SGCO 2000: Parts Manual Parts Manual Parts Manual

314 West 90th Street
Minneapolis, MN 55420
Direct
Parts Manual
SGCO 2000
TK 509524PM (Rev. 4.11)
©2011 Ingersoll Rand Company
Printed in U.S.A.
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Hussmann, a manufacturer of refrigeration
and food merchandising solutions, Thermo King, the leader in transport temperature control
and Trane, a provider of energy efficient heating, ventilating and air conditioning systems,
building and contracting services, parts support and advanced controls for commercial
buildings and homes.
Distributed by:
Thermo King Corporate
(952) 887-2200
SGCO 2000
TK 50952-4.11
Pri
nt
ed
( Friday,
December 16, 2011)

Copyright©2000 -
Thermo King Corp.
- Minneapolis, MN,
U.S.A.
Printed (December 16, 2011)
Copyright © 2000 - Thermo King Corp. - Minneapolis, MN U.S.A.

Electronically printed in U.S.A.
General Information Assemblies and Subassemblies
When parts are indented in the description list, they are
Tables of Contents
preceded with a bullet ( • ). This indicates that the
This Parts Manual contains a numerical table of con- part(s) is available separately or included in an assem-
tents listing each assembly name, its associated Grid bly.
number and page number. The numerical table of con-
tents is arranged numerically by Grid number. There GRID NO. 67D6
are references in a parts list referring to other Grid num- SWITCH PANEL ASSEMBLY
bers, the numerical table of contents is arranged to facil- REF PART# DESCRIPTION QTY
itate finding the referenced illustrations. At the rear of
45-1239 PANEL - assy, switch 1
this parts manual are two indexes, a numerical and
alphabetical. The indexes contain all of the part num- 1 99-1960 • PANEL 1
bers and descriptions which appear in this manual. 99-6280 • • NAMEPLATE - panel 1
2 33-743 • GASKET 1
For example: the switch panel nameplate (99-6280) is

available separately, available as part of the switch
panel (99-1960) and with the panel assembly (45-1239).
ABBREVIATIONS The following abbreviations appear in parts manuals

A AC . . . . . . . . . alternating E (continued) O os . . . . . . . . . . oversized
current evap . . . . . . . . evaporator od . . . . . . . . . . outside diameter
A/R . . . . . . . . as required exch . . . . . . . . exchanger
P pcb . . . . . . . . . printed circuit
accum . . . . . . accumulator exp . . . . . . . . . expansion
board
adj . . . . . . . . . adjusting ext . . . . . . . . . external
pkg . . . . . . . . . package
al . . . . . . . . . . aluminum
F F. . . . . . . . . . . Farenheit ph . . . . . . . . . . phase
alt. . . . . . . . . . alternator
fill . . . . . . . . . . fillister pos . . . . . . . . . positive
A or amp . . . . ampere
fi . . . . . . . . . . . fuel injection psi . . . . . . . . . . pounds per
assy . . . . . . . . assembly
fl . . . . . . . . . . . flare square inch
B bd . . . . . . . . . board fpt . . . . . . . . . . female pipe
R rad . . . . . . . . . radiator
brg . . . . . . . . . bearing thread
rcvr . . . . . . . . . receiver
brkr . . . . . . . . breaker ft . . . . . . . . . . . feet
ref . . . . . . . . . . reference
brkt . . . . . . . . bracket ftg . . . . . . . . . . fitting
reg . . . . . . . . . regulator
C C . . . . . . . . . . Celsius H hex . . . . . . . . . hexagon req . . . . . . . . . required
cw . . . . . . . . . clockwise hh . . . . . . . . . . hexagon head rpm . . . . . . . . . revolutions per
ccw . . . . . . . . counter- hd . . . . . . . . . . head minute
clockwise hp . . . . . . . . . . horsepower
S sec . . . . . . . . . second
cam . . . . . . . . camshaft hsg . . . . . . . . . housing
sld . . . . . . . . . . solder
compr . . . . . . compressor
I id . . . . . . . . . . inside diameter soc hd . . . . . . . socket head
cond. . . . . . . . condenser
in . . . . . . . . . . inch (2.54 sol . . . . . . . . . . solenoid
conn. . . . . . . . connecting,
centimeters) spl . . . . . . . . . . special
connector
incl . . . . . . . . . includes sq . . . . . . . . . . square
cyl . . . . . . . . . cylinder
inj . . . . . . . . . . injection ss . . . . . . . . . . stainless steel
D def . . . . . . . . . defrost int . . . . . . . . . . internal std. . . . . . . . . . standard
deg . . . . . . . . degree int th . . . . . . . . internal tooth stl . . . . . . . . . . steel
dehyd. . . . . . . dehydrator suct . . . . . . . . . suction
L liq . . . . . . . . . . liquid
dia . . . . . . . . . diameter sw . . . . . . . . . . switch
lg . . . . . . . . . . long
DC . . . . . . . . . direct current
T term . . . . . . . . terminal
disch . . . . . . . discharge M mm . . . . . . . . . milimeter
temp . . . . . . . . temperature
diff . . . . . . . . . differential mpt . . . . . . . . . male pipe thread
thk. . . . . . . . . . thick
mod . . . . . . . . modulating
E EMI . . . . . . . . Extended
U us . . . . . . . . . . undersize
. . . . . . . . . . . Maintenance N neg . . . . . . . . . negative
Interval No. . . . . . . . . . number V vib . . . . . . . . . . vibrasorber
EEC . . . . . . . . European NS . . . . . . . . . not supplied
W W . . . . . . . . . . watt
Economic NSS . . . . . . . . not sold
w/ . . . . . . . . . . with
Community separately
w/o . . . . . . . . . without
eng . . . . . . . . engine
SGCO 2000
Contents
Name Grid Page
SGCO 2000 REFERENCE SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . .5U93. . . . . . . . . . . . . . . . . . . . . .3
UNIT MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105C8. . . . . . . . . . . . . . . . . . . .91
CONNECTORS - DEUTSCH IN-LINE . . . . . . . . . . . . . . . . . . . . . . . . . .112D9. . . . . . . . . . . . . . . . . . . .69
RECTIFIER GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119G2. . . . . . . . . . . . . . . . . . . .77
FUEL TANK GROUP (SGCO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130G3. . . . . . . . . . . . . . . . . . . .45
EXCITER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131B4 . . . . . . . . . . . . . . . . . . . .73
RECTIFIER PLATE GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131B5 . . . . . . . . . . . . . . . . . . . .79
GEAR CASE GROUP (TK486/486E & TK482/482E) . . . . . . . . . . . . . .142C10. . . . . . . . . . . . . . . . . . . .7
FLYWHEEL HOUSING GROUP (TK486/486E & TK482/482E) . . . . . .142C11. . . . . . . . . . . . . . . . . . . .9
OIL SUMP GROUP (TK486/486E & TK482/482E) . . . . . . . . . . . . . . . .142C12. . . . . . . . . . . . . . . . . . .11
CYLINDER HEAD & VALVE COVER (TK486/486E & TK482/482E) . .142C13. . . . . . . . . . . . . . . . . . .13
CRANKSHAFT & PISTON GROUP (TK486/486E) . . . . . . . . . . . . . . . .142C14. . . . . . . . . . . . . . . . . . .17
INTAKE & EXHAUST MANIFOLD (TK486/486E & TK482/482E) . . . . .142F4 . . . . . . . . . . . . . . . . . . . .19
OIL FILTER & PUMP GROUP (TK486/486E & TK482/482E). . . . . . . .142F6 . . . . . . . . . . . . . . . . . . . .23
FUEL PUMP ASSEMBLY (TK486/486E, TK482/482E & TK486V) . . . .142F8 . . . . . . . . . . . . . . . . . . . .27
FUEL INJECTION GROUP (TK486/486E) . . . . . . . . . . . . . . . . . . . . . .142F10 . . . . . . . . . . . . . . . . . . .33
FUEL INJECTION NOZZLE (TK486/486E) . . . . . . . . . . . . . . . . . . . . . .142F11 . . . . . . . . . . . . . . . . . . .35
STARTER ASSEMBLY (TK486/486E & TK482/482E) . . . . . . . . . . . . .142F12 . . . . . . . . . . . . . . . . . . .37
GASKET SET (TK486/486E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142F13 . . . . . . . . . . . . . . . . . . .39
NAMEPLATES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146G2. . . . . . . . . . . . . . . . . . . .93
CONTROL BOX COVER - mP-G (SGCM, SGSM, SGCO) . . . . . . . . . .146G6. . . . . . . . . . . . . . . . . . . .65
CIRCUIT BOARD & RELAYS - mP-G (SGCM, SGSM, SGCO) . . . . . .148G1. . . . . . . . . . . . . . . . . . . .63
WATER PUMP ASSEMBLY (TK486/486E & TK482/482E) . . . . . . . . .149C12. . . . . . . . . . . . . . . . . . .25
CYLINDER BLOCK GROUP (TK486E, Engines Manufactured 1/99
& After). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152D2. . . . . . . . . . . . . . . . . . . . .5
CAMSHAFT & DRIVE GEAR GROUP (Tier 2 engine TK486E, 1/99
& after) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152D3. . . . . . . . . . . . . . . . . . . .21
FUEL INJECTION PUMP GROUP (Tier 2 engine TK486E, 1/99 &
after) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152D4. . . . . . . . . . . . . . . . . . . .29
ALTERNATOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158B0 . . . . . . . . . . . . . . . . . . . .57
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158B8 . . . . . . . . . . . . . . . . . . . .51
MUFFLER GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158B9 . . . . . . . . . . . . . . . . . . . .49
BELTS, PULLEY & FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C0. . . . . . . . . . . . . . . . . . . .55
CONTROL BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C1. . . . . . . . . . . . . . . . . . . .59
MAIN HARNESS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C2. . . . . . . . . . . . . . . . . . . .67
STRUCTURAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C3. . . . . . . . . . . . . . . . . . . .85
STRUCTURAL COMPONENTS (REAR VIEW) . . . . . . . . . . . . . . . . . .158C5. . . . . . . . . . . . . . . . . . . .89
BATTERY & CABLE GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C6. . . . . . . . . . . . . . . . . . . .83
FUEL FILTER & HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C7. . . . . . . . . . . . . . . . . . . .43
OIL BASE GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158C8. . . . . . . . . . . . . . . . . . . .41
AIR CLEANER GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158D1. . . . . . . . . . . . . . . . . . . .47
ALTERNATOR GROUP (SGCO 2000, SGSM 2000, SGCM 2000) . . .166C8. . . . . . . . . . . . . . . . . . . .81
5U93 SGCO 2000 REFERENCE SHEET
Revised
11/30/07
SGCO 2000 REF-

ERENCE SHEET
5U93
11/30/07
3
Revised
11/30/07 SGCO 2000 REFERENCE SHEET 5U93
B/M DESCRIPTION Date
062307 SGCO 2000 11/07
718201 SGCO 2000 11/07
062298 Battery 11/07
062312 Add Frame, Clip-On Header Pin Option 11/07
062246 Nameplates 11/07
062294 230V 11/07
4
CYLINDER BLOCK GROUP (TK486E, Engines
152D2 Manufactured 1/99 & After)
Revised
5/14/09
CYLINDER BLOCK
GROUP (TK486E,
Engines Manufac-
tured 1/99 & After)
152D2
5/14/09
5
CYLINDER BLOCK GROUP (TK486E, Engines
Revised
5/14/09 Manufactured 1/99 & After) 152D2
REF PART# DESCRIPTION QTY
8101-336 ENGINE (TK486E, 12V, Remanufactured) 1
101-351 ENGINE (TK486EH, 12V, 2600 rpm) 1
8101-351 ENGINE (TK486EH, 12V, 2600 rpm, Remanufactured) 1
1 12-743 • BLOCK - cylinder 1
2 11-5499 • PLUG - frost (30 mm) 8
3 55-193 • PLUG - pipe (3/8) 1
4 55-6229 • PLUG 1
5 55-6231 • PLUG - frost (50 mm) 1
6 55-6176 • PLUG - pipe (1/4) 3
7 55-6177 • PLUG - pipe (1/8) 1
8 11-6555 • PLUG - frost (12 mm) 2
9 13-926 • BUSHING - camshaft 1
10 13-927 • BEARING - thrust (std) 2
13-928 BEARING - thrust (0.25 mm os) 2
11 13-920 • BEARING - main 5
13-921 • BEARING - main (0.25 mm us) 5
12 NSS • CAP - bearing 4
13 55-8853 • BOLT - bearing cap 10
14 55-5989 • PLUG (10 x 14 mm) 1
15 11-8919 LINER - service 4
16 41-2317 HEATER - frost plug 1
NOTE: This grid is for engines built after 1/99.

