Service Parts. John Deere TO4039D 4039TL CD4039DF CD4039TF 4045DF 4045TF. Engine. Engine Models:

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1 Service s Engine Engine Models: John Deere TO4039D 4039TL CD4039DF CD4039TF 4045DF 4045TF Generator Models: ROZJ/REOZJ DSJ/DSEJ 50/60ROZJ serial nos and above 50/60REOZJ/REOZJB 50/60DSJ/DSEJ/DSEJB 80REOZJB 80DSEJB TP /03e

2 Table of Contents SUBJECT PAGE SUBJECT PAGE Introduction... 1 Group 12a: Exhaust Manifold Significance... 1 Group 12b: Exhaust Elbow How to Find s... 1 Group 13a: Flywheel Specification Index... 2 Group 13b: Flywheel Housing Group 1: Air Intake... 7 Group 14: Fuel Pump Group 2a: Water Pump... 8 Group 15: Fuel Filter Group 2b: Thermostat Group 2c: Fan Belt Group 16: Balancer Shafts Group 2d: Fan Drive Group 18: Timing Gear Cover Group 3: Vent Tube Group 21a: Oil Pan Group 4a: Camshaft Group 21b: Oil Fill Tube Group 4b: Valve Train Group 21c: Oil Cooler Group 4c: Rocker Arm Cover Group 22: Piston and Connecting Rod Group 5a: Fuel Injection Pump Group 25: Oil Pump Group 5b: Fuel Injection Nozzle Group 26: Front Plate Group 7: Cylinder Block Group 39a: Cylinder Head Gasket Set Group 8a: Crankshaft Group 39b: Overhaul Gasket Kit Group 8b: Crankshaft Pulley Group 9: Cylinder Head Group 42: Short Block Group 10a: Oil Filter Group 50a: Turbocharger and Oil Lines Group 10b: Dipstick Group 51a: Alternator Group 11a: Starter Motor Group 51b: Alternator Brackets Group 11b: Starter Motor Components Group 51c: Alternator Components... 77

3 This manual lists service replacement parts for John Deere 4039 and 4045 engines. At the time of print this manual applied to the engine models listed in the Specification Index. On occasion this manual may apply to engines not listed in the Specification Index. Information in this publication represents data available at the time of print. The generator set manufacturer reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. This manual includes the following main sections: Table of Contents. Lists the sections of the manual. Introduction (and other information sections). Contains introductory material about part numbers, illustrations, and hardware. Index. Lists the engine models and groups. Group s Lists. List the part numbers of parts in the groups. ing System Significance This manual uses the following numbering systems: Engine Model. The product identification number located on the engine nameplate. Engines break down into groups. Group. A unique number representing a parts group needed to assemble an engine function. For example, Group 1 is the Air Intake group. Variation. A group might have several variations. Each variation performs the same function with different parts lists. For example, a 12-volt alternator and 24-volt alternator both perform the same function, but, with different parts. Each difference requires a group variation or module number.. The part number identifies an individual assembly, subassembly, component, or accessory kit. Illustrations Illustrations (or exploded-view drawings) best representing the widest range of variations accompany most groups in this manual. Illustrations do not depict all details and may not show all parts. Do not use illustrations for assembly or disassembly. Introduction x:in:004:004a How to Find s Use the following steps to locate a service replacement part. 1. Locate the engine nameplate to identify the engine model number. 2. Turn to the Specification Index. The first column lists the engine model numbers. The headings identify the groups of parts that make up the engine. 3. Identify the group most likely to include the service part number. 4. Find the group variation number at the intersection of the model row and the group column. Note the variation number. If 2 or more variation numbers are listed, note all variation numbers. 5. Page forward to locate the group identified in step 3 or find the appropriate page in the Table of Contents. 6. Find the part on the illustration and note the item number of the part or find the part description in the parts list. 7. Select the part number that corresponds to your group variation. The first column lists the illustration item number. Find the variation(s) identified in the Specification Index in the appropriate column on the right side of the parts list table. Find the quantity used at the intersection of the item number row and the variation column. A blank space at the intersection means the variation/module does not use that part number. Hardware References Many common hardware items do not appear in parts manuals or will appear as common hardware entries. A common hardware entry lists the size of the hardware. For example, an item that appears as Hardware, 3/8-16 in the text means that the piece is 3/8-16 size. Obtain common hardware locally. Some hardware items require a specific size or some other characteristic. In that case, use the part number listed in the text. When replacing hardware, do not substitute inferior grade hardware. Replacement hardware grade should be equal to or better than the grade of the manufacturer s original hardware. TP /03 1

4 Specification Index Group Title Group No. 1 2a 2b 2c 2d 3 4a 4b 4c 5a 5b 7 8a 8b Variation Model 20-40ROZJ or 20-40DSJ TO4039D CD4039DF REOZJ or 20-40DSEJ TO4045DF, 12 V 1705 TO4045DF, 24 V /60ROZJ* or 50/60DSJ 4039TL CD4039TF /60REOZJ or 50/60DSEJ TO4045TF, 12 V 1701 TO4045TF, 24 V 1701 TO4045TF, 12 V 4S7 alternator TO4045TF, 24 V 4S7 alternator /60REOZJB or 50/60DSEJB 4045TF120, 12 V, 50 Hz 4045TF150, 12 V, 60 Hz 4045TF120, 24 V, 50 Hz 4045TF150, 24 V, 60 Hz B B B B MT 16MT LZ or LZ or MU 16MU MA or MA or * These units used John Deere 4239TL engines on early model 50/60 kw (serial numbers below ) generator sets and John Deere 4039TL/CD4039TF engines on newer model 50/60 kw (serial number and above) generator sets. Check the generator set nameplate for the serial number and the engine nameplate for the engine model. Refer to s Catalog TP-5368 P/C John Deere 4239DL/TL if the generator set uses John Deere 4239TL engine. Use fuel injection pump variation 16LZ on generator set specification GM21199-GA5. Use fuel injection pump variation 16MA on generator set specification GM21199-GA7. 2 TP /03

