240PKJ-1B TCM PARTS MANUAL DIESEL ENGINE C240PKJ C240PKJ-06 C240PKJ-11 C240PKJ-12 C240PKJ-17 C240PKJ-20 ISUZU TCM CORPORATIONCRAODE COK-YASOF, TEM Te PFI OLY FY ORBMBHERBLTET. BACERICOWT BRCORLOML, DTRMOUR- VRES (SH), LLY OWR- WEES (S @), BRESSLVRLMEARULTC LEN, RMOBKES (SH) MMA, LYYLONMES (BM) E, SULFFOy ETM THRE TET. MES (SH) CRAIC OWT BREW D D> BAERT, BHUZb AFANOWB, B COS#, BLES OHSS (FG. No.) € REZOOR, BH EMUEVE RI, =} RTTET. om OmmEL aT Eb» > BRERT, BEAR ERSBRES, 1 COSH, SLES OBES (FIG. No) & B, SRP RED ERY KOE SR, > RNGET. DUET. MBS KLOCS ASSY #URERLET. op BREGBERLET. 0. s. A-NGAAEMBRERLET. LH JO4 KI — WMP SAT ules PLEPAABRERLEF. EMERLET. stp SREGRERLET. RH JI4 1 - WAP EAT * LY BEUAY LOMBBRE AMERLET. RUST. t MAERLET. AR BRCGULMERALET. z WHERLET. L RSERLET. GRD YULHRF LEST FORD # MARIE L EA RIL-EBLUSIFLER + BMRLTUREA, hLOTEMIL-KERLE t. BAL, BEALOKOFER<. RETSCEKHVETOT, SSPUHTTRK KS.INTRODUCTION This Parts Catalogue contains the component parts of the engine mounted on 7M FORKLIFT TRUCK. How to order parts When ordering, be sure to specify the model name and serial number (machine number), engine type and serial number (engine number) of your machine, as well as the part number and desired quantity for each part. The machine serial number (machine number) is indicated on the machine name plate, the engine serial number (engine number) is punched on the cylinder block, Serial number Seehine| Traber) (engine number) ID Plate o Engine type Engine type name = peaartre Engine seve —~ manufacture Wsuzu se wae | Years 1D Plate How to use the Parts Catalogue To find a part number after Search the section from Confirm illustration part understanding the part =| Contents, find the FIG. number and machine name. number of the parts number. number list. os Search the Contents, find ‘The part number, shape, the FIG. number of name and record are ilustration. clear. To find a part number after understanding the location of assembly Abbreviations and symbols ASSY Assembled unit. RH - Left-hand side as viewed Os. Oversize. from the flywheel side. US. + Undersize. Thickness. STD: Standard. Number of teech on the gear. * AR Materals and specifications subject to change without notice. The marketable part set or kit. Quantity required. Length. Not sold separately. Not illustrated. Optional parts. Right-hand side as viewed from the flywheel side. The grade of the tighetening allowance between a cylinder body and a liner and the grade of the clearance between a liner and a piston are shown. For parts replacement procedures, refer to the Shop Manual.APPLICABLE MODEL eS ENGINE TYPE "APPLICABLE MODEL FDISCoH D208 FOISTOH Fo20TS FO18C9H 02508 FOtTOH Fo2sTs c2s0PKs FDISCOH Fo20T6 FDISTOH Fo2sT6 FO1ECoH FosoTs FDIBTOH (C240Ps-08 FOTSWoH Fo20we FOTEWoH Fo2swe FDIOTSEXR, FD20T6EXR FOISTOEXR FD2STEEXR |FDIsTOEXR FOSOTBEXR FD1sCoH FD2008 FDISTOH FD20TS FD1ecoH Fo2sc6 FD1eToH FO2STS Fo1s9H FD20TS FOISToH FD2STS FDtecoH FDs0TS FDteToHCONTENTS A:O240PKs Dp: C240PK-2 8 R B:C2a0PK.06 EB: Ga4OPKa7 C:GeM0PKIAs_F:G2d0PRI-20 SECTION sm FIG.No. Bes ENGINE BODY Ey oUaRE CYLINDER BLOCK _ yretoy? 