NOTE: Engines with serial numbers before EK00251 use radial seal 33-2759. Engines with serial numbers
EK00251 and after use axial oil seal 33-2974.
6
142C10 GEAR CASE GROUP (TK486/486E & TK482/482E)
Revised
12/3/08
GEAR CASE
GROUP (TK486/
486E & TK482/
482E)
142C10
12/3/08
7
Revised
12/3/08 GEAR CASE GROUP (TK486/486E & TK482/482E) 142C10
1 11-8920 CASE - gear 1
2 55-5784 • STUD - injection pump 3
3 55-5810 NUT 3
4 33-1953 O-RING - injection pump 1
5 203-348 GASKET - adhesive (RTV silicone) A/R
6 33-1910 O-RING 2
7 55-6234 PIN - dowel 2
8 55-5816 PIN - dowel 2
9 55-8441 SCREW - case 3
10 11-5091 CAP - oil fill 1
11 33-1954 O-RING - cap 1
12 10-371 COVER - gear case 1
13 33-4088 • SEAL - oil 1
14 55-6367 • STUD - fuel pump 3
15 55-5809 SCREW - cover (45 mm) 7
16 55-6236 SCREW - cover (55 mm) 3
17 55-6188 SCREW - cover (20 mm) 1
18 55-4622 WASHER - sealing 5
19 11-8921 COVER - sound shield 1
20 33-2933 GASKET 1
21 55-6237 SCREW - cover (85 mm) 6
22 55-8441 SCREW - cover (22 mm) 1
23 55-8854 SCREW - cover (12mm) 4
24 11-5082 COVER 1
25 33-1500 GASKET - cover 1
26 55-8441 SCREW - plug (see note) 1
27 11-9592 SPEEDI SLEEVE - front seal 1
28 204-1011 TOOL - injection pump gear remover 1
NOTE: Use screw 55-5768 for plugging the hole in the gear cover on engines with short oil line 11-8992.
8
FLYWHEEL HOUSING GROUP (TK486/486E & TK482/
142C11 482E)
Revised
12/8/03
FLYWHEEL HOUS-
ING GROUP
(TK486/486E &
TK482/482E)
142C11
12/8/03
9
FLYWHEEL HOUSING GROUP (TK486/486E & TK482/
Revised
12/8/03 482E) 142C11
1 12-823 HOUSING - flywheel 1
2 11-6031 PLUG - access hole 1
3 55-8856 SCREW - housing (30 mm) 4
4 55-6537 SCREW - housing (25 mm) 6
5 55-8855 SCREW - plug (M12 x 16) 1
6 55-5816 PIN - dowel 2
7 11-8924 CASE - oil seal 1
8 33-2974 SEAL - oil (axial, see note) 1
33-2759 SEAL - oil (radial, see note) 1
9 33-2969 GASKET - oil seal case 1
10 55-8857 SCREW - case (30 mm) 6
11 55-6191 SCREW - case (25 mm) 3
12 55-5816 PIN - dowel 2
13 204-952 TOOL - seal installer 1
14 204-994 TOOL - seal remover 1
NOTE: Engines with serial numbers before K00251 use radial seal 33-2759. Engines with serial numbers
K00251 and after use axial oil seal 33-2974.
10
142C12 OIL SUMP GROUP (TK486/486E & TK482/482E)
Revised
7/2/10
OIL SUMP GROUP

(TK486/486E &
TK482/482E)
142C12
7/2/10
11
Revised
7/2/10 OIL SUMP GROUP (TK486/486E & TK482/482E) 142C12
1 12-882 SUMP - oil (upper) 1
2 12-746 SUMP - oil (lower) 1
3 55-8437 PLUG - drain 2
5 55-6246 SCREW - oil base (25 mm) 15
6 55-5809 SCREW - oil base (45 mm) 19
7 55-6237 SCREW - oil base (85 mm) 12
8 11-8667 DIPSTICK 1
9 33-1954 O-RING - dipstick 1
10 11-8923 CAP (units w/o oil level switch, push-in type) 1
11 41-402 SWITCH - oil level (push-in type) 1
33-3877 • GASKET - switch 1
41-4470 SWITCH - oil level (threaded type) 1
33-4160 • O-RING - switch 1
12 11-8984 HOSE - oil drain 1
13 55-5081 CAP - hose 1
14 91-4823 CLIP - hose 1
55-1587 SCREW - clip 1
55-2086 FLATWASHER 1
55-4953 NUT 1
15 55-9167 ELBOW - hose 1
16 91-7191 BRACKET - clip 1
17 11-9338 VALVE - oil drain 1
18 11-9448 FITTING - oil drain (ESOC) 1
19 55-3744 ELBOW - hose (45 degree) 1
12
CYLINDER HEAD & VALVE COVER (TK486/486E &
142C13 TK482/482E)
Revised
12/11/08
CYLINDER HEAD &

VALVE COVER
(TK486/486E &
TK482/482E)
142C13
12/11/08
13
Revised
12/11/08 TK482/482E) 142C13
1 13-381 PIPE - breather 1
2 55-8442 • CLAMP - hose (24) 4
3 11-8994 • ORIFICE - breather 1
4 11-8941 COVER - valve 1
5 33-2935 • GASKET - valve cover 1
6 11-5103 • KNOB - valve cover 3
7 33-3512 • O-RING - cover 3
8 11-8670 • COVER - breather 1
9 11-8672 • PLATE - screen 1
10 33-2762 • O-RING 1
11 11-8671 • BAFFLE - breather 1
12 55-8441 • SCREW - cover 2
13 11-8938 SHAFT - rocker arm 1
11-8939 • SHAFT - rocker arm 1
14 11-6702 • SUPPORT - rocker arm 2
11-6703 • SUPPORT - rocker arm 3
15 55-6245 • STUD - valve cover 3
16 55-4632 • NUT - stud 3
17 11-6704 • SPRING 4
18 11-8940 • ARM - rocker 8
19 55-8859 •• SCREW - valve adjust 8
20 55-8860 •• NUT 8
21 55-6193 SCREW - support (50 mm) 7
22 55-6246 SCREW - support (25 mm) 3
23 12-747 HEAD - cylinder 1
24 11-6708 • RETAINER - nozzle 4
25 11-8937 • PROTECTOR - nozzle 4
26 11-6707 • GASKET - copper (nozzle seat) 4
27 55-5138 • STUD - nozzle retainer 8
28 55-5792 • NUT 8
29 11-6567 • PLUG - frost (40 mm) 1
30 55-5803 • PIN - spring 2
31 11-8930 • VALVE - intake 4
32 11-8926 • SEAT - valve (intake) 4
33 11-8928 • GUIDE - valve (intake) 4
34 11-8935 • SEAL - valve stem (intake) 4
35 13-659 • VALVE - exhaust 4
36 11-8927 • SEAT - valve (exhaust) 4
14
142C13 TK482/482E)
Revised
12/11/08
15
Revised
12/11/08 TK482/482E) 142C13
37 11-8929 • GUIDE - valve (exhaust) 4
38 11-8934 • SEAL - valve stem (exhaust, marked w/ yellow stripe) 4
39 11-8932 • SPRING - valve 8
40 11-8933 • RETAINER - spring 8
41 55-8858 • KEEPER - valve 8
42 11-8936 • CAP - valve 8
43 13-126 LIFTER - engine 2
44 55-5801 SCREW - lifter 4
45 11-8942 FLANGE 1
46 55-5763 • PLUG 1
47 33-2934 GASKET - flange 1
48 55-8441 SCREW - flange 4
49 33-2932 GASKET - cylinder head (TK486/486E) 1
33-2999 GASKET - cylinder head (TK482/482E) 1
50 55-8853 STUD - cylinder head 18
51 91-3542 TUBE - sponge (insulation, cut to 11.0 in lg) 1
16
142C14 CRANKSHAFT & PISTON GROUP (TK486/486E)
Revised
9/14/11
CRANKSHAFT &
PISTON GROUP
(TK486/486E)
142C14
9/14/11
17
Revised
9/14/11 CRANKSHAFT & PISTON GROUP (TK486/486E) 142C14
1 11-8948 PISTON (std, incl 2-4) 4
11-8955 PISTON (w/ ring, 0.25 os) 4
11-8958 PISTON (w/ ring, 0.50 os) 4
2 11-8949 RING SET (std) 4
11-8956 RING SET (0.25 os) 4
11-8959 RING SET (0.50 os) 4
3 11-8950 PIN - piston 4
4 11-8951 CIRCLIP 8
5 11-8952 ROD - connecting 4
6 11-8953 BUSHING - piston pin 4
7 13-924 BEARING - connecting rod (std) 4
13-925 BEARING - connecting rod (0.25 mm us) 4
8 55-8865 BOLT - connecting rod 8
9 12-750 FLYWHEEL 1
10 11-8947 • GEAR - ring (before 11/08) 1
13-1138 • GEAR - ring (11/08 & after) 1
11 55-8864 BOLT - flywheel 6
12 55-5816 PIN - dowel 1
13 12-749 CRANKSHAFT 1
14 11-6719 • KEY - gear 1
15 11-6724 GEAR - crankshaft 1
16 55-5834 PIN - spring 1
17 70-212 PULLEY - crankshaft 1
18 55-6249 WASHER 1
19 55-6250 BOLT - v-pulley 1
20 11-9592 SPEEDI SLEEVE - front seal 1
NOTE: Engines before serial number EA00749 use gear ring 11-8947. Engines with serial number EA00749
and after use gear ring 13-1138.
18
INTAKE & EXHAUST MANIFOLD (TK486/486E &
142F4 TK482/482E)
Revised
4/21/04
INTAKE &
EXHAUST MANI-
FOLD (TK486/486E
& TK482/482E)
142F4
4/21/04
19
INTAKE & EXHAUST MANIFOLD (TK486/486E &
Revised
4/21/04 TK482/482E) 142F4
1 33-2936 GASKET - intake manifold 1
2 11-8943 MANIFOLD - intake 1
3 55-5763 • PLUG 1
4 55-8861 • JOINT - breather 1
5 55-6188 SCREW - intake manifold (20 mm) 6
6 55-8717 SCREW - intake manifold (80 mm) 1
7 11-9266 INLET - intake manifold 1
8 33-2764 GASKET - inlet 1
9 41-2147 HEATER - air 1
10 33-2765 GASKET - air heater 1
11 55-6236 SCREW - inlet (55 mm) 4
12 11-8944 MANIFOLD - exhaust 1
13 33-2937 GASKET - exhaust manifold 1
14 55-8862 STUD - exhaust manifold 2
15 55-5791 NUT 2
16 55-5772 SCREW - exhaust manifold (40 mm) 7
20
CAMSHAFT & DRIVE GEAR GROUP (Tier 2 engine
152D3 TK486E, 1/99 & after)
Revised
12/26/07
CAMSHAFT &
DRIVE GEAR
GROUP (Tier 2
engine TK486E, 1/
99 & after)
152D3
12/26/07
21
CAMSHAFT & DRIVE GEAR GROUP (Tier 2 engine
Revised
12/26/07 TK486E, 1/99 & after) 152D3
1 11-9261 CAMSHAFT (incl items 2 thru 5) 1
2 11-6719 • KEY - gear 1
3 NSS • BEARING - thrust 1
4 55-8441 • BOLT - plate 2
5 NSS • GEAR - camshaft 1
6 11-6717 TAPPET 8
7 11-8945 ROD - push 8
8 11-9248 GEAR (w/ bushing) 1
9 11-6722 • BUSHING - idler gear 1
10 11-6721 SHAFT - idler gear 1
11 11-8993 NOZZLE - oil 1
12 55-8967 SCREW - nozzle 2
13 55-5809 SCREW - gear 2
14 101-321 PUMP - fuel injection (see 149F9) 1
15 51-624 KEY - gear 1
16 11-9204 FLANGE 1
17 11-9202 GEAR - injection pump 1
18 55-9222 SCREW - gear 4
19 11-9203 CAM - feed pump 1
20 55-9223 SCREW - cam 4
21 55-8863 WASHER 1
22 55-6254 NUT 1
NOTE: This grid is for engines built after 1/99. Engines built after 1/99 have a serial number beginning with an
"L".
22
OIL FILTER & PUMP GROUP (TK486/486E & TK482/
142F6 482E)
Revised
3/5/09
OIL FILTER &