5 Specification Index Group Title Group No. 1 2a 2b 2c 2d 3 4a 4b 4c 5a 5b 7 8a 8b Variation Model 80REOZJB or 80DSEJB 4045TF220, 12 V, 50 Hz D GQ 16GQ TF250, 12 V, 60 Hz D C 161C TF220, 24 V, 50 Hz D LV 16LV TF250, 24 V, 60 Hz D D 161D TP /03 3

6 Specification Index Group Title Group No. 9 10a 10b 11a 11b 12a 12b 13a 13b Model 20-40ROZJ or 20-40DSJ Variation TO4039D CD4039DF REOZJ or 20-40DSEJ 4045DF, 12 Volt DF, 24 Volt /60ROZJ* or 50/60DSJ 4039TL CD4039TF /60REOZJ or 50/60DSEJ TO4045TF, 12 V TO4045TF, 24 V TO4045TF, 12 V 4S7 alternator TO4045TF, 24 V 4S7 alternator /60REOZJB or 50/60DSEJB 4045TF,120, 12 V, 50 Hz TF150, 12 V, 60 Hz TF120, 24 V, 50 Hz TF150, 24 V, 60 Hz REOZJB or 80DSEJB 4045TF220, 12 V, 50 Hz TF250, 12 V, 60 Hz TF220, 24 V, 50 Hz TF250, 24 V, 60 Hz Group parts not supplied with engine. * These units used John Deere 4239TL engines on early model 50/60 kw (serial numbers below ) generator sets and John Deere 4039TL/CD4039TF engines on newer model 50/60 kw (serial number and above) generator sets. Check the generator set nameplate for the serial number and the engine nameplate for the engine model. Refer to s Catalog TP-5368 P/C John Deere 4239DL/TL if the generator set uses John Deere 4239TL engine. 4 TP /03

7 Specification Index Group Title Group No. 21a 21b 21c a 39b a 51b 51c Variation Model 20-40ROZJ or 20-40DSJ TO4039D CD4039DF REOZJ or 20-40DSEJ TO4045DF, 12 V TO4045DF, 24 V /60ROZJ* or 50/60DSJ 4039TL CD4039TF /60REOZJ or 50/60DSEJ TO4045TF, 12 V TO4045TF, 24 V TO4045TF, 12 V 4S7 alternator TO4045TF, 24 V 4S7 alternator /60REOZJB or 50/60DSEJB 4045TF120, 12 V, 50 Hz CQ TF150, 12 V, 60 Hz CT TF120, 24 V, 50 Hz CQ TF150, 24 V, 60 Hz CT REOZJB or 80DSEJB 4045TF220, 12 V, 50 Hz DC TF250, 12 V, 60 Hz CT TF220, 24 V, 50 Hz DC TF250, 24 V, 60 Hz CT Group parts not supplied with engine. * These units used John Deere 4239TL engines on early model 50/60 kw (serial numbers below ) generator sets and John Deere 4039TL/CD4039TF engines on newer model 50/60 kw (serial number and above) generator sets. Check the generator set nameplate for the serial number and the engine nameplate for the engine model. Refer to s Catalog TP-5368 P/C John Deere 4239DL/TL if the generator set uses John Deere 4239TL engine. TP /03 5

8 Notes 6 TP /03

9 Group 1: Air Intake Variation Item Description # Plug, 3/8 NPT pipe Gasket # Washer, 3/8 in. lock 2 4 # Screw, 3/8-16 x 1 1/4 in. cap 2 4 # Screw, M10 x Elbow, air intake Air Intake 1 TP25401 Variation Item Description # Clamp # Hose, 2 in. ID x 2 1/2 in Hose Duct, air Air Intake 1 4 # Screw, 3/8-16 x 1 1/4 in. 2 4 # Screw, M10 x # Washer, 3/8 lock 2 6 # Plug, 3/8 NPT 1 6 # Plug Gasket # Plug, 1/8 NPT pipe 1 # Common hardware; procure locally. TP14910 (was CD25559) TP /03 7

10 Group 2a: Water Pump 23 TP25407 Variation Item Description Gasket 1 2 X Cover 1 3 X Gasket 1 4 X Impeller 1 5 # Plug, 1/2 in. pipe 1 6 X Seal kit (w/insert tool) 2 7 # Screw, 3/8-16 x 1 3/8 in. 1 8 X Bearing, ball 1 9 X Fitting, hose Hose 3 11 # Washer, 3/8 in. lock 1 12 # Screw, 3/8-16 x 3 1/2 in # Screw, 3/8-16 x 2 in Pulley 1 14 # Screw, 3/8-16 x 3 1/4 in # Nut, 3/ Stud 1 17 X Tube 1 18 X Pump, water 1 19 X Hub 1 20 # Screw, 5/16-18 x 7/8 in Pump assembly, water 1 22 # Clamp Water pump kit 1 X Item not sold separately. 8 TP /03

