314 West 90th Street

Minneapolis, MN 55420
Direct

Parts Manual

©2011 Ingersoll Rand Company

Printed in U.S.A.
SGCM 3000
TK 53725-4-PM (Rev. 2.0)

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
 SGCM 3000
TK 53725-2.0

Pri
nt
ed
( Wednesday,

November 21,
2012)
Copyright©2007 -
Thermo King Corp.
- Minneapolis, MN,
U.S.A.

Printed (November 21, 2012)

Copyright © 2007 - 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
SGCM 3000
Contents
Name Grid Page
SGCM 3000 TIER 2 ENGINE REFERENCE SHEET . . . . . . . . . . . . . .12U40. . . . . . . . . . . . . . . . . . . . .3
CONNECTORS - DEUTSCH IN-LINE . . . . . . . . . . . . . . . . . . . . . . . . . .112D9. . . . . . . . . . . . . . . . . . . .73
CONNECTORS - WEATHER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . .115D14. . . . . . . . . . . . . . . . . . .87
CAP & CHAIN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119E11 . . . . . . . . . . . . . . . . . . .61
FUEL PUMP ASSEMBLY (TK486/486E, TK482/482E & TK486V) . . . .142F8 . . . . . . . . . . . . . . . . . . . .33
FUEL TANK ASSEMBLY (80 GALLON) . . . . . . . . . . . . . . . . . . . . . . . .149C1. . . . . . . . . . . . . . . . . . . .43
PRE-CLEANER GROUP (CGCM & SGCM, OPTION 062224). . . . . . .151D8. . . . . . . . . . . . . . . . . . . .51
POWER RECEPTACLE GROUP (CGCM & SGCM OPTION 062295,
10/99 & After). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160H2. . . . . . . . . . . . . . . . . . . .83
ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161G0. . . . . . . . . . . . . . . . . . . .65
THROTTLE SOLENOID GROUP (TK486V) . . . . . . . . . . . . . . . . . . . . .201E6 . . . . . . . . . . . . . . . . . . . .47
WATER PUMP ASSEMBLY (TK486V) . . . . . . . . . . . . . . . . . . . . . . . . .204F0 . . . . . . . . . . . . . . . . . . . .23
GEAR CASE GROUP (TK486V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204F2 . . . . . . . . . . . . . . . . . . . .11
FLYWHEEL HOUSING GROUP (TK486V) . . . . . . . . . . . . . . . . . . . . . .204F3 . . . . . . . . . . . . . . . . . . . .13
OIL SUMP GROUP (TK486V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204F4 . . . . . . . . . . . . . . . . . . . .15
CYLINDER HEAD & VALVE COVER (TK486V) . . . . . . . . . . . . . . . . . .204F5 . . . . . . . . . . . . . . . . . . . . .7
CRANKSHAFT & PISTON GROUP (TK486V) . . . . . . . . . . . . . . . . . . .204F6 . . . . . . . . . . . . . . . . . . . .17
INTAKE & EXHAUST MANIFOLD (TK486V) . . . . . . . . . . . . . . . . . . . .204F7 . . . . . . . . . . . . . . . . . . . .19
CAMSHAFT & DRIVE GEAR GROUP (TK486V) . . . . . . . . . . . . . . . . .204F8 . . . . . . . . . . . . . . . . . . . .21
OIL FILTER & PUMP GROUP (TK486V) . . . . . . . . . . . . . . . . . . . . . . .204F9 . . . . . . . . . . . . . . . . . . . .25
FUEL INJECTION GROUP (TK486V) . . . . . . . . . . . . . . . . . . . . . . . . . .204G1. . . . . . . . . . . . . . . . . . . .27
FUEL INJECTION PUMP GROUP (TK486V, 2200 RPM). . . . . . . . . . .204G2. . . . . . . . . . . . . . . . . . . .29
STARTER ASSEMBLY 12 VOLT (TK486V) . . . . . . . . . . . . . . . . . . . . .204G3. . . . . . . . . . . . . . . . . . . .37
GASKET SET (TK486V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204G4. . . . . . . . . . . . . . . . . . . .39
FUEL INJECTION NOZZLE (TK486V) . . . . . . . . . . . . . . . . . . . . . . . . .204G5. . . . . . . . . . . . . . . . . . . .35
NAMEPLATES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208C5. . . . . . . . . . . . . . . . . . . .95
BELTS, PULLEY & FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208C7. . . . . . . . . . . . . . . . . . . .63
ENGINE COOLING SYSTEM (w/ fuel heater). . . . . . . . . . . . . . . . . . . .209C0. . . . . . . . . . . . . . . . . . . .57
ENGINE ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . .209C4. . . . . . . . . . . . . . . . . . . .67
BATTERY GROUP & GROUND STRAP. . . . . . . . . . . . . . . . . . . . . . . .209G2. . . . . . . . . . . . . . . . . . . .79
FUEL TANK ASSEMBLY (50 GALLON) . . . . . . . . . . . . . . . . . . . . . . . .209G4. . . . . . . . . . . . . . . . . . . .45
AIR INTAKE & EXHAUST GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . .209G5. . . . . . . . . . . . . . . . . . . .49
POWER RECEPTACLE GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212A6 . . . . . . . . . . . . . . . . . . . .81
CONTROL BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221H0. . . . . . . . . . . . . . . . . . . .69
ALTERNATOR GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222D1. . . . . . . . . . . . . . . . . . . .77
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222G9. . . . . . . . . . . . . . . . . . . .53
STRUCTURAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223C2. . . . . . . . . . . . . . . . . . . .89
DOWNLOAD CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226E2 . . . . . . . . . . . . . . . . . . . .71
CYLINDER BLOCK GROUP (TK486V) . . . . . . . . . . . . . . . . . . . . . . . . .236E0 . . . . . . . . . . . . . . . . . . . . .5
FUEL FILTER & HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236G5. . . . . . . . . . . . . . . . . . . .41
CM BOTTOM PANEL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261G3. . . . . . . . . . . . . . . . . . . .93
 12U40 SGCM 3000 TIER 2 ENGINE REFERENCE SHEET
Revised
5/8/09

SGCM 3000 TIER 2

ENGINE REFER-
ENCE SHEET
12U40
5/8/09

3
Revised
5/8/09 SGCM 3000 TIER 2 ENGINE REFERENCE SHEET 12U40
B/M DESCRIPTION Date
718203 System - SGCM 2000 Tier 2 Engine 10/12
062342 SGCM 2000 Tier 2 Engine 10/12
062004 Threaded Battery Post 03/07
062006 Document holder 03/07
062008 SG+ 3000 Controller 03/07
062016 Clip Holder (Crowley) 03/07
062027 Tamper Evident Fuel Cap 03/07
062029 Air Restriction Indicator 03/07
062038 Nameplate - Crowley 03/07
062080 Fuel Strainer 5/09
062212 230V Receptacle 03/07
062224 Precleaner 03/07
062228 Drain Cock 03/07
062255 Nameplate - TAL 03/07
062256 Nameplate - Flexi-Van 03/07
062257 Nameplate - OOCL 03/07
062258 Nameplate - HMM 03/07
062278 Nameplate - Triton 03/07
062282 Nameplate - Genstar 03/07
062285 Dipstick 03/07
062295 Dual Voltage 03/07
062301 80 Gallon Fuel Tank 03/07
062322 Nameplate 03/07
062324 Nameplate 03/07
062332 TOYO SGCM Frame 03/07
062339 50 Gallon Fuel Tank 03/07
702868 Panel Kit 10/12
062097 OPTION ECOPOWER + 10/12

4
 236E0 CYLINDER BLOCK GROUP (TK486V)
Revised
6/26/11

CYLINDER BLOCK
GROUP (TK486V)
236E0
6/26/11

5
Revised
6/26/11 CYLINDER BLOCK GROUP (TK486V) 236E0
REF PART# DESCRIPTION QTY
101-379 ENGINE (TK486V, 12V, 2200 rpm) 1
1 NSS • BLOCK - cylinder 1
2 11-5499 • PLUG - frost (30 mm) 8
3 55-6176 • PLUG - pipe (1/4) 3
4 55-6229 • PLUG 1
5 55-4593 • PLUG - pipe (1/8) 1
6 51-1145 • PLUG - frost (50 mm) 1
7 11-6555 • PLUG - frost (12 mm) 2
8 13-318 • SPACER 1
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 55-8852 • BOLT - bearing cap 10
14 11-8919 LINER - service 4
15 41-2317 HEATER - frost plug 1

6
 204F5 CYLINDER HEAD & VALVE COVER (TK486V)
Revised
7/26/12

CYLINDER HEAD &

VALVE COVER
(TK486V)
204F5
7/26/12

7
Revised
7/26/12 CYLINDER HEAD & VALVE COVER (TK486V) 204F5
REF PART# DESCRIPTION QTY
1 13-344 PIPE - breather 1
2 55-8442 • CLAMP - hose (24) 2
3 91-3542 TUBE - sponge (insulation, cut to 11.0 in lg) 1
4 13-337 COVER - valve 1
5 13-340 • GASKET - valve cover 1
6 11-5103 • KNOB - valve cover 3
7 33-3512 • O-RING - cover 3
8 11-8671 • BAFFLE - breather 1
9 13-338 • PLATE - baffle 1
10 33-2762 • O-RING 1
11 13-339 • COVER - breather 1
12 51-598 • SCREW - cover 8
13 13-332 SHAFT - rocker arm 1
13-335 • SHAFT - rocker arm 1
14 13-333 • SUPPORT - rocker arm 2
15 13-334 • SUPPORT - rocker arm 3
16 55-6245 • STUD - valve cover 3
17 11-6704 • SPRING 4
18 13-336 • 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 12-870 HEAD - cylinder 1
24 13-342 • RETAINER - nozzle 4
25 13-341 • PROTECTOR - nozzle 4
26 11-6707 • GASKET - copper (nozzle seat) 4
27 55-6191 • SCREW - nozzle retainer 4
28 51-1151 • WASHER 4
29 11-6567 • PLUG - frost (40 mm) 1
30 55-5803 • PIN - spring 2
31 13-932 • VALVE - intake 4
32 11-8928 • GUIDE - valve (intake) 4
33 11-8935 • SEAL - valve stem (intake) 4
34 13-659 • VALVE - exhaust 4
35 11-8929 • GUIDE - valve (exhaust) 4
36 11-8934 • SEAL - valve stem (exhaust, marked w/ yellow stripe) 4
37 11-8932 • SPRING - valve 8

8
204F5 CYLINDER HEAD & VALVE COVER (TK486V)
Revised
7/26/12

9
Revised
7/26/12 CYLINDER HEAD & VALVE COVER (TK486V) 204F5
REF PART# DESCRIPTION QTY
38 11-8933 • RETAINER - spring 8
39 55-8858 • KEEPER - valve 8
40 11-8936 • CAP - valve 8
41 55-8853 SCREW - cylinder head 18
42 33-4122 GASKET - cylinder head (SB-210/130/230) 1
33-4515 GASKET - cylinder head (SB-310/330) 1
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
49 203-348 GASKET - liquid A/R
50 13-648 SEAT - valve (intake) 4
51 11-8927 SEAT - valve (exhaust) 4

10
 204F2 GEAR CASE GROUP (TK486V)
Revised
5/2/09

GEAR CASE
GROUP (TK486V)
204F2
5/2/09

11
Revised
5/2/09 GEAR CASE GROUP (TK486V) 204F2
REF PART# DESCRIPTION QTY
1 13-319 CASE - gear 1
2 51-1146 STUD - injection pump 3
3 51-594 NUT 3
4 33-1953 O-RING - injection pump 1
5 203-348 GASKET - adhesive A/R
6 55-5816 PIN - dowel 1
7 55-6234 PIN - dowel 2
8 55-8441 SCREW - case (16 mm) 3
9 55-5809 SCREW - case (45 mm) 1
10 33-3821 O-RING - gear case (16 mm) 1
11 33-4089 O-RING - gear case (20 mm) 1
12 13-322 COVER - gear case 1
13 33-4088 • SEAL - oil 1
14 55-6367 • STUD - fuel pump 3
15 55-6236 SCREW - cover (55 mm) 8
16 11-5082 COVER 1
17 55-4622 WASHER - sealing 4
18 55-8854 SCREW - cover (12 mm) 4
19 13-321 COVER - sound shield 1
20 33-4087 GASKET - cover 1
21 55-6237 SCREW - cover (85 mm) 7
22 11-5091 CAP - oil fill 1
23 33-1954 O-RING - cap 1
24 11-9592 SPEEDI SLEEVE - front seal 1
25 204-1011 TOOL - injection pump gear remover 1

12
 204F3 FLYWHEEL HOUSING GROUP (TK486V)
Revised
3/11/05

FLYWHEEL HOUS-
ING GROUP
(TK486V)
204F3
3/11/05

13
Revised
3/11/05 FLYWHEEL HOUSING GROUP (TK486V) 204F3
REF PART# DESCRIPTION QTY
1 12-867 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) 1
9 33-2969 GASKET - oil seal case 1
10 51-1149 SCREW - case (30 mm) 6
11 55-6191 SCREW - case (35 mm) 3
12 55-5816 PIN - dowel 2
13 51-1162 SCREW - housing 1
14 204-952 TOOL - seal installer 1
15 204-994 TOOL - seal remover 1

