' RING

Fig. Part No. Special Data Description Qty. for Qty. for Remarks
No. TBD 3V12 TBD3V12
123300190877 Set of 'O' rings for TBD3V12 RC -
cooled Engine- Consisting of
following parts
1 604931301401 14 X 3 MM 'O' ring for Push Rod Sleeve 26 26
2 604931041243 124 X 3 MM 'O' Ring on FIP cover 1 1
3 604931040423 'O' Ring - for Techo Drive cover 2 2
4 604931000204 'O' Ring for Brather pipe 1 1
5 604931040803 O' Ring for FIP drive 1 1
6 106900000033 'O' ring for Fuel Pre -filter 1 1
7 001200240901 'O' ring for Fuel Filter 2 2
8 604931040203 20 X 3 MM 'O' Ring - Injector 12 12
9 604931041404 140 X 4 MM 'O ring with above cover 1 1
10 604922500051 'O' ring for Filler Neck cap 1 1
11 604931302202 22 X 4 MM 'O' ring - Lub oil Pump Mounting 1 1
12 604931060353 35 X 3MM 'O' Ring - for Lub oil Suction pipe 1 1
13 604931060243 O' ring for Filter Head 3 3
14 604931302403 'O' Ring 2 2
15 604931040534 'O' ring 2 2
** LINER ‘O’ RINGS AND ‘O’ RINGS BETWEEN CYLINDER HEAD AND CRANKCASE NOT COVERED
IN ABOVE SET. FOR THESE ‘O’ RINGS PLEASE REFER CYLINDER OVER HAUL KIT GIVEN ON
PAGE NO. 81
76
SET OF SPARES
SET OF 'O' RING

123300190887 Set of 'O' rings for TBD3V12 HE -
cooled Engine- Consisting of
following parts
1 604931301401 14 X 3 MM 'O' ring for Push Rod Sleeve 26 26
2 604931041243 124 X 3 MM 'O' Ring on FIP cover 1 1
3 604931040423 'O' Ring - for Techo Drive cover 2 2
4 604931000204 'O' Ring for Brather pipe 1 1
5 604931040803 O' Ring for FIP drive 1 1
6 106900000033 'O' ring for Fuel Pre -filter 1 1
7 001200240901 'O' ring for Fuel Filter 2 2
8 604931040203 20 X 3 MM 'O' Ring - Injector 12 12

9 604931041404 140 X 4 MM 'O ring with above cover 1 1
10 604922500051 'O' ring for Filler Neck cap 1 1
11 604931302202 22 X 4 MM 'O' ring - Lub oil Pump Mounting 1 1
12 604931060353 35 X 3MM 'O' Ring - for Lub oil Suction pipe 1 1
13 604931060243 O' ring for Filter Head 3 3
14 604931302403 'O' Ring 2 2
15 6049310405 04 NBR 50 X 4 'O' ring 2 2
** LINER ‘O’ RINGS AND ‘O’ RINGS BETWEEN CYLINDER HEAD AND CRANKCASE NOT COVERED
IN ABOVE SET. FOR THESE ‘O’ RINGS PLEASE REFER CYLINDER OVER HAUL KIT GIVEN ON
PAGE NO. 81
SET OF FLEXIBLE PIPES

123500190847 Set of Flexible Pipes
Consisting of following parts
1 100099390374 Flexible Pipe 1 1
2 100099392095 Junction Injection overflow 1 1

combined
3 632109390304 450 MM Long Flexible Pipe - Hand priming 1 1
pump to Fuel Lift Pump
4 123209390124 840 MM Long Flexible Pipe - Feed Pump to 1 1
Fuel Filter
5 632109390324 580 MM Long Flexible Pipe - Fuel Filter to FIP 1 1
6 *100099390744 1500 MM Flexible Fuel Pipe 2 2

Long
7 632109390304 Flexible pipe 1 1
8 600099395045 Flexible pipe 1 1
77
SET OF SPARES
SET OF HOSES
123200190897 Set of Hoses for
TBD3V12 RC
consisting of
1 604010104255 following
HOSE hoses
PIPE 2 2 COMMON
2 604010106065 HOSE PIPE 1 1 COMMON


7 623208610304 HOSE PIPE 4 4 RC Cooled
10 620708610104 HOSE Bend 1 1 RC Cooled
123300190907 Set of Hoses for

TBD3V12 HE
consisting of
1 604010104255 42X 5P X 55 DIN following
Hose Pipe hoses 2 2 COMMON
73411
2 604010106065 60X5PX65 Hose Pipe 1 1 COMMON
DIN73411
3 623408613014 Hose Pipe 2 2 COMMON
4 123208612084 Humped Hose Pipe 4 4 COMMON
5 123408610094 86 I/D x 45L Hose Pipe 2 2 COMMON
6 123408610104 200 I/D x 150L Hose Pipe 1 1 COMMON
7 623208610304 50 Dia X 55 L Hose Pipe 4 4 HE COOLED
8 623208610254 40mm Dia X 60 L Hose Pipe 3 3 HE COOLED
9 623208610384 60mm Dia X 90 L Hose for above pipe 1 1 HE COOLED