11 Group 2a: Water Pump, TP53331 Variation Item Description X Impeller 1 2 X Seal 1 3 X Housing 1 4 X Bearing, ball 1 5 X Ring 1 6 X Shaft Ring, snap O-ring Seal Plug 1 11 # Screw, M6 x # Screw, M6 x Gasket 1 14 GM29383 Pump, water Kit, water pump repair (includes items 1--7, 9) Pulley, water pump Pulley, water pump 1 17 # Screw, M6 x # Screw, M8 x # Screw, M8 x Adapter, water pump O-ring 1 X Item not sold separately. TP /03 9

12 Group 2b: Thermostat TP26841 Variation Item Description # Screw, 3/8-16 x 1 1/4 in. 2 1 # Screw, 3/8-16 x 1 1/2 in. 2 2 # Washer, plain, 13/32 x 11/16 x in Cover Cover Gasket Gasket 1 5 # Plug, 1/2 NPT pipe Not Used Thermostat Housing Tube # Clamp, hose Hose Gasket, thermostat housing # Screw, 3/8-16 x 2 3/4 in # Washer, lock, 3/8 in TP /03

13 Group 2b: Thermostat TP26869 Variation Item Description # Screw, 3/8-16 x 1 1/4 in. 2 1 # Screw, 3/8-16 x 1 1/2 in. 2 2 # Washer, 13/32 x 11/16 x.06 in Not Used Cover Cover Gasket Gasket Thermostat Housing # Plug, 1/2 NPT pipe # Screw, 3/8-16 x 2 3/4 in. cap # Washer, 3/8 in. lock Gasket, thermostat housing Fitting, hose # Clamp Hose 1 1 TP /03 11

14 Group 2b: Thermostat, continued TP53276 Variation Item Description Cover, thermostat # Screw, M10 x Plug # Screw, M10 x Seal Tube 1 6 GM23839 Tube 1 7 # Washer, x x 3/8 in Clamp # Screw, M8 x # Pipe Plug, 1/2 in Gasket, thermostat cover Clamp # Screw, M8 x # Screw, M12 x Thermostat TP /03

15 Group 2c: Fan Belt See Group 2d TP26258 Variation Item Description B 240D Beltset(matchedsetof2) Belt, 11/16 x 49 1/2 in Belt, fan 1 1 GM28308 Belt (1515 mm) 1 1 GM23827 Belt (1545 mm) Spacer Pulley Sleeve 1 5 # Screw, M10 x 65 1 TP /03 13

16 Group 2d: Fan Drive Variation Item Description GM23844 Support Bearing housing Ring, snap Ring, snap 1 3 X Shaft Bearing 1 4 X Hub Hub 1 5 # Screw, M12 x GM23831 Bracket 1 7 GM23826 Washer 1 8 # Screw, M10 x # Screw, M10 x GM23830 Spacer 1 11 # Screw, M10 x GM23855 Washer Pulley, fan Pulley, fan 1 14 # Screw 4 4 X Item not sold separately. 14 TP /03

17 Group 2d: Fan Drive, continued See Group 51b 6 5 Variation Item Description GM23835 Spacer 1 2 GM17529 Pulley 1 3 GM17488 Sleeve 1 4 # Screw, M10 x # Screw Bracket, tensioner 1 TP /03 15

18 Group 3: Vent Tube See Group 4c TP10829 Variation Item Description Hose Hose 1 1 GM17459 Hose 1 2 # Screw, 3/8-16 x 7/8 in. cap 1 2 # Screw, M8 x # Washer, 13/32 x 11/16 x.06 in. 1 3 # Washer, lock, 3/8 in. 1 4 # Clamp # Clamp Elbow, fitting Elbow, fitting O-ring O-ring TP /03

19 Group 4a: Camshaft 7 Note: Camshaft bushings/bearings are not used in this application. TP14248 Variation Item Description Gear, 12 teeth Camshaft (without gear) 1 2 Camshaft (order item 7) Key, shaft Key, shaft Plate, thrust 1 5 # Screw, 3/8-16 x 1 in. cap Gear, 48 teeth 1 6 Gear, 60 teeth (order item 7) GM17530 Kit, camshaft and gear 1 1 TP /03 17

20 Group 4b: Valve Train For Valves, see Group 9, Cylinder Head TP857 (was TP16446) Variation Item Description Plug Shaft Shaft Washer Spring Support Support Arm, rocker Arm, rocker Arm, rocker 8 6 # Nut, M8 (not shown) 8 7 # Screw, 3/8-16 x 2 1/2 in. cap Stud Washer Rod, push Rod, push Rod, push Tappet Tappet 8 18 TP /03

21 Group 4c: Rocker Arm Cover T49114F Variation Item Description # Screw, w/washer Gasket Gasket Gasket 1 3 # Screw, 1/4-20 x 7/8 in. 1 4 # Washer, lock, 1/4 in Washer Cap Cap Cap Gasket Cover Cover Cover Plug Nut O-ring Packing 1 TP /03 19

