service repair manual

1. Fig. 001 CYLINDER BLOCK
DX520LC

2. Fig. 001 CYLINDER BLOCK
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.01101-6128D BLOCK;CYLINDER 1 ~061020 I 65.01101-6128F 1
1 65.01101-6128F BLOCK;CYLINDER 1 ~071030 Y 65.01101-6128H 1
1 65.01101-6128H BLOCK;CYLINDER 1 ~090530 Y 150102-00008 1
1 150102-00008 BLOCK;CYLINDER 1 090531~120524 I 150102-00411A 1
1 150102-00411A BLOCK ASSY,CYLINDER 1 120525~
1-1 65.01101-6111D BLOCK;CYLINDER 1 D ~061020
1-1 65.01101-6111F BLOCK;CYLINDER 1 D ~071030
1-1 65.01101-6111H BLOCK;CYLINDER 1 D ~090530
1-1 150102-00009 BLOCK;CYLINDER 1 D 090531~120524
1-1 150102-00412A BLOCK;CYLINDER 1 D 120525~
1-1A 65.01101-0111C BLOCK;CYLINDER 1 D ~071030
1-1A 65.01101-0111D BLOCK;CYLINDER 1 D ~090530
1-1A 65.01101-0111F BLOCK,CYLINDER 1 D 090531~120524
1-1A 150102-00401A BLOCK;CYLINDER 1 D 120525~
1-1B 65.01105-6014A BEARING CAP ASS'Y(TH) 1 D ~071030
1-1B 65.01105-6007 BEARING CAP ASS'Y(TH) 1 D ~090530
1-1B 140202-00020 CAP ASSY,BEARING;THRUST 1 D 090531~120524
1-1B 140110-00036 CAP ASSY;BEARING THRUST 1 D 120525~
1-1BA 65.01105-1181 CAP;BEARING 1 D ~071030
1-1BA 65.01105-1053 CAP;BEARING 1 D ~090530
1-1BA 140202-00011 CAP;BEARING 1 D 090531~
1-1BB 65.91301-0071 PIN 2
1-1C 65.01105-6013A BEARING CAP ASS'Y 3 D ~090530
1-1C 140202-00008 BEARING CAP ASS'Y 3 D 090531~
1-1CA 65.01105-1162C CAP;BEARING 1 D ~090530
1-1CA 140202-00011 CAP;BEARING 1 D 090531~
1-1CB 06.22022-3061 PIN;DOWEL 2
1-1D 65.90020-0293B BOLT;BEARING CAP 8
1-1E 06.01494-4316 BOLT;HEX. M12X1.5X85 8
1-1F 65.04410-0018 BUSH;CAMSHAFT 1 B
1-1G 65.04410-0078 BUSH;CAMSHAFT 3 B
1-1H 65.01113-1001B CAP;CP PUMP 1 D ~061020
1-1H 65.01113-1007A CAP;CP PUMP 1 D ~071030
1-1H 65.01113-1008 CAP;CP PUMP 1 D ~090530
1-1H 110910-00022 CAP;CP PUMP 1 D 090531~
1-1I 06.22022-1063 PIN 2
1
DX520LC

3. Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1-1J 65.90020-0094 BOLT;COLLARED HEX. 4
1-2 06.08041-2214 SCREW;PLUG 1 ~090530
1-3 06.56190-0739 RING;SEAL 1 ~090530
1-4 65.91606-0039 PLUG;CORE 4
1-5 65.91606-0037 PLUG;CORE 1
1-6 06.15090-2319 PLUG;CORE 2
1-7 65.90310-0149A SCREW;PLUG M26X1.5 3
1-8 06.56190-0726 SEAL;RING 3
1-9 65.90310-0147 SCREW;PLUG 2
1-10 65.90310-0131 SCREW;PLUG 1
1-11 06.56190-0713 RING;SEAL A18X24 1
1-12 06.08041-2203 SCREW;PLUG M14X1.5 1
1-13 06.56190-0706 SEAL RING A14X20 1
1-14 65.90310-0132 SCREW;PLUG 1
1-15 06.56190-0718 RING;SEAL 1
1-16 06.31641-0615 BALL;STEEL 1
1-17 06.31641-0624 BALL;STEEL 4
10 06.22022-1063 PIN 2
11 06.22022-3563 PIN;DOWEL 2
12 65.91030-0005 PIN 4
13 65.98131-5010 NIPPLE 1
14 06.56190-0706 SEAL RING A14X20 1
15 65.90310-0134 SCREW;PLUG 1
16 06.56190-0732 SEAL;RING 1
17 65.90310-0133 SCREW;PLUG 1
18 06.56190-0726 SEAL;RING 1
19 06.08040-2214 SOCKET SCREW;PLUG 1
20 06.56190-0739 RING;SEAL 1
30 65.06312-0003 CONNECTION 1
31 65.96601-0054 GASKET(C/W PIPE FLANGE) 1
32 06.06225-0812 BOLT;STUD M10X50 2
33 06.16731-2108 WASHER;SPRING 2
34 06.11063-8215 NUT;HEX. M10 2
35 06.08041-2202 SCREW;PLUG M12X1.5 1
36 06.56190-0704 RING;SEAL 1
37 65.91605-0013 COVER 1
40 65.01201-0073B LINER;CYLINDER 6
41 65.96501-0059 O-RING 6 ~120509 Y 401002-00785 6
2
DX520LC

