SEBM010023
fl This Shop Manual is made by adding the special descriptions for the 102E-2 series to the Shop Manual for the current 102E-1 series.
© 2008 1 All Rights Reserved Printed in Japan 10-08(02)
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CONTENTS No. of page
01
GENERAL ............................................................................................................ 01-1
11
STRUCTURE AND FUNCTION
12
TESTING AND ADJUSTING
13
DISASSEMBLY AND ASSEMBLY ..................................................... 13-1
14
MAINTENANCE STANDARD ............................................................... 14-1
15
REPAIR AND REPLACEMENT OF PARTS
00-2 2
........................................................... 11-1
................................................................ 12-1
.................................. 15-1
102 SERIES
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102 SERIES
SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
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To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •
Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
00-4
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
FOREWORD
GENERAL
FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
REVISED EDITION MARK
VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
W h en a m an u a l is r e vis ed , a n e d itio n ma rk ( ....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models
REVISIONS
}
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
00-6
123
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
Symbol
Item
Remarks
¤
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
Places that require special attention for the tightening torque during assembly.
Coat
Places to be coated with adhesives and lubricants, etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water m u s t b e d r a i n e d , a nd quantity to be drained.
s
4 3 2 5 6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING
¤ •
Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol
4
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.
WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter
★
Allowable load
mm
kN
tons
10 11.5 12.5 14 16 18 20 22.4 30 40 50 60
9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2
1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41% SAD00479
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
¤
4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ ¤
Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Disconnection 1) Release the residual pressure from the hydraulic tan k. Fo r d e tails , se e TES TIN G AN D ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 3
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
•
•
Disassembly
Type 2
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS ★ ★
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
09940-00030
50 g
Polyethylene container
LT-3
790-129-9060 (Set of adhesive and hardening agent)
Adhesive: 1 kg Hardenin g agent: 500 g
Can
LT-4
790-129-9040
250 g
Polyethylene container
Holtz MH 705
790-126-9120
75 g
Tube
Three bond 1735
790-129-9140
50 g
Polyethylene container
2g
Polyethylene container
Adhesives
Aron-alpha 201
790-129-9130
Loctite 648-50
79A-129-9110
50 cc
Polyethylene container
LG-1
790-129-9010
200 g
Tube
LG-5
790-129-9070
1 kg
Can
Main applications, featuresr •
Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.
•
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl oride), rubber, metal and non-metal.
•
Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs.
• •
Used as adhesive or sealant for metal, glass and plastic.
•
Used as sealant for machined holes.
•
Used as heat-resisting sealant for repairing engine.
• • •
Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods.
• •
Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals.
• • •
Resistance to heat, chemicals Used at joint portions subject to high temperatures.
•
Used as adhesive or sealant for gaskets and packing of power train case, etc.
•
Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
•
Gasket sealant • LG-6
790-129-9020
200 g
Tube
• •
00-10
Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. mab Used as sealant for oil pan, final drive case, etc.
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr •
LG-7
790-129-9070
1g
Tube
Three bond 1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
•
Adhesives
Molybdenum disulphide lubricant
LM-P
09940-00040
200 g
•
Used as heat-resisting sealant for repairing engine.
•
Used as lubricant for sliding portion (to prevent from squeaking).
•
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
Tube •
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
Various
Various
Molybdenum disulphide lubricant
SYG2-400M
400 g (10 per case)
Belows type
Grease
Various
Ftures: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.
•
General purpose type
•
Used for normal temperature, light load bearing at places in contact with water or steam.
•
Used for places with heavy load
Various
00-11
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12 14
10 13 17 19 22
13.2 ± 1.4 31 ± 3 66 ± 7 113 ± 10 177 ± 19
1.35 ± 0.15 3.2 ± 0.3 6.7 ± 0.7 11.5 ± 1 18 ± 2
16 18 20 22 24
24 27 30 32 36
279 ± 30 382 ± 39 549 ± 59 745 ± 83 927 ± 103
28.5 ± 3 39 ± 4 56 ± 6 76 ± 8.5 94.5 ± 10.5
27 30 33 36 39
41 46 50 55 60
1320 ± 140 1720 ± 190 2210 ± 240 2750 ± 290 3290 ± 340
135 ± 15 175 ± 20 225 ± 25 280 ± 30 335 ± 35
Thread diameter of bolt
Width across flats
mm
mm
Nm
kgm
6 8 10 12
10 12 14 17
7.85 ± 1.95 18.6 ± 4.9 40.2 ± 5.9 82.35 ± 7.85
0.8 ± 0.2 1.9 ± 0.5 4.1 ± 0.6 8.4 ± 0.8
Tightening torque
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14 18 22 24 30 33 36 42
19 24 27 32 36 41 46 55
24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49
2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5
00-12 (23)
Tightening torque
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10 12 16
14 17 22
65.7 0 6.8 112 0 9.8 279 0 29
6.7 0 0.7 11.5 0 1 28.5 0 3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
14 20 24 33 42
Varies depending on type of connector.
34.3 0 4.9 93.1 0 9.8 142.1 0 19.6 421.4 0 58.8 877.1 0 132.3
3.5 0 0.5 9.5 0 1 14.5 0 2 43 0 6 89.5 0 13.5
Norminal No.
02 03, 04 05, 06 10, 12 14
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
08 10 12 14 16 18 20 24 30 33 36 42 52
14 17 19 22 24 27 30 32 32 n 36 n n
7.35 0 1.47 11.27 0 1.47 17.64 0 1.96 22.54 0 1.96 29.4 0 4.9 39.2 0 4.9 49 0 4.9 68.6 0 9.8 107.8 0 14.7 127.4 0 19.6 151.9 0 24.5 210.7 0 29.4 323.4 0 44.1
0.75 0 0.15 1.15 0 0.15 1.8 0 0.2 2.3 0 0.2 3 0 0.5 4 0 0.5 5 0 0.5 701 11 0 1.5 13 0 2 15.5 0 2.5 21.5 0 3 33 0 4.5
Norminal No.
08 10 12 14 16 18 20 24 30 33 36 42 52
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
6 8 10 12
10 ± 2 24 ± 4 43 ± 6 77 ± 12
1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22
2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter
Tightening torque
mm
Nm
kgm
6 8 10 12 14
8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Size Thread
Actual Thread O.D.
in
in
1/16 1/8 1/4 3/8 1/2 3/4 1 1 - 1/4 1 - 1/2
0.32 0.41 0.54 0.68 0.85 1.05 1.32 1.66 1.90
Torque
Torque
In Aluminum Components
In Cast Iron or Steel Components
kgm 0.51 1.5 2.0 2.5 3.7 4.6 6.1 7.6 8.7
N•m
ft-lb
kgm
N•m
ft-lb
5 15 20 25 35 45 60 75 85
45 in-lb 10 15 20 25 35 45 55 65
1.5 2.0 2.5 3.7 5.6 7.6 9.7 11.7 13.8
15 20 25 35 55 75 95 115 135
10 15 20 25 40 55 70 85 100
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats
Taper seal type
Face seal type
Nominal thread Thread size size - Threads per Root diameter (mm) (mm) (Reference) inch, Thread series
Range
Target
19
35 – 63 {3.5 – 6.5}
44 {4.5}
14
22
54 – 93 {5.5 – 9.5}
74 {7.5}
–
24
59 – 98 {6.0 – 10.0}
78 {8.0}
18
04
27
84 – 132 {8.5 – 13.5}
103 {10.5}
22
05
32
128 – 186 {13.0 – 19.0}
157 {16.0}
24
06
36
177 – 245 {18.0 – 25.0}
216 {22.0}
30
(10)
41
177 – 245 {18.0 – 25.0}
216 {22.0}
33
3 1 — – 12UNF 16 –
(12)
46
197 – 294 {20.0 – 30.0}
245 {25.0}
36
–
–
(14)
55
246 – 343 {25.0 – 35.0}
294 {30.0}
42
–
–
02
03
00-14 (23)
9 — – 18UNF 16 11 — – 16UN 16 – 13 — – 16UN 16 1 – 14UNS
14.3 17.5 – 20.7 25.4 30.3 –
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire Cable O.D. (mm)
Current rating (A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Norminal number
Number of strands
Dia. of strands (mm2)
Cross section (mm 2)
0.85
11
0.32
2
26
5
CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification
1
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
2 Color White & Red Code
WB
3 Color White & Black Code 4
Auxiliary
WL
Color White & Blue Code
WG
5 Color White & Green Code 6 Color
n n
n n n n n n n n n n
White & Black Red & White Rellow & Red Green & White Blue & White BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR
RY
Black & Red Red & Yellow
n n n n
RG
YG
GY
LY
Yellow & Green
Green & Yellow
Blue & Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black RL
YW
GL
Red & Blue Yellow & White Green & Blue
n n 00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line from . (2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from . (3) Take the point where the two lines cross as . This point gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
A B
C
C
A
B
B Millimeters to inches 1 mm = 0.03937 in
A
00-16
0
1
2
3
4
5
6
7
8
9
0 10 20 30 40
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
0.197 0.591 0.984 1.378 1.772
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.536 1.929
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
C
FOREWORD
CONVERSION TABLE
Millimeters to Inches 1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
0
Kilogram to Pound 1 kg = 2.2046 lb
0 0
0
1
2
3
4
5
6
7
8
9
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon 1l = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
0
Liter to U.K. Gallon 1l = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
0
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb 1 kgm = 7.233 ft. lb
0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2
0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F
°C
°F
°C
°F
°C
°F
°C
°F
–40.4 –37.2 –34.4 –31.7 –28.9
–40 –35 –30 –25 –20
–40.0 –31.0 –22.0 –13.0 –4.0
–11.7 –11.1 –10.6 –10.0 –9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
–28.3 –27.8 –27.2 –26.7 –26.1
–19 –18 –17 –16 –15
–2.2 –0.4 1.4 3.2 5.0
–8.9 –8.3 –7.8 –7.2 –6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
–25.6 –25.0 –24.4 –23.9 –23.3
–14 –13 –12 –11 –10
6.8 8.6 10.4 12.2 14.0
–6.1 –5.6 –5.0 –4.4 –3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 0
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
–22.8 –22.2 –21.7 –21.1 –20.6
–9 –8 –7 –6 –5
15.8 17.6 19.4 21.2 23.0
–3.3 –2.8 –2.2 –1.7 –1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
–20.0 –19.4 –18.9 –18.3 –17.8
–4 –3 –2 –1 0
24.8 26.6 28.4 30.2 32.0
–0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
–17.2 –16.7 –16.1 –15.6 –15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
–14.4 –13.9 –13.3 –12.8 –12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-21
FOREWORD
UNITS
UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
00-22
}.
FOREWORD
CAPSCREW MARKINGS AND TORQUE VALUES
CAPSCREW MARKINGS AND TORQUE VALUES Caution: When replacing capscrews, always use a capscrew of the same measurement and strength as the capscrew being replaced. Using the wrong capscrews can result in engine damage. Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head of the capscrew. The following examples indicate how capscrews are identified: Metric - M8 − 1.25 × 25 M8 1.25 25 Major Distance Length Thread Between in Diameter in Threads in Millimeters Millimeters Millimeters
U.S. Customary (5/16 × 18 × 1-1/2) 5/16 18 1-1/2 Major Number Length Thread Threads in Diameter per Inch Inches in Inches
NOTES: 1. Always use the torque values listed in the following tables when specific torque values are not available. 2. Do not use the torque values in place of those specified in other sections of this manual. 3. The torque values in the table are based on the use of lubricated threads. 4. When the ft-lb value is less than 10, give consideration to converting the ft-lb value to in-lb to obtain a better torque with an in-lb torque wrench. Example: 6 ft-lb equals 72 in-lb.
102 SERIES
00-23 B
CAPSCREW MARKINGS AND TORQUE VALUES
FOREWORD
Capscrew Markings and torque values - Metric Commercial Steel Class 8.8
10.9
12.9
Torque
Torque
Capscrew Head Markings
Body Size Diam. mm 6 7 8 10 12 14 16 18
00-24 C
Torque Cast Iron
Aluminum
Cast Iron
Aluminum
Cast Iron
Aluminum
kgm N•m ft-lb kgm N•m ft-lb kgm N•m ft-lb kgm N•m ft-lb kgm N•m ft-lb kgm N•m ft-lb 0.92 9 5 1.4 14 9 2.5 25 18 4.6 45 33 8.2 80 60 12.7 125 90 18.4 180 130 23.5 230 170
0.71 7 4 1.1 11 7 1.8 18 14 3.1 30 25 5.6 55 40 9.2 90 65 14.3 140 100 18.4 180 135
1.2 1.8 3.4 6.1 10.7 16.8 24.5 32.6
12 9 18 14 33 25 60 45 105 75 165 122 240 175 320 240
0.71 7 4 1.1 11 7 1.8 18 14 3.1 30 25 5.6 55 40 9.2 90 65 14.3 140 100 18.4 180 135
1.4 2.3 4.1 7.1 12.7 19.9 29.6 40.8
14 9 23 18 40 29 70 50 125 95 195 145 290 210 400 290
0.71 7 4 1.1 11 7 1.8 18 14 3.1 30 25 5.6 55 40 9.2 90 65 14.2 140 100 18.4 180 135
102 SERIES
CAPSCREW MARKINGS AND TORQUE VALUES
FOREWORD
Capscrew Markings and torque values - U.S. Customary SAE grade number
5
8
Capscrew Torque - Grade 5 Capscrew
Capscrew Torque - Grade 8 Capscrew
Capscrew Head Markings These are all SAE Grade 5 (3) line.
Capscrew Body Size
1/4 - 20 - 28 5/16 - 18 - 24 3/8 - 16 - 24 7/16 - 14 - 20 1/2 - 13 - 20 9/16 - 12 - 18 5/8 - 11 - 18 3/4 - 10 - 16 7/8 - 9 - 14 1-8 - 14
102 SERIES
Cast Iron
Aluminum
Cast Iron
Aluminum
kgm
N•m
ft-lb
kgm
N•m
ft-lb
kgm
N•m
ft-lb
kgm
N•m
ft-lb
0.92 1.2 2.0 2.3 4.1 4.1 6.1 6.6 9.7 10.2 13.8 15.3 18.4 21.4 33.1 37.2 50 54 73.4 81.6
9 12 20 23 40 40 60 65 95 100 135 150 180 210 325 365 490 530 720 800
7 9 15 17 30 30 45 50 70 75 100 110 135 155 240 270 360 390 530 590
0.82 0.92 1.6 1.9 2.5 3.6 4.6 5.6 7.6 8.2 11.2 11.7 15.3 16.3 26 29.1 38.7 42.8 58.1 66.3
8 9 16 19 25 35 45 55 75 80 110 115 150 160 255 285 380 420 570 650
6 7 12 14 20 25 35 40 55 60 80 85 110 120 190 210 280 310 420 480
1.5 1.8 3.1 3.4 5.6 6.1 9.2 9.7 13.3 15.3 19.4 21.4 26 29.6 46.9 52.5 76 84.1 112.2 122.4
15 18 30 33 55 60 90 95 130 150 190 210 255 290 460 515 745 825 1100 1200
11 13 22 24 40 45 65 70 95 110 140 155 190 215 340 380 550 610 820 890
0.82 0.92 1.6 1.9 2.5 3.6 4.6 5.6 7.6 8.2 11.2 11.7 15.3 16.3 26 29.1 38.7 42.8 58.1 66.5
8 9 16 19 25 35 45 55 75 80 110 115 150 160 255 285 380 420 570 650
6 7 12 14 20 25 35 40 55 60 80 85 110 120 190 210 280 310 420 480
00-25 C
FOREWORD
SYMBOLS
SYMBOLS The following symbols have been used in this manual to help communicate the intent of the instructions. When one of the symbols appears, it conveys the meaning defined below:
¤
WARNING - Serious personal injury or extensive property damage can result if the warning instructions are not followed.
CAUTION - Minor personal injury can result or a part, an assembly, or the engine can be damaged if the caution instructions are not followed.
Indicates a REMOVAL or DISASSEMBLY step.