22 Group 5a: Fuel Injection Pump 27 TP TP /03

23 Group 5a: Fuel Injection Pump, continued Variation Item Description Clamp (clip) Tube Fuel line Nut (fitting) Nut Packing Tube Tube # Rivet, 1/4 x 5/8 in Plug Screw, cap Line, fuel no Line, fuel no Line, fuel no Line, fuel no Line, fuel no Line, fuel no Line, fuel no Line, fuel no Line, fuel no Line, fuel no Line, fuel no Line, fuel no Clamp # Screw, M6 x 10 cap Clamp # Screw, cap M6 x 10, full thread Elbow, fitting Fitting O-ring O-ring # Nut, 5/ # Nut, M # Washer, 5/16 in # Washer, 11/32 x 11/16 x 1/16 in Washer Stud Stud Nut Washer, lock Gear Gear Gear Ring Shaft, key 5/32 x 5/8 in Pump, fuel injection* Pump, fuel injection Pump, fuel injection Pump, fuel injection Pump, fuel injection Pump, fuel injection Pump, fuel injection Fitting Fitting Solenoid, fuel shutoff #Common hardware, procure locally. * Variation 1, engine serial numbers and below. Variation 1, engine serial numbers and above. TP /03 21

24 Group 5a: Fuel Injection Pump, continued TP TP /03

25 Group 5a: Fuel Injection Pump, continued Variation Item Description 16GQ 16LV 16LZ 16MA 16MT 16MU 161C 161D Nut Plug Tube GM17549 Fuel line Clamp # Screw, M6 x 12 cap Line, fuel no Line, fuel no Line, fuel no Line, fuel no Elbow, fitting # Washer, lock 8 mm Washer GM17487 O-ring Clamp # Screw, M6 x 12 cap O-ring Fitting # Nut, M Screw Not applicable 22 GM23843 Pump, fuel injection 1 22 GM23847 Pump, fuel injection 1 22 GM23846 Pump, fuel injection 1 22 GM23848 Pump, fuel injection 1 22 GM23845 Pump, fuel injection 1 22 GM23849 Pump, fuel injection 1 22 GM23851 Pump, fuel injection 1 22 GM23852 Pump, fuel injection Gear GM17456 Washer Nut Not applicable Fitting, tee Sleeve See Group 5b Nut, tube See Group 5b Packing See Group 5b Washer See Group 5b Plug See Group 5b Injection nozzle Not applicable TP /03 23

26 Group 5b: Fuel Injection Nozzle TP26862 Variation Item Description Fitting, tee Fitting, tee Washer (sleeve) Nut Plug (use for servicing nozzle) Screw, cap Screw X Nozzle Washer Packing Washer X Plug, plastic (protective shipping cover) Nozzle, injection Nozzle, injection Nozzle, injection Nozzle, injection 1 1 X Item not sold separately. 24 TP /03

27 Group 5b: Fuel Injection Nozzle, continued TP26862 Variation Item Description 16GQ 16LV 16LZ 16MA 16MT 16MU 161C 161D Fitting, tee Washer, sleeve Nut Not applicable Screw X Nozzle Packing GM17473 Washer X Plug, plastic (protective shipping cover) Nozzle, injection X Item not sold separately. TP /03 25

28 Group 7: Cylinder Block TP TP /03

29 Group 7: Cylinder Block, continued Variation Item Description Pin, dowel # Plug, pipe, 3/4 NPT, 3/8 in., recess. hex Pin, dowel # Plug, pipe, 1/4 NPT Plug, drain O-ring # Plug, pipe Stud # Plug, pipe # Cap Bushing, standard Bushing, in., oversize X Bushing # Pin, dowel Spring Valve Cap, bearing # Washer Screw, cap Cap, rear # Plug, pipe 3/8 square drive O-ring O-ring Nipple, threaded X Orifice (w/piston cooling) X Block, cylinder, basic See group 42 Block, cylinder X Item not sold separately. TP /03 27

30 Group 7: Cylinder Block, continued 14 TP TP /03

31 Group 7: Cylinder Block, continued Variation Item Description Pin, dowel # Cap X Block, cylinder (order short block) Plug, pipe Plug, pipe Bushing, camshaft Plate # Screw, M8 x Valve, engine oil bypass Spring Bushing, oil pressure regulating Bushing, balancer shaft Pin, dowel # Plug, pipe Bushing O-ring Cap, bearing Washer Screw Cap, bearing Orifice Plug, drain O-ring Gasket (plastic gasket) Plug # Plug, pipe, 1/2 in Plug, drain 1 1 X Item not sold separately. TP /03 29

32 Group 8a: Crankshaft TP26293 Variation Item Description Seal, rear oil Pin, dowel Key, shaft, 1/8 x 5/8 in Key, shaft Gear, 24 teeth Gear, 30 teeth Crankshaft Crankshaft Washer, thrust, rear Washer, thrust, rear Pin (shaft) Pin (shaft) Pin, spring 3/16 diameter x 1 in Pin Bushing Gear, 55 teeth Gear (w/bushing) Washer, thrust Washer, thrust Washer, thrust Screw # Screw, M10 x Slinger, oil Seal, front oil Screw # Screw, M10 x Washer Washer Bushing Bushing 1 Variation Item Description Gear, 45 teeth Gear 1 19 # Pin, spring, 3/16 x 1 1/8 in Bearing, standard (set of 2) Bearing, standard (set of 2) Bearing, 0.05 mm (0.002 in.) Bearing, 0.25 mm (0.010 in.) Bearing, 0.25 mm (0.010 in.) Bearing, 0.51 mm (0.020 in.) Bearing, 0.76 mm (0.030 in.) Bearing, standard (set of 2) Bearing, standard (set of 2) Bearing, 0.05 mm (0.002 in.) Bearing, 0.25 mm (0.010 in.) Bearing, 0.25 mm (0.010 in.) Bearing, 0.51 mm (0.020 in.) Bearing, 0.76 mm (0.030 in.) Pin (shaft) Pin (shaft) 1 23 # Nut, 1/ Ring Sleeve, wear ring Sleeve Washer, thrust, rear Washer, thrust, rear Washer TP /03