4. Key No Part No Description Qty S.C Serial No ICA Replacable Qty
41 401002-00785 O-RING;CYL LINER 6 120510~
42 51.96501-0412 O-RING 6 ~070327 Y 65.96501-0082 6
42 65.96501-0082 O-RING 6 070328~120509 Y 401002-00786 6
42 401002-00786 O-RING;CYL LINER 6 120510~
43 65.96501-0078 O-RING 6 ~120509 Y 401002-00786 6
43 401002-00786 O-RING;CYL LINER 6 120510~
45 65.01601-2016A FLANGE ASS'Y 6
45A 06.22180-0804 PIN;SPIRAL 1
45B 65.01601-0007A FLANGE;OIL SPRAY NOZZLE 1
46 65.96601A0237 GASKET 6
47 65.98150-0051 SCREW;HOLLOW 6
48 06.56190-0706 SEAL RING A14X20 6
49 65.01601-5065 OIL SPRAY NOZZLE ASS'Y 6 ~070723 I 65.01601-5071 6
49 65.01601-5071 OIL SPRAY NOZZLE ASS'Y 6 070724~120514
49 65.01601-5080 NOZZLE ASSY,OIL SPRAY 6 120515~
50 65.90001-0129 BOLT;HEX 12 ~120514 I 120106-00539 12
50 120106-00539 BOLT,HEX FLANGE 12 120515~
51 06.16044-0208 WASHER;SPRING 12
52 06.08041-2203 SCREW;PLUG M14X1.5 1
53 06.56190-0706 SEAL RING A14X20 1
54 65.90310-0147 SCREW;PLUG 1
3
DX520LC

5. Fig. 002 FLYWHEEL HOUSING
DX520LC

6. Fig. 002 FLYWHEEL HOUSING
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.01401-5035 HOUSING;FLYWHEEL 1
2 65.01402-0010 COVER;FLYWHEEL HOUSING 1
3 65.01904-0029 GASKET 1 ~070123 Y 65.01904-0029B 1
3 65.01904-0029B GASKET 1 070124~
4 06.01923-3118 BOLT ASS'Y M8X35 4
5 65.01510-0141 OIL SEAL;RR 1
6 65.90720-0109 WASHER;THRUST 1 ~130107 I 120816-00123 1
6 120816-00123 WASHER,THRUST 1 130108~
7 65.90020-0065 BOLT;HEX. 2 ~060504
7 65.90020-0137 BOLT;HEX. 2 ~071120
7 65.90020-0144 BOLT;HEX. 2 ~080130
7 65.90020-0146 BOLT;HEX. 2 080131~
8 65.96501-0104 O-RING 2 ~071120
8 65.96501-0105 O-RING 2 ~080130
8 65.96501-0107 O-RING 2 080131~
9 65.01904-0030 GASKET 1 ~060629 I 65.01904-0038 1
9 65.01904-0038 GASKET 1 060630~
10 65.01904-0031 GASKET 1 ~060425 I 65.01904-0031A 1
10 65.01904-0031A GASKET 1 ~060629 I 65.01904-0037 1
10 65.01904-0037 GASKET 1 060630~
20 65.90020-0223 BOLT;F.W.H 8
21 65.90020-0183B BOLT;HEX 6
22 65.90020-0133 BOLT;HEX 1
23 65.90020-0130 BOLT;HEX 2
24 06.01954-3331 BOLT;SPACER M12X1.5X100 2
25 65.91701-0468 SPACER 2
26 06.16731-6109 WASHER;SPRING A12 2
27 65.01414-0004A COVER 1
28 06.01923-3110 BOLT ASS'Y M8X12 2
1
DX520LC