(HE side)
10 623208610514 80mm Dia X 70 L Hose for above pipe 1 1 HE COOLED
(Water Pump side)
78
SET OF SPARES
SET OF HOSE CLIPS
No. TBD3V12 TBD3V12
123300190917 Set of Hose Clips for
TBD 3 V12 RC cooled
consisting of
1 604015360380 following
Hose clip hose clips 4 4 Common
2 604015120072 Hose clip 2 2 Common

5 604015310801 80x100 Hose clip 4 4 Common
6 604015342101 210- 230 Hose clip 2 2 Common
7 604015360380 Hose clip 16 16 RC COOLED
8 604015300850 Hose clip 4 4 RC COOLED
1233001909 27 Set of Hose clip for

TBD3V12 HE
consisting following
1 604015360380 hose clips
Hose clip 4 4 Common

5 604015310801 80x100 Hose clip 4 4 Common
604015342101 210- 230 Hose clip 2 2 Common
604015360380 40-60(2X)/9THK Hose clip 14 14 HE COOLED

604015300650 60 - 80 / 3X Hose clip 2 2 HE COOLE D
604015300850 Hose clip 2 2 HE COOLED
79
CYLINDER HEAD DECARBONSING KIT &OVERHAULING KIT
CYLINDER HEAD DECARBONSING KIT

No. TBD3V12 TBD3V 12
Emission Non emission
123300190777 Cylinder head De-carbon sing
Kit
1 123403450042 Valve seat Insert - Inlet 1 1
2 123403450032 Valve sea Insert - Exhaust 1 1
3 604931301001 Valve guide '0' ring 2 2
4 623404600064 Valve - Inlet 1 1

5 P23304600014 Valve - Exhaust 1 1
6 623404620014 Valve Collets 4 4
7 604931302404 24 X 5.5 MM
CYLINDER HEAD OVERHAULING KIT
123300190787 Cylinder head Overhauling Kit

1 123403450042 Valve seat Insert - Inlet I 1
2 123403450032 Valve sea Insert - Exhaust 1 1

3 604931301001 Valve Guide 'O'ring 2 2
4 623404600064 Valve - Inlet 1 1
5 P23304600014 Valve - Exhaust 1 1

6 623404620014 Valve Collets 4 4
7 603262001703 Roto cap 2 2
8 623403420014 Spring Cap 2 2
9 602403701220 Valve Spring - Outer 2 2
10 602402701130 Valve Spring - Inner 2 2
11 623403329014 Valve guide with 'O' ring 2 2
12 604931302404 Injector 'O' ring 1 1

80
SET OF SPARES
TOP OVERHAULING KIT FOR CYLINDER

No. TBD3V 12 TBD3V12
123300190757 Top Overhauling kit per
Cylinder for - D3 Series As Reqd As Reqd
Engines - Consisting of
following parts
1 604931300902 9.0x4.5 MM 'O' ring Viton 4 4
1
2 604931301802 18.0x5.0 MM 'O ring Viton 4 4
3 123408550054 Cylinder head Gasket 1 1
4 623408530084 Rocker cover gasket 1 1
5 123408520024 Exhaust Gasket 1 1
6 623408530064 Intake Gasket 1 1
OVERHAULING KIT FOR CYLINDER
Overhauling Kit - Cylinder

123300190767 for D3 Series Engines - Per As Reqd As Reqd
Cylinder - Consisting of
following parts
1 623408530084 Gasket - Cylinder Head 1 1
Cover (Rocker Cover)
2 604931300902 9 X 4.5 MM O RING VITON 4 4
3 604931301802 18 X 5.0 MM O RING VITON 4 4
4 123408550034 128DIA Gasket Cylinder Head 1 1
(Alternative to above)
6 123408520024 Gasket - Exhaust Manifold 1 1
7 623408530064 Gasket Air Intake Manifold 1 1
8 123400190077 Set of Piston Rings 1 1
123400190077 Piston Ring set (Alternative 1 1
to above) - Or
9 123301320024 Liner (Plateau Honed) 1 1
604931314202 Liner 'O'ring 2 2
81
SET OF SPARES
SET OF LUB OIL COOLER

No. TBD3V12 TBD3V12
123500190647 Lub oil Cooler Repair Kit

consisting of following
parts
1 604931308001 80 X 3.8 MM 'O' Ring 8 8
2 623208610044 Packing washer 2 2
3 604931310101 101 X 4.5 MM Round cord ring 4 4
4 604931302001 20 X 4 'O' Ring 2 2
123207402505 Centrifuge Servicing Kit
1 6049313011 23 112 X 3.2 MM 'O' ring for Rotor assembly 1 1
2 604931061582 158 X 2.3 MM 'O ring for Centrifuge cover 1 1
3 106908740006 Paper Insert 1 1
4 604931041003 100 X 3 MM 'O' ring NBR 1 1
5 123208530234 Gasket - Lub oil Centrifuge 1 1
82
SET OF SPARES
SET OF OVERHALL KIT FOR HE