14
 204F4 OIL SUMP GROUP (TK486V)
Revised
7/26/12

OIL SUMP GROUP

(TK486V)
204F4
7/26/12

15
Revised
7/26/12 OIL SUMP GROUP (TK486V) 204F4
REF PART# DESCRIPTION QTY
1 12-868 SUMP - oil (upper) 1
2 12-869 SUMP - oil (lower) 1
3 55-8437 • PLUG - drain 2
4 203-348 GASKET - adhesive (RTV silicone) A/R
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 51-1150 SCREW - oil base (120 mm) 1
9 11-8667 DIPSTICK 1
10 33-4090 O-RING - dipstick 1
11 11-8923 CAP (units w/o oil level switch, push-in type) 1
12 55-9167 ELBOW - hose (90 degree) 1
13 11-8984 HOSE - oil drain (10 in long) 1
11-5911 HOSE - oil drain (17 in long) 1
14 55-5081 CAP - hose 1
15 91-4823 CLIP - hose 1
55-1587 SCREW - clip 1
55-2086 FLATWASHER 1
55-4953 NUT 1
16 91-7191 BRACKET - clip 1
17 41-4470 SWITCH - oil level (threaded type) 1
33-4160 • O-RING - switch 1
18 11-9338 VALVE - oil drain 1
19 11-9448 FITTING - oil drain (ESOC) 1
20 55-3744 ELBOW - hose (45 degree) 1
21 13-1063 FITTING - oil drain w/cap 1

16
 204F6 CRANKSHAFT & PISTON GROUP (TK486V)
Revised
9/14/11

CRANKSHAFT &
PISTON GROUP
(TK486V)
204F6
9/14/11

17
Revised
9/14/11 CRANKSHAFT & PISTON GROUP (TK486V) 204F6
REF PART# DESCRIPTION QTY
1 13-1064 PISTON (std, incl 2-4) 4
13-1065 PISTON (w/ ring, 0.25 mm os) 4
13-1066 PISTON (w/ ring, 0.50 mm os) 4
2 13-355 RING SET (std) 2
13-461 RING SET (0.25 mm os) 4
13-455 RING SET (0.50 mm 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 13-351 CRANKSHAFT 1
14 11-6719 • KEY - gear 1
15 13-352 GEAR - crankshaft 1
16 55-4668 PIN - spring 1
17 13-353 PULLEY - crankshaft 1
18 55-6249 WASHER 1
19 55-6250 BOLT - v-pulley 1
20 11-9592 SPEEDI SLEEVE - front seal 1

NOTE: NOTE: Engines before serial number EA00749, use gear ring 11-8947. Engines with serial number
EA00749 and after, use gear ring 13-1138.

18
 204F7 INTAKE & EXHAUST MANIFOLD (TK486V)
Revised
3/15/05

INTAKE &
EXHAUST MANI-
FOLD (TK486V)
204F7
3/15/05

19
Revised
3/15/05 INTAKE & EXHAUST MANIFOLD (TK486V) 204F7
REF PART# DESCRIPTION QTY
1 33-2936 GASKET - intake manifold 1
2 13-343 MANIFOLD - intake 1
3 55-5763 • PLUG 1
4 55-6188 SCREW - intake manifold (20 mm) 6
5 55-8717 SCREW - intake manifold (80 mm) 1
6 33-2765 GASKET - air heater 1
7 41-2147 HEATER - air 1
8 33-2764 GASKET - inlet 1
9 11-9266 INLET - intake manifold 1
10 55-6191 SCREW - inlet (35 mm) 4
11 33-2937 GASKET - exhaust manifold 1
12 11-8944 MANIFOLD - exhaust 1
13 51-1153 STUD - exhaust manifold 2
14 51-594 NUT 2
15 51-1152 SCREW - exhaust manifold (40 mm) 7

20
 204F8 CAMSHAFT & DRIVE GEAR GROUP (TK486V)
Revised
5/3/07

CAMSHAFT &
DRIVE GEAR
GROUP (TK486V)
204F8
5/3/07

21
Revised
5/3/07 CAMSHAFT & DRIVE GEAR GROUP (TK486V) 204F8
REF PART# DESCRIPTION QTY
1 11-9261 CAMSHAFT (incl items 2 thru 5) 1
2 11-6719 • KEY - gear 1
3 NSS • BEARING - thrust 1
4 55-5801 • BOLT - plate 2
5 NSS • GEAR - camshaft 1
6 11-6717 TAPPET 8
7 11-8945 ROD - push 8
8 13-930 GEAR (w/ bushing) 1
9 13-348 • BUSHING - idler gear 1
10 13-345 SHAFT - idler gear 1
11 55-5772 SCREW - gear 2
12 101-362 PUMP - fuel injection (2200 rpm, see 204G1) 1
101-354 PUMP - fuel injection (2600 rpm, see 205C5) 1
13 51-2009 KEY - gear 1
14 13-350 FLANGE 1
15 13-349 GEAR - injection pump 1
16 55-9222 SCREW - gear 4
17 13-346 CAM - feed pump 1
18 55-9223 SCREW - cam 4
19 51-1154 WASHER 1
20 51-1155 NUT 1

22
 204F0 WATER PUMP ASSEMBLY (TK486V)
Revised
11/16/11

WATER PUMP
ASSEMBLY
(TK486V)
204F0
11/16/11

23
Revised
11/16/11 WATER PUMP ASSEMBLY (TK486V) 204F0
REF PART# DESCRIPTION QTY
1 13-509 PUMP - water (ELC compatible) 1
813-509 PUMP - water (ELC compatible, remanufactured) 1
2 51-607 • PLUG 2
3 33-3096 •• GASKET - water pump 1
30-295 GASKET SET (inc items 3, 4, 6, 16) 1
4 33-2768 GASKET 1
5 13-385 THERMOSTAT (160 F, 71 C) 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 13-358 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 13-815 JOINT - pump 1
15 33-3097 GASKET - joint 1
16 33-3098 O-RING - joint 1
17 55-8441 SCREW - joint 3
18 33-1745 WASHER - sealing 1
19 11-9256 PLUG 1
20 55-5780 COCK - drain 1
21 13-360 HOSE - drain 1
22 13-363 HOSE - inj pump to water pump 1
23 13-514 HOSE - inj pump to water pump 1
51-588 CLAMP - hose 4

24
 204F9 OIL FILTER & PUMP GROUP (TK486V)
Revised
6/23/09

OIL FILTER &

PUMP GROUP
(TK486V)
204F9
6/23/09

25
Revised
6/23/09 OIL FILTER & PUMP GROUP (TK486V) 204F9
REF PART# DESCRIPTION QTY
1 13-357 PIPE - oil 1
2 55-4644 BOLT - eye 1
3 33-3833 SEAL - washer (10) 2
4 55-5792 NUT 1
5 51-1158 BOLT - eye 1
6 55-4622 WASHER - sealing (8) 2
7 101-362 PUMP - fuel injection (2200 rpm, see 204G1) 1
8 51-1159 PLUG 1
9 33-4089 O-RING - pipe 1
10 13-356 PIPE - oil pickup 1
11 55-8441 SCREW - pipe (16 mm) 2
12 13-323 COVER - oil pump 1
13 51-1147 • PLUG 1
14 13-325 • SPRING 1
15 13-324 • VALVE - check 1
16 13-326 • COVER - oil pump 1
17 13-328 ROTOR - outer 1
18 13-327 ROTOR - inner 1
19 51-592 SCREW - oil pump 7
20 33-2931 GASKET - oil filter bracket 1
21 11-9354 BRACKET - filter (incl 22 - 30) 1
22 11-8964 • ORIFICE 1
23 51-593 • PLUG (3/8) 1
24 55-5763 • PLUG (1/8) 2
25 11-8995 • VALVE - check 1
26 51-1157 •• WASHER - sealing (14) 1
27 11-8965 •• SPRING 1
28 55-8868 • BALL 1
29 51-1156 • PLUG 1
30 51-1157 • WASHER - sealing (14) 1
31 55-6188 SCREW - bracket (20 mm) 1
32 55-5809 SCREW - bracket (45 mm) 1
33 55-8869 SCREW - bracket (75 mm) 1
34 11-9182 FILTER - oil (EMI 3000) 1
35 11-9447 FITTING - oil inlet (ESOC) 1

26
 204G1 FUEL INJECTION GROUP (TK486V)
Revised
11/21/12

FUEL INJECTION
GROUP (TK486V)
204G1
11/21/12

27
Revised
11/21/12 FUEL INJECTION GROUP (TK486V) 204G1
REF PART# DESCRIPTION QTY
1 101-362 PUMP - fuel injection (2200 rpm, see 204G2) 1
101-354 PUMP - fuel injection (2600 rpm, see 205C5) 1
2 13-356 SUPPORT - pump 1
3 55-6188 SCREW - support 2
4 13-371 PIPE - fuel injection 1
5 13-391 PIPE - fuel injection 1
6 13-392 PIPE - fuel injection 1
7 13-393 PIPE - fuel injection 1
8 13-368 RETAINER - tube (4 tubes) 1
9 55-8626 SCREW - retainer 1
10 11-6109 RETAINER - tube (3 tubes) 1
11 55-8626 SCREW - retainer 1
12 13-388 NOZZLE - injection (2200 rpm engine, see 204G5) 4
13-389 NOZZLE - injection (2600 rpm engine, see 205C10) 4
13 10-373 KIT - fuel return 1
14 13-310 • HOSE & CLAMPS (nozzle to nozzle) 3
15 13-451 • HOSE & CLAMPS (nozzle to pump) 1
16 204-1848 ADAPTER - compression tester 1
11-9446 • VALVE (Schrader) 1
55-1819 • SEAL - copper 1
55-4607 • FLATWASHER 2
204-542 TESTER - compression 1

28
 204G2 FUEL INJECTION PUMP GROUP (TK486V, 2200 RPM)
Revised
3/4/12

FUEL INJECTION
PUMP GROUP
(TK486V, 2200
RPM)
204G2
3/4/12

29
Revised
3/4/12 FUEL INJECTION PUMP GROUP (TK486V, 2200 RPM) 204G2
REF PART# DESCRIPTION QTY
1 101-362 PUMP - fuel injection (2200 rpm) 1
2 42-100 • SOLENOID - stop 1
3 33-2230 • O-RING - solenoid 1
4 55-8448 • SCREW - solenoid 2
5 13-440 • COVER - governor 1
6 33-4168 • GASKET - cover 1
7 55-6230 • PLUG (12 mm) 1
8 33-4169 • WASHER - sealing (12 mm) 1
9 12-925 • LEVER - control 1
10 13-442 • SPRING - lever 1
11 51-1205 • NUT - lever 1
12 51-1206 • NUT - ball joint 1
13 11-6125 • RETAINER - shaft 1
14 55-5822 • SCREW - retainer 1
15 51-1207 • PLUG 1
16 33-4170 • WASHER - sealing (18 mm) 1
17 13-444 • LIFTER 1
18 55-4676 • O-RING - lifter 1
19 55-5822 • SCREW - lifter 1
20 13-445 • STOPPER 1
21 33-4171 • O-RING - stopper & eye bolt 2
22 13-450 • JOINT - banjo (water) 1
23 55-5846 • NUT 1
24 51-1155 • NUT 1
25 51-1154 • LOCKWASHER 1
26 13-446 • JOINT - banjo (fuel in) 1
27 13-447 • BOLT - eye 1
28 55-8620 • WASHER - sealing (12 mm) 4
29 33-4172 • O-RING - plug 1
30 33-4173 • O-RING - plug 1
31 13-448 • JOINT - banjo (fuel out) 1
32 13-449 • BOLT - eye 1
33 13-511 • PUMP - feed 1
34 33-4190 •• O-RING - pump 1
35 33-4192 •• O-RING - pump 1
36 33-4193 •• O-RING - inner 1
37 55-6187 •• SCREW - pump (socket head) 2

30
204G2 FUEL INJECTION PUMP GROUP (TK486V, 2200 RPM)
Revised
3/4/12

31
Revised
3/4/12 FUEL INJECTION PUMP GROUP (TK486V, 2200 RPM) 204G2
REF PART# DESCRIPTION QTY
38 51-1269 •• SCREW - pump (hex head) 4
39 51-612 • SCREW - idler limit 1
55-7802 SCREW - idler limit (Genset units) 1

32
 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

33
 FUEL PUMP ASSEMBLY (TK486/486E, TK482/482E &
Revised
6/29/10 TK486V) 142F8
REF PART# DESCRIPTION QTY
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

34
 204G5 FUEL INJECTION NOZZLE (TK486V)
Revised
11/23/10

FUEL INJECTION
NOZZLE (TK486V)
204G5
11/23/10

35
Revised
11/23/10 FUEL INJECTION NOZZLE (TK486V) 204G5
REF PART# DESCRIPTION QTY
13-388 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 11-6790 • PIN 1
6 11-6789 • PLATE - stop 1
7 13-370 • NOZZLE 1
8 11-6786 • NUT - nozzle case 1
9 33-4174 • GASKET - nozzle 1
10 13-341 PROTECTOR - nozzle 4
11 11-6707 GASKET - copper (nozzle seat) 4

36
 204G3 STARTER ASSEMBLY 12 VOLT (TK486V)
Revised
12/6/05

STARTER ASSEM-
BLY 12 VOLT
(TK486V)
204G3
12/6/05

37
Revised
12/6/05 STARTER ASSEMBLY 12 VOLT (TK486V) 204G3
REF PART# DESCRIPTION QTY
45-2177 STARTER (12V) 1
1 41-6508 • ARMATURE (12V) 1
2 77-2468 • BEARING 1
3 77-2469 • BEARING 1
4 41-6509 • YOKE - assembly 1
5 55-8894 •• SCREW - field coil 4
6 41-6510 •• BRUSH - positive (not for 24V) 2
7 41-6513 • COVER - rear 1
8 41-6511 • HOLDER - brush (not for 24V) 1
9 41-6512 •• SPRING - brush 4
10 41-6510 •• BRUSH (not for 24V) 2
11 55-8897 • SCREW - cover 2
12 51-1161 • BOLT - thru 2
13 41-6518 • PINION - assembly 1
14 41-6519 • SHAFT - pinion 1
15 77-2833 • RETAINER 1
16 41-6520 • CLUTCH - assembly 1
17 41-6521 •• BEARING - ball 1
18 77-2834 •• BEARING - ball 1
19 41-2156 • STOPPER - pinion 1
20 41-6514 • CASE - cover 1
21 41-6515 • SOLENOID (12V) 1
22 41-6516 • LEVER 1
23 41-6517 • COVER - dust 1
24 55-8898 SCREW - starter 2

NOTE: NOTE: See grid 212B9 for 24 volt starter.

