PARTS MANUAL MOBILE POWERSOURCE GENERATOR

Doosan 1293 GleStatesvilwww.doo

Book 22

Doosan pu2007. Anyservice mato Ingersoin nature,Ingersoll-either.

Revis

PARTS MANUAL

MOBILE POWERSOURCE GENERATOR

G10 50Hz

Infracore Portable Powernway Drive

le, NC 28625-9218sanportablepower.com

rchased Bobcat Company from Ingersoll-Rand Company in reference to Ingersoll-Rand Company or use of trademarks,rks, logos, or other proprietary identifying marks belongingll-Rand Company in this manual is historical or nominative and is not meant to suggest a current affiliation betweenRand Company and Doosan Company or the products of

926166 Revision E (6/08)

ed (01-13)

TABLE OF CONTENTSParts Book

TITLE PAGEParts List

Engine and Engine Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Engine Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Cooling System Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Cooling System Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Engine Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Exhaust Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Alternator, Alternator Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Alternator, Alternator Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Enclosure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Enclosure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Foam Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Fuel Tank & Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Fuel Tank Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Central Drains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Control Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Control Panel - Standard Sockets - 1 Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Control Panel - UK Sockets - 3 Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Control Panel - UK Sockets - 3 Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Control Panel - CE Sockets - 3 Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Decal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Forklift Skid Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Fuel / Water Separator Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Recommended Spares & Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Recommended Spares & Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Wiring Diagrams

1 Phase, AC Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 891 Phase, DC Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903 Phase, AC Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 923 Phase, DC Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

2

**Always use Ingersoll Rand Replacement parts!**

4

GENERAL

This publication, which contains an illustrated parts breakdown, has been prepared as an aid in locating those parts which may be required in the maintenance of the unit. Always insist on genuine Ingersoll Rand branded parts for your unit.

Doosan Infracore Portable Power can bear no responsibility for injury or damages resulting directly from the use of non-approved repair parts.

Portable Power service facilities and Ingersoll Rand parts are available worldwide. Consult local yellow pages or visit: www.dooasnportablepower.com.

Special order parts may not be included in this manual. Contact the Portable Power Parts Department with the unit serial number for assistance with these special parts.

Description

The illustrated parts breakdown illustrates and lists the various assemblies, subassemblies and detailed parts which make up this particular machine. This covers the standard models and the more popular options that are available.

In referring to the rear, the front or to either side of the unit, always consider the drawbar end of the unit as the front.

Standing at the rear of the unit facing the drawbar (front) will determine the right and left sides.

Fasteners

Both SAE/inch and ISO/metric hardware have been used in the design and assembly of these units. In the disassembly and reassembly of parts, extreme care must be taken to avoid damaging threads by the use of wrong fasteners.

How To Order

Always specify the model and serial number of the unit.

Specify the part number and description.

Parts List

57

Engine and Engine Mounting

22926166_060_06/08_B

ITEM COMM. NO. DESCRIPTION QTY DIMENSIONS/NOTES

1 22755177 Engine 12 22662258 Engine Mounting Bracket, LH 13 96729595 Screw, Hex 8 M8 - 1.25 X 304 22662266 Engine Mounting Bracket, RH 15 96730411 Screw, Hex 2 M16 - 2.0 X 756 36899037 Washer, Snubbing 27 36875565 Isolator 28 35273366 Nut, Hex 2 M10 - 1.59 35279025 Screw, Tapping 4 M8 - 1.25 X 20

10 22806400 Support, Engine 111 22662282 Radiator Bracket Support 112 35279025 Screw, Tapping 4 M8 - 1.25 X 2013 22611610 Plate, Relay Mounting 114 96749627 Screw 2 M12 - 1.25 X 1615 22607436 Wiring Harness, Engine (Not Shown) 116 35578194 Strap, Ground 1 14”17 96749627 Screw, Tapping 1 3/8 - 16 X 1.0

2

4

13

6

7

511

8

12

9

3

1

10

1416

17

14

58 22926166

f2

Engine Spare Parts

fuel filter 85426815oil pump,

22926166_061_05/06_A


54757935 Oil Pressure Switch 122554224 Water Temperature Switch 122741714 Washer, Sealing, (Temp. Switch) 1

fan rotor 22754006

water pump assy 22845127

an cooling 2844971

fuel/water filter 54525506

oil filter 85426849

v belt 22844526

thermostat 22844443

injector 85400216

starter motor 22843965

alternator 22843585

fuel pump 22671747

engine 23054695

59

Cooling System Parts

22926166_062_05/06_A


1 22662357 Radiator 12 22662332 Plate, Radiator Mounting 23 96702824 Screw, Hex 44 22278360 Sandwich Mount 35 95923298 Nut 66 22702674 Fan Guard, Left 17 22702682 Fan Guard, Right 18 22662365 Shroud, Fan 19 22806947 Adapter 1

10 35369511 Hose Fitting 211 22702690 Support, Guard 112 22843312 Hose, Radiator Top 113 22843320 Hose, Radiator Bottom 114 22671721 Clamp, Hose 215 22671739 Clamp, Hose 2

Continued on next page

2

54

313

15

1

9

11

6

8

14

16

17

17

20

18

20

10

4

12

7

21

5

radiator cap 85623718

60 22926166

Cooling System Parts

22926166_062_05/06_A

ITEM COMM. NO. DESCRIPTION QTY DIMENSIONS/NOTES.....Continued

16 36884948 Bottle, Coolant Recovery 117 35296342 Clamp, Hose 218 35360775 Hose, Fuel ( 36 inches ) 119 96701461 Screw 5 M6 - 1.0 X 2520 36898104 Nut 5 M6 - 1.021 23037849 Bracket, Coolant Recovery 1

2

54

313

15

1

9

11

6

8

14

16

17

17

20

18

20

10

4

12

7

21

5

61

Engine Air Intake

22926166_064_06/08_B


1 22173561 Air Cleaner Assembly 12 36890135 Element, Air Filter (Not Shown) 13 54564737 Hose, Air Intake 14 95953493 Nipple 1 1/8” X 3/4”5 35314939 Indicator, Restriction 16 96702824 Screw 27 35221662 Clamp 2

1

3

5 4

7

6

62 22926166

Exhaust Assembly

22926166_065_05/06_A


1 22892699 Muffler, Exhaust 12 35846484 Cap, Rain 13 36881886 Nut, Hex Flange 4

3

2

1

63

Battery

22926166_066_05/06_A


1 22890628 Battery Module 12 22662183 Bracket, Battery Mounting 13 22494983 Angle 14 23050982 J-Bolt 2 8.5”5 36853265 Washer, Plastic 26 35144492 Nut, Hex 27 35279025 Screw, Tapping 48 35582410 Cable, Battery Positive 19 36780609 Cable, Battery Negative 1

10 22730972 Cable, Jumper (From Switch to Starter) 111 36896975 Switch, Battery Disconnect 1

3

2

7

6

1

4

9

8

10

11

64 22926166

Alternator, Alternator Mounting

22926166_067_05/06_A


1 22757322 Alternator, LSA 422S4 50 Hz 12 22662290 Support, Alternator 13 96740782 Screw, Hex 2 M12 - 1.75 X 904 22429641 Isolator 25 54429295 Washer, Snubbing 26 35304047 Nut 27 35279025 Screw, Tapping 4 M8 - 1.25 X 208 96708037 Bolt, Engine-Generator 8 M8 - 1.25 X 169 96741970 Bolt, Drive Disk 8 M10 - 1.25 X 30

10 22878615 Alternator Wire Assembly, 1Phase (Not Shown) 122878607 Alternator Wire Assembly, 3Phase (Not Shown) 1

11 22742563 Plate, Isolator 2

6

7

5

2

3

9

1

4

8

711

not in BOM?

