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Thread: SA 200 Thermo King ( Isuzu D201) conversion

  1. #1
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    SA 200 Thermo King ( Isuzu D201) conversion

    Has anyone Converted a Thermo King Isuzu D201 Into a SA 200? I know most popular swaps are Kubota, Yanmar, And Perkins. I found this reefer unit and was wondering if it would work and have enough power. The info I found was that it makes around 34 hp @ 2200 rpms, but at 1550 rpm, maybe it has enough torque to handle max output of the generator. The other question is adapting the flywheel to armature, and bell housing.
    SA 200s : 1944 1945 1963 1965 1969
    1981 SA 250 D3.152 DC only
    2004 Ranger 10,000
    Lincoln Pro Mig 135
    Miller Load Bank
    Hobart GPB 258 Pipeliner
    Hobart GPB 261 Mainliner
    Hobart Airforce 250
    Everlast PA 200st

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  3. #2
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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    Quote Originally Posted by BYW200 View Post
    Has anyone Converted a Thermo King Isuzu D201 Into a SA 200? I know most popular swaps are Kubota, Yanmar, And Perkins. I found this reefer unit and was wondering if it would work and have enough power. The info I found was that it makes around 34 hp @ 2200 rpms, but at 1550 rpm, maybe it has enough torque to handle max output of the generator. The other question is adapting the flywheel to armature, and bell housing.
    My first question would be on changing the RPM of the engine. I think these engines are built to run on one RPM only.

    Good luck.

    Tom

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    The Red-D-Arc welders run Kubota engines at a constant speed.

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    I have found that the biggest issues are the expense of modifying the Flywheel and an adapter for the armature besides adapting the generator housing to the back of the engine from what I was told, and from what I understand, Isuzu built this engine model just for Thermo King, and didn't use it in any other applications, was wondering if anyone here has found an easier way.

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    thinking MQ Wisperweld ran Isuzu engine

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    Quote Originally Posted by BYW200 View Post
    Has anyone Converted a Thermo King Isuzu D201 Into a SA 200? I know most popular swaps are Kubota, Yanmar, And Perkins. I found this reefer unit and was wondering if it would work and have enough power. The info I found was that it makes around 34 hp @ 2200 rpms, but at 1550 rpm, maybe it has enough torque to handle max output of the generator. The other question is adapting the flywheel to armature, and bell housing.

    I'm in the process now...I did it to a 63 SA200...cut the center of the Isuzu flywheel to make a spacer/bolt temp plate....had to make a .30" additional spacer to that to get the right spacing...used the TK bellhousing(after centering it on the Continental backing plate) to drill the holes and bolted that original backing plate to the Isuzu...the frame had to be modified(I had to cut out the left side and strengthen the frame)...the starter was kind of tricky...I was going to just use the two batteries in series trick I use on my 46 SA200 but the diesel takes 3 batteries(36 volts) to spin it fast(24 volts cranks the heck out of a worn out continental but just turns the Isuzu over)....any way it fits in the frame just 2" lower to keep the same generator mounts....I had to modify the old flywheel to put the Isuzu ring gear on it(in retrospect I'd use the shorter starter they sell for the SA200...my long one was too long and would have hit the oil filter housing) and that was a pain...But I got to use my lathes and welders alot so it has been awesome ...I'm new to this site so no pictures yet but I took a few.

    The starter slowed me down or I'd be welding with it but I'll let you know if you want...Michael

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    If your handy you just do it yourself....I did have some time in it to say the least so if you had to pay someone, ya, spendy! ....You need; a dial indecator to center the bellhousing(Isuzu) to the old backing plate, clamps to hold it while you drill the holes(none of them interfer with the SA stuff), a drill press and drill bits, a welder and grinder to fill in some of the old unneeded holes were you need metal, a hole saw to cut out the starter hole(I used a 3 5/8), die grinder to make the starter hole fit and a lathe to make the spacer(center of the Isuzu flywheel(I cut it out with 6" slicer blades) plus I had to make an additional .30" spacer(male on one side female on the other so it's centered)....learned alot about my lathe doing that....michael

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    I'm using a modified electric fan out of an old Chevy Citation to cool it...I used this TK diesel to power my bucked truck for years and had a Geo metro electric fan and small radiator and it never got hot...I could rev it up or down and shut it off or start it from the ground or the bucket....I'll add this to my remote so it doesn't have to run all day as I'm really high up most of the time and work by myself....

  12. #9
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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    sound good like see some pictures?

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    Quote Originally Posted by charlie53843 View Post
    sound good like see some pictures?
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    Re: SA 200 Thermo King ( Isuzu D201) conversion

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    I've been working so away from my computer....I don't seem to know which way is up on my camera so sorry...first time on uploading pics so that was a pain...hope to finish this weekend....would have been done but I decided to modify the flywheel to except the Isuzu ring gear(will do that different next time)...didn't want to have to lug around 3 batteries to start it with the generator(welder)...if 24 volts would have turned it over I wouldn't have went through that pain but the Isuzu takes 36 volts back fed through the leads(lowest setting) to turn over really nice(24 volts almost stops on every compression stroke)....the extra frame will be the trailer for this....but I need it on a job next week so it will just be slid in my van and I'll paint it when I get time....