38
 204G4 GASKET SET (TK486V)
Revised
12/10/10

GASKET SET
(TK486V)
204G4
12/10/10

39
Revised
12/10/10 GASKET SET (TK486V) 204G4
REF PART# DESCRIPTION QTY
30-291 KIT - gasket set 1
1 33-4122 • GASKET - cylinder head (2200 rpm engine & 2600 rpm 1
engines bulit before 3/08)
2 33-3098 • 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 13-341 • PROTECTOR - nozzle 4
6 11-6707 • GASKET - copper (nozzle seat) 4
7 13-340 • GASKET - valve cover 1
8 33-2764 • GASKET 1
9 33-2936 • GASKET - intake manifold 1
10 33-2937 • GASKET - exhaust manifold 1
11 33-2931 • GASKET 1
12 33-3096 • GASKET - water pump 1
13 33-1745 • WASHER - sealing (16) 1
33-3833 • WASHER - sealing (10) 2
55-4622 • WASHER - sealing (8) 12
14 33-2767 • GASKET 1
15 33-2768 • GASKET 1
16 33-2765 • GASKET - air heater 1
17 33-2934 • GASKET - flange 1
18 33-2969 • GASKET - oil seal case 1
19 33-3097 • GASKET - thermostat case 1
20 33-3512 • O-RING (12.0) 3
33-3821 • O-RING (16.0) 2
33-4089 • O-RING (20.0) 1
33-4090 • O-RING (31.5) 1
33-1954 • O-RING (32.0) 3
33-2762 • O-RING (50.0) 1
21 203-348 • GASKET - adhesive (RTV silicone) A/R
22 33-4517 GASKET - cylinder head (2600 rpm engines built after 3/08) 1

40
 236G5 FUEL FILTER & HOSES
Revised
11/14/12

FUEL FILTER &

HOSES
236G5
11/14/12

41
Revised
11/14/12 FUEL FILTER & HOSES 236G5
REF PART# DESCRIPTION QTY
1 11-9015 HEAD - fuel filter 1
55-3490 SCREW - base 2
55-4954 NUT - base 2
55-2958 FLATWASHER 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) 2
6 10-243 KIT - sleeve & eyelet (1/4) 4
7 11-4841 NUT (1/4) 4
8 11-4367 HOSE (1/4 od x 35 ft lg) A/R
9 11-4380 ELBOW - hose fitting (3/8) 2
10 10-242 KIT - sleeve & eyelet (3/8) 8
11 11-4941 NUT (3/8) 8
12 11-4372 HOSE (3/8 od x 35 ft lg) A/R
13 55-4203 CLAMP - hose 2
55-5022 SCREW - clamp 2
55-2958 FLATWASHER 2
55-2959 LOCKWASHER 2
14 41-8319 HEATER - fuel (12V) 1
15 91-960 CLAMP - fuel heater 1
16 101-362 PUMP - injection (see 204G2) 1
17 11-7433 PUMP - fuel (see 142F8) 1
18 92-7755 BRACKET - fuel strainer 1
55-8711 INSERT 2
55-3018 SCREW 2
55-2086 FLATWASHER 2
55-1800 LOCKWASHER 2
19 13-972 STRAINER - fuel (complete) 1
20 33-4458 • GASKET - strainer 1
21 13-973 • SCREEN - strainer 1
22 11-5437 CONNECTOR 1
23 11-4959 ELBOW 1
24 91-372 CLAMP 2
55-3462 SCREW 2
55-2086 FLATWASHER 2
55-1800 LOCKWASHER 2

42
 149C1 FUEL TANK ASSEMBLY (80 GALLON)
Revised
11/13/12

FUEL TANK
ASSEMBLY (80
GALLON)
149C1
11/13/12

43
Revised
11/13/12 FUEL TANK ASSEMBLY (80 GALLON) 149C1
REF PART# DESCRIPTION QTY
1 12-790 TANK - fuel (80 gallons, standard, side gauge, item 7) 1
12-794 TANK - fuel (80 gallons, optional, top gauge, item 24) 1
2 11-8026 CAP - fuel tank 1
3 55-5617 VENT - ball check 1
4 11-9087 TUBE - fuel feed line 2
203-385 SEALER - thread A/R
5 11-7265 PLUG - fuse 2
6 11-7489 DIPSTICK (optional) 1
55-4306 WASHER 1
7 11-7491 GAUGE - fuel (display reads 10-70 gal) 1
11-8044 • DIAL - gauge (display reads 10-70 gal) 1
8 55-8306 DRAIN COCK 1
9 98-4073 BRACKET - tank 3
10 91-3434 PAD - fuel tank (rubber) 3
203-397 ADHESIVE A/R
11 98-4074 STRAP - tank 3
12 91-3435 EXTRUSION - strap (rubber) 3
13 55-2173 FLATWASHER 18
14 55-4952 NUT 18
15 91-3436 BOLTSTRIP - bracket 6
16 11-4959 ELBOW (3/8) 2
203-385 SEALER - thread A/R
17 10-242 KIT - sleeve & eyelet (3/8) 2
18 11-4941 NUT (3/8) 2
19 11-4372 HOSE - fuel (3/8 od x 35 ft lg) A/R
20 91-9011 NAMEPLATE - 80 gallons 1
21 40-1129 SENSOR - fuel level 1
22 33-3878 • GASKET - fuel sensor 1
23 92-7236 COVER - fuel sensor 1
55-1510 SCREW - sensor/cover 5
55-431 LOCKWASHER 5
55-1511 FLATWASHER 5
24 13-975 GAUGE - fuel (vertical style) 1

44
 209G4 FUEL TANK ASSEMBLY (50 GALLON)
Revised
4/14/12

FUEL TANK
ASSEMBLY (50
GALLON)
209G4
4/14/12

45
Revised
4/14/12 FUEL TANK ASSEMBLY (50 GALLON) 209G4
REF PART# DESCRIPTION QTY
1 12-934 TANK - fuel (alum, alternator end of GenSet) 1
12-934 TANK - fuel (alum, engine side of GenSet) 1
2 13-946 CAP - fuel tank 1
13-934 CAP - fuel tank (tamper evident) 1
3 55-5617 VENT - ball check 1
4 11-9087 TUBE - fuel feed line 2
203-385 SEALER - thread A/R
5 11-7265 PLUG - fuse 2
6 55-4315 PLUG - pipe (1/4-18) 1
55-4761 PLUG - pipe (1/2-14) 1
7 55-6829 PLUG - pipe (3/4-14) 1
8 13-669 GAUGE - fuel (display reads E, 1/4, 1/2, 3/4, F) 1
13-936 • DIAL - fuel gauge 1
9 98-4073 BRACKET - tank 2
98-7349 BRACKET - tank (Maersk blue) 2
10 91-3434 PAD - fuel tank (rubber) 2
203-397 ADHESIVE A/R
11 98-4074 STRAP - tank 2
98-4074 STRAP - tank (Maersk blue) 2
12 91-3435 EXTRUSION - strap (rubber) 2
13 55-2173 FLATWASHER 12
14 55-4952 NUT 12
15 91-3436 BOLTSTRIP - bracket 4
16 11-4959 ELBOW (3/8) 2
203-385 SEALER - thread A/R
17 10-242 KIT - sleeve & eyelet (3/8) 2
18 11-4941 NUT (3/8) 2
19 11-4372 HOSE - fuel (3/8 od x 35 ft lg) A/R
20 40-1129 SENSOR - fuel level 1
21 33-3878 GASKET - fuel sensor 1
22 92-7236 COVER - fuel sensor 1
55-1510 SCREW - sensor/cover 5
55-431 LOCKWASHER 5
55-1511 FLATWASHER 5

46
 201E6 THROTTLE SOLENOID GROUP (TK486V)
Revised
4/24/10

THROTTLE SOLE-
NOID GROUP
(TK486V)
201E6
4/24/10

47
Revised
4/24/10 THROTTLE SOLENOID GROUP (TK486V) 201E6
REF PART# DESCRIPTION QTY
1 41-1566 SOLENOID - throttle 1
44-9181 • SOLENOID (less plunger & eye bolt) 1
2 44-8198 • PLUNGER 1
204-475 • GREASE - plunger A/R
3 91-3095 • BOOT - plunger 1
4 55-2762 • BOLT - eye 1
55-1533 • NUT 1
55-1800 • LOCKWASHER 1
5 92-7051 BRACKET - solenoid 1
6 55-5022 SCREW - bracket 4
55-790 LOCKWASHER 4
55-4613 FLATWASHER 4
7 55-4118 NUT - solenoid 4
55-411 FLATWASHER 4
8 44-5087 TERMINAL - solenoid (part of main harness) 1
9 44-2756 DIODE 1
203-436 SEALER - diode A/R
55-346 NUT - harness & diode 4
55-2996 LOCKWASHER (internal tooth) 4
55-401 FLATWASHER 4
10 11-8014 JOINT - solenoid to rod 1
11 55-5292 NUT 1
12 92-3865 ROD - speed control 1
13 55-2752 NUT 2
14 13-383 JOINT - rod to lever 1
15 12-925 LEVER - injection control 1

48
 209G5 AIR INTAKE & EXHAUST GROUP
Revised
10/31/12

AIR INTAKE &

EXHAUST GROUP
209G5
10/31/12

49
Revised
10/31/12 AIR INTAKE & EXHAUST GROUP 209G5
REF PART# DESCRIPTION QTY
1 11-9299 CLEANER - air 1
2 11-9300 • ELEMENT - air cleaner 1
3 92-861 CLAMP - air cleaner 1
55-3490 SCREW - clamp 2
55-2958 FLATWASHER 2
55-2959 LOCKWASHER 2
55-2114 NUT 2
4 55-9568 CLAMP - hose 2
5 13-670 HOSE - air cleaner 1
6 11-9326 ELBOW - air intake 1
55-6191 SCREW - elbow 4
7 33-2764 GASKET - elbow (see 204F7) 1
8 11-7757 INDICATOR - air restriction {Threaded Fitting} 1
11-7828 FITTING - indicator 1
11-9262 INDICATOR - air restriction (flange mount, optional) 1
11-4367 HOSE - indicator to manifold A/R
55-2201 FLATWASHER 4
55-4223 NUT 2
9 11-9328 BRACKET - exhaust tube 1
92-5311 BRACKET - exhaust tube (Maersk blue) 1
55-2963 SCREW - bracket 2
55-2959 LOCKWASHER 2
55-2958 FLATWASHER 2
10 91-7233 SADDLE 3
11 91-7234 U-BOLT 3
55-1801 NUT 6
55-1800 LOCKWASHER 6
55-2086 FLATWASHER 6
12 55-3089 SCREW - muffler 2
13 55-2173 FLATWASHER 2
14 33-2314 GASKET - exhaust 1
15 55-2959 LOCKWASHER 2
16 55-2114 NUT 2
17 12-804 MUFFLER (stainless steel) 1
18 55-2959 LOCKWASHER 2
55-2958 FLATWASHER 2
19 55-5579 SCREW - muffler 2
20 11-9327 TUBE - exhaust 1
21 13-1240 TUBE - exhaust 1