33 Group 8b: Crankshaft Pulley Variation Item Description See Group 2c Pulley Pulley Pulley Pulley Washer Screw, cap Key Variation Item Description Pulley Pulley 1 2 GM17474 Flange Screw, cap, M10 x TP /03 31

34 Group 9: Cylinder Head TP TP /03

35 Group 9: Cylinder Head, continued Variation Item Description Not Used Sender, temperature Screw Strap Lock Rotator Spring Cap Cap Cap Insert, intake valve seat, standard Insert, intake valve seat, oversize Insert, exhaust valve seat, standard Insert, exhaust valve seat, oversize Cap Valve, exhaust, standard Valve, exhaust, in. oversize Valve, exhaust, in. oversize Valve, intake, standard Valve, intake, in. oversize Valve, intake, in. oversize Gasket, cylinder head Gasket, cylinder head Strap # Screw,1/2x1in Head, cylinder Head, cylinder Plug, pipe Seal Seal, in. oversize Seal, in. oversize Fitting (not shown) 1 TP /03 33

36 Group 10a: Oil Filter Engine model 4039 only. Engine model 4045 only TP16416 Variation Item Description Filter, oil Filter, oil Nipple, threaded Gasket Plug 2 10 # Screw, M8 x # Screw, M8 x Adapter 1 34 TP /03

37 Group 10b: Dipstick Engine model 4039 only. Use the Serial -Contingent Dipsticks table below and the engine model and serial number from the engine nameplate to verify the dipstick on 4039 engine models. TP16416 Variation Item Description See Table Dipstick O-ring Nipple, threaded (4039D) Nipple, threaded (CD4039TF below ) Guide (CD4039TF and above) Tube, dipstick 1 6 # Nut, 1/2 in Plug (not shown) 1 Serial -Contingent Dipsticks Engine Serial Dipstick 4039D 3xxxxx CD4039DF Below CD4039DF and above T 3xxxxx CD4039TF 1xxxxx All TP /03 35

38 Group 11a: Starter Motor TP12774 Variation Item Description Kit, starter motor Kit (includes starter and cover kit) 1 2 # Screw, cap, 3/8-16 x 1 1/4 in. 2 3 # Washer, 3/8 in. lock Stud 1 5 # Nut, 3/ # Washer, M10 lock 1 7 # Nut, M # Washer, M5 lock 1 9 # Screw, M5 x TP53261 Variation Item Description Gasket X Label Motor, starting Motor, starting (24 V) 1 4 Use Item # Screw, M10 x # Nut, flange, M # Stud # Screw # Washer, lock # Nut # Nut # Washer, lock 1 1 X Item not sold separately. 36 TP /03

39 Group 11a: Starter Motor, continued 14 Variation Item Description X Solenoid, motor GM17463 Seal GM29783 Seal 1 3 GM17464 O-ring GM29781 Switch 1 4 GM29784 Switch 1 4 GM17544 Switch 1 4 GM17546 Switch 1 5 GM17545 Clutch GM29785 Clutch 1 5 GM17547 Clutch 1 6 GM18874 Screw with washer, M5 x X Motor, starter GM23699 Motor, starter 12 V 1 8 X Cover GM17495 Band, tie GM17554 Label GM17548 Kit, solenoid GM29782 Kit, starter motor, 24 V 1 12 GM23699 Kit, starter motor, 12 V Kit, starter motor, 12 V 1 12 GM16801 Kit, starter motor, 24 V 1 13 # Screw, M10 x Gasket 1 # Common hardware; procure locally. X Item not sold separately. TP /03 37

40 Group 11b: Starter Motor Components 22 TP17980 Variation Item Description 1 1 X Bolt 2 2 X Screw 2 3 X Frame 1 4 X Holder 1 5 X Yoke 1 6 X Bearing, ball 1 7 X Bearing, ball 1 8 X Armature 1 9 X Washer 1 10 X Pinion 1 11 X Roller Clutch 1 13 X Screw 3 14 X Housing 1 15 X Retainer 1 16 X Ball 1 17 X Spring 1 18 X Switch 1 19 X Washer 1 20 X Nut 1 21 X Cover Kit (includes starter and cover kit) 1 22 X Starter (rebuilt) 1 X Item not sold separately. 38 TP /03

41 Group 11b: Starter Motor Components, continued TP48938 Variation Item Description X Label X Tie X Tie Switch, solenoid Switch, solenoid Bushing Stop Bendix Drive Bendix Drive Brush kit Brush kit O-ring Kit, solenoid protection Starter Starter (24 V) 1 12 X Housing X Frame X Yoke X Screw 1 1 X Item not sold separately. TP /03 39

42 Group 12a: Exhaust Manifold 5 TP12126 Variation Item Description # Screw, 3/8-16 x 1 1/4 in. cap 8 1 # Screw, M10 x # Washer, plain, 13/32 x 23/32 x 0.12 in Gasket Manifold, exhaust Manifold, exhaust Gasket, exhaust 1 1 Variation Item Description Manifold, exhaust Manifold, exhaust 1 2 # Screw, 3/8-16 x 4 1/4 in. cap 2 2 # Screw, M10 x # Washer, plain, 13/32 x 23/32 x 0.12 in. 7 TP26831 (was TP25160) Variation Item Description # Screw, cap, 3/8-16 x 4 in. 1 4 # Screw, M10 x # Screw, cap, 3/8-16 x 5 in. 2 5 # Screw, M10 x # Screw, 3/8-16 x 1 1/4 in. 3 6 # Screw, M10 x Gasket TP /03

