Description

FG Wilson 27 kVA, 200 kVA 2013 Parts Catalog

You have a FG Wilson genset – 27 kVA or 200 kVA – on the floor and the parts list the counter guy handed you is wrong. I have seen it a hundred times. A mechanic pulls a cylinder block assembly, gets the wrong crank kit, and the job turns into a two-day wait for a return. That is why this FG Wilson 27 kVA, 200 kVA 2013 Parts Catalog matters. It is the exact document FG Wilson dealers use. 583 pages of factory part numbers, exploded views, and kit breakdowns. No aftermarket cross-reference fluff.

I have been turning wrenches for 28 years, and I will tell you straight: if you order a crankshaft kit without the OEM catalog number, you are gambling. Page 2 alone lists the entire engine section – Short Engine, Cylinder Block Assembly, Crankshaft Kit, Main Bearing Kit – all with the correct FG Wilson OEM references. This catalog is for the 27 kVA and 200 kVA diesel sets with the 1104C-TAG2 engine governed electronically (RJ51407 blue).

Parts Catalog, Not a Service Manual

This is a Parts Catalog, not a repair procedure manual. If you need torque specs or disassembly steps, get the service manual separately. Here you get exploded diagrams and callouts for every component – from the short engine assembly down to the oil filler cap. You see exactly which piston and ring kit fits the 27 kVA or the 200 kVA. The catalog organizes parts by engine groups: Short Engine, Cylinder Head Assembly, Rocker Shaft Assembly, Timing Gear & Camshaft, and Crankshaft, Main & Big End Bearings. Each section has its own parts list with FG Wilson part numbers.

For example, look at the Crankshaft Kit listings. They appear both under the short engine and again in the dedicated Crankshaft, Main & Big End Bearings section. That is deliberate – you can order the crank as a complete overhaul item or as an individual component. The catalog also includes three overhaul kit sizes: Standard, 0.5mm Oversize, and 1.0mm Oversize. Each kit packs an Engine Overhaul Kit, Gasket Kit – Top, Gasket Kit – Bottom, and Seal Kit. If you are rebuilding a 27 kVA engine that has been bored once before, you need the 0.5mm oversize kit – not the standard. The catalog saves you that mistake.

What This 583-Page Document Actually Covers

The catalog covers the 27 kVA and 200 kVA diesel gensets with the 1104C-TAG2 engine. But it also includes common parts across the range: fuel injection equipment, flywheel housing, starter motor, fan drive, lubricating oil sump, oil filter and cooler, water pump and thermostat, timing case and gear, and alternator. Every section has its own parts breakdown. For instance, the Fuel Injection Equipment section lists the Fuel Injection Pump, High Pressure Fuel Pipes, Atomisers (injectors), Throttle & Stop Controls, and the Electronic Governor Kit. The governor kit is critical because if you swap a pump without verifying the governor part number, the engine may not hold load. Page references in the table of contents (like pages 101–132) guide you to the exact fuel injection spread.

Note: the catalog is dated 2013. FG Wilson may have superseded some parts since then. Always cross-reference the part number with a dealer before ordering. But at least you start with the right number, not a guess.

Engine Breakdown: Cylinder Block, Crankshaft, and Connecting Rods

Three of the most critical assemblies in any diesel engine are the Cylinder Block, the Crankshaft, and the connecting rods. The catalog shows them individually and as kits. For the 27 kVA and 200 kVA units, the Cylinder Block Assembly is listed as a separate breakdown with part numbers for liners, bearings, and plugs. The Crankshaft Kit includes the crankshaft itself plus bearings – main and big end. The Connecting Rod section lists both Con Rod Assembly and Conrod Kit (rod with bolts and bearings). If you are building a short engine from scratch, you order the Short Engine – Assembly kit (which includes con rods, piston and ring kit, cylinder block, and crankshaft). The catalog lets you compare part numbers between the 27 kVA and the 200 kVA – they share many bottom-end components, but the piston and ring kits may differ. That is the kind of detail you need on the bench.