50
 PRE-CLEANER GROUP (CGCM & SGCM, OPTION
151D8 062224)
Revised
1/7/10

PRE-CLEANER
GROUP (CGCM &
SGCM, OPTION
062224)
151D8
1/7/10

51
 PRE-CLEANER GROUP (CGCM & SGCM, OPTION
Revised
1/7/10 062224) 151D8
REF PART# DESCRIPTION QTY
1 11-9206 HOSE - pre-cleaner to air cleaner (EPDM) 1
11-8495 HOSE - pre-cleaner to air cleaner (silicone) 1
2 91-6607 BRACKET - pre-cleaner 1
3 91-6608 CLAMP - pre-cleaner 1
55-2977 SCREW - bracket/clamp 4
55-2086 FLATWASHER 4
55-1800 LOCKWASHER 4
91-5315 SPACER - clamp 2
4 11-8494 PRE CLEANER 1
5 55-8304 CLAMP - hose 2
55-3834 SCREW - bracket 2
55-2958 FLATWASHER 4
55-4954 NUT 2
6 13-1072 HOSE - pre-cleaner to air cleaner (silicone) 1

52
 222G9 ENGINE COOLING SYSTEM
Revised
1/13/09

ENGINE COOLING
SYSTEM
222G9
1/13/09

53
Revised
1/13/09 ENGINE COOLING SYSTEM 222G9
REF PART# DESCRIPTION QTY
1 12-810 RADIATOR 1
2 55-1983 • CAP - vent 1
3 11-7983 CAP - radiator (steel) 1
11-8913 CAP - radiator (stainless steel) 1
4 11-8912 TANK - expansion 1
13-668 TANK - expansion (Maersk blue) 1
55-3021 SCREW - tank 4
55-1800 LOCKWASHER 4
55-2086 FLATWASHER 4
5 91-8039 BRACKET - radiator 1
92-5308 BRACKET - radiator (Maersk blue) 1
55-2957 SCREW - bracket 2
55-2945 WASHER 4
55-4953 NUT 2
6 91-8041 PAD - expansion tank 1
7 91-7782 PAD - radiator (top) 1
8 91-1834 PAD - radiator (bottom) 1
203-396 ADHESIVE - radiator pad A/R
9 55-9011 COCK - drain (radiator) 1
10 99-8301 CAP & CHAIN - overflow tank (see 119E11) 1
11 11-4607 TANK - overflow 1
12 11-4693 HANGER - overflow tank 1
55-1587 SCREW - hanger 2
55-2086 FLATWASHER 2
55-4953 NUT 2
13 98-771 HOSE - overflow (25 ft) A/R
14 55-2796 CLAMP - hose 2
15 11-8891 HOSE - outlet 1
16 11-9525 HOSE - engine to radiator 1
17 55-6156 CLAMP - hose support 1
18 98-7353 SHROUD - radiator 1
98-7366 SHROUD - radiator (Maersk blue) 1
55-6721 INSERT - threaded 6
19 98-7354 ORIFICE - radiator 1
98-7339 ORIFICE - radiator (Maersk blue) 1
55-2995 SCREW - orifice 6
55-4740 FLATWASHER 6
20 11-9524 HOSE - radiator to engine (top) 1
21 12-538 HOSE - inlet (silicone) A/R
22 55-5400 CLAMP - hose 8
23 13-509 PUMP - water (ELC compatible, see 204F0) 1
24 41-6539 SENSOR - water temperature 1

54
222G9 ENGINE COOLING SYSTEM
Revised
1/13/09

55
Revised
1/13/09 ENGINE COOLING SYSTEM 222G9
REF PART# DESCRIPTION QTY
25 41-1818 SENSOR - water level 1
26 55-1592 CONNECTOR - hose 1
27 92-7350 NUTSTRIP 1

56
 209C0 ENGINE COOLING SYSTEM (w/ fuel heater)
Revised
10/30/12

ENGINE COOLING
SYSTEM (w/ fuel
heater)
209C0
10/30/12

57
Revised
10/30/12 ENGINE COOLING SYSTEM (w/ fuel heater) 209C0
REF PART# DESCRIPTION QTY
1 12-883 RADIATOR (incl item 12) 1
2 91-8039 BRACKET - radiator 1
92-5308 BRACKET - radiator (Maersk blue) 1
55-2957 SCREW - bracket 2
55-2945 WASHER 4
55-4953 NUT 2
3 91-8041 PAD - expansion tank 1
4 11-7983 CAP - radiator (steel) 1
11-8913 CAP - radiator (stainless steel) 1
5 55-5400 CLAMP - hose 8
6 11-9525 HOSE - engine to radiator (silicone) 1
13-493 HOSE - engine to radiator (EPDM) 1
7 98-771 HOSE - overflow (25 ft) A/R
55-2796 CLAMP 2
8 99-8301 CAP & CHAIN - overflow tank (see 119E11) 1
9 11-4607 TANK - overflow 1
10 11-4693 HANGER - overflow tank 1
55-1587 SCREW - hanger 2
55-2086 FLATWASHER 2
55-4953 NUT 2
11 91-1834 PAD - radiator (bottom) 1
203-396 ADHESIVE A/R
12 55-9011 COCK - drain (radiator) 1
13 98-7365 SHROUD - radiator 1
98-7366 SHROUD - radiator (Maersk blue) 1
55-6721 INSERT - threaded 6
14 98-7338 ORIFICE - radiator 1
98-7339 ORIFICE - radiator (Maersk blue) 1
55-2995 SCREW - orifice 6
55-4740 FLATWASHER 6
15 41-6539 SENSOR - water temperature 1
16 13-509 PUMP - water (ELC compatible, see 204F0) 1
17 91-5739 PAD - fuel heater 1
18 91-7782 PAD - radiator (top) 1
19 11-8912 TANK - expansion 1
13-668 TANK - expansion (Maersk blue) 1
55-3021 SCREW - tank 4
55-1800 LOCKWASHER 4
55-2086 FLATWASHER 4
20 11-9524 HOSE - radiator to engine (top, silicone) 1
11-9331 HOSE - radiator to engine (top, EPDM) 1
21 55-1983 CAP - vent 1

58
209C0 ENGINE COOLING SYSTEM (w/ fuel heater)
Revised
10/30/12

59
Revised
10/30/12 ENGINE COOLING SYSTEM (w/ fuel heater) 209C0
REF PART# DESCRIPTION QTY
21 55-5094 DRAIN COCK 1
22 55-6156 CLAMP - hose support 1
23 11-6246 HEATER - fuel 1
24 55-5074 CLAMP - hose 4
25 91-438 CLAMP - fuel heater 2
55-2991 SCREW - clamp 4
55-2001 FLATWASHER 4
55-4560 NUT 4
26 12-383 HOSE - fuel heater (bulk) A/R
27 41-1818 SENSOR - water level 1
28 51-1336 TEE 1
29 55-1592 CONNECTOR - hose 1
30 55-9091 ELBOW - hose 1
31 51-1335 NIPPLE 1
32 12-538 HOSE - inlet (silicone) A/R
11-8890 HOSE - inlet (EPDM) 1
33 11-8891 HOSE - outlet 1

60
 119E11 CAP & CHAIN ASSEMBLY
Revised
5/24/09

CAP & CHAIN

ASSEMBLY
119E11
5/24/09

61
Revised
5/24/09 CAP & CHAIN ASSEMBLY 119E11
REF PART# DESCRIPTION QTY
1 99-8301 CAP & CHAIN - overflow tank 1
11-4665 • CAP 1
2 99-3685 • CHAIN 1
3 55-2991 • SCREW - chain 1
4 55-2965 • NUT 1
5 55-4560 • NUT (hexstop) 1

62
 208C7 BELTS, PULLEY & FAN
Revised
11/13/12

BELTS, PULLEY &

FAN
208C7
11/13/12

63
Revised
11/13/12 BELTS, PULLEY & FAN 208C7
REF PART# DESCRIPTION QTY
1 13-353 PULLEY - crankshaft (see 204F6) 1
2 55-6249 WASHER 1
3 55-6250 SCREW - pulley 1
4 13-358 PULLEY - water pump (see 204F0) 1
5 77-1472 • SHIM - (1 mm) A/R
77-2752 • SHIM - (0.5 mm) A/R
6 77-1428 • SPACER 1
7 90-331 KIT - fan spacer 1
8 55-5792 • NUT 4
9 55-9828 • STUD - fan spacer (water pump, 5 mm longer than std) 4
10 78-618 FAN - radiator 1
11 55-3834 SCREW - fan (CGCO & SGCO) 3
55-6764 SCREW - fan (CGSM, SGSM, CGCM & SGCM) 3
12 55-2959 LOCKWASHER 3
13 78-1340 BELT - fan & water pump 1
14 204-427 GAUGE - belt tension 1

64
 161G0 ENGINE MOUNTING
Revised
9/21/12

ENGINE MOUNT-
ING
161G0
9/21/12

65
Revised
9/21/12 ENGINE MOUNTING 161G0
REF PART# DESCRIPTION QTY
1 98-5826 BRACKET - alternator 1
55-7412 SCREW - bracket 4
55-8337 LOCKWASHER 4
55-6999 FLATWASHER 4
2 55-6814 STUD - mounting (CGCO & SGCO) 4
203-393 SEALER - thread A/R
3 55-4558 SCREW - mounting 6
4 55-3512 WASHER - special 12
5 99-1433 MOUNT - vibration 6
6 99-1916 MOUNT - vibration 6
7 99-1642 SPACER 6
55-2576 FLATWASHER 6
8 55-5205 NUT 6
9 91-5700 BRACKET - engine (left) 1
10 91-5699 BRACKET - engine (right) 1
55-7730 SCREW - bracket 6
55-7123 WASHER - belleville 6
11 404-153 ALTERNATOR (see 222D1) 1
55-2683 SCREW - alternator 8
55-2363 LOCKWASHER 8
55-2641 FLATWASHER 8
12 77-2654 BLOWER 1
13 55-8137 SCREW - blower 6
55-7066 LOCKWASHER 6
55-6988 FLATWASHER 6
14 11-4421 DISC - flex 1
15 55-9497 PIN - dowel 2

66
 209C4 ENGINE ELECTRICAL COMPONENTS
Revised
3/24/12

ENGINE ELECTRI-
CAL COMPO-
NENTS
209C4
3/24/12

67
Revised
3/24/12 ENGINE ELECTRICAL COMPONENTS 209C4
REF PART# DESCRIPTION QTY
1 41-8283 SWITCH - oil pressure 1
2 41-4470 SWITCH - oil level 1
33-4160 • O-RING - switch 1
3 45-2177 STARTER (see 204G3) 1
4 42-100 SOLENOID - stop (see 204G2) 1
5 41-2147 HEATER - air (see 204F7) 1
6 41-6539 SENSOR - water temperature 1
7 44-9298 SENSOR - rpm 1
8 41-2704 HARNESS - sensor 1
9 44-9181 SOLENOID - speed 1

68
 221H0 CONTROL BOX
Revised
7/11/11

CONTROL BOX
221H0
7/11/11

69
Revised
7/11/11 CONTROL BOX 221H0
REF PART# DESCRIPTION QTY
1 41-7841 KEYPAD 1
92-8090 DOOR (with nameplate) 1
55-4526 NUT - captive 4
2 41-7836 RELAY - power 2
3 45-2185 CONTROLLER 1
4 41-1771 • FUSE (30 AMP) 2
5 44-9758 • FUSE (10 AMP) 1
6 41-7904 • RELAY 2
55-4953 NUT 4
55-2086 FLATWASHER 4
7 44-9282 BOARD TERMINAL (6 terminals) 1
91-860 MARKSTRIP 1
8 44-5555 BOARD TERMINAL (3 terminals) 1
99-3855 MARKSTRIP 1
55-4223 NUT - terminal board 4
55-2201 FLATWASHER 4
9 55-3539 FITTING - barb 1
33-1056 O-RING 1
55-2636 NUT - fitting 1
10 51-1648 PLUG - button 1
11 55-2965 NUT - ground 2
55-2996 LOCKWASHER (int tooth) 2
55-2964 LOCKWASHER 1
55-2001 FLATWASHER 1
12 55-5112 CONNECTOR - harness grip 1
13 41-7837 HARNESS - main 1
14 41-3608 • CONNECTOR - plug (18 pin) 1
15 41-7838 HARNESS - relay 1
16 504-843 • CONNECTOR - plug (6 pin) 1
17 44-5219 • CONNECTOR - relay 2
18 41-7839 HARNESS - exciter 1
19 41-7842 • CONNECTOR - plug (5 pin) 1
20 41-7835 HARNESS - switch 1
44-1196 • SWITCH - on/off 1
21 44-739 BOOT - switch 1
22 99-7642 NAMEPLATE- on/off 1
23 98-7807 BOX - control 1
24 41-8064 HARNESS - download (PC board to box) 1
25 41-8065 HARNESS - download (computer, see 226E2) 1
26 41-8067 MODULE 1