43 Group 12b: Exhaust Elbow 5 TP26809 (was TP25160) Variation Item Description Fitting, elbow Elbow 1 2 # Screw, 3/8-16 x 1 1/2 in., grade # Screw, M10 x # Nut, flange, M10 (not shown) 2 3 # Washer, 13/32 x 13/16 x.06 in Screw 2 4 # Screw, M10 x # Nut, flange, M10 (not shown) Adapter Adapter Clamp (not shown) 1 TP /03 41

44 Group 13a: Flywheel TP26795 Variation Item Description # Screw, 1/2-13 x 1 1/2 in., grade # Bolt Gear, 142 teeth Gear Flywheel Flywheel 1 3 GM17501 Flywheel 1 3 GM23840 Flywheel Washer 4 42 TP /03

45 Group 13b: Flywheel Housing TP26793 (was TP25770) Variation Item Description # Plug, pipe, 1/8 NPT Seal Gasket Housing, flywheel Housing, flywheel Cover Cover, timing tool hole Plug 1 11 # Screw, cap, 1/2 x 1/2 in # Screw,5/8x51/ # Screw, M12 x # Screw, 3/8-16 x 1 1/2 in., grade # Screw,3/8x13/8in Bolt Washer 8 14 # Screw, 5/8 x 2 1/2 in., grade # Screw, 5/8 x 2 1/4 in., grade # Screw, M12 x 50 2 TP /03 43

46 Group 13b: Flywheel Housing, continued Variation Item Description GM17454 Housing Housing 1 2 # O-ring 1 2 GM24540 O-ring Seal GM17553 Cap 1 5 # Plug, pipe 1 5 GM15403 Plug, pipe 1 6 GM17449 Plate 1 7 # Screw, cap, M6 x Not Used 9 Not Used 10 Not Used 11 GM17453 Plug Plug 1 12 # Screw, M12 x Bolt GM17468 Fitting 1 # Common hardware; procure locally. 44 TP /03

47 Group 14: Fuel Pump 5 TP26808 (was R21292N) Variation Item Description Gasket Pump, fuel (order item 1 also) Pump, fuel Washer, aluminum 2 3 # Washer, 8.4 x 16 x 1.6 mm 2 4 # Screw, cap, 5/16-18 x 1 1/4 in. 2 4 # Screw, cap Rod, push 1 TP /03 45

48 Group 15: Fuel Filter CD TP /03

49 Group 15: Fuel Filter, continued Variation Item Description # Screw,3/8x11/2in # Screw, M10 x # Washer, 3/8 in Housing, fuel filter Head, filter Bracket 1 5 # Nut, lock, 3/8 in. 2 6 # Screw, 3/8 in. x 7/8 in. 2 7 # Washer, 3/8 in Fitting, elbow Fitting 2 9 # Plug, x in Plug Line, fuel inlet Line, fuel 1 11 # Screw,3/8x2in # Screw, M8 x Bracket Bracket 1 13 # Screw, 5/16 x 3/4 in Clamp Clamp 1 15 # Nut, flange, 5/16 in # Nut, flange, M Filter, fuel (round)* Filter, fuel (round) Kit, fuel filter Kit, fuel filter seal Kit, bleed plug and drain valve Line, fuel O-ring 1 #Common hardware, procure locally. * See table 4039 Engine Serial -Contingent Fuel Filters below for 4039 engine models 4039 Engine Serial -Contingent Fuel Filters Use the engine serial number to verify the fuel filter type on 4039 engine models. Find your serial number on the engine nameplate and choose the fuel filter type from the chart below. The square filter (variation 1) is shown on the following page. Model Serial Fuel Filter Type ROZJ and before After Square Round 50/60ROZJ and before Square After Round TP /03 47

50 Group 15: Fuel Filter, continued Fuel Injection Pump TP TP /03

51 Group 15: Fuel Filter, continued Variation Item Description 1 1 # Screw, 5/16-18 x 3/4 in Strap Line, fuel; filter to injection pump 1 4 # Screw, 3/8-16 x 7/8 in Fitting, elbow O-ring Washer Plug, drain Fitting, elbow Line, fuel; transfer pump to filter Fitting, elbow Clamp Filter, fuel, square* 1 14 # Washer, 13/32 x 23/32 x in # Plug, pipe, 1/8 NPT Housing Fitting, hose 1 18 # Nut, 5/ # Washer, lock, 5/16 in # Washer, 13/32 x 11/16 x.06 in Clamp 1 22 # Washer, lock, 3/8 in Fitting Line, fuel 1 #Common hardware, procure locally. * See table 4039 Engine Serial -Contingent Fuel Filters below for 4039 engine models 4039 Engine Serial -Contingent Fuel Filters Use the engine serial number to verify the fuel filter type on 4039 engine models. Find your serial number on the engine nameplate and choose the fuel filter type from the chart below. The round filter (variation 2) is shown on the previous page. Model Serial Fuel Filter Type ROZJ and before After Square Round 50/60ROZJ and before Square After Round TP /03 49

52 Group 16: Balancer Shafts TP25610 Variation Item Description Bushing, standard Bushing, standard Bushing, oversize Key, shaft # Key, shaft 4 x 16 mm Stop, plate Stop, plate Plate Gear, right hand, 12 teeth Gear, left hand, 12 teeth, pinion Gear, left hand, 15 teeth Shaft, right hand Shaft, right hand Shaft, right hand 1 6 # Washer, lock, 3/8 in # Screw, cap, 3/8-16 x 5/8 in # Screw, M8 x Shaft, left hand Shaft, left hand Shaft, left hand 1 50 TP /03

