107 Engine and Fuel System

107 Engine
 PC200-8 Engine Outline
Unit
Cylinder number x bore x stroke [High output]
Engine displacement
* Increased emission
* Output upgrading per projected area of
Aspiration
engine
Rated output/revolution
* Low speed torque upgrading with HPCR
C09 rated fuel consumption ratio

4 valves/cylinder

Low fuel consumption

* High injection pressure
* Multi-stage injection
* Injection timing control
ｺﾓﾝﾚｰﾙ
Common rail
Advanced combustion
technology
* Low NOx technology to
suppress deterioration of fuel
economy
ﾘﾔｷﾞﾔﾄﾚｰﾝ
Rear gear train

[Emission]
4 valves/cylinderIncreased
intake air capacity
* Uniform fuel spray
[Fuel air mix enhancement]
* High injection pressure
* Multi-stage injection
* Injection timing control
Advanced combustion ｴﾝｼﾞﾝﾏｳﾝﾄ
Engine mountECM
ECM
technology
* Low NOx technology
*Control compliance enabled
without EGR

107 Engine Page 2 / 35

PC200-8 Engine Outline

[Low noise]
* Supply pump drive torque reduction
* Combustion noise reduction with pilot
injection
Rear gear train
* Gear noise reduction
Tappet cover discontinuation and integrated
block structure
* Suppression of cover section vibration with
enhanced rigidity
High rigidity cylinder block
* Vibration suppression with rib layout,
contour and change of skirt contour

High rigidity cylinder block

Standard large capacity F

sump oil pan

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Means for complying to the next generation
emission control
Concept of fuel combustion

HPCR injector Optimized swirl

PM reduction with pilot Optimizes spray fuel and
and post injections air mixture -- PM reduction

Reduced protrusion at the center of the

fuel chamber
Promotes mixing of air with spray fuel

DSA (Deep Spray Angle) Chamfered combustion chamber rims

Suppresses fuel diffusion by having spray Prevents fuel spray flame from spreading
along the bottom of the combustion over the lower surface of the head -- PM
chamber -- NOx reduction reduction

Combustion flame area of spreading is

Protrusion at the center is lowered to controlled through optimized combustion Later combustion is induced to the chamfered portion
promote the mixing of air with spray chamber bottom-wall angle, subsequently to prevent the spreading of flame to the lower surface
to reduce PM suppressing NOx emission of the head ---PM reduction

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DSA piston (Deep Spray Angle)

Head is ball-shaped

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Flow of fuel (3D)

Fuel main element 2m

Fuel air bleeder pump

Water sump

Fuel pre-element 10m

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Common rail (High Pressure Common Rail)
fuel system

 Bosch HPCR pump (High

Pressure Common Rail)
 Common rail
 Electronically controlled
Injector

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 PC200-8 Fuel system diagram
Pressure limiter

Common rail

* Return
Overflow valve check
valve
Injector

Priming pump

Main filter

Fuel cooler
IMV valve
Gear pump
Supply pump
Prefilter

Fuel tank

* Even if Zero-delivery choke (: dia. 0.4mm) IMV valve is

(1) Pressure limiter 1,850 bar (3) Return check valve 0.48 bar closed, little amount of fuel flows to the supply pump plunger,
(2) Relief valve 10.5 bar to 13 bar (4) Bypass valve 0.1 bar this fuel is directed to the returning side via the choke to
retain the state of zero-delivery
Normally no fuel flows

107 Engine
Supply Pump and Gear Pump

Gear pump
Supply pump

107 Engine Page 10 / 35

Supply Pump Pipe
IMV valve
(1) Gear pump inlet port (from prefilter)
(2) Gear pump outlet port (to main filter)
(3) Supply pump inlet port (from main filter)
(5)
(4) Supply pump outlet port (to common rail)
(5) Pump fuel return (to fuel cooler)

(1) (3)

(2)

(4)