70
 226E2 DOWNLOAD CABLES
Revised
1/17/12

DOWNLOAD
CABLES
226E2
1/17/12

71
Revised
1/17/12 DOWNLOAD CABLES 226E2
REF PART# DESCRIPTION QTY
1 41-2406 CAP - dust (5-pin Deutsch) 1
99-3685 CHAIN - cap 1
2 204-918 CABLE - data (5-pin Deutsch to 15-pin D connectors) 1
204-974 CABLE - data (5-pin Cannon bayonet to 15-pin D connectors) 1
204-975 CABLE - data (5-pin Cannon threaded to 15-pin D) 1
3 44-9417 CABLE - data (15-pin D connector, 9-pin D PC, 20 ft) 1
44-9418 CABLE - data (15-pin D connector, 9-pin D PC, 50 ft) 1
4 204-1109 ADAPTER - 9-pin D PC connector to USB 1
5 N/A ADAPTER - 9-pin D PC to PC card (see service bulletin 1
C061)
6 41-8065 CABLE - data download 1
7 41-3588 CAP - dust (5-pin Cannon) 1

72
 112D9 CONNECTORS - DEUTSCH IN-LINE
Revised
10/2/12

CONNECTORS -
DEUTSCH IN-LINE
112D9
10/2/12

73
Revised
10/2/12 CONNECTORS - DEUTSCH IN-LINE 112D9
REF PART# DESCRIPTION QTY
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 PLUG (3 pin, w/ seal) 1
9 33-2393 SEAL 1
10 44-9536 WEDGE 1
11 44-9545 WEDGE 1
12 44-9544 RECEPTACLE (3 pin) 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
17 44-8915 RECEPTACLE (4 pin) 1
18 44-8920 PLUG (6 pin, w/ seal) 1
19 33-2395 SEAL 1
20 44-8921 WEDGE 1
21 44-8917 WEDGE 1
22 44-8914 RECEPTACLE (6 pin) 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
27 44-9900 RECEPTACLE (8 pin) 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
32 44-9904 RECEPTACLE (12 pin) 1
33 41-2323 PLUG - assembly (w/ 6 in wires) 1
34 41-2322 RECEPTACLE - assembly (w/ 6 in wires) 1
35 41-2325 PLUG - assembly (w/ 6 in wires) 1
36 41-2324 RECEPTACLE - assembly (w/ 6 in wires) 1
37 41-2327 PLUG - assembly (w/ 6 in wires) 1
38 41-2326 RECEPTACLE - assembly (w/ 6 in wires) 1
39 41-4524 SOCKET (8-10 ga) 1

74
112D9 CONNECTORS - DEUTSCH IN-LINE
Revised
10/2/12

75
Revised
10/2/12 CONNECTORS - DEUTSCH IN-LINE 112D9
REF PART# DESCRIPTION QTY
40 41-3073 PLUG (1 terminal, 8-10 ga) 1
41 41-3069 RECEPTACLE (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

76
 222D1 ALTERNATOR GROUP
Revised
5/6/09

ALTERNATOR
GROUP
222D1
5/6/09

77
Revised
5/6/09 ALTERNATOR GROUP 222D1
REF PART# DESCRIPTION QTY
1 404-153 ALTERNATOR 1
2 55-3985 • STUD - housing 4
55-1800 • LOCKWASHER 4
55-2640 • NUT 4
3 11-9482 • DISC - flex 1
4 77-2747 • BEARING 1
5 44-4678 • RECTIFIER - positive 1
6 44-4679 • RECTIFIER - negative 1
55-664 • NUT - rectifier 6
55-2964 • LOCKWASHER 6
55-2001 • FLATWASHER 6
7 55-9820 • SPACER - fan 6
8 77-2654 • BLOWER 1
9 55-8137 • SCREW - fan 6
55-7066 • LOCKWASHER 7
55-6988 • FLATWASHER 6
10 45-2301 • EXCITER - stator (14 ohm) 1
11 55-9497 PIN - dowel 2
12 55-8137 SCREW - disc to flywheel 6
55-7066 LOCKWASHER 6
55-6988 FLATWASHER 6
13 55-3539 CONNECTOR - barb 1
33-1056 O-RING 1
55-2636 NUT 1
14 98-5035 HOSE - harness (cut to 26.0 inches) A/R
15 91-3439 COVER - harness 1
16 33-1420 GASKET - cover 1
17 55-1587 SCREW - cover 2
55-2086 FLATWASHER 2
55-1800 LOCKWASHER 2

78
 209G2 BATTERY GROUP & GROUND STRAP
Revised
5/27/09

BATTERY GROUP
& GROUND STRAP
209G2
5/27/09

79
Revised
5/27/09 BATTERY GROUP & GROUND STRAP 209G2
REF PART# DESCRIPTION QTY
1 203-732 BATTERY - (950 CCA, posts) 1
203-733 BATTERY (950 CCA G31, threaded) 1
92-6531 NAMEPLATE - Battery (950 CCA) 1
2 55-4954 NUT (stop) 2
55-2958 FLATWASHER 2
3 91-4146 ROD - holddown 2
4 92-5393 TRAY - battery 1
92-5315 TRAY - battery (Maersk blue) 1
55-1587 SCREW - tray 4
55-2086 FLATWASHER 8
55-4953 NUT 2
55-7422 INSERT - threaded 2
5 41-7018 CABLE - positive (post connection) 1
44-5709 CABLE - positive (threaded connection) 1
6 44-7051 BOOT - cable 1
7 41-7019 CABLE - negative (post connection) 1
44-7782 CABLE - negative (threaded connection) 1
8 91-1344 ANGLE - battery holddown 1
9 44-1644 STRAP - ground (13.5 in lg) 1
10 55-329 SCREW - strap to engine 1
11 55-3672 LOCKWASHER 2
12 55-402 FLATWASHER 2
14 55-2969 SCREW - strap to frame 1
15 55-3066 LOCKWASHER (internal tooth) 2
16 55-2086 FLATWASHER 2
17 55-2114 NUT 1

80
 212A6 POWER RECEPTACLE GROUP
Revised
6/3/07

POWER RECEPTA-
CLE GROUP
212A6
6/3/07

81
Revised
6/3/07 POWER RECEPTACLE GROUP 212A6
REF PART# DESCRIPTION QTY
1 91-9917 PLATE - receptacle 1
55-2977 SCREW - plate 4
55-1800 LOCKWASHER 4
55-2086 FLATWASHER 4
2 41-3403 RECEPTACLE (230V) 1
41-3404 RECEPTACLE (460V) 1
3 41-7918 COVER - receptacle (460V) 1
41-3406 COVER - receptacle (230V) 1
55-2977 SCREW - receptacle 4
55-2086 FLATWASHER 8
55-4953 NUT 4
4 33-3168 GASKET - receptacle (460V) 1
33-3167 GASKET - receptacle (230V) 1
5 45-2136 CABLE - power (230V, 10 ft) 1
45-2135 CABLE - power (460V, 10 ft) 1
44-6310 • TERMINAL - pin 4
44-2792 • TERMINAL - ring 4
6 55-6016 CLAMP (0.750 dia) 2
55-2977 SCREW - clamp 2
55-1800 LOCKWASHER 2
55-2086 FLATWASHER 2

82
 POWER RECEPTACLE GROUP (CGCM & SGCM
160H2 OPTION 062295, 10/99 & After)
Revised
12/5/07

POWER RECEPTA-
CLE GROUP
(CGCM & SGCM
OPTION 062295,
10/99 & After)
160H2
12/5/07

83
 POWER RECEPTACLE GROUP (CGCM & SGCM
Revised
12/5/07 OPTION 062295, 10/99 & After) 160H2
REF PART# DESCRIPTION QTY
1 98-5828 BOX - power receptacle 1
55-3018 SCREW - box 4
55-2086 FLATWASHER 4
55-1800 LOCKWASHER 4
2 91-5822 POINTER - voltage 1
91-5814 NAMEPLATE - pointer 1
55-3027 SCREW - pointer 2
55-2001 FLATWASHER 2
3 91-5821 TAB - chain 2
4 41-3403 RECEPTACLE (230V) 1
5 41-3404 RECEPTACLE (460V) 1
55-3843 SCREW - receptacle 8
55-2001 FLATWASHER 8
55-2964 LOCKWASHER 8
55-6721 INSERT - threaded 8
6 91-1096 NUTSTRIP - control box 2
55-2988 RIVET - nutstrip 2
7 44-5555 BOARD - terminal 2
8 44-9282 BOARD - terminal 1
55-4474 SCREW - terminal board 6
55-2201 FLATWASHER 6
55-2202 LOCKWASHER 6
55-6743 INSERT 6
9 99-3855 MARKSTRIP 2
10 91-860 MARKSTRIP 1
11 99-7246 STRIP - gasket (50 ft) A/R
12 91-5816 COVER - box 1
13 55-2086 FLATWASHER 2
14 55-1800 LOCKWASHER 2
15 55-2977 SCREW - cover 2
16 55-3059 NUT - captive 2
17 99-3407 NAMEPLATE - Caution 230 Volts 1
18 91-5817 NAMEPLATE - Wiring (230V) 1
19 91-5818 NAMEPLATE - Wiring (460V) 1
20 99-5307 NAMEPLATE - Caution High Voltage 1
21 99-3522 NAMEPLATE - Caution 460 Volts 1
22 55-5112 CONNECTOR - liquid tite 1
23 41-595 HARNESS - receptacle 1
24 55-4552 CLAMP - harness 2
55-2977 SCREW - clamp 2
55-2086 FLATWASHER 2
55-1800 LOCKWASHER 2

84
 POWER RECEPTACLE GROUP (CGCM & SGCM
160H2 OPTION 062295, 10/99 & After)
Revised
12/5/07

85
 POWER RECEPTACLE GROUP (CGCM & SGCM
Revised
12/5/07 OPTION 062295, 10/99 & After) 160H2
REF PART# DESCRIPTION QTY
25 55-3000 SCREW - ground 1
55-2001 FLATWASHER 2
55-2996 LOCKWASHER 2
55-2965 NUT 2
26 33-3167 GASKET - receptacle (230V) 1
27 33-3168 GASKET - receptacle (460V) 1

86
 115D14 CONNECTORS - WEATHER PACK
Revised
4/28/08

CONNECTORS -
WEATHER PACK
115D14
4/28/08

87
Revised
4/28/08 CONNECTORS - WEATHER PACK 115D14
REF PART# DESCRIPTION QTY
1 44-5836 TERMINAL - male (14-16 ga) A/R
44-5883 TERMINAL - male (18-20 ga) A/R
44-8851 TERMINAL - male (22 gauge) A/R
41-7403 TERMINAL - male (12 gauge) A/R
2 44-8681 SEAL - cable (red, 18-20 ga) A/R
44-5885 SEAL - cable (green, 18-22 ga) A/R
44-5837 SEAL - cable (gray, 14-16 ga) A/R
44-6324 SEAL - cable (blue, 12-14 ga) A/R
44-7812 PLUG - cavity (green) A/R
3 44-7330 CONNECTOR - shroud (1 pin) 1
4 44-7327 CONNECTOR - tower (1 pin) 1
5 44-5839 TERMINAL - female (14-16 ga) A/R
44-5884 TERMINAL - female (18-20 ga) A/R
44-8853 TERMINAL (22 gauge, female) A/R
41-8207 TERMINAL (12 gauge, female) A/R
6 44-5835 CONNECTOR - shroud (black, 2 pin) 1
41-8208 CONNECTOR - shroud (grey, 2 pin) 1
7 44-5838 CONNECTOR - tower (2 pin) 1
41-8209 CONNECTOR - tower (grey, 2 pin) 1
8 44-9569 CONNECTOR - shroud (3 pin) 1
9 44-6959 CONNECTOR - tower (3 pin) 1
10 44-7880 CONNECTOR - shroud (4 pin) 1
11 44-7881 CONNECTOR - tower (4 pin) 1
12 44-8294 CONNECTOR - shroud (6 pin) 1
13 44-7872 CONNECTOR - tower (6 pin) 1
14 44-7884 CONNECTOR - shroud (22 pin) 1
15 44-7829 CONNECTOR - tower (22 pin) 1
16 44-7811 LOCK - secondary 2
17 41-1527 CONNECTOR - tower (4 pin) 1
18 41-1310 CONNECTOR - shroud (4 pin) 1
19 204-623 TOOL - pin removal 1
20 204-624 TOOL - terminal crimper 1
21 55-9704 CLIP - self-locking A/R

