TS-500 w/TK 3.

95 Engine

Contents

Name Grid Page

TS-500 w/TK 3.95 ENGINE REFERENCE

SHEET . . . . . . . . . . . . . . . .5U36. . . . . . . . . . . . . . . . . . . . . .5

JACKSHAFT
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7B12 . . . . . . . . . . . . . . . . . . . . .75

BATTERY BOX ASSEMBLY

(DOMESTIC) . . . . . . . . . . . . . . . . . . . . . .38B2 . . . . . . . . . . . . . . . . . . . .185

THROTTLE SOLENOID GROUP (6/92 &

After) . . . . . . . . . . . . . . . . . .106A1 . . . . . . . . . . . . . . . . . . . .41

DEUTSCH IN-LINE
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . .112D9. . . . . . . . . . . . . . . . . . .119

WEATHER PACK CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . .115D14. . . . . . . . . . . . . . . . . .123

POWER RECEPTACLE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124G14. . . . . . . . . . . . . . . . . .133

RECEIVER TANK
GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125F4 . . . . . . . . . . . . . . . . . . .107

EVAPORATOR
COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131B10 . . . . . . . . . . . . . . . . . .181

STARTER
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132A8 . . . . . . . . . . . . . . . . . . . .39

CYLINDER BLOCK GROUP (TK

3.95) . . . . . . . . . . . . . . . . . . . . . . . . .132C1. . . . . . . . . . . . . . . . . . . . .7

GEAR HOUSING GROUP (TK

3.95) . . . . . . . . . . . . . . . . . . . . . . . . . . .132C2. . . . . . . . . . . . . . . . . . . . .9

MOUNTING FLANGE GROUP (TK

3.95) . . . . . . . . . . . . . . . . . . . . . . .132C3. . . . . . . . . . . . . . . . . . . .11

OIL SUMP GROUP (TK

3.95) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132C4. . . . . . . . . . . . . . . . . . . .13

CYLINDER HEAD & VALVE GROUP (TK

3.95) . . . . . . . . . . . . . . . . . .132C5. . . . . . . . . . . . . . . . . . . .15

INTAKE & EXHAUST MANIFOLD (TK

3.95) . . . . . . . . . . . . . . . . . . . . .132C6. . . . . . . . . . . . . . . . . . . .17

CAMSHAFT & DRIVING GEAR (TK

3.95) . . . . . . . . . . . . . . . . . . . . . .132C7. . . . . . . . . . . . . . . . . . . .19

CRANKSHAFT & PISTON GROUP (TK 3.95) . . . . . . . . . . . . . . . . . . .132C8. . . . . . . . . . . . . . . . . . . .21

OIL SYSTEM (TK
3.95) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132C9. . . . . . . . . . . . . . . . . . . .23

WATER PUMP GROUP (TK

3.95) . . . . . . . . . . . . . . . . . . . . . . . . . . . .132C10. . . . . . . . . . . . . . . . . . .25

FUEL INJECTION PUMP & VALVE GROUP (TK 3.95) . . . . . . . . . . . .132C11. . . . . . . . . . . . . . . . . . .27

GOVERNOR (TK
3.95) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132C12. . . . . . . . . . . . . . . . . . .31

GASKET SET (TK

3.95) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132C13. . . . . . . . . . . . . . . . . . .35

STARTER & GLOW PLUG GROUP (TK

3.95) . . . . . . . . . . . . . . . . . . .132C14. . . . . . . . . . . . . . . . . . .37

FUEL FILTER, HOSES &

FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . .136D7. . . . . . . . . . . . . . . . . . . .43

REMOTE LIGHT BOX (KIT 40-

708) . . . . . . . . . . . . . . . . . . . . . . . . . . .136G2. . . . . . . . . . . . . . . . . . .137

FUEL TANK & PUMP

GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136G5. . . . . . . . . . . . . . . . . . .187

REMOTE LIGHTS PC
BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136G6. . . . . . . . . . . . . . . . . . .135

REMOTE CONTROL BOX

MOUNTING . . . . . . . . . . . . . . . . . . . . . . . .136G7. . . . . . . . . . . . . . . . . . .149

SOLENOID VALVE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138A11 . . . . . . . . . . . . . . . . . .111

FUEL & OIL FILTERS, HOSES & FITTINGS (KIT 088693) . . . . . . . . .139B14 . . . . . . . . . . . . . . . . . . .47

BELTS, PULLEYS & FAN

GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . .139E3 . . . . . . . . . . . . . . . . . . . .65

IDLER PULLEY
GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139E5 . . . . . . . . . . . . . . . . . . . .79

ENGINE MOUNTING GROUP (After 8/91) . . . . . . . . . . . . . . . . . . . . . .139E6 . . . . . . . . . . . . . . . . . . .

.81

COMPRESSOR
GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139E8 . . . . . . . . . . . . . . . . . . .103

THROTTLING VALVE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .139E9 . . . . . . . . . . . . . . . . . . .105

DEHYDRATOR
GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139E11 . . . . . . . . . . . . . . . . . .113
ALTERNATOR
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139E13 . . . . . . . . . . . . . . . . . .153

NAMEPLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143D11. . . . . . . . . . . . . . . . . .1
91

ALTERNATOR (23 AMP PRESTOLITE

8MR21301) . . . . . . . . . . . . . .143E14 . . . . . . . . . . . . . . . . . .155

FANSHAFT ASSEMBLY & ROLLER BEARING . . . . . . . . . . . . . . . . . .144B1 . . . . . . . . . . . . . . . . . . . .71

HIGH VOLTAGE TRAY - 3

PHASE . . . . . . . . . . . . . . . . . . . . . . . . . . . .144F9 . . . . . . . . . . . . . . . . . . .131

AIR SWITCH
GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144F10 . . . . . . . . . . . . . . . . . .151

CLUTCH ASSEMBLY (107-

291) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145F4 . . . . . . . . . . . . . . . . . . . .69

ENGINE IDLER PULLEY GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . .147C14. . . . . . . . . . . . . . . . . . .77

REFRIGERATION COMPONENTS - EVAPORATOR . . . . . . . . . . . . .148B1 . . . . . . . . . . . . . . . . . . . .93

JACKSHAFT
GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148B6 . . . . . . . . . . . . . . . . . . . .73

CONTROL
BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152G5. . . . . . . . . . . . . . . . . . .125

FUSE LINK, BATTERY CABLES & HOSE MANAGEMENT (KIT

715610) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152G6. . . . . . . . . . . . . . . . . . .
143
TS-500 w/TK 3.95 Engine

Contents

Name Grid Page

INTAKE & EXHAUST

GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152G8. . . . . . . . . . . . . . . . . . . .51

ENGINE COOLING SYSTEM (6/01 &

Before) . . . . . . . . . . . . . . . . . . .152G9. . . . . . . . . . . . . . . . . . . .57

REFRIGERATION COMPONENTS - CONDENSER (Before 7/01) . . .152G11. . . . . . . . . . . . . . . . . . .85

REFRIGERATION TUBES, CLAMPS & MOUNTING (Before

7/01) . . .152G12. . . . . . . . . . . . . . . . . . .95

ELECTRICAL
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152G13. . . . . . . . . . . . . . . . . .115

NAMEPLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152G14. . . . . . . . . . . . . . . . . .1
89

TRUCK DAS DATALOGGER GROUP (KIT 088741 &

088747) . . . . . .153F1 . . . . . . . . . . . . . . . . . . .141

3-WAY VALVE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153F10 . . . . . . . . . . . . . . . . . .109