Indicates an INSTALLATION or ASSEMBLY step.
INSPECTION is required.
CLEAN the part or assembly.
PERFORM a mechanical or time MEASUREMENT.
LUBRICATE the part or assembly.
Indicates that a WRENCH or TOOL SIZE will be given. TIGHTEN to a specific torque.
PERFORM an electrical MEASUREMENT.
Refer to another location in this manual or another publication for additional information. The component weights 23 kg (50 lb) or more. To avoid personal injury, use a hoist or get assistance to lift the component.
102 SERIES
00-27 6
FOREWORD
ILLUSTRATIONS
ILLUSTRATIONS The illustrations used in the "Repair Sections" of this manual are intended to give an example of a problem, and to show what to look for and where the problem can be found. Some of the illustrations are 'generic" and will not look exactly like the engine or parts used in your application. Some illustrations contain symbols to indicate and action required, and an acceptable or not acceptable condition.
The illustrations are intended to show repair or replacement procedures with the engine "in-chassis". The illustration can differ from your application, but the procedure given will be the same.
00-28 C
102 SERIES
GENERAL
APPLICABLE MACHINE
APPLICABLE MACHINE 102-1 Engine
fl Serial No. shows for engine serial No. Serial No.
Applicable machine PC60-7, PC60-7B, PC70-7
Hydraulic excavator
BR100J-1, BR100JG, RG-1
Mobile crusher (Gara-Pagos)
PC100-6, PC100-6EXCEL
Hydraulic excavator
PC120-6, PC120-6MIGHTY, PC120-6EXCEL
Hydraulic excavator
PC128UU-1, PC128US-1, PC128US-2
Hydraulic excavator
PC158US-2
Hydraulic excavator
D31E, S, Q, P-20, D31PL, PLL-20, D31P-20A
Bulldozer
D37E-5, D37P-5A
Bulldozer
WA120-3, WA120-3D
Wheel loader
GD305A-3
Motor grader
D41A-6
Bulldozer
PC200, 200LC-6, PC200, 200LC-6HYPER GX
Hydraulic excavator
PC200-6CUSTOM, EXCEL(BKC), PC210, 210LC-6MIGHTY
Hydraulic excavator
PC228USL-1, PC228USLC-2
Hydraulic excavator
BR200S-1, BR210JG-1
Mobile crusher (Gara-Pagos)
CD60RE-1
Crawler carrier
D41E, P-6
Bulldozer
WA180-3, WA180-3 (For EU), WA180PT-3, WA180-3 (For CIS)
Wheel loader
WA250-3, WA250L-3 (For USA), WA250PT-3
Wheel loader
GD405A-3, GD521A-1E
Motor grader
JV100WA-2, JV100WP-2
Vibratory roller
PC220, 220LC-6, PC220-6EXCEL
Hydraulic excavator
PC250HD-1, PC250, 250LC-6
Hydraulic excavator
BR250RG-1, BR350JG-1
Mobile crusher (Gara-Pagos)
WA300L-3 (For USA), WA320-3, WA320-3CUSTOM
Wheel loader
DCA-125SSK
DENYO generator
4D102E-1
S4D102E-1
6D102E-1
S6D102E-1
SA6D102E-1
01-1-1 (23)
102 SERIES
GENERAL
APPLICABLE MACHINE
102-2 Engine
Serial No.
Applicable machine D31EX-21, D31PX-21
Bulldozer
D37EX-21, D37PX-21
Bulldozer
D39EX-21, D39PX-21
Bulldozer
PC160LC-7
Hydraulic excavator
PC200-7, PC200LC-7, PC228US-3, PC228USLC-3, PC270-7, PC308USLC-3, PC220-7, PC220LC-7
Hydraulic excavator
BR120T-1, BR380JG-1
Mobile crusher (Gara-Pagos)
WA150-5
Wheel loader
WA200-5
Wheel loader
WA250-5, WA250PT-5
Wheel loader
WA320-5, WA320PT-5
Wheel loader
GD555-3A, GD555-3C
Motor grader
DCA-150ESK
Wheel loader
SAA4D102E-2
SAA6D102E-2
102 SERIES
01-1-2 (21)
GENERAL
SPECIFICATIONS
SPECIFICATIONS 102-1 Engine
4D102E-1 PC60-7, PC60-7B PC70-7
Applicable model
BR100J, BR100, JG, RG-1
No. of cylinders - Bore x Stroke
mm
4 – 102 x 120
Total piston displacement
¬ {cc}
3.92 {3,920}
Performance
Dimensions
Firing order
1–3–4–2
Overall length
mm
976
976
Overall width
mm
690
690
Overall height (excluding exhaust pipe)
mm
—
—
Overall height (including exhaust pipe)
mm
1,074
1,074
Flywheel horsepower
kW{HP}/rpm
40.5/1,750 {54.3/1,750} (Net)
40.5/1,750 {54.3/1,750} (Net)
Max. torque
Nm{kgm}/rpm
245/1,200 {25.0/1,200} (Net)
245/1,200 {25.0/1,200} (Net)
High idling speed
rpm
1,900 – 2,000
1,900 – 2,000
Low idling speed
rpm
1,000 – 1,050
1,000 – 1,050
g/kW•h {g/HP•h}
238 {177}
238 {177}
kg
380
380
Min. fuel consumption ratio
Dry weight Fuel injection pump
BOSCH PES-A type
Governor Lubricating oil amount
BOSCH RSV centrifugal, all speed type 14.5
14.5
(14.0)
(14.0)
7.0 (engine only)
7.0 (engine only)
24V, 25A
24V, 25A
24V, 4.5kW
24V, 4.5kW
12V65Ah x 2
12V65Ah x 2
Turbocharger
—
—
Air compressor
—
—
Others
—
—
(refil capacity)
Coolant amount
Alternator Starting motor Battery
01-2 0
¬
¬
102 SERIES
GENERAL
SPECIFICATIONS
Engine
S6D102E-1 PC200, 200LC-6 PC200, 200LC-6 HYPER GX PC210,210LC-6 MIGHTY, BR200S-1
Applicable model No. of cylinders - Bore x Stroke
mm
Total piston displacement
¬ {cc}
Performance
Dimensions
Firing order
PC200LC-6 PC200-6 CUSTOM PC200-6 EXCEL, (BKC)
6–102 x 120 5.88 {5,883} 1–5–3–6–2–4
Overall length
mm
1,361
1,361
Overall width
mm
760
760
Overall height (excluding exhaust pipe)
mm
1,301
1,301
Overall height (including exhaust pipe)
mm
—
—
Flywheel horsepower
kW{HP}/rpm
99.3/2,000 {133/2,00} (Net)
95.6/2,000 {128/2,000} (Net)
Max. torque
Nm{kgm}/rpm
563/1,350 {57.4/1,350} (Net)
545/1,350 {55.6/1,350} (Net)
High idling speed
rpm
2,140 – 2,260
2,140 – 2,260
Low idling speed
rpm
1,000 – 1,050
1,000 – 1,050
g/kW•h {g/HP•h}
228 {170}
228 {170}
kg
540
510
Min. fuel consumption ratio
Dry weight Fuel injection pump
BOSCH PES-A type
Governor Lubricating oil amount
BOSCH RSV centrifugal, all speed type 26.3
26.3
(24.0)
(24.0)
9.0 (engine only)
9.0 (engine only)
24V, 35A
24V, 35A
24V, 4.5kW
24V, 4.5kW
12V110Ah x 2
12V110Ah x 2
HOLSET HX35 type
HOLSET HX35 type
Air compressor
—
—
Others
—
—
(refil capacity)
Coolant amount
Alternator Starting motor Battery Turbocharger
01-6 (23)
¬
¬
102 SERIES
GENERAL
SPECIFICATIONS
S6D102E-1 CD60RE-1 BR200S-1, BR210JG-1
PC228USL-1
PC228USLC-2
D41E, P-6
WA180-3 WA180-3 (for EU) WA180PT-3 WA180-3 (for CIS)
6 – 102 x 120 5.88 {5,883} 1–5–3–6–2–4
1,361
1,092
1,092
1,015
1,129
760
705
705
659
789
1,301
—
—
975
1,338
—
1,301
1,301
—
—
96.0/2,000 {128/2,000} (Net)
95.6/2,000 {128/2,000} (Net)
95.6/2,000 {128/2,000} (Net)
78.0/2,400 {105/2,400} (Net)
81.0/2,400 {109/2,400} (Net)
545/1,350 {55.6/1,350} (Net)
545/1,350 {55.6/1,350} (Net)
545/1,350 {55.6/1,350} (Net)
461/1,300 {47.0/1,300} (Net)
417/1,600 {42.5/1,600} (Net)
2,140 – 2,260
2,140 – 2,260
2,140 – 2,260
2,650
2,600 – 2,700
1,000 – 1,050
1,000 – 1,050
1,000 – 1,050
825
750 – 800
228 {170}
228 {170}
228 {170}
211 {157}
218 {163}
510
520
520
530
510
BOSCH PES-A type BOSCH RSV centrifugal, all speed type 26.3
26.3
26.3
26.8
22.0
(24.0)
(24.0)
(24.0)
(22.8)
(21.5)
9.0 (engine only)
9.0 (engine only)
9.0 (engine only)
9.0 (engine only)
9.0 (engine only)
24V, 35A
24V, 35A
24V, 35A
24V, 35A
24V, 35A
24V, 4.5kW
24V, 4.5kW
24V, 4.5kW
24V, 5.5kW
24V, 4.5kW
12V110Ah x 2
12V110Ah x 2
12V110Ah x 2
12V65Ah x 2
12V110Ah x 2
HOLSET HX35 type
HOLSET HX35 type
HOLSET HX35 type
HOLSET HX35 type
HOLSET HX35 type
—
—
—
—
—
—
—
—
—
—
102 SERIES
01-7 (23)
GENERAL
SPECIFICATIONS
SA6D102E-1 WA320-3 WA320-3 CUSTOM
DCA-125SSK (DENYO generator) 6 – 102 x 120 5.88 {5,883} 1–5–3–6–2–4
1,131
1,276
710
674
1,041
1,105
—
—
114/2,350 {153/2,350} (Net)
115.5/1,800 (60 Hz) {154/1,800} (60 Hz) (Net)
608/1,600 {62.0/1,600} (Net)
—
2,535 – 2,635
Max. 1,890 (60 Hz)
775 – 825
750 – 850
237 {177}
226 (60 Hz) {168} (60 Hz)}
500
520 BOSCH PES-A type BOSCH RSV centrifugal, all speed type
22.0
22
(21.5)
(21)
9.0 (engine only)
10.0 (engine only)
24V, 35A
24V, 35A
24V, 4.5kW
24V, 4.5kW
12V140Ah x 2
12V100Ah x 2
HOLSET HX35 type (with waste gate) —
HOLSET HX35 type (with waste gate) —
With aftercooler
—
102 SERIES
01-7-6 B
GENERAL
SPECIFICATIONS
102-2 Engine
SAA4D102E-2 D31EX-21 D31PX-21
Applicable model No. of cylinders - Bore x Stroke
mm
Total piston displacement
¬ {cc}
Dimensions
D39EX-21 D39PX-21
4 – 102 x 120 3.92 {3,920}
Firing order
Performance
D37EX-21 D37PX-21
1– 3–4–2
Overall length
mm
920
920
920
Overall width
mm
658
658
658
Overall height (excluding exhaust pipe)
mm
947
947
947
Overall height (including exhaust pipe)
mm
—
—
—
Flywheel horsepower
kW{HP}/rpm
58.2{78.0}/2,000 (Net)
63.3{84.9}/2,000 (Net)
70{94}/2,200 (Net)
Max. torque
Nm{kgm}/rpm
384{39.2}/1,300 (Net)
412{42}/1,300 (Net)
434{44.3}/1,300 (Net)
rpm
2,200 ± 50
2,200 ± 50
2,400 ± 50
rpm
+50 800 0
+50 800 0
g/kW•h {g/HP•h}
224 {165}
224 {165}
218 {162}
kg
400
400
400
High idling speed Low idling speed Min. fuel consumption ratio
Dry weight Fuel injection pump
(refil capacity)
Coolant amount
Alternator Starting motor Battery Turbocharger Air compressor Others
01-7-7 (19)
+50 0
BOSCH PES-A type
Governor Lubricating oil amount
800
BOSCH RSV centrifugal, all speed type
¬
¬
14
14
14
(12.5)
(12.5)
(12.5)
7.0 (engine only)
7.0 (engine only)
7.0 (engine only)
24V, 25A
24V, 25A
24V, 25A
24V, 5.5kW
24V, 5.5kW
24V, 4.5kW
12V92Ah x 2
12V92Ah x 2
12V88Ah x 2
HOLSET HX25 type HOLSET HX25 type HOLSET HX25 type — With air cooled aftercooler
— With air cooled aftercooler
— With air cooled aftercooler
102 SERIES
GENERAL
SPECIFICATIONS
SAA4D102E-2 PC160LC-7
WA150-5 4 – 102 x 120 3.92 {3,920} 1– 3–4–2
1,013
786
722
715
—
1,924
1,293
—
82{110}/2,200 (Net)
70.8{94.9}/2,000 (Net)
431{44}/1,500 (Net)
402{41}/1,300 (Net)
2,490 ± 50
2,250 ± 50
1,050 ± 50
825 ± 50
212 {156}
219 {161}
415
450 BOSCH PES-A type BOSCH RSV centrifugal, all speed type
17.5
14
(16)
(12.5)
7.0 (engine only)
7.0 (engine only)
24V, 35A
24V, 35A
24V, 4.5kW
24V, 5.5kW
12V95Ah x 2
12V95Ah x 2
HOLSET HX25 type
HOLSET HX25 type
— With air cooled aftercooler
102 SERIES
— With air cooled aftercooler
01-7-8 (19)
SPECIFICATIONS
GENERAL
Engine
SAA6D102E-2 PC200-7 PC200LC-7
Applicable model No. of cylinders - Bore x Stroke
mm
Total piston displacement
¬ {cc}
Dimensions
PC308USLC-3 BR380JG-1 PC270-7
6 – 102 x 120 5.88 {5,883}
Firing order
Performance
PC228US-3 PC228USLC-3
1–5–3–6–2–4
Overall length
mm
1,320
1,320
1,320
Overall width
mm
750
750
750
Overall height (excluding exhaust pipe)
mm
1,380
1,380
1,443
Overall height (including exhaust pipe)
mm
—
—
—
Flywheel horsepower
kW{HP}/rpm
107{143}/1,950 (Net)
107{143}/1,950 (Net)
134{180}/2,050 (Net)
Max. torque
Nm{kgm}/rpm
610{62.2}/1,500 (Net)
610{62.2}/1,500 (Net)
718{73.3}/1,500 (Net)
High idling speed
rpm
2,200 ± 30
2,200 ± 30
2,330 _ 30
Low idling speed
rpm
1,050 ± 25
1,050 ± 25
1,050 ± 25
g/kW•h {g/HP•h}
203 {151}
203 {151}
218 {160}
kg
550
550
550
Min. fuel consumption ratio
Dry weight Fuel injection pump
BOSCH PES-A type
Governor Lubricating oil amount (refil capacity)
Coolant amount
Alternator Starting motor Battery Turbocharger Air compressor Others
01-7-9 (18)
+70
BOSCH RSV centrifugal, all speed type
¬
¬
26.3
26.3
26.3
(24.0)
(24.0)
(24.0)
9.0 (engine only)
9.0 (engine only)
9.0 (engine only)
24V, 35A
24V, 35A
24V, 35A
24V, 4.5kW
24V, 4.5kW
24V, 4.5kW
12V120Ah x 2
12V120Ah x 2
12V120Ah x 2
HOLSET HX35 type
HOLSET HX35 type
HOLSET HX35 type
— With air cooled aftercooler
— With air cooled aftercooler
— With air cooled aftercooler
102 SERIES
GENERAL
SPECIFICATIONS
SAA6D102E-2 BR120T-1
WA200-5 WA200PT-5
WA250-5 WA250PT-5
WA320-5 WA320PT-5
GD555-3A GD555-3C
6 – 102 x 120 5.88 {5,883} 1 – 5 – 3 – 6– 2 – 4
1,210
1,069
1,069
1,069
1,070
750
785
785
785
747
1,380
1,483
1,483
1,483
1,123
—
—
—
—
—
141{189}/2,050 (Gross)
95.2{127.7}/2,000 (Gross)
104.1{139.5}/2,000 (Gross)
127{170}/2,000 (Gross)
124.5{167}/2,000 (Gross)
740{75.7}/1,500 (Gross)
586{59.8}/1,400 (Gross)
627{64}/1,400 (Gross)
672{68.5}/1,500 (Gross)
743{75.7}/1,500 (Gross)
2,330 ± 50
2,250 ± 50
2,250 ± 50
2,250 ± 50
2,230 ± 50
1,050 ± 25
825 ± 50
825 ± 50
900 ± 25
900 ± 50
203 {151}
224 {167}
224 {167}
224 {167}
227
550
580
580
600
550
BOSCH PES-A type BOSCH RSV centrifugal, all speed type 26.3
21.8
21.8
21.8
26.3
(24.0)
(19.5)
(19.5)
(19.5)
(24.0)
9.0 (engine only)
9.0 (engine only)
9.0 (engine only)
9.0 (engine only)
9.0 (engine only)
24V, 35A
24V, 35A
24V, 35A
24V, 60A
24V, 35A
24V, 4.5kW
24V, 4.5kW
24V, 4.5kW
24V, 5.5kW
24V, 5.5kW
12V120Ah x 2
12V120Ah x 2
12V120Ah x 2
12V120Ah x 2
12V140Ah x 2
HOLSET HX35 type
HOLSET HX35 type
HOLSET HX35 type
HOLSET HX35 type
HOLSET HX35 type
— With air cooled aftercooler
— With air cooled aftercooler
— With air cooled aftercooler
— With air cooled aftercooler
— With air cooled aftercooler
102 SERIES
01-7-10 (20)
SPECIFICATIONS
GENERAL
Engine
SAA6D102E-2
Applicable model
PC308USLC-3
No. of cylinders - Bore x Stroke
mm
Total piston displacement
¬ {cc}
Dimensions
DCA-150ESK (DENYO generator)
6 – 102 x 120 5.88 {5,883}
Firing order
Performance
PC220-7 PC220LC-7
1–5–3–6–2–4
Overall length
mm
1,320
1,320
1,360
Overall width
mm
750
750
710
Overall height (excluding exhaust pipe)
mm
—
1,383
1.240
Overall height (including exhaust pipe)
mm
1,443
—
—
Flywheel horsepower
kW{HP}/rpm
134{180}/2,050 (Net)
125{168}/2,000 (Net)
113{151}/1,500(50Hz) 135{180}/1,800(60Hz) (Net)
Max. torque
Nm{kgm}/rpm
718{73.3}/1,500 (Net)
684{69.8}/1,500 (Net)
—
+70 _ 30
+80
Max.1,580(50Hz) Max.1,890(60Hz)
High idling speed
rpm
2,330
Low idling speed
rpm
1,050 ± 25
1,050 ± 25
800 ± 50
g/kW•h {g/HP•h}
218 {163}
218 {163}
218{163}(50Hz) 224{167}(60Hz)
kg
550
550
670
Min. fuel consumption ratio
Dry weight Fuel injection pump
BOSCH PES-A type
Governor Lubricating oil amount (refil capacity)
Coolant amount
Alternator Starting motor Battery Turbocharger Air compressor Others
01-7-11 (21)
2,260 _ 20
BOSCH RSV centrifugal, all speed type
¬
¬
26.3
26.3
22
(24.0)
(24.0)
(21.0)
9.0 (engine only)
9.0 (engine only)
9.0 (engine only)
24V, 35A
24V, 35A
24V, 25A
24V, 4.5kW
24V, 4.5kW
24V, 4.5kW
12V120Ah x 2
12V120Ah x 2
12V100Ah x 2
HOLSET HX35 type
HOLSET HX35 type
MHI TE06H
— With air cooled aftercooler
— With air cooled aftercooler
— With air cooled aftercooler
102 SERIES
GENERAL
GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING 4D102E-1 (PC60-7) LEFT-HAND VIEW fl Depending on the applicable model, the view may be different from the drawing.