88
 223C2 STRUCTURAL COMPONENTS
Revised
6/17/10

STRUCTURAL
COMPONENTS
223C2
6/17/10

89
Revised
6/17/10 STRUCTURAL COMPONENTS 223C2
REF PART# DESCRIPTION QTY
1 98-7364 FRAME - assembly (w/ welded fork pockets) 1
98-7337 FRAME - assembly (Maersk blue,w/ welded fork pockets) 1
98-7367 FRAME - assembly (Toyo, w/ welded fork pockets) 1
2 98-7204 PANEL - top, rear 1
98-7204 PANEL - top, rear (Maersk blue) 1
3 98-7202 PANEL - top 1
98-7344 PANEL - top (Maersk blue) 1
4 98-7822 PANEL - lower, rear 1
98-7347 PANEL - lower, rear (Maersk blue) 1
5 98-7206 PANEL - front 1
98-7206 PANEL - front (Maersk blue) 1
6 98-7208 PANEL - radiator 1
98-7340 PANEL - radiator (Maersk blue) 1
7 98-7207 PANEL - upper right 1
98-7341 PANEL - upper right (Maersk blue) 1
8 55-7731 SCREW - door A/R
55-1800 LOCKWASHER A/R
55-4742 WASHER - special A/R
51-1170 WASHER - nylon A/R
55-6721 INSERT - threaded A/R
9 98-7859 DOOR - front right 1
98-7802 DOOR - front right (Maersk blue) 1
10 92-6380 HINGE - door 2
11 92-260 LATCH - door (includes nut) 2
12 92-6306 BRACKET - latch 1
55-3027 SCREW - bracket 4
55-1800 LOCKWASHER 4
55-2001 FLATWASHER 4
13 98-7860 DOOR - rear right 1
98-7903 PANEL - rear right (Maersk blue) 1
14 92-5403 ANGLE - unit mounting (rear) 1
15 98-5514 ANGLE - unit mounting (front) 1
55-5204 SCREW - angle 8
55-2576 FLATWASHER 16
55-5205 NUT 8
16 51-1654 PIN - spring 4
17 55-4470 NUT 4
18 92-3438 CLIP - unit mounting 4
19 92-6720 BRACKET - clip 4
20 91-632 CHANNEL - unit mounting 4
21 55-7502 BOLT - unit 4
55-7731 SCREW - hinge 8

90
223C2 STRUCTURAL COMPONENTS
Revised
6/17/10

91
Revised
6/17/10 STRUCTURAL COMPONENTS 223C2
REF PART# DESCRIPTION QTY
55-1587 SCREW - hinge (hh) 8
55-4953 NUT 8
55-1800 LOCKWASHER 16
22 91-5703 POUCH - service records 1
91-9447 SUPPORT - pouch 1
55-1587 SCREW - pouch 2
55-2086 FLATWASHER 2
55-4953 NUT 2
23 92-5307 POCKET - fork (Maersk blue) 2
55-2173 FLATWASHER 8
55-4952 NUT 8

92
 261G3 CM BOTTOM PANEL KIT
Revised
11/13/12

CM BOTTOM
PANEL KIT
261G3
11/13/12

93
Revised
11/13/12 CM BOTTOM PANEL KIT 261G3
REF PART# DESCRIPTION QTY
90-2449 KIT - CM bottom panels 1
1 98-9174 • PANEL - rear (muffler side) 1
2 98-9175 • PANEL - rear (engine side) 1
3 98-7206 • PANEL - front (upper) 1
4 98-7208 • PANEL - front (lower) 1
5 98-9176 • PANEL - bottom (generator end) 1
6 98-9177 • PANEL - bottom (center) 1
7 98-9178 • PANEL - bottom (receptacle end) 1
55-2864 • RIVET - panel 25
55-4740 • WASHER - special 25

94
 208C5 NAMEPLATES
Revised
6/2/09

NAMEPLATES
208C5
6/2/09

95
Revised
6/2/09 NAMEPLATES 208C5
REF PART# DESCRIPTION QTY
1 91-4511 NAMEPLATE - TK (CGCM & SGCM) 1
2 91-6284 NAMEPLATE - 15 kW 1
3 91-7171 NAMEPLATE - California Proposition 1
4 91-5703 POUCH - Service Information Records 1
91-9447 SUPPORT - 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 92-5115 NAMEPLATE - Smart Gen-Set Operating Instructions 1
92-5116 NAMEPLATE - Smart Gen-Set Operating Instructions (Span- 1
ish)
16 92-1236 NAMEPLATE - Maintenance 1
17 99-3522 NAMEPLATE - Caution 460 Volts 1
18 92-4305 NAMEPLATE - IR logo 1
19 91-2389 NAMEPLATE - Diesel Fuel Only 1
20 99-3407 NAMEPLATE - Caution 230 Volts 1
21 91-8810 NAMEPLATE - CE 1
22 92-4977 NAMEPLATE - Warning, Ether 1
23 91-8684 NAMEPLATE - FHWA 1
24 92-5112 NAMEPLATE - Wiring/Schematic Diagram 1
25 92-3828 NAMEPLATE - Caution 1
26 92-5113 NAMEPLATE - Smart Gen-Set Menu List 1
92-5114 NAMEPLATE - Smart Gen-Set Menu List (Spanish) 1
27 91-8699 NAMEPLATE - Operating Instructions (CGCM) 1
91-9920 NAMEPLATE - Operating Instructions (CGSM) 1
28 99-9938 NAMEPLATE - Caution, Start/Stop 1
29 99-9939 NAMEPLATE - Caution, Start/Stop (multi-language) 1
30 91-9269 NAMEPLATE - Texaco 1
31 92-5271 NAMEPLATE - MAEG 2
32 92-6424 NAMEPLATE - Maersk 1

96
 INDEX NUMERICAL BY PART NUMBER

101-354 22, 28 11-8681 34 11-9448 16

101-362 22, 26, 28, 30, 42 11-8682 34 11-9482 78
101-379 6 11-8890 60 11-9524 54, 58
10-242 42, 44, 46 11-8891 54, 60 11-9525 54, 58
10-243 42 11-8912 54, 58 11-9592 12, 18
10-373 28 11-8913 54, 58 12-383 60
11-2854 34 11-8919 6 12-538 54, 60
11-4367 42, 50 11-8923 16 12-750 18
11-4372 42, 44, 46 11-8924 14 12-790 44
11-4380 42 11-8927 10 12-794 44
11-4421 66 11-8928 8 12-804 50
11-4607 54, 58 11-8929 8 12-810 54
11-4665 62 11-8932 8 12-867 14
11-4693 54, 58 11-8933 10 12-868 16
11-4841 42 11-8934 8, 40 12-869 16
11-4941 42, 44, 46 11-8935 8, 40 12-870 8
11-4959 42, 44, 46 11-8936 10 12-883 58
11-5082 12 11-8942 10 12-925 30, 48
11-5091 12 11-8944 20 12-934 46
11-5103 8 11-8945 22 13-1063 16
11-5320 42 11-8947 18 13-1064 18
11-5437 42 11-8950 18 13-1065 18
11-5499 6 11-8951 18 13-1066 18
11-5911 16 11-8952 18 13-1072 52
11-6031 14 11-8953 18 13-1138 18
11-6106 36 11-8964 26 13-1240 50
11-6108 36 11-8965 26 13-126 10
11-6109 28 11-8970 34 13-127 34
11-6125 30 11-8971 34 13-128 34
11-6246 60 11-8972 34 13-310 28
11-6555 6 11-8973 34 13-318 6
11-6567 8 11-8974 34 13-319 12
11-6704 8 11-8975 34 13-321 12
11-6707 8, 36, 40 11-8976 34 13-322 12
11-6717 22 11-8977 34 13-323 26
11-6719 18, 22 11-8984 16 13-324 26
11-6786 36 11-8995 26 13-325 26
11-6787 36 11-8998 34 13-326 26
11-6788 36 11-9015 42 13-327 26
11-6789 36 11-9016 42 13-328 26
11-6790 36 11-9017 42 13-332 8
11-7265 44, 46 11-9087 44, 46 13-333 8
11-7433 34, 42 11-9182 26 13-334 8
11-7489 44 11-9206 52 13-335 8
11-7491 44 11-9256 24 13-336 8
11-7499 34 11-9261 22 13-337 8
11-7707 34 11-9262 50 13-338 8
11-7757 50 11-9266 20 13-339 8
11-7828 50 11-9299 50 13-340 8, 40
11-7983 54, 58 11-9300 50 13-341 8, 36, 40
11-8014 48 11-9326 50 13-342 8
11-8026 44 11-9327 50 13-343 20
11-8044 44 11-9328 50 13-344 8
11-8494 52 11-9331 58 13-345 22
11-8495 52 11-9338 16 13-346 22
11-8667 16 11-9342 42 13-348 22
11-8671 8 11-9354 26 13-349 22
11-8675 24 11-9446 28 13-350 22
11-8680 34 11-9447 26 13-351 18

INDEX - 1
 INDEX NUMERICAL BY PART NUMBER

13-352 18 203-397 44, 46 33-3878 44, 46

13-353 18, 64 203-436 48 33-4087 12
13-355 18 203-732 80 33-4088 12
13-356 26, 28 203-733 80 33-4089 12, 26, 40
13-357 26 204-1011 12 33-4090 16, 40
13-358 24, 64 204-1038 76 33-4122 10, 40
13-360 24 204-1109 72 33-4160 16, 68
13-363 24 204-1848 28 33-4168 30
13-368 28 204-427 64 33-4169 30
13-370 36 204-475 48 33-4170 30
13-371 28 204-542 28 33-4171 30
13-383 48 204-623 88 33-4172 30
13-385 24 204-624 88 33-4173 30
13-388 28, 36 204-703 76 33-4174 36
13-389 28 204-799 76 33-4190 30
13-391 28 204-918 72 33-4192 30
13-392 28 204-952 14 33-4193 30
13-393 28 204-974 72 33-4458 42
13-440 30 204-975 72 33-4515 10
13-442 30 204-994 14 33-4517 40
13-444 30 30-291 40 40-1129 44, 46
13-445 30 30-295 24 404-153 66, 78
13-446 30 33-1056 70, 78 41-1310 88
13-447 30 33-1420 78 41-1527 88
13-448 30 33-1745 24, 40 41-1566 48
13-449 30 33-1749 34 41-1771 70
13-450 30 33-1953 12, 40 41-1818 56, 60
13-451 28 33-1954 12, 40 41-2147 20, 68
13-455 18 33-2230 30 41-2156 38
13-461 18 33-2314 50 41-2317 6
13-493 58 33-2392 74 41-2322 74
13-509 24, 54, 58 33-2393 74 41-2323 74
13-511 30 33-2394 74 41-2324 74
13-514 24 33-2395 74 41-2325 74
13-648 10 33-2396 74 41-2326 74
13-659 8 33-2397 74 41-2327 74
13-668 54, 58 33-2762 8, 40 41-2406 72
13-669 46 33-2764 20, 40, 50 41-2628 74
13-670 50 33-2765 20, 40 41-2704 68
13-815 24 33-2767 24, 40 41-3069 76
13-920 6 33-2768 24, 40 41-3073 76
13-921 6 33-2771 34 41-3403 82, 84
13-924 18 33-2931 26, 40 41-3404 82, 84
13-925 18 33-2934 10, 40 41-3406 82
13-926 6 33-2936 20, 40 41-3588 72
13-927 6 33-2937 20, 40 41-3608 70
13-928 6 33-2940 34 41-4470 16, 68
13-930 22 33-2941 34 41-4524 74
13-932 8 33-2942 34 41-595 84
13-934 46 33-2969 14, 40 41-6508 38
13-936 46 33-2974 14 41-6509 38
13-946 46 33-3096 24, 40 41-6510 38
13-972 42 33-3097 24, 40 41-6511 38
13-973 42 33-3098 24, 40 41-6512 38
13-975 44 33-3167 82, 86 41-6513 38
203-348 10, 12, 16, 40 33-3168 82, 86 41-6514 38
203-385 44, 46 33-3512 8, 40 41-6515 38
203-393 42, 66 33-3821 12, 40 41-6516 38
203-396 54, 58 33-3833 26, 40 41-6517 38