7. Fig. 003 OIL SEAL
DX520LC

8. Fig. 003 OIL SEAL
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.01501-5017D COVER;SEALING 1 ~080221 Y 65.01501-5017E 1
1 65.01501-5017E COVER;SEALING 1 080222~
2 65.01510-0153A SEAL;OIL 1 ~080521
2 65.01510-0041 SEAL;OIL 1 080522~
3 65.01905-0032 GASKET 1
4 06.01923-3116 BOLT ASS'Y M8X28 6
1
DX520LC

9. Fig. 004 BREATHER [061222]
DX520LC

10. Fig. 004 BREATHER [061222]
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.01801-5038 HOUSING;BREATHER 1 ~061222
2 06.01923-3118 BOLT ASS'Y M8X35 4
3 65.96301-0422 HOSE;RUBBER 1
4 06.67020-0101 CLAMP;HOSE 2
5 65.05701-5552 PIPE;BREATHER 1
6 06.01923-3111 BOLT, M8X16 2
7 65.96301-0386 HOSE;RUBBER 1
8 06.67020-0101 CLAMP;HOSE 2
9 65.98131-0135 PIPE;CONNECTION 1 ~061019 Y 65.98131-0119 1
9 65.98131-0119 NIPPLE 1 061020~
10 06.56190-0719 RING;SEAL 1
20 65.01801-5041 HOUSING;BREATHER 1
21 65.01908-0014 GASKET 1
22 06.01923-3129 BOLT ASS'Y M8X90 4
25 65.96301-0441 HOSE;RUBBER 1 ~061201 Y 65.96301-0441A 1
25 65.96301-0441A HOSE;RUBBER 1 061202~
26 06.67020-0105 CLAMP;HOSE 1
28 65.01805-0001 SCREEN;HEAT;BREATHER 1
29 06.01913-2911 BOLT ASS'Y M6X16 2
1
DX520LC

11. Fig. 004A BREATHER [091215]
DX520LC

12. Fig. 004A BREATHER [091215]
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.01801-5100 HOUSING;BREATHER 1 ~070129
2 06.01923-3114 BOLT ASS'Y M8X22 4
3 65.96301-0422A HOSE;RUBBER 1
4 06.67020-0101 CLAMP;HOSE 2
5 65.05701-5552 PIPE;BREATHER 1
6 06.01923-3111 BOLT, M8X16 2
7 65.96301-0386 HOSE;RUBBER 1
8 06.67020-0101 CLAMP;HOSE 2
9 65.98131-0119 NIPPLE 1
10 06.56190-0719 RING;SEAL 1
20 65.01840-5006A BRACKET;BREATHER 1
21 65.01908-0014 GASKET 1
22 06.01923-3118 BOLT ASS'Y M8X35 4
25 65.96301-0441A HOSE;RUBBER 1
26 06.67020-0105 CLAMP;HOSE 1
27 65.96301-0505 HOSE;RUBBER 1
28 06.67020-0105 CLAMP;HOSE 2
30 65.01805-0002 SCREEN;HEAT 1
31 06.01913-2911 BOLT ASS'Y M6X16 2
1
DX520LC