PUMP GROUP
(TK486/486E &
TK482/482E)
142F6
3/5/09
23
OIL FILTER & PUMP GROUP (TK486/486E & TK482/
Revised
3/5/09 482E) 142F6
1 11-7382 FILTER - oil 1
2 11-9182 FILTER - oil (EMI 3000) 1
3 55-4644 BOLT - eye 1
4 55-4733 SEAL - washer (10) 2
5 55-4645 BOLT - eye 1
6 55-4622 WASHER - sealing (8) 2
7 11-8668 PIPE - oil injection 1
8 55-6177 PLUG 1
9 11-8962 BRACKET - filter (engines before TK486 S/N L32014 & 1
TK482 S/N A08750 use w/ oil filter 11-7382)
10 11-8964 • ORIFICE 1
11 55-8867 • BUSHING 1
12 55-5763 • PLUG 2
13 11-8995 • VALVE - check (assembly) 1
14 55-8868 •• BALL 1
15 11-8965 •• SPRING 1
16 33-2970 •• GASKET 1
17 33-2931 GASKET - bracket 1
18 55-6188 SCREW - bracket (20 mm) 1
19 55-5809 SCREW - bracket 1
20 55-8869 SCREW - bracket (75 mm) 1
21 11-9354 BRACKET - filter (incl 10-16, eng after TK486 S/N L32014 & 1
TK482 S/N A08750 use w/ filter 11-9182)
22 11-8961 PIPE - oil pickup 1
23 33-4237 GASKET - pipe 1
24 55-6191 SCREW - pipe (35 mm) 2
25 11-9249 PUMP - oil 1
26 11-9250 GASKET - oil pump 1
27 55-6251 SCREW - oil pump (25 mm) 4
28 11-9447 FITTING - oil inlet (ESOC) 1
24
WATER PUMP ASSEMBLY (TK486/486E & TK482/
149C12 482E)
Revised
6/17/10
WATER PUMP
ASSEMBLY
(TK486/486E &
TK482/482E)
149C12
6/17/10
25
WATER PUMP ASSEMBLY (TK486/486E & TK482/
Revised
6/17/10 482E) 149C12
1 13-509 PUMP - water (ELC compatible, low mount, current style) 1
813-509 PUMP - water (remanufactured) 1
55-5138 • STUD - pulley 3
2 55-8443 • PLUG 2
3 33-3096 • GASKET - water pump 1
30-295 • GASKET SET - water pump (includes items 3, 4, 6, 16) 1
4 33-2768 GASKET 1
5 11-9624 THERMOSTAT 1
6 33-2767 GASKET 1
7 11-8675 COVER - thermostat 1
8 55-6188 SCREW - thermostat 2
9 55-6248 SCREW - pump 3
10 77-1426 PULLEY - water pump 1
11 77-1427 • SHIM (1 mm) A/R
77-2752 • SHIM (0.5 mm) A/R
12 77-1428 SPACER 1
13 55-5792 NUT 4
14 11-8996 JOINT - pump 1
15 33-3097 GASKET - joint 1
16 33-3098 O-RING - joint 1
17 55-8441 SCREW - joint 3
18 55-5780 DRAIN COCK 1
19 33-1745 WASHER - sealing 1
20 11-9256 PLUG 1
26
FUEL PUMP ASSEMBLY (TK486/486E, TK482/482E &
142F8 TK486V)
Revised
6/29/10
FUEL PUMP
ASSEMBLY
(TK486/486E,
TK482/482E &
TK486V)
142F8
6/29/10
27
FUEL PUMP ASSEMBLY (TK486/486E, TK482/482E &
Revised
6/29/10 TK486V) 142F8
1 11-7433 PUMP - fuel 1
2 11-8970 • PISTON 1
3 11-8971 • SPRING - piston 1
4 55-8871 • RETAINER 1
5 33-2940 • GASKET 1
6 11-8998 • TAPPET 1
7 55-8872 • PIN - snap 1
8 11-8972 • VALVE 2
9 11-8973 • SPRING 2
10 11-8974 • RETAINER - valve 1
11 33-2941 • O-RING 1
12 11-8680 • PUMP 1
13 11-8975 • JOINT - banjo 1
14 33-2771 • O-RING 1
15 11-8976 • BOLT - eye 1
16 11-8977 • GASKET 2
17 11-7499 • JOINT - banjo (elbow, before engine S/N L68462) 1
13-128 • JOINT - banjo (elbow, engine S/N L68462 & after) 1
18 11-8681 • BOLT - eye (with filter) 1
11-2854 •• SCREEN (brass, #30) 1
19 33-1749 • GASKET 4
20 13-127 • JOINT - banjo (straight, engine S/N L68462 & after) 1
11-7707 • JOINT - banjo (straight, before engine S/N L68462) 1
21 11-8682 • BOLT - eye 1
22 33-2942 O-RING 1
23 55-4750 NUT 3
24 55-6367 STUD - fuel pump 3
28
FUEL INJECTION PUMP GROUP (Tier 2 engine
152D4 TK486E, 1/99 & after)
Revised
8/2/10
FUEL INJECTION
PUMP GROUP
(Tier 2 engine
TK486E, 1/99 &
after)
152D4
8/2/10
29
Revised
8/2/10 TK486E, 1/99 & after) 152D4
1 101-321 PUMP - fuel injection (TK 486E, 2200 rpm) 1
101-331 PUMP - fuel injection (TK 486EH, 2600 rpm) 1
2 33-1953 • O-RING - injection pump 1
3 55-5784 • STUD - injection pump 3
4 55-5810 • NUT 3
5 11-6125 • RETAINER - shaft 1
6 55-5822 • SCREW - retainer 1
7 12-925 • LEVER - control 1
8 55-5810 • NUT 1
9 41-9100 • SOLENOID - stop (12V) 1
41-2444 • SOLENOID - stop (24V) 1
10 55-8448 • SCREW - solenoid 2
11 55-8870 • BOLT - fuel control 1
12 55-4615 • NUT 1
13 55-4670 • NUT - cap 1
14 11-5170 • SEAL - lead 1
11-9205 • SEAL - lead 1
15 51-612 • SCREW - idle limit 1
55-5846 • NUT - lock 1
16 33-3940 • O-RING 1
17 11-8966 • COVER 1
55-5822 • SCREW - cover 4
30-267 KIT - gasket (injection pump) 1
18 33-3941 • GASKET - side cover 1
19 11-9613 • COVER - side 1
20 51-269 • SCREW - cover 11
21 33-3689 • GASKET - bottom cover 1
22 11-9612 • COVER - bottom 1
23 33-1970 • O-RING - screw 1
24 33-3690 • SEAL - washer 1
25 33-1753 • O-RING - tappet 4
26 33-1530 • O-RING - delivery 4
27 33-1973 • O-RING - deflector check 1
28 33-3942 • O-RING - cover 1
30-270 KIT - seal 1
29 33-3833 • SEAL - washer 1
30 33-3939 • GASKET - governor 1
31 33-2230 • O-RING - solenoid 1
30
152D4 TK486E, 1/99 & after)
Revised
8/2/10
31
Revised
8/2/10 TK486E, 1/99 & after) 152D4
32 55-8620 • WASHER - seal 2
33 204-1083 • TOOL - plunger spring support plate 1
34 33-1748 • O-RING - control lever 1
35 33-1753 • O-RING - governor 1
NOTE: This grid is for engines built after 1/99. Engines built after 1/99 have a serial number beginning with an
"L".
32
142F10 FUEL INJECTION GROUP (TK486/486E)
Revised
12/11/08
FUEL INJECTION
GROUP (TK486/
486E)
142F10
12/11/08
33
Revised
12/11/08 FUEL INJECTION GROUP (TK486/486E) 142F10
1 11-6110 SCREW - banjo 1
2 11-8979 BANJO - fuel inlet 1
3 55-8620 GASKET 2
4 11-8823 RETAINER 3
5 55-8626 SCREW - retainer 3
6 11-8728 PIPE - fuel injection 1
10 11-8715 VALVE - fuel injection (see 142F11) 4
10-373 KIT - fuel return hose end cap & clamps 1
11 11-9730 • CAP - set w/fuel return clamp 1
12 11-9728 • HOSE & CLAMPS (short fuel return hose, set of three) 1
13 11-9729 • HOSE & CLAMP (long fuel return hose) 1
14 11-9731 •• SLEEVE - fuel return hose (corrugated) 1
15 10-342 KIT - check valve 1
16 55-8620 • GASKET 2
17 11-6110 • BOLT - air bleed 1
18 11-8937 PROTECTOR - nozzle 4
19 11-6707 GASKET - copper (nozzle seat) 4
20 33-3325 O-RING - dust 4
21 13-317 BANJO - fuel return 1
22 11-6708 RETAINER - nozzle 4
23 55-5138 STUD - retainer 8
24 55-5792 NUT 8
25 204-1848 ADAPTER - compression tester 1
11-9446 • VALVE - Schrader 1
55-1819 • SEAL - copper 1
55-4607 • WASHER 2
204-542 TESTER - compression 1
34
142F11 FUEL INJECTION NOZZLE (TK486/486E)
Revised
5/29/03
FUEL INJECTION
NOZZLE (TK486/
486E)
142F11
5/29/03
35
Revised
5/29/03 FUEL INJECTION NOZZLE (TK486/486E) 142F11
11-8715 VALVE - fuel injection 4
1 11-6787 • HOLDER - nozzle 1
2 11-6108 • SHIM SET 1
3 11-6788 • SPRING - nozzle 1
4 11-6106 • RETAINER - nozzle spring 1
5 11-6789 • PLATE - stop 1
6 11-6790 • PIN 1
7 11-8978 • NOZZLE 1
8 11-6786 • NUT - nozzle case 1
9 11-8937 PROTECTOR - nozzle 4
10 11-6707 GASKET - copper (nozzle seat) 4
11 33-3325 O-RING - dust 4
36
142F12 STARTER ASSEMBLY (TK486/486E & TK482/482E)
Revised
4/4/09
STARTER ASSEM-
BLY (TK486/486E &
TK482/482E)
142F12
4/4/09
37
Revised
4/4/09 STARTER ASSEMBLY (TK486/486E & TK482/482E) 142F12
45-1688 STARTER (12V) 1
45-1823 STARTER (24V) 1
1 41-2149 • ARMATURE (not for 24V) 1
2 77-2468 • BEARING 1
3 77-2469 • BEARING 1
4 NSS • YOKE - assembly 1
5 41-2150 • COIL - field (not for 24V starter) 1
55-8894 •• SCREW - field coil 4
6 41-2151 •• BRUSH (not for 24V) 2
7 91-8112 • COVER - rear 1
8 41-2152 • HOLDER - brush (not for 24V) 1
9 41-2153 •• SPRING - brush 4
10 41-2151 •• BRUSH (not for 24V) 2
11 55-8897 • SCREW - cover 2
12 55-8895 • BOLT - thru 2
13 41-2162 • SWITCH - thermo (early units) 1
14 55-790 •• LOCKWASHER 1
15 41-2154 • PINION - assembly 1
16 41-2155 •• CLUTCH - assembly 1
17 77-2470 •• BEARING - ball 1
18 77-2471 •• BEARING - ball 1
19 41-2156 •• STOPPER - pinion 1
20 41-2154 • RETAINER 1
21 55-8896 • SCREW - retainer 3
22 41-2160 • HOUSING - gear 1
23 41-2158 • SOLENOID (12V) 1
41-2444 • SOLENOID (24V) 1
24 41-2157 • LEVER 1
25 41-2159 • COVER - dust 1
26 55-5770 • SCREW - solenoid 2
27 55-8898 SCREW - starter 2
38
142F13 GASKET SET (TK486/486E)
Revised
10/16/03
GASKET SET
(TK486/486E)
142F13
10/16/03
39
Revised
10/16/03 GASKET SET (TK486/486E) 142F13
30-264 KIT - gasket set 1
1 33-2932 • GASKET - cylinder head 1
2 33-1500 • GASKET 1
3 33-1953 • O-RING - fuel injection pump 1
4 11-8935 • SEAL - valve stem (exhaust) 4
11-8934 • SEAL - valve stem (intake) 4
5 11-8937 • PROTECTOR - nozzle 4
6 11-6707 • GASKET - copper (nozzle seat) 4
7 33-2935 • GASKET - valve cover 1
8 33-2764 • GASKET 1
9 33-2936 • GASKET - intake manifold 1
10 33-2937 • GASKET - exhaust manifold 1
11 11-9250 • GASKET - oil pump 1
12 33-4237 • GASKET 1
13 33-2931 • GASKET 1
14 33-3096 • GASKET - water pump (low mount) 1
33-3259 • GASKET - water pump (high mount) 1
15 33-3097 • GASKET - thermostat case 1
16 33-2767 • GASKET 1
17 33-2768 • GASKET 1
18 33-2765 • GASKET - air heater 1
19 33-2934 • GASKET - flange 1
20 55-4733 • GASKET - round (10) 2
55-8620 • GASKET (12) 2
33-1975 • GASKET (12, round) 2
55-4622 • WASHER - sealing (8) 9
21 33-3512 • O-RING (12.0) 3
33-1910 • O-RING (16.0) 2
33-2942 • O-RING (31.5) 1
33-1954 • O-RING (32.0) 3
33-2762 • O-RING (50.0) 1
22 33-2969 • GASKET - oil seal case 1
23 33-1531 • GASKET - eye bolt 2
24 33-3098 • O-RING - water pump (low mount) 1
33-3263 • O-RING - water pump (high mount) 1
25 33-2974 • SEAL - oil (rear, axial) 1
26 33-4088 • SEAL - oil (front) 1
40
158C8 OIL BASE GROUP
Revised
7/31/11
OIL BASE GROUP

158C8
7/31/11
41
Revised
7/31/11 OIL BASE GROUP 158C8
1 41-402 SWITCH - oil level 1
33-3877 • GASKET - switch 1
2 55-3744 ELBOW - hose 1
3 11-6829 HOSE - oil drain (16.5 in lg) 1
4 92-258 CLIP - hose 1
55-1587 SCREW - clip 1
55-4953 NUT 1
5 55-5081 CAP - drain hose 1
6 10-242 KIT - sleeve & eyelet (3/8) 1
7 11-4941 NUT - hose (3/8) 2
8 11-4372 HOSE (3/8 od x 35 ft lg) 1
9 55-4515 FITTING - hose (3/8) 2
10 55-8665 ELBOW - oil pressure switch 1
11 44-8883 SENSOR - oil pressure transducer 1
12 55-3031 SCREW - elbow 2
13 55-2001 FLATWASHER 2
14 55-7616 WASHER - insulating 2
55-7062 INSERT 2
15 33-2458 MAT - insulating 1
16 55-2964 LOCKWASHER 2
17 55-2998 LOCKWASHER (internal tooth) 1
19 55-3513 SCREW - terminal 1
20 91-8677 BRACKET - oil sensor 1
21 55-665 TEE - oil pressure switch 1
22 41-7063 SWITCH - oil pressure 1
23 11-7382 FILTER - oil (dual element) 1
11-9182 FILTER - oil (EMI 3000) 1
24 44-9298 SENSOR - rpm 1
42
158C7 FUEL FILTER & HOSES
Revised
5/2/09
FUEL FILTER &