INDEX - 2
 INDEX NUMERICAL BY PART NUMBER

41-6518 38 44-7884 88 51-1155 22, 30

41-6519 38 44-8198 48 51-1156 26
41-6520 38 44-8294 88 51-1157 26
41-6521 38 44-8681 88 51-1158 26
41-6539 54, 58, 68 44-8851 88 51-1159 26
41-7018 80 44-8853 88 51-1161 38
41-7019 80 44-8914 74 51-1162 14
41-7403 88 44-8915 74 51-1170 90
41-7835 70 44-8917 74 51-1205 30
41-7836 70 44-8918 74 51-1206 30
41-7837 70 44-8920 74 51-1207 30
41-7838 70 44-8921 74 51-1269 32
41-7839 70 44-8935 74 51-1335 60
41-7841 70 44-8936 74 51-1336 60
41-7842 70 44-9181 48, 68 51-1648 70
41-7904 70 44-9282 70, 84 51-1654 90
41-7918 82 44-9298 68 51-2009 22
41-8064 70 44-9417 72 51-588 24
41-8065 70, 72 44-9418 72 51-592 26
41-8067 70 44-9536 74 51-593 26
41-8207 88 44-9544 74 51-594 12, 20
41-8208 88 44-9545 74 51-598 8
41-8209 88 44-9569 88 51-607 24
41-8283 68 44-9585 74 51-612 32
41-8319 42 44-9586 74 55-1510 44, 46
42-100 30, 68 44-9587 74 55-1511 44, 46
44-1196 70 44-9589 74 55-1533 48
44-1644 80 44-9590 74 55-1587 16, 54, 58, 78, 80, 92
44-2756 48 44-9591 74 55-1592 56, 60
44-2792 82 44-9600 74 55-1800 42, 48, 50, 52, 54, 58,
44-4678 78 44-9601 74 78, 82, 84, 90, 92
44-4679 78 44-9602 76 55-1801 50
44-5087 48 44-9631 74 55-1819 28
44-5219 70 44-9700 74 55-1983 54, 58
44-5555 70, 84 44-9701 74 55-2001 60, 70, 78, 84, 86, 90
44-5709 80 44-9758 70 55-2086 16, 42, 50, 52, 54, 58,
44-5835 88 44-9900 74 70, 78, 80, 82, 84, 92
44-5836 88 44-9901 74 55-2114 50, 80
44-5837 88 44-9902 74 55-2173 44, 46, 50, 92
44-5838 88 44-9903 74 55-2201 50, 70, 84
44-5839 88 44-9904 74 55-2202 84
44-5883 88 44-9905 74 55-2363 66
44-5884 88 44-9906 76 55-2576 66, 90
44-5885 88 44-9907 76 55-2636 70, 78
44-6310 82 45-2135 82 55-2640 78
44-6324 88 45-2136 82 55-2641 66
44-6850 76 45-2177 38, 68 55-2683 66
44-6959 88 45-2185 70 55-2752 48
44-7051 80 45-2301 78 55-2762 48
44-7327 88 504-843 70 55-2796 54, 58
44-7330 88 51-1145 6 55-2864 94
44-739 70 51-1146 12 55-2945 54, 58
44-7782 80 51-1147 26 55-2957 54, 58
44-7811 88 51-1149 14 55-2958 42, 50, 52, 80
44-7812 88 51-1150 16 55-2959 42, 50, 64
44-7829 88 51-1151 8 55-2963 50
44-7872 88 51-1152 20 55-2964 70, 78, 84
44-7880 88 51-1153 20 55-2965 62, 70, 86
44-7881 88 51-1154 22, 30 55-2969 80

INDEX - 3
 INDEX NUMERICAL BY PART NUMBER

55-2977 52, 82, 84 55-5292 48 55-8626 28

55-2988 84 55-5400 54, 58 55-8711 42
55-2991 60, 62 55-5579 50 55-8717 20
55-2995 54, 58 55-5617 44, 46 55-8852 6
55-2996 48, 70, 86 55-5763 10, 20, 26 55-8853 10
55-3000 86 55-5772 22 55-8854 12
55-3018 42, 84 55-5780 24 55-8855 14
55-3021 54, 58 55-5792 24, 26, 64 55-8856 14
55-3027 84, 90 55-5801 10, 22 55-8858 10
55-3059 84 55-5803 8 55-8859 8
55-3066 80 55-5809 12, 16, 26 55-8860 8
55-3089 50 55-5816 12, 14, 18 55-8864 18
55-329 80 55-5822 30 55-8865 18
55-346 48 55-5846 30 55-8868 26
55-3462 42 55-6016 82 55-8869 26
55-3490 42, 50 55-6156 54, 60 55-8871 34
55-3512 66 55-6176 6 55-8872 34
55-3539 70, 78 55-6187 30 55-8894 38
55-3672 80 55-6188 20, 24, 26, 28 55-8897 38
55-3744 16 55-6191 8, 14, 20, 50 55-8898 38
55-3834 52, 64 55-6193 8 55-9011 54, 58
55-3843 84 55-6229 6 55-9091 60
55-3985 78 55-6230 30 55-9167 16
55-401 48 55-6234 12 55-9222 22
55-402 80 55-6236 12 55-9223 22
55-411 48 55-6237 12, 16 55-9497 66, 78
55-4118 48 55-6245 8 55-9568 50
55-4203 42 55-6246 8, 16 55-9704 88
55-4223 50, 70 55-6248 24 55-9820 78
55-4306 44 55-6249 18, 64 55-9828 64
55-431 44, 46 55-6250 18, 64 77-1427 24
55-4315 46 55-6367 12, 34 77-1428 24, 64
55-4470 90 55-6537 14 77-1472 64
55-4474 84 55-664 78 77-2468 38
55-4526 70 55-6721 54, 58, 84, 90 77-2469 38
55-4552 84 55-6743 84 77-2654 66, 78
55-4558 66 55-6764 64 77-2747 78
55-4560 60, 62 55-6814 66 77-2752 24, 64
55-4593 6 55-6829 46 77-2833 38
55-4607 28 55-6988 66, 78 77-2834 38
55-4613 48 55-6999 66 78-1340 64
55-4622 12, 26, 40 55-7066 66, 78 78-618 64
55-4644 26 55-7123 66 813-509 24
55-4668 18 55-7412 66 90-2449 94
55-4676 30 55-7422 80 90-331 64
55-4740 54, 58, 94 55-7502 90 91-1096 84
55-4742 90 55-7730 66 91-1344 80
55-4750 34 55-7731 90 91-1834 54, 58
55-4761 46 55-7802 32 91-2383 96
55-4952 44, 46, 92 55-790 48 91-2384 96
55-4953 16, 54, 58, 70, 80, 82, 92 55-8137 66, 78 91-2389 96
55-4954 42, 52, 80 55-8304 52 91-3095 48
55-5022 42, 48 55-8306 44 91-338 96
55-5074 60 55-8337 66 91-3423 96
55-5081 16 55-8437 16 91-3425 96
55-5094 60 55-8441 10, 12, 24, 26 91-3434 44, 46
55-5112 70, 84 55-8442 8 91-3435 44, 46
55-5204 90 55-8448 30 91-3436 44, 46
55-5205 66, 90 55-8620 30 91-3439 78

INDEX - 4
 INDEX NUMERICAL BY PART NUMBER

91-3542 8 92-5311 50 99-5307 84

91-372 42 92-5315 80 99-7246 84
91-4146 80 92-5393 80 99-7642 70
91-4148 96 92-5403 90 99-8301 54, 58, 62
91-438 60 92-6306 90 99-9234 96
91-4511 96 92-6380 90 99-9938 96
91-4512 96 92-6424 96 99-9939 96
91-4823 16 92-6531 80
91-5315 52 92-6720 90
91-5699 66 92-7051 48
91-5700 66 92-7236 44, 46
91-5703 92, 96 92-7350 56
91-5739 58 92-7755 42
91-5814 84 92-8090 70
91-5816 84 92-861 50
91-5817 84 98-4073 44, 46
91-5818 84 98-4074 44, 46
91-5821 84 98-5035 78
91-5822 84 98-5514 90
91-6284 96 98-5826 66
91-632 90 98-5828 84
91-6607 52 98-7202 90
91-6608 52 98-7204 90
91-7012 96 98-7206 90, 94
91-7171 96 98-7207 90
91-7191 16 98-7208 90, 94
91-7233 50 98-7337 90
91-7234 50 98-7338 58
91-7782 54, 58 98-7339 54, 58
91-8039 54, 58 98-7340 90
91-8041 54, 58 98-7341 90
91-860 70, 84 98-7344 90
91-8684 96 98-7347 90
91-8699 96 98-7349 46
91-8810 96 98-7353 54
91-9011 44 98-7354 54
91-9269 96 98-7364 90
91-9447 92, 96 98-7365 58
91-960 42 98-7366 54, 58
91-9917 82 98-7367 90
91-9918 96 98-771 54, 58
91-9919 96 98-7802 90
91-9920 96 98-7807 70
92-1236 96 98-7822 90
92-2504 96 98-7859 90
92-260 90 98-7860 90
92-3438 90 98-7903 90
92-3828 96 98-9174 94
92-3865 48 98-9175 94
92-4305 96 98-9176 94
92-4977 96 98-9177 94
92-5112 96 98-9178 94
92-5113 96 99-1433 66
92-5114 96 99-1642 66
92-5115 96 99-1916 66
92-5116 96 99-3407 84, 96
92-5271 96 99-3522 84, 96
92-5307 92 99-3685 62, 72
92-5308 54, 58 99-3855 70, 84

INDEX - 5
INDEX NUMERICAL BY PART NUMBER

INDEX - 6
 INDEX ALPHABETICAL BY DESCRIPTION

A C COVER - rear 38
ADAPTER - 9-pin D PC connector to CABLE - data 72 COVER - receptacle 82
USB 72 CABLE - data download 72 COVER - sound shield 12
ADAPTER - 9-pin D PC to PC card 72 CABLE - negative 80 COVER - thermostat 24
ADAPTER - compression tester 28 CABLE - positive 80 COVER - valve 8
ADHESIVE 44, 46, 58 CABLE - power 82 CRANKSHAFT 18
ADHESIVE - radiator pad 54 CAM - feed pump 22
ALTERNATOR 66, 78 CAMSHAFT 22 D
ANGLE - battery holddown 80 CAP 16, 62 DIAL - fuel gauge 46
ANGLE - unit mounting 90 CAP - bearing 6 DIAL - gauge 44
ARM - rocker 8 CAP - dust 72 DIODE 48
ARMATURE 38 CAP - fuel tank 44, 46 DIPSTICK 16, 44
CAP - hose 16 DISC - flex 66, 78
B CAP - oil fill 12 DOOR 70
BAFFLE - breather 8 CAP - radiator 54, 58 DOOR - front right 90
BALL 26 CAP - valve 10 DOOR - rear right 90
BATTERY 80 CAP - vent 54, 58 DRAIN COCK 44, 60
BATTERY - 80 CAP & CHAIN - overflow tank 54, 58,
BEARING 38, 78 62 E
BEARING - ball 38 CASE - cover 38 ELBOW 42, 44, 46
BEARING - connecting rod 18 CASE - gear 12 ELBOW - air intake 50
BEARING - main 6 CASE - oil seal 14 ELBOW - hose 16, 60
BEARING - thrust 6, 22 CHAIN 62 ELBOW - hose fitting 42
BELT - fan & water pump 64 CHAIN - cap 72 ELEMENT - air cleaner 50
BLOCK - cylinder 6 CHANNEL - unit mounting 90 ENGINE 6
BLOWER 66, 78 CIRCLIP 18 EXCITER - stator 78
BOARD - terminal 84 CLAMP 42, 58, 82 EXTRUSION - strap 44, 46
BOARD TERMINAL 70 CLAMP - air cleaner 50
BOLT - bearing cap 6 CLAMP - fuel heater 42, 60 F
BOLT - connecting rod 18 CLAMP - harness 84 FAN - radiator 64
BOLT - eye 26, 30, 34, 48 CLAMP - hose 8, 24, 42, 50, 52, 54, FILTER - fuel 42
BOLT - flywheel 18 58, 60 FILTER - oil 26
BOLT - plate 22 CLAMP - hose support 54, 60 FITTING - barb 70
BOLT - thru 38 CLAMP - pre-cleaner 52 FITTING - indicator 50
BOLT - unit 90 CLEANER - air 50 FITTING - oil drain 16
BOLT - v-pulley 18 CLIP - hose 16 FITTING - oil drain w/cap 16
BOLTSTRIP - bracket 44, 46 CLIP - self-locking 88 FITTING - oil inlet 26
BOOT - cable 80 CLIP - unit mounting 90 FLANGE 10, 22
BOOT - plunger 48 CLUTCH - assembly 38 FLATWASHER 16, 28, 42, 44, 46, 48,
BOOT - switch 70 COCK - drain 24, 54, 58 50, 52, 54, 58, 60, 66,
BOX - control 70 CONNECTOR 42 70, 78, 80, 82, 84, 86,
BOX - power receptacle 84 CONNECTOR - barb 78 90, 92
BRACKET - alternator 66 CONNECTOR - harness grip 70 FLYWHEEL 18
BRACKET - clip 16, 90 CONNECTOR - hose 56, 60 FRAME - assembly 90
BRACKET - engine 66 CONNECTOR - liquid tite 84 FUSE 70
BRACKET - exhaust tube 50 CONNECTOR - plug 70
BRACKET - filter 26 CONNECTOR - relay 70 G
BRACKET - fuel strainer 42 CONNECTOR - shroud 88 GASKET 24, 34, 40
BRACKET - latch 90 CONNECTOR - tower 88 GASKET - adhesive 12, 16, 40
BRACKET - pre-cleaner 52 CONTROLLER 70 GASKET - air heater 20, 40
BRACKET - radiator 54, 58 COVER 12 GASKET - copper 8, 36, 40
BRACKET - solenoid 48 COVER - box 84 GASKET - cover 12, 30, 78
BRACKET - tank 44, 46 COVER - breather 8 GASKET - cylinder head 10, 40
BRUSH 38 COVER - dust 38 GASKET - elbow 50
BRUSH - positive 38 COVER - fuel sensor 44, 46 GASKET - exhaust 50
BUSHING - camshaft 6 COVER - gear case 12 GASKET - exhaust manifold 20, 40
BUSHING - idler gear 22 COVER - governor 30 GASKET - flange 10, 40
BUSHING - piston pin 18 COVER - harness 78 GASKET - fuel sensor 44, 46
COVER - oil pump 26 GASKET - inlet 20

