1

To make participants

1) Familiar on Greaves History & Business.

2) Competent in Basics of Diesel engine.

3) Competent in carrying out quality service during commissioning of equipment

& schedule maintenance.

4) Familiar with Greaves Engine FAB’s.

2
1) Greaves Company Overview.
2) Basics of Diesel Engine – General
1) Systems of engine
2) Components of system & their function
3) Care & Maintenance of System components
3) Greaves Engine Familiarization.
4) Greaves Engine Features, Advantages & Benefits.
5) Greaves Product Maintenance Schedule & Preventive Maintenance.
6) Minor troubleshooting, adjustment & repairs of engine.

3
 BRIEF HISTORY
1859- James GREAVES and George COTTON founded the Company

1937- Greaves Cotton entered into a Joint Venture with Crompton Parkinson of England to introduce
ceiling fans and a range of other electrical products in India (now known as Crompton Greaves Limited).

1939- Joint Venture with Ruston & Hornsby Ltd., U.K. and started manufacturing diesel engines in India

1947- Pioneering industrialist Mr. Lala Karamchand Thapar bought Greaves Cotton became an Indian
Company.

1962- Greaves Power Transmission Unit set up in Pune in collaboration with David Brown Gear
Industries, U.K., and pioneered the manufacturing of industrial and marine Gearboxes in India.

1980- Greaves started manufacturing high power MWM diesel engines needed for Gensets and Marine
propulsion.

4
 BRIEF HISTORY

1986-Greaves Joint Venture with Morganite Crucible Ltd., U.K. to manufacture Silicon Carbide Crucibles.
Technical collaboration with BOMAG GmbH, Germany, to manufacture Vibratory Compactors.

1994-Acquired two Plants from Enfield India Ltd., to manufacture Petrol / Kerosene engines.

1996-Launched Transit Mixer and Batching Plants.

2000 - Launched lightweight diesel engine model GL 400, complying with Bharat Stage I (Euro I)
emission norms, for three wheelers.

2004 – A Millionth light diesel engine rolled out.

2006 - Greaves opens a new Technology Centre to design and develop new generation engines at
Aurangabad.

2007 - Greaves acquires Bukh-Farymann GmbH Diesel, Germany

2012 - Greaves crosses three million mark in light diesel engines

5
6
• Largest Business of the Company

• Produces Highly fuel efficient, Greaves lightweight diesel

engines ideal for Automotive applications like 2-wheelers, 3- Light Engines Unit IV - Aurangabad

wheelers, mini cars etc. We are already over 2 million light

diesel engines in the market

• Single cylinder engine 4.4 to 20 HP

• two cylinder engine Diesel Engine – GL 435A III

• These engines with high power-to-weight ratio are also used

Twin cylinder engine with
extensively for portable agricultural pumpsets, gensets, small power pack

boats, construction equipments and host of other applications.

7
 AUTOMOTIVE DIVISION
PRODUCT

Single Cylinder Engine Double Cylinder Engine

Diesel Gasoline 870

KOBRA

Air Cooled Water Cooled Air Cooled Water Cooled

G 435 G 510 G 600 G 510 G 400 G 400 G 4510

A III A III W III W III AG III WG III WG III 8
• Petrol / Kerosene engines & pumpsets
• Portable / Conventional diesel pumpsets
• Power Tillers Electric Pumpset

• Reapers and Mini agro equipment

• Electric pumpsets

• Facility to design and develop IC engines / applications Power Tiller

• A wide range of agro equipments that help enhance farm

productivity
• Market leader in Petrol / Kerosene engine business

• 2 manufacturing units In Gummidipoondi

• State-of-the-art Machine Shop
Assembly

Farmers 9
• Concreting: Concrete mixers, pumps, batching plants, truck mounted
pumps and Metro Pump
• Compaction: Vibratory rollers, Pneumatic tyred roller, paver finisher, Transit Mixer

cold milling machine, stabiliser

• Earthmoving: Motor Grader

Batching Plant
Greaves construction equipment are mainly used for construction of
roads, bridges, buildings, ready mix concrete applications, etc

19 Ton Vibratory Compactor

• Hindustan Construction Company, L&T ECC, Reliance Infrastructure
Limited, Gammon India Limited, IRB Infrastructure Limited, Essar
Construction Limited, India Bulls, Shapoorjee Palonji Construction
Limited
10 Mixer Assembly Line
 • Diesel engines : 1.4 to 1000 HP range
• Dual fuel engines also available