One thing I appreciate: the catalog also lists Rear End Oil Seal separately. Many mechanics overlook that until the engine is assembled and they realize the seal is not in the gasket kit. Not a problem with this catalog – you see the seal as a line item under the short engine section.

3 Kits for Overhaul Sizes

The Engine Kits section is organized by size: 1.0mm Oversize, 0.5mm Oversize, and Standard. Each size includes an Engine Overhaul Kit (which itself contains a Piston and Ring Kit, Piston Ring Kit, Gasket Kit – Top, Seal Kit, Gasket Kit – Bottom). If you are rebuilding a 200 kVA with worn cylinder liners, you can order the 1.0mm oversize overhaul kit and get all the gaskets and seals in one basket. That saves the headache of piecing together top and bottom gasket sets from different suppliers. The catalog shows the exact FG Wilson part numbers for each kit. No aftermarket cross-reference that may be wrong – you get the OEM number and order that.

For a DIY shop owner or a technician working on a rental fleet, this catalog pays for itself the first time you avoid ordering the wrong piston ring kit. A set of rings for the 27 kVA may look identical to the 200 kVA but have a different groove width. The catalog lists them separately. Trust the factory data.

Fuel Injection and Governor System Coverage

The Fuel Injection Equipment section is extensive. It covers the Fuel Injection Pump (with a dedicated breakdown page), High Pressure Fuel Pipes, Atomisers (injectors), Throttle & Stop Controls, and the Control Unit (Electronic Governor Kit). The Electronic Governor Kit includes the actuator and control module. The Pick-Up Sensor is listed separately. If you are troubleshooting a 27 kVA that hunts at idle, you need the governor part number. The catalog gives you that number. Also, it lists the Sensors section (generic) and Fuel Leak-Off Pipe assembly. This level of detail matters when you are rebuilding a fuel system because the high-pressure pipes are specific to engine serial numbers. The catalog does not give you pipe lengths; it gives you the part number. Order that number and the pipe will fit.

I have seen mechanics replace a fuel injection pump on a 200 kVA using a generic pump and then spend hours adjusting the engine to run. With this catalog, you get the OEM pump part number and the matching governor kit. That is how you keep the genset on load.

Why OEM Data Beats Aftermarket Cross-References

Aftermarket parts catalogs are compiled from third-party databases that merge part numbers from multiple manufacturers. They get the basics right, but for a FG Wilson engine with a specific electronic governor (RJ51407 blue), they often miss subtle variants. The OEM catalog was printed from FG Wilson’s own parts database. Every number has been verified against the serial number range of the 27 kVA and 200 kVA gensets. You can see the serial number on the cover: FGWPPEU3CRPC04841. That serial number corresponds to a specific build. If your genset falls in that range, the part numbers in this catalog are correct.

For a broader look at how industrial engines work, see the Internal Combustion Engine explanation. For an overview of the automotive and genset industry, check Automotive Industry Overview. But for FG Wilson part numbers, this catalog is the only source you need.

Does this catalog include repair procedures like torque specs?

No. It is a Parts Catalog only. You get exploded views and part numbers, not assembly instructions. For torque values, get the service manual.

Can 27 kVA parts be used on the 200 kVA?

Some bottom-end parts (crankshaft, bearings) are the same between the 27 kVA and 200 kVA, but piston and ring kits differ. The catalog lists each separately. Always compare the part number on the page before ordering. For example, the Crankshaft Kit appears in both engine sections but the part number is identical; the Cylinder Block Assembly may differ. The catalog shows the differences explicitly.

You need the correct parts the first time. That is what this FG Wilson factory catalog delivers. 583 pages of OEM part numbers, kit groupings, and exploded views for the 27 kVA and 200 kVA diesel gensets. Access the Factory Manual and keep a copy in your shop binder. When a piston ring kit arrives, you can check the part number against the catalog before you open the box. That is how you stay ahead of the job.