36783488 strap ground

65

Alternator, Alternator Mounting

22926166_068_06/08_B


1 85425882 Bearing 12 85509032 Wavey Washer 13 85508893 Wound Exciter Field 14 85402451 Voltage Regulator 15 85425965 Drive Disc LSA 422S4 16 85425858 Diode Bridge Assembly 17 85425866 Surge Suppressor 18 85508992 O-Ring 19 22754006 Fan 1

10 85626968 Fuse, AVR (Not Shown) 111 22980031 Tie-Rods12 22980049 Stud Terminal Blocks (Not Shown)13 22980072 Stud Nuts (Not Shown)

4

5

7

1 8 23

6

NSS

NSS

NSS

NSS

9 11

66 22926166

part nvalve

Enclosure Assembly

22926166_069_06/08_B


1 22800783 Hose Fitting 12 22219026 Connector, Bulkhead 23 22647325 Baffle, Radiator 14 22647366 Angle, Door 2

4A 36797652 Screw, Tapping 85 22312409 Cover, Radiator 16 22647291 Door, Side 27 36793602 Latch Door 1

7A 36794816 Rivet 88 22806681 Handle, Latch 29 23051410 Panel, Rear 1

10 22806566 Panel, Center, LH 110A 36797652 Screw, Tapping 1211 22647309 Panel, Center, RH 1

11A 36797652 Screw, Tapping 12

Continued on next page

78 7A

1313A

10 10A

15 15A

9

3

11 11A

2

1

16

44A

1212A

5

6

17

1414A

?

umber for required

drawing missing grill

67

Enclosure Assembly

22926166_069_06/08_B


12 22647077 Panel, Exhaust Grill 112A 36797652 Screw, Tapping 1013 22647101 Panel, Front 1

13A 36797652 Screw, Tapping 1414 22647085 Panel, Side, Front 2

14A 36797652 Screw, Tapping 815 22875181 Panel, Side, Rear 2

15A 36797652 Screw, Tapping 1216 22892921 Panel, Roof 117 22892566 Frame G10 1

78 7A

1313A

10 10A

15 15A

9

3

11 11A

2

1

16

44A

1212A

5

6

17

1414A

?

68 22926166

Foam Assembly

22926166_071_05/06_A


1 22704993 Foam, Exhaust Baffle 42 22705008 Foam, Side Door 2

2

1

missing foam panels are required in revised manual

FOAM SHEETS

Supplying foam sheets for current Doosan Portable Power Products is a very time consuming process, even more so for old machines. Due to such small quantities involved it proves very expensive and time consuming process. To address this problem Doosan Portable Power offer complete foam sheets ex stock from which the customer can cut to their own individual application. PART NUMBER SIZES 92949742 1.9m x 1.5m x 25mm thick (7' x 5' x 1” thick) 92949759 .95m x 1.5m x 25mm thick (3' x 5' x 1” thick) 92949767 1.9m x 1.5m x 50mm thick (7' x 5' x 2” thick) 92949775 .95m x 1.5m x 50mm thick (3' x 5' x 22 thick)

69

Fuel Tank & Hardware

22926166_072_06/08_B


1 22662415 Fuel Tank Assembly 12 36845022 Strainer, Fuel Tank 13 36845014 Cap, Fuel Filler 14 22783245 Bracket, Tank Mounting 25 22765523 Bracket, Tank Mounting 26 22765549 Bracket, Tank Mounting 17 22785539 Bracket, Tank Mounting 1

7A 36889608 Screw, Hex 4 M8 - 1.25 X 257B 36881886 Nut, Hex 4 M8 - 1.257C 22959936 Screw, Tapping 4 M8 - 1.25 X 208 22580351 Containment Level Switch 19 22616353 U-Bolt 2

10 95923298 Nut, Self Locking 411 22580336 Bracket, Switch 112 96738802 Screw, Tapping 613 54525506 Fuel/Water Separator Filter 114 22630628 Bracket, Fuel/Water Separator 215 22747380 Fuel Tank Gauge 116 22585111 Pad, Fuel Tank 3

4

8

9

12

10

11

15

5

14

13

2

3

6

7

7A

7B

7C

1

16

error, switch not fitted

70 22926166

Fuel Tank Piping

22926166_073_06/08_B


1 95992392 Plug 12 35378538 Elbow, Barbed (Fuel Feed) 13 95940748 Bushing (Fuel Feed) 14 35363506 Elbow, Barbed (Fuel Return) 15 35369339 Connector, Female 26 35369347 Connector, Male 27 35356484 Tubing 2 24”8 35322395 Silencer 29 35363498 Hose, Pick Up to Pump (Not Shown) 1 8”

10 35363498 Hose, Pump to Engine (Not Shown) 2 22”11 35363498 Hose, Return (Not Shown) 2 25”12 35253038 Clamp, Hose 213 92368687 Screw, Tapping 2 M6 - 1.0 X 1414 35296342 Clamp (Not Shown) 8

7

6

513

12

8

7

6

513

12

8

3

2

1

4

71

Central Drains

22926166_075_05/06_A


1 35363498 Hose 1 10”2 35296342 Clamp 23 95928222 Plug 24 35306125 Hose Assembly 15 35283126 Connector 16 22686133 Elbow 17 22375141 Valve 28 95092318 Nipple 29 22219026 Bulkhead Fitting 2

10 35369511 Adapter 111 22800783 Adapter 112 22806947 Adapter 1

RADIATOR6

4

2

1

8

3

3

9

8

7

5

10

12

2

11

7

9

72 22926166

Control Panel Assembly

22926166_076_05/06_A


1 22857932 Control Box 12 22857817 Control Panel, 3 Phase CE Sockets 1

22881585 Control Panel, 1 Phase Stnadard 123129729 Control Panel, 1 Phase, 3 Phase UK Sockets 1

2

1

standard

73

Control Panel - Standard Sockets - 1 Phase

22926166_077_06/08_B


1 22127385 Switch, Start 12 22578447 Controller, Electronic 13 22650451 Socket, 16A, 230V 14 22672471 Voltmeter 15 22681373 Socket, 16A, 230V 16 22688717 Switch, E-Stop 17 22711865 Module, 2 Warning Lights 18 22780985 Hourmeter, 100,000 Hr 19 22857932 Control Box 1

10 22862486 Bracket 111 22881262 Assembly, DIN rail 112 22881288 Breaker 113 22881585 Panel, Control 114 22881643 Decal, Control Panel 115 22881700 Ampermeter 116 22894273 Label, E-Stop 117 36889608 Screw 1 M8 - 1.25 X 25

1

2

3

4

5

679 10

11

12

13

14

15

17 16 8

74 22926166

Control Panel - UK Sockets - 3 Phase

22926166_077_06/08_B

ITEM COMM. NO. DESCRIPTION QTY DIMENSIONS/NOTES1 22127385 Switch, Start 12 22578447 Controller 13 22650444 Socket, 16A, 400V 14 22650469 Socket, 32A, 400V 15 22666093 Bridge, PE 16 22672471 Voltmeter 17 22681431 Breaker, Circuit 18 22688717 Switch, E-Stop 19 22711865 Module, 2 Warning Lights 1

10 22734859 Rail, DIN 111 22747893 Ammeter 112 22750970 Terminal, Lock 513 22780985 Hourmeter, 100,000 hr 114 22862155 Dinrail Assembly 115 22885768 Breaker, Circuit 1

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20 21

22 23

24 25 26 27

28

29

30

75

Control Panel - UK Sockets - 3 Phase

22926166_077_06/08_B

ITEM COMM. NO. DESCRIPTION QTY DIMENSIONS/NOTES16 22894273 Label, E-Stop 117 22966089 Ampermeter 118 22967970 Breaker, RCD 119 23059637 Socket, 16A, 110V 220 23109549 Relay, Overcurrent 121 23109556 Contactor, 25A 122 23129729 Panel, Control 123 23129745 Decal, Control Panel 124 23133986 Box, Control 125 23134075 Bracket 126 23134083 Rail, DIN 127 23135866 Breaker, Circuit 128 23137227 Cover, Power Pedestal 129 36889608 Screw 1 M8 - 1.25 X 2530 96705058 Screw 8 M6 - 1.0 X 12