No. TBD3V12 TBD3V12
Overhauling kit for HE

123300190837 (Marine Type) consisting of
following parts
1 604931041405 140 X 5 MM 'O' ring for HE element 4 4
2 604931050803 80 X 3.8 MM 'O' ring for Flange socket 3 3
3 604931041655 165 X 5 MM 'O' ring for Housing 4 4
4 604931040354 'O' ring for HE cap 1 1
5 604920100814 Copper Washer 1 1
6 604920154249 A42X49 DIN Copper Washer 1 1

7603 Cu-
7 604920102227 A22X 27 DIN Copper Washer 2 2
7603 - Cu
8 604920101418 A14X18 DIN Copper Washer 2 2
7603 - Cu
Overhauling kit for HE (Non

123300190677 Marine Type) consisting of
following parts.
1 * 604931315001 ‘O’ Ring 1 1
2 * 123208532214 Gasket 2
2
3 * 604931040354 ‘O ring 1
1
83
NUMERICAL INDEX
PART No. TO PAGE No. AND FIG
CODE NO FIG NO PAGE NO CODE NO FIG NO PAGE NO

000090012002 8 64 100077600018 1 69
000090012002 36 67 100090770277 3 69
000090014228 6 64 100090770437 26 72
000090014228 35 67 100090770787 26A 72
000090014228 5 69 100099320275 1 62
000090014228 31 72 100099320656 1 62
000127585017 20 64 100099390374 29 22
000127585017 59 68 100099390744 61 23
000127585017 9 69 100099392095 57 23
000127585017 32 72 1000993920 95 12 24
000127585019 6 69 100099500894 9 48
000127585019 28 72 100099500894 4 62
000137760082 41 67 100099800917 29 72
000137760084 40 67 100099800996 1 64
000207371009 19 30 100099800996 29 67
000207585031 18 64 103010154001 23 65
000207585031 61 68 103010154001 49 68
000207760380 60 68 103460211016 30 43
000207760380 29 70 103460211143 19 60
000207760380 42 73 104041110002 10 32
000207760585 55 73 104532960001 40 22
000207761304 10 69 104961500005 7 36
000207761304 33 72 1049801000 04 3 64
001200240183 32 22 105200100005 26 26
001200240901 36 22 105292000069 1 50
001200240911 33 22 105292000069 1 53
001200240912 34 22 105292000073 1 50
001200243950 28 22 105292000073 1 53
001200530786 64 68 105300100056 7 24
001200530786 7 69 105302000001 1 24
001200530786 30 72 105302000004 7 24
001260733735 8 45 105413100062 27 22
001700530031 8 61 105413100099 1 57
001700530031 39 67 105413100102 22 58
001700530096 43 73 105413100103 23 58
001700530098 5 64 105413100114 1 57
001700530098 37 67 105612412501 2 61
001700530098 28 70 105612412501 43 68
001700530098 41 73 105652020109 22 65
100007230017 1 71 105652020109 48 68
100007760776 2 69 105652190001 3 66
100007760776 25 72 105652190001 31 70
100007760793 66 105652190001 3 71
100007760793 32 70 105685000620 1 61
100007760793 3 71 105685000620 42 68
84
NUMERICAL INDEX

105685090027 10 61 123203710096 2 16
105685090027 18 66 123203750054 16 13
105710100117 1 60 123203810294 14 37
105720520016 20 60 123203810394 15 60
105760100002 20 58 123204010624 19 38
105782010018 9 61 123204300017 8
105782010018 19 66 123204306107 11 15
105782010018 30 70 123206230314 43 23
105782010018 56 73 123206300444 9 60
105950200128 2 64 123206300454 10 60
105950200128 38 67 123206372034 40 65
105950200131 21 58 123206372034 18 69
106900000033 26 22 123206372044 19 69
106902090002 2 66 123206372815 1 45
106902090002 4 71 123206373207 60 52
106902090005 1 66 123206373794 34 72
106902090005 2 71 123206500254 25 26
106902090057 66 123206520234 9 35
106902090057 2 71 123206700014 5 13
106902090058 66 123207010380 2 12
106902090058 4 71 123207010384 1 12
106907210008 2 50 123207110036 1 20
106908740006 21 35 123207350537 1 37
106972100014 2 50 123207400447 25 22
107460100008 4 64 123207430055 5 30
107677190070 9 64 123207500147 19 42
123200330026 25 20 123207520054 41 34
123200520926 1 41 123207520064 40 34
123200521486 1 41 123207800164 1A 10
123201450815 14 13 123207800166 1 10
123203000124 3 20 123207870044 24 65
123203100074 3 37 123207870044 50 68
123203200284 5A 66 123207880054 2 37
123203200284 24 72 123208520044 30 65
123203290095 9 30 123208520044 56 68
123203300194 12 60 123208530094 4 30
123203302124 31 46 123208530146 15 30
123203400064 10 37 123208530234 7 35
123203410016 13 39 123208612084 41 51
123203510224 5 46 123208612084 41 53
123203510264 6 46 123209011665 18 35
123203510264 27 46 123209121005 3 40
123203510264 5 48 123209121495 2 40
123203520134 2 30 123209302566 1 46
123203551544 17 35 123209302576 2 46
123209390124 59 23
85
NUMERICAL INDEX