INTAKE & EXHAUST SYSTEM (OIL BATH, KIT 088753) . . . . . . . . . .153F11 . . . . . . . . . . . . . . . . . . .55

DOOR SWITCH (OPTIONAL, KIT

715176) . . . . . . . . . . . . . . . . . . . . . .153F12 . . . . . . . . . . . . . . . . . .139

BOTTOM COVERS & TOP SCREEN GROUP (6/01 &

Before) . . . . . .153F13 . . . . . . . . . . . . . . . . . .175

ROADSIDE COVER GROUP (6/01 &

Before). . . . . . . . . . . . . . . . . . . .153F14 . . . . . . . . . . . . . . . . . .171

CONDENSER FRAME GROUP (6/01 &

Before) . . . . . . . . . . . . . . . . . .154F1 . . . . . . . . . . . . . . . . . . .157

FRONT GRILLE GROUP (6/01 &

Before) . . . . . . . . . . . . . . . . . . . . . . .154F2 . . . . . . . . . . . . . . . . . . .161

GULLWING & ENGINE DOOR GROUP (6/01 &

Before) . . . . . . . . . . .154F3 . . . . . . . . . . . . . . . . . . .165

BATTERY CONNECTIONS (w/INLINE

FUSE) . . . . . . . . . . . . . . . . . . .161G6. . . . . . . . . . . . . . . . . . .147

BOTTOM COVERS & TOP SCREEN GROUP (7/01 &

After) . . . . . . . .167H0. . . . . . . . . . . . . . . . . . .179

CONDENSER FRAME GROUP (7/01 &

After) . . . . . . . . . . . . . . . . . . .167H6. . . . . . . . . . . . . . . . . . .159
FRONT GRILLE GROUP (7/01 &
After) . . . . . . . . . . . . . . . . . . . . . . . .167H7. . . . . . . . . . . . . . . . . . .163

GULLWING & ENGINE DOOR GROUP (7/01 &

After) . . . . . . . . . . . . .167H8. . . . . . . . . . . . . . . . . . .169

ROADSIDE COVER GROUP (7/01 &

After) . . . . . . . . . . . . . . . . . . . . .167H9. . . . . . . . . . . . . . . . . . .173

ENGINE COOLING SYSTEM (7/01 &

After) . . . . . . . . . . . . . . . . . . . . .169D1. . . . . . . . . . . . . . . . . . . .61

REFRIGERATION COMPONENTS - CONDENSER (After

6/01) . . . . .169D2. . . . . . . . . . . . . . . . . . . .89

REFRIGERATION TUBES, CLAMPS & MOUNTING (After

6/01) . . . .169D3. . . . . . . . . . . . . . . . . . . .99
TS-500 w/TK 3.95 Engine

Contents

Name Grid Page

 5U36 TS-500 w/TK 3.95 ENGINE REFERENCE SHEET

Revised

7/17/01

TS-500 w/TK 3.95

ENGINE REFER-

ENCE SHEET

5U36

7/17/01

5
Revised

7/17/01 TS-500 w/TK 3.95 ENGINE REFERENCE SHEET 5U36

B/M DESCRIPTION Date

918310 System TS-500 30 SR 10/99

918311 System TS-500 50 SR 230V 10/99

918312 System TS-500 50 SR 380/460V 10/99

919200 System TS-500 50 SR (PHASE II) 7/01

919201 System TS-500 50 SR 230V (PHASE II) 7/01

919202 System TS-500 50 SR 380/460V (PHASE II) 7/01

088728 TS-500 Generic 10/99

088771 TS-500 Generic (PHASE II) 7/01

088729 TS-500 30 SR 10/99

088730 TS-500 50 SR 230/3/60 10/99

088731 TS-500 50 SR 380/460V 10/99

088692 Silicone Hoses 10/99

088693 Bypass Oil Filter 10/99

088741 DAS Datalogger 10/99

088753 Oil Bath Air Cleaner 10/99

088761 Electric Heater TS-500 230V 10/99

088762 Electric Heater TS-500 460V 10/99

088780 Roadside Hose Management Kit (PHASE II) 7/01

715173 Fuel Tank (30 gal) 7/01

715176 Door Switch 10/99

715610 Hose Management Kit 10/99

719181 Offset Curved Hose Manuagemant Kit (PHASE II) 7/01

719182 Additional Straight Section Hose Managemant Kit 7/01

(PHASE II)

718350 DAS Sensor - 10 ft 10/99

718351 DAS Sensor - 20 ft 10/99

718352 DAS Sensor - 40 ft 10/99

810044 Battery Box Kit 10/99

818310 Installation Kit 10/99

818200 Installation Kit (PHASE II) 7/01

6
 132C1 CYLINDER BLOCK GROUP (TK 3.95)

Revised

5/29/01

CYLINDER BLOCK

GROUP (TK 3.95)

132C1

5/29/01

7
Revised

5/29/01 CYLINDER BLOCK GROUP (TK 3.95) 132C1

REF PART# DESCRIPTION QTY

101-327 ENGINE (complete, TK 3.95 engine w/fuel stop solenoid, RD- 1

II, TD-II, XDS)

101-379 ENGINE (complete, TK 3.95 engine w/fuel stop solenoid, 1

URD)

101-307 ENGINE (complete, TK 3.95 engine w/fuel stop solenoid, 1

LND)

101-308 SHORT BLOCK - assembly (TK 3.95 engine) 1

1 12-725 • BLOCK - cylinder 1

2 55-6176 •• PLUG (pt 1/4) 1

3 55-6177 •• PLUG (pt 1/8) 1

4 11-6554 •• PLUG (45 mm) 1

5 11-6555 •• PLUG (12 mm) 1

6 11-5499 •• PLUG - expansion 6

7 55-6232 •• BOLT - main 8

8 11-6557 •• BEARING - main (standard) 4

11-6560 •• BEARING - main (.25 mm us) 4

9 11-6558 •• BEARING - thrust 2

10 11-6976 •• BUSHING - camshaft 1

11 NSS •• CAP - bearing housing 2

12 55-5798 • BOLT (M6 x 12 mm) 2

13 55-6179 • BOLT - cylinder head 14

14 * 33-2826 • GASKET - cylinder head 1

15 55-5780 • DRAIN COCK 1

16 11-6034 • FLANGE 1

17 11-8845 SLEEVE - cylinder 3

* 30-236 KIT - gasket (see 132C13) 1

8
 132C2 GEAR HOUSING GROUP (TK 3.95)

Revised

4/14/00

GEAR HOUSING

GROUP (TK 3.95)

132C2

4/14/00

9
Revised

4/14/00 GEAR HOUSING GROUP (TK 3.95) 132C2

REF PART# DESCRIPTION QTY

1 11-6561 HOUSING - gear 1

2 55-6208 • PIN - dowel 1

3 55-5784 • STUD - fuel injection (M8 x 22 mm) 4

4 55-5834 • PIN - governor (4 x 10) 2

5 11-8783 COVER - gear case 1

6 33-1727 • SEAL - oil 1

7 55-5785 PIPE 4

8 * 33-1728 SHIM PACK 1

9 55-5791 NUT (w/washer, M8) 4

10 33-1729 O-RING 2

11 55-5786 BOLT - cover (6 x 16 mm) 8

12 55-5787 BOLT - cover (6 x 30 mm) 8

13 55-5766 BOLT - cover (6 x 60 mm) 4

14 * 55-8613 WASHER - sealing 1

15 55-6181 BOLT - cover (6 x 80 mm) 6

16 11-6135 COVER 1

17 * 33-1754 GASKET 1

18 55-5859 STUD (6 x 12 mm) 4

19 11-5091 CAP - lube (oil supply) 1

20 33-1954 O-RING - cap 1

21 55-5792 NUT (M6) 4

22 11-5119 COVER 1

23 * 33-2814 O-RING 1

24 55-5826 BOLT - cover (6 x 18 mm) 2

25 * 33-1542 GASKET - cover 1

26 11-5084 COVER 1

27 55-5786 BOLT - cover (6 x 16 mm) 2

28 203-348 GASKET - adhesive (RTV silicone) A/R

* 30-236 KIT - gasket (see 132C13) 1

10
 132C3 MOUNTING FLANGE GROUP (TK 3.95)