01-8 B
102 SERIES
GENERAL
ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE 102E-1 Engine 4D102E-1
Serial No.
Applicable machine
Page
PC60-7, PC60-7B, PC70-7
01-22
PC100-6, PC100-6L-6
01-22-1
PC120-6 EXCEL
01-22-2
PC120-6, PC130-6
01-22-3
PC128UU-1
01-22-4
PC100, 100L-6, PC100-6 EXCEL
01-23
PC120-6, PC130-6 MIGHTY
01-24
PC120-6 EXCEL
01-25
PC128UU-1
01-26
PC128US-1, PC128US-2
01-27
PC158US--2
01-27-1
WA120-3, WA120-3D
01-28
D31E, S, Q, P, PL, PLL-20, D31P-20A
01-29
D37E-5, D37P-5A
01-30
GD305A-3
01-31
PC200, 200LC-6, PC200, 200LC-6 HYPER GX, PC210, 210LC-6 MIGHTY, BR200S-1 PC200LC-6 EXCEL, PC200-6 CUSTOM, PC228UU, 228USLC-1, 228USLC-2, CD60RE-1
01-32
WA180-3, WA180-3 (For EU), WA180PT-3, WA180-3 (For CIS)
01-34
WA250-3, WA250PT-3
01-34-1
JV100WA-2, JV100WP-2
01-34-2
GD521A-1E
01-34-3
PC220, 220LC-6, PC250HD-1, PC250, 250LC-6
01-34-5
PC220, 220LC-6 EXCEL
01-34-6
WA300L-3 (For USA), WA320-3, WA320-3 CUSTOM
01-34-8
S4D102E-1
S6D102E-1
SA6D102E-1
01-21-1 (23)
01-33
102 SERIES
GENERAL
ENGINE PERFORMANCE CURVE
102E-2 Engine
Serial No.
Applicable machine
Page
D31EX, PX-21
01-34-18
D37EX, PX-21
01-34-19
D39EX, PX-21
01-34-20
PC160LC-7
01-34-21
PC200-7, PC200LC-7, PC228US, USLC-3
01-34-31
BR120T-1
01-34-32
PC270-7, PC308USLC-3, BR380JG-1
01-34-33
WA150-5
01-34-22
WA200-5, WA200PT-5
01-34-37
WA250-5, WA250PT-5
01-34-34
WA320-5, WA320PT-5
01-34-35
GD555-3A, GD555-3C
01-34-36
PC220-7, PC220LC-7
01-34-38
SAA4D102E-2
SAA6D102E-2
102 SERIES
01-21-2 (20)
GENERAL
ENGINE PERFORMANCE CURVE
S6D102E-1 (WA180-3, WA180-3 (FOR EU), WA180PT-3, WA180-3 (FOR CIS)) Flywheel horsepower : 81.0 kW {108 HP} /2,400 rpm (Net) Maximum torque : 417 Nm {42.5 kgm} /1,600 rpm (Net)
01-34 (23)
102 SERIES
GENERAL
ENGINE PERFORMANCE CURVE
SAA4D102E-2 (D31EX-21, D31PX-21) Flywheel horsepower : 58.2 kW {78 HP} /2,000 rpm (Net) Maximum torque : 384 Nm {39.2 kgm} /1,300 rpm (Net)
01-34-18 (19)
102 SERIES
GENERAL
ENGINE PERFORMANCE CURVE
SAA4D102E-2 (D37EX-21, D37PX-21) Flywheel horsepower : 63.3 kW {84.9 HP} /2,000 rpm (Net) Maximum torque : 412 Nm {42 kgm} /1,300 rpm (Net)
102 SERIES
01-34-19 (19)
GENERAL
ENGINE PERFORMANCE CURVE
SAA4D102E-2 (D39EX-21, D39PX-21) Flywheel horsepower : 70 kW {94 HP} /2,200 rpm (Net) Maximum torque : 434 Nm {44.3 kgm} /1,300 rpm (Net)
01-34-20 0
102 SERIES
GENERAL
ENGINE PERFORMANCE CURVE
SAA4D102E-2 (PC160LC-7) Flywheel horsepower : 82.4 kW {110.5 HP} /2,200 rpm (Net) Maximum torque : 431 Nm {44 kgm} /1,500 rpm (Net)
102 SERIES
01-34-21 C
GENERAL
ENGINE PERFORMANCE CURVE
SAA4D102E-2 (WA150-5) Flywheel horsepower : 74.2 kW {99.5 HP} /2,000 rpm (Gross) Maximum torque : 408 Nm {41.6 kgm} /1,300 rpm (Gross)
01-34-22 (19)
102 SERIES
GENERAL
ENGINE PERFORMANCE CURVE
SAA6D102E-2 (PC200-7, PC200LC-7, PC228US-3, PC228USLC-3) Flywheel horsepower : 107 kW {143 HP} /1,950 rpm (Net) Maximum torque : 610 Nm {62.2 kgm} /1,500 rpm (Net)
102 SERIES
01-34-31 C
GENERAL
ENGINE PERFORMANCE CURVE
SAA6D102E-2 (BR120T-1) Flywheel horsepower : 141 kW {189 HP} /2,050 rpm (Gross) Maximum torque : 740 Nm {75.7 kgm} /1,500 rpm (Gross)
01-34-32 C
102 SERIES
GENERAL
ENGINE PERFORMANCE CURVE
SAA6D102E-2 (PC270-7, PC308USLC-3, BR380JG-1) Flywheel horsepower : 134 kW {180 HP} /2,050 rpm (Net) Maximum torque : 718 Nm {73.3 kgm} /1,500 rpm (Net)
102 SERIES
01-34-33 (18)
GENERAL
ENGINE PERFORMANCE CURVE
SAA6D102E-2 (WA250-5, WA250PT-5) Flywheel horsepower : 104.1 kW {139.5 HP} /2,000 rpm (Gross) Maximum torque : 627 Nm {64 kgm} /1,400 rpm (Gross)
01-34-34 (19)
102 SERIES
GENERAL
ENGINE PERFORMANCE CURVE
SAA6D102E-2 (WA320-5, WA320PT-5) Flywheel horsepower : 127 kW {170 HP} /2,000 rpm (Gross) Maximum torque : 672 Nm {68.5 kgm} /1,500 rpm (Gross)
102 SERIES
01-34-35 (20)
GENERAL
ENGINE PERFORMANCE CURVE
SAA6D102E-2 (WA200-5, WA200PT-5) Flywheel horsepower : 95.2 kW {127.7 HP} /2,000 rpm (Gross) Maximum torque : 586 Nm {59.8 kgm} /1,400 rpm (Gross)
102 SERIES
01-34-37 (19)
GENERAL
ENGINE PERFORMANCE CURVE
SAA6D102E-2 (PC220-7, PC220LC-7) Flywheel horsepower : 125 kW {168 HP} /2,000 rpm (Net) Maximum torque : 684 Nm {69.8 kgm} /1,500 rpm (Net)
01-34-38 (19)
102 SERIES
STRUCTURE AND FUNCTION
TURBOCHARGER
Lubrication of turbocharger (engine with turbocharger)
1. Oil supply pipe 2. Oil drain pipe The oil to the turbocharger is filtered, cooled, and pressurized, then passes from the filter head and goes through the oil supply pipe (1) to the turbocharger. The oil then passes through the oil drain pipe (2) connected to the bottom of the turbocharger housing, goes through the block fitting and returns to the oil pan.
102 SERIES
11-9 C
STRUCTURE AND FUNCTION
CYLINDER HEAD
CYLINDER HEAD (S)4D102E-1 SAA4D102E-2
1. Cylinder head 2. Oil filler cap 3. Head cover
11-10 B
fl Depending on the machine model, the actual component may be different from the diagram.
4. Head bolt 5. Nozzle holder 6. Gasket
Head cover • Float mount type
102 SERIES
STRUCTURE AND FUNCTION
CYLINDER BLOCK
CYLINDER BLOCK (S)4D102E-1 SAA4D102E-2
1. 2. 3. 4. 5.
Main bearing cap Main bearing cap bolt Cylinder block Cam bushing (journal No. 1) Dowel ring (main bearing cap positioner)
11-14 (17)
fl Depending on the machine model, the actual component may be different from the diagram.
a. Piston cooling nozzle b. Thrust face (top face only, No. 4 journal)
102 SERIES
STRUCTURE AND FUNCTION
CYLINDER BLOCK
(S)6D102E-1, SA6D102E-1 SAA6D102E-2 fl Depending on the machine model, the actual component may be different from the diagram.
1. 2. 3. 4. 5. 6. 7.
Main bearing cap Main bearing cap bolt Cylinder block Cam bushing (journal No. 1) Dowel ring (main bearing cap positioner) Cam follower cover Breather hose
11-15-1 (17)
a. Piston cooling nozzle b. Thrust face (top face only, No. 6 journal)
102 SERIES
STRUCTURE AND FUNCTION
MAIN MOVING PARTS
MAIN MOVING PARTS (S)4D102E-1 SAA4D102E-2 fl Depending on the machine model, the actual component may be different from the diagram.
d
1. Crankshaft 2. Crankshaft gear (No. of teeth: 36) 3. Main bearing 4. Connecting rod bearing 5. Connecting rod 6. Cylinder block (no lining) 7. Piston 8. Connecting rod bushing 9. Piston pin 10. Top ring
11-18 (17)
11. 12. 13. 14. 15. 16. 17.
Second ring Oil ring Connecting rod cap Main cap Main cap bolt Connecting rod cap bolt Thrust bearing (top face only No. 4 journal) 18. Pin 19. Crankshaft pulley
a: b: c: d:
Ring carrier Toroidal Re-entrant Piston cooling nozzle
102 SERIES
MAIN MOVING PARTS
STRUCTURE AND FUNCTION
(S)6D102E-1, SA6D102E-1 SAA6D102E-2 fl Depending on the machine model, the actual component may be different from the diagram.
1. Crankshaft 2. Crankshaft gear (No. of teeth: 36) 3. Main bearing 4. Connecting rod bearing 5. Connecting rod 6. Cylinder block (no lining) 7. Piston 8. Connecting rod bushing 9. Piston pin 10. Top ring
11-19-1 (17)
11. 12. 13. 14. 15. 16. 17.
Second ring Oil ring Connecting rod cap Main cap Main cap bolt Connecting rod cap bolt Thrust bearing (top face only No. 6 journal) 18. Pin 19. Crankshaft pulley
a: b: c: d:
Ring carrier Toroidal Re-entrant Piston cooling nozzle
102 SERIES
VALVE MECHANISM
STRUCTURE AND FUNCTION
Valve timing
Valve lift
Intake
Valve angle (Open, closed) 4D102E-1 6D102E-1
S4D102E-1 S6D102E-1 SA6D102E-1 SAA4D102E-2 SAA6D102E-2
10.6 mm
9.9 mm
4D102E-1 6D102E-1
S4D102E-1 S6D102E-1 SA6D102E-1 SAA4D102E-2 SAA6D102E-2
a
10˚
11.5˚
b
30˚
9.5˚
c
53˚
53˚
d
19˚
19˚
Intake Exhaust
11.7 mm
11.7 mm Exhaust
12. 13. 14. 15. 16.
Spring seat Valve cotter Valve spring Valve stem seal (intake, exhaust) Rocker arm
102 SERIES
11-27 (17)
STRUCTURE AND FUNCTION
OIL PAN
S6D102E-1 (For CIS) fl Depending on the machine model, the actual component may be different from the diagram.
1. 2. 3. 4. 5.