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20 21

22 23

24 25 26 27

28

29

30

76 22926166

Control Panel - CE Sockets - 3 Phase

22926166_077_06/08_B

ITEM COMM. NO. DESCRIPTION QTY DIMENSIONS/NOTES1 22127385 Swwitch, Start 12 22578447 Controller 13 22650444 Socket, 16A, 400V 14 22650451 Socket, 16A, 230V 15 22672471 Voltmeter 16 22681373 Socket, 16A, 230V 17 22688717 Switch, E-Stop 18 22711865 Module, 2 Warning Lights 19 22747893 Switch, Ammeter 1

10 22780985 Hourmeter, 100,000 hr 111 22857817 Panel, Control 112 22857932 Box, Control 113 22857965 Breaker 114 22862155 Assembly, Dinrail 115 22862486 Bracket 116 22862874 Decal, Control Panel 117 22966089 Ampermeter 118 36889608 Screw 1 M8 - 1.25 X 2519 22894273 Label, E-Stop 1

1

2

3

4

5

6

78

9

101112 13

14

15

16

17

18 19

77

Decal Location

22926166_078_06/08_B

ITEM COMM. NO. DESCRIPTION QTY DIMENSIONS/NOTES1 93171254 Decal, Diesel Fuel 12 23047566 Decal, No Water 23 92867449 Decal, Refer to Manual 14 92930593 Decal, Hazardous Voltage 15 93171262 Decal, Lift Point 26 92912559 Decal, Earth Warning 17 23047608 Decal, No Flame 18 23047582 Decal, Crush Hazard 29 54642327 Decal, Battery Disconnect 1

10 23047624 Decal, Coolant Level 111 22873681 Decal, IR Side Logo 212 22895247 Decal, IR Front Logo 113 22762512 Decal, 12” Powersource 214 22810634 Decal, G10 Model 215 22916720 Decal, IR Powered 116 22713648 Decal, IR Logo 22” Rear 117 23250756 Data plate 50Hz (Not Shown) 1

36794816 Rivet 218 23062893 Decal, 91dB Sound Power (Not Shown) 2

4

1

9

7

11

12

13

14

11

15

10

2

28

8

1314

3

5

5

6

16

78 22926166

Frame Assembly

22926166_079_06/08_B


1 22892566 Frame, Nova G10 12 23131279 Lifting Bail, Top 13 36880995 Screw, Hex 84 36879195 Nut, Hex Flange 85 23131287 Lifting Bail, Side 26 22668677 Plate, Lifting 1

6A 23138985 Eyebolt 16B 96720933 Nut, Hex Flange 1 1” - 87 36880995 Screw 48 36879195 Nut 4

23140866 Lift Bail Assembly 1

1

4

3

6

5

2

6A 6B

8

7

?

?9

22668677 lifting plate, not shown

switch number?

79

Forklift Skid Option

22926166_079_06/08_B


1 22828123 Skid, Forklift 12 36879302 Screw 4 M16 - 2.0 X 503 36879211 Nut 4 M16 - 2.0

1

4

3

6

5

2

6A 6B

8

7

wrong drawing insert skid drawing is 22828123

80 22926166

Fuel / Water Separator Option

22926166_074_06/08_B


1 54480512 Head Assembly 12 35358381 Cover, Check Ball 13 54480520 Plug, Vent 14 54525530 Element Assembly, Fuel/Water 15 54480504 Bowl 16 54525506 Fuel/Water Separator Filter Assembly - Complete 17 22630628 Bracket, Fuel / Water Separator 18 35279025 Screw, Tapping 2 M8 - 1.25 X 209 36889608 Screw 2 M8 - 1.25 X 25

10 36881886 Nut 2 M8 - 1.25

1

2

3

4

5

6

7

8

9

10

3

2

81

Recommended Spares & Service Kits


RECOMMENDED SPARE PARTS

CLASS 1: RECOMMENDED MAINTENANCE AND REPAIR ITEMS

89311716 Oil Protec 15W4085426815 Fuel Filter Primary54525530 Element Assembly, Fuel/Water85426849 Oil Filter36890135 Air Filter Element22843346 Cap, Radiator22843312 Upper Radiator Hose22843320 Lower Radiator Hose22844526 Fan Belt54757935 Oil Pressure Switch22554224 Water Temperature Switch22842736 Solenoid Assembly22843270 Thermostat22843759 Gasket, Rocker Cover22688717 Emergency Stop Switch44003929 250 Hr. Maintenance Kit - Without Fluids44003937 500 Hr. Maintenance Kit - Without Fluids

CLASS 2: PARTS REQUIRED TO PREVENT EXTENDED DOWNTIME IN REMOTE LOCATIONS

85400216 Injector22843965 Starter22843585 Charging Alternator22671747 Electric Fuel Pump85400612 Glow Plug22845127 Water Pump22757322 AC Alternator Assembly85626968 Fuse Voltage Regulator85402451 Automatic Voltage Regulator85425882 Bearing85509032 Wavy Washer85425858 Diode Bridge85425866 Surge Suppressor22754006 Alternator Cooling Fan22980031 Tie Rods22578447 Control Module, CM22711865 Module Warning22127385 Start Switch S122672471 Voltmeter, M522881700 Ammeter 1Ph, M622966089 Ammeter 3Ph, M6

Continued.....

qty?

alternator

82 22926166

Recommended Spares & Service Kits


CLASS 2: PARTS REQUIRED TO PREVENT EXTENDED DOWNTIME IN REMOTE LOCATIONS

23161466 Fuse, F1, F2, 1 Amp36793651 Fuse, F4, 25 Amp22780134 Fuse, F5, 250MA22881668 Circuit Breaker 1Ph, CB122967970 Circuit Breaker 3Ph, CB122885768 Circuit Breaker 3Ph, CB222511505 Relay 70 Amp 12VDC, K1 K222780985 Hour Meter M122747315 Shunt Trip Relay ST

not in the BOM

83

84 22926166

86 22926166

Wiring Diagrams

87

89

ram

PHASE VOLTAGEL-L 230L-M 115

L LM

2 6

3

8

115

1 4 7 10

9

12FF

0V

M6AC Amps

M5AC VOLTS

CB140A

RCDRCD 30mA

1041 3N

117A

2 4N

262

EM-4

GND

210 211

F11A1A

212

211A220A

261

263

4mm

0.75mm

0.75mm

RI2k2/2W

CB1-ST

0.75mm

0.75mm

1 Phase, AC Wiring Diag

X2 Z1 X1 Z2 E+ E- SH 230V

AVRR438LSE- E+ X1 X2 Z1 Z2

EXCITATION WIRING

TI (L)TI0 (L)

PE

NL

PE

NL

PE

NL

ALTERNATOR LSA 42.2 S4

X416ACE

X316ACE

X216A

SCHUCKO

PEBRIDGE

4N2

1 3NCB416A

256 255

2.5mm

4N2

1 3NCB316A

254 253

2.5mm

4N2

1 3NCB216A

252 251

2.5mm

1 2 6

4

OPTION

230B230C

230D

PE

230220210

5 3

7 8 12

10 11 9

PE

PENL

4mm

2.5mm

230A

4mm

1P+N 10mm BUS BAR

T1T9T3

SUPBLK

WHITE

BLKBLK

BLU

90

ram

F5A B

116

18111(+)

+

-

M1HOURMETER

126

128A128

101

131

DS1HIGHENG TEMP

DS2LOWOILPRESSURE

+ +

10

S2HIGHENGINECOOLANTN.C.