Marine engine

• These engines can be used for various applications like Marine,

Agricultural equipment, Fire fighting pumpsets, Mining & construction,
Material handling (cranes, forklifts), Rail cars, road sweepers etc.
Twin cylinder engine

• Engines are manufactured at state-of-the-art manufacturing

facilities in Pune, Aurangabad (Maharashtra), Gummidipoondi and
G series engine
Ranipet (Tamil Nadu)

• Mather & Platt, Pune; Flowmore Pumps, Delhi; CED, Chennai

11 D series engine
Pan Agro, Patiala; Raina Engineering, Mumbai.
 • Portable Genset in the range of 1-1.5 kVA
• Range: 25 kVA to 500 kVA single unit and upto 2500 kVA in parallel
running Portable Genset

• Fuel - efficient, rugged and reliable gensets compliant with

emission norms
G Series Genset
• Innovative 125 to 400 kVA dual fuel engines / gensets operating on
combined fuels
• Gensets (25 - 520 kVA) specially packaged for international market

• 1 Manufacturing facility in Pune G series Machining Centre

• In-house Foundry with specialized skills to cater to a wide range of
complex and custom built castings

• Ramoji Film City , Hyderabad; Tata Motors, Pune; Country INN

12 Suites, Goa; Reliance Fresh, Mumbai; Manipal University G series Machining Centre
13
14
Engine : Machine that Converts Chemical energy of fuel into Heat energy,
which is converted into mechanical work.

15
• Engine system – Valve & Power train, Cylinder block & head.

• Air Intake & Exhaust System

• Fuel supply & Injection system

• Lubrication system

• Cooling system

• Engine electrical system

16
 Fuel + Air
(Carbon + Hydrogen) + (Nitrogen + Oxygen)
17
18
1
2
3
4
5
6

19
 A four stroke
Combustion Diesel
/ Power Enginestroke
/ Expansion cycle consists of following stroke illustrated ABOVE
Exhaust
• Duringstroke
Compression stroke
Intake /this stroke both Inlet & Exhaust valves are kept closed.
Suction stroke
• ••During
Burnt charge
Dieselthis converts
stroke
is sprayed both as smoke.
Inlet
in a finely This form
&atomized
exhaust smoke
valves needs
are keptto
through FIPinbe exhausted.
&closed
nozzlecondition.
into highly compressed air which is at very high
• When the piston travels from TDC to BDC, Inlet valve is opened. In this position exhaust valve is kept closed.
• •When
During
thethis
temperature. stroke
piston Inletfrom
travels valveBDC
is kept closed
to TDC, the&air
Exhaust
whichvalve is kept
is inside the opened.
cylinder is compressed. Due to this the
•temperature
Due to the downward movement of the piston, clean atmospheric air is sucked through the air cleaner into the
• When
Due tothe &diesel
pressure
this,piston travelsoffrom
ignites the
andair
theincreases.
BDC to TDC,pressure
charge smoke is&forced out through
temperature the exhaust
increases several valve.
times.
cylinder.
• •When the piston
The power reachesbyTDC,
generated this the air is compressed
tremendous pressure completely
pushes the and its downwards;
piston pressure & temperature
this power isattains
utilizeda very
to high
•level.
When the piston reaches BDC, Inlet valve is closed. Fresh air is filled inside the cylinder
operate the engine. This power reaches the flywheel through the crankshaft. 20
Compression Ignition Spark Ignition

21
Power train Valve train

22
To provide clean & sufficient amount of air to the engine

ATMOSPHERE AIR

AIR FILTER

TURBOCHARGER

AFTER COOLER

INLET MANIFOLD

23
Define Filtration …….

Segregation / separating of matter by density, particle size, colour, surface

tension, material property etc

24
 µm = micrometer or micron

1 µm = 1 thousandth of one millimeter.

40 to 90 µm = human hair diameter. 40 µm
20 µm = grain of table salt.
10 µm = grain talcum powder.

20 µm

10 µm

5 µm

Below 40 µm - visible only with magnification

25
 As dirty air passes over the fins, the air swirls in a circular motion which causes the dirt to move to
the outside of the housing.

 At the end of the housing is a collection pan for the dirt.

 By keeping the dirt away from the filter we get more service life.

 Cracks in the housing interrupts the flow pattern and causes short filter life and increased filter
costs.