Revised

2/6/01

MOUNTING

FLANGE GROUP

(TK 3.95)

132C3

2/6/01

11
Revised

2/6/01 MOUNTING FLANGE GROUP (TK 3.95) 132C3

REF PART# DESCRIPTION QTY

1 55-5816 PIN - dowel (8 x 16 mm) 2

2 11-7248 FLANGE - mounting 1

3 55-5848 BOLT - flange (10 x 20 mm) 6

4 55-6537 BOLT - flange (10 x 25 mm) 3

5 55-5860 BOLT 4

6 55-5795 PIN - dowel (6 x 10) 2

7 11-6032 HOUSING - oil seal 1

8 33-1506 • SEAL - oil 1

9 55-5849 BOLT - housing (6 x 22 mm) 6

10 203-348 GASKET - adhesive (RTV silicone) A/R

11 11-5967 SLEEVE - repair 1

12
 132C4 OIL SUMP GROUP (TK 3.95)

Revised

4/28/99

OIL SUMP GROUP

(TK 3.95)

132C4

4/28/99

13
Revised

4/28/99 OIL SUMP GROUP (TK 3.95) 132C4

REF PART# DESCRIPTION QTY

1 55-5762 PLUG 1

2 11-6564 COVER - oil sump 1

3 55-4610 • PLUG (npt 1/2) 1

4 11-8784 SUMP - oil 1

5 55-5763 • PLUG (npt 1/8) 1

6 55-5764 • PLUG (16 mm) 1

7 33-1729 O-RING 1

8 55-5765 BOLT - cover (6 x 25 mm) 24

9 55-5769 BOLT - sump (6 x 28 mm) 14

10 55-5836 BOLT - sump (6 x 70 mm) 6

11 11-6566 PIPE - oil inlet 1

12 33-1736 O-RING 1

13 55-5798 BOLT - oil pipe (6 x 12 mm) 3

14 55-193 PLUG - pipe (PT 3/8) 1

15 203-348 GASKET - adhesive (RTV silicone) A/R

16 11-7067 HOSE - oil drain (23 in) 1

11-6177 HOSE - oil drain (28 in) 1

11-8416 HOSE - oil drain (36 in) 1

17 55-2702 CAP - oil drain 1

18 91-734 CLIP - oil drain hose 1

55-3000 SCREW - clip 1

55-2001 FLATWASHER 2

55-4560 NUT 1

19 55-6557 ELBOW 1

203-393 SEALER - Loctite A/R

20 55-7732 PLUG - oil sump 1

33-3060 • GASKET - switch 1

21 41-402 SWITCH - oil level 1

14
 132C5 CYLINDER HEAD & VALVE GROUP (TK 3.95)

Revised

8/13/98

CYLINDER HEAD &

VALVE GROUP (TK

3.95)

132C5

8/13/98

15
Revised

8/13/98 CYLINDER HEAD & VALVE GROUP (TK 3.95) 132C5

REF PART# DESCRIPTION QTY

1 11-8786 HEAD - cylinder 1

2 55-5803 • PIN - spring 2

3 55-5804 • PLUG (pt 1/4) 2

4 55-5805 • PLUG (5 x 8 mm) 1

5 11-6567 • PLUG (40 mm) 2

6 11-8788 • VALVE - intake 3

7 11-6569 • VALVE - exhaust 3

8 11-6570 • SPRING - valve 6

9 11-6571 • RETAINER - spring 6

10 11-5482 • KEEPER - valve 6

11 33-1512 • SEAL - valve stem (intake) 3

12 33-1902 • SEAL - valve stem (exchange) 3

13 11-5093 • RETAINER 6

14 11-8787 • PLUG - hot 3

15 11-6574 • GUIDE - valve 6

16 * 11-6045 • PROTECTOR - nozzle 3

17 * 33-1733 • GASKET - nozzle 6

18 11-8785 LIFTER - engine 1

19 11-6036 LIFTER - engine 1

20 55-5801 BOLT - lifter 4

21 55-5810 NUT 2

22 11-6576 SHAFT - rocker 1

23 11-7068 ARM - rocker 3

24 11-6134 • ADJUSTER - valve 3

25 55-5846 • LOCKNUT 3

26 11-6977 ARM - rocker 3

27 11-6134 • ADJUSTER - valve 3

28 55-5846 • LOCKNUT 3
29 11-6577 SUPPORT - rocker arm 3

30 11-6578 SPRING 2

31 11-6579 CIRCLIP 2

32 55-6207 SCREW 1

33 55-5808 STUD 2

34 55-5809 BOLT - rocker 1

35 11-8863 SEAT - suction valve 3

36 11-6979 SEAT - exhaust valve 3

* 30-236 KIT - gasket (see 132C13) 1

16
 132C6 INTAKE & EXHAUST MANIFOLD (TK 3.95)

Revised

9/17/98

INTAKE &

EXHAUST MANI-

FOLD (TK 3.95)

132C6

9/17/98

17
Revised

9/17/98 INTAKE & EXHAUST MANIFOLD (TK 3.95) 132C6

REF PART# DESCRIPTION QTY

1 * 33-1905 GASKET - intake 1

2 11-6586 MANIFOLD - intake 1

3 11-8792 • JOINT - breather 1

4 55-5763 • PLUG (npt 1/8) 1

5 55-5988 BOLT (M6 x 45 mm) 1

6 55-5786 BOLT (M6 x 16 mm) 2

7 * 33-1906 GASKET - exhaust 1

8 * 33-1907 GASKET - muffler 1

9 55-6183 LOCKWASHER (M8) 4

10 55-5772 BOLT (M8 x 40 mm) 4

11 55-6184 STUD (M8 x 22 mm) 4

12 55-6383 STUD (M8 x 55 mm) 2

13 55-6186 NUT (M8) 4

14 55-5791 NUT (w/washer, M8) 2

15 11-6587 MANIFOLD - exhaust 1

* 30-236 KIT - gasket (see 132C13) 1

18
 132C7 CAMSHAFT & DRIVING GEAR (TK 3.95)

Revised

6/14/00

CAMSHAFT &

DRIVING GEAR

(TK 3.95)

132C7

6/14/00

19
Revised

6/14/00 CAMSHAFT & DRIVING GEAR (TK 3.95) 132C7

REF PART# DESCRIPTION QTY

1 11-8793 CAMSHAFT (incl 2, 5, 20) 1

2 11-6589 • GEAR - camshaft 1

3 11-6590 TAPPET 6

4 11-8090 ROD - push 6

5 55-5813 KEY - camshaft 1

6 11-6080 PLATE - idler gear 1

7 11-8748 SHAFT - idler gear 1

8 11-6592 GEAR - idler (incl 12) 1

9 55-4657 CIRCLIP - gear 1

10 55-5798 BOLT - shaft 3

11 NSS GEAR - injection camshaft 1

12 11-6083 BUSHING - idler gear 1

13 11-6062 CASE - bearing 1

14 11-6594 CAMSHAFT - injection pump (incl 11, 15, 17) 1

15 55-5813 KEY - injection camshaft 1

16 11-6060 BEARING - ball 1

17 11-6595 BEARING - ball 1

18 55-5786 BOLT - case 3

19 55-4635 SCREW - case 1

20 11-6034 BEARING - thrust 1

21 55-5798 SCREW - thrust bearing 2

20
 132C8 CRANKSHAFT & PISTON GROUP (TK 3.95)

