service repair manual

1. Fig. 011 CYLINDER BLOCK
DL500

2. Fig. 011 CYLINDER BLOCK
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 K9003409 CYLINDER BLOCK ASS'Y 1
2 - BLOCK;CYLINDER 1 D
3 K9002985 PIN;DOWEL 2
4 K9002991 PLUG;RETAINER 1
5 K9003016 WASHER;PLAIN 1
6 K9003017 DISC;VALVE 1
7 K9003018 SPRING;COMPRESSION 1
8 K9003271 BUSHING 7
9 K9003005 PLUG;PIPE 2
10 K9003046 SEAT;PRS REGULATOR VALVE 1
11 K9003407 CAP;MAIN BEARING NO4 1
13 K9003047 CAP;MAIN BEARING 6
14 K9003250 KIT;SCREW HEX HEAD CAP 14 D
15 K9003028 WASHER;PLAIN 1
16 K9003194 SCREW;CAP 1
17 K9003329 STUD 7
18 K9002972 PIN;DOWEL 1
19 K9002983 PIN;DOWEL 2
20 K9003004 PLUG;EXPANSION 4
21 K9003003 PLUG;EXPANSION 9
22 K9003433 PIN;DOWEL 3
23 K9002321 PLUG;PIPE 1
24 K9003044 DOWEL;RING 3
25 K9003069 PLUG;THREADED 4
26 K9003069 PLUG;THREADED 1
27 K9003070 SEAL;O-RING 1
28 K9003089 PLUG;THREADED 1
29 - PLUG;THREADED 1 D
30 K9002326 SEAL;O-RING 1
31 K9003119 SENSOR;VISCOSITY 1
32 K9003116 PLUNGER;PRS REGULATOR 1
33 K9003013 SPRING;COMPRESSION 1
34 K9003285 PLUG;RETAINER 1
35 K9003082 NIPPLE;COUPLING 1
37 K9003252 KIT;CYLINDER LINER 6
38 - LINER;CYLINDER 1 D
1
DL500

3. Key No Part No Description Qty S.C Serial No ICA Replacable Qty
39 K9003093 SEAL;RECTANGULAR 1
42 K9003136 NOZZLE;PISTON COOLING 6
43 K9003127 SCREW;HEX FLANGE HEAD CAP 6
2
DL500

4. Fig. 012 TIMING GEAR CASE
DL500

5. Fig. 012 TIMING GEAR CASE
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 K9003431 GEAR HOUSING ASS'Y 1
2 - HOUSING;GEAR 1 D
3 K9003036 BEARING;NEEDLE 1
4 K9003317 BEARING;NEEDLE 1
5 K9003302 SEAL;O-RING 1
6 K9003256 SCREW;CAPTIVE WASHER CAP 11
7 K9003268 SCREW;CAPTIVE WASHER CAP 5
8 K9003179 SEAL;RECTANGULAR RING 6
9 K9003281 SEAL;RECTANGULAR RING 1
10 K9003282 SEAL;RECTANGULAR RING 1
11 K9003145 IDLER GEAR ASS'Y 1
12 - GEAR;IDLER 1 D
13 K9003042 BUSHING 1
14 K9003040 SHAFT;IDLER 1
15 K9003045 RETAINER;GEAR 1
16 K9003147 BEARING;THRUST 2
17 K9003150 PLATE;THRUST 1
18 K9003073 SCREW;CAP 3
19 K9003146 IDLER GEAR ASS'Y 1
20 - GEAR;IDLER 1 D
21 K9003043 BUSHING 1
22 K9003045 RETAINER;GEAR 1
23 K9003147 BEARING;THRUST 2
24 K9003073 SCREW;CAP 3
25 K9003041 SHAFT;IDLER 1
26 K9003072 IDLER GEAR ASS'Y 1
27 - GEAR;IDLER 1 D
28 K9003043 BUSHING 1
29 K9003147 BEARING;THRUST 2
30 K9003041 SHAFT;IDLER 1
31 K9003291 RETAINER;GEAR 1
32 K9003298 SCREW;TWELVE POINT CAP 3
33 K9003306 SEAL;RECTANGULAR RING 1
34 K9003290 SPACER;MOUNTING 1
35 K9003277 SUPPORT;HYDRAULIC PUMP 1
36 K9003265 ADAPTER;HYDRAULIC PUMP 1
1
DL500

6. Key No Part No Description Qty S.C Serial No ICA Replacable Qty
37 K9003036 BEARING;NEEDLE 1
38 K9003052 GEAR;PUMP 1
39 K9003035 ADAPTER;SPLINE 1
40 K9003170 GEAR;PUMP 1
41 K9002986 GASKET;HYDRAULIC PUMP 1
42 K9003167 SCREW;CAPTIVE WASHER CAP 3
43 K9003299 SEAL;O-RING 1
2
DL500

7. Fig. 013 TIMING GEAR CASE COVER
DL500

8. Fig. 013 TIMING GEAR CASE COVER
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 K9003428 KIT;GEAR COVER 1
2 - COVER;GEAR 1 D
3 K9003427 KIT;STRIP SEAL 1
4 K9003418 PLUG;GEAR COVER 1
5 K9003413 SCREW;HEX FLANGE HEAD CAP 5
6 K9003412 SCREW;HEX FLANGE HEAD CAP 33
7 K9003254 OIL SEAL KIT 1
8 - SEAL;OIL 1 D
9 K9003434 GASKET;CARRIER 1
10 K9003340 SEAL;DUST 1
11 K9003255 OIL SEAL KIT 1
12 - SEAL;OIL 1 D
13 - GASKET;CARRIER 1 D
14 K9003318 SEAL;DUST 1
19 K9003090 PULLEY;ACCESSORY DRIVE 1
20 K9003259 SCREW;CAP 1
21 K9003260 WASHER;PLAIN 1
1
DL500