26
 A few people think that the inner element is a secondary filter. (such as in case of some fuel systems
which utilize a primary and secondary fuel filter). They therefore believe the purpose of the inner element
is to remove very small contaminant that may pass through the outer filter --- This is an
MISCONCEPTION

Safety Element……….. the safety net

NOT SECOND STAGE FILTRATION

Safety / inner element

 The primary purpose of the inner element is to keep dirt and other contaminant from directly falling into the air intake system of
the engine while the outer filter is being serviced.

 Hence the inner filter – better stated as “Safety Element” is provided for reasons of insurance, keeping the air intake system
SEALED during primary element servicing. Also, in case of primary element failure or malfunction the safety will plug very rapidly
causing restriction while providing the necessary safety net to minimize engine damage .

27
 Always Clean from Never from outside to Keep a distance between Do not tap the element
inside to outside inside the nozzle and the element
& air pressure should not
exceed 2 kg/cm2

Do not remove safety Check for any holes using the electric bulb test. In case
element you see a hole, replace the element.
28
Excessive Dust entry or overheating will lead to
1) Excessive wear of piston, piston rings and liners.
2) Excessive wear of above components will lead to
a) Loss of power with excessive black smoke
b) High lube oil consumption
c) High Fuel consumption
d) Excessive blow by
 Turbocharger in simple is an air supplying pump.
 With turbocharger engine HP can be increased with out increasing engine CC.

Compressor housing

Back plate
Central housing
Compressor wheel Turbine wheel assy.

Thrust plate Journals

Boost pressure pipe

Turbine housing assy.
Actuator assy.
 Waste gate

A bypass valve (waste gate/regulator) allows the turbo system to develop

peak charge-air pressure for maximum engine boost response while
eliminating the chance of excessive manifold pressure (over boost) at high
speed.
Need of After cooler : when the AIR is compressed in turbocharger, temperature
of air increases so the density of air decreases. Decreased density affects engine
power, so hot compressed air from turbocharger is routed through after cooler to
reduce air temperature & there by supplying dense air to engine.
1) On start up, run the engine with out Load for at least 2 minutes.
2) Before stopping the engine, run the engine for at least 2 minutes with out load.
Oil leak / Smoke Blockage in Air Intake System
Turbo Oil Drain Block
At Turbocharger compressor inlet
Engine Breather Hose Kink/block

At Turbocharger Turbine outlet Excessive Blow by

Compressed air or Exhaust gas

Leakage at turbo charger
Whistling Noise
Turbocharger Complaint

Air Filter Choke, Fuel Pump Complaint

Engine not taking load
Turbocharger Complaint
 INJECTOR

PUMP

TANK

FILTER

The fuel system supplies, transfers, cleans and delivers fuel to the engines’ cylinders to
enable combustion, thereby producing power.
The fuel system should meter the exact amount of fuel and deliver the fuel to the injector
assembly with precise timing.

The major components of the fuel system that are involved in the fuel delivery process are:
1) The fuel tank
2) The fuel transfer pump
3) The injection pump assembly and injectors
4) The fuel filtration system
The injection pump assembly moves the fuel to the fuel injectors. The injection
pump and injectors controls the volume and timing of this fuel delivery.

Fuel injection pumps are

1) Mechanically controlled
2) Electronically controlled.
 Injector is a device where fuel (diesel) gets atomized (Breaking bigger drops of
fuel into small droplets), by which more oxygen will be available for each fuel
droplets & small droplets heats up quickly
 Filtration remove unwanted contaminants from the fuel before it reaches the other
system components.
Two basic types of fuel filters are primary and secondary filters.

 Primary fuel filters are located between the fuel Engine

tank and the fuel transfer pump. Fuel
Tank
 They are know as suction side filters, as fuel is Lift pump FIP
sucked through the filter by the pump.
 Their purpose is to remove contaminants before Primary: Suction Side Filter
the fuel flows through the lift pump.

 Secondary filters are located between fuel Engine

lift pump and FIP Fuel
Tank Lift pump FIP
 They are known as pressure side filters as
fuel is pushed through the filter and pressure
is created.
 Their function is to remove contaminants Secondary: Pressure Side Filter
before the fuel gets to the fuel injection
pump and engine.
 Injectors

Injection
Heat Pump

Fuel
Tank
Pump
• Lubricate - Reduce friction and wear

• Cooling - Heat transfer media

• Sealing - Fills uneven surfaces in engine

• Cleaning - Prevents deposits

The oil must maintain a lubricating oil film between load bearing surfaces.
In rod bearings this film ranges between 5 and 15 microns in thickness. This film
prevents metal to metal contact reducing wear.
A Centrifuge is an oil cleansing device, it is not intended to purify foul oil in one
pass, but to remove the contaminants from oil that cannot be removed by the
lowest rating of washable filter
 Recommended Procedure
To ensure engine oil drains with possible sediments
A Engine should be warm
(Sludge etc.,)