Revised

6/12/96

CRANKSHAFT &

PISTON GROUP

(TK 3.95)

132C8

6/12/96

21
Revised

6/12/96 CRANKSHAFT & PISTON GROUP (TK 3.95) 132C8

REF PART# DESCRIPTION QTY

1 12-726 CRANKSHAFT 1

2 55-5813 • KEY - crankshaft 1

3 11-8794 • GEAR - crankshaft 1

4 55-5816 • PIN - dowel 1

5 55-6382 BOLT - flywheel 5

6 11-8795 FLYWHEEL 1

7 11-7031 • GEAR - ring 1

8 77-2371 PULLEY - crankshaft 1

9 55-5818 BOLT - pulley 1

10 55-5819 WASHER 1

11 11-8796 PISTON (w/rings, standard) 3

11-8800 PISTON (w/rings, .25 os) 3

11-8802 PISTON (w/rings, .50 os) 3

12 11-8797 RING SET (standard) 3

11-8801 RING SET (0.25 os) 3

11-8803 RING SET (0.50 os) 3

13 11-8798 PIN - piston 3

14 11-6598 CIRCLIP 6

15 11-6599 ROD - connecting (incl 16, 17 & 18) 3

16 11-5042 • BOLT - rod 6

17 11-6607 BEARING - rod (standard) 3

11-6608 BEARING - rod (0.25 os) 3

18 11-6606 BUSHING - finished 3

11-8616 • BUSHING - unfinished 3

22
 132C9 OIL SYSTEM (TK 3.95)

Revised

8/17/00

OIL SYSTEM (TK

3.95)

132C9

8/17/00

23
Revised

8/17/00 OIL SYSTEM (TK 3.95) 132C9

REF PART# DESCRIPTION QTY

1 11-6610 PUMP - oil 1

2 * 33-1740 GASKET - oil pump 1

3 55-6187 BOLT - pump (6 x 20 mm) 3

4 11-6086 GUIDE - dipstick 1

5 11-6609 GUIDE - dipstick 1

6 11-6611 DIPSTICK 1

7 33-1736 O-RING 1

8 55-5822 BOLT - dipstick (6 x 10 mm) 1

9 11-6612 BRACKET - oil filter 1

10 * 33-1908 GASKET - bracket 1

11 11-6182 FILTER - oil (4.0 in lg) 1

11-7987 FILTER - oil (3.45 in lg) 1

11-9267 FILTER - oil (2.83 in lg, LND-II only) 1

12 33-1909 • O-RING - oil filter 1

13 11-6613 VALVE - oil pressure 1

14 55-5823 NUT 1

15 33-1910 O-RING 1

16 55-6188 BOLT - bracket (8 x 20 mm) 3

17 55-8391 ADAPTER 1

55-5763 • PLUG (npt 1/8) 1

18 55-5989 PLUG - dipstick hole (URD only) 1

* 30-236 KIT - gasket (see 132C13) 1

24
 132C10 WATER PUMP GROUP (TK 3.95)

Revised

6/14/01

WATER PUMP

GROUP (TK 3.95)

132C10

6/14/01

25
Revised

6/14/01 WATER PUMP GROUP (TK 3.95) 132C10

REF PART# DESCRIPTION QTY

1 11-9450 PUMP - water (ELC compatible) 1

2 * 33-3477 GASKET 1

3 55-5809 BOLT - water pump 4

4 11-8805 COVER - thermostat (includes 8) 1

5 * 33-1520 GASKET 1

6 11-7894 THERMOSTAT 1

7 33-2829 O-RING 1

8 55-5763 PLUG 1

9 55-6236 BOLT - cover (8 x 55 mm) 1

10 55-6246 BOLT - cover (8 x 25 mm) 1

11 78-1026 BELT - water pump 1

12 77-1426 PULLEY (split sheave) 1

13 77-1427 • SHIM 4

14 77-1428 • SPACER 1

15 55-5792 NUT 4

16 55-8443 PLUG - water pump 2

17 55-5138 STUD - water pump 4

18 41-2330 SENSOR - water temperature 1

203-385 SEALER - thread A/R

* 30-236 KIT - gasket (see 132C13) 1

26
 132C11 FUEL INJECTION PUMP & VALVE GROUP (TK 3.95)

Revised

11/10/99

FUEL INJECTION

PUMP & VALVE

GROUP (TK 3.95)

132C11

11/10/99

27
Revised

11/10/99 FUEL INJECTION PUMP & VALVE GROUP (TK 3.95) 132C11

REF PART# DESCRIPTION QTY

1 11-6617 PUMP - fuel injection 1

2 11-6618 • PLUNGER (w/barrel) 3

3 11-6095 • RETAINER 3

4 11-6096 • RETAINER 3

5 11-6097 • SPRING - plunger 3

6 11-6098 • SHIM SET 3

7 11-6619 • VALVE - delivery 3

8 11-6019 • SPRING - delivery valve 3

9 11-6166 • HOLDER - valve 3

10 33-1746 • GASKET 3

11 33-1747 • O-RING 3

12 11-6147 • GUIDE - plunger 3

13 11-6148 • PIN 1

14 11-6149 • RACK 1

15 11-6150 • PINION 3

16 11-6152 • RETAINER - rack 1

17 11-6153 • PLATE 2

18 55-5773 • SCREW - plate 2

19 55-5774 • PIN 2

20 55-5775 • PIN 1

21 11-6101 • TAPPET 3

22 55-6194 • FLATWASHER (M4) 2

23 55-4752 • LOCKWASHER (M4) 2

24 55-5828 • SCREW - retainer (4 x 8 mm) 4

25 55-5829 • SCREW - plate (4 x 10 mm) 2

26 11-8769 VALVE - fuel injection 3

27 11-6102 • NOZZLE - injection 3

28 11-6103 • HOLDER - valve (w/case) 3

29 11-6104 • BODY - valve 3

30 11-6105 • SPRING - valve 3

31 11-6106 • SEAT - spring 3

32 11-6107 • SPACER - valve stop 3

33 11-6108 • SHIM SET 3

34 33-1748 • O-RING 3

35 11-6109 CLAMP - injection pipe 1

36 55-8626 BOLT - clamp (4 x 14 mm) 2

37 11-6115 NUT - injector 3

38 11-6551 PIPE - fuel injection (1) 1

28
132C11 FUEL INJECTION PUMP & VALVE GROUP (TK 3.95)

Revised

11/10/99

29
Revised

11/10/99 FUEL INJECTION PUMP & VALVE GROUP (TK 3.95) 132C11

REF PART# DESCRIPTION QTY

39 11-6552 PIPE - fuel injection (2) 1

40 11-6553 PIPE - fuel injection (3) 1

41 33-1531 GASKET 2

42 11-6110 BOLT 1

43 NSS • BOLT - joint 1

44 55-5831 • PLUG - air bleed 1

45 55-8613 • WASHER - sealing 1

46 11-6622 JOINT 1

47 33-1749 GASKET 3

48 11-8808 PIPE - fuel return 1

49 11-6136 • FITTING - injection 1

50 11-6137 • FITTING - injection 2

51 11-6623 • PIPE - fuel return 2

52 55-6195 • CLAMP - pipe 4

30
 132C12 GOVERNOR (TK 3.95)

Revised

9/7/00

GOVERNOR (TK

3.95)