5

50

31

4

7

6

18

P3-3

P3-8

P3-7

P3-1

P3-5

P3-9

P3-10

P3-11

P3-13

P3-12

P3-4

P3-14

P5

WHT

VIO

BLU

YEL

BRN

WHT

ORN

BRN

BLU

GRY

WHT

9

80

26

8

12

GRY

WHT

BRN

S3ENGINEOILPRESSURE

C

C

16

03

9

10

12

3120

114

117

121

122

31C

16

31B

80B

PULLWHITE

HOLDRED

L1FUELSOLENOID

NEUTRALBLACK

FP1FUELPUMP

118

80A

250MA

CB1-ST

117A

12

NODE

SP1

1 Phase, DC Wiring Diag

102

P3-15

130

RED

1

12

B

A

F425A

30C

12RED

30B

30 86K1START ORSAFETY RELAY

30A 87 85

8 BRN050

12RED

12RED YEL

8RED

4RED

S6BATTERY

4RED

BT1BATTERY

12V4

BLK31

B1STARTERMOTOR

30

50YEL

30C

P3-6

16BLU

05786 30 K2

ENGINEINTAKEHEATER

85 87

58

12BLU

16BRN

31A

1

2

R1ENGINEGLOWPLUGHEATER

VIOP4

B+ P ORN

6

31G

G1ALTERNATOR

R

L

7

16

18

CM P2

LED VOLTS

LOW COOL LED

ENG TEMP LED

ENG OIL PR LED

LOW FUEL LED

CONTAIN LED

12

34

56789101112

ALT-S (TACH)

FUEL LVL SW IN

CONTAIN LVL OK

P1

FUEL SOL

ALT-R(IG)

HOURMETER

FUEL PULL-IN

ENG OIL OK

CRANK

STARTER COIL

ALT-L

12V/LOW COOL

GND/ENG BLK

LOW COOL OK

ENG TEMP SW

ENG TEMP OK

ENG OIL PR SW

ALT-S/TACH

12V IN

12V SW

12V/CONTAIN SW

START COIL GND

HRMTR GND

GND

1234

56789

101112

13141516

17181920212223

111(+)

1

10

1

1

11

125

126

128

101

131

AC

116

118

S

POS

+ -

30D

31A31B 31C

P3-2 30D

14RED

M5X0.8

AC

0FF

B+C+D

B+C

A

B

S1STARTSW

119

1

2

12

EM

3

4 EM

12

18CB1-ST 104 PINK

ORN102A

RED

18

ONPREHEATSTART

BB+C

B+C+D

16

150

18

150

18

92

ram

230 W−N, L3−N 230V−N, L2−N230U−N, L1−N400U−W, L1−L3400V−W, L2−L3400U−V, L1−L2

230/400PHASE

L3

L2 L1

N

CT3

7

10

1

4

11

85

2

12

96

3

D

V

W

U

380V 0V

251

252253

254255

256

64

3 5

2

1

8N

7N

3 51 7N

4 62 8N

P2

P1

S2S1

S11AMMETER

SWITCH

0

1

2

3

M6AC AMPS

2

9259

260

2.5mm

2.5mm

18

17

8

3

1

6

0.75mm

M5AC VOLTS

F1 − F21A

222

212

0.75mm

210A

220A

261104

117A262

EM−4

GND

0.75mm

0.75mm

RI2k2/2W

CB1−ST

CT2 CT1

CB220A

6kA/B

CB125ARCD

RCD 30mA

T1 − CT3URRENTSFORMERS

263

3 Phase, AC Wiring Diag

22926166_087_02/06_A

T1T9T3

SUPBLK

WHITE

BLKBLK

EXCITATION WIRING

E− E+ X1 X2 Z1 Z2 AVRR438LS

X2 Z1 X1 Z2 E+ E− SH

1 3 2

4 6 5

7

10 12 11

89

T10(N)BLU

T2(L2)

T3(L3)

PE

L1 L2 L3 N PE

210 220 230 280 240

2.5mm

PE

L3L2

PE

NL

PE

NL

X316A

X416ACE

X516A

SCHUCKO

PEBRIDGE

64

3 5CB316A

271 272

2.5mm

274 275 276 277

2

1

8N

7N

4N2

1 3NCB416A

2.5mm

4N2

1 3N

CB516A

2.5mm

2.5mm

270 273

L1 N

240B

240C

240A

240D2.5mm

3F+N 10mm BUS BAR

ALTERNATOR LSA 42.2 S4

281231

221

CC

TRAN

281A

2.5mm PE

93

ram

F5A B

116

18

111(+)

+

−

M1HOURMETER

126

128A128

101

131

DS1HIGHENG TEMP

DS2LOWOILPRESSURE

+ +

10

S2HIGHENGINECOOLANTN.C.

5

50

31

4

7

6

18

P3−3

P3−8

P3−7

P3−1

P3−5

P3−9

P3−10

P3−11

P3−13

P3−12

P3−4

P3−14

P5

WHT

VIO

BLU

YEL

BRN

WHT

ORN

BRN

BLU

GRY

WHT

9

80

26

8

12

GRY

WHT

BRN

S3ENGINEOILPRESSURE

C

C

16

11(+)

103

109

110

112

113120

114

117

121

122

125

126

128

101

131

31C

SP1

16

31B

80B

PULLWHITE

HOLDRED

L1FUELSOLENOID

NEUTRALBLACK

FP1FUELPUMP

118

80A

250MA

CB1−ST

117A

12

NODE

3 Phase, DC Wiring Diag

22926166_088_02/06_A

18

18

150

102

P3−15

130

12

RED

1

2

1

12

B

A

F425A

30C

12

RED

30B

30 86K1START ORSAFETY RELAY

30A 87 85

8BRN

05012

RED

12

RED YEL

8RED

4RED

S6BATTERY

4RED

BT1BATTERY

12V4

BLK31

B1STARTERMOTOR

30

50YEL

30C

P3−6

16BLU

057

86 30K2ENGINEINTAKEHEATER

85 87

58

12BLU

16BRN

31A

1

2

R1ENGINEGLOWPLUGHEATER

VIO

P4

�� P ORN

6

31G

G1ALTERNATOR

R

L

7

16

18

CM P2

LED VOLTSLOW COOL LED

ENG TEMP LED

ENG OIL PR LED

LOW FUEL LED

CONTAIN LED

1

2

34

5

6

7

8

9

1011

12

ALT−S (TACH)FUEL LVL SW IN

CONTAIN LVL OK

P1

FUEL SOL

ALT−R(IG)

HOURMETER

FUEL PULL−IN

ENG OIL OK

CRANK

STARTER COIL

ALT−L

12V/LOW COOL

GND/ENG BLKLOW COOL OK

ENG TEMP SW

ENG TEMP OK

ENG OIL PR SWALT−S/TACH

12V IN

12V SW12V/CONTAIN SW

START COIL GND

HRMTR GNDGND

1

2

3

4

5

6

7

8

9

10

11

12

1314

15

16

17

18

192021

22

23

1

AC

116

118

S

POS

+ −

30D

31A

31B 31C

12

EM

P3−230D

14RED

M5 X 0.8

AC

0FF

��

��

A

�

S1STARTSW

119

16

3

4 EM

18CB1−ST 104 PINK

ORN102A

18

ONPREHEATSTART

��

��

RED

150

WORD INDEX

CPN250 Hr. Maintenance Kit - Without Fluids . . . . . . . 83500 Hr. Maintenance Kit - Without Fluids . . . . . . . 83

AAC Alternator Assembly . . . . . . . . . . . . . . . . . . . . 83Air Cleaner Assembly . . . . . . . . . . . . . . . . . . . . . . 62Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . 83Alternator