HOSES
158C7
5/2/09
43
Revised
5/2/09 FUEL FILTER & HOSES 158C7
1 11-9015 HEAD - fuel filter 1
55-3490 SCREW - base 2
55-4954 NUT - base 2
2 11-9342 FILTER - fuel (EMI 3000) 1
3 11-9016 SHAFT - water bleed 1
4 11-9017 SPUD - fuel filter 1
203-393 SEALER - thread A/R
5 11-5320 ELBOW (1/4) 3
7 11-4841 NUT (1/4) 4
8 11-4367 HOSE (1/4 od x 35 ft lg) A/R
10 11-4941 NUT (3/8) 3
11 11-4372 HOSE (3/8 od x 35 ft lg) A/R
12 55-4203 CLAMP - hose 2
55-5022 SCREW - clamp 2
55-2959 LOCKWASHER 2
13 11-4380 ELBOW (3/8) 1
14 101-321 PUMP - fuel injection (see 152D4) 1
15 11-7433 PUMP - fuel (see 142F8) 1
16 55-9752 ELBOW - fuel 1
17 40-1016 HEATER - fuel (electric, optional) 1
18 11-6246 HEATER - fuel (coolant) 1
91-5739 PAD - fuel heater 1
91-438 CLAMP - fuel heater 2
44
130G3 FUEL TANK GROUP (SGCO)
Revised
11/12/11
FUEL TANK
GROUP (SGCO)
130G3
11/12/11
45
Revised
11/12/11 FUEL TANK GROUP (SGCO) 130G3
1 NSS TANK - fuel (see Structural Component grid) 1
2 55-5617 VENT 2
3 11-8719 PLUG - fuse 2
4 11-8048 CAP - fuel tank 2
13-934 CAP - fuel tank (tamper evident) 2
13-946 CAP - fuel tank 2
5 11-4372 HOSE (3/8 od x 35 ft lg) A/R
6 11-4941 NUT - hose fitting (3/8) 2
8 11-4380 ELBOW (3/8) 2
9 11-8718 GAUGE - fuel 2
11-9594 • DIAL - gauge 1
10 11-8887 TUBE - fuel feed 2
11 55-2313 BALL - check 1
12 55-3364 PLUG - pipe 1
13 98-876 HOSE - vent (16.0 lg) A/R
14 40-1129 SENSOR - fuel level 1
15 33-3878 GASKET - fuel sensor 1
16 92-7236 COVER - fuel sensor 1
55-1510 SCREW - sensor/cover 5
55-431 LOCKWASHER 5
46
158D1 AIR CLEANER GROUP
Revised
6/26/10
AIR CLEANER
GROUP
158D1
6/26/10
47
Revised
6/26/10 AIR CLEANER GROUP 158D1
1 11-3733 CLEANER - air (oil bath, before 11/02) 1
2 99-1400 • CLAMP - oil cup 1
3 11-2610 • CUP - air cleaner 1
4 11-2457 CLAMP 1
5 55-8116 • SCREW - clamp 1
6 55-3472 • NUT 1
55-4954 NUT 2
7 91-8744 CLAMP - air cleaner 1
55-4955 NUT - clamp 2
8 91-8678 BRACKET - clamp 1
55-2969 SCREW - bracket 2
55-4954 NUT 2
9 55-3991 CLAMP - hose 2
10 11-9289 HOSE - air 1
10-317 KIT - adapter & hose 1
11 11-8858 • ADAPTER - air intake 1
12 33-2854 • O-RING 1
13 91-7555 • SPACER 2
14 11-8900 • HOSE - breather 1
15 11-8901 • HOSE - insulation 1
16 55-1592 • CONNECTOR - hose 1
55-5022 SCREW - adapter 2
17 55-2332 BANDWRAP 2
18 11-9299 CLEANER - air (dry, 11/02 & after) 1
19 11-9300 • ELEMENT - air cleaner 1
20 55-9568 CLAMP - hose 2
21 11-9913 HOSE - air cleaner 1
22 11-7757 INDICATOR - air restriction 1
23 11-7828 FITTING - indicator 1
24 92-861 CLAMP - air cleaner 1
55-2114 NUT 2
25 92-3341 BRACKET - air cleaner 1
48
158B9 MUFFLER GROUP
Revised
9/26/05
MUFFLER GROUP
158B9
9/26/05
49
Revised
9/26/05 MUFFLER GROUP 158B9
1 12-800 MUFFLER 1
2 33-2314 GASKET - muffler 1
3 55-3089 SCREW - muffler 2
6 55-2114 NUT 2
7 55-5022 SCREW - muffler 2
9 91-7234 U-BOLT 2
10 91-7233 SADDLE - u-bolt 2
55-3472 LOCKNUT 4
12 11-9286 TUBE - exhaust 1
13 92-256 BRACKET - exhaust tube 1
92-5265 BRACKET - exhaust tube (Maersk blue) 1
55-4953 LOCKNUT 2
50
158B8 ENGINE COOLING SYSTEM
Revised
1/15/10
ENGINE COOLING
SYSTEM
158B8
1/15/10
51
Revised
1/15/10 ENGINE COOLING SYSTEM 158B8
1 12-799 RADIATOR 1
55-8752 • INSERT 6
55-3018 SCREW - radiator 6
2 11-8913 CAP - radiator 1
3 55-9011 DRAIN COCK - radiator 1
4 91-8036 BRACKET - radiator (top) 1
55-4953 NUT 7
5 92-1350 SCREEN - radiator 1
6 91-8035 ANGLE - radiator (front) 1
55-2957 SCREW - angle 5
55-2979 SCREW 2
55-4953 NUT 7
7 98-5711 SHROUD - radiator 1
55-3018 SCREW - shroud 6
8 98-5723 ORIFICE - radiator 1
55-3018 SCREW - orifice 6
55-3045 WASHER - dome 6
9 11-9524 HOSE - water pump to radiator (silicone) 1
10 11-9525 HOSE - radiator to engine (silicone) 1
11 55-5400 CLAMP - hose 4
12 11-4693 HANGER - overflow tank 1
55-2977 SCREW - hanger 2
55-6526 INSERT 2
13 99-8301 CAP & CHAIN - overflow tank 1
14 11-4607 TANK - overflow 1
15 99-1655 HOSE - overflow 1
55-2796 CLAMP - hose 4
16 41-6539 SENSOR - water temperature 1
55-5023 BUSHING 1
17 55-2554 PLUG - pipe 1
18 55-5090 TEE - pipe 1
19 55-9091 ELBOW - pipe 1
20 13-509 PUMP - water (ELC compatible, see 149C12) 1
21 12-538 HOSE - water pump 1
52
158B8 ENGINE COOLING SYSTEM
Revised
1/15/10
53
Revised
1/15/10 ENGINE COOLING SYSTEM 158B8
22 55-6731 CLAMP - hose 2
23 91-7217 BRACKET - overflow tank 1
55-4953 LOCKNUT 4
24 91-7782 PAD - radiator 1
25 11-8888 TANK - expansion 1
55-3021 SCREW - tank 4
26 55-5400 CLAMP - hose 2
27 11-8891 HOSE - outlet 1
28 91-7497 COVER - access 1
55-2955 SCREW - cover 2
29 41-1818 SENSOR - water level 1
54
158C0 BELTS, PULLEY & FAN
Revised
1/13/03
BELTS, PULLEY &

FAN
158C0
1/13/03
55
Revised
1/13/03 BELTS, PULLEY & FAN 158C0
1 78-1340 BELT - fan & water pump 1
2 70-212 PULLEY - crankshaft (see 142C14) 1
3 90-331 SPACER - fan 1
4 78-618 FAN - radiator 1
5 55-7660 SCREW - fan (CGCO & SGCO) 3
55-6764 SCREW - fan (CGSM, SGSM, CGCM & SGCM) 3
7 77-1345 PULLEY - water pump (see 149C12) 1
8 204-427 GAUGE - belt tension 1
NOTE: Crankshaft pulley belt adjustment.
56
158B0 ALTERNATOR MOUNTING
Revised
1/10/08
ALTERNATOR
MOUNTING
158B0
1/10/08
57
Revised
1/10/08 ALTERNATOR MOUNTING 158B0
1 92-226 BRACKET - generator (rear) 1
2 55-2557 SCREW - frame 2
4 55-3595 WASHER - special 4
5 55-4952 NUT 4
6 99-3649 MOUNT - vibration 2
7 92-224 BRACKET - generator (bottom) 1
55-8137 SCREW - bracket, generator 6
8 55-6814 STUD - power pack 6
12 99-1642 SPACER 6
13 55-5205 NUT 6
14 92-225 BRACKET - engine 1
15 92-228 BRACKET - engine (rear) 1
16 92-229 BRACKET - engine (front) 1
55-7412 SCREW - bracket, engine 8
55-7122 WASHER - belleville (3/8, ss) 8
17 44-9298 SENSOR - rpm 1
58
158C1 CONTROL BOX
Revised
4/29/10
CONTROL BOX
158C1
4/29/10
59
Revised
4/29/10 CONTROL BOX 158C1
1 92-255 BOX - control 1
55-2977 SCREW - box 4
2 55-2965 NUT - ground 2
55-2996 LOCKWASHER (internal tooth) 2
3 44-3345 REGULATOR - voltage 1
55-2995 SCREW - regulator 3
4 41-1418 PLUG (12 contact, 10 amp) 1
5 44-5555 BOARD - terminal (3 terminal, 55 amp) 1
6 44-9282 BOARD - terminal (6 terminal, 55 amp) 1
55-2990 NUT - terminal board 4
7 99-3855 MARKSTRIP 1
9 45-1719 EXCITER (see 131B4) 1
55-4953 NUT - exciter 4
10 41-3614 HARNESS - main (see 146G4) 1
11 44-5030 • CONNECTOR (6 pin, female) 1
15 55-3539 CONNECTOR - barb 1
16 33-1056 O-RING 1
17 55-2636 LOCKNUT 1
18 98-5305 HOSE - harness 1
19 45-1797 CONTROLLER - mP-G (see 146G6) 1
55-2979 SCREW - cover 4
55-3059 NUT - captive 4
20 91-6841 BRACKET - plug support 1
21 33-3167 GASKET - receptacle (230V) 1
33-3168 GASKET - receptacle (460V) 1
22 41-3403 RECEPTACLE (230V) 1
41-3404 RECEPTACLE (460V) 1
60
158C1 CONTROL BOX
Revised
4/29/10
61
Revised
4/29/10 CONTROL BOX 158C1
23 41-7067 MODULE - timer 1
44-5827 • CONNECTOR - male (4 pin) 1
44-5139 • TERMINAL - fingrip (16-14 ga) 4
55-5279 SCREW - module 2
55-2998 LOCKWASHER - module 2
55-9127 SPACER - module 2
24 41-893 RELAY - solenoid timer (used with previous solenoid timers) 1
62
CIRCUIT BOARD & RELAYS - mP-G (SGCM, SGSM,
148G1 SGCO)
Revised
9/11/10
CIRCUIT BOARD &