123209400227 1 33 123309010085 10 53
123209410065 43 34 123309010095 13 51
123209420715 16 41 123309010095 13 53
123209422735 36 44 123309050127 46* 26
123209423207 34 11 123309310136 19 46
123209424345 17 41 123309310146 20 46
123209500344 42 44 123309420035 55 52
123209860015 18 60 123309420045 72 52
123209950445 18 45 123309420065 53 52
123284300137 9 123309420075 54 52
123284300157 9 123309420305 7 42
123284300177 9 123309420375 14 42
123284300197 9 123309420385 9 42
123290773077 62 68 123309420395 34 43
123290776837 4 69 123400190077 2B 14
123290777037 27 72 123400190527 22 36
123299330565 8 48 123403450032 25 19
123299330565 7 62 123403450042 24 19
123299800507 19 64 123403550014 5 61
123299800507 63 68 123404000014 3 36
123299800507 8 69 123404300137 9
123299810045 17 64 123406100016 1A 17
123299810045 30 67 123406230135 8 57
123300190647 44 34 123406230155 8a 57
123300190837 43 44 123406370215 17A 64
123301100067 1 7 123406370215 31 67
123301400066 1 13 123406370575 11 69
123301500016 7 14 123406370575 35 72
123301500017 7A 14 123406500144 9 57
123301600014 1 14 123406500154 10 57
123301600016 1A 14 123406520015 11 46
123301700063 1 16 123407253266 1 21
123301800015 2 18 123407300076 1 31
123301800017 1 18 123407310037 1 36
123304310014 8 14 123407400517 1 35
123304650015 15 7 123407402516 5 35
123306373165 11 66 123408520024 7 46
123306373165 9 71 123408520044 32 51
123306500045 16 31 123408520044 32 53
123307230017 1 71 123408520054 17 51
123307400016 2 32 123408520064 17 53
123307520065 51 54 123408530024 33 43
123309010055 31 51 123408530344 14 46
123309010055 31 53 123408530354 13 46
123309010085 10 51 123408530364 17 46
86
NUMERICAL INDEX

123408550054 36 19 602000100885 6 10
123408610094 4 57 602000100885 5 12
123408610104 6 57 602000100895 22 10
123409010075 10 31 602000100895 37 22
123409010275 27 51 602000101045 53 23
123409010275 27 53 602000101045 16 47
123409200030 3 57 602000101060 3 47
123409210024 35 53 602000101080 4 47
123409210034 36 53 602000101245 14 60
123409310016 1 48 602000101260 12 12
123409310114 3 62 602000101460 7 39
123409340035 1 49 602000110813 7 10
123409340035 10 49 602000110815 15 10
123409390044 8 24 602000110815 13 35
123409420315 9 17 602000110816 20 36
123409420615 35 11 602000111013 8 10
123409520056 32 43 602000111018 16 37
123490770066 21A 64 602000111018 23 43
123490770066 17A 66 602000111019 70 55
123490770066 58A 68 602000111050 5 32
123490770067 17 66 602000111212 8 60
123490770867 20 70 602000121055 45 52
123490770867 45 73 602000121055 72 55
123499390075 33 21 602000121065 11 17
123500190737 22 35 602000121065 4 32
123503550014 5 61 602000121065 25 43
132406500024 2 60 602000121260 3 39
600099395045 3 61 602000121275 3 39
600099395045 44 68 602000121690 6 13
600099775194 21 21 602000132013 7 37
602000100680 18 36 602000181856 6 7
602000100830 11 64 602000500610 30 34
602000100840 6 27 602000500610 9 49
602000100840 9 29 602000500612 38 11
602000100840 21 29 602000500612 24 25
602000100840 19 36 602000500612 7 49
602000100845 17 7 602000500612 7 59
602000100845 8 12 602000500615 24 67
602000100845 2 45 602000500620 16 29
602000100850 26 31 602000500620 17 36
602000100855 32 19 602000500620 37 65
602000100860 4 10 602000500620 25 67
602000100860 41 65 602000500620 46 73
602000100865 42 65 602000500625 25 28
602000100870 5 10 602000500625 9 37
87
NUMERICAL INDEX