LSA 422S4 50 Hz . . . . . . . . . . . . . . . . . . . . . . 65Alternator Assembly . . . . . . . . . . . . . . . . . . . . . . . 49Alternator Cooling Fan . . . . . . . . . . . . . . . . . . . . . 83Alternator Wire Assembly

1Phase (Not Shown) . . . . . . . . . . . . . . . . . . . 653Phase (Not Shown) . . . . . . . . . . . . . . . . . . . 65

Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Ammeter 1Ph

M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Ammeter 3Ph

M6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Ampermeter . . . . . . . . . . . . . . . . . . . . . . . 75, 77, 78Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Assembly

DIN rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Dinrail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Automatic Voltage Regulator . . . . . . . . . . . . . . . . 83

BBaffle

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Ball

Steel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 18Battery Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Bearing

Radial Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Bearing Set

0.25 Undersized . . . . . . . . . . . . . . . . . . . . . . . 200.50 Undersized . . . . . . . . . . . . . . . . . . . . . . . 200.75 Undersized . . . . . . . . . . . . . . . . . . . . . . . 20Connecting Rod

0.25 Oversized . . . . . . . . . . . . . . . . . . . . . 250.50 Oversized . . . . . . . . . . . . . . . . . . . . . 250.75 Oversized . . . . . . . . . . . . . . . . . . . . . 25Standard . . . . . . . . . . . . . . . . . . . . . . . . . 25

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Belt

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Block

Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Block Assembly

Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Block Sub Assembly

Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Body Sub Assembly . . . . . . . . . . . . . . . . . . . . . . . 38

BoltAlternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Bearing Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 16Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . 25Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . 11Drive Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Engine-Generator . . . . . . . . . . . . . . . . . . . . . . 65Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 49Governor Case . . . . . . . . . . . . . . . . . . . . . . . . 42High Speed Set . . . . . . . . . . . . . . . . . . . . . . . . 40Low Idle Set . . . . . . . . . . . . . . . . . . . . . . . . . . 41Rocker Bracket . . . . . . . . . . . . . . . . . . . . . . . . 13Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Washer Head . . . . . . . . . . . . . . . . . . . . . . . . . 44with Washer 11, 14, 15, 21, 22, 23, 29, 34, 35, 36, 37, 39, 42, 46, 47

Bolt AssemblyHigh Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

BottleCoolant Recovery . . . . . . . . . . . . . . . . . . . . . . 61

Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Box

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 77, 78Bracket

Battery Mounting . . . . . . . . . . . . . . . . . . . . . . . 64Coolant Recovery . . . . . . . . . . . . . . . . . . . . . . 61Fuel / Water Separator . . . . . . . . . . . . . . . . . . 82Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Fuel/Water Separator . . . . . . . . . . . . . . . . . . . 71Rocker Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 13Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Tank Mounting . . . . . . . . . . . . . . . . . . . . . . . . 71

Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 78Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76, 77RCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

BridgePE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Bulkhead Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Bushing

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Knock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Bushing (Fuel Feed) . . . . . . . . . . . . . . . . . . . . . . . 72

CCable

Battery Negative . . . . . . . . . . . . . . . . . . . . . . . 64Battery Positive . . . . . . . . . . . . . . . . . . . . . . . . 64Jumper (From Switch to Starter) . . . . . . . . . . . 64

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

95

WORD INDEX

CapBearing Front . . . . . . . . . . . . . . . . . . . . . . . . . 16Bearing No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . 16Bearing No. 3 . . . . . . . . . . . . . . . . . . . . . . . . . 16Bearing Rear . . . . . . . . . . . . . . . . . . . . . . . . . 17Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . 25Fuel Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Oil Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Rain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Sealing . . . . . . . . . . . . . . . . . . 10, 13, 16, 17, 18Torque Set . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Valve Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Vinyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Cap Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Cap Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Cap Set

Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Case

Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Case AssemblyGovernor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Charging Alternator . . . . . . . . . . . . . . . . . . . . . . . . 83Circuit Breaker 1Ph

CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Circuit Breaker 3Ph

CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84CB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

ClampFilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Hose . . . . . . . . . . . . . . . . . . . . . . . 52, 60, 61, 72

Clamp (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . 72Clamp A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Clamp B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37CLASS 1

RECOMMENDED MAINTENANCE AND REPAIR ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

CLASS 2PARTS REQUIRED TO PREVENT EXTENDED DOWNTIME IN REMOTE LOCATIONS . . 83, 84

ClipHose . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 37, 39

Cock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Collar

Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Connector

Bulkhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Male . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Contactor25A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Containment Level Switch . . . . . . . . . . . . . . . . . . 71Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . 74, 75

Control ModuleCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Control Panel1 Phase

3 Phase UK Sockets . . . . . . . . . . . . . . . . 741 Phase Stnadard . . . . . . . . . . . . . . . . . . . . . . 743 Phase CE Sockets . . . . . . . . . . . . . . . . . . . . 74

Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76, 78Electronic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

CoverCheck Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Governor Shaft . . . . . . . . . . . . . . . . . . . . . . . . 41Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Power Pedestal . . . . . . . . . . . . . . . . . . . . . . . . 77Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Torque Set . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Cover AssemblyInlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26C-Ring

High Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Torque Set . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

DData plate 50Hz (Not Shown) . . . . . . . . . . . . . . . . 79Decal

12” Powersource . . . . . . . . . . . . . . . . . . . . . . . 7991dB Sound Power (Not Shown) . . . . . . . . . . 79Battery Disconnect . . . . . . . . . . . . . . . . . . . . . 79Control Panel . . . . . . . . . . . . . . . . . . . 75, 77, 78Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . 79Crush Hazard . . . . . . . . . . . . . . . . . . . . . . . . . 79Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Earth Warning . . . . . . . . . . . . . . . . . . . . . . . . . 79G10 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Hazardous Voltage . . . . . . . . . . . . . . . . . . . . . 79IR Front Logo . . . . . . . . . . . . . . . . . . . . . . . . . 79IR Logo 22” Rear . . . . . . . . . . . . . . . . . . . . . . 79IR Powered . . . . . . . . . . . . . . . . . . . . . . . . . . . 79IR Side Logo . . . . . . . . . . . . . . . . . . . . . . . . . . 79Lift Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79No Flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79No Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Refer to Manual . . . . . . . . . . . . . . . . . . . . . . . 79

Dinrail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 76Diode Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Diode Bridge Assembly . . . . . . . . . . . . . . . . . . . . . 67Door

Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Drive Disc LSA 422S4 . . . . . . . . . . . . . . . . . . . . . . 67

96 Parts Book

WORD INDEX

EElbow

Barbed (Fuel Feed) . . . . . . . . . . . . . . . . . . . . 72Barbed (Fuel Return) . . . . . . . . . . . . . . . . . . . 72

Electric Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . 83Element

Air Filter (Not Shown) . . . . . . . . . . . . . . . . . . . 62Element Assembly

Fuel/Water . . . . . . . . . . . . . . . . . . . . . . . . 82, 83Element Sub Assembly . . . . . . . . . . . . . . . . . . . . . 43Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . 83Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Engine Mounting Bracket

LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Eyebolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

FFan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Fan Guard

Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

FilterFuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Flywheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . 27Foam

Exhaust Baffle . . . . . . . . . . . . . . . . . . . . . . . . 70Side Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

FrameNova G10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Frame G10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Fuel Filter Primary . . . . . . . . . . . . . . . . . . . . . . . . . 83Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . . . 52Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . 71Fuel Tank Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 71Fuel/Water Separator Filter . . . . . . . . . . . . . . . . . . 71Fuel/Water Separator Filter Assembly - Complete 82Fuse

AVR (Not Shown) . . . . . . . . . . . . . . . . . . . . . . 67F1

F21 Amp . . . . . . . . . . . . . . . . . . . . . . . . 84

F425 Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

F5250MA . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Fuse Voltage Regulator . . . . . . . . . . . . . . . . . . . . 83