13. Fig. 004B BREATHER [091216 ~ ]
DX520LC

14. Fig. 004B BREATHER [091216 ~ ]
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.01801-5100 HOUSING;BREATHER 1 070130~
2 06.01923-3114 BOLT ASS'Y M8X22 4
3 65.96301-0422A HOSE;RUBBER 1
4 06.67020-0101 CLAMP;HOSE 2
5 420218-00009 PIPE;BREATHER 1
6 06.01923-3111 BOLT, M8X16 1
7 65.96301-0422A HOSE;RUBBER 1
8 06.67020-0101 CLAMP;HOSE 2
10 65.01840-5006A BRACKET;BREATHER 1
11 65.01908-0014 GASKET 1
12 06.01923-3118 BOLT ASS'Y M8X35 4
13 65.96301-0441A HOSE;RUBBER 1
14 06.67020-0105 CLAMP;HOSE 1
15 65.96301-0505 HOSE;RUBBER 1
16 06.67020-0105 CLAMP;HOSE 2
17 65.01805-0002 SCREEN;HEAT 1
18 06.01913-2911 BOLT ASS'Y M6X16 2
20 65.01816-5001 PIPE;CONNECTION 1
21 06.56190-0706 SEAL RING A14X20 1
22 06.56190-0706 SEAL RING A14X20 2
23 06.78144-8404 SCREW;HOLLOW 1
24 430201-00033 ADAPTER;UNION 1
25 65.98130-0202 ADAPTER 1
26 06.56190-0706 SEAL RING A14X20 1
1
DX520LC

15. Fig. 005 DRIVING SYSTEM [120315]
DX520LC

16. Fig. 005 DRIVING SYSTEM [120315]
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.02101-7065B CRANK SHAFT 1
2 65.02130-0001 RING;WEAR(FRONT) 1 ~080521
3 06.22022-3065 PIN;PARALLEL 1
4 65.02115-0066 GEAR;C.R.S 1
5 65.01505-0007 RING;OIL THROWER. 1
6 65.01110-6529 METAL;MAIN 3 ~120314
6 65.01110-6529 METAL;MAIN 4 120315~
6 65.01110-6531 METAL,MAIN 0.10 3 US ~120314
6 65.01110-6531 METAL,MAIN 0.10 4 US 120315~
6 65.01110-6532 METAL,MAIN 0.25 3 US ~120314
6 65.01110-6532 METAL,MAIN 0.25 4 US 120315~
7 65.01111-6539 WASHER;THRUST 1 ~120314
7 140110-00041 WASHER,THRUST;UPPER 2 120315~
7 140110-00042 WASHER,THRUST;LOWER 2 120315~
7 65.01111-6541 WASHER,THRUST 0.10 1 OS
7 65.01111-6542 WASHER,THRUST 0.25 1 OS
10 65.02201-7032 DAMPER;VIBRATION 1
11 65.90020-0062B BOLT;HEX M10X20 6
20 65.02301-5142 FLYWHEEL 1
20A 65.02301-0286 FLYWHEEL 1
20B 65.02310-0073D GEAR;STARTER RING 1
21 65.02130-0002 RING;WEAR(REAR) 1
22 65.91303-0005 PIN;TAPER 1
23 65.90020-0127 BOLT;FLY WHEEL. 10
30 65.02401-6027B ROD;CONNECTING 6
30A 65.02401-0015B ROD;CONNECTING 1 D
30B 65.02411-0008 BOLT;CONNECTING ROD 2
31 65.02410-0110B METAL;CONNECTING ROD 6
31 65.02410-0111B METAL;CON. ROD(0.10) 6 US
31 65.02410-0112B METAL;CON. ROD(0.25) 6 US
32 65.02410-0120B METAL;CONNECTING ROD 6
32 65.02410-0121B METAL;CON. ROD(0.10) 6 US
32 65.02410-0122B METAL;CON. ROD(0.25) 6 US
40 65.02501-0705 PISTON 6 ~061010 Y 65.02501-0705A 6
40 65.02501-0705A PISTON 6 ~071001 I 65.02501-0712 6
40 65.02501-0712 PISTON 6 ~090530 I 130602-00114 6
1
DX520LC

17. Key No Part No Description Qty S.C Serial No ICA Replacable Qty
40 130602-00114 PISTON 6 090531~
41 401004-00022 RING KIT,PISTON 6 080823~
41A - RING;PISTON 1 K
41B - RING;PISTON 1 K
41C - RING;PISTON OIL 1 K
44 65.02502-0081 PIN;PISTON 6
45 65.90815-0022A RING;LOCK 12
50 65.02601-0220 PULLEY;V-BELT 1
51 06.02106-0824 BOLT 8
2
DX520LC