Gear pump
107 Engine Page 11 / 35
IMV (Inlet Metering Valve)
Adjusts the amount of fuel from the gear pump to the
fuel pressure required by the engine and feed fuel to the
inlet port of the supply pump plunger
When the solenoid current is OFF, the piston is
pressed to the right by the force of spring. The triangle
slot connects to the fuel inlet port groove to maximize
the flow rate
When the current is ON, magnetic force of
proportional solenoid works on the armature to press
the piston to the left. The opening of the groove is
choked to reduce the flow rate.
Therefore, feed oil capacity is determined by the value
of the current to the solenoid
ピストン
Piston ママチュア
Armature

マグネットコア
Magnet core

ピストンのスロット
Piston slot
Fuel inlet port from the gear pump
ギヤーポンプからの燃料入口

スプリング
Spring ソレノイドコイル
Solenoid coil

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IMV (Inlet Metering Valve) operation

Click on the photograph

107 Engine Page 13 / 35

Supply Pump section diagram
Inlet check valve
(3 sets)

Inlet check valve

Cam lobe

Plunger (3 sets)

Outlet check valve

Bosch CP3.3 Supply Pump
CP3.3 pump
Gear ratio 1.33
Plunger dia mm 7.5
Stroke mm 8.2
Displacement/rev mm3 1087
Peak torque Nm 50
@ 1600bar

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Supply pump illustration

Intake valve (3 in total)

Camshaft

Plunger (3 in total)

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Supply pump operation

Click on the photograph

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Supply Pump and Gear Pump

St.140/150 St.50/60

MPROP (ZME) Plungers St.10.1 St.130 St.140/150 St.130

Housing High Pressure Plugs Gear Pump High Pressure Connector

Balls

St.190

KÜV (Overflow Valve)l

St.90

Seal Plug

St.180.1/100
St.70
Flange
Screw Plugs

St.20/180.2/200 St.180.3 St.100 St.80 St.80 St.60

Bushing Seal Ring Shim Eccentric Shaft Angular Ring Spring

= Manufactured in ChW

107 Engine Page 18 / 35

Gear Pump (Feed pump: Low pressure)
Feeds fuel to the supply pump inlet port

O-ring Rivets
Coupling Lip seal

Bolts
Gears
O-rings
Housing

Driven by the supply pump

drive shaft

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Gear pump illustration

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 Overflow valve
 Overflow valve is installed to the supply
pump housing
 Returns oil to the gear pump inlet port
when the pressure of fuel fed from the gear
pump becomes constant
 Overflown fuel lubricates the supply pump
Fuel inlet port from
drive shaft chamber the gear pump
IMV valve

Overflow valve

Supply pump housing

107 Engine
 Pressure limiter valve
Controls maximum pressure of
common rail
Pressure limiter set pressure
1850bar
Special equipment required to
replace the valve Because the tip
is tool edge machined

The tip is tool edged

107 Engine
Electronically controlled Injector
Optimal injection timing and amount of injection
are determined by closing/opening a 2-way valve
Notch
with the solenoid of the head
Solenoid operating voltage is 80 V
Return fuel flows to the rear of the engine via
collecting passage in the cylinder head

Injector positioning pin

Injector concave ball and convex ball at the end of high

pressure connector make contact to seal high pressure
fuel with the thrust force

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 Injector wire harness

Wire harnesses for two injectors run

through a connector

Wiring for injector

107 Engine
Injector and High Pressure Connector

Causes for increased injector fuel return

Defective solenoid seat surface
Defective high pressure fuel connector
seat surface
Solenoid seat surface
Increased clearance between the valve
piston and injector body, etc.

Clearance between the valve

piston and injector body

High pressure fuel connector seat surface

Edge filter

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 Injector Section Diagram
16 32 22 31
1. Nozzle Body
2. Nozzle Needle
12. Spacer Disc
18 20 24
13. Spacer Disc
3. Nozzle Nut
4. Injector Body
14. Spacer Disc 14
5. Interm. Pin
15. Armature Plate
28 25
16. Armature Spring
6. Nozzle Spring
7. Valve Body
17. Shim Washer 12
8. Valve Piston 26
9. Seal Ring
10. Valve Ball
10 23
11. Retaining Screw (nut)

7 21

6 8 30 19
4 27 13 15 17
9 29 11
2
1
18. Lock Ring 26. Armature Bolt
19. Magnet Core 27. Ball Holder
20. Tube 28. Armature Guide
5 21. O-Ring 29. Support Washer
22. Interm. Piece 30. O-Ring
23. Seal Ball 31. Support Plate
24. Valve Spring 32. Tension Nut
25. Connector Base Ass.