GGage

Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

GasketCylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . 54Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Engine Cylinder Head . . . . . . . . . . . . . . . . . . . 11Exhaust Manifold . . . . . . . . . . . . . . . . . . . 30, 54Front Plate . . . . . . . . . . . . . . . . . . . . . . . . 21, 54Fuel Return . . . . . . . . . . . . . . . . . . . . . . . . 37, 53Gear Case . . . . . . . . . . . . . . . . . . . . . . . . 21, 54Governor Case . . . . . . . . . . . . . . . . . . . . . 41, 54Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 53Inlet Cover . . . . . . . . . . . . . . . . . . . . . . . . 29, 54Inlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 52, 54Liquid (Not Shown) . . . . . . . . . . . . . . . . . . . . . 54Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Oil Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Oil Seal Case . . . . . . . . . . . . . . . . . . . . . . 19, 53Rocker Cover . . . . . . . . . . . . . . . . . . . 14, 54, 83Thermostat . . . . . . . . . . . . . . . . . . . . . . . . 35, 54Thermostat Case . . . . . . . . . . . . . . . . . . . 35, 54Tie-Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Tie-Rod Cover . . . . . . . . . . . . . . . . . . . . . . . . . 53Water Pump . . . . . . . . . . . . . . . . . . . . . . . 34, 53

Gasket (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . 53Gasket Kit

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Gear

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . 28Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Gear AssemblyIdler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Guide

Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . 10Inlet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Oil Level Gage . . . . . . . . . . . . . . . . . . . . . . . . 17

HHandle

Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Hanger

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Head

Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 10, 11Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Holder

Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

97

HoseAir Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37, 39Fuel ( 36 inches ) . . . . . . . . . . . . . . . . . . . . . . 61Pick Up to Pump (Not Shown) . . . . . . . . . . . . 72Pump to Engine (Not Shown) . . . . . . . . . . . . . 72Radiator Bottom . . . . . . . . . . . . . . . . . . . . . . . 60Radiator Top . . . . . . . . . . . . . . . . . . . . . . . . . . 60Return (Not Shown) . . . . . . . . . . . . . . . . . . . . 72Water Lower . . . . . . . . . . . . . . . . . . . . . . . . . . 52Water Upper . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Hose AssemblyAir Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Hose Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 68Hour Meter M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Hourmeter

100000 Hr . . . . . . . . . . . . . . . . . . . . . . . . . . . 75000 hr . . . . . . . . . . . . . . . . . . . . . . . . . 76, 78

HousingFlywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Sub Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 43

IIndicator

Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 83Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58, 65

JJ-Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Jet

Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . 11Joint

3 Way . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 34

KKey

Sunk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Woodruff . . . . . . . . . . . . . . . . . . . . . . . . . . 15, 26

LLabel

E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . 75, 77, 78Latch Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Lever

Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Governor Spring . . . . . . . . . . . . . . . . . . . . . . . 41Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . 41

Lever AssemblyTension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Lift Bail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 80Lifting Bail

Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

LockValve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Lower Radiator Hose . . . . . . . . . . . . . . . . . . . . . . . 83

MManifold

Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Module

2 Warning Lights . . . . . . . . . . . . . . . . . 75, 76, 78Module Warning . . . . . . . . . . . . . . . . . . . . . . . . . . 83Mount

Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Muffler

Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

NNozzle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 38Nut

Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . 25Hex . . . . . . . . . . . . . . . . . . . . . . . . . . . 58, 64, 71Hex Flange . . . . . . . . . . . . . . . . . . . . . . . . 63, 80High Speed Set . . . . . . . . . . . . . . . . . . . . . . . . 40Jam . . . . . . . . . . . . . . . . . . . . . . . . . . . 13, 32, 40Nozzle Retaining . . . . . . . . . . . . . . . . . . . . . . . 38Self Locking . . . . . . . . . . . . . . . . . . . . . . . . . . 71Torque Set . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

OOil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . 59, 83Oil Protec 15W40 . . . . . . . . . . . . . . . . . . . . . . . . . 83

PPacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31, 54Pad

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Pan

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Pan Assembly

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Panel

CenterLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Control . . . . . . . . . . . . . . . . . . . . . . . . 75, 77, 78Exhaust Grill . . . . . . . . . . . . . . . . . . . . . . . . . . 69Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Side

Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Parts Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Piece

Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

98

WORD INDEX

PinDowel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17, 18Grooved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Knock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14#1 Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . 37#2 Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . 37#3 Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Breather . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 29Fuel Leak-Off . . . . . . . . . . . . . . . . . . . . . . . . . 37Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Piston0.25 Oversized . . . . . . . . . . . . . . . . . . . . . . . . 240.50 Oversized . . . . . . . . . . . . . . . . . . . . . . . . 24Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . 44, 49Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Radiator Mounting . . . . . . . . . . . . . . . . . . . . . 60Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Relay Mounting . . . . . . . . . . . . . . . . . . . . . . . . 58Tappet Shim . . . . . . . . . . . . . . . . . . . . . . . . . . 44Thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 34

PlugDrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23, 51Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Glow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Tapered . . . . . . . . . . . . . . . . . . . . . . . 11, 18, 19Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

PulleyCrankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Pump AssemblyFuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . 43Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

RRack Assembly

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . . 52Radiator Bracket Support . . . . . . . . . . . . . . . . . . . 58Rail

DIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76, 77RECOMMENDED SPARE PARTS . . . . . . . . . . . . 83Relay

Overcurrent . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Relay 70 Amp 12VDCK1 K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

RetainerValve Stem . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

RingPiston no. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Piston no. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Snap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Ring AssemblyOil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Ring SetPiston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Piston 0.25 Oversized . . . . . . . . . . . . . . . . . . . 24Piston 0.50 Oversized . . . . . . . . . . . . . . . . . . . 24

RivetSerration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Rocker & Shaft Assembly . . . . . . . . . . . . . . . . . . . 12Rocker Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Rocker Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 12Rod

Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Push . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Rod AssemblyConnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SSandwich Mount . . . . . . . . . . . . . . . . . . . . . . . . . . 60Screw

Air Bleeder . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Hex . . . . . . . . . . . . . . . . . . . . . 58, 60, 65, 71, 80Hollow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Rack Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Tapping . . . . . . . . . 58, 64, 65, 68, 69, 71, 72, 82

Screw AssemblyRack Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

SealOil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19, 21Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Valve Stem . . . . . . . . . . . . . . . . . . . . . . . . 12, 53

Seal Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Seat

Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . 10Inlet Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

ShaftFuel Injector Pump . . . . . . . . . . . . . . . . . . . . . 46Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Idler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Sliding Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . 42

Shaft AssemblyIdler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

99

WORD INDEX

ShimGovernor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41T=0.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45T=0.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45T=0.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45T=0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45T=0.6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45T=0.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45T=0.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45T=0.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45T=1.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

ShroudFan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Shunt Trip Relay ST . . . . . . . . . . . . . . . . . . . . . . . 84Silencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Skid

Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Sleeve

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Sliding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Socket16A

110V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77230V . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 78400V . . . . . . . . . . . . . . . . . . . . . . . . . . 76, 78

32A400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Solenoid & Nut Set . . . . . . . . . . . . . . . . . . . . . . . . 50Solenoid Assembly . . . . . . . . . . . . . . . . . . . . . 50, 83Spring

Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Rocker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Tie-Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Start Switch S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Starter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 47Strainer

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Strainer Assembly

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Strap

Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Stud Nuts (Not Shown) . . . . . . . . . . . . . . . . . . . . . 67Stud Terminal Blocks (Not Shown) . . . . . . . . . . . . 67Support

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Surge Suppressor . . . . . . . . . . . . . . . . . . . . . . 67, 83

SwitchAmmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Battery Disconnect . . . . . . . . . . . . . . . . . . . . . 64E-Stop . . . . . . . . . . . . . . . . . . . . . . . . . 75, 76, 78Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 76

SwwitchStart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

TTappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Tappet Sub Assembly . . . . . . . . . . . . . . . . . . . . . . 43Terminal

Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . 35, 83Thermostat Assembly . . . . . . . . . . . . . . . . . . . . . . 35Tie Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Tie-Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Tie-Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

UUpper Radiator Hose . . . . . . . . . . . . . . . . . . . . . . . 83

VValve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Valve AssemblyRelief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Valve Sub Assembly . . . . . . . . . . . . . . . . . . . . . . . 43Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 67Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 76, 78

M5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

WWasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46, 49

Pipe Union . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Plain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 49Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . 45, 51

(Temp. Switch) . . . . . . . . . . . . . . . . . . . . . 59Snubbing . . . . . . . . . . . . . . . . . . . . . . . . . . 58, 65Spring . . . . . . . . . . . . . . . . . . . . . . 26, 40, 47, 49T=1.25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38T=1.30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38T=1.35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38T=1.40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38T=1.45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38T=1.50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38T=1.55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38T=1.60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38T=1.65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38T=1.70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Water Temperature Switch . . . . . . . . . . . . . . . 59, 83Wavey Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Wavy Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

100 Parts Book

WORD INDEX

Weight Assembly Governor . . . . . . . . . . . . . . . . . 42Wiring Harness

Engine (Not Shown) . . . . . . . . . . . . . . . . . . . . 58Wound Exciter Field . . . . . . . . . . . . . . . . . . . . . . . 67

101

WORD INDEX

102 Parts Book

NUMERICAL INDEX

COMM.NO. PAGE COMM.NO. PAGE COMM.NO. PAGE
22127385 ........................... 75 .......................................... 76 .......................................... 78 .......................................... 83
22173561 ........................... 6222219026 ........................... 68 .......................................... 73

22278360 ........................... 6022312409 ........................... 6822375141 ........................... 7322429641 ........................... 6522494983 ........................... 6422511505 ........................... 8422554224 ........................... 59 .......................................... 83

22578447 ........................... 75 .......................................... 76 .......................................... 78 .......................................... 83

22580336 ........................... 7122580351 ........................... 7122585111 ........................... 7122607436 ........................... 5822611610 ........................... 5822616353 ........................... 7122630628 ........................... 71 .......................................... 82

22647077 ........................... 6922647085 ........................... 6922647101 ........................... 6922647291 ........................... 6822647309 ........................... 6822647325 ........................... 6822647366 ........................... 6822650444 ........................... 76 .......................................... 78

22650451 ........................... 75 .......................................... 78

22650469 ........................... 7622662183 ........................... 6422662258 ........................... 5822662266 ........................... 5822662282 ........................... 5822662290 ........................... 6522662332 ........................... 6022662357 ........................... 52 .......................................... 60

22662365 ........................... 6022662415 ........................... 7122666093 ........................... 7622668677 ........................... 8022671622 ........................... 52 .......................................... 54

22671648 ........................... 5222671721 ........................... 52 .......................................... 60

22671739 ............................52 ...........................................6022671747 ............................52 ...........................................8322672471 ............................75 ...........................................76 ...........................................78 ...........................................8322681373 ............................75 ...........................................7822681431 ............................7622686133 ............................7322688717 ............................75 ...........................................76 ...........................................78 ...........................................8322702674 ............................6022702682 ............................6022702690 ............................6022704993 ............................7022705008 ............................7022711865 ............................75 ...........................................76 ...........................................78 ...........................................8322713648 ............................7922730972 ............................6422734859 ............................7622741714 ............................5922742563 ............................6622747315 ............................8422747380 ............................7122747893 ............................76 ...........................................7822750970 ............................7622754006 ............................67 ...........................................8322755177 ............................5822757322 ............................65 ...........................................8322762512 ............................7922765523 ............................7122765549 ............................7122780134 ............................8422780985 ............................75 ...........................................76 ...........................................78 ...........................................8422783245 ............................7122785539 ............................7122800783 ............................68 ...........................................7322801666 ............................1622801682 ............................1622801732 ............................1522801880 ............................53

22802003 ............................33 ...........................................5322802136 ............................1822802284 ............................1322803027 ............................3322804728 ............................1322804785 ............................1922804801 ............................4922804819 ............................2322804827 ............................3722804967 ............................4922804975 ............................3522805014 ............................15 ...........................................21 ...........................................23 ...........................................3922805055 ............................4622805097 ............................2922805105 ............................1422805154 ............................3522805170 ............................1122805188 ............................4722805212 ............................3722805279 ............................1222805295 ............................5122805303 ............................3722805311 ............................3722805402 ............................1122806400 ............................5822806566 ............................6822806681 ............................6822806947 ............................60 ...........................................7322810634 ............................7922828123 ............................8122842330 ............................2222842348 ............................5122842355 ............................4422842363 ............................4322842371 ............................4322842389 ............................4322842397 ............................4322842405 ............................4322842413 ............................4322842421 ............................4322842439 ............................4322842447 ............................4322842454 ............................4322842462 ............................4422842470 ............................4322842488 ............................4422842496 ............................4422842504 ............................4322842512 ............................4422842520 ............................3822842538 ............................38

103

NUMERICAL INDEX

22842546 ........................... 3822842553 ........................... 3822842561 ........................... 3822842579 ........................... 3822842587 ........................... 3822842595 ........................... 3822842603 ........................... 3822842611 ........................... 3822842629 ........................... 3822842637 ........................... 4422842645 ........................... 2222842652 ........................... 2522842660 ........................... 2522842678 ........................... 2522842686 ........................... 2522842694 ........................... 5222842702 ........................... 3922842710 ........................... 42 .......................................... 53
22842728 ........................... 5022842736 ........................... 50 .......................................... 83

22842744 ........................... 34 .......................................... 53

22842751 ........................... 4022842769 ........................... 4022842777 ........................... 4022842785 ........................... 4022842801 ........................... 4022842819 ........................... 4022842827 ........................... 4222842835 ........................... 4022842843 ........................... 1022842850 ........................... 1022842868 ........................... 1122842876 ........................... 1122842884 ........................... 1222842892 ........................... 1222842900 ........................... 1222842918 ........................... 1222842926 ........................... 1222842934 ........................... 1322842942 ........................... 1322842959 ........................... 1522842967 ........................... 1522842975 ........................... 1622842983 ........................... 1922842991 ........................... 1622843007 ........................... 2222843015 ........................... 1922843023 ........................... 19 .......................................... 53

22843031 ........................... 21 .......................................... 54

22843049 ........................... 18 .......................................... 54

22843056 ............................2022843064 ............................2022843072 ............................2022843080 ............................2022843098 ............................2122843106 ............................2122843114 ............................21 ...........................................5422843122 ............................2422843130 ............................2422843148 ............................2422843155 ............................2422843163 ............................1822843189 ............................2822843197 ............................2822843205 ............................2822843213 ............................31 ...........................................5422843221 ............................3222843239 ............................3122843247 ............................3322843254 ............................3422843262 ............................3522843270 ............................8322843288 ............................5422843296 ............................35 ...........................................5422843304 ............................3522843312 ............................52 ...........................................60 ...........................................8322843320 ............................52 ...........................................60 ...........................................8322843338 ............................3722843346 ............................37 ...........................................8322843353 ............................3722843361 ............................3722843379 ............................3722843387 ............................4122843395 ............................4122843403 ............................4222843411 ............................4222843429 ............................4122843437 ............................4122843445 ............................4122843452 ............................4122843478 ............................4222843486 ............................4122843494 ............................4122843502 ............................4122843510 ............................4122843528 ............................4222843536 ............................4222843544 ............................41