53 Group 18: Timing Gear Cover TP26827 (was TP22840) Variation Item Description Stud # Washer, 13/32 x 23/32 x 0.12 in # Screw, 3/8-16 x 1 7/8 in. cap # Nut, 3/ Gasket Cover Plug 1 7 # Screw, 3/8-16 x 7/8 in. cap # Screw, 3/8-16 x 2 1/2 in. cap # Screw, 3/8-16 x 1 7/8 in. cap Plug, fitting Plug, fitting Washer, aluminum (seal) Cover (w/inserts) Cover (w/inserts) Gasket # Washer, 3/8 in. lock 2 2 TP /03 51

54 Group 18: Timing Gear Cover, continued TP49599 Variation Item Description Gasket Cover Plug, drain O-ring 1 5 # Screw, M8 x # Screw, M8 x Screw 1 6 # Screw, M8 x # Screw, M8 x O-ring Cover 1 9 # Screw, M6 x Screw Kit, seal Valve Spring Washer Plug, fitting 1 16 # Nut, flange, M # Screw, M8 x Stud Stud (not shown) 2 52 TP /03

55 Group 21a: Oil Pan Code 1901 Serial -Contingent Oil Pans Use engine model and serial number to verify the oil pan for your generator set. Find your model and serial number on the engine nameplate and choose the oil pan code from the chart below. Then turn to the oil pan page containing the oil pan code to identify parts. Model Serial Code 4039D All T All 1908 CD4039DF Before CD4039DF and after 1910 CD4039TF Before CD4039TF and after DF All TF All 1904 TP25403 Qty. Var. Item Description Gasket, oil pan Pan, oil (also order items 5--7 and 11) 1 3 # Washer, lock 28 4 # Screw, 3/8-16 x 7/8 in Washer, seal Plug, drain 1 7 # Plug, pipe, recess. hex, 3/4 NPT 1 8 # Screw, 3/8-16 x 3/4 in Not Used 10 Not Used 11 # Plug, pipe, 1/2 NPT 1 TP /03 53

56 Group 21a: Oil Pan, continued Code Qty. Var. Item Description Gasket, oil pan Pan, oil 1 3 # Screw, M8 x O-ring Plug 2 6 # Plug, pipe, 3/4 in. 1 7 # Screw, M8 x Serial -Contingent Oil Pans TP26802 (was TP16412) Use engine model and serial number to verify the oil pan for your generator set. Find your model and serial number on the engine nameplate and choose the oil pan code from the chart below. Then turn to the oil pan page containing the oil pan code to identify parts. Model Serial Code 4039D All T All 1908 CD4039DF Before CD4039DF and after 1910 CD4039TF Before CD4039TF and after DF All TF All TP /03

57 Group 21a: Oil Pan, continued Code TP26802 (was TP16412) Serial -Contingent Oil Pans Use engine model and serial number to verify the oil pan for your generator set. Find your model and serial number on the engine nameplate and choose the oil pan code from the chart below. Then turn to the oil pan page containing the oil pan code to identify parts. Model Serial Code 4039D All T All 1908 CD4039DF Before CD4039DF and after 1910 CD4039TF Before CD4039TF and after DF All TF All 1904 Qty. Var. Item Description Gasket, oil pan Fitting O-ring Oil pan 1 5 # Screw, M8 x # Screw, M8 x # Screw, M8 x # Pipe plug, 3/4 in Plug 3 TP /03 55

58 Group 21a: Oil Pan, continued Code 1908 Qty. Var. Item Description Gasket, oil pan Pan, oil 1 3 # Washer, lock, 3/8 in # Screw, cap, 3/8-16 x 1 1/4 in # Screw, cap, 3/8-16 x 2 in Plug, drain Washer, seal O-ring Plug, drain 2 Serial -Contingent Oil Pans TP26802 (was TP16412) Use engine model and serial number to verify the oil pan for your generator set. Find your model and serial number on the engine nameplate and choose the oil pan code from the chart below. Then turn to the oil pan page containing the oil pan code to identify parts. Model Serial Code 4039D All T All 1908 CD4039DF Before CD4039DF and after 1910 CD4039TF Before CD4039TF and after DF All TF All TP /03

59 Group 21a: Oil Pan, continued Code 1910 CD40501 Serial -Contingent Oil Pans Use engine model and serial number to verify the oil pan for your generator set. Find your model and serial number on the engine nameplate and choose the oil pan code from the chart below. Then turn to the oil pan page containing the oil pan code to identify parts. Model Serial Code 4039D All T All 1908 CD4039DF Before CD4039DF and after 1910 CD4039TF Before CD4039TF and after DF All TF All 1904 Qty. Var. Item Description # Screw, 3/8 x 3/4 in # Washer, lock, 3/8 in # Strap Pan, oil Gasket Plug, drain O-ring 2 8 # Plug, pipe, 1/2 in.-14 NPT 1 TP /03 57

60 Group 21b: Oil Fill Tube 1, 7, 8 Not Used 11 TP26810 (was T30588) Variation Item Description Not Used Plug Gasket 1 4 # Screw, cap, 3/8-16 x 1 5/8 in Screw, cap 1 5 # Washer, 13/32 x 23/32 x 0.12 in. 2 6 # Screw, 3/8-16 x 3 in Screw, cap 1 7 Not Used 8 Not Used 9 See item 10 Gasket Gasket Neck, filler Cover 2 58 TP /03