132C12

9/7/00
TS-500 w/TK 3.95 Engine

Contents

Name Grid Page

TS-500 w/TK 3.95 ENGINE REFERENCE

SHEET . . . . . . . . . . . . . . . .5U36. . . . . . . . . . . . . . . . . . . . . .5

JACKSHAFT
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7B12 . . . . . . . . . . . . . . . . . . . . .75

BATTERY BOX ASSEMBLY

(DOMESTIC) . . . . . . . . . . . . . . . . . . . . . .38B2 . . . . . . . . . . . . . . . . . . . .185

THROTTLE SOLENOID GROUP (6/92 &

After) . . . . . . . . . . . . . . . . . .106A1 . . . . . . . . . . . . . . . . . . . .41

DEUTSCH IN-LINE
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . .112D9. . . . . . . . . . . . . . . . . . .119

WEATHER PACK CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . .115D14. . . . . . . . . . . . . . . . . .123

POWER RECEPTACLE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124G14. . . . . . . . . . . . . . . . . .133

RECEIVER TANK
GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125F4 . . . . . . . . . . . . . . . . . . .107

EVAPORATOR
COMPARTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131B10 . . . . . . . . . . . . . . . . . .181

STARTER
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132A8 . . . . . . . . . . . . . . . . . . . .39

CYLINDER BLOCK GROUP (TK

3.95) . . . . . . . . . . . . . . . . . . . . . . . . .132C1. . . . . . . . . . . . . . . . . . . . .7

GEAR HOUSING GROUP (TK

3.95) . . . . . . . . . . . . . . . . . . . . . . . . . . .132C2. . . . . . . . . . . . . . . . . . . . .9

MOUNTING FLANGE GROUP (TK

3.95) . . . . . . . . . . . . . . . . . . . . . . .132C3. . . . . . . . . . . . . . . . . . . .11

OIL SUMP GROUP (TK

3.95) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132C4. . . . . . . . . . . . . . . . . . . .13

CYLINDER HEAD & VALVE GROUP (TK

3.95) . . . . . . . . . . . . . . . . . .132C5. . . . . . . . . . . . . . . . . . . .15

INTAKE & EXHAUST MANIFOLD (TK

3.95) . . . . . . . . . . . . . . . . . . . . .132C6. . . . . . . . . . . . . . . . . . . .17

CAMSHAFT & DRIVING GEAR (TK

3.95) . . . . . . . . . . . . . . . . . . . . . .132C7. . . . . . . . . . . . . . . . . . . .19

CRANKSHAFT & PISTON GROUP (TK 3.95) . . . . . . . . . . . . . . . . . . .132C8. . . . . . . . . . . . . . . . . . . .21

OIL SYSTEM (TK
3.95) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132C9. . . . . . . . . . . . . . . . . . . .23

WATER PUMP GROUP (TK

3.95) . . . . . . . . . . . . . . . . . . . . . . . . . . . .132C10. . . . . . . . . . . . . . . . . . .25

FUEL INJECTION PUMP & VALVE GROUP (TK 3.95) . . . . . . . . . . . .132C11. . . . . . . . . . . . . . . . . . .27

GOVERNOR (TK
3.95) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132C12. . . . . . . . . . . . . . . . . . .31

GASKET SET (TK

3.95) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132C13. . . . . . . . . . . . . . . . . . .35

STARTER & GLOW PLUG GROUP (TK

3.95) . . . . . . . . . . . . . . . . . . .132C14. . . . . . . . . . . . . . . . . . .37

FUEL FILTER, HOSES &

FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . .136D7. . . . . . . . . . . . . . . . . . . .43

REMOTE LIGHT BOX (KIT 40-

708) . . . . . . . . . . . . . . . . . . . . . . . . . . .136G2. . . . . . . . . . . . . . . . . . .137

FUEL TANK & PUMP

GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136G5. . . . . . . . . . . . . . . . . . .187

REMOTE LIGHTS PC
BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136G6. . . . . . . . . . . . . . . . . . .135

REMOTE CONTROL BOX

MOUNTING . . . . . . . . . . . . . . . . . . . . . . . .136G7. . . . . . . . . . . . . . . . . . .149

SOLENOID VALVE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138A11 . . . . . . . . . . . . . . . . . .111

FUEL & OIL FILTERS, HOSES & FITTINGS (KIT 088693) . . . . . . . . .139B14 . . . . . . . . . . . . . . . . . . .47

BELTS, PULLEYS & FAN

GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . .139E3 . . . . . . . . . . . . . . . . . . . .65

IDLER PULLEY
GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139E5 . . . . . . . . . . . . . . . . . . . .79

ENGINE MOUNTING GROUP (After 8/91) . . . . . . . . . . . . . . . . . . . . . .139E6 . . . . . . . . . . . . . . . . . . .

.81

COMPRESSOR
GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139E8 . . . . . . . . . . . . . . . . . . .103

THROTTLING VALVE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .139E9 . . . . . . . . . . . . . . . . . . .105

DEHYDRATOR
GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139E11 . . . . . . . . . . . . . . . . . .113
ALTERNATOR
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139E13 . . . . . . . . . . . . . . . . . .153

NAMEPLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143D11. . . . . . . . . . . . . . . . . .1
91

ALTERNATOR (23 AMP PRESTOLITE

8MR21301) . . . . . . . . . . . . . .143E14 . . . . . . . . . . . . . . . . . .155

FANSHAFT ASSEMBLY & ROLLER BEARING . . . . . . . . . . . . . . . . . .144B1 . . . . . . . . . . . . . . . . . . . .71

HIGH VOLTAGE TRAY - 3

PHASE . . . . . . . . . . . . . . . . . . . . . . . . . . . .144F9 . . . . . . . . . . . . . . . . . . .131

AIR SWITCH
GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144F10 . . . . . . . . . . . . . . . . . .151

CLUTCH ASSEMBLY (107-

291) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145F4 . . . . . . . . . . . . . . . . . . . .69

ENGINE IDLER PULLEY GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . .147C14. . . . . . . . . . . . . . . . . . .77

REFRIGERATION COMPONENTS - EVAPORATOR . . . . . . . . . . . . .148B1 . . . . . . . . . . . . . . . . . . . .93

JACKSHAFT
GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148B6 . . . . . . . . . . . . . . . . . . . .73

CONTROL
BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152G5. . . . . . . . . . . . . . . . . . .125

FUSE LINK, BATTERY CABLES & HOSE MANAGEMENT (KIT

715610) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152G6. . . . . . . . . . . . . . . . . . .
143
TS-500 w/TK 3.95 Engine

Contents

Name Grid Page

INTAKE & EXHAUST

GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152G8. . . . . . . . . . . . . . . . . . . .51

ENGINE COOLING SYSTEM (6/01 &

Before) . . . . . . . . . . . . . . . . . . .152G9. . . . . . . . . . . . . . . . . . . .57

REFRIGERATION COMPONENTS - CONDENSER (Before 7/01) . . .152G11. . . . . . . . . . . . . . . . . . .85

REFRIGERATION TUBES, CLAMPS & MOUNTING (Before

7/01) . . .152G12. . . . . . . . . . . . . . . . . . .95

ELECTRICAL
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152G13. . . . . . . . . . . . . . . . . .115

NAMEPLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152G14. . . . . . . . . . . . . . . . . .1
89

TRUCK DAS DATALOGGER GROUP (KIT 088741 &

088747) . . . . . .153F1 . . . . . . . . . . . . . . . . . . .141

3-WAY VALVE
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153F10 . . . . . . . . . . . . . . . . . .109