22843551 ............................41 ...........................................5422843569 ............................4122843577 ............................4222843585 ............................49 ...........................................8322843593 ............................4922843601 ............................4922843619 ............................3822843627 ............................3822843635 ............................3822843643 ............................3822843650 ............................3822843668 ............................1322843676 ............................1322843684 ............................4422843692 ............................4422843700 ............................4422843718 ............................11 ...........................................5422843726 ............................1022843734 ............................1322843742 ............................1422843759 ............................14 ...........................................54 ...........................................8322843767 ............................1522843775 ............................1622843783 ............................2322843791 ............................2522843809 ............................2622843817 ............................2622843825 ............................2722843833 ............................29 ...........................................5422843841 ............................2922843858 ............................3022843866 ............................30 ...........................................5422843874 ............................3722843882 ............................3722843890 ............................3922843908 ............................4122843916 ............................4122843932 ............................4522843940 ............................4622843957 ............................4322843965 ............................47 ...........................................8322843973 ............................4822843981 ............................5322843999 ............................5422844005 ............................4422844146 ............................1222844153 ............................3022844161 ............................18

104

NUMERICAL INDEX

22844179 ........................... 4022844187 ........................... 4022844195 ........................... 1822844203 ........................... 4022844427 ........................... 1022844435 ........................... 4622844443 ........................... 3522844450 ........................... 2522844468 ........................... 2122844476 ........................... 1222844484 ........................... 2522844492 ........................... 1322844500 ........................... 1822844518 ........................... 2722844526 ........................... 36 .......................................... 83
22844534 ........................... 12 .......................................... 53

22844542 ........................... 4622844559 ........................... 2722844567 ........................... 19 .......................................... 45

22844575 ........................... 21 .......................................... 42

22844583 ........................... 1822844591 ........................... 3122844609 ........................... 3022844617 ........................... 3422844625 ........................... 36 .......................................... 39

22844633 ........................... 4222844641 ........................... 2222844658 ........................... 2222844666 ........................... 3422844674 ........................... 3422844682 ........................... 3022844690 ........................... 4022844708 ........................... 47 .......................................... 49

22844716 ........................... 2622844724 ........................... 4022844732 ........................... 3222844740 ........................... 4922844757 ........................... 2622844765 ........................... 4022844773 ........................... 47 .......................................... 49

22844781 ........................... 2622844799 ........................... 1722844807 ........................... 4622844815 ........................... 15 .......................................... 26

22844823 ........................... 4222844831 ........................... 32 .......................................... 53

22844849 ........................... 42

22844856 ............................1722844864 ............................1722844872 ............................1722844880 ............................1822844898 ............................1022844906 ............................4522844914 ............................5222844922 ............................5222844930 ............................5222844955 ............................1422844963 ............................3922844971 ............................3622844989 ............................2222844997 ............................1122845002 ............................5322845010 ............................4522845028 ............................4522845036 ............................4522845044 ............................4522845051 ............................4522845077 ............................4522845085 ............................4522845093 ............................4522845101 ............................4522845119 ............................4222845127 ............................34 ...........................................8322845135 ............................3522845143 ............................3422845150 ............................34 ...........................................5322845168 ............................3422845176 ............................4722845184 ............................1822845192 ............................5022845200 ............................3522845218 ............................3722845226 ............................1722845234 ............................1222845242 ............................2422845259 ............................2422845275 ............................2422845283 ............................1722845291 ............................1722845309 ............................1722845317 ............................3922845325 ............................3522845333 ............................3722845341 ............................3922845358 ............................3522845366 ............................3722857817 ............................74 ...........................................7822857932 ............................74 ...........................................75 ...........................................78

22857965 ............................7822862155 ............................76 ...........................................7822862486 ............................75 ...........................................7822862874 ............................7822873681 ............................7922875181 ............................6922878607 ............................6522878615 ............................6522881262 ............................7522881288 ............................7522881585 ............................74 ...........................................7522881643 ............................7522881668 ............................8422881700 ............................75 ...........................................8322885768 ............................76 ...........................................8422890628 ............................6422892566 ............................69 ...........................................8022892699 ............................6322892921 ............................6922894273 ............................75 ...........................................77 ...........................................7822895247 ............................7922916720 ............................7922959936 ............................7122966089 ............................77 ...........................................78 ...........................................8322967970 ............................77 ...........................................8422980031 ............................67 ...........................................8322980049 ............................6722980072 ............................6723037849 ............................6123047566 ............................7923047582 ............................7923047608 ............................7923047624 ............................7923048424 ............................2823048432 ............................4023048481 ............................4223050982 ............................6423051410 ............................6823059637 ............................7723062893 ............................7923109549 ............................7723109556 ............................7723129729 ............................74 ...........................................77

105

NUMERICAL INDEX

23129745 ........................... 7723131279 ........................... 8023131287 ........................... 8023133986 ........................... 7723134075 ........................... 7723134083 ........................... 7723135866 ........................... 7723137227 ........................... 7723138985 ........................... 8023140866 ........................... 8023161466 ........................... 8423250756 ........................... 7935144492 ........................... 6435221662 ........................... 6235253038 ........................... 7235273366 ........................... 5835279025 ........................... 58 .......................................... 64 .......................................... 65 .......................................... 82
35283126 ........................... 7335296342 ........................... 61 .......................................... 72 .......................................... 73

35304047 ........................... 6535306125 ........................... 7335314939 ........................... 6235322395 ........................... 7235356484 ........................... 7235358381 ........................... 8235360775 ........................... 6135363498 ........................... 72 .......................................... 73

35363506 ........................... 7235369339 ........................... 7235369347 ........................... 7235369511 ........................... 60 .......................................... 73

35378538 ........................... 7235578194 ........................... 5835582410 ........................... 6435846484 ........................... 6336780609 ........................... 6436793602 ........................... 6836793651 ........................... 8436794816 ........................... 68 .......................................... 79

36797652 ........................... 68 .......................................... 69

36845014 ........................... 7136845022 ........................... 7136853265 ........................... 6436875565 ........................... 5836879195 ........................... 8036879211 ........................... 8136879302 ........................... 81

36880995 ............................8036881886 ............................63 ...........................................71 ...........................................8236884948 ............................6136889608 ............................71 ...........................................75 ...........................................77 ...........................................78 ...........................................8236890135 ............................62 ...........................................8336896975 ............................6436898104 ............................6136899037 ............................5844003929 ............................8344003937 ............................8354429295 ............................6554480504 ............................8254480512 ............................8254480520 ............................8254525506 ............................71 ...........................................8254525530 ............................82 ...........................................8354564737 ............................6254642327 ............................7954757935 ............................59 ...........................................8385400109 ............................37 ...........................................5385400117 ............................37 ...........................................5385400216 ............................38 ...........................................8385400612 ............................48 ...........................................8385402451 ............................67 ...........................................8385425858 ............................67 ...........................................8385425866 ............................67 ...........................................8385425882 ............................67 ...........................................8385425965 ............................6785426815 ............................39 ...........................................8385426849 ............................33 ...........................................8385508562 ............................1485508893 ............................6785508992 ............................6785509032 ............................67 ...........................................83

85625135 ............................23 ...........................................5385626968 ............................67 ...........................................8389311716 ............................8392368687 ............................7292867449 ............................7992912559 ............................7992930593 ............................7993171254 ............................7993171262 ............................7995092318 ............................7395923298 ............................60 ...........................................7195928222 ............................7395940748 ............................7295953493 ............................6295992392 ............................7296701461 ............................6196702824 ............................60 ...........................................6296705058 ............................7796708037 ............................6596720933 ............................8096729595 ............................5896730411 ............................5896738802 ............................7196740782 ............................6596741970 ............................6596749627 ............................58

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