602000500625 8 66 602000500855 25 38
602000500630 17 21 602000500870 25A 38
602000500630 27 26 602000501015 26 67
602000500812 19 31 602000501020 32 34
602000500815 23 21 602000501020 21 40
602000500815 43 26 602000501020 23 45
602000500815 9 45 602000501020 12 69
602000500815 46 52 602000501025 45 23
602000500815 46 65 602000501025 35 34
602000500815 21 67 602000501025 8 40
602000500820 50 8 602000501025 16 40
602000500820 9 10 602000501025 4 45
602000500820 28 16 602000501025 16 58
602000500820 51 23 602000501025 6 60
602000500820 12 27 602000501030 11 60
602000500820 13 30 602000501035 20 45
602000500820 17 31 602000501040 9 41
602000500820 22 38 602000501040 5 42
602000500820 4 49 602000501040 13 47
602000500820 15 51 602000501040 44 52
602000500820 15 53 602000501045 16 60
602000500820 16 66 602000501220 43 65
602000500820 21 70 602000501220 49 73
602000500820 10 71 602000501225 7 40
602000500820 22 72 602000501225 37 44
602000500820 36 72 602000501235 2 63
602000500820 47 73 602000501290 6 63
602000500825 16 10 602000501640 16 12
602000500825 14 27 602000501645 39 44
602000500825 13 29 602000501645 11 48
602000500825 16 30 602000501645 5 62
602000500825 15 31 602000502040 65 8
602000500825 16 33 602001001665 7 12
602000500825 14 35 602001014401 30 13
602000500825 19 51 602001016401 10 13
602000500825 19 53 602001501024 25 34
602000500825 54 54 602007000825 34 51
602000500825 32 65 602007000825 34 53
602000500825 12 66 602007000836 12 56
602000500825 22 70 602007000890 56 54
602000500825 48 73 602007001025 70 52
602000500830 47 54 602007001025 79 55
602000500830 19 71 602007001030 3 16
602000500835 10 29 602007011010 69 52
602000500835 4 31 602007011010 77 55
88
NUMERICAL INDEX

602007011216 62 11 602100540060 39 65
602007011216 13 12 602100540060 6 66
602007011216 85 55 602100540060 15 69
602007041035 12 20 602100540060 17 71
602007041640 21 60 602100540060 21 72
602007051015 9 46 602100540060 39 73
602011000615 5 59 602100540080 45 8
602011000815 29 43 602100540080 13 10
602011001020 71 55 602100540080 3 24
602011001025 52 54 602100540080 7 27
602011001030 2 42 602100540080 4 29
602011001060 26 38 602100540080 7 30
602011010811 46 8 602100540080 31 43
602011010811 12 10 602100540080 64 52
602011011010 8 35 602100540080 15 57
602011031018 24 43 602100540080 33 65
602012020820 6 30 602100540080 13 66
602032100612 34 8 602100540080 23 70
602032100815 52 8 602100540080 50 73
602032100815 32 11 602100540100 7 17
602041000620 8 33 602100540100 48 23
602060420012 6 47 602100540100 56 23
602060420012 2 48 602100540100 10 35
602060500815 30 8 602100540100 17 37
602060501215 27 7 602100540100 13 41
602060501215 57 54 602100540100 4 42
602060501415 39 22 602100540100 26 43
602060501415 23 602100540100 7 45
602060501415 20 34 602100540100 22 45
602060501415 25 47 602100540100 15 47
602060501415 59 54 602100540100 47 52
602060501815 22 34 602100540100 62 54
602060502215 17 30 602100540100 19 58
602060551215 13 56 602100540100 13 60
602100101815 26 65 602100540120 64 11
602100101815 52 68 602100540120 82 55
602100500040 14 64 602100540120 3 60
602100540040 33 67 602100540160 13 48
602100540060 40 11 602100540160 6 62
602100540060 19 21 602100540200 8 37
602100540060 41 26 602101000006 20 28
602100540060 21 28 602101000006 29 29
602100540060 23 29 602101000006 7 66
602100540060 9 33 602101000006 18 71
602100540060 6 59 602101020630 2 59
89
NUMERICAL INDEX