As oil change is happening in dusty environment, engine

B Filling oil filter is not recommended
parts damage is possible
Ensure cleanliness as filling unfiltered oil might lead to
C In case Oil to be filled into oil filter, premature wear of internal components of engine

This ensures proper sealing & easy removal of filter in

D Apply engine oil on oil filter O ring
future

After filling engine oil in sump, dead Dead cranking ensures engine oil fill up in all oil galleries
E crack the engine for 10 sec. (by of engine & prevent metal to metal contact on start of
holding mechanical stop lever). engine, reduces abnormal wear of engine components

Repeat dead cranking for at least 2 10 sec. Gap between cranking, allows starter motor
F times, keeping 10 secs. Gap between internal parts to cools down & avoid damage of starter
the cranks motor armature
 Check Points Action
Oil pressure switch / transducer
1 Check with Multimeter for continuity, if found defective replace with new one
defective
2 Very Low Engine oil Level Check & top up as required
3 Excessive External Oil leakages Check for oil leakges, arrest the leakages.

Take out dipstick & put one or two drops of engine oil on blatting paper, if oil is
Engine Oil Level is High - Fuel observed quickly by paper, indicates fuel dilution with oil. Also oil would be
4
dilution with Engine oil thin & appears to be darker than normal oil. Reason for dilution could be FIP
shaft oil seal / Feed pump shaft seal defective, Injectors dribbling.
Low Engine
Oil pressure
Engine Oil filter choked / Check for Low oil level indicator warning is ON, if above mentioned parameters
5
Clogged found to be OK, check machine history & replace the oil filter.

Engine oil cooler choked / Check machine service history to ascertain regular services are carried out,
6
clogged replace the cooler element if found choked.
7 Excessive Internal oil leakages Ref. Engine repair manual
Pressure relief valve in oil pump Remove oil pump from engine & check relief valve condition, if found defective
8
stuck in partial open condition replace with new one.
9 Oil pump defective Ref. Engine repair manual
Excessive clearance in Main /
10 Ref. Engine repair manual
connecting rod bearings
 Heat generated from fuel – air combustion
33% - Horsepower
30% - Exhaust
7% - Radiation
30% - Cooling System
The cooling system removes heat to protect the engine.
• WATER PUMP – Circulate / Coolant Flow

• THERMOSTAT – Maintain Operating Temperature

• COOLING FAN – Sucks Air through radiator fins

• OIL COOLER – Cools the engine oil

• RADIATOR – Heat changer, coolant temperature exchanged to atmosphere air.

• RADIATOR PRESSURE CAP – To Maintain pressure in cooling system, there by increasing boiling
point of coolant.

• Condenser /RECOVERY TANK/DEGASSING TANK – Receives hot coolant / Vapour from radiator ,
to condense & returning to cooling system when pressure drops inside radiator.

• DRIVE BELTS & HOSES – To drive the water pump & cooling fan.
 Increase cooling system pressure increases boiling point of water or coolant

 To increase cooling system pressure, radiator pressure cap is used.

 Radiator cap – how it works

 Pressure valve
 Vacuum valve
Boiling Point means the temperature at which water converts to gas state from liquid state

Coolant is a mixture of water and Ethylene Glycol (C2H6O2), also known as Antifreeze &
Anticorrosive. By adding ethylene glycol to water, the boiling and freezing points are improved
significantly.

1. Coolant – Increase the boiling Point of mixture

a) Boiling point of Pure water =100⁰ C
b) Boiling Point of 50:50 ratio coolant & water = 106⁰ C

2.Anti freeze – Prevent mixture from freezing (icing)