INTAKE & EXHAUST SYSTEM (OIL BATH, KIT 088753) . . . . . . . . . .153F11 . . . . . . . . . . . . . . . . . . .55

DOOR SWITCH (OPTIONAL, KIT

715176) . . . . . . . . . . . . . . . . . . . . . .153F12 . . . . . . . . . . . . . . . . . .139

BOTTOM COVERS & TOP SCREEN GROUP (6/01 &

Before) . . . . . .153F13 . . . . . . . . . . . . . . . . . .175

ROADSIDE COVER GROUP (6/01 &

Before). . . . . . . . . . . . . . . . . . . .153F14 . . . . . . . . . . . . . . . . . .171

CONDENSER FRAME GROUP (6/01 &

Before) . . . . . . . . . . . . . . . . . .154F1 . . . . . . . . . . . . . . . . . . .157

FRONT GRILLE GROUP (6/01 &

Before) . . . . . . . . . . . . . . . . . . . . . . .154F2 . . . . . . . . . . . . . . . . . . .161

GULLWING & ENGINE DOOR GROUP (6/01 &

Before) . . . . . . . . . . .154F3 . . . . . . . . . . . . . . . . . . .165

BATTERY CONNECTIONS (w/INLINE

FUSE) . . . . . . . . . . . . . . . . . . .161G6. . . . . . . . . . . . . . . . . . .147

BOTTOM COVERS & TOP SCREEN GROUP (7/01 &

After) . . . . . . . .167H0. . . . . . . . . . . . . . . . . . .179

CONDENSER FRAME GROUP (7/01 &

After) . . . . . . . . . . . . . . . . . . .167H6. . . . . . . . . . . . . . . . . . .159
FRONT GRILLE GROUP (7/01 &
After) . . . . . . . . . . . . . . . . . . . . . . . .167H7. . . . . . . . . . . . . . . . . . .163

GULLWING & ENGINE DOOR GROUP (7/01 &

After) . . . . . . . . . . . . .167H8. . . . . . . . . . . . . . . . . . .169

ROADSIDE COVER GROUP (7/01 &

After) . . . . . . . . . . . . . . . . . . . . .167H9. . . . . . . . . . . . . . . . . . .173

ENGINE COOLING SYSTEM (7/01 &

After) . . . . . . . . . . . . . . . . . . . . .169D1. . . . . . . . . . . . . . . . . . . .61

REFRIGERATION COMPONENTS - CONDENSER (After

6/01) . . . . .169D2. . . . . . . . . . . . . . . . . . . .89

REFRIGERATION TUBES, CLAMPS & MOUNTING (After

6/01) . . . .169D3. . . . . . . . . . . . . . . . . . . .99
TS-500 w/TK 3.95 Engine

Contents

Name Grid Page

 5U36 TS-500 w/TK 3.95 ENGINE REFERENCE SHEET

Revised

7/17/01

TS-500 w/TK 3.95

ENGINE REFER-

ENCE SHEET

5U36

7/17/01

5
Revised

7/17/01 TS-500 w/TK 3.95 ENGINE REFERENCE SHEET 5U36

B/M DESCRIPTION Date

918310 System TS-500 30 SR 10/99

918311 System TS-500 50 SR 230V 10/99

918312 System TS-500 50 SR 380/460V 10/99

919200 System TS-500 50 SR (PHASE II) 7/01

919201 System TS-500 50 SR 230V (PHASE II) 7/01

919202 System TS-500 50 SR 380/460V (PHASE II) 7/01

088728 TS-500 Generic 10/99

088771 TS-500 Generic (PHASE II) 7/01

088729 TS-500 30 SR 10/99

088730 TS-500 50 SR 230/3/60 10/99

088731 TS-500 50 SR 380/460V 10/99

088692 Silicone Hoses 10/99

088693 Bypass Oil Filter 10/99

088741 DAS Datalogger 10/99

088753 Oil Bath Air Cleaner 10/99

088761 Electric Heater TS-500 230V 10/99

088762 Electric Heater TS-500 460V 10/99

088780 Roadside Hose Management Kit (PHASE II) 7/01

715173 Fuel Tank (30 gal) 7/01

715176 Door Switch 10/99

715610 Hose Management Kit 10/99

719181 Offset Curved Hose Manuagemant Kit (PHASE II) 7/01

719182 Additional Straight Section Hose Managemant Kit 7/01

(PHASE II)

718350 DAS Sensor - 10 ft 10/99

718351 DAS Sensor - 20 ft 10/99

718352 DAS Sensor - 40 ft 10/99

810044 Battery Box Kit 10/99

818310 Installation Kit 10/99

818200 Installation Kit (PHASE II) 7/01

6
 132C1 CYLINDER BLOCK GROUP (TK 3.95)

Revised

5/29/01

CYLINDER BLOCK

GROUP (TK 3.95)

132C1

5/29/01

7
Revised

5/29/01 CYLINDER BLOCK GROUP (TK 3.95) 132C1

REF PART# DESCRIPTION QTY

101-327 ENGINE (complete, TK 3.95 engine w/fuel stop solenoid, RD- 1

II, TD-II, XDS)

101-379 ENGINE (complete, TK 3.95 engine w/fuel stop solenoid, 1

URD)

101-307 ENGINE (complete, TK 3.95 engine w/fuel stop solenoid, 1

LND)

101-308 SHORT BLOCK - assembly (TK 3.95 engine) 1

1 12-725 • BLOCK - cylinder 1

2 55-6176 •• PLUG (pt 1/4) 1

3 55-6177 •• PLUG (pt 1/8) 1

4 11-6554 •• PLUG (45 mm) 1

5 11-6555 •• PLUG (12 mm) 1

6 11-5499 •• PLUG - expansion 6

7 55-6232 •• BOLT - main 8

8 11-6557 •• BEARING - main (standard) 4

11-6560 •• BEARING - main (.25 mm us) 4

9 11-6558 •• BEARING - thrust 2

10 11-6976 •• BUSHING - camshaft 1

11 NSS •• CAP - bearing housing 2

12 55-5798 • BOLT (M6 x 12 mm) 2

13 55-6179 • BOLT - cylinder head 14

14 * 33-2826 • GASKET - cylinder head 1

15 55-5780 • DRAIN COCK 1

16 11-6034 • FLANGE 1

17 11-8845 SLEEVE - cylinder 3

* 30-236 KIT - gasket (see 132C13) 1

8
 132C2 GEAR HOUSING GROUP (TK 3.95)

Revised

4/14/00

GEAR HOUSING

GROUP (TK 3.95)

132C2

4/14/00

9
Revised

4/14/00 GEAR HOUSING GROUP (TK 3.95) 132C2

REF PART# DESCRIPTION QTY

1 11-6561 HOUSING - gear 1

2 55-6208 • PIN - dowel 1

3 55-5784 • STUD - fuel injection (M8 x 22 mm) 4

4 55-5834 • PIN - governor (4 x 10) 2

5 11-8783 COVER - gear case 1

6 33-1727 • SEAL - oil 1

7 55-5785 PIPE 4

8 * 33-1728 SHIM PACK 1

9 55-5791 NUT (w/washer, M8) 4

10 33-1729 O-RING 2

11 55-5786 BOLT - cover (6 x 16 mm) 8

12 55-5787 BOLT - cover (6 x 30 mm) 8

13 55-5766 BOLT - cover (6 x 60 mm) 4

14 * 55-8613 WASHER - sealing 1

15 55-6181 BOLT - cover (6 x 80 mm) 6

16 11-6135 COVER 1

17 * 33-1754 GASKET 1

18 55-5859 STUD (6 x 12 mm) 4

19 11-5091 CAP - lube (oil supply) 1

20 33-1954 O-RING - cap 1

21 55-5792 NUT (M6) 4

22 11-5119 COVER 1

23 * 33-2814 O-RING 1

24 55-5826 BOLT - cover (6 x 18 mm) 2

25 * 33-1542 GASKET - cover 1

26 11-5084 COVER 1

27 55-5786 BOLT - cover (6 x 16 mm) 2

28 203-348 GASKET - adhesive (RTV silicone) A/R

* 30-236 KIT - gasket (see 132C13) 1

10
 132C3 MOUNTING FLANGE GROUP (TK 3.95)