602007011216 62 11 602100540060 39 65
602007011216 13 12 602100540060 6 66
602007011216 85 55 602100540060 15 69
602007041035 12 20 602100540060 17 71
602007041640 21 60 602100540060 21 72
602007051015 9 46 602100540060 39 73
602011000615 5 59 602100540080 45 8
602011000815 29 43 602100540080 13 10
602011001020 71 55 602100540080 3 24
602011001025 52 54 602100540080 7 27
602011001030 2 42 602100540080 4 29
602011001060 26 38 602100540080 7 30
602011010811 46 8 602100540080 31 43
602011010811 12 10 602100540080 64 52
602011011010 8 35 602100540080 15 57
602011031018 24 43 602100540080 33 65
602012020820 6 30 602100540080 13 66
602032100612 34 8 602100540080 23 70
602032100815 52 8 602100540080 50 73
602032100815 32 11 602100540100 7 17
602041000620 8 33 602100540100 48 23
602060420012 6 47 602100540100 56 23
602060420012 2 48 602100540100 10 35
602060500815 30 8 602100540100 17 37
602060501215 27 7 602100540100 13 41
602060501215 57 54 602100540100 4 42
602060501415 39 22 602100540100 26 43
602060501415 23 602100540100 7 45
602060501415 20 34 602100540100 22 45
602060501415 25 47 602100540100 15 47
602060501415 59 54 602100540100 47 52
602060501815 22 34 602100540100 62 54
602060502215 17 30 602100540100 19 58
602060551215 13 56 602100540100 13 60
602100101815 26 65 602100540120 64 11
602100101815 52 68 602100540120 82 55
602100500040 14 64 602100540120 3 60
602100540040 33 67 602100540160 13 48
602100540060 40 11 602100540160 6 62
602100540060 19 21 602100540200 8 37
602100540060 41 26 602101000006 20 28
602100540060 21 28 602101000006 29 29
602100540060 23 29 602101000006 7 66
602100540060 9 33 602101000006 18 71
602100540060 6 59 602101020630 2 59
89
NUMERICAL INDEX

602160100100 22 40 602401302500 24 34
602160100100 10 41 602402701130 13 18
602160100100 27 43 602403701220 12 18
602160100100 6 45 602421902130 34 29
602160100100 18 58 602700100816 20 29
602160100100 7 60 602700550081 4 66
602160100100 27 67 602700550081 12 71
602160100100 13 69 602700550082 5 66
602160100100 25 70 602700550082 13 71
602160100120 11 12 602701010010 19 27
602160100120 4 39 602701010010 27 29
602160100120 23 40 602701011010 17 27
602160100120 38 44 602701011010 26 29
602160100120 4 60 603050100022 5 17
602160100120 3 63 603050100035 12 37
602160100120 53 73 603050200050 6 14
602160100140 6 39 603050200090 6 20
602160100160 15 12 603050510520 11 36
602160100160 41 44 603200406011 5 20
602160100160 12 48 603200406206 4 20
602160100160 22 60 603200736304 10 36
602160310060 16 36 603200746204 9 39
602160310080 19 7 603200756207 4 37
602160310080 10 10 603251000170 12 32
602160310080 6 12 603251100024 23 34
602160310080 8 30 603262001703 9 18
602160310080 23 30 603460211676 5 41
602160310080 7 31 604010104255 4 40
602160310080 49 54 604010106065 21 47
602160310100 3 42 604010900700 20 42
602160310100 5 47 604015120072 23 47
602160310100 14 47 604015200001 5 33
602160310100 51 52 604015200001 5 34
602160310100 61 54 604015210503 4 33
602160310160 9 12 604015210503 4 34
602160542080 11 56 604015300650 16 42
602201001024 43 8 604015300850 22 41
602201500408 35 8 604015300850 18 42
602201500420 10 14 604015310701 40 51
602201500614 7 13 604015310701 40 53
602201500614 5 16 604015310801 5 57
602201500624 11 20 604015310901 42 51
602201500624 4 63 604015310901 42 53
602352006010 8 20 604015342101 7 57
602360102206 5 39 604015360380 18 40
91
NUMERICAL INDEX

604015360380 20 41 604920101218 31 21
604015360380 11 42 604920101218 80 55
604020101418 60 54 604920101218 11 61
604021001015 23 25 604920101418 31 22
604021002415 37 11 604920101418 41 22
604021011820 34 65 604920101418 23
604021011820 22 67 604920101418 31 26
604021011820 54 73 604920101418 19 33
604021032020 28 34 604920101418 19 35
604021071215 65 54 604920101418 51 44
604021072215 63 52 604920101418 26 47
604021091820 26 70 604920101418 20 66
604042300080 30 21 604920101420 32 21
604043200004 25 21 604920101824 3 30
604043200004 7 61 604920101824 21 34
604043200004 46 68 604920101824 16 35
604043200006 29 21 604920102227 10 17
604043200008 30 22 604920102227 18 30
604043200008 42 22 604920102227 50 44
604043200008 30 26 604920102227 7 47
604043200008 20 35 604920102227 3 48
604043350613 10 24 604920102227 59 52
604043913121 26 51 604920103036 14 32
604043913121 26 53 604920154249 49 44
604043930120 25 51 604920600262 26 34
604043930120 25 53 604920690092 5 24
604071072216 67 55 604922500051 20 30
604520480014 18 33 604931000204 36 11
604910121250 10 48 604931000504 35 44
604910121250 2 62 604931040203 6 24
604910121500 2 62 604931040354 47 44
604911004015 15 40 604931040423 31 11
604911005015 6 42 604931040423 29 65
604911005015 12 47 604931040423 55 68
604911005615 9 40 604931040534 4 41
604920100610 9 24 604931040803 13 20
604920100814 33 19 604931041003 12 35
604920100814 38 22 604931041243 29 11
604920100814 48 44 604931041404 14 30
604920101014 29 8 604931041405 44 44
604920101014 26 21 604931041655 46 44
604920101014 6 61 604931050803 45 44
604920101014 47 68 604931051014 14 36
604920101215 14 56 604931060243 3 32
604920101218 28 7 604931060353 14 31
92
NUMERICAL INDEX