1 PISTON.CRANKSHAFT & FLYWHEEL RNY, 29L7 eI NADIA AIM 2 TIMING GEAR & CASE S487 FH B-K 3 OIL PAN. AMR ra FLYWHEEL HOUSING DIT RIA-NWADG ED 5 HEAD & VALVE MECHANISM Ry FINI AHEKL CYLINDER HEAD Usa K 6 VALVE MECHANISM. KUPAH=ERL 7 INLET & EXHAUST SYSTEM Tyby h&LeI—-Zb AIR INTAKE & EXHAUST SYSTEM (A,B,C,E.F) zrrP-ty J; 8 AIR INTAKE & EXHAUST SYSTEM (0) EP— 15 ° THROTTLE VALVE (D) ABy hIT 10. INTAKE SHUTTER (D) ALF -FYe ys 11 LUBRICATION SYSTEM eee OIL PUMP_ AAWRET 42 OIL FILTER AAW AMS 13 OWL PIPE AAA T 14 COOLING SYSTEM eee COOLING SYSTEM gard 15 FUEL SYSTEM Rae FUEL SYSTEM (A.8,C,E.F) arIWy ZF 16 FUEL SYSTEM (0) Za=IWyZFhs 17 NOZZLE EW 18 INJECTION PUMP (1/2)(A,B,C,E,F) ALP EI ay RET 49 INJECTION PUMP (2/2){A, FY AvP ey ar Re 20 INJECTION PUMP (D) ALP Iya rR YT 24 GOVERNOR (INNER PARTS)(D) BNF ALFNHY) 22 FEEDPUMP(D) DA=KRYT 23 FUEL FILTER (A,B,C,F) Ja-INI74 We 24 FUEL FILTER (0) Ja-zW74Ws 5 FUEL FILTER (E) - Ja Ew 4 26 ELECTRICAL PARTS EL RYN STARTER,GENERATOR & ELECTRICAL PARTS. ASB, FrRU-FRIVI VAN a7 STARTER (INNER PARTS)(A.B.E.F) Maecer aces 28 STARTER (INNER PARTS)(C) ABB (4 FIX 29 STARTER (INNER PARTS)(D) ZEB (FEF) Ed (GENERATOR (INNER PARTS)(A.C,D.E.F) xR—B (4 VFN—Y) at GENERATOR (INNER PARTS)(B) ERS (1 2FR—Y) 32 PARTS NUMBER INDEX _ BOE BIRT 125FIG. 1 CYLINDER BLOCK NAT DyFIG.1 ASC2WOPK) Di cago K-12 BiCoaopkdoe =: Gas0PK-17 CC240PKI-11 —FCaK0PKI-20 item No. Part No. Mark| Description Reqd] Remarks : serial No. aues| BRS BS BEA fae 8S : RSH 26 [z-8-97113-742.0 | * [PACKING WAT 1 27 |7-0-2868-0820-0 BOLT me 2 28 |Z-0-2868-0820-0 BOLT a 2 ~ |Z-0-2808-0820-0 BOLT ae 2 29 |z-8-97045-928.0 | * |GASKET Who 1 30 |Z-0-5004-1026-0 BOLT&WASHER, EI 2 - |Z-0-5004-1022.0 BOLT&WASHER: ae wRIe 6 31 |z-9-09664-001-0 PLUG Hr 1 32 |z-9-09878-597-0 PIN ey 2 33, |z-9-89112-911-0 BOLT am 1 34 |z-6-94459-44-0 DOWEL rou 2 35 |z-5-11740-021-2 BREATHERAIR me 1 finc.43 36 |z-9-09921-099.0 | * |PACKING ee 1 37 |z-5-09966-086-0 PIPE,VINYL war 1 38 |z-9-09915-238.0 cur Mr 1 39 |z-0-2808-0816-0 BOLT ah 1 40 |Z-9-0916-4508.0 WASHER 1 at |z-o-12963-112-4 SPACER wt 1 42 |z-8-94111-750-1 | * |SEALOIL ah 1 |ABDEF - |55599-62961 * |SEALOIL ae 1 |e 43, |z-9-11745.024-0 ELEMENT ih 1 44 |z-8-94915-495-0 FOOT,RH ob 1FIG. 1 CYLINDER BLOCK NAT DyFIG.1 AC2OPK) DO: Ca40pK 412 BiGeaopKi-os —E: Caq0pK-17 C:C240PKI-TT _F:C240PKI-20 Item Nol PartNo. | Mark] Description | Reqd] Remarks : serial No Suts| RES [eS BRIE ‘R HE: TSH A |z-5-41210-17-4 CYLINDER BLOCK ASSY Wa TDyMrAY | 1 [INC.1-10,13 1 |NO PART NO. # |BLOCK,CYLINDER, 709 1 2 |z-9-09802-591-0 BOLT om 10 3 |z-5-11219-.008-0 cup wo 2 4 |20801-08311 BEARING KIT NPA 1 |sTD - |z-5-11631-008-0 BEARING KIT,FRONT NAIA ob 1 |U.S.-0.25mm BEARING KIT,CENTER NANA ok 1 |US.