RELAYS - mP-G
(SGCM, SGSM,
SGCO)
148G1
9/11/10
63
CIRCUIT BOARD & RELAYS - mP-G (SGCM, SGSM,
Revised
9/11/10 SGCO) 148G1
1 45-1797 CONTROLLER - mP-G (see 146G6) 1
2 N/A BRACKET - relay board (has been replaced with item 3) 1
3 91-8920 BRACKET - relay board 1
4 41-5219 BOARD - relay (mP-G) 1
41-8291 • BUZZER - warning 1
5 91-1277 • RETAINER - harness connector 8
55-2262 • RIVET - retainer 8
55-3550 • FLATWASHER 8
6 41-895 • RELAY 4
7 44-8244 FUSE LINK 1
55-346 NUT - jumper & link 6
55-401 FLATWASHER 3
8 44-1458 JUMPER 1
9 41-2530 HARNESS - voltmeter 1
10 44-5622 • CONNECTOR (6 pin) 1
11 41-2586 CABLE - ribbon 1
12 55-9127 SPACER - pc board 2
13 41-2585 BOARD - printed circuit, interconnecting 1
55-5279 SCREW - pc board 2
64
CONTROL BOX COVER - mP-G (SGCM, SGSM,
146G6 SGCO)
Revised
11/8/05
CONTROL BOX
COVER - mP-G
(SGCM, SGSM,
SGCO)
146G6
11/8/05
65
CONTROL BOX COVER - mP-G (SGCM, SGSM,
Revised
11/8/05 SGCO) 146G6
1 45-1797 CONTROLLER - mP-G (w/o chip) 1
2 40-913 KIT - eprom chip (V0432) 1
55-3000 SCREW - controller 8
3 91-7143 BEZEL - TG VI (complete) 1
4 33-2797 • GASKET - bezel 2
5 91-7142 • WINDOW - bezel 1
6 91-8680 COVER - mP-G 1
92-5310 COVER - mP-G (Maersk blue) 1
7 99-7246 STRIP - gasket (9.7 & 10.2 lg) A/R
8 91-8681 NAMEPLATE - cover, microprocessor 1
9 41-2527 HARNESS - on/off 1
10 44-7792 • SWITCH - on/off 1
44-5620 • CONNECTOR (2 pin, male) 1
11 44-739 • BOOT - switch 1
12 41-2528 BOARD - pc (indicator) 1
13 91-1277 RETAINER - harness connector 1
55-2262 RIVET - retainer 1
55-3256 SCREW - board 4
14 41-2529 HARNESS - indicator 1
66
158C2 MAIN HARNESS ASSEMBLY
Revised
9/3/09
MAIN HARNESS
ASSEMBLY
158C2
9/3/09
67
Revised
9/3/09 MAIN HARNESS ASSEMBLY 158C2
1 41-3614 HARNESS - main (pre Tier 2 engine) 1
41-3772 HARNESS - main (Tier 2 engine) 1
2 44-5814 • CONNECTOR (4 terminal, female) 2
3 41-1325 • SOCKET - relay 1
6 44-5219 • CONNECTOR (2 terminal, female) 2
9 44-2792 • TERMINAL - ring (yellow #10) 4
44-2793 • TERMINAL - ring (yellow 1/4) 1
44-2791 • TERMINAL - ring (blue # 10, 16-14 ga) 5
44-2786 • TERMINAL - ring (blue 3/8, 16-14 ga) 1
10 41-4973 • TERMINAL - fork (yellow # 6, 12-10 ga) 1
41-280 • TERMINAL - fork (red # 6, 22-16 ga) 1
41-438 • TERMINAL - fork (blue # 6, 16-14 ga) 2
68
112D9 CONNECTORS - DEUTSCH IN-LINE
Revised
1/21/08
CONNECTORS -
DEUTSCH IN-LINE
112D9
1/21/08
69
Revised
1/21/08 CONNECTORS - DEUTSCH IN-LINE 112D9
1 44-9700 TERMINAL - socket (w/ 6 in wire lead) 2
44-9587 TERMINAL - socket (without wire) 2
2 44-9585 PLUG (2 pin, w/ seal) 1
3 33-2392 SEAL 1
4 44-9586 WEDGE 1
5 44-9590 WEDGE 1
6 44-9589 RECEPTACLE (2 pin) 1
7 44-9701 TERMINAL - pin (w/ 6 in wire lead) 2
44-9591 TERMINAL - pin (16-18 ga) 2
8 44-9631 CONNECTOR (3 pin, w/ seal) 1
9 33-2393 SEAL 1
10 44-9536 WEDGE 1
11 44-9545 WEDGE 1
13 44-8935 PLUG (4 pin, w/ seal) 1
14 33-2394 SEAL 1
15 44-8936 WEDGE 1
16 44-8918 WEDGE 1
18 44-8920 CONNECTOR (6 pin, w/ seal) 1
19 33-2395 SEAL 1
20 44-8921 WEDGE 1
21 44-8917 WEDGE 1
23 44-9903 PLUG (8 pin, w/ seal) 1
24 33-2396 SEAL 1
25 44-9902 WEDGE 1
26 44-9901 WEDGE 1
41-2628 RECEPTACLE (8 pin, brown) 1
28 44-9600 PLUG (12 pin, w/ seal) 1
29 33-2397 SEAL 1
30 44-9601 WEDGE 1
31 44-9905 WEDGE 1
33 41-2323 PLUG - assembly (w/ 6 in wires) 1
34 41-2322 RECEPTACLE - assembly (w/ 6 in wires) 1
39 41-4524 SOCKET (8-10 ga) 1
70
112D9 CONNECTORS - DEUTSCH IN-LINE
Revised
1/21/08
71
Revised
1/21/08 CONNECTORS - DEUTSCH IN-LINE 112D9
40 41-3073 PLUG (1 terminal, 8-10 ga) 1
41 41-3069 CONNECTOR (1 terminal, 8-10 ga) 1
42 44-6850 PIN (8-10 ga) 1
43 44-9602 PIN - sealing A/R
44 44-9906 TAB - mounting (for all connectors except the 8 pin connector) A/R
45 44-9907 TAB - mounting (for 8 pin connector only) A/R
46 204-703 KIT - crimper (w/ terminals) 1
204-1038 • TOOL - crimper 1
204-799 • TOOL - wedge remover 1
72
131B4 EXCITER ASSEMBLY
Revised
8/16/05
EXCITER ASSEM-
BLY
131B4
8/16/05
73
Revised
8/16/05 EXCITER ASSEMBLY 131B4
45-1719 EXCITER 1
1 44-3351 • RESISTOR 2
55-3123 • SCREW - resistor 2
55-3507 • SCREW - resistor (3/4 lg) 1
55-1511 • LOCKWASHER 2
55-3006 • WASHER - shoulder 2
55-2752 • NUT 2
2 44-5354 • RESISTOR 1
55-3506 • SCREW - resistor (10-32 x 1) 1
55-3507 • SCREW - resistor (10-32 x 3/4) 1
55-346 • NUT 4
3 44-4108 • RECTIFIER (see 119G2) 1
4 44-3224 • TRANSFORMER - current 1
5 55-3520 • SPACER 8
6 44-4902 • SPACER 4
7 51-1271 • SCREW - transformer 8
8 55-431 • FLATWASHER 8
9 55-2752 • NUT 8
10 91-7339 • PLATE - rectifier (see 131B5) 1
11 55-6828 • CLAMP - harness (9/16) 1
55-1350 • CLAMP - harness (3/8) 1
12 44-5712 • CONNECTOR & HARNESS - voltage regulator 1
13 41-1615 • TRANSFORMER (incl 14 & 15) 1
14 41-1421 •• SOCKET (12 contact, tin plated terminals) 1
15 41-1420 •• PLUG (12 contact, tin plated terminals) 1
16 44-4901 • COVER - connector 2
17 55-3355 • SCREW - connector cover 4
18 55-2851 • SCREW - diode 1
55-3525 • NUT 2
74
131B4 EXCITER ASSEMBLY
Revised
8/16/05
75
Revised
8/16/05 EXCITER ASSEMBLY 131B4
19 41-2533 • RECTIFIER 1
41-1974 • INSULATOR - rectifier 1
20 55-857 • SCREW - diode 1
55-295 • NUT 1
21 44-4208 • PLATE - assembly (incl items 1, 2, 3, 16, 18, 19 & 20) 1
99-3566 •• PLATE 1
22 44-6181 • CAPACITOR 1
23 91-7528 • PLATE - capacitor 1
24 55-5237 • SPACER - standoff 2
55-735 • SCREW - plate 2
25 55-2330 • BANDWRAP 2
26 99-3427 • MOUNT - bandwrap 2
55-3583 • RIVET - mount 2
27 44-3345 REGULATOR - voltage (see control box) 1
76
119G2 RECTIFIER GROUP
Revised
7/8/96
RECTIFIER
GROUP
119G2
7/8/96
77
Revised
7/8/96 RECTIFIER GROUP 119G2
1 44-4108 RECTIFIER 1
2 99-3564 PLATE - heat sink (top) 1
203-454 MASTIC - heat transfer A/R
3 99-3563 PLATE - heat sink (rectifier) 1
4 55-735 SCREW - rectifier plate 2
7 55-3519 NUT 2
78
131B5 RECTIFIER PLATE GROUP
Revised
8/23/00
RECTIFIER PLATE
GROUP
131B5
8/23/00
79
Revised
8/23/00 RECTIFIER PLATE GROUP 131B5
1 91-7339 PLATE - rectifier 1
2 44-4108 RECTIFIER - 3 phase (15 amp) 2
55-3580 SCREW - rectifier 4
55-415 LOCKWASHER 4
3 41-1614 DIODE (D4) 1
4 41-1613 DIODE (D5) 1
5 33-1055 GROMMET 1
6 44-2558 BOARD - terminal 1
55-735 SCREW - board 2
55-415 LOCKWASHER 2
8 41-1612 BUSBAR 1
9 44-3181 BREAKER - circuit 1
55-5046 SCREW - breaker 1
55-366 LOCKWASHER 1
55-411 FLATWASHER 1
55-2752 NUT - breaker terminal 2
55-396 LOCKWASHER 2
55-431 FLATWASHER 2
80
ALTERNATOR GROUP (SGCO 2000, SGSM 2000,
166C8 SGCM 2000)
Revised
5/6/09
ALTERNATOR
GROUP (SGCO
2000, SGSM 2000,
SGCM 2000)
166C8
5/6/09
81
ALTERNATOR GROUP (SGCO 2000, SGSM 2000,
Revised
5/6/09 SGCM 2000) 166C8
1 404-150 ALTERNATOR (Yanmar engine only) 1
2 45-1956 • STATOR 1
3 55-3985 •• STUD - housing 4
55-1800 •• LOCKWASHER 4
55-2640 •• NUT 4
4 45-1955 • ROTOR (incl blower & flex disc) 1
5 11-9482 •• DISC - flex 1
6 77-2747 •• BEARING 1
7 44-4678 •• RECTIFIER - positive 1
8 44-4679 •• RECTIFIER - negative 1
55-664 •• NUT - rectifier 6
55-2001 •• FLATWASHER 6
9 55-9820 •• SPACER - fan 6
10 55-9818 •• SCREW - fan 6
55-9819 •• FLATWASHER 6
11 77-2654 •• BLOWER 1
12 45-605 •• EXCITER - stator (2.8 ohm) 1
13 55-3539 CONNECTOR - barb 1
33-1056 O-RING 1
55-2636 NUT 1
14 99-3583 PLATE - cover 1
92-5255 PLATE - cover (Maersk blue) 1
15 41-1416 PLUG - exciter (12 contact, 10 amp) 1
16 44-5620 CONNECTOR (2 pin) 1
17 33-1062 GASKET - plate 1
18 98-5035 HOSE - harness (cut to 26.0 inches) A/R
19 55-8137 SCREW - disc to flywheel 6
20 55-9497 PIN - dowel 2
21 91-3439 COVER - harness 1
22 33-1420 GASKET - cover 1
23 55-1587 SCREW - cover 2
82
158C6 BATTERY & CABLE GROUP
Revised
11/30/07
BATTERY & CABLE

GROUP
158C6
11/30/07
83
Revised
11/30/07 BATTERY & CABLE GROUP 158C6
1 203-600 BATTERY - threaded post (750CCA G31) 1
203-601 BATTERY - tapered post (750CCA G31) 1
2 92-269 STRAP - battery holddown 1
3 41-4240 CABLE - battery (tapered post) 2
4 41-1551 CABLE - battery (threaded post) 2
5 55-4436 • NUT 2
6 91-7530 BRACKET - battery cable 1
55-2240 CLAMP 4
7 55-5022 SCREW - strap to engine 1
10 41-808 STRAP - ground (20 in lg) 1
11 55-1587 SCREW - strap to frame 1
12 55-2993 LOCKWASHER (internal tooth) 2
14 55-4953 NUT 1
15 91-4146 ROD - holddown 2
55-4954 NUT - holddown 2
84
158C3 STRUCTURAL COMPONENTS
Revised
6/26/11
STRUCTURAL
COMPONENTS
158C3
6/26/11
85
Revised
6/26/11 STRUCTURAL COMPONENTS 158C3
1 98-7220 PANEL - top (curbside) 1
98-8001 PANEL - top (curbside, Maersk blue) 1
2 90-384 PANEL - top (center) 1
90-383 PANEL - top (center, Maersk blue) 1
55-2969 SCREW - panel 9
3 90-384 PANEL - top (roadside) 1
98-7229 PANEL - top (roadside, Maersk blue) 1
4 92-251 CHANNEL - top (curbside) 1
5 92-252 SUPPORT - right 1
55-2977 SCREW - support 3
6 92-249 CHANNEL - center 1
7 92-250 SUPPORT - center 1
8 92-253 CHANNEL - top (roadside) 1
9 92-254 SUPPORT - vertical (roadside) 1
10 92-5117 BUMPER - bulkhead 1
91-5315 SPACER - bumper 4
55-3121 SCREW - bumper 4
11 98-7980 SUPPORT - frame (top shelf) 1
12 98-5716 FRAME - fuel tank (before 1/05) 1
98-7294 FRAME - fuel tank (1/05 & after) 1
98-5724 FRAME - fuel tank (header pin, option 062312) 1
91-9499 ROD - mounting (clip-on) 2
13 98-7222 DOOR - curbside 1
98-7222 DOOR - curbside (Maersk blue) 1
14 98-7221 DOOR - roadside 1
98-7221 DOOR - roadside (Maersk blue) 1
15 92-260 LATCH - door 2
16 99-6599 LATCH - door A/R
91-5315 SPACER - door latch 4
55-3003 SCREW - spacer 8
55-2999 NUT 8
55-7527 SCREW - door 6
55-7729 WASHER - belleville 6
17 91-3161 BRACKET - clip-on (left, see 105C8) 1
91-3162 BRACKET - clip-on (right, see 105C8) 1
86
158C3 STRUCTURAL COMPONENTS
Revised
6/26/11
87
Revised
6/26/11 STRUCTURAL COMPONENTS 158C3
18 91-7227 BOLTSTRIP - bracket 4
55-5418 NUT 4
19 91-2382 SPACER - bracket 2
20 92-266 COVER - retainer bolt, curbside (incl latch #16) 1
22 92-267 COVER - retainer bolt, roadside (incl latch #16) 1
23 99-6377 STRIP - bumper 6
24 91-7229 BAR - locking 2
25 91-7230 LANYARD 2
91-7231 LANYARD 2
91-6826 RING - key 4
91-6825 COTTER - loop 4
26 92-5118 BUMPER - lower 2
27 92-265 SPACER - bumper 2
55-3121 SCREW - bumper 2
55-4953 NUT 2
28 11-9292 KIT - pin mount option 1
30 55-5941 SCREW - mounting 2
31 91-6824 FASTENER - push-on 2
88
158C5 STRUCTURAL COMPONENTS (REAR VIEW)
Revised
3/10/08
STRUCTURAL
COMPONENTS
(REAR VIEW)
158C5
3/10/08
89
Revised
3/10/08 STRUCTURAL COMPONENTS (REAR VIEW) 158C5
1 92-6717 SHIELD - radiator fan 1
92-6428 SHIELD - radiator fan (Maersk blue) 1
55-8979 • INSERT 2
2 92-6716 SHIELD - muffler 1
98-7227 SHIELD - muffler (Maersk blue) 1
55-8979 • INSERT 4
3 92-6718 SHIELD - exhaust tube 1
92-6420 SHIELD - exhaust tube (Maersk blue) 1
55-8979 • INSERT 3
55-1587 SCREW - shield 9
4 91-6831 STRIP - foam 1
90
105C8 UNIT MOUNTING BRACKET
Revised
9/6/94
UNIT MOUNTING
BRACKET
105C8
9/6/94
91
Revised
9/6/94 UNIT MOUNTING BRACKET 105C8
91-3161 BRACKET (lefthand) 1
91-3162 BRACKET (righthand) 1
1 55-2925 • PIN - spring (slotted) 1
2 91-3160 • SHAFT - clamp 1
3 55-6030 • SCREW - shoulder 2
4 91-112 • BASE - clamp 1
5 55-4021 • FITTING - grease 2
55-2155 • SCREW - set 2
6 91-114 • PAW - clamp 1
7 55-4118 • NUT 2
8 91-113 • HANDLE - clamp 1
9 55-6028 • WASHER - spring 2
10 55-6029 • WASHER - special 1
11 55-6027 • NUT 1
92
146G2 NAMEPLATES
Revised
5/25/10
NAMEPLATES
146G2
5/25/10
93
Revised
5/25/10 NAMEPLATES 146G2
1 91-2388 NAMEPLATE - TK (CGCO & SGCO) 1
91-4510 NAMEPLATE - TK (CGCM & SGCM) 1
2 91-6284 NAMEPLATE - 15 kW 1
3 92-4305 NAMEPLATE - Ingersoll Rand 1
4 91-5703 NAMEPLATE - Service Information Records Pouch 1
5 91-2384 NAMEPLATE - Caution Left 1
6 92-2504 NAMEPLATE - Clean Filter Screen 1
7 91-9918 NAMEPLATE - Thermo King (black letters) 1
91-9919 NAMEPLATE - Thermo King (white letters) 1
8 91-2383 NAMEPLATE - Caution Right 1
9 99-9234 NAMEPLATE - Fan Universal 1
10 91-4512 NAMEPLATE - arrow 1
11 91-3423 NAMEPLATE - 460V 1
12 91-4148 NAMEPLATE - Installation Instructions (CGCO & SGCO) 1
91-3425 NAMEPLATE - Installation Instructions (CGCM & SGCM) 1
13 91-338 NAMEPLATE - Document Holder 1
14 91-7012 NAMEPLATE - Radiator Fill 1
15 99-7314 NAMEPLATE - Coolant Level 1
16 91-7013 NAMEPLATE - TK CG II Maintenance 1
17 99-3522 NAMEPLATE - Caution 460 Volts 1
18 99-4732 NAMEPLATE - 460 Volts 1
19 91-2389 NAMEPLATE - Diesel Fuel Only 1
20 99-4660 NAMEPLATE - Positive 1
21 99-4661 NAMEPLATE - Negative 1
22 99-6596 NAMEPLATE - Coolant 1
23 91-8684 NAMEPLATE - FHWA 1
24 92-5112 NAMEPLATE - Wiring Diagram 1
25 91-8686 NAMEPLATE - Schematic Diagram 1
26 92-5113 NAMEPLATE - Smart Gen-Set Menu List 1
92-5114 NAMEPLATE - Smart Gen-Set Menu List (Spanish) 1
27 91-8688 NAMEPLATE - Smart Gen-Set (SGCO) 1
92-1362 NAMEPLATE - Smart Gen-Set operating instructions (Span- 1
ish SGCO 2000-151)
91-9506 NAMEPLATE - Smart Gen-Set (SGSM) 1
91-9507 NAMEPLATE - Smart Gen-Set (SGCM) 1
28 91-8689 NAMEPLATE - Smart Gen-Set Operating Instructions 1
92-275 NAMEPLATE - Smart Gen-Set Operating Instructions (Span- 1
ish)
29 91-8810 NAMEPLATE - CE 1
30 91-8699 NAMEPLATE - Operating Instructions (CGCM) 1
91-9920 NAMEPLATE - Operating Instructions (CGSM) 1
31 91-8700 NAMEPLATE - Schematic/Wiring Diagram (CGCO & SGCO) 1
32 91-7171 NAMEPLATE - California Proposition 1
94
146G2 NAMEPLATES
Revised
5/25/10
95
Revised
5/25/10 NAMEPLATES 146G2
33 91-3424 NAMEPLATE - 230V 1
34 99-3407 NAMEPLATE - Caution 230 Volts 1
35 99-9938 NAMEPLATE - Caution, Start/Stop 1
36 99-9939 NAMEPLATE - Caution, Start/Stop (multi-language) 1
37 91-9269 NAMEPLATE - Texaco 1
38 92-109 NAMEPLATE - 1245 Max Weight KG. 1
96
INDEX NUMERICAL BY PART NUMBER
101-321 22, 30, 44 11-8670 14 11-8964 24