604931061582 3 35 620513270014 12 7
604931300902 37 19 620609760014 25 7
604931301001 23 19 620609760014 21 18
604931301123 2 35 620609760024 14 7
604931301401 63 8 620703300034 4 59
604931301401 27 31 620708610104 24 41
604931301802 39 19 620799730055 44 23
604931302001 14 33 623200330027 24 20
604931302001 14 34 623201153165 1 30
604931302001 6 40 623203000194 27 65
604931302202 3 31 623203000194 53 68
604931302403 14 51 623203010035 27 20
604931302403 14 53 623203100014 3 7
604931302404 27 19 623203100024 4 7
604931308001 6 33 623203120015 9 27
604931308001 6 34 623203200154 16 27
604931310101 11 33 623203200214 25 29
604931310101 11 34 623203210034 15 17
604960103040 7 20 623203300144 22 7
604960650901 2 10 623203300164 4 27
604960651332 3 12 623203300224 5 7
604961550001 5 36 623203300234 19 45
605020305001 5 14 623203300234 10 64
605202030027 12 21 623203300244 3 59
605250100010 2 41 623203300254 9 36
605250100010 8 42 623203300324 15 37
605411880008 1 32 623203300344 10 39
605654850002 28 65 623203300354 11 39
605654850002 54 68 623203300464 49 23
606500100001 11 57 623203300634 35 29
606500100007 28 43 623203300654 6 37
606500100210 13 64 623203308024 11 24
606500100210 32 67 623203400044 11 37
606500110304 14 69 623203400064 9 13
606500110584 38 73 623203400074 32 8
606901290363 10 56 623203400084 31 8
606902053121 13 32 623203400122 33 8
606902971202 11 32 623203400174 1 39
606903780602 35 22 623203400314 2 39
606904550104 15 32 623203400714 21 46
606907241107 16 25 623203410086 13 39
606907241108 15 25 623203440014 26 16
606907241109 14 25 623203440014 31 65
607120170004 1 29 623203440014 57 68
612613020634 10 27 623203500074 21 25
93
NUMERICAL INDEX

623203520024 27 34 623208610044 10 34
623203530014 9 14 623208610254 23 41
623203550125 25 65 623208610254 12 42
623203550125 51 68 623208610304 7 41
623203580024 6 17 623208610304 10 42
623203710014 3 13 623208610384 15 42
623203710204 9 20 623208610514 21 41
623203710214 22 16 623208610514 17 42
623203710294 23 16 623209060285 19 25
623203810084 8 39 623209060295 20 25
623203810144 32 13 623209120065 15 41
623203810344 17 13 623209120105 14 40
623203810474 13 36 623209390304 58 23
623203810524 13 36 623209390324 60 23
623203810604 8 39 623209400165 2 33
623204110024 21 38 623209410265 12 33
623204110174 21 13 623209420155 13 33
623204110264 20 38 623209500734 5 37
623204300017 70 8 623209520224 6 35
623204306107 11 15 623209720074 3 33
623206010294 1 63 623209760034 27 11
623206010304 5 63 623209770104 21 31
623206320014 2 27 623209820024 28 67
623206370324 27 70 623209820034 36 65
623206400084 3 27 623209820294 35 65
623206400094 12 39 623284300037 9
623206410094 3 29 623284300057 9
623206500244 23 28 623284300077 9
623206500294 14 21 623284300097 9
623206500294 22 25 623284306027 12 15
623206500294 23 67 623284306047 13 15
623206500384 13 27 623284306067 14 15
623206500494 21 10 623284326087 15 15
623206730014 27 16 623400190077 2A 14
623207030164 20 13 623401803055 2 18
623207110064 2 20 623403000064 4 36
623207220216 1 27 623403250014 16 17
623207870164 12 30 623403300044 19 18
623207870214 17 10 623403300084 67 52
623207880524 47 8 623403300084 76 55
623208500104 4 48 623403300114 23 7
623208530094 3 10 623403300124 43 19
623208530094 4 12 623403300134 44 19
623208530154 49 8 623403300184 30 29
623208610044 10 33 623403329014 26 19
94
NUMERICAL INDEX