18. Fig. 005A DRIVING SYSTEM [120316 ~ ]
DX520LC

19. Fig. 005A DRIVING SYSTEM [120316 ~ ]
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.02101-7033 CRANKSHAFT ASSY 1
3 06.22022-3065 PIN;PARALLEL 1
4 65.02115-0066 GEAR;C.R.S 1
5 65.01505-0007 RING;OIL THROWER. 1 ~130523 I 401102-00033 1
5 401102-00033 HOLDER,OIL SEAL 1 130524~
6 65.01110-6529 METAL;MAIN 4
6 65.01110-6531 METAL,MAIN 0.10 4 US
6 65.01110-6532 METAL,MAIN 0.25 4 US
7 65.01150-0058A WASHER,THRUST;UPPER 2 ~120624
7 140110-00041 WASHER,THRUST;UPPER 2 120625~
8 65.01150-0059A WASHER,THRUST;LOWER 2 ~120624
8 140110-00042 WASHER,THRUST;LOWER 2 120625~
10 65.02201-7032 DAMPER;VIBRATION 1
11 65.90020-0062B BOLT;HEX M10X20 6
20 65.02301-5142 FLYWHEEL 1
20A 65.02301-0286 FLYWHEEL 1
20B 65.02310-0073D GEAR;STARTER RING 1
21 65.02130-0002 RING;WEAR(REAR) 1
22 65.91303-0005 PIN;TAPER 1
23 65.90020-0127 BOLT;FLY WHEEL. 10
30 65.02401-6033A ROD,CONNECTING 6
30A - ROD,CONNECTING 1 D
30B 65.02411-0010A BOLT 2
31 65.02410-0130 METAL,CON ROD;UPPER 6 ~131029 I 140112-00067 6
31 140112-00067 BEARING,CON-ROD;STD 6 131030~
31 65.02410-0131 METAL,CON ROD;(0.10) 6 US ~131029 I 140112-00068 6
31 140112-00068 BEARING,CON-ROD;0.10 6 US 131030~
31 65.02410-0132 METAL,CON ROD;(0.25) 6 US ~131029 I 140112-00069 6
31 140112-00069 BEARING,CON-ROD;0.25 6 US 131030~
32 65.02410-0078A METAL,CON ROD;LOWER 6
32 65.02410-0781A METAL,CON ROD;(0.10) 6 US
32 65.02410-0782A METAL,CON ROD;(0.25) 6 US
40 65.02501-0715 PISTON 6
41 401004-00022 RING KIT,PISTON 6
41A - RING;PISTON 1 K
41B - RING;PISTON 1 K
1
DX520LC

20. Key No Part No Description Qty S.C Serial No ICA Replacable Qty
41C - RING;PISTON OIL 1 K
44 65.02502-0033 PIN,PISTON 6
45 06.29020-0130 RING,SNAP 12
50 65.02601-0220 PULLEY;V-BELT 1
51 06.02106-0824 BOLT 8
2
DX520LC

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22. Fig. 006 CYLINDER HEAD
DX520LC

23. Fig. 006 CYLINDER HEAD
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.03101-6074D HEAD;CYLINDER 2 ~061207 Y 65.03101-6074F 2
1 65.03101-6074F HEAD;CYLINDER 2 ~070902 I 65.03101-6074G 2
1 65.03101-6074G HEAD;CYLINDER 2 070903~
1A 65.03101-1054B HEAD;CYLINDER 1 D ~061207
1A 65.03101-1054C HEAD;CYLINDER 1 D 061208~
1B 65.03201-1014A GUIDE;VALVE 12 B ~061207 I 65.03201-1015B 12
1B 65.03201-1015B GUIDE;VALVE 12 B ~070902 Y 65.03201-1015C 12
1B 65.03201-1015C GUIDE;VALVE 12 B 070903~
1C 65.03203-1057A SEAT;VALVE 6 B
1D 65.03203-1058A SEAT;VALVE 6 B
1E 65.90302-0048 CORE;PLUG 5
1F 65.90302-0042 PLUG;CORE 2
1G 65.03205-0006B BUSH;INJ. NOZZLE 3
1H 65.96501-0088 O-RING 6
2 65.90201-0112 BOLT;STUD 10
3 65.90201-0114 BOLT;STUD 2
4 65.90021-0006 BOLT;COLLARED 28
5 65.03901-0067 GASKET;CYLINDER HEAD 2
1
DX520LC

24. Fig. 007 CYLINDER HEAD COVER
DX520LC