Revised

2/6/01

MOUNTING

FLANGE GROUP

(TK 3.95)

132C3

2/6/01

11
Revised

2/6/01 MOUNTING FLANGE GROUP (TK 3.95) 132C3

REF PART# DESCRIPTION QTY

1 55-5816 PIN - dowel (8 x 16 mm) 2

2 11-7248 FLANGE - mounting 1

3 55-5848 BOLT - flange (10 x 20 mm) 6

4 55-6537 BOLT - flange (10 x 25 mm) 3

5 55-5860 BOLT 4

6 55-5795 PIN - dowel (6 x 10) 2

7 11-6032 HOUSING - oil seal 1

8 33-1506 • SEAL - oil 1

9 55-5849 BOLT - housing (6 x 22 mm) 6

10 203-348 GASKET - adhesive (RTV silicone) A/R

11 11-5967 SLEEVE - repair 1

12
 132C4 OIL SUMP GROUP (TK 3.95)

Revised

4/28/99

OIL SUMP GROUP

(TK 3.95)

132C4

4/28/99

13
Revised

4/28/99 OIL SUMP GROUP (TK 3.95) 132C4

REF PART# DESCRIPTION QTY

1 55-5762 PLUG 1

2 11-6564 COVER - oil sump 1

3 55-4610 • PLUG (npt 1/2) 1

4 11-8784 SUMP - oil 1

5 55-5763 • PLUG (npt 1/8) 1

6 55-5764 • PLUG (16 mm) 1

7 33-1729 O-RING 1

8 55-5765 BOLT - cover (6 x 25 mm) 24

9 55-5769 BOLT - sump (6 x 28 mm) 14

10 55-5836 BOLT - sump (6 x 70 mm) 6

11 11-6566 PIPE - oil inlet 1

12 33-1736 O-RING 1

13 55-5798 BOLT - oil pipe (6 x 12 mm) 3

14 55-193 PLUG - pipe (PT 3/8) 1

15 203-348 GASKET - adhesive (RTV silicone) A/R

16 11-7067 HOSE - oil drain (23 in) 1

11-6177 HOSE - oil drain (28 in) 1

11-8416 HOSE - oil drain (36 in) 1

17 55-2702 CAP - oil drain 1

18 91-734 CLIP - oil drain hose 1

55-3000 SCREW - clip 1

55-2001 FLATWASHER 2

55-4560 NUT 1

19 55-6557 ELBOW 1

203-393 SEALER - Loctite A/R

20 55-7732 PLUG - oil sump 1

33-3060 • GASKET - switch 1

21 41-402 SWITCH - oil level 1

14
 132C5 CYLINDER HEAD & VALVE GROUP (TK 3.95)

Revised

8/13/98

CYLINDER HEAD &

VALVE GROUP (TK

3.95)

132C5

8/13/98

15
Revised

8/13/98 CYLINDER HEAD & VALVE GROUP (TK 3.95) 132C5

REF PART# DESCRIPTION QTY

1 11-8786 HEAD - cylinder 1

2 55-5803 • PIN - spring 2

3 55-5804 • PLUG (pt 1/4) 2

4 55-5805 • PLUG (5 x 8 mm) 1

5 11-6567 • PLUG (40 mm) 2

6 11-8788 • VALVE - intake 3

7 11-6569 • VALVE - exhaust 3

8 11-6570 • SPRING - valve 6

9 11-6571 • RETAINER - spring 6

10 11-5482 • KEEPER - valve 6

11 33-1512 • SEAL - valve stem (intake) 3

12 33-1902 • SEAL - valve stem (exchange) 3

13 11-5093 • RETAINER 6

14 11-8787 • PLUG - hot 3

15 11-6574 • GUIDE - valve 6

16 * 11-6045 • PROTECTOR - nozzle 3

17 * 33-1733 • GASKET - nozzle 6

18 11-8785 LIFTER - engine 1

19 11-6036 LIFTER - engine 1

20 55-5801 BOLT - lifter 4

21 55-5810 NUT 2

22 11-6576 SHAFT - rocker 1

23 11-7068 ARM - rocker 3

24 11-6134 • ADJUSTER - valve 3

25 55-5846 • LOCKNUT 3

26 11-6977 ARM - rocker 3

27 11-6134 • ADJUSTER - valve 3

28 55-5846 • LOCKNUT 3
29 11-6577 SUPPORT - rocker arm 3

30 11-6578 SPRING 2

31 11-6579 CIRCLIP 2

32 55-6207 SCREW 1

33 55-5808 STUD 2

34 55-5809 BOLT - rocker 1

35 11-8863 SEAT - suction valve 3

36 11-6979 SEAT - exhaust valve 3

* 30-236 KIT - gasket (see 132C13) 1

16
 132C6 INTAKE & EXHAUST MANIFOLD (TK 3.95)

Revised

9/17/98

INTAKE &

EXHAUST MANI-

FOLD (TK 3.95)

132C6

9/17/98

17
Revised

9/17/98 INTAKE & EXHAUST MANIFOLD (TK 3.95) 132C6

REF PART# DESCRIPTION QTY

1 * 33-1905 GASKET - intake 1

2 11-6586 MANIFOLD - intake 1

3 11-8792 • JOINT - breather 1

4 55-5763 • PLUG (npt 1/8) 1

5 55-5988 BOLT (M6 x 45 mm) 1

6 55-5786 BOLT (M6 x 16 mm) 2

7 * 33-1906 GASKET - exhaust 1

8 * 33-1907 GASKET - muffler 1

9 55-6183 LOCKWASHER (M8) 4

10 55-5772 BOLT (M8 x 40 mm) 4

11 55-6184 STUD (M8 x 22 mm) 4

12 55-6383 STUD (M8 x 55 mm) 2

13 55-6186 NUT (M8) 4

14 55-5791 NUT (w/washer, M8) 2

15 11-6587 MANIFOLD - exhaust 1

* 30-236 KIT - gasket (see 132C13) 1

18
 132C7 CAMSHAFT & DRIVING GEAR (TK 3.95)

Revised

6/14/00

CAMSHAFT &

DRIVING GEAR

(TK 3.95)

132C7

6/14/00

19
Revised

6/14/00 CAMSHAFT & DRIVING GEAR (TK 3.95) 132C7

REF PART# DESCRIPTION QTY

1 11-8793 CAMSHAFT (incl 2, 5, 20) 1

2 11-6589 • GEAR - camshaft 1

3 11-6590 TAPPET 6

4 11-8090 ROD - push 6

5 55-5813 KEY - camshaft 1

6 11-6080 PLATE - idler gear 1

7 11-8748 SHAFT - idler gear 1

8 11-6592 GEAR - idler (incl 12) 1

9 55-4657 CIRCLIP - gear 1

10 55-5798 BOLT - shaft 3

11 NSS GEAR - injection camshaft 1

12 11-6083 BUSHING - idler gear 1

13 11-6062 CASE - bearing 1

14 11-6594 CAMSHAFT - injection pump (incl 11, 15, 17) 1

15 55-5813 KEY - injection camshaft 1

16 11-6060 BEARING - ball 1

17 11-6595 BEARING - ball 1

18 55-5786 BOLT - case 3

19 55-4635 SCREW - case 1

20 11-6034 BEARING - thrust 1

21 55-5798 SCREW - thrust bearing 2

20
 132C8 CRANKSHAFT & PISTON GROUP (TK 3.95)