101-331 30 11-8671 14 11-8965 24
101-351 6 11-8672 14 11-8966 30
10-242 42, 44, 46 11-8675 26 11-8970 28
10-243 44 11-8680 28 11-8971 28
10-317 48 11-8681 28 11-8972 28
10-342 34 11-8682 28 11-8973 28
10-371 8 11-8715 34, 36 11-8974 28
10-373 34 11-8718 46 11-8975 28
11-2457 48 11-8719 46 11-8976 28
11-2610 48 11-8728 34 11-8977 28
11-2854 28 11-8729 34 11-8978 36
11-3733 48 11-8730 34 11-8979 34
11-4367 44 11-8731 34 11-8984 12
11-4372 42, 44, 46 11-8823 34 11-8993 22
11-4380 44, 46 11-8858 48 11-8994 14
11-4607 52 11-8887 46 11-8995 24
11-4693 52 11-8888 54 11-8996 26
11-4841 44 11-8891 54 11-8998 28
11-4941 42, 44, 46 11-8900 48 11-9015 44
11-5082 8 11-8901 48 11-9016 44
11-5091 8 11-8913 52 11-9017 44
11-5103 14 11-8919 6 11-9182 24, 42
11-5170 30 11-8920 8 11-9202 22
11-5320 44 11-8921 8 11-9203 22
11-5499 6 11-8923 12 11-9204 22
11-6031 10 11-8924 10 11-9205 30
11-6106 36 11-8926 14 11-9248 22
11-6108 36 11-8927 14 11-9249 24
11-6110 34 11-8928 14 11-9250 24, 40
11-6125 30 11-8929 16 11-9256 26
11-6246 44 11-8930 14 11-9261 22
11-6555 6 11-8932 16 11-9266 20
11-6567 14 11-8933 16 11-9286 50
11-6702 14 11-8934 16, 40 11-9289 48
11-6703 14 11-8935 14, 40 11-9292 88
11-6704 14 11-8936 16 11-9299 48
11-6707 14, 34, 36, 40 11-8937 14, 34, 36, 40 11-9300 48
11-6708 14, 34 11-8938 14 11-9338 12
11-6717 22 11-8939 14 11-9342 44
11-6719 18, 22 11-8940 14 11-9354 24
11-6721 22 11-8941 14 11-9446 34
11-6722 22 11-8942 16 11-9447 24
11-6724 18 11-8943 20 11-9448 12
11-6786 36 11-8944 20 11-9482 82
11-6787 36 11-8945 22 11-9524 52
11-6788 36 11-8947 18 11-9525 52
11-6789 36 11-8948 18 11-9592 8, 18
11-6790 36 11-8949 18 11-9594 46
11-6829 42 11-8950 18 11-9612 30
11-7382 24, 42 11-8951 18 11-9613 30
11-7433 28, 44 11-8952 18 11-9624 26
11-7499 28 11-8953 18 11-9728 34
11-7707 28 11-8955 18 11-9729 34
11-7757 48 11-8956 18 11-9730 34
11-7828 48 11-8958 18 11-9731 34
11-8048 46 11-8959 18 11-9913 48
11-8667 12 11-8961 24 12-538 52
11-8668 24 11-8962 24 12-743 6
INDEX - 1
12-746 12 33-1970 30 40-913 66

12-747 14 33-1973 30 41-1325 68
12-749 18 33-1975 40 41-1416 82
12-750 18 33-2230 30 41-1418 60
12-799 52 33-2314 50 41-1420 74
12-800 50 33-2392 70 41-1421 74
12-823 10 33-2393 70 41-1551 84
12-882 12 33-2394 70 41-1612 80
12-925 30 33-2395 70 41-1613 80
13-1138 18 33-2396 70 41-1614 80
13-126 16 33-2397 70 41-1615 74
13-127 28 33-2458 42 41-1818 54
13-128 28 33-2759 10 41-1974 76
13-317 34 33-2762 14, 40 41-2147 20
13-381 14 33-2764 20, 40 41-2149 38
13-509 26, 52 33-2765 20, 40 41-2150 38
13-659 14 33-2767 26, 40 41-2151 38
13-920 6 33-2768 26, 40 41-2152 38
13-921 6 33-2771 28 41-2153 38
13-924 18 33-2797 66 41-2154 38
13-925 18 33-2854 48 41-2155 38
13-926 6 33-2931 24, 40 41-2156 38
13-927 6 33-2932 16, 40 41-2157 38
13-928 6 33-2933 8 41-2158 38
13-934 46 33-2934 16, 40 41-2159 38
13-946 46 33-2935 14, 40 41-2160 38
203-348 8, 12, 40 33-2936 20, 40 41-2162 38
203-393 44 33-2937 20, 40 41-2317 6
203-454 78 33-2940 28 41-2322 70
203-600 84 33-2941 28 41-2323 70
203-601 84 33-2942 28, 40 41-2324 70
204-1011 8 33-2969 10, 40 41-2325 70
204-1038 72 33-2970 24 41-2326 70
204-1083 32 33-2974 10, 40 41-2327 70
204-1848 34 33-2999 16 41-2444 30, 38
204-427 56 33-3096 26, 40 41-2527 66
204-542 34 33-3097 26, 40 41-2528 66
204-703 72 33-3098 26, 40 41-2529 66
204-799 72 33-3167 60 41-2530 64
204-952 10 33-3168 60 41-2533 76
204-994 10 33-3259 40 41-2585 64
30-264 40 33-3263 40 41-2586 64
30-267 30 33-3325 34, 36 41-2628 70
30-270 30 33-3512 14, 40 41-280 68
30-295 26 33-3689 30 41-3069 72
33-1055 80 33-3690 30 41-3073 72
33-1056 60, 82 33-3833 30 41-3403 60
33-1062 82 33-3877 12, 42 41-3404 60
33-1420 82 33-3878 46 41-3614 60, 68
33-1500 8, 40 33-3939 30 41-3772 68
33-1530 30 33-3940 30 41-402 12, 42
33-1531 40 33-3941 30 41-4240 84
33-1745 26 33-3942 30 41-438 68
33-1748 32 33-4088 8, 40 41-4470 12
33-1749 28 33-4160 12 41-4524 70
33-1753 30, 32 33-4237 24, 40 41-4973 68
33-1910 8, 40 40-1016 44 41-5219 64
33-1953 8, 30, 40 40-1129 46 41-6539 52
33-1954 8, 12, 40 404-150 82 41-7063 42
INDEX - 2
41-7067 62 44-9587 70 55-2851 74

41-808 84 44-9589 70 55-2925 92
41-8291 64 44-9590 70 55-295 76
41-893 62 44-9591 70 55-2955 54
41-895 64 44-9600 70 55-2957 52
41-9100 30 44-9601 70 55-2958 44, 48, 50, 58, 84
44-1458 64 44-9602 72 55-2959 44, 48, 50, 56, 58, 84, 86
44-2558 80 44-9631 70 55-2963 58
44-2786 68 44-9700 70 55-2964 42, 60, 82
44-2788 68 44-9701 70 55-2965 60
44-2791 68 44-9900 70 55-2969 48, 86
44-2792 68 44-9901 70 55-2977 50, 52, 54, 60, 86
44-2793 68 44-9902 70 55-2979 52, 60
44-3181 80 44-9903 70 55-2990 60
44-3224 74 44-9904 70 55-2993 84
44-3345 60, 76 44-9905 70 55-2995 60
44-3351 74 44-9906 72 55-2996 60, 64, 66
44-4108 74, 78, 80 44-9907 72 55-2998 42, 62, 64, 66
44-4208 76 44-9995 68 55-2999 86
44-4653 68 45-1688 38 55-3000 64, 66
44-4678 82 45-1719 60, 74 55-3003 86
44-4679 82 45-1797 60, 64, 66 55-3006 74
44-4901 74 45-1823 38 55-3013 42, 64, 66, 86
44-4902 74 45-1955 82 55-3014 86
44-5030 60, 68 45-1956 82 55-3018 52
44-5089 68 45-605 82 55-3021 54
44-5139 62 51-1271 74 55-3031 42
44-5219 68 51-269 30 55-3045 52
44-5224 66 51-612 30 55-3059 60
44-5354 74 51-624 22 55-3089 50
44-5555 60 55-1266 78, 80 55-3121 86, 88
44-5620 66, 82 55-1350 74 55-3123 74
44-5622 60, 64, 66, 68 55-1510 46 55-3233 78
44-5712 74 55-1511 46, 74 55-3256 66
44-5719 60, 68 55-1587 12, 42, 82, 84, 90 55-3355 74
44-5814 60, 68 55-1592 48 55-3364 46
44-5827 62 55-1800 50, 52, 54, 60, 82, 86, 90 55-346 64, 74
44-6181 76 55-1819 34 55-3469 74
44-6451 68 55-1852 64, 74 55-3472 48, 50
44-6850 72 55-193 6 55-3490 44, 48
44-739 66 55-2001 42, 60, 64, 66, 82 55-3506 74
44-7792 66 55-2038 58 55-3507 74
44-8244 64 55-2086 12, 42, 50, 52, 54, 60, 55-3508 74
44-8883 42 82, 84, 86, 88 55-3509 74
44-8914 70 55-2114 48, 50 55-3512 58
44-8915 70 55-2155 92 55-3513 42
44-8917 70 55-2201 60 55-3519 78
44-8918 70 55-2202 60 55-3520 74
44-8920 70 55-2240 84 55-3524 74, 76
44-8921 70 55-2262 64, 66 55-3525 74
44-8935 70 55-2313 46 55-3539 60, 82
44-8936 70 55-2330 76 55-3550 64, 66
44-9282 60 55-2332 48 55-3580 80
44-9298 42, 58 55-2554 52 55-3583 76
44-9536 70 55-2557 58 55-3595 58
44-9544 70 55-2636 60, 82 55-366 80
44-9545 70 55-2640 82 55-3744 12, 42
44-9585 70 55-2752 74, 80 55-396 74, 80
44-9586 70 55-2796 52 55-3985 82
INDEX - 3
55-3991 48 55-6029 92 55-8860 14