3.Anti Rust – Prevent Metal parts from getting rusted

1. Knowing Coolant level without opening radiator cap.

2. Minimize coolant loss

3. Emergency reservoir, in case of coolant loss from radiator or engine.

• Ambient Temperature

• Fan belt tension

• Radiator fins clogged

• Radiator shroud missing / damaged

 Air + Fuel
N(Nitrogen) + Ox(Oxygen) + Carbon + Hydrogen

1. Co – Carbon Monoxide
Turbo Charging / High Pressure Fuel Injection
2. Co2 – Carbon Dioxdie

3. Nox – Oxides of Nitrogen – EGR / SCR (Selective Catalytic Reduction)

4. H2O - Water
D- SERIES ENGINES G - SERIES ENGINES
 D- SERIES ENGINES

D3 D4
313 HP – 484 HP 604 HP
1500 RPM 1500 RPM

ENGINE MODEL ENGINE MODEL

TBD3V6 MK II TBD4V12

TBD3V8 MK II
TBD3V12 MK I
 MODEL NO GROSS BHP @ 1500 rpm Rating
TBD3V6 MK II 344.3 250 KVA

TBD3V8 MK II 435.6 320 KVA

TBD3V12 MK I 532.4 400 KVA

TBD4V12 664.4 500 KVA

63
G - SERIES ENGINES

ENGINE MODEL
3G11 (NA/T/TA)
4G11 (NA/T/TA)
6G11 (T/TA)
68
INTEGRAL PLATE TYPE OIL COOLER INTERNAL GEAR DRIVEN WATER PUMP
Cartridge type Integral Oil cooler. Lesser connections. Eliminates a failure avenue in the engine.
Leakage Eliminated

INDIVIDUAL CYLINDER HEADS COMMONALITY OF PARTS

Easy Maintenance and greatly reduced Common working parts right from 3
engine down times. Cylinder to 6 Cylinder.
Reduced spare cost while replacing.
Less spares to store for user.

INDEPENDENT FAN MOUNTING AUTOMOTIVE GRADE GEAR TRAIN

Fan is mounted independent of the water pump. Ensure that this engine has the most silent sound map
Enables total flexibility in fan positioning. among all competition.

DEEP SKIRTED CRANK CASE TWIN BELT DRIVE FOR FAN

Gives rigidity and Stability to the design of Two belts drive the fan. Ensures extra safety.
the engine. Engine runs even if one belt fails.
70
71
1) Open the de-aeration plug provided on thermostat housing.
2) Open the radiator cap.
3) Ensure all hoses are in place & tight.
4) Prepare coolant mixture in ratio of 20:80 i.e. 20 % Greaves maxtherm or and 80%
distilled water.
5) Slowly pour coolant through radiator cap.
6) Between pouring Wait for few seconds to allow entrapped air to escape.
7) Fill the Coolant until it overflows from de-aeration plug opening.
8) Close the de-aeration plug.
9) Keep on filling the coolant till it fills up to filler neck in radiator top tank.
10) Start the engine with out closing the radiator & run for 2 minutes, so to allow entrapped
air to escape.
11) Stop the engine, check coolant level in radiator, if found low top up & fit radiator cap
firmly.

72
1) For draining coolant 3 drain plugs are provided in cooling system.

1) The drain plug on oil cooler head is for draining the coolant only up to
cylinder head level.
2) The drain plug on crankcase is for draining coolant from engine.
3) The drain plug on the radiator is for draining the entire system.
2) Drain the coolant in a tray.
3) Dispose off the coolant safely in an environmentally friendly way.

73
What is fuel system bleeding : Removal of trapped Air from System

When to bleed fuel system

1. Air lock due to low fuel level, leakages, defective washers etc.,
2. On replacing fuel filters
3. On removal of High pressure pipes
4. In case engine is been stored for long duration

Fuel system Bleeding Procedure

1) Check & ensure required fuel level in fuel tank.
2) Loosen feed pump knob.
3) Loosen bleeding screw on fuel filter head or
fuel outlet banjo on FIP
4) Operate feed pump manually, till fuel comes
out of bleeding screw or banjo & free from air
bubbles.
5) Once bleeding is done tighten feed pump Knob.
74
75
1) Remove all seals. Clean up the engine. Remove rust preventive coat.
2) Fit air cleaner, fuel filter, Lube oil filter, and belts. Use new filter elements. Apply
correct tension to the belts.
3) If rubber components (Hoses, belts, etc) are cracked or brittle, replace them.

4) Fill up correct grade oil up to the high level mark on dipstick.

5) Fill up coolant. Remove trapped air.

6) Connect supply of clean fuel. Remove trapped air.

7) Fit a charged battery. Check the electrical connections.

8) Run the engine at rated speed at no load for 5 minutes. Observe and look for any
irregular noise, vibration, etc. If some irregular behavior is observed take corrective
actions or call authorized service dealer.
9) Start the engine and put it into service.

76
1) Engine doesn't cranks
2) Engine cranks but doesn’t start
3) Excessive Black smoke
4) Excessive White smoke
5) High coolant temperature
6) High Lube oil consumption
7) High fuel consumption
78