9. Fig. 014 FLY WHEEL HOUSING
DL500

10. Fig. 014 FLY WHEEL HOUSING
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 K9002979 WASHER;PLAIN 14
2 K9002992 GASKET;WATER HEADER COVER 1
3 K9002322 PLUG;PIPE 1
4 K9002323 PLUG;PIPE 1
5 K9003026 SCREW;CAP 2
6 K9003031 SCREW;CAP 12
7 K9003037 SCREW;CAP 2
8 K9003038 GASKET;COVER PLATE 1
9 K9003039 COVER;ACCESS HOLE 1
10 K9003101 PLUG;THREADED 3
11 K9003173 PLATE;COVER 1
12 K9003202 SCREW;CAP 4
13 K9003234 HOUSING;FLYWHEEL 1
14 - HOUSING;FLYWHEEL 1 D
15 K9003267 SLEEVE 1
16 K9003425 KIT;REAR SEAL CRANK 1
17 - SEAL;OIL 1 D
18 K9003421 SCREW;CAP 12
1
DL500

11. Fig. 015 CRANK SHAFT & PISTON
DL500

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13. Fig. 015 CRANK SHAFT & PISTON
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 K9003130 CRANKSHAFT 1
2 K9003435 KEY;PLAIN WOODRUFF 1
3 K9003144 GEAR;CRANKSHAFT 1
4 K9003398 OIL SEAL KIT 1
4 K9003249 OIL SEAL KIT 1
5 K9003280 SLEEVE;WEAR 1
6 K9003400 MAIN METAL KIT (STD) 1
6 K9003401 MAIN METAL KIT (0.25) 1
6 K9003402 MAIN METAL KIT (0.5) 1
7 K9003023 METAL,MAIN(UPPER) 7
8 K9003024 METAL,MAIN(LOWER) 7
9 K9003393 WASHER;THRUST(LOWER) 2
9 K9003394 WASHER;THRUST(LOWER-0.25) 2 OS
10 K9003395 WASHER;THRUST(UPPER) 2
10 K9003396 WASHER;THRUST(UPPER-0.25) 2 OS
15 K9003183 FLYWHEEL ASS'Y 1
16 K9003182 FLYWHEEL 1
17 K9002969 GEAR;FLYWHEEL RING 1
18 K9003416 SCREW;HEX FLANGE HEAD CAP 8
19 K9003177 DAMPER;VIBRATION 1
20 K9003214 PULLEY;CRANKSHAFT 1
21 K9003295 PLATE;CLAMPING 1
22 K9003269 SCREW;CAP 5
23 K9003411 PLATE;CLAMPING 1
24 K9003426 PISTON KIT 6
25 K9004010 PISTON ASS'Y 1
26 - TOP;PISTON 1 D
27 - SKIRT;PISTON 1 D
28 K9003019 RING;RETAINING 2
29 K9003423 PIN;PISTON 1
30 K9003253 SET;PISTON RING 6
31 K9003160 RING;OIL PISTON 1
32 K9003343 RING;COMPRESSION PISTON 1
33 K9003315 RING;COMPRESSION PISTON 1
34 K9003344 ROD;ENGINE CONNECTING 6
35 - ROD;ENGINE CONNECTING 6 D
1
DL500

14. Key No Part No Description Qty S.C Serial No ICA Replacable Qty
36 K9003341 BUSHING 1
37 K9003048 DOWEL;RING 2
38 K9003049 SCREW;CAP 2
39 K9003020 MAIN METAL CON-ROD (STD) 12
39 K9003021 MAIN METAL CON-ROD (0.25) 12 US
39 K9003022 MAIN METAL CON-ROD (0.50) 12 US
2
DL500

15. Fig. 016 CYLINDER HEAD
DL500

16. Fig. 016 CYLINDER HEAD
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 K9003165 HEAD;CYLINDER TLA 1
2 - HEAD;CYLINDER 1 D
3 K9003003 PLUG;EXPANSION 2
4 K9002999 PLUG;EXPANSION 2
5 K9003004 PLUG;EXPANSION 8
6 K9003063 SEAL;O-RING 6
7 K9003236 SLEEVE;INJECTOR 6
8 K9003153 INSERT;VALVE 24
9 K9003195 GUIDE;VALVE 24
10 K9003330 SPRING;VALVE 24
11 K9003246 KIT;INTAKE VALVE 12
12 - VALVE;INTAKE 12 D
13 K9003186 COLLET;VALVE 24
14 K9003247 KIT;EXHAUST VALVE 12
15 - VALVE;EXHAUST 12 D
13 K9003186 COLLET;VALVE 24
17 K9003307 RETAINER;VALVE SPRING 24
18 K9003121 GUIDE;VALVE SPRING 24
19 K9002320 PLUG;PIPE 16
20 K9003276 PLUG;ORIFICE 6
21 K9003366 SEAL;VALVE STEM 24
22 K9003322 PLUG;EXPANSION 2
23 K9003086 SCREW;HEX FLANGE HEAD CAP 29
24 K9003436 SCREW;HEX FLANGE HEAD CAP 3
25 K9003374 GASKET;CYLINDER HEAD 1
26 K9003188 WASHER;SEALING 7
27 K9003191 SCREW;HEX FLANGE HEAD CAP 5
28 K9003189 SCREW;HEX FLANGE HEAD CAP 2
1
DL500

17. Fig. 017 CAM SHAFT MOUNTING
DL500