55-401 64, 74 55-6030 92 55-8861 20
55-4021 92 55-6176 6 55-8862 20
55-406 76 55-6177 6, 24 55-8863 22
55-411 80 55-6188 8, 20, 24, 26 55-8864 18
55-4118 92 55-6191 10, 24 55-8865 18
55-415 80 55-6193 14 55-8867 24
55-4203 44 55-6229 6 55-8868 24
55-431 46, 74, 80 55-6231 6 55-8869 24
55-4436 84 55-6234 8 55-8870 30
55-4515 42 55-6236 8, 20 55-8871 28
55-4607 34 55-6237 8, 12 55-8872 28
55-4613 48 55-6245 14 55-8894 38
55-4615 30 55-6246 12, 14 55-8895 38
55-4622 8, 24, 40 55-6248 26 55-8896 38
55-4632 14 55-6249 18 55-8897 38
55-4644 24 55-6250 18 55-8898 38
55-4645 24 55-6251 24 55-8967 22
55-4670 30 55-6254 22 55-8979 90
55-4733 24, 40 55-6367 8, 28 55-9011 52
55-4750 28 55-6526 52 55-9091 52
55-4767 88 55-6537 10 55-9127 62, 64
55-4952 58 55-664 82 55-9167 12
55-4953 12, 42, 50, 52, 54, 60, 55-665 42 55-9222 22
84, 88 55-6731 54 55-9223 22
55-4954 44, 48, 84 55-6764 56 55-9497 82
55-4955 48 55-6814 58 55-9568 48
55-5022 44, 48, 50, 84 55-6828 74 55-9752 44
55-5023 52 55-6988 58, 82 55-9817 82
55-5046 80 55-7062 42 55-9818 82
55-5081 12, 42 55-7066 58, 82 55-9819 82
55-5090 52 55-7122 58 55-9820 82
55-5138 14, 26, 34 55-735 76, 78, 80 70-212 18, 56
55-5205 58 55-7412 58 77-1345 56
55-5237 76 55-7527 86 77-1426 26
55-5279 62, 64 55-7616 42 77-1427 26
55-5400 52, 54 55-7660 56 77-1428 26
55-5418 88 55-7729 86 77-2468 38
55-5617 46 55-790 38 77-2469 38
55-5761 76 55-8116 48 77-2470 38
55-5763 16, 20, 24 55-8137 58, 82 77-2471 38
55-5770 38 55-8437 12 77-2654 82
55-5772 20 55-8441 8, 14, 16, 22, 26 77-2747 82
55-5780 26 55-8442 14 77-2752 26
55-5784 8, 30 55-8443 26 78-1340 56
55-5791 20 55-8448 30 78-618 56
55-5792 14, 26, 34 55-857 76 8101-336 6
55-5801 16 55-8620 32, 34, 40 8101-351 6
55-5803 14 55-8626 34 813-509 26
55-5809 8, 12, 22, 24 55-8665 42 90-331 56
55-5810 8, 30 55-8717 20 90-383 86
55-5816 8, 10, 18 55-8752 52 90-384 86
55-5822 30 55-8853 6, 16 91-112 92
55-5834 18 55-8854 8 91-113 92
55-5846 30 55-8855 10 91-114 92
55-5941 88 55-8856 10 91-1277 64, 66
55-5989 6 55-8857 10 91-2382 88
55-6027 92 55-8858 16 91-2383 94
55-6028 92 55-8859 14 91-2384 94
INDEX - 4
91-2388 94 91-8689 94 98-5724 86

91-2389 94 91-8699 94 98-7220 86
91-3160 92 91-8700 94 98-7221 86
91-3161 86, 92 91-8744 48 98-7222 86
91-3162 86, 92 91-8810 94 98-7227 90
91-338 94 91-8920 64 98-7229 86
91-3423 94 91-9269 96 98-7294 86
91-3424 96 91-9499 86 98-7980 86
91-3425 94 91-9506 94 98-8001 86
91-3439 82 91-9507 94 98-876 46
91-3542 16 91-9918 94 99-1400 48
91-4146 84 91-9919 94 99-1433 58
91-4148 94 91-9920 94 99-1642 58
91-438 44 92-109 96 99-1655 52
91-4510 94 92-1350 52 99-1916 58
91-4512 94 92-1362 94 99-3407 96
91-4823 12 92-224 58 99-3427 76
91-5315 86 92-225 58 99-3522 94
91-5703 94 92-226 58 99-3563 78
91-5739 44 92-228 58 99-3564 78
91-6284 94 92-229 58 99-3566 76
91-6824 88 92-249 86 99-3583 82
91-6825 88 92-250 86 99-3649 58
91-6826 88 92-2504 94 99-3855 60
91-6831 90 92-251 86 99-4660 94
91-6841 60 92-252 86 99-4661 94
91-7012 94 92-253 86 99-4732 94
91-7013 94 92-254 86 99-6377 88
91-7142 66 92-255 60 99-6596 94
91-7143 66 92-256 50 99-6599 86
91-7171 94 92-258 42 99-7246 66
91-7191 12 92-260 86 99-7314 94
91-7217 54 92-265 88 99-8301 52
91-7227 88 92-266 88 99-9234 94
91-7228 88 92-267 88 99-9938 96
91-7229 88 92-269 84 99-9939 96
91-7230 88 92-275 94
91-7231 88 92-3341 48
91-7233 50 92-4305 94
91-7234 50 92-5112 94
91-7339 74, 80 92-5113 94
91-7340 80 92-5114 94
91-7497 54 92-5117 86
91-7527 80 92-5118 88
91-7528 76 92-5255 82
91-7530 84 92-5265 50
91-7555 48 92-5310 66
91-7782 54 92-6420 90
91-8035 52 92-6428 90
91-8036 52 92-6716 90
91-8112 38 92-6717 90
91-860 60 92-6718 90
91-8677 42 92-7236 46
91-8678 48 92-861 48
91-8680 66 98-5035 82
91-8681 66 98-5305 60
91-8684 94 98-5711 52
91-8686 94 98-5716 86
91-8688 94 98-5723 52
INDEX - 5
INDEX - 6
INDEX ALPHABETICAL BY DESCRIPTION
A BRACKET - relay board 64 COVER - gear case 8

ADAPTER - air intake 48 BREAKER - circuit 80 COVER - harness 82
ADAPTER - compression tester 34 BRUSH 38 COVER - mP-G 66
ALTERNATOR 82 BUMPER - bulkhead 86 COVER - rear 38
ANGLE - radiator 52 BUMPER - lower 88 COVER - retainer bolt, curbside 88
ARM - rocker 14 BUSBAR 80 COVER - retainer bolt, roadside 88
ARMATURE 38 BUSHING 24, 52 COVER - side 30
BUSHING - camshaft 6 COVER - sound shield 8
B BUSHING - idler gear 22 COVER - thermostat 26
BAFFLE - breather 14 BUSHING - piston pin 18 COVER - valve 14
BALL 24 BUZZER - warning 64 CRANKSHAFT 18
BALL - check 46 CUP - air cleaner 48
BANDWRAP 48, 76 C
BANJO - fuel inlet 34 CABLE - battery 84 D
BANJO - fuel return 34 CABLE - ribbon 64 DIAL - gauge 46
BAR - locking 88 CAM - feed pump 22 DIODE 80
BASE - clamp 92 CAMSHAFT 22 DIPSTICK 12
BATTERY - tapered post 84 CAP 12 DISC - flex 82
BATTERY - threaded post 84 CAP - bearing 6 DOOR - curbside 86
BEARING 38, 82 CAP - drain hose 42 DOOR - roadside 86
BEARING - ball 38 CAP - fuel tank 46 DRAIN COCK 26
BEARING - connecting rod 18 CAP - hose 12 DRAIN COCK - radiator 52
BEARING - main 6 CAP - oil fill 8
BEARING - thrust 6, 22 CAP - radiator 52 E
BELT - fan & water pump 56 CAP - set w/fuel return clamp 34 ELBOW 44, 46
BEZEL - TG VI 66 CAP - valve 16 ELBOW - fuel 44
BLOCK - cylinder 6 CAP & CHAIN - overflow tank 52 ELBOW - hose 12, 42
BLOWER 82 CAPACITOR 76 ELBOW - oil pressure switch 42
BOARD - pc 66 CASE - gear 8 ELBOW - pipe 52
BOARD - printed circuit, CASE - oil seal 10 ELEMENT - air cleaner 48
interconnecting 64 CHANNEL - center 86 ENGINE 6
BOARD - relay 64 CHANNEL - top 86 EXCITER 60, 74
BOARD - terminal 60, 80 CIRCLIP 18 EXCITER - stator 82
BOLT - air bleed 34 CLAMP 48, 84
BOLT - bearing cap 6 CLAMP - air cleaner 48 F
BOLT - connecting rod 18 CLAMP - fuel heater 44 FAN - radiator 56
BOLT - eye 24, 28 CLAMP - harness 74 FASTENER - push-on 88
BOLT - flywheel 18 CLAMP - hose 14, 44, 48, 52, 54 FILTER - fuel 44
BOLT - fuel control 30 CLAMP - oil cup 48 FILTER - oil 24, 42
BOLT - plate 22 CLEANER - air 48 FITTING - grease 92
BOLT - thru 38 CLIP - hose 12, 42 FITTING - hose 42
BOLT - v-pulley 18 CLUTCH - assembly 38 FITTING - indicator 48
BOLTSTRIP - bracket 88 COIL - field 38 FITTING - oil drain 12
BOOT - switch 66 CONNECTOR 60, 64, 66, 68, 70, 72, FITTING - oil inlet 24
BOX - control 60 82 FLANGE 16, 22
BRACKET 92 CONNECTOR - barb 60, 82 FLATWASHER 12, 42, 44, 46, 48, 50,
BRACKET - air cleaner 48 CONNECTOR - hose 48 52, 54, 58, 60, 64, 66,
BRACKET - battery cable 84 CONNECTOR - male 62 74, 76, 78, 80, 82, 84,
BRACKET - clamp 48 CONNECTOR & HARNESS - voltage 86, 88
BRACKET - clip 12 regulator 74 FLYWHEEL 18
BRACKET - clip-on 86 CONTROLLER - mP-G 60, 64, 66 FRAME - fuel tank 86
BRACKET - engine 58 COTTER - loop 88 FUSE LINK 64
BRACKET - exhaust tube 50 COVER 8, 30
BRACKET - filter 24 COVER - access 54 G
BRACKET - generator 58 COVER - bottom 30 GASKET 8, 24, 26, 28, 34, 40
BRACKET - oil sensor 42 COVER - breather 14 GASKET - adhesive 8, 12, 40
BRACKET - overflow tank 54 COVER - connector 74 GASKET - air heater 20, 40
BRACKET - plug support 60 COVER - dust 38 GASKET - bezel 66
BRACKET - radiator 52 COVER - fuel sensor 46 GASKET - bottom cover 30
INDEX - 1
GASKET - bracket 24 HOSE - vent 46 MUFFLER 50