Underplate Oil pan Drain plug Drain hose Oil pan heater
102 SERIES
11-29-2 (23)
STRUCTURE AND FUNCTION
LUBRICATION SYSTEM DIAGRAM
Oil cooler On this engine, a full-flow plate shape oil cooler (3) is used. The oil flows through the passage cast in the cooler cover and goes to the element, where it is cooled in the element by the engine cooling water flowing through the plate. On the 4-cycle engine, element (A) with five plates is used, and on the 6-cycle engine, element (B) with seven plates is used. There is a difference in the resistance and pump volume of the plates, so there is no interchangeability in the oil cooler components between the two engines. If the correct component is not used, it will cause high temperature, low temperature, or the formation of varnish or sludge. Caution: Up to 10/21/86, a 9-plate oil cooler element was used for the 6-cylinder engine. Oil filter After the oil is cooled, it is sent to full-flow oil filter (4). The filter on the 6-cylinder engine is slightly longer than the filter on the 4-cylinder engine. Caution: Even if the 6-cylinder engine filter is used on the 4-cylinder engine, there will be no increase in the replacement interval. Do not use a 4-cylinder engine filter on the 6-cylinder engine under any circumstances. This will cause a drop in the filtering capacity and will cause an increase in clogging. Oil cooler bypass valve Bypass valve (5) is installed in the oil cooler cover to allow the oil to flow through the bypass when the filter is clogged. The valve is designed so that when the filter is clogged and the drop in pressure on both sides of the filter exceeds 1.4 kg/cm2 (138 kPa) (20 psi), the valve opens and allows the oil to flow to the engine. When the filter is clogged, the oil pressure drops within 0.6 kg/cm2 (60 kPa) (10 psi) lower than the normal operating oil pressure. This can be observed on the oil pressure gauge. To avoid this condition, it is best to replace the filter at the drain interval given in the Operation and Maintenance Manual, Bulletin No. 3810205-10.
102 SERIES
11-35 C
STRUCTURE AND FUNCTION
LUBRICATION SYSTEM DIAGRAM
Lubrication of output power related equipment
11-36 C
102 SERIES
STRUCTURE AND FUNCTION
FUEL SYSTEM DIAGRAM
FUEL SYSTEM DIAGRAM (S)4D102E-1 fl Depending on the machine model, the actual component may be different from the diagram.
1. 2. 3. 4.
Fuel tank Gauze filter Priming pump Feed pump
102 SERIES
5. 6. 7. 8.
Fuel filter Overflow valve Fuel injection pump Fuel injection nozzle
11-43 B
STRUCTURE AND FUNCTION
FUEL SYSTEM DIAGRAM
(S)4D102E-1, SAA4D102E-2 fl Depending on the machine model, the actual component may be different from the diagram.
1. 2. 3. 4.
Fuel tank Gauze filter Priming pump Feed pump
11-44 C
5. 6. 7. 8.
Fuel filter Overflow valve Fuel injection pump Fuel injection nozzle
102 SERIES
STRUCTURE AND FUNCTION
FUEL SYSTEM DIAGRAM
Components of fuel system and flow of fuel The diagram below shows the components of the fuel system.
1. 2. 3. 4. 5. 6. 7.
Fuel from fuel tank Pre-filter or screen Lift pump Fuel/water separator Fuel filter Low pressure fuel supply line Turbo boost control line
102 SERIES
8. Robot Bosch P7100 injection pump 8A. Robot Bosch rotary injection pump 9. Fuel drain manifold 10. High pressure line 11. Robot Bosch 17 mm nozzle, hole-type injector 12. Fuel returns to fuel tank
11-47 C
STRUCTURE AND FUNCTION
FUEL INJECTION PUMP
FUEL INJECTION PUMP (S)4D102E-1 SAA4D102E-2
1. Oil tube 2. Feed pump 3. Drive shaft 4. Fuel pump drive gear (No. of teeth: 72) 5. Priming pump 6. Priming pump body 7. Fuel filter 8. Fuel injection pipe (No. 1) 9. Fuel injection pipe (No. 2)
11-48 B
fl Depending on the machine model, the actual component may be different from the diagram.
10. Fuel injection pipe (No. 3) 11. Fuel injection pipe (No. 4) 12. Spill tube 13. Overflow valve 14. Fuel injection pump (boost compensator) 15. Fuel injection pump (governor) 16. Boost compensator tube 17. Pressure piping for boost compensator cancel 18. Timing lock
102 SERIES
STRUCTURE AND FUNCTION
FAN DRIVE
102E-2 fl All the pulleys are for polyvinyl V-belts. Outside diameter of pulley (mm) Engine
SAA4D102E-2
Machine model
a
b
(Alternator)
(Fan)
D31EX-21 D31PX-21 D37EX-21 D37PX-21 D39EX-21 D39PX-21
80
209
73.9
173
88
PC160LC-7
77.5
195
73.9
173
88
WA150-5
77.5
157
73.9
173
88
77.5
182
73.9
173
88
77.5
204
73.9
173
88
BR120T-1
77.5
177
73.9
173
88
BR380JG-1
77.5
172
73.9
173
88
WA200-5 WA200PT-5 WA250-5 WA250PT-5 WA320-5, WA320PT-5
77.5
157
73.9
173
88
80
157
73.9
173
88
77.5
172
73.9
173
88
80
181.8
73.9
174.4
88
PC200-7 PC200LC-7 PC228US-3 PC228USLC-3
SAA6D102E-2
GD555-3A GD555-3C PC220-7 PC220LC-7 PC270-7 PC308USLC-3
c
(ª1)
(ª1)
(ª1)
(ª1)
d
e
(Tension) (Crankshaft) (Water pump)
DCA-150ESK (DENYO generator) ª1. Engine without fan.
102 SERIES
11-59-2 (21)
FAN DRIVE
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Water pump Alternator Auto tension Fan (inclined axial flow fan or axial flow fan) Fan hub Fan bracket Crankshaft pulley Accessory drive pulley Poly V-belt Fan drive V-belt
A. From radiator B. Direction of air flow a, b, c, d, e: Outside diameter of pulley f: Hole for square wrench
Pulley diameter (mm) Engine
Model
PC220-6 SA6D102E-1
S6D102E-1
11-59-3 B
PC220-6 EXCEL PC200-6 PC200-6 EXCEL
a
b
c
d
e
(Alternator)
(Fan)
(Accessory*) (Crankshaft) (Water pump)
77.5
185
(Poly V-belt)
(V-belt)
157 185 (V-belt) 88 (Poly V-belt) (Poly V173 belt) (Poly V-belt) (V-belt)
77.5
185
(Poly V-belt)
(V-belt)
157 165 (V-belt) 88 (Poly V-belt) 173 (Poly V- (Poly V-belt) (V-belt) belt)
102 SERIES
STRUCTURE AND FUNCTION
AIR COMPRESSOR
AIR COMPRESSOR Outline of air compressor system Normally, the compressed air system consists of a gear driven air compressor, air governor, air tank, and piping.
Caution: The cylinder head and unload components on the Holset SS161B air compressor are used for various engines, so maintenance can be carried out without removing the air compressor. In this manual, the explanation of the methods for maintenance of the air compressor unloader components are given for the condition when the compressor is still installed to the engine. When carrying out maintenance on components or other parts inside the air compressor, the compressor must be removed from the engine. For details of the procedure for disassembly and assembly of the air compressor, see SS192B shop manual, Bulletin No. 3810433.
The Holset SS191 air compressor (1) is an engine driven piston type compressor which supplies compressed air to drive the air operated components. The compressor operates continuously, but it has two operating modes (“load” and “unload”). The operating mode is controlled by a pressure operated governor and compressor unloading assembly. When the air line reaches the set pressure, the governor (2) sends an air signal to the air compressor unloader assembly and sets the unloader valve with the compressor suction valve open, so this stops the flow of compressed air into the air line. It uses the air in the air line, so the pressure goes down. When the air pressure reaches the set pressure, the governor exhausts the air signal sent to the compressor unloader assembly, so the compressor again starts to send compressed air to the air line.
The Holset SS296 air compressor is an engine driven piston type compressor which supplies compressed air to drive the air operated components. The compressor operates continuously, but it has two operating modes (“load” and “unload”). The operating mode is controlled by a pressure operated governor and compressor unloading assembly.
There are two types of cooling for the air compressor: air cooled and water cooled. The only difference between these two types of cooling is that modification has been made to the cylinder head to include a water passage. There are two types of installation for the air compressor: one type is installed to the power steering pump housing, and the other is not installed to it. On the 102 series engine, it is possible to use other brands of compressor. The troubleshooting procedures for these air compressors is very similar to the Holset SS191B. For details of the torque value and repair methods, see the manual issued by the air compressor manufacturer.
11-60 C
The SS296 air compressor used on the B series engine uses an (E type) unloader. The economy (E type) unloader system is designed to reduce the pumping loss and engine boost pressure loss by the compressor intake valve when operating in the unloader mode. When the air line reaches the set pressure, the governor sends an air signal to the air compressor unloader assembly and sets the unloader valve with the compressor suction valve open, so this stops the flow of compressed air into the air line. Caution: The pressure inside the system must be maintained by keeping the discharge valve closed at the outlet port end of the discharge valve. It uses the air in the air line, so the pressure goes down. When the air pressure reaches the set pressure, the governor exhausts the air signal sent to the compressor unloader assembly, so the compressor again starts to send compressed air to the air line.
102 SERIES
STRUCTURE AND FUNCTION
AIR COMPRESSOR
Caution:Machines which use a Holset (E type) air compressor and are equipped with a dehumidifier to carry out ventilation during operation of the unload compressor must have an air compressor valve installed to prevent excessive oil consumption. If it is impossible to maintain the air line pressure with the exhaust valve during unload operations, air is sent out from the compressor cylinder to lower the pressure (back pressure) inside the cylinder. If the seal of the intake valve in the unloader cap is loosened and the exhaust valve becomes a one way pressure starting valve, air will stop flowing to the cylinder. When the compressor cylinder pressure becomes lower than the crankcase pressure, oil is sucked in from the piston ring and sent to the oil line.
102 SERIES
11-61
STRUCTURE AND FUNCTION
FLOW DIAGRAMS-COMPRESSED AIR SYSTEM
FLOW DIAGRAMS-COMPRESSED AIR SYSTEM With air dryer
Without air dryer
1. 2. 3. 4.
Compressor Governor Air dryer Check valve (normally built into dryer) 5. Reservoir (wet tank)
11-62 C
102 SERIES
STRUCTURE AND FUNCTION
FLOW DIAGRAMS-COMPRESSED AIR SYSTEM
E type Holset SS296BE with humidifier
1. 2. 3. 4. 5. 6. 7.
Compressor Governor Air conditioner valve Air dryer Check valve (normally built into dryer) Reservoir (wet tank) Check valve
102 SERIES
11-63 C
STRUCTURE AND FUNCTION
ALTERNATOR
ALTERNATOR Alternator with built-in regulator (25A, 30A) fl Depending on the machine model, the actual component may be different from the diagram.
1. 2. 3. 4. 5.
Alternator Alternator pulley Terminal R Terminal B Terminal E
6. Internal electric circuit diagram 6A. Field coil 6B. Primary energized resistance 6C. Regulator
Pulley Engine
Machine model
Type
Specification No. of steps
Outside diameter (mm)
Weight (kg)
4D102E-1
PC60-7, PC70-7 PC75UU-3
Nikko Denki, open type
24V, 25A
Polyethylene Vbelt, 8 grooves
80
6.5
S4D102E-1
PC100-6, PC120-6 PC158US-2
Nikko Denki, open type
24V, 25A
Polyethylene Vbelt, 8 grooves
80
6.5
S6D102E-1
PC228US-1 JV100-2
Nikko Denki, open type
24V, 25A
Polyethylene Vbelt, 8 grooves
80
6.5
WA300-3 SA6D102E-1 DCA-125SSK (DENYO generator)
Nikko Denki, open type
24V, 30A
Polyethylene Vbelt, 8 grooves
80
6.5
DCA-150ESK (DENYO generator)
Nikko Denki, open type
24V, 25A
Polyethylene Vbelt, 8 grooves
80
6.5
SAA6D102E-2
11-64 (21)
102 SERIES
STRUCTURE AND FUNCTION
ALTERNATOR
Alternator with built-in regulator (25A) fl Depending on the machine model, the actual component may be different from the diagram.
1. 2. 3. 4. 5.
6. Internal electric circuit diagram 6A. Field coil 6B. Primary energized resistance 6C. Regulator
Alternator Alternator pulley Terminal R Terminal B Terminal E
Pulley Engine
SAA4D102E-2
102 SERIES
Machine model
D31EX-21 D31PX-21 D37EX-21 D37PX-21 D39EX-21 D39PX-21 PC128US-2 PC138US-2
Type
Nikko Denki, open type
Specification
24V, 25A
No. of steps
Outside diameter (mm)
Polyethylene Vbelt, 8 grooves
80
Weight (kg)
6.5
11-64-1 (19)
STRUCTURE AND FUNCTION
ALTERNATOR
Alternator with built-in regulator (35A) fl Depending on the machine model, the actual component may be different from the diagram.
1. 2. 3. 4. 5.
Alternator Alternator pulley Terminal R Terminal B Terminal E
6. Internal electric circuit diagram 6A. Field coil 6B. Primary energized resistance 6C. Regulator
Pulley Engine
Machine model
Type
Specification No. of steps
Outside diameter (mm)
Weight (kg)
S4D102E-1
Nikko Denki, WA100-3 GD305A-3, GD355A-3 open type
24V, 35A
Polyethylene Vbelt, 8 grooves
80
8.0
S6D102E-1
GD405A-3 GD505A-3A
Nikko Denki, open type
24V, 35A
Polyethylene Vbelt, 8 grooves
80
8.0
SA6D102E-1
WA300-3
Nikko Denki, open type
24V, 35A
Polyethylene Vbelt, 8 grooves
80
8.0
Nikko Denki, open type
24V, 35A
Polyethylene Vbelt, 8 grooves
80
8.0
D31EX-21, D31PX-21 SAA4D102E-2 D37EX-21, D37PX-21 D39EX-21, D39PX-21
11-64-2 (19)
102 SERIES
STRUCTURE AND FUNCTION
ALTERNATOR
Alternator with built-in regulator (35A)
1. 2. 3. 4.
Alternator Alternator pulley Terminal B Terminal L
fl Depending on the machine model, the actual component may be different from the diagram.
5. Terminal IG 6. Internal connection diagram 6A. Alternator assembly 6B. Regulator
6C. Load of L terminal 6D. Key switch 6E. Battery Pulley
Engine
Machine model
Type
Specification No. of steps
S6D102E-1
PC200-6 PC200-6 EXCEL
SA6D102E-1
PC220-6
SAA4D102E-2 WA150-5
Nihon denso, open type Nihon denso, open type Nihon denso, open type
PC200-7 (26282900 – 26328689) PC200LC-7 (26282900 – 26328689) PC220-7 (26287717 – 26335033) PC220LC-7 (26287717 – 26335033) PC228US-3 (26274903 – 26307087) PC228USLC-3 Nihon denso, SAA6D102E-2 (26274903 – 26307087) open type PC270-7 GD555-3A, 3C BR120T-1 BR380JG-1 WA200-5, WA200PT-5 WA250-5, WA250PT-5
102 SERIES
24V, 35A 24V, 35A 24V, 35A
24V, 35A
Polyethylene Vbelt, 8 grooves Polyethylene Vbelt, 8 grooves Polyethylene Vbelt, 8 grooves
Polyethylene Vbelt, 8 grooves
Outside diameter (mm)
Weight (kg)
77.5
4.7
77.5
4.7
77.5
4.7
77.5
4.7
11-64-3 (19)
STRUCTURE AND FUNCTION
ALTERNATOR
Alternator with built-in regulator (35A)
1. 2. 3. 4.
fl Depending on the machine model, the actual component may be different from the diagram.