61 Group 21c: Oil Cooler TP26821 Variation Item Description # Clamp # Hose,.625IDx1.0ODx20in Hose Flange Clamp 1 4 # Screw Tube, lower Tube, lower Hose, lower Hose, lower 1 7 # Clamp Plug, drain Washer Valve, relief Cooler, oil Cooler, oil Nipple, threaded Nipple, threaded Hose, upper Hose, upper Tube, upper Tube, upper Washer, spacer Washer, spacer Clamp Clamp 1 TP /03 59

62 Group 21c: Oil Cooler, continued TP49346 Variation Item Description # Screw Cooler, oil Gasket O-ring Housing Plug Plug Gasket O-ring Tube Adapter 1 12 # Screw, M8 x # Screw, M8 x # Screw, M8 x TP /03

63 Group 22: Piston and Connecting Rod Item 12 not shown. TP2835 Variation Item Description Screw, connecting rod Screw, connecting rod GM17477 Screw, connecting rod Bushing Bushing GM17451 Bushing 4 2 GM17446 Bushing Rod, connecting Rod, connecting GM17499 Rod, connecting 4 3 GM17610 Rod, connecting Ring, snap Ring, snap Pin, piston Pin, piston Pin, piston GM17450 Pin, piston Ring kit, piston (set 3) Ring kit, piston (set 3) Piston Piston 4 7 X Piston X Liner, cylinder X O-ring kit O-ring kit Kit, piston assembly Kit, piston assembly Kit, piston assembly Kit, piston assembly Kit, piston assembly Bearing (set of 2) standard Bearing (set of 2) standard Bearing (set of 2) standard Bearing (set of 2).002 in., undersize Bearing (set of 2).002 in., undersize Bearing (set of 2).010 in., undersize Bearing (set of 2).010 in., undersize Bearing (set of 2).010 in., undersize Bearing (set of 2).020 in., undersize Bearing (set of 2).020 in., undersize Bearing (set of 2).030 in., undersize Bearing (set of 2).030 in., undersize Lubricating soap (not shown) 1 1 X Item not sold separately. TP /03 61

64 Group 25: Oil Pump Engine model 4039 and engine model CD4039TF with engine serial numbers below TP26839 Variation Item Description Screw Screw # Washer, lock, 3/8 in X Cover Pin, groove X Pinion X Pin, dowel X Housing X Gear, 7 teeth O-ring O-ring # Nut, 1/2 in Kit, oil pump Washer Intake, oil pump Intake, oil pump Tube, oil Gear, 33 teeth 1 1 X Item not sold separately. 62 TP /03

65 Group 25: Oil Pump, continued Engine model 4045 and engine model CD4039TF with engine serial numbers and above CD39105 Variation Item Description # Nut, 1/2-13 in. 1 1 # Nut, M Gear Gear Pump, oil Pump, oil Screw, cap, 2.75 in. 3 4 # Screw, M8 x # Lock washer, 3/8 in Screw, cap, 3.89 in. 2 6 # Screw, M8 x Oil pump intake Oil pump intake O-ring O-ring O-ring Tube, oil Tube, oil 1 TP /03 63

66 Group 26: Front Plate T16883F (was TP1130) Variation Item Description Gasket Screw, set Screw, set 1 3 # Washer, ext. tooth lock, 3/8 in Screw Screw Plate Plate 1 64 TP /03

67 Group 26: Front Plate, continued T16883F (was TP1130) Variation Item Description GM23829 Plate Stud Stud Stud Washer, thrust Shaft Bushing 1 8 GM23841 Gear, upper idler Washer, thrust 1 10 # Screw, M6 x Shaft Screw 4 TP /03 65

68 Group 39a: Cylinder Head Gasket Set TP26212 Variation Item Description Gasket, rocker arm cover Gasket, cylinder head O-ring, valve stem O-ring, vent tube Gasket, thermostat housing Gasket, exhaust manifold Not Used Gasket, thermostat cover Gasket, air inlet Gasket, turbocharger outlet Gasket, turbocharger 1 11 X Gasket, turbocharger Gasket kit, cylinder head 1 1 X Item not sold separately. TP49292 Variation Item Description Gasket set, cylinder head 1 66 TP /03

69 Group 39b: Overhaul Gasket Kit Items are not shown. TP26471 Qty. Var. Item No. Description O-ring, valve stem Not Used Washer, tach. drive shaft Washer, oil drain plug Gasket, oil filler cap O-ring, vent tube O-ring, oil pump tube outlet Washer, oil cooler Gasket, cylinder head Gasket, turbo oil outlet Gasket, thermostat housing X Gasket, fuel injection pump Gasket, water pump cover Gasket, oil filler inlet Gasket, fuel pump X Gasket, turbo oil inlet Gasket, air inlet Gasket, turbocharger Gasket, injection pump gear cover 1 1 Qty. Var. Item No. Description Gasket, exhaust manifold Gasket, timing gear cover Gasket, cylinder block plate Gasket, timing gear cover Gasket, flywheel housing Gasket, oil pan Gasket, oil pan Gasket, single thermo. cover Not Used Gasket, thermostat cover Gasket kit O-ring, cylinder liner Washer, F.I. nozzle (not shown) Washer, F.I. nozzle (not shown) Seal, oil, crankshaft (not shown) Seal, oil, crankshaft (not shown) Gasket, thermostat hsg. (not shown) 1 1 X Item not sold separately. Note: For a complete set of gaskets, order items TP /03 67

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