GASKET - copper 14, 34, 36, 40 HOSE - water pump 52
GASKET - cover 8, 82 HOSE - water pump to radiator 52 N
GASKET - cylinder head 16, 40 HOSE & CLAMP 34 NAMEPLATE - 1245 Max Weight KG.
GASKET - exhaust manifold 20, 40 HOSE & CLAMPS 34 96
GASKET - eye bolt 40 HOUSING - flywheel 10 NAMEPLATE - 15 kW 94
GASKET - flange 16, 40 HOUSING - gear 38 NAMEPLATE - 230V 96
GASKET - fuel sensor 46 NAMEPLATE - 460 Volts 94
GASKET - governor 30 I NAMEPLATE - 460V 94
GASKET - inlet 20 INDICATOR - air restriction 48 NAMEPLATE - arrow 94
GASKET - intake manifold 20, 40 INLET - intake manifold 20 NAMEPLATE - California Proposition
GASKET - joint 26 INSERT 42, 52, 90 94
GASKET - muffler 50 INSULATOR - rectifier 76 NAMEPLATE - Caution 230 Volts 96
GASKET - oil pump 24, 40 NAMEPLATE - Caution 460 Volts 94
GASKET - oil seal case 10, 40 J NAMEPLATE - Caution Left 94
GASKET - pipe 24 JOINT - banjo 28 NAMEPLATE - Caution Right 94
GASKET - plate 82 JOINT - breather 20 NAMEPLATE - Caution, Start/Stop 96
GASKET - receptacle 60 JOINT - pump 26 NAMEPLATE - CE 94
GASKET - round 40 JUMPER 64 NAMEPLATE - Clean Filter Screen 94
GASKET - side cover 30 NAMEPLATE - Coolant 94
GASKET - switch 12, 42 K NAMEPLATE - Coolant Level 94
GASKET - thermostat case 40 KEEPER - valve 16 NAMEPLATE - cover, microprocessor
GASKET - valve cover 14, 40 KEY - gear 18, 22 66
GASKET - water pump 26, 40 KIT - adapter & hose 48 NAMEPLATE - Diesel Fuel Only 94
GASKET SET - water pump 26 KIT - check valve 34 NAMEPLATE - Document Holder 94
GAUGE - belt tension 56 KIT - crimper 72 NAMEPLATE - Fan Universal 94
GAUGE - fuel 46 KIT - eprom chip 66 NAMEPLATE - FHWA 94
GEAR 22 KIT - fuel return hose end cap & clamps NAMEPLATE - Ingersoll Rand 94
GEAR - camshaft 22 34 NAMEPLATE - Installation Instructions
GEAR - crankshaft 18 KIT - gasket 30 94
GEAR - injection pump 22 KIT - gasket set 40 NAMEPLATE - Negative 94
GEAR - ring 18 KIT - pin mount option 88 NAMEPLATE - Operating Instructions
GROMMET 80 KIT - seal 30 94
GUIDE - valve 14, 16 KIT - sleeve & eyelet 42, 44, 46 NAMEPLATE - Positive 94
KNOB - valve cover 14 NAMEPLATE - Radiator Fill 94
H NAMEPLATE - Schematic Diagram 94
HANDLE - clamp 92 L NAMEPLATE - Schematic/Wiring
HANGER - overflow tank 52 LANYARD 88 Diagram 94
HARNESS - indicator 66 LATCH - door 86 NAMEPLATE - Service Information
HARNESS - main 60, 68 LEVER 38 Records Pouch 94
HARNESS - on/off 66 LEVER - control 30 NAMEPLATE - Smart Gen-Set 94
HARNESS - voltmeter 64 LIFTER - engine 16 NAMEPLATE - Smart Gen-Set Menu
HEAD - cylinder 14 LINER - service 6 List 94
HEAD - fuel filter 44 LOCKNUT 50, 54, 60 NAMEPLATE - Smart Gen-Set
HEATER - air 20 LOCKWASHER 38, 42, 44, 46, 48, 50, Operating Instructions 94
HEATER - frost plug 6 52, 54, 56, 58, 60, 64, NAMEPLATE - Smart Gen-Set
HEATER - fuel 44 66, 74, 76, 78, 80, 82, operating instructions 94
HOLDER - brush 38 84, 86, 90 NAMEPLATE - Texaco 96
HOLDER - nozzle 36 LOCKWASHER - module 62 NAMEPLATE - Thermo King 94
HOSE 42, 44, 46 NAMEPLATE - TK 94
HOSE - air 48 M NAMEPLATE - TK CG II Maintenance
HOSE - air cleaner 48 MANIFOLD - exhaust 20 94
HOSE - breather 48 MANIFOLD - intake 20 NAMEPLATE - Wiring Diagram 94
HOSE - harness 60, 82 MARKSTRIP 60, 80 NOZZLE 36
HOSE - insulation 48 MASTIC - heat transfer 78 NOZZLE - oil 22
HOSE - oil drain 12, 42 MAT - insulating 42 NUT 8, 12, 14, 20, 22, 26, 28, 30, 34,
HOSE - outlet 54 MODULE - timer 62 42, 44, 48, 50, 52, 58,
HOSE - overflow 52 MOUNT - bandwrap 76 74, 76, 78, 82, 84, 86,
HOSE - radiator to engine 52 MOUNT - vibration 58 88, 92
INDEX - 2
NUT - base 44 PLATE - cover 82 SCREW - base 44

NUT - breaker terminal 80 PLATE - heat sink 78 SCREW - board 66, 80
NUT - cap 30 PLATE - rectifier 74, 80 SCREW - box 60
NUT - captive 60 PLATE - screen 14 SCREW - bracket 24, 48, 50, 52, 54,
NUT - clamp 48 PLATE - stop 36 58, 64, 84
NUT - exciter 60 PLUG 6, 16, 20, 24, 26, 60, 70, 72, 74
SCREW - bracket, engine 58
NUT - ground 60 PLUG - access hole 10 SCREW - bracket, generator 58
NUT - holddown 84 PLUG - assembly 70 SCREW - breaker 80
NUT - hose 42 PLUG - drain 12 SCREW - bumper 86, 88
NUT - hose fitting 46 PLUG - exciter 82 SCREW - cam 22
NUT - jumper & link 64 PLUG - frost 6, 14 SCREW - case 8, 10
NUT - lock 30 PLUG - fuse 46 SCREW - clamp 44, 48
NUT - nozzle case 36 PLUG - pipe 6, 46, 52 SCREW - clip 12, 42
NUT - rectifier 82 PROTECTOR - nozzle 14, 34, 36, 40 SCREW - connector cover 74
NUT - stud 14 PULLEY - crankshaft 18, 56 SCREW - controller 66
NUT - terminal board 60 PULLEY - water pump 26, 56 SCREW - cover 8, 14, 30, 38, 54, 60,
PUMP 28 82
O PUMP - fuel 28, 44 SCREW - diode 74, 76
ORIFICE 24 PUMP - fuel injection 22, 30, 44 SCREW - disc to flywheel 82
ORIFICE - breather 14 PUMP - oil 24 SCREW - door 86
ORIFICE - radiator 52 PUMP - water 26, 52 SCREW - elbow 42
O-RING 8, 14, 28, 30, 40, 48, 60, 82 SCREW - exhaust manifold 20
O-RING - cap 8 R SCREW - fan 56, 82
O-RING - control lever 32 RADIATOR 52 SCREW - field coil 38
O-RING - cover 14, 30 RECEPTACLE 60, 70 SCREW - flange 16
O-RING - deflector check 30 RECEPTACLE - assembly 70 SCREW - frame 58
O-RING - delivery 30 RECTIFIER 74, 76, 78 SCREW - gear 22
O-RING - dipstick 12 RECTIFIER - 3 phase 80 SCREW - hanger 52
O-RING - dust 34, 36 RECTIFIER - negative 82 SCREW - housing 10
O-RING - fuel injection pump 40 RECTIFIER - positive 82 SCREW - idle limit 30
O-RING - governor 32 REGULATOR - voltage 60, 76 SCREW - inlet 20
O-RING - injection pump 8, 30 RELAY 64 SCREW - intake manifold 20
O-RING - joint 26 RELAY - solenoid timer 62 SCREW - joint 26
O-RING - screw 30 RESISTOR 74 SCREW - lifter 16
O-RING - solenoid 30 RETAINER 28, 34, 38 SCREW - module 62
O-RING - switch 12 RETAINER - harness connector 64, 66 SCREW - mounting 88
O-RING - tappet 30 RETAINER - nozzle 14, 34 SCREW - muffler 50
O-RING - water pump 40 RETAINER - nozzle spring 36 SCREW - nozzle 22
RETAINER - shaft 30 SCREW - oil base 12
P RETAINER - spring 16 SCREW - oil pump 24
PAD - fuel heater 44 RETAINER - valve 28 SCREW - orifice 52
PAD - radiator 54 RING - key 88 SCREW - panel 86
PANEL - top 86 RING SET 18 SCREW - pc board 64
PAW - clamp 92 RIVET - mount 76 SCREW - pipe 24
PIN 36, 72 RIVET - retainer 64, 66 SCREW - plate 76
PIN - dowel 8, 10, 18, 82 ROD - connecting 18 SCREW - plug 8, 10
PIN - piston 18 ROD - holddown 84 SCREW - pump 26
PIN - sealing 72 ROD - mounting 86 SCREW - radiator 52
PIN - snap 28 ROD - push 22 SCREW - rectifier 80
PIN - spring 14, 18, 92 ROTOR 82 SCREW - rectifier plate 78
PINION - assembly 38 SCREW - regulator 60
PIPE - breather 14 S SCREW - resistor 74
PIPE - fuel injection 34 SADDLE - u-bolt 50 SCREW - retainer 30, 34, 38
PIPE - oil injection 24 SCREEN 28 SCREW - sensor/cover 46
PIPE - oil pickup 24 SCREEN - radiator 52 SCREW - set 92
PISTON 18, 28 SCREW 52 SCREW - shield 90
PLATE 76 SCREW - adapter 48 SCREW - shoulder 92
PLATE - assembly 76 SCREW - angle 52 SCREW - shroud 52
PLATE - capacitor 76 SCREW - banjo 34 SCREW - solenoid 30, 38
INDEX - 3
SCREW - spacer 86 STRIP - foam 90 VALVE - oil drain 12

SCREW - starter 38 STRIP - gasket 66 VALVE - Schrader 34
SCREW - strap to engine 84 STUD - cylinder head 16 VENT 46
SCREW - strap to frame 84 STUD - exhaust manifold 20
SCREW - support 14, 86 STUD - fuel pump 8, 28 W
SCREW - tank 54 STUD - housing 82 WASHER 18, 22, 34
SCREW - terminal 42 STUD - injection pump 8, 30 WASHER - belleville 58, 86
SCREW - thermostat 26 STUD - nozzle retainer 14 WASHER - dome 52
SCREW - transformer 74 STUD - power pack 58 WASHER - insulating 42
SCREW - valve adjust 14 STUD - pulley 26 WASHER - seal 32
SEAL 70 STUD - retainer 34 WASHER - sealing 8, 24, 26, 40
SEAL - copper 34 STUD - valve cover 14 WASHER - shoulder 74, 76
SEAL - lead 30 SUMP - oil 12 WASHER - special 58, 88, 92
SEAL - oil 8, 10, 40 SUPPORT - center 86 WASHER - spring 92
SEAL - valve stem 14, 16, 40 SUPPORT - frame 86 WEDGE 70
SEAL - washer 24, 30 SUPPORT - right 86 WINDOW - bezel 66
SEALER - thread 44 SUPPORT - rocker arm 14
SEAT - valve 14 SUPPORT - vertical 86 Y
SENSOR - fuel level 46 SWITCH - oil level 12, 42 YOKE - assembly 38
SENSOR - oil pressure transducer 42 SWITCH - oil pressure 42
SENSOR - rpm 42, 58 SWITCH - on/off 66
SENSOR - water level 54 SWITCH - thermo 38
SENSOR - water temperature 52
SHAFT - clamp 92 T
SHAFT - idler gear 22 TAB - mounting 72
SHAFT - rocker arm 14 TANK - expansion 54
SHAFT - water bleed 44 TANK - fuel 46
SHIELD - exhaust tube 90 TANK - overflow 52
SHIELD - muffler 90 TAPPET 22, 28
SHIELD - radiator fan 90 TEE - oil pressure switch 42
SHIM 26 TEE - pipe 52
SHIM SET 36 TERMINAL - fingrip 62
SHROUD - radiator 52 TERMINAL - fork 68
SLEEVE - fuel return hose 34 TERMINAL - pin 70
SOCKET 70, 74 TERMINAL - ring 68
SOCKET - relay 68 TERMINAL - socket 70
SOLENOID 38 TESTER - compression 34
SOLENOID - stop 30 THERMOSTAT 26
SPACER 26, 48, 58, 74 TOOL - crimper 72
SPACER - bracket 88 TOOL - injection pump gear remover 8
SPACER - bumper 86, 88 TOOL - plunger spring support plate 32
SPACER - door latch 86 TOOL - seal installer 10
SPACER - fan 56, 82 TOOL - seal remover 10
SPACER - module 62 TOOL - wedge remover 72
SPACER - pc board 64 TRANSFORMER 74
SPACER - standoff 76 TRANSFORMER - current 74
SPEEDI SLEEVE - front seal 8, 18 TUBE - exhaust 50
SPRING 14, 24, 28 TUBE - fuel feed 46
SPRING - brush 38 TUBE - sponge 16
SPRING - nozzle 36
SPRING - piston 28 U
SPRING - valve 16 U-BOLT 50
SPUD - fuel filter 44
STARTER 38 V
STATOR 82 VALVE 28
STOPPER - pinion 38 VALVE - check 24
STRAP - battery holddown 84 VALVE - exhaust 14
STRAP - ground 84 VALVE - fuel injection 34, 36
STRIP - bumper 88 VALVE - intake 14
INDEX - 4
Parts Manual
SB-230 & SB-230 RR

SB-210+
Additional text information
30 & 50
to be placed here
TK 5XXXX-X-PL
TK 54899-2-PM (Rev. 1.1)
Ingersoll Rand’s Climate Solutions sector delivers energy-efficient HVACR solutions for
customers globally. Its world class brands include Hussmann, a manufacturer of refrigeration
and food merchandising solutions, Thermo King, the leader in transport temperature control
and Trane, a provider of energy efficient heating, ventilating and air conditioning systems,
building and contracting services, parts support and advanced controls for commercial
buildings and homes.
Distributed by:
Thermo King Corporate

314 West 90th Street
Minneapolis, MN 55420
Direct (952) 887-2200
TK 50952-4-PM
©2011 Ingersoll Rand Company

Printed in U.S.A.

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What are the different brands mentioned in the document?

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What does the document discuss regarding parts?

What does the document discuss regarding parts?

314 West 90th Street

Thermo King Corporate

December 16, 2011)

Printed (December 16, 2011)

Copyright © 2000 - Thermo King Corp. - Minneapolis, MN U.S.A.

For example: the switch panel nameplate (99-6280) is

ABBREVIATIONS The following abbreviations appear in parts manuals

SGCO 2000 REF-

NOTE: This grid is for engines built after 1/99.

OIL SUMP GROUP

CYLINDER HEAD &

OIL FILTER &

OIL BASE GROUP

FUEL FILTER &

BELTS, PULLEY &

NOTE: Crankshaft pulley belt adjustment.

CIRCUIT BOARD &

BATTERY & CABLE

101-321 22, 30, 44 11-8670 14 11-8964 24

12-746 12 33-1970 30 40-913 66

41-7067 62 44-9587 70 55-2851 74

55-3991 48 55-6029 92 55-8860 14

91-2388 94 91-8689 94 98-5724 86

A BRACKET - relay board 64 COVER - gear case 8

GASKET - bracket 24 HOSE - vent 46 MUFFLER 50

NUT - base 44 PLATE - cover 82 SCREW - base 44

SCREW - spacer 86 STRIP - foam 90 VALVE - oil drain 12

SB-230 & SB-230 RR

Thermo King Corporate

©2011 Ingersoll Rand Company

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