Alternator Alternator pulley Terminal B Internal connection diagram 4A. Alternator assembly
4B. Regulator 4C. Load of L terminal 4D. Key switch 4E. Battery
Pulley Engine
Machine model
SAA4D102E-2 PC160LC-7 WA150-5 PC200-7 (26328690 and up) PC200LC-7 (26328690 and up) PC228US-3 (26307088 and up) PC228USLC-3 SAA6D102E-2 (26307088 and up) PC220-7 (26335034 and up) PC220LC-7 (26335034 and up) WA200-5, WA200PT-5 WA250-5, WA250PT-5
11-64-4 (19)
Type
Specification No. of steps
Outside diameter (mm)
Weight (kg)
Nihon denso, open type
24V, 35A
Polyethylene Vbelt, 8 grooves
77.5
4.7
Nihon denso, open type
24V, 35A
Polyethylene Vbelt, 8 grooves
77.5
4.7
102 SERIES
STRUCTURE AND FUNCTION
ALTERNATOR
Alternator with built-in regulator (50A) fl Depending on the machine model, the actual component may be different from the diagram.
1. 2. 3. 4. 5.
Alternator Alternator pulley Terminal R Terminal B Terminal E
6. Internal electric circuit diagram 6A. Field coil 6B. Primary energized resistance 6C. Regulator
Pulley Engine
S6D102E-1
102 SERIES
Machine model
WA180-3 (For CIS)
Type
Nikko Denki, open type
Specification
24V, 50A
No. of steps
Outside diameter (mm)
Polyethylene Vbelt, 2 grooves
85
Weight (kg)
11
11-64-5 (23)
STRUCTURE AND FUNCTION
ALTERNATOR
Alternator with built-in regulator (60A) fl Depending on the machine model, the actual component may be different from the diagram.
1. 2. 3. 4.
Alternator Alternator pulley Terminal B Terminal L
5. Terminal IG 6. Internal connection diagram 6A. Alternator assembly 6B. Regulator
6C. Load of L terminal 6D. Key switch 6E. Battery Pulley
Engine
Machine model
Type
Specification No. of steps
S4D102E-1
PW128UU-1
S6D102E-1
PC228UU-1 (tunnel specification)
SAA4D102E-2 WA150-5
Nihon denso, open type Nihon denso, open type Nihon denso, open type
PC200-7 (26282900 – 26328689) PC200LC-7 (26282900 – 26328689) PC228US-3 (26274903 – 26307087) PC228USLC-3 (26274903 – 26307087) Nihon denso, (tunnel specification) SAA6D102E-2 PC220-7 (26287717 – 26335033) open type PC220LC-7 (26287717 – 26335033) PC270-7 PC308USLC-3 WA200-5, WA200PT-5 WA250-5, WA250PT-5
11-64-6 (23)
24V, 60A
Polyethylene Vbelt, 8 grooves Polyethylene Vbelt, 8 grooves Polyethylene Vbelt, 8 grooves
24V, 60A
Polyethylene Vbelt, 8 grooves
24V, 60A 24V, 60A
Outside diameter (mm)
Weight (kg)
77.5
6.3
77.5
6.3
77.5
6.3
77.5
6.3
102 SERIES
STRUCTURE AND FUNCTION
ALTERNATOR
Alternator with built-in regulator (60A) fl Depending on the machine model, the actual component may be different from the diagram.
1. 2. 3. 4.
Alternator Alternator pulley Terminal B Internal connection diagram 4A. Alternator assembly
4B. Regulator 4C. Load of L terminal 4D. Key switch 4E. Battery
Pulley Engine
Machine model
Type
Specification No. of steps
Outside diameter (mm)
Polyethylene Vbelt, 8 grooves
77.5
Weight (kg)
SAA4D102E-2 WA150-5 PC200-7 (26328690 and up) PC200LC-7 (26328690 and up) PC220-7 (26335034 and up) PC220LC-7 (26335034 and up) SAA6D102E-2 PC228US-3 (26307088 and up) PC228USLC-3 (26307088 and up) (tunnel specification) WA200-5, WA200PT-5 WA250-5, WA250PT-5 WA320-5, WA320PT-5
102 SERIES
Nihon denso, open type
24V, 60A
6.3
11-64-7 (23)
STRUCTURE AND FUNCTION
STARTING MOTOR
STARTING MOTOR With separate safety relay (4.5 kW) fl Depending on the machine model, the actual component may be different from the diagram.
1. 2. 3. 4.
Pinion gear Magnetic switch Starting motor (yoke) Internal connection diagram 4A. Battery 4B. Starting switch 4C. To alternator R 4D. Safety relay 4E. Starting motor 4F. Terminal B 4G. Terminal C
Engine
Machine model
Type
Specification
No. of pinion teeth
Weight (kg)
4D102E-1 S4D102E-1
All model
Nikko Denki, sealed type
24V, 4.5kw
10
8.7
EG125BS-2 Nikko Denki, DCA-125SSK (DENYO generator) sealed type
24V, 4.5kw
10
8.7
SA6D102E-1
102 SERIES
11-65 (15)
STARTING MOTOR
STRUCTURE AND FUNCTION
fl Depending on the machine model, the actual component may be different from the diagram.
With separate safety relay (4.5 kW)
1. 2. 3. 4.
Pinion gear Magnetic switch Starting motor assembly Warning plate (For jump start prohibition) Engine
5. 6. 7. 8.
Machine model
PC120 tunnel specification PC200-6 S6D102E-1 SA6D102E-1 GD405A-3 GD505A-3A, WA180-3 (for CIS) D39EX-21 SAA4D102E-2 D39PX-21 PC160LC-7 PC200-7 PC200LC-7 PC220-7 PC220LC-7 PC228US-3 SAA6D102E-2 PC228USLC-3 PC270-7 WA200-5, WA200PT-5 WA250-5, WA250PT-5 BR120T-1 DCA-150ESK (DENYO generator) S4D102E-1
11-66 (23)
8B. Starting switch 8C. Battery 8D. 30 (Terminal B) 8E. 50 (Terminal C)
Jump start protective cover 50 (Terminal C) 30 (Terminal B) Internal connection diagram 8A. Relay Type
Specification
No. of pinion teeth
Weight (kg)
Nihon denso, sealed type
24V, 4.5kW
10
8.4
Nihon denso, sealed type
24V, 4.5kW
10
8.4
Nihon denso, sealed type
24V, 4.5kW
10
8.4
Nihon denso, sealed type
24V, 4.5kW
10
8.4
102 SERIES
STARTING MOTOR
STRUCTURE AND FUNCTION
With separate safety relay (5.5 kW) fl Depending on the machine model, the actual component may be different from the diagram.
1. 2. 3. 4. 5. 6. 7.
Pinion gear Magnetic switch Starting motor assembly Warning plate (For jump start prohibition) Jump start protective cover 50 (Terminal C) 30 (Terminal B) Engine
Machine model
D31EX-21, D31PX-21 SAA4D102E-2 D37EX-21, D37PX-21 D39EX-21, D39PX-21 WA150-5 SA6D102E-1
PC220-6 WA300-3
PC200-7, PC200LC-7 PC220-7 PC228US-3, PC228USLC-3 PC270-7 SAA6D102E-2 BR120T-1, BR380JG-1 WA320-5, WA320PT-5 GD555-3A, 3C PC308USLC-3
102 SERIES
8. Internal connection diagram 8A. Relay 8B. Starting switch 8C. Battery 8D. 30 (Terminal B) 8E. 50 (Terminal C)
Type
Specification
No. of pinion teeth
Weight (kg)
Nihon denso, sealed type
24V, 5.5kW
10
10.5
Nihon denso, sealed type
24V, 5.5kW
10
10.5
Nihon denso, sealed type
24V, 5.5kW
10
10.5
11-66-1 (20)
STRUCTURE AND FUNCTION
STARTING AID
STARTING AID Electrical heater (electrical intake air heater) fl Depending on the machine model, the actual component may be different from the diagram.
1. Heater coil 2. Housing 3. Internal connection diagram Electrical heater (electrical intake air heater) • Rated current: 100 A/22 V Coolant heater Specification • 230 V, 1.0 kW
102 SERIES
11-67 (23)
TESTING AND ADJUSTING
FUEL INJECTION PUMP CALIBRATION DATA
FUEL INJECTION PUMP CALIBRATION DATA 102-1 Engine model 4D102E-1
S4D102E-1
Pump assembly No.
Page
PC60-7, 7B, PC70-7, BR100JG, RG-1
12-50
6732-71-1120
PC100, 100L-6, PC100-6 EXCEL
12-50-1
6732-71-1121 6732-71-1122 6732-71-1130 6732-71-1131 6732-71-1132 6732-71-1141 6732-71-1150 6732-71-1151 6732-71-1190 6732-71-1191
PC100, 100L-6 PC100,100L-6 m/c, PC100-6 EXCEL PC120-6, PC130-6 MIGHTY
12-50-2 12-50-3 12-50-4
PC120-6, PC130-6 MIGHTY
12-50-5
WA120-3 PC128UU-1 PC128UU-1 PC120-6 EXCEL PC120-6 EXCEL D31E, S, Q, P-20, D31PL, PLL-20 D31P-20A D37E-5, D37P-5A GD305A-3 PC128US-2
12-50-13 12-50-8 12-50-40 12-50-6 12-50-7
12-50-12 12-50-15 12-50-10
PC128US-1
12-50-9
WA120-3D PC158US-2 D41E, P-6 PC200, 200LC-6 PC200, 200LC-6 HYPER GX PC210, 210LC-6 MIGHTY, BR200S-1 PC200, 200LC-6 PC200, 200LC-6 HYPER GX PC210, 210LC-6 MIGHTY, BR200S-1 PC200-6 EXCEL, PC200-6 CUSTOM PC200-6 (BKC), CD60RE-1 WA180-3, WA180PT-3 WA180-3 (for CIS)
12-50-14 12-50-41 12-50-29
WA250PT-3
12-50-25
JV100WA-2, JV100WP-2 PC228UU-1 PC228USLC-1 GD505A-3A
12-50-27 12-50-19 12-50-20 12-50-51
PC200-6Z
12-50-52
WA250-3 WA250L-3 (for USA)
12-50-24 12-50-26
PC228USLC-2
12-50-21
GD521A-1E WA180-3 (for EU)
12-50-28 12-50-23
6732-71-1240 6732-71-1260 6732-71-1361 6732-71-1380 6732-71-1381 6732-71-1390 6732-71-1420 6735-71-1120 6735-71-1140
6735-71-1141
6735-71-1150
102 SERIES
Applicable machine
6731-71-1110
6732-71-1230
S6D102E-1
Engine serial No.
6735-71-1160 6735-71-1161 6735-71-1170 6735-71-1171 6735-71-1181 6735-71-1210 6735-71-1210 6735-71-1260 6735-71-1410 6735-71-1411 6735-71-1420 6735-71-1420 6735-71-1440 6735-71-1441 6735-71-1460 6735-71-1470
12-50-11
12-50-16
12-50-17
12-50-18 12-50-22
12-49 (23)
FUEL INJECTION PUMP CALIBRATION DATA
TESTING AND ADJUSTING
102-2 Engine model
Pump assembly No.
Engine serial No.
Applicable machine
Page
6737-71-1110
D39EX-21, D39PX-21
12-50-67
6737-71-1120
D31EX-21, D31PX-21
12-50-68
6737-71-1130
D37EX-21, D37PX-21
12-50-69
6737-71-1140
WA150-5
12-50-70
6738-71-1110
PC200, LC-7, PC228US, USLC-3
12-50-71
6738-71-1130
BR120T-1
12-50-72
6738-71-1150
WA320-5, WA320PT-5
12-50-73
6738-71-1160
WA250-5, WA250PT-5
12-50-74
6738-71-1170
WA200-5, WA200PT-5
12-50-76
6738-71-1210
PC220-7, PC220LC-7
12-50-77
6738-71-1310
PC270-7, PC308USLC-3
12-50-75
6738-71-1620
DCA-150ESK (DENYO generator)
12-50-78
SAA4D102E-2
SAA6D102E-2
102 SERIES
12-49-2 (21)
FUEL INJECTION PUMP CALIBRATION DATA
TESTING AND ADJUSTING Injection Pump Assembly Number
Applicable Machine
6731-71-1110 (101402-3801)
Model ( ): Injection Pump Manufacture's part No. Injection Pump Type
Injection Pump Manufactuer
PES-A
ZEXEL
Injection order Injection interval
Serial No.
Model
PC60-7, 7B
Serial No.
4D102E-1
PC70-7 BR100JG, RG-1
Injection Pump Specification Rotating direction
Applicable Engine
Engine Specification Clockwise
Flywheel horsepower 42.1{56.4}/1,750 (Gross) (kw{HP)/rpm}
1–3–4–2
Maximum torque (Nm{kgm)/rpm} 249{25.4}/1,200 (Gross)
89˚ 30' – 90˚ 30'
High idling speed
(rpm)
1,900 – 2,000
Plunger prestroke (mm)
2.45 – 2.55
Low idling speed
(rpm)
1,020 – 1,070
Delivery valve 3 retraction volume (mm /st)
59
Pump tester capacity for Service standard
Calibration Standard
(
Conditions • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test parts.
Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia.x Inside dia.x Length ) Test oil Oil temperature (˚C) Nozzle opening pressure (MPa{kg/cm2}) Transfer pump pressure (kPa{kg/cm2})
Injection volume
Rack point
Rack position (mm)
• Rack positions B to E are the refernce volume 10.2 A(Basic point) when adjusting the 10.2 B injection volume. • Marks fl are Approx.7.4 C average volumes. D —
Governor perfomance curve
12-50 B
Pump speed (rpm)
Motor: 7.5 kW
) : Injenction pump manufacture's part number Service standard
Manufacturer standard
(105780 – 8140) (105780 – 0000) (105780 – 2080)
6732 – 11 – 3120
6 ✕ 2 ✕ 600
6 ✕ 1.8 ✕ 600
ASTM D975 No.2 diesel fuel or equivalent 40 – 45 17.2 {175} 21.6 {220} 157 {1.6} 157 {1.6} Service standard (cc/1,000 st) Injection volume
Maximum variance between cylinder
Manufacturer standard (cc/1,000 st) Injection volume
875
fl 77.5 – 79.5
± 2.5
fl 59.5
600 510 100
fl 71.5 – 75.5 # fl 14 – 16 85 – 95
— ± 15 —
fl 67.0 fl 15 100
Maximum variance between cylinder
#: Rack position is approx. 8.2 mm
102 SERIES
TESTING AND ADJUSTING
FUEL INJECTION PUMP CALIBRATION DATA
Injection Pump Assembly Number
Applicable Machine
6735-71-1160 (101609-3222) 6735-71-1161 (101609-3223) ( ): Injection Pump Manufacture's part No. Injection Pump Type
Injection Pump Manufactuer
PES-A
ZEXEL
Model
Model
Serial No.
S6D102E-1
Engine Specification
Rotating direction
Clockwise 1–5–3–6–2–4
Injection interval
Serial No.
WA180-3 WA180PT-3 WA180-3 (for CIS)
Injection Pump Specification
Injection order
Applicable Engine
Flywheel horsepower (kw{HP)/rpm}
83.4{111.8}/2,400 (Gross)
Maximum torque (Nm{kgm)/rpm}
422{43}/1,600 (Gross)
59˚ 30' – 60˚ 30'
High idling speed
(rpm)
2,600 – 2,700
Plunger prestroke (mm)
2.45 – 2.55
Low idling speed
(rpm)
750 – 800
Delivery valve 3 retraction volume (mm /st)
59
Pump tester capacity for Service standard
Calibration Standard
(
Conditions • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test parts.
Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia.x Inside dia.x Length )
) : Injenction pump manufacture's part number Service standard
Manufacturer standard
(105780 – 8140) (105780 – 0000) (105780 – 2080)
6732 – 11 – 3120
6 ✕ 2 ✕ 600
6 ✕ 1.8 ✕ 800
ASTM D975 No.2 diesel fuel or equivalent 40 – 50 17.2 {175} 21.6 {220} 157 {1.6} 157 {1.6}
Test oil Oil temperature
(˚C) 2
Nozzle opening pressure (MPa{kg/cm }) 2
Transfer pump pressure (kPa{kg/cm })
Injection volume
Rack point
Rack position (mm)
• Rack positions B to E are the refernce volume 9.5 A(Basic point) when adjusting the B 9.9 injection volume. • Marks fl are C 9.7 average volumes. D Approx. 8.2 E
—
Pump speed (rpm) 1,200 500 800 385 100
Motor: 7.5 kW
Service standard (cc/1,000 st) Injection volume
Maximum variance between cylinder
Manufacturer standard (cc/1,000 st) Injection volume
fl 71 – 73
± 2.5
fl 64.5
fl 54.5 – 58.5 fl 59.5 – 63.5 fl 8.5 – 10.5 70 – 80
— — ± 15 —
fl 79 fl 70.5 fl 15 fl 85
Maximum variance between cylinder
Governor perfomance curve
12-50-22 (23)
102 SERIES
FUEL INJECTION PUMP CALIBRATION DATA
TESTING AND ADJUSTING
Injection Pump Assembly Number
Applicable Machine
6737-71-1110 (101405-3250)
Model ( ): Injection Pump Manufacture's part No. Injection Pump Type
Injection Pump Manufactuer
PES-A
BOSCH automotive system
Serial No.
D39EX-21
Model
Serial No.
SAA4D102E-2
D39PX-21
Injection Pump Specification
Engine Specification Clockwise
Flywheel horsepower (kw{HP)/rpm}
74{99}/2,200 (Gross)
1–3–4–2
Maximum torque (Nm{kgm)/rpm}
441{45}/1,300 (Gross)
Rotating direction Injection order
Applicable Engine
89˚ 30' – 90˚ 30'
High idling speed
(rpm)
2,350 – 2,450
Plunger prestroke (mm)
2.45 – 2.55
Low idling speed
(rpm)
800 – 850
Delivery valve 3 retraction volume (mm /st)
59
Injection interval
Pump tester capacity for Service standard
Calibration Standard
(
Conditions • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test parts.
Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia.x Inside dia.x Length ) Test oil Oil temperature (˚C) Nozzle opening pressure (MPa{kg/cm2}) Transfer pump pressure (kPa{kg/cm2})
Injection volume
Rack point
• Rack positions B to E are the refernce volume A(Basic point) when adjusting the B injection volume. • Marks fl are C average volumes. E
Governor perfomance curve
102 SERIES
Motor: 7.5 kW
) : Injenction pump manufacture's part number Service standard
Manufacturer standard
(105780 – 8140) (105780 – 0000) (105780 – 2080)
(105158 – 5010) (105017 – 2910)
6 ✕ 2 ✕ 600
6 ✕ 1.8 ✕ 600
(105088 – 2000)
ASTM D975 No.2 diesel fuel or equivalent 40 – 50 21.6 {220} 17.2 {175} 255 {2.6} 255 {2.6}
Rack position (mm)
Pump speed (rpm)
Service standard (cc/1,000 st)
9.8
1,100
fl 102 – 104
± 2.5
fl 92.5
650 420 100
fl 104 – 108 fl 9 – 11 fl 50 – 60
— ± 15 —
fl 116 fl 10 fl 70
10.35 6.4 18 – 21
Injection volume
Maximum variance between cylinder
Manufacturer standard (cc/1,000 st) Injection volume
Maximum variance between cylinder
Boost compensator performance curve
12-50-67 (19)
TESTING AND ADJUSTING
FUEL INJECTION PUMP CALIBRATION DATA
Injection Pump Assembly Number
Applicable Machine
6737-71-1120 (101405-3261)
Model ( ): Injection Pump Manufacture's part No. Injection Pump Type
Injection Pump Manufactuer
PES-A
BOSCH automotive system
Injection order
Serial No.
D31EX-21
Model
Serial No.
SAA4D102E-2
D31PX-21
Injection Pump Specification Rotating direction
Applicable Engine
Engine Specification Clockwise
Flywheel horsepower (kw{HP)/rpm} 59.6{79.9}/2,000 (Gross)
1–3–4–2
Maximum torque (Nm{kgm)/rpm} 394.7{40.3}/1,300 (Gross)
89˚ 30' – 90˚ 30'
High idling speed
(rpm)
2,200 ± 50
Plunger prestroke (mm)
2.45 – 2.55
Low idling speed
(rpm)
800 +50 0
Delivery valve 3 retraction volume (mm /st)
59
Injection interval
Pump tester capacity for Service standard
Calibration Standard
(
Conditions • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test parts.
Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia.x Inside dia.x Length )
) : Injenction pump manufacture's part number Service standard
Manufacturer standard
(105780 – 8140) (105780 – 0000) (105780 – 2080)
(105158 – 5012) (105017 – 2910)
6 ✕ 2 ✕ 600
6 ✕ 1.8 ✕ 600
Test oil
Rack point
Rack position (mm)
• Rack positions B to E are the refernce volume 9.0 A(Basic point) when adjusting the 9.75 B injection volume. • Marks fl are C Apporox 6.4 average volumes. E 18.0 +30
Governor perfomance curve
12-50-68 (19)
(105088 – 2002)
ASTM D975 No.2 diesel fuel or equivalent 40 – 50 22.0 {224.3} 17.2 {175} 255 {2.6} 255 {2.6}
Oil temperature (˚C) Nozzle opening pressure (MPa{kg/cm2}) Transfer pump pressure (kPa{kg/cm2})
Injection volume
Motor: 7.5 kW
Pump speed (rpm)
Service standard (cc/1,000 st)
1,000
fl 79 ± 1
± 2.5
fl 81.5
± 2.5
fl 92.5 ± 2 fl 10 ± 1 fl 70 ± 5
— ± 15 —
fl 106 fl 10 fl 92
— ± 15 —
650 420 100
Injection volume
Maximum variance between cylinder
Manufacturer standard (cc/1,000 st) Injection volume
Maximum variance between cylinder
Boost compensator performance curve
102 SERIES
FUEL INJECTION PUMP CALIBRATION DATA
TESTING AND ADJUSTING
Injection Pump Assembly Number
Applicable Machine
6737-71-1130 (101405-3271)
Model ( ): Injection Pump Manufacture's part No. Injection Pump Type
Injection Pump Manufactuer
PES-A
BOSCH automotive system
Injection order
Serial No.
D37EX-21
Model
Serial No.
SAA4D102E-2
D37PX-21
Injection Pump Specification Rotating direction
Applicable Engine
Engine Specification Clockwise
Flywheel horsepower (kw{HP)/rpm} 67.7{90.8}/2,000 (Gross)
1–3–4–2
Maximum torque (Nm{kgm)/rpm} 420.7{42.9}/1,300 (Gross)
89˚ 30' – 90˚ 30'
High idling speed
(rpm)
2,200 ± 50
Plunger prestroke (mm)
2.45 – 2.55
Low idling speed
(rpm)
800 +50 0
Delivery valve 3 retraction volume (mm /st)
59
Injection interval
Pump tester capacity for Service standard
Calibration Standard
(
Conditions • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test parts.
Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia.x Inside dia.x Length )
) : Injenction pump manufacture's part number Service standard
Manufacturer standard
(105780 – 8140) (105780 – 0000) (105780 – 2080)
(105158 – 5012) (105017 – 2910)
6 ✕ 2 ✕ 600
6 ✕ 1.8 ✕ 600
Test oil
Rack point
Rack position (mm)
• Rack positions B to E are the refernce volume 9.7 A(Basic point) when adjusting the 10.35 B injection volume. • Marks fl are C Apporox 6.4 average volumes. E 18.0 +30
Governor perfomance curve
102 SERIES
(105088 – 2002)
ASTM D975 No.2 diesel fuel or equivalent 40 – 50 22.0 {224.3} 17.2 {175} 255 {2.6} 255 {2.6}
Oil temperature (˚C) Nozzle opening pressure (MPa{kg/cm2}) Transfer pump pressure (kPa{kg/cm2})
Injection volume
Motor: 7.5 kW
Pump speed (rpm)
Service standard (cc/1,000 st)
1,000
fl 93 ± 1
± 2.5
fl 90
± 2.5
fl 104 ± 2 fl 10 ± 1 fl 70 ± 5
— ± 15 —
fl 114.5 fl 10 fl 92
— ± 15 —
650 420 100
Injection volume
Maximum variance between cylinder
Manufacturer standard (cc/1,000 st) Injection volume
Maximum variance between cylinder
Boost compensator performance curve
12-50-69 (19)
TESTING AND ADJUSTING
FUEL INJECTION PUMP CALIBRATION DATA
Injection Pump Assembly Number
Applicable Machine
6737-71-1140 (101405-3340)
Model ( ): Injection Pump Manufacture's part No. Injection Pump Type
Injection Pump Manufactuer
PES-A
BOSCH automotive system
Serial No.
WA150-5
Injection Pump Specification
Model
Serial No.
SAA4D102E-2
Engine Specification Clockwise
Flywheel horsepower (kw{HP)/rpm} 74.2{99.5}/2,000 (Gross)
1–3–4–2
Maximum torque (Nm{kgm)/rpm} 408{41.6}/1,300 (Gross)
Rotating direction Injection order
Applicable Engine
89˚ 30' – 90˚ 30'
High idling speed
(rpm)
2,250 ± 50
Plunger prestroke (mm)
2.45 – 2.55
Low idling speed
(rpm)
825 ± 50
Delivery valve 3 retraction volume (mm /st)
59
Injection interval
Pump tester capacity for Service standard
Calibration Standard
(
Conditions • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test parts.
Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia.x Inside dia.x Length )
) : Injenction pump manufacture's part number Service standard
Manufacturer standard
(105780 – 8140) (105780 – 0000) (105780 – 2080)
(105158 – 5012) (105017 – 2910)
6 ✕ 2 ✕ 600
6 ✕ 1.8 ✕ 600
Test oil
Rack point
• Rack positions B to E are the refernce volume A(Basic point) when adjusting the B injection volume. • Marks fl are C average volumes. D E
Governor perfomance curve
12-50-70 (19)
(105088 – 2002)
ASTM D975 No.2 diesel fuel or equivalent 40 – 50 22.0 {224} 17.2 {175} 255 {2.6} 255 {2.6}
Oil temperature (˚C) Nozzle opening pressure (MPa{kg/cm2}) Transfer pump pressure (kPa{kg/cm2})
Injection volume
Motor: 7.5 kW
Rack position (mm)
Pump speed (rpm)
Service standard (cc/1,000 st)
10.9
1,000
fl 116 ± 1
± 2.5
fl 102 ± 1
± 2.5
18.0 +30
650 415 100
— ± 15 —
fl (116) ± 2 fl 20 ± 1 fl (85)
— ± 15 —
9.35
650
— fl 20 ± 1 — —
(10.9) 7.4
Injection volume
Maximum variance between cylinder
Manufacturer standard (cc/1,000 st) Injection volume
Maximum variance between cylinder
—
Boost compensator performance curve
102 SERIES
TESTING AND ADJUSTING
FUEL INJECTION PUMP CALIBRATION DATA
Fuel Injection Pump Assembly Number
Applicable Machine
6738-71-1150 (101609-3710)
Model ( ): Fuel Injection Pump Manufacture's part No. Fuel Injection Pump Type
Fuel Injection Pump Manufactuer
PES-A
BOSCH automotive system
Rotating direction
Model
Serial No.
SAA6D102E-2
Engine Specification Flywheel horsepower (kw{HP)/rpm} 127{170}/2,000 (Gross)
Clockwise
Fuel Injection order
Serial No.
WA320-5 WA320PT-5
Fuel Injection Pump Specification
Applicable Engine
Maximum torque (Nm{kgm)/rpm} 672{68.5}/1,500 (Gross)
1–5–3–6–2–4
Fuel Injection interval
59˚ 30' – 60˚ 30'
High idling speed
(rpm)
2,200 – 2,300
Plunger prestroke (mm)
2.55 – 2.65
Low idling speed
(rpm)
875 – 925
Delivery valve 3 retraction volume (mm /st)
59
Pump tester capacity for Service standard
Calibration Standard
(
Conditions • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test parts.
Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia.x Inside dia.x Length )
Test oil Oil temperature
(˚C) 2
Nozzle opening pressure (MPa{kg/cm }) Transfer pump pressure (kPa{kg/cm2})
Injection volume
Rack point
Rack position (mm)
• Rack positions B to E are the refA(Basic point) ernce volume 11.3 when adjusting the 11.3 B injection volume. • Marks fl are C Approx. 7.5 average volumes. D 9.5 — E F
Governor perfomance curve
102 SERIES
11.3
Pump speed (rpm) 1,000 750 410 100 100 800
Motor: 7.5 kW
) : Fuel Injenction pump manufacture's part number Service standard
Manufacturer standard
(105780 – 8140) (105780 – 0000)
(105158 – 5002) (105017 – 2910)
(105780 – 2080)
(105088 – 2002)
6 ✕ 2 ✕ 600
6 ✕ 1.8 ✕ 750
ASTM D975 No.2 diesel fuel or equivalent 40 – 50 22.0 {224} 17.2 {175} 255 {2.6} 255 {2.6} Service standard (cc/1,000 st) Fuel Injection volume
Maximum variance between cylinder
Manufacturer standard (cc/1,000 st) Fuel Injection volume
Maximum variance between cylinder
fl 108.5 ± 1
± 2.5
fl 120 fl 9.5 ± 1 fl 57 ± 5 fl 130 ± 5 (survey)
— ± 15 — — —
Boost compensator performance curve
12-50-73 (20)
FUEL INJECTION PUMP CALIBRATION DATA
TESTING AND ADJUSTING
Fuel Injection Pump Assembly Number
Applicable Machine
6738-71-1160 (101609-3690)
Model ( ): Fuel Injection Pump Manufacture's part No. Fuel Injection Pump Type
Fuel Injection Pump Manufactuer
PES-A
BOSCH automotive system
Serial No.
WA250-5
Model
Serial No.
SAA6D102E-2
WA250PT-5
Fuel Injection Pump Specification Rotating direction
Engine Specification Flywheel horsepower (kw{HP)/rpm} 104.1{139.5}/2,000 (Gross)
Clockwise
Fuel Injection order
Applicable Engine
Maximum torque (Nm{kgm)/rpm}
1–5–3–6–2–4
627{64}/1,400 (Gross)
Fuel Injection interval
59˚ 30' – 60˚ 30'
High idling speed
(rpm)
2,200 – 2,300
Plunger prestroke (mm)
2.65 – 2.75
Low idling speed
(rpm)
775 – 875
Delivery valve 3 retraction volume (mm /st)
59
Pump tester capacity for Service standard
Calibration Standard
(
Conditions • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test parts.
Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia.x Inside dia.x Length ) Test oil Oil temperature (˚C) Nozzle opening pressure (MPa{kg/cm2}) Transfer pump pressure (kPa{kg/cm2})
Injection volume
Rack point
• Rack positions B to E are the refernce volume A(Basic point) when adjusting the B injection volume. • Marks fl are C average volumes. D E
Governor perfomance curve
12-50-74 (19)
Rack position (mm)
Pump speed (rpm)
9.7
1,000
10.0
700 420 100 100
6.5 8.8 —
Motor: 7.5 kW
) : Fuel Injenction pump manufacture's part number Service standard
Manufacturer standard
(105780 – 8140) (105780 – 0000) (105780 – 2080)
(105158 – 5012) (105017 – 2910)
6 ✕ 2 ✕ 600
6 ✕ 1.8 ✕ 750
(105088 – 2002)
ASTM D975 No.2 diesel fuel or equivalent 40 – 50 22.0 {224} 17.2 {175} 255 {2.6} 255 {2.6} Service standard (cc/1,000 st) Fuel Injection volume
Maximum variance between cylinder
Manufacturer standard (cc/1,000 st) Fuel Injection volume
fl 100.5 – 102.5
± 2.5
fl 93.5
fl 105 fl 8.5 – 10.5 fl 31 – 41 fl 75 – 85
— ± 15 — —
fl 110 fl 9.5 fl 58 fl 105
Maximum variance between cylinder
Boost compensator performance curve
102 SERIES
FUEL INJECTION PUMP CALIBRATION DATA
TESTING AND ADJUSTING Fuel Injection Pump Assembly Number
Applicable Machine
6738-71-1310 (101609-3650)
Model ( ): Fuel Injection Pump Manufacture's part No. Fuel Injection Pump Type
Fuel Injection Pump Manufactuer
PES-A
BOSCH automotive system
Model SAA6D102E-2
Flywheel horsepower (kw{HP)/rpm} 141.1{189.1}/2,050 (Gross)
Maximum torque (Nm{kgm)/rpm} 742.4{75.7}/1,500 (Gross)
1–5–3–6–2–4
Fuel Injection interval
59˚ 30' – 60˚ 30'
High idling speed
(rpm)
Plunger prestroke (mm)
2.55 – 2.65
Low idling speed
(rpm)
Delivery valve 3 retraction volume (mm /st)
59
Pump tester capacity for Service standard
Calibration Standard
(
Conditions • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test parts.
Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia.x Inside dia.x Length )
Test oil
• Rack positions B to E are the refA(Basic point) ernce volume when adjusting the B injection volume. • Marks fl are C average volumes. D E
Governor perfomance curve
102 SERIES
1,025 – 1,075 Motor: 7.5 kW
) : Fuel Injenction pump manufacture's part number Service standard
Manufacturer standard
(105780 – 8140) (105780 – 0000)
(105158 – 5002) (105017 – 2910)
(105780 – 2080)
(105088 – 2002)
6 ✕ 2 ✕ 600
6 ✕ 1.8 ✕ 750
(˚C)
40 – 50 2
Rack point
2,300 – 2,400
ASTM D975 No.2 diesel fuel or equivalent
Oil temperature
Nozzle opening pressure (MPa{kg/cm }) Transfer pump pressure (kPa{kg/cm2})
Injection volume
Serial No.
Engine Specification
Clockwise
Fuel Injection order
Serial No.
PC270-7 PC308USLC-3 BR380JG-1
Fuel Injection Pump Specification Rotating direction
Applicable Engine
17.2 {175}
22.0 {224}
255 {2.6}
255 {2.6}
Service standard (cc/1,000 st)
Manufacturer standard (cc/1,000 st)
Rack position (mm)
Pump speed (rpm)
12.2
1,025
fl 131 – 133
± 2.5
fl 116
12.2 7.0
750 525
fl 130 fl 8.5 – 10.5
— ± 15
fl 127 fl 9.5
10.3 —
100 100
fl 45 – 55 fl 110 – 120
— —
fl 65 fl 130
Fuel Injection volume
Maximum variance between cylinder
Fuel Injection volume
Maximum variance between cylinder
Boost compensator performance curve
12-50-75 (18)
TESTING AND ADJUSTING
FUEL INJECTION PUMP CALIBRATION DATA
Fuel Injection Pump Assembly Number
Applicable Machine
6738-71-1170 (101609-3700)
Model ( ): Fuel Injection Pump Manufacture's part No. Fuel Injection Pump Type
Fuel Injection Pump Manufactuer
PES-A
BOSCH automotive system
Serial No.
WA200-5
Model
Serial No.
SAA6D102E-2
WA200PT-5
Fuel Injection Pump Specification Rotating direction
Engine Specification Flywheel horsepower (kw{HP)/rpm} 95.2{127.7}/2,000 (Gross)
Clockwise
Fuel Injection order
Applicable Engine
Maximum torque (Nm{kgm)/rpm} 586{59.8}/1,400 (Gross)
1–5–3–6–2–4
Fuel Injection interval
59˚ 30' – 60˚ 30'
High idling speed
(rpm)
2,200 – 2,300
Plunger prestroke (mm)
2.55 – 2.65
Low idling speed
(rpm)
775 – 875
Delivery valve 3 retraction volume (mm /st)
59
Pump tester capacity for Service standard
Calibration Standard
(
Conditions • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test parts.
Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia.x Inside dia.x Length )
) : Fuel Injenction pump manufacture's part number Service standard
Manufacturer standard
(105780 – 8140) (105780 – 0000) (105780 – 2080)
(105158 – 5002) (105017 – 2910)
6 ✕ 2 ✕ 600
6 ✕ 1.8 ✕ 750
Test oil Oil temperature (˚C) Nozzle opening pressure (MPa{kg/cm2})
Rack point
• Rack positions B to E are the refernce volume A(Basic point) when adjusting the B injection volume. • Marks fl are C average volumes. D E F
Governor perfomance curve
12-50-76 (19)
(105088 – 2002)
ASTM D975 No.2 diesel fuel or equivalent 40 – 50 22.0 {224} 17.2 {175} 255 {2.6} 255 {2.6}
Transfer pump pressure (kPa{kg/cm2})
Injection volume
Motor: 7.5 kW
Service standard (cc/1,000 st)
Manufacturer standard (cc/1,000 st)
Rack position (mm)
Pump speed (rpm)
9.1
1,000
fl 81 ± 1
± 2.5
fl 82
9.75 6.5 8.55 —
700 420 100 100 650
fl 95.5 fl 9.5 ± 1 fl 31 ± 5 fl 85 ± 5 fl 93 ± 3
— ± 15 — — —
fl 103 fl 9.5 fl 54 fl 105 fl 105
9.75
Fuel Injection volume
Maximum variance between cylinder
Fuel Injection volume
Maximum variance between cylinder
Boost compensator performance curve
102 SERIES
FUEL INJECTION PUMP CALIBRATION DATA
TESTING AND ADJUSTING Fuel Injection Pump Assembly Number
Applicable Machine
6738-71-1210 (101609-3640)
Model ( ): Fuel Injection Pump Manufacture's part No. Fuel Injection Pump Type
Fuel Injection Pump Manufactuer
PES-A
BOSCH automotive system
Serial No.
Model
PC220-7
Rotating direction
SAA6D102E-2
Engine Specification Flywheel horsepower (kw{HP)/rpm} 133.1{178.4}/2,000 (Gross)
Clockwise
Maximum torque (Nm{kgm)/rpm} 708{72.3}/1,500 (Gross)
1–5–3–6–2–4
Fuel Injection interval
59˚ 30' – 60˚ 30'
High idling speed
(rpm)
Plunger prestroke (mm)
2.65 – 2.75
Low idling speed
(rpm)
Delivery valve 3 retraction volume (mm /st)
59
(
Conditions Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia.x Inside dia.x Length )
Test oil
• Rack positions B to E are the refA(Basic point) ernce volume when adjusting the B injection volume. • Marks fl are C average volumes. D E
Governor perfomance curve
102 SERIES
Motor: 7.5 kW
) : Fuel Injenction pump manufacture's part number Service standard
Manufacturer standard
(105780 – 8140) (105780 – 0000)
(105158 – 5002) (105017 – 2910)
(105780 – 2080)
(105088 – 2002)
6 ✕ 2 ✕ 600
6 ✕ 1.8 ✕ 750
(˚C)
40 – 50 2
Rack point
1,025 – 1,075
ASTM D975 No.2 diesel fuel or equivalent
Oil temperature
Nozzle opening pressure (MPa{kg/cm }) Transfer pump pressure (kPa{kg/cm2})
Injection volume
2,240 – 2,340
Pump tester capacity for Service standard
Calibration Standard • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test parts.
Serial No.
PC220LC-7
Fuel Injection Pump Specification
Fuel Injection order
Applicable Engine
Rack position (mm)
Pump speed (rpm)
12.0
1,000
12.0 7.0 10.3 —
17.2 {175}
21.6 {220}
255 {2.6}
255 {2.6}
Service standard (cc/1,000 st) Fuel Injection volume
Maximum variance between cylinder
Manufacturer standard (cc/1,000 st) Fuel Injection volume
fl 127.5 – 129.5
± 2.5
fl 111.5
750 525
fl 127.5 fl 8.5 – 10.5
— ± 15
fl 124 fl 9.5
100 100
fl 45 – 55 fl 115 – 125
— —
fl 65 fl 145
Maximum variance between cylinder
Boost compensator performance curve
12-50-77 (19)
TESTING AND ADJUSTING
FUEL INJECTION PUMP CALIBRATION DATA
Fuel Injection Pump Assembly Number
Applicable Machine
6738-71-1620 (101609-3830)
Model ( ): Fuel Injection Pump Manufacture's part No. Fuel Injection Pump Type
Fuel Injection Pump Manufactuer
PES-A
BOSCH automotive system
Model
Serial No.
SAA6D102E-2
Engine Specification 101.4{136.0}/1,500(50Hz)(Gross) Flywheel horsepower (kw{HP)/rpm} 120.8{162.0}/1,800(60Hz)(Gross)
Clockwise
Fuel Injection order
Serial No.
DCA-150ESK (DENYO generator)
Fuel Injection Pump Specification Rotating direction
Applicable Engine
1–5–3–6–2–4
Fuel Injection interval
60˚ ± 30'
High idling speed
(rpm)
Max. 1,580 (50Hz) Max. 1,890 (60Hz)
Plunger prestroke (mm)
2.6 ± 0.05
Low idling speed
(rpm)
800 ± 50
Delivery valve 3 retraction volume (mm /st)
59
Pump tester capacity for Service standard
Calibration Standard
(
Conditions • Service standard indicates data using calibration test parts. • Manufacture standard is data for factory test parts.
Nozzle & Nozzle holder part No. Nozzle part No. Nozzle holder part No. Injection pipe (mm) (Outside dia.x Inside dia.x Length )
Test oil
Rack point
Rack position (mm)
• Rack positions B to E are the ref10.8 A(Basic point) ernce volume B 11.3 when adjusting the injection volume. Approx. 7.6 C • Marks fl are 10.8 D average volumes. E 9.75 F 13.2 — G
Governor perfomance curve
12-50-78 (21)
) : Fuel Injenction pump manufacture's part number Service standard
Manufacturer standard
(105780 – 8140) (105780 – 0000) (105780 – 2080)
(105158 – 5002) (105017 – 2910)
6 ✕ 2 ✕ 600
6 ✕ 1.8 ✕ 750
(105088 – 2002)
ASTM D975 No.2 diesel fuel or equivalent
Oil temperature (˚C) Nozzle opening pressure (MPa{kg/cm2}) Transfer pump pressure (kPa{kg/cm2})
Injection volume
Motor: 7.5 kW
Pump speed (rpm) 900 900 400 750 100 100 —
40 – 50 17.2 {175} 255 {2.6}
24.5 {250} 255 {2.6}
Service standard (cc/1,000 st) Fuel Injection volume
Maximum variance between cylinder
Manufacturer standard (cc/1,000 st) Fuel Injection volume fl 124 ± 1 — fl 10 ± 1 — fl 55 ± 5 fl 145 ± 5 —
Maximum variance between cylinder
± 2.5 — ± 15 — — — —
Boost compensator performance curve
102 SERIES
TESTING AND ADJUSTING
RUNNING IN STANDARD
fl The table gives the standard values for machines with fan. fl The loads for the dynamometer are at an arm's length of 716 mm. Engine model
Applicable machine WA120-3D
Order
Item 1
2
3
4
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 800–850 0{0} 0{0}
10 2 3 1,000 1,200 1,600 98{10} 147{15} 245{25} 7.4{9.9} 13.2{17.7} 29.4{39.4}
D31E,S,Q,P-20 Running time D31,PL,PLL-20 Engine speed D31P-20A Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 900–950 0{0} 0{0}
10 2 3 1,000 1,200 1,600 98{10} 147{15} 245{25} 7.4{9.9} 13.2{17.7} 29.4{39.4}
D37E-5 D37P-5
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 800–850 0{0} 0{0}
10 2 3 1,000 1,200 1,600 98{10} 147{15} 245{25} 7.4{9.9} 13.2{17.7} 29.4{39.4}
GD305A-3
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 650–700 0{0} 0{0}
10 2 3 1,000 1,200 1,600 98{10} 147{15} 245{25} 7.4{9.9} 13.2{17.7} 29.4{39.4}
D41A-6
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
3 700 0{0} 0{0}
Running time Engine speed Load Flywheel hosepower
min 2 10 1,000–1,050 1,000 rpm N{kg} 0{0} 98{10} kW{HP} 0{0} 7.4{9.9}
2 1,200 250{25} 22{29.6}
3 1,600 440{45} 53{71}
PC228USLC-1
Running time Engine speed Load Flywheel hosepower
min 2 10 1,000–1,050 1,000 rpm N{kg} 0{0} 98{10} kW{HP} 0{0} 7.4{9.9}
2 1,200 250{25} 22{29.6}
3 1,600 440{45} 53{71}
PC228USLC-2
Running time Engine speed Load Flywheel hosepower
min 2 10 rpm 1,000–1,050 1,000 N{kg} 0{0} 98{10} kW{HP} 0{0} 7.4{9.9}
2 1,200 250{25} 22{29.6}
3 1,600 440{45} 53{71}
D41E, P-6
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
3 700 0{0} 0{0}
WA180-3 WA180-3 (for CIS)
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 750–800 0{0} 0{0}
5
6
S4D102E-1
6D102E-1
PC200,200LC-6 PC200,200LC-6 HYPER GX BR200S-1 PC210,210LC-6 MIGHTY
S6D102E-1
12-51-1 (23)
4 2 2 10 5 1,200 1,400 1,400 1,400 2,400 88{9.0} 176{18.0} 264{27.0} 343{35.0} 282{29.0} 10.9{14.8} 25.5{34.7} 38.2{52.0} 50.4{68.5} 70.0{95.0}
4 2 2 10 5 1,200 1,300 1,300 1,300 2,400 115{9.0} 230{23.0} 345{35.0} 461{47.0} 325{33.0} 14.0{19.0} 30.9{42.0} 46.3{63.0} 61.8{84.0} 80.9{110} 10 1,000 98{10} 7.4{9.9}
2 1,200 250{25} 22{29.6}
3 1,600 440{45} 53{71}
102 SERIES
RUNNING IN STANDARD
TESTING AND ADJUSTING
102-2 fl The table gives the standard values for machines with fan. fl The loads for the dynamometer are at an arm's length of 716 mm. Engine model
SAA4D 102E-2
102 SERIES
Applicable machine
Order
Item 1
2
3
4
5
6
D31EX-21 D31PX-21
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 800 0{0} 0{0}
10 1,000 49{5} 3.7{5}
2 3 3 1,200 1,600 2,000 98{10} 206{21} 397{40} 8.8{11.8} 25{33.5} 60{80.4}
D37EX-21 D37PX-21
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 800 0{0} 0{0}
10 1,000 49{5} 3.7{5}
2 3 3 1,200 1,600 2,000 98{10} 206{21} 451{46} 8.8{11.8} 25{33.5} 67{89.8}
D39EX-21 D39PX-21
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 800 0{0} 0{0}
10 1,000 49{5} 3.7{5}
2 3 3 1,200 1,600 2,200 98{10} 206{21} 440{45} 8.8{11.8} 25{33.5} 73{97.9}
WA150-5
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 825 0{0} 0{0}
10 1,000 49{5} 3.7{5}
2 3 3 1,200 1,600 2,000 98{10} 206{21} 490{50} 8.8{11.8} 25{33.5} 73{97.9}
12-51-10 (19)
RUNNING IN STANDARD
TESTING AND ADJUSTING
fl The table gives the standard values for machines with fan. fl The loads for the dynamometer are at an arm's length of 716 mm. Engine model
Applicable machine PC200-7 PC200LC-7 PC228US-3 PC228USLC-3
SAA6D 102E-2
1
2
3
4
5
6
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 1,050 0{0} 0{0}
10 1,000 98{10} 7.4{9.7}
2 1,200 245{25} 22{29}
3 3 1,600 1,950 440{45} 765{78} 53{71} 112{150}
PC270-7 Running time PC308USLC-3 Engine speed BR380JG-1 Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 1,050 0{0} 0{0}
10 1,000 98{10} 7.4{9.7}
2 1,200 245{25} 22{29}
3 3 1,600 2,050 440{45} 911{93} 53{71} 140{188}
PC220-7 PC220LC-7
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 1,050 0{0} 0{0}
10 1,000 98{10} 7.4{9.7}
2 1,200 245{25} 22{29}
3 3 1,600 2,000 440{45} 882{90} 53{71} 132{180}
WA200-5 WA200PT-5
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 825 0{0} 0{0}
10 1,000 98{10} 7.4{9.7}
2 1,200 245{25} 22{29}
3 1,600 440{45} 53{71}
WA250-5 WA250PT-5
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 825 0{0} 0{0}
10 1,000 98{10} 7.4{9.7}
2 1,200 245{25} 22{29}
3 3 1,600 2,000 440{45} 696{71} 53{71} 104{140}
WA320-5 WA320PT-5
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 900 0{0} 0{0}
10 1,000 98{10} 7.4{9.7}
2 1,200 245{25} 22{29}
3 3 1,600 2,000 440{45} 843{86} 53{71} 127{170}
GD555-3A GD555-3C
Running time Engine speed Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 1,050 0{0} 0{0}
10 1,000 98{10} 7.4{9.7}
2 1,200 245{25} 22{29}
3 3 1,600 2,000 440{45} 830{85} 53{71} 124{166}
DCA-150ESK Running time (DENYO Engine speed generator) Load Flywheel hosepower
min rpm N{kg} kW{HP}
2 800 0{0} 0{0}
10 1,100 98{10} 7.4{10}
2 1,300 245{25} 24{33}
3 3 1,500 1,800 440{45} 887{90.5} 50{67} 120{161}
12-51-11 (21)
Order
Item
3 2,000 628{64} 95{127}
102 SERIES
PERFORMANCE TEST CRITERIA
TESTING AND ADJUSTING
PERFORMANCE TEST CRITERIA fl This table gives the standard values using the JIS compensation factor. fl The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opened (if installed). fl The loads for the dynamometer are at an arm's length of 716 mm.