Revised

6/12/96

CRANKSHAFT &

PISTON GROUP

(TK 3.95)

132C8

6/12/96

21
Revised

6/12/96 CRANKSHAFT & PISTON GROUP (TK 3.95) 132C8

REF PART# DESCRIPTION QTY

1 12-726 CRANKSHAFT 1

2 55-5813 • KEY - crankshaft 1

3 11-8794 • GEAR - crankshaft 1

4 55-5816 • PIN - dowel 1

5 55-6382 BOLT - flywheel 5

6 11-8795 FLYWHEEL 1

7 11-7031 • GEAR - ring 1

8 77-2371 PULLEY - crankshaft 1

9 55-5818 BOLT - pulley 1

10 55-5819 WASHER 1

11 11-8796 PISTON (w/rings, standard) 3

11-8800 PISTON (w/rings, .25 os) 3

11-8802 PISTON (w/rings, .50 os) 3

12 11-8797 RING SET (standard) 3

11-8801 RING SET (0.25 os) 3

11-8803 RING SET (0.50 os) 3

13 11-8798 PIN - piston 3

14 11-6598 CIRCLIP 6

15 11-6599 ROD - connecting (incl 16, 17 & 18) 3

16 11-5042 • BOLT - rod 6

17 11-6607 BEARING - rod (standard) 3

11-6608 BEARING - rod (0.25 os) 3

18 11-6606 BUSHING - finished 3

11-8616 • BUSHING - unfinished 3

22
 132C9 OIL SYSTEM (TK 3.95)

Revised

8/17/00

OIL SYSTEM (TK

3.95)

132C9

8/17/00

23
Revised

8/17/00 OIL SYSTEM (TK 3.95) 132C9

REF PART# DESCRIPTION QTY

1 11-6610 PUMP - oil 1

2 * 33-1740 GASKET - oil pump 1

3 55-6187 BOLT - pump (6 x 20 mm) 3

4 11-6086 GUIDE - dipstick 1

5 11-6609 GUIDE - dipstick 1

6 11-6611 DIPSTICK 1

7 33-1736 O-RING 1

8 55-5822 BOLT - dipstick (6 x 10 mm) 1

9 11-6612 BRACKET - oil filter 1

10 * 33-1908 GASKET - bracket 1

11 11-6182 FILTER - oil (4.0 in lg) 1

11-7987 FILTER - oil (3.45 in lg) 1

11-9267 FILTER - oil (2.83 in lg, LND-II only) 1

12 33-1909 • O-RING - oil filter 1

13 11-6613 VALVE - oil pressure 1

14 55-5823 NUT 1

15 33-1910 O-RING 1

16 55-6188 BOLT - bracket (8 x 20 mm) 3

17 55-8391 ADAPTER 1

55-5763 • PLUG (npt 1/8) 1

18 55-5989 PLUG - dipstick hole (URD only) 1

* 30-236 KIT - gasket (see 132C13) 1

24
 132C10 WATER PUMP GROUP (TK 3.95)

Revised

6/14/01

WATER PUMP

GROUP (TK 3.95)

132C10

6/14/01

25
Revised

6/14/01 WATER PUMP GROUP (TK 3.95) 132C10

REF PART# DESCRIPTION QTY

1 11-9450 PUMP - water (ELC compatible) 1

2 * 33-3477 GASKET 1

3 55-5809 BOLT - water pump 4

4 11-8805 COVER - thermostat (includes 8) 1

5 * 33-1520 GASKET 1

6 11-7894 THERMOSTAT 1

7 33-2829 O-RING 1

8 55-5763 PLUG 1

9 55-6236 BOLT - cover (8 x 55 mm) 1

10 55-6246 BOLT - cover (8 x 25 mm) 1

11 78-1026 BELT - water pump 1

12 77-1426 PULLEY (split sheave) 1

13 77-1427 • SHIM 4

14 77-1428 • SPACER 1

15 55-5792 NUT 4

16 55-8443 PLUG - water pump 2

17 55-5138 STUD - water pump 4

18 41-2330 SENSOR - water temperature 1

203-385 SEALER - thread A/R

* 30-236 KIT - gasket (see 132C13) 1

26
 132C11 FUEL INJECTION PUMP & VALVE GROUP (TK 3.95)

Revised

11/10/99

FUEL INJECTION

PUMP & VALVE

GROUP (TK 3.95)

132C11

11/10/99

27
Revised

11/10/99 FUEL INJECTION PUMP & VALVE GROUP (TK 3.95) 132C11

REF PART# DESCRIPTION QTY

1 11-6617 PUMP - fuel injection 1

2 11-6618 • PLUNGER (w/barrel) 3

3 11-6095 • RETAINER 3

4 11-6096 • RETAINER 3

5 11-6097 • SPRING - plunger 3

6 11-6098 • SHIM SET 3

7 11-6619 • VALVE - delivery 3

8 11-6019 • SPRING - delivery valve 3

9 11-6166 • HOLDER - valve 3

10 33-1746 • GASKET 3

11 33-1747 • O-RING 3

12 11-6147 • GUIDE - plunger 3

13 11-6148 • PIN 1

14 11-6149 • RACK 1

15 11-6150 • PINION 3

16 11-6152 • RETAINER - rack 1

17 11-6153 • PLATE 2

18 55-5773 • SCREW - plate 2

19 55-5774 • PIN 2

20 55-5775 • PIN 1

21 11-6101 • TAPPET 3

22 55-6194 • FLATWASHER (M4) 2

23 55-4752 • LOCKWASHER (M4) 2

24 55-5828 • SCREW - retainer (4 x 8 mm) 4

25 55-5829 • SCREW - plate (4 x 10 mm) 2

26 11-8769 VALVE - fuel injection 3

27 11-6102 • NOZZLE - injection 3

28 11-6103 • HOLDER - valve (w/case) 3

29 11-6104 • BODY - valve 3

30 11-6105 • SPRING - valve 3

31 11-6106 • SEAT - spring 3

32 11-6107 • SPACER - valve stop 3

33 11-6108 • SHIM SET 3

34 33-1748 • O-RING 3

35 11-6109 CLAMP - injection pipe 1

36 55-8626 BOLT - clamp (4 x 14 mm) 2

37 11-6115 NUT - injector 3

38 11-6551 PIPE - fuel injection (1) 1

28
132C11 FUEL INJECTION PUMP & VALVE GROUP (TK 3.95)

Revised

11/10/99

29
Revised

11/10/99 FUEL INJECTION PUMP & VALVE GROUP (TK 3.95) 132C11

REF PART# DESCRIPTION QTY

39 11-6552 PIPE - fuel injection (2) 1

40 11-6553 PIPE - fuel injection (3) 1

41 33-1531 GASKET 2

42 11-6110 BOLT 1

43 NSS • BOLT - joint 1

44 55-5831 • PLUG - air bleed 1

45 55-8613 • WASHER - sealing 1

46 11-6622 JOINT 1

47 33-1749 GASKET 3

48 11-8808 PIPE - fuel return 1

49 11-6136 • FITTING - injection 1

50 11-6137 • FITTING - injection 2

51 11-6623 • PIPE - fuel return 2

52 55-6195 • CLAMP - pipe 4

30
 132C12 GOVERNOR (TK 3.95)

Revised

9/7/00

GOVERNOR (TK

3.95)

132C12

9/7/00