-0.25mm : BEARING KITREAR NPA ok 1 [US.-0.25mm : BEARING KITFRONT AP 1 : BEARING KIT,CENTER API ak 1 + |Z-5-11643-001-0 BEARING KIT REAR NPA ak 1 5 |z5-11219.018.0 cur 1 1 6 |z511219.017.0 cur at 1 7 |z-5-11219.015.0 cup i 2 8 |z-5-09600.013.0 cup wt 1 9 |Z-1-09800.005-1 cup a 3 St |2.5-87813-280-0 LINER SET Stheyk 4 JINC.10 & ete. GRD-1 - |Z-5-87813-281-0 LINER SET tek 4 |INC.10 & ete, |@RD=2 + |Z-5-87813-282.0 LINER SET Hteoh 4 |INC.10 &ete. 10 |LINER,CYLINDER ut 4 - |LINER,CYLINDER Ht 4 - |LINER,CYLINDER, ut 4 - |z97176-8990 | * |LINER,CYLINDER ut 4 |GRD=2, cx - |z897176-0000 | * |LINER,CYLINDER, xt 4 |@RD=3, Ax - |z897176-901-0 | * |LINER,CYLINDER, Ht 4 |GRD=3, cx 11 |2-8-94250514.0 cur bo 1 12 |2-5-11129-006-0 Jour 2 13 |2-8-94155-815-2 DUCT,WATER 1 14 |2-5-09605-019-2 PLUG 2. |-2000.2 - |Z-5-09605-.019-2 PLUG 3 |2000.3- 15 |2-9-9920-28140 PLUG 1 16 |Z-9-0957-1414.0 GASKET 1 17 |26-1171-190-1 FOOT,LH 1 18 |z-8-97127-049-0 covER 1 19 |z5-11811-046-1 PLATE TF 1 sz |z-6-87811-341-1 GASKET SET I pyhtoh 1 |AB,.0E INC.20,26,20,36,42 & ete. - |z-6-87811-3904 GASKET SET BRbyheok 1 |e INC.20,26,29,96,42 & etc. + |z5-87812-644-1 GASKET SET Aba 1 iF INC.20,26,29,36,42 & etc. 20 97365-6900 | + |PACKING NA 1 a 0815-1040-0 PIN ey 2 22 5004-0822-0 BOLT om 5 23 09902-299-0 NIPPLE a 1 24 0816-1032-0 PIN ey 1 25 11219-083-0 COVER an 1FIG. 2 PISTON,CRANKSHAFT & FLYWHEEL EAR II ATRRIIA 8 oF. Secoups FIG. 2 D: C2sopKA2 item No| Description | [Reqd] Remarks: serial No. rd BEL 8 HS: RSH 1 [20801-07131 BUSHING KIT 1 [incz STD + |20801-07141 BUSHING KIT rok 1 fine.2 U.S.-0.25mm + |20801-07151 BUSHING KIT TVA tok 1 jinc.2 2 |Z-8-94453-520-0 WASHER, THRUST im 2 + |z-8-97042-262-1 WASHER, THRUST a 2 si |z-5-87813-280.0 LINER SET te 4 |INC3-68 & etc. GRD-1 - |z-5-87813-281-0 LINER SET tek 4 |INC.268 & etc. GRD=2 + |z5-87813-282.0 LINER SET Hite 4 |INC268 & eto. GRD-3 3 |ze-07176-864.0 | « |PISTON ea 4 |GRD-ax - |z8-97176-865-0 | * |PISTON ean 4 |GRD-cx 4 |z8-04871-4420 | * |RING SET WA ok 4 5 |z6-12011-017-0 | # |PINPISTON ey 4 6 |z-5-09587-001-0 | * |RING,SNAP 8 A |z-5-12290-039-1 CONNECTING ROD ASSY 4 |iNcz-10 7 |NO PART NO. # |ROD 4 8 |z-5-12251-005-0 | * |BUSHING 4 9 |z-5-12295-009-0 BOLT 8 10 |Z-5-09409.016-0 NUT 8 11 |Z-8-94142-208-0 BUSHING 4 |stD + |z9-94163-174.0 BUSHING Te 4 |us.-0.25mm - |z-9-94168175.0 BUSHING ar 4 12 |Z-8.04109-860-0 (CRANKSHAFT DATE 1 13 |Z-9-0816-1220-0 PINSTRAIGHT ey 1 14 |Z-8-97176-264-0 BEARING aa 1 |ABDEF - |03020-06302 BEARING ar 1 Ic 16 |z-5-12890-116-1 FLYWHEEL Tem 1 |ABDEF INC.16 ~ |58693-62341 FLYWHEEL THe 1 |c INC.AB 16 |z-9-12999-605-1 GEAR,RING 1 17 |Z-9.0815-0616-0 PINSTRAIGHT 2 18 |z-8-97085-984-1 BOLT 6 19 |z-5-12996-010-1 WASHER 1 20 |z-9-0803-0743.0 KEY,FEATHER 1 21 |2-5-12521-025.0 GEAR 1 22 |Z-9-12962-03.0 THROWEROIL 1 23 |2-9-12973-605-2 PULLEY ry 1 24 |2-9-09802-606-0 BOLT am 1 25 |z-9-12979.0160 WASHER ie 1