INDEX - 1
 INDEX ALPHABETICAL BY DESCRIPTION

GASKET - intake manifold 20, 40 INDICATOR - air restriction {Threaded 84

GASKET - joint 24 Fitting} 50 NAMEPLATE - Caution Left 96
GASKET - liquid 10 INLET - intake manifold 20 NAMEPLATE - Caution Right 96
GASKET - nozzle 36 INSERT 42, 84 NAMEPLATE - Caution, Start/Stop 96
GASKET - oil filter bracket 26 INSERT - threaded 54, 58, 80, 84, 90 NAMEPLATE - CE 96
GASKET - oil seal case 14, 40 NAMEPLATE - Clean Filter Screen 96
GASKET - receptacle 82, 86 J NAMEPLATE - Diesel Fuel Only 96
GASKET - strainer 42 JOINT - banjo 30, 34 NAMEPLATE - Document Holder 96
GASKET - thermostat case 40 JOINT - pump 24 NAMEPLATE - Fan Universal 96
GASKET - valve cover 8, 40 JOINT - rod to lever 48 NAMEPLATE - FHWA 96
GASKET - water pump 24, 40 JOINT - solenoid to rod 48 NAMEPLATE - Installation Instructions
GASKET SET 24 96
GAUGE - belt tension 64 K NAMEPLATE - IR logo 96
GAUGE - fuel 44, 46 KEEPER - valve 10 NAMEPLATE - MAEG 96
GEAR 22 KEY - gear 18, 22 NAMEPLATE - Maersk 96
GEAR - camshaft 22 KEYPAD 70 NAMEPLATE - Maintenance 96
GEAR - crankshaft 18 KIT - CM bottom panels 94 NAMEPLATE - Operating Instructions
GEAR - injection pump 22 KIT - crimper 76 96
GEAR - ring 18 KIT - fan spacer 64 NAMEPLATE - pointer 84
GREASE - plunger 48 KIT - fuel return 28 NAMEPLATE - Radiator Fill 96
GUIDE - valve 8 KIT - gasket set 40 NAMEPLATE - Smart Gen-Set Menu
KIT - sleeve & eyelet 42, 44, 46 List 96
H KNOB - valve cover 8 NAMEPLATE - Smart Gen-Set
HANGER - overflow tank 54, 58 Operating Instructions 96
HARNESS - download 70 L NAMEPLATE - Texaco 96
HARNESS - exciter 70 LATCH - door 90 NAMEPLATE - Thermo King 96
HARNESS - main 70 LEVER 38 NAMEPLATE - TK 96
HARNESS - receptacle 84 LEVER - control 30 NAMEPLATE - Warning, Ether 96
HARNESS - relay 70 LEVER - injection control 48 NAMEPLATE - Wiring 84
HARNESS - sensor 68 LIFTER 30 NAMEPLATE - Wiring/Schematic
HARNESS - switch 70 LIFTER - engine 10 Diagram 96
HEAD - cylinder 8 LINER - service 6 NAMEPLATE- on/off 70
HEAD - fuel filter 42 LOCK - secondary 88 NIPPLE 60
HEATER - air 20, 68 LOCKWASHER 30, 42, 44, 46, 48, 50, NOZZLE 36
HEATER - frost plug 6 52, 54, 58, 64, 66, 70, NOZZLE - injection 28
HEATER - fuel 42, 60 78, 80, 82, 84, 86, 90, 92 NUT 8, 12, 16, 20, 22, 24, 26, 30, 34,
HINGE - door 90 42, 44, 46, 48, 50, 52,
HOLDER - brush 38 M 54, 58, 60, 62, 64, 66,
HOLDER - nozzle 36 MANIFOLD - exhaust 20 70, 78, 80, 82, 86, 90, 92
HOSE 42 MANIFOLD - intake 20 NUT - ball joint 30
HOSE - air cleaner 50 MARKSTRIP 70, 84 NUT - base 42
HOSE - drain 24 MODULE 70 NUT - captive 70, 84
HOSE - engine to radiator 54, 58 MOUNT - vibration 66 NUT - fitting 70
HOSE - fuel 44, 46 MUFFLER 50 NUT - ground 70
HOSE - fuel heater 60 NUT - harness & diode 48
HOSE - harness 78 N NUT - lever 30
HOSE - indicator to manifold 50 NAMEPLATE - 15 kW 96 NUT - nozzle case 36
HOSE - inj pump to water pump 24 NAMEPLATE - 460V 96 NUT - rectifier 78
HOSE - inlet 54, 60 NAMEPLATE - 80 gallons 44 NUT - solenoid 48
HOSE - oil drain 16 NAMEPLATE - arrow 96 NUT - terminal board 70
HOSE - outlet 54, 60 NAMEPLATE - Battery 80 NUTSTRIP 56
HOSE - overflow 54, 58 NAMEPLATE - California Proposition NUTSTRIP - control box 84
HOSE - pre-cleaner to air cleaner 52 96
HOSE - radiator to engine 54, 58 NAMEPLATE - Caution 96 O
HOSE & CLAMPS 28 NAMEPLATE - Caution 230 Volts 84, ORIFICE 26
HOUSING - flywheel 14 96 ORIFICE - radiator 54, 58
NAMEPLATE - Caution 460 Volts 84, O-RING 8, 34, 40, 70, 78
I 96 O-RING - cap 12
INDICATOR - air restriction 50 NAMEPLATE - Caution High Voltage O-RING - cover 8

INDEX - 2
 INDEX ALPHABETICAL BY DESCRIPTION

O-RING - dipstick 16 PROTECTOR - nozzle 8, 36, 40 SCREW - fan 64, 78

O-RING - fuel injection pump 40 PULLEY - crankshaft 18, 64 SCREW - field coil 38
O-RING - gear case 12 PULLEY - water pump 24, 64 SCREW - flange 10
O-RING - injection pump 12 PUMP 34 SCREW - gear 22
O-RING - inner 30 PUMP - feed 30 SCREW - ground 86
O-RING - joint 24 PUMP - fuel 34, 42 SCREW - hanger 54, 58
O-RING - lifter 30 PUMP - fuel injection 22, 26, 28, 30 SCREW - hinge 90, 92
O-RING - pipe 26 PUMP - injection 42 SCREW - housing 14
O-RING - plug 30 PUMP - water 24, 54, 58 SCREW - idler limit 32
O-RING - pump 30 SCREW - inlet 20
O-RING - solenoid 30 R SCREW - intake manifold 20
O-RING - stopper & eye bolt 30 RADIATOR 54, 58 SCREW - joint 24
O-RING - switch 16, 68 RECEPTACLE 74, 76, 82, 84 SCREW - lifter 10, 30
RECEPTACLE - assembly 74 SCREW - mounting 66
P RECTIFIER - negative 78 SCREW - muffler 50
PAD - expansion tank 54, 58 RECTIFIER - positive 78 SCREW - nozzle retainer 8
PAD - fuel heater 58 RELAY 70 SCREW - oil base 16
PAD - fuel tank 44, 46 RELAY - power 70 SCREW - oil pump 26
PAD - radiator 54, 58 RETAINER 34, 38 SCREW - orifice 54, 58
PANEL - bottom 94 RETAINER - nozzle 8 SCREW - pipe 26
PANEL - front 90, 94 RETAINER - nozzle spring 36 SCREW - plate 82
PANEL - lower, rear 90 RETAINER - shaft 30 SCREW - plug 14
PANEL - radiator 90 RETAINER - spring 10 SCREW - pointer 84
PANEL - rear 94 RETAINER - tube 28 SCREW - pouch 92
PANEL - rear right 90 RETAINER - valve 34 SCREW - pulley 64
PANEL - top 90 RING SET 18 SCREW - pump 24, 30, 32
PANEL - top, rear 90 RIVET - nutstrip 84 SCREW - receptacle 82, 84
PANEL - upper right 90 RIVET - panel 94 SCREW - retainer 28, 30
PIN 36, 76 ROD - connecting 18 SCREW - sensor/cover 44, 46
PIN - dowel 12, 14, 18, 66, 78 ROD - holddown 80 SCREW - solenoid 30
PIN - piston 18 ROD - push 22 SCREW - starter 38
PIN - sealing 76 ROD - speed control 48 SCREW - strap to engine 80
PIN - snap 34 ROTOR - inner 26 SCREW - strap to frame 80
PIN - spring 8, 18, 90 ROTOR - outer 26 SCREW - support 8, 28
PINION - assembly 38 SCREW - tank 54, 58
PIPE - breather 8 S SCREW - terminal board 84
PIPE - fuel injection 28 SADDLE 50 SCREW - thermostat 24
PIPE - oil 26 SCREEN 34 SCREW - tray 80
PIPE - oil pickup 26 SCREEN - strainer 42 SCREW - valve adjust 8
PISTON 18, 34 SCREW 42 SEAL 74
PLATE - baffle 8 SCREW - alternator 66 SEAL - cable 88
PLATE - receptacle 82 SCREW - angle 90 SEAL - copper 28
PLATE - stop 36 SCREW - base 42 SEAL - oil 12, 14
PLUG 6, 10, 20, 24, 26, 30, 74, 76 SCREW - blower 66 SEAL - valve stem 8, 40
PLUG - access hole 14 SCREW - box 84 SEAL - washer 26
PLUG - assembly 74 SCREW - bracket 26, 48, 50, 52, 54, SEALER - diode 48
PLUG - button 70 58, 66, 90 SEALER - thread 42, 44, 46, 66
PLUG - cavity 88 SCREW - bracket/clamp 52 SEAT - valve 10
PLUG - drain 16 SCREW - cam 22 SENSOR - fuel level 44, 46
PLUG - frost 6, 8 SCREW - case 12, 14 SENSOR - rpm 68
PLUG - fuse 44, 46 SCREW - chain 62 SENSOR - water level 56, 60
PLUG - pipe 6, 46 SCREW - clamp 42, 50, 60, 82, 84 SENSOR - water temperature 54, 58,
PLUNGER 48 SCREW - clip 16 68
POCKET - fork 92 SCREW - cover 8, 12, 38, 78, 84 SHAFT - idler gear 22
POINTER - voltage 84 SCREW - cylinder head 10 SHAFT - pinion 38
POUCH - Service Information Records SCREW - disc to flywheel 78 SHAFT - rocker arm 8
96 SCREW - door 90 SHAFT - water bleed 42
POUCH - service records 92 SCREW - elbow 50 SHIM 24
PRE CLEANER 52 SCREW - exhaust manifold 20 SHIM - 64

INDEX - 3
 INDEX ALPHABETICAL BY DESCRIPTION

SHIM SET 36 12
SHROUD - radiator 54, 58 TOOL - pin removal 88
SOCKET 74 TOOL - seal installer 14
SOLENOID 38, 48 TOOL - seal remover 14
SOLENOID - speed 68 TOOL - terminal crimper 88
SOLENOID - stop 30, 68 TOOL - wedge remover 76
SOLENOID - throttle 48 TRAY - battery 80
SPACER 6, 24, 64, 66 TUBE - exhaust 50
SPACER - clamp 52 TUBE - fuel feed line 44, 46
SPACER - fan 78 TUBE - sponge 8
SPEEDI SLEEVE - front seal 12, 18
SPRING 8, 26, 34 U
SPRING - brush 38 U-BOLT 50
SPRING - lever 30
SPRING - nozzle 36 V
SPRING - piston 34 VALVE 28, 34
SPRING - valve 8 VALVE - check 26
SPUD - fuel filter 42 VALVE - exhaust 8
STARTER 38, 68 VALVE - fuel injection 36
STOPPER 30 VALVE - intake 8
STOPPER - pinion 38 VALVE - oil drain 16
STRAINER - fuel 42 VENT - ball check 44, 46
STRAP - ground 80
STRAP - tank 44, 46 W
STRIP - gasket 84 WASHER 8, 18, 22, 44, 54, 58, 64
STUD - exhaust manifold 20 WASHER - belleville 66
STUD - fan spacer 64 WASHER - nylon 90
STUD - fuel pump 12, 34 WASHER - sealing 12, 24, 26, 30, 40
STUD - housing 78 WASHER - special 66, 90, 94
STUD - injection pump 12 WEDGE 74
STUD - mounting 66
STUD - valve cover 8 Y
SUMP - oil 16 YOKE - assembly 38
SUPPORT - pouch 92, 96
SUPPORT - pump 28
SUPPORT - rocker arm 8
SWITCH - oil level 16, 68
SWITCH - oil pressure 68
SWITCH - on/off 70

T
TAB - chain 84
TAB - mounting 76
TANK - expansion 54, 58
TANK - fuel 44, 46
TANK - overflow 54, 58
TAPPET 22, 34
TEE 60
TERMINAL 88
TERMINAL - female 88
TERMINAL - male 88
TERMINAL - pin 74, 82
TERMINAL - ring 82
TERMINAL - socket 74
TERMINAL - solenoid 48
TESTER - compression 28
THERMOSTAT 24
TOOL - crimper 76
TOOL - injection pump gear remover

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 53725­4-PM

©2011 Ingersoll Rand Company

Printed in U.S.A.