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    The left side of the frame did not have to be changed at all....I used the c-channel to lower the mount and stiffen the frame back up since the whole top side by the motor on the right side needed to go(it doesn't go outside of the frame however)....the c-channel frame cutout and removal of the old motor mount is all I did...and everything else fits so far....will post more pics if anyone cares....Michael

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    looking good

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    Quote Originally Posted by BYW200 View Post
    Has anyone Converted a Thermo King Isuzu D201 Into a SA 200? I know most popular swaps are Kubota, Yanmar, And Perkins. I found this reefer unit and was wondering if it would work and have enough power. The info I found was that it makes around 34 hp @ 2200 rpms, but at 1550 rpm, maybe it has enough torque to handle max output of the generator. The other question is adapting the flywheel to armature, and bell housing.
    I didn't really answer your question...sorry...I haven't run it yet but when I used the D201 on my bucket truck it did the trick but I'll let you know when it's done....I cut the center of the D201 flywheel outName:  2216.jpg
Views: 221
Size:  19.5 KB then used my lathe to center it on the SA200 flywheelName:  2219.jpg
Views: 216
Size:  19.3 KBI was hoping this would be too much so I could just take some off but I needed .300" more to line up the housing and the armature Name:  2231.jpg
Views: 214
Size:  19.7 KBName:  2237.jpg
Views: 221
Size:  21.7 KB I used the holes from the D201 "adaptor" I made to drill new holes in my SA200 flywheel and .30" additional spacer....I used the D201 bellhousing as a template to drill the holes in the SA200 to Continental adaptor plate(filling in holes as needed...but it did bolt up to the back of the D201 quite nicely)Name:  2351.jpg
Views: 209
Size:  21.5 KB both flywheels are not externally balanced so the SA200 flywheel works(I started It on the floor and rev'ed it up and it ran as smooth as a Honda)(I was not very impressed with the SA200 flywheel's quality it was off center, poorly welded and looked like a bunch of scrap metal they found on the floor(but now I know I can make my own flywheel if I need too(1200 rpm max)).... Getting pictures on here is a pain for me but I'm getting a little better(maybe)...If you have any other questions just let me know....Michael

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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    Quote Originally Posted by PlasmaGuy View Post
    My first question would be on changing the RPM of the engine. I think these engines are built to run on one RPM only.

    Good luck.

    Tom
    The Thermo King; D201 and the earlier Isuzu and Mercedes motors I've used to power my bucket trucks all have electrical solenoids to rev them up and can be set to any rpm or you can hook a throttle to them....I will be experimenting to see if I can get the SA wiring to rev it up....If not I'll add it to my three way switch on my remote as I did in my bucket trucks so I can start, stop and rev it up from my remote....I don't like stuff running all day if I'm not using it!

  24. #21
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    Re: SA 200 Thermo King ( Isuzu D201) conversion

    Quote Originally Posted by R&I View Post
    I didn't really answer your question...sorry...I haven't run it yet but when I used the D201 on my bucket truck it did the trick but I'll let you know when it's done....I cut the center of the D201 flywheel outName:  2216.jpg
Views: 221
Size:  19.5 KB then used my lathe to center it on the SA200 flywheelName:  2219.jpg
Views: 216
Size:  19.3 KBI was hoping this would be too much so I could just take some off but I needed .300" more to line up the housing and the armature Name:  2231.jpg
Views: 214
Size:  19.7 KBName:  2237.jpg
Views: 221
Size:  21.7 KB I used the holes from the D201 "adaptor" I made to drill new holes in my SA200 flywheel and .30" additional spacer....I used the D201 bellhousing as a template to drill the holes in the SA200 to Continental adaptor plate(filling in holes as needed...but it did bolt up to the back of the D201 quite nicely)Name:  2351.jpg
Views: 209
Size:  21.5 KB both flywheels are not externally balanced so the SA200 flywheel works(I started It on the floor and rev'ed it up and it ran as smooth as a Honda)(I was not very impressed with the SA200 flywheel's quality it was off center, poorly welded and looked like a bunch of scrap metal they found on the floor(but now I know I can make my own flywheel if I need too(1200 rpm max)).... Getting pictures on here is a pain for me but I'm getting a little better(maybe)...If you have any other questions just let me know....Michael

    WOW! That alot more than I figured it would take to convert. Your doing a great job!
    Last edited by BYW200; 03-06-2021 at 03:49 AM.
    SA 200s : 1944 1945 1963 1965 1969
    1981 SA 250 D3.152 DC only
    2004 Ranger 10,000
    Lincoln Pro Mig 135
    Miller Load Bank
    Hobart GPB 258 Pipeliner
    Hobart GPB 261 Mainliner
    Hobart Airforce 250
    Everlast PA 200st

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