107 Engine
Injector Components
Magnet Nut Armature Spring Residual Air Gap Injector Body Armature Lift Shim Valve Retaining Ball Holder
Shim Nut

Magnetspannmutter Ankerfeder Einstellscheibe Hub- Einstellring Ventilspannmutter Kugelführung

Injektorkörper
Seal Ball Valve Ball

Dichtkugel Ventilkugel

Magnet Group Nozzle Spring

Düsenfeder

Nozzle Needle

Düsennadel
Magnetgruppe

Lock Ring Nozzle Body

Sicherungsscheibe Düsenkörper
Valve Group
Armature Plate Armature Bolt Armature Guide Valve Body and Piston Nozzle Spring Shim Thrust washer with Nozzle Nut
Bushing

Brac
Ventilgruppe Einstellscheibe mit
Ankerplatte Ankerbolzen Ankerscheibe Ventilstück und Ventilkolben Ausgleichsscheibe Hülse 28/1
Düsenspannmutter

107 Engine Page 28 / 35

Fuel prefilter
● With water separator, 10U
● With water detector sensor (WIF)
● Manual priming pump
● To replace, remove the connector of
crystal ball with the sensor, install it to
new element for reuse

Priming pump Water-presence sensor

WIF：water in fuel
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Replacement of Main filter

Remember to replace a small diameter

rubber seal to the thread portions when
replacing the main filter

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Fuel filter

● Main filter 2U
Cautions at replacement
To replace, install filter without filling fuel to
the element
Fill the fuel by operating priming pump

Fuel cooler
Suppresses the fuel temperature in the tank to 80 C or under

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Measuring injector return capacity (1)

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Measuring fuel pressure in the low pressure
fuel circuit

Adaptor: 6732-81-3170
O-ring: 6215-81-9710
Standard value
Low idling: 5.1 to 13.3 kg/cm2
Cranking: 3.1 to 11.3 kg/cm2

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Measuring fuel pressure in the low pressure
fuel circuit

Adaptor: 6732-81-3170
O-ring: 6215-81-9710
Standard value
Low idling: 5.1 to 13.3 kg/cm2
Cranking: 3.1 to 11.3 kg/cm2

107 Engine Page 34 / 35

Fuel Low Pressure Line
Nylon tube on low
pressure side Tube is
used (60 C to 130 C)

Quick coupler is used

for connection (press the
knob to disconnect)
Moving images of quick coupler

Quick coupler

Moving
image
operation
panel

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Rear gear train

Timing gear
With rear gear train
Flywheel housing is aluminum made

Supply pump gear Cam gear Rear crank gear

Reference: The photo shows D61 bulldozer specifications

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Connecting rod
1.Cautions at assembly 2. Destructive machining (laser
The longer portion to the exhaust side machining)
(If reversed, it leads to earlier burning-out Eliminates error combination of
accident) the connecting rod caps

Exhaust
side

Machined broken-out section

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Locker arm

4 valves/cylinder
Valve clearance adjustment
Locker arm, crosshead (guideless)

Crosshead

Locker arm end

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Piston cooling nozzle
Piston cooling nozzle

Piston is attached with cooling gallery

Oil pump

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Front seal

Cassette seal type

Insert both the outer and inner seal cylinders simultaneously

Encircled portion
is the rotary
sealing portion

Crankshaft Seal insertion tool

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Crankcase breather

Located in the rear of the engine,

it separates oil mists in the blow-by
with the baffle on the lower surface
of the head cover Breather
Two circuits for blow-by and oil
are provided

Blow-by outlet port

Oil return circuit

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