623403329016 26 19 623408550044 5 24
623403400034 4 17 623408550054 36 19
623403400074 6 36 623408613014 39 51
623403400174 17 18 623408613014 39 53
623403400214 41 19 623409010205 13 21
623403400224 42 19 623409010474 29 51
623403400494 10 46 623409010474 29 53
623403420014 10 18 623409010484 30 51
623403500044 40 19 623409010484 30 53
623403500074 57 52 623409010545 74 55
623403510034 4 18 623409010715 25 31
623403600014 20 18 623409121655 3 41
623404320012 10 7 623409200364 1 47
623404320012 21 16 623409210034 45 54
623404320022 7 7 623409340165 1 49
623404320022 20 16 623409422585 43 54
623404600064 5 18 623409450044 2 56
623404620014 11 18 623409500274 24 47
623406100014 2 17 623409520035 1 42
623406100017 1 17 623409520044 20 47
623406220014 21 43 623409520094 15 36
623406220024 22 43 623409710014 21A 43
623406340075 17 29 623409740084 9 59
623406340094 6 29 623409740204 37 51
623406340145 2 29 623409740204 37 53
623406340215 2A 29 623409820345 69 55
623406370104 2 49 623409860045 1 59
623406370114 64 8 623413270014 2 13
623406370144 3 49 630503400104 5 27
623406450014 3 17 630507870124 30 11
623406500134 66 52 630899280065 4 61
623406500134 75 55 630899280065 45 68
623406500144 31 29 631349770014 15 21
623406520104 22A 43 632109390304 29 26
623406530034 2 24 632113400014 34 13
623407253266 1 21 632143300124 32 29
623407310074 2 36 632403300234 24 28
623407310087 1 36 632403400364 83 55
623407520055 50 54 632403400364 45 65
623407960034 30 19 632413270014 22 19
623408510014 53 54 632413270024 13 7
623408510024 46 54 632449770124 16 21
623408510034 19 47 632503400024 12 57
623408530064 2 47 632593300074 52 52
623408530084 31 19 632593300074 73 55
95
NUMERICAL INDEX
CODE NO FIG NO PAGE NO

E05302000050 24
E23209061105 1 25
E23209061115 2 25
E23209061125 3 25
E23209061135 4 25
E23209061145 5 25
E23209061155 6 25
E23209061165 7 25
E23209061175 8 25
E23209061185 9 25
E23209061195 10 25
E23209061205 11 25
E23209061215 12 25
E23301600014 1 14
E23301600016 1A 14
E23301800017 1 18
E23403510034 4 18
J00090770988 44 73
J23490770067 21 64
J23490770067 58 68
J23490770868 17 69
P23303710014 4 13
P23304600014 6 18
96
CODE NO. : 1.233.0.006.006.4 (02) 10/07
In view of continuous improvements the specifications are subject to change without notice.

Greaves Engine

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USER'S MANUAL GREAVES DIESEL ENGINE D3

Part 1; ENGINE DATA AND DESCRIPTION

Part 2 : OPERATION AND POL PRODUCTS

2.1 Preparation for First -Time Operation

3. 1.1 Other Additives

01.1 Genera l R emarks

1 of these Operating Instructions are broken down in the following assemblies

1 thes e as semblies are shown in ( he engine s ectional drawings.

01.4 Warranty claims

01.5 Measuring Units

Symbol Value Unit Denomination Further units Remarks/conversions

a Plane angle rad Radian * Degree 1 rad = 1 m/m=360

m Mass Kg Kilogram g (Grams)

f Frequency Hz Hertz 1 Hz= 1/S

P Force of liquids bar Pa (Pascal) 1pa=1N/m2

E Energy J joule Ws (watt second) 1J = 1 Ws = 1Nm

W Work KW/h (ki lowatt hour) 1kwh=3600 KJ

T Temperature K kelvin 'C (degrees Celsius) O c =273.15K

Prefix Abbrevation Value

Mega M 105 = 1000000

Equations for engine characteristic values:

1- Mean piston speed

4 Specific fuel consumption

(calculated witn a lower cal. valuo ol J2 7 hJ/g)

n t/ mm revolutions per minute

Vh dm3 Total swept volume

B g/h fuel consumption per hour

1/1Part 1 ENGINE DATA AND DESCRIPTION

1.0 Views of Engine

1.1 Engine Data

1.1.2 Cylinder Numbering

1.1.3 Construction Data

1.1.4 Adjusting Data

1.1.5 Performance Data

1.1.6 Filling Quantities

1.2 OVERALL DIMENSIONS AND WEIGHTS

1.3 DESCRIPTION OF ENGINE

1.3.0 Function of Engine

1.3.1 Cylinder Crankcase and Oil Pan

1.3.2 Cylinder Heads

1.3.3 Crank Assembly

1.3.4 Gear Drive and Camshaft

1.3.5 Fuel System

1.3.6 Lube. Oil System

1.3.7 Cooling System

1.3.8 Turbo charging System

1.3.9 Starting System

1.3.11 Engine Monitoring

1 Engine Data and Description

1.0 Views of Engine

Fig. 1 Engine TBD 3,

1 Radiator fan 7 Injector

4 Engine foot 10 Exhaust manifold

Engine data and description

Fig 1001 Generating set, A-Side

2 Camshaft 13 Injection pump

3 Camshaft bearing 14 Speed governor

4 Big-end bearing 15 Speed fine adjustment

5 Main bearing 16 Fuel pressure pipe