102-1 Engine model
4D102E-1
Applicable machine PC60-7 PC70-7 PC60-7B
Specifications
Flywheel horsepower
40.5 kW/1,750 rpm(Net) {54.2 HP/1,750 rpm}(Net) 245 Nm/1,200 rpm(Net) {25 kgm/1,200 rpm}(Net) 1,900 – 2,000 rpm 1,020 – 1,070 rpm
1,745 – 1,755
60.3 kW/2,100 rpm(Net) {80.9 HP/2,100 rpm}(Net) 329 Nm/1,300 rpm(Net) {33.5 kgm/1,300 rpm}(Net) 2,240 – 2,360 rpm 900 – 950 rpm
2,095 – 2,105
Max. torque High idling speed Low idling speed
PC100-6 PC100L-6
Flywheel horsepower Max. torque High idling speed Low idling speed
PC100-6 EXCEL
Flywheel horsepower Max. torque High idling speed Low idling speed
S4D102E-1
PC120-6 PC130-6 MIGHTY
Flywheel horsepower Max. torque High idling speed Low idling speed
PC120-6 EXCEL
Flywheel horsepower Max. torque High idling speed Low idling speed
PC128UU-1 Flywheel horsepower Max. torque High idling speed Low idling speed
12-52 (14)
Engine Speed (rpm)
Test item
60.3 kW/2,100 rpm(Net) {80.9 HP/2,100 rpm}(Net) 329 Nm/1,300 rpm(Net) {33.5 kgm/1,300 rpm}(Net) 2,240 – 2,360 rpm 900 – 950 rpm 64.0 kW/2,200 rpm(Net) {85.8 HP/2,200 rpm}(Net) 329 Nm/1,300 rpm(Net) {33.5 kgm/1,300 rpm}(Net) 2,340 – 2,460 rpm 900 – 950 rpm 62.5 kW/2,000 rpm(Net) {83.8 HP/2,000 rpm}(Net) 328 Nm/1,300 rpm(Net) {33.5 kgm/1,300 rpm}(Net) 2,140 – 2,260 rpm 900 – 950 rpm 62.5 kW/1,900 rpm(Net) {83.8 HP/1,900 rpm}(Net) 329 Nm/1,300 rpm(Net) {33.5 kgm/1,300 rpm}(Net) 2,040 – 2,160 rpm 900 – 950 rpm
1,100 – 1,300 1,900 – 2,000 1,020 – 1,070
1,200 – 1,400 2,240 – 2,360 900 – 950 2,095 – 2,105 1,200 – 1,400 2,240 – 2,360 900 – 950 2,195 – 2,205 1,200 – 1,400 2,340 – 2,460 900 – 950 1,995 – 2,005 1,200 – 1,400 2,140 – 2,260 900 – 950 1,895 – 1,905 1,200 – 1,400 2,040 – 2,160 900 – 950
Dynamometer (N{kg}) 312 – 331 {31.8 – 33.8} 348 – 364 {35.5 – 37.1} — — 388 – 411 {39.6 – 41.9} 466 – 520 {47.5 – 53.0} — — 388 – 411 {39.6 – 41.9} 466 – 520 {47.5 – 53.0} — — 395 – 417 {40.3 – 42.5} 466 – 520 {47.5 – 53.0} — — 419 – 444 {42.8 – 45.4} 465 – 520 {47.5 – 53.1} — — 434 – 460 {44.3 – 46.9} Min. 465 {Min. 47.5} — —
102 SERIES
PERFORMANCE TEST CRITERIA
TESTING AND ADJUSTING
fl For fuel, use ASTM D975 No. 1 or No. 2. fl For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel hosepower (kW{HP})
Torque (Nm{kgm})
Fuel Cooling water Lubricating oil Lubricating oil Exhaust consumption temperature temperature pressure temperature (sec/100cc) (°C) (kPa{kg/cm2}) (°C) (°C)
40.9–43.4 (Gross) — {54.8–58.2}(Gross) — 249–261 (Gross) {25.4–26.6}(Gross) — — — —
Min. 29.1
75 – 95
90 – 110 90 – 110
340 – 590 {3.5 – 6.0} —
—
75 – 95
— —
61.1–64.8 (Gross) — {83.0–88.1}(Gross) — 333–273 (Gross) {34.0–38.0}(Gross) — — — —
Max. 650
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
Min. 19.4
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
Max. 650
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
61.1–64.8 (Gross) — {83.1–88.1}(Gross) — 333–373 (Gross) {34.0–38.0}(Gross) — — — —
Min. 19.7
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
Max. 650
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
65.1–68.9 (Gross) — {87.2–92.4}(Gross) — 333–373 (Gross) {34.0–38.0} — — — —
Min. 19.4
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
Max. 650
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
62.9–66.7 (Gross) — – }(Gross) — 333–372 (Gross) {34.0–38.0}(Gross) — — — —
Min. 19.0
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
Min. 19.0
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
— —
74 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
{
61.8–65.6 (Gross) — {84.0–89.2}(Gross) — Min. 330(Gross) {Min. 34}(Gross) — — — —
102 SERIES
Max. 600
—
—
12-53 (17)
PERFORMANCE TEST CRITERIA
TESTING AND ADJUSTING
fl This table gives the standard values using the JIS compensation factor. fl The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opened (if installed). fl The loads for the dynamometer are at an arm's length of 716 mm.
Engine model
Applicable machine
Test item
D31E,S,Q,P-20 Flywheel horsepower D31,PL,PLL-20 D31P-20A Max. torque High idling speed Low idling speed D37E-5 D37P-5A
Flywheel horsepower Max. torque High idling speed Low idling speed
PC128US-1 Flywheel horsepower Max. torque High idling speed Low idling speed
Specifications
52.2 kW/2,350 rpm(Net) {70.0 HP/2,350 rpm}(Net) 265 Nm/1,400 rpm(Net) {27 kgm/1,400 rpm}(Net) 2,420 – 2,520 rpm 900 – 950 rpm 56.2 kW/2,500 rpm(Net) {75.3 HP/2,500 rpm}(Net) 293 Nm/1,400 rpm(Net) {29.9 kgm/1,400 rpm}(Net) 2,600 – 2,650 rpm 800 – 850 rpm 64.0 kW/2,200 rpm(Net) {85.8 HP/2,200 rpm}(Net) 329 Nm/1,300 rpm(Net) {33.5 kgm/1,300 rpm}(Net) 2,440 – 2,560 rpm 925 – 975 rpm
Engine Speed (rpm) 2,345 – 2,355 1,300 – 1,500 2,420 – 2,520 900 – 950 2,495 – 2,505 1,300 – 1,500 2,600 – 2,650 800 – 850 2,195 – 2,205 1,200 – 1,400 2,440 – 2,560 925 – 975
Dynamometer (N{kg}) 309 – 325 {31.5 – 33.2} 402 – 425 {41.0 – 43.04} — — 305 – 323 {31.1 – 32.9} 402 – 426 {41.0 – 43.4} — — 395 – 417 {40.3 – 42.5} 466 – 520 {47.5 – 53.0} — —
S4D102E-1 PC128US-2 Flywheel horsepower Max. torque High idling speed Low idling speed PC158US-2 Flywheel horsepower
2,340 – 2,460 925 – 975
1,400 – 1,600
High idling speed
2,440 – 2,560
Low idling speed
925 – 975 rpm
925 – 975
—
63 kW/2,500 rpm(Net) {85 HP/2,500 rpm}(Net) 343 Nm/1,500 rpm(Net) {35 kgm/1,500 rpm}(Net) 2,700 – 2,800 rpm 650 – 700 rpm
2,495 – 2,505
347 – 367 {35.4 – 37.4} 472 – 499 {48.2 – 50.9} — —
Flywheel horsepower
High idling speed Low idling speed
(17)
1,200 – 1,400
2,295 – 2,305
395 – 417 {40.3 – 42.5} 466 – 520 {47.5 – 53.0} — — 432 – 475 {44.0 – 48.4} 525 – 580 {53.5 – 59.1} —
Max. torque
12-53-1
2,195 – 2,205
73.6 kW/2,300 rpm(Net) {98.7 HP/2,300 rpm}(Net) 387 Nm/1,500 rpm(Net) {39.5 kgm/1,500 rpm}(Net) 2,440 – 2,560 rpm
Max. torque
GD305A-3
64.0 kW/2,200 rpm(Net) {85.8 HP/2,200 rpm}(Net) 329 Nm/1,300 rpm(Net) {33.5 kgm/1,300 rpm}(Net) 2,340 – 2,460 rpm 925 – 975 rpm
1,400 – 1,600 2,700 – 2,800 650 – 700
102 SERIES
TESTING AND ADJUSTING
PERFORMANCE TEST CRITERIA
fl For fuel, use ASTM D975 No. 1 or No. 2. fl For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel hosepower (kW{HP})
Torque (Nm{kgm})
Fuel Cooling water Lubricating oil Lubricating oil Exhaust consumption temperature temperature pressure temperature (sec/100cc) (°C) (kPa{kg/cm2}) (°C) (°C)
54.3–57.5 (Gross) — {73.8–78.2}(Gross) — 287–305 (Gross) {29.3–31.1}(Gross) — — — —
Min. 20.9
75 – 95
90 – 110
—
75 – 95
— —
57.1–60.6 (Gross) — {76.5–81.2}(Gross) — 287–305 (Gross) {29.3–31.1}(Gross) — — — — 65.1–68.9 (Gross) — {87.3–92.4}(Gross) — 333–373 (Gross) {34.0–38.0}(Gross) — — — — 65.1–68.9 (Gross) — {87.3–92.4}(Gross) — 333–373 (Gross) {34.0–38.0}(Gross) — — — — 74.5–81.9 (Gross) — {100.0–109.8}(Gross) — 376–415 (Gross) {38.3–42.3}(Gross) — — —
—
65.0–68.8 (Gross) — {87.2–92.3}(Gross) — 338–358 (Gross) {34.5–36.5}(Gross) — — — —
102 SERIES
90 – 110
390 – 590 {3.5 – 6.0} —
Max. 550 Max. 600
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
Min. 19.6
75 – 95
90 – 110
Max. 550
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
Max. 600
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
75 – 95
90 – 110
Max. 650
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
80 – 110
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} Min.147 {Min.1.5}
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
390 – 590 {3.5 – 6.0} —
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.118 {Min.1.2}
— —
Max. 650
Max. 650
Max. 650 — —
Max. 650
12-53-2 (17)
PERFORMANCE TEST CRITERIA
TESTING AND ADJUSTING
fl This table gives the standard values using the JIS compensation factor. fl The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opened (if installed). fl The loads for the dynamometer are at an arm's length of 716 mm.
Engine model
Applicable machine WA120-3
Test item
Specifications
Flywheel horsepower
67.7 kW/2,400 rpm(Net) {90.7 HP/2,400 rpm}(Net) 348 Nm/1,600 rpm(Net) {35.5 kgm/1,600 rpm}(Net) 2,600 – 2,700 rpm 800 – 850 rpm
Max. torque High idling speed Low idling speed
Engine Speed (rpm) 2,395 – 2,405 1,500 – 1,700 2,600 – 2,700 800 – 850
Dynamometer (N{kg}) 369 – 390 {37.6 – 39.8} 479 – 508 {48.8 – 51.8} — —
S4D102E-1 WA120-3D
Flywheel horsepower Max. torque High idling speed Low idling speed
D41A-6
Flywheel horsepower Max. torque
6D102E-1
High idling speed Low idling speed PC200,200LC-6 PC200,200LC-6 HYPER GX PC210,210LC-6 MIGHTY BR200S-1 PC200LC-6 EXCEL PC200-6 S6D102E-1 CUSTOM CD60RE-1
Flywheel horsepower Max. torque High idling speed Low idling speed Flywheel horsepower Max. torque High idling speed Low idling speed
PC228UU-1 Flywheel horsepower Max. torque High idling speed Low idling speed
12-53-3 (17)
67.7 kW/2,400 rpm(Net) {90.7 HP/2,400 rpm}(Net) 348 Nm/1,600 rpm(Net) {35.5 kgm/1,600 rpm}(Net) 2,600 – 2,700 rpm 800 – 850 rpm 59.7 kW/2,400 rpm(Net) {80.0 HP/2,400 rpm}(Net) 343 Nm/1,300 rpm(Net) {35.0 kgm/1,300 rpm}(Net) 2,650 rpm 825 rpm 99.3 kW/2,000 rpm(Net) {133 HP/2,000 rpm}(Net) 563 Nm/1,350 rpm(Net) {57.4 kgm/1,350 rpm}(Net) 2,340 – 2,460 rpm 1,000 – 1,050 rpm 95.6 kW/2,000 rpm(Net) {128 HP/2,000 rpm}(Net) 545 Nm/1,350 rpm(Net) {55.6 kgm/1,350 rpm}(Net) 2,140 – 2,260 rpm 975 – 1,025 rpm 95.6 kW/2,000 rpm(Net) {128 HP/2,000 rpm}(Net) 545 Nm/1,350 rpm(Net) {55.6 kgm/1,350 rpm}(Net) 2,140 – 2,260 rpm 1,000 – 1,050 rpm
2,395 – 2,405 1,500 – 1,700 2,600 – 2,700 800 – 850
369 – 390 {37.6 – 39.8} 479 – 508 {48.8 – 51.8} — —
2,395 – 2,405 1,200 – 1,400 2,600 – 2,700 775 – 875
— —
1,995 – 2,005
682 – 721 {69.5 – 73.5} 782 – 827 {79.7 – 84.3} — —
1,250 – 1,450 2,340 – 2,460 1,000 – 1,050 1,995 – 2,005 1,250 – 1,450 2,140 – 2,260 975 – 1,025 1,995 – 2,005 1,250 – 1,450 2,140 – 2,260 1,000 – 1,050
658 – 695 {67.1 – 70.9} 756 – 802 {77.1 – 81.8} — — 658 – 695 {67.1 – 70.9} 756 – 802 {77.1 – 81.8} — —
102 SERIES
TESTING AND ADJUSTING
PERFORMANCE TEST CRITERIA
fl For fuel, use ASTM D975 No. 1 or No. 2. fl For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel hosepower (kW{HP})
Torque (Nm{kgm})
66.3–70.4 (Gross) — {90.2–95.7}(Gross) — 322–364 (Gross) {34.9–37.1}(Gross) — — — —
Max. 650
90 – 110
390 – 590 {3.5 – 6.0} —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
75 – 95
90 – 110
Max. 650
—
75 – 95
90 – 110
390 – 590 {3.5 – 6.0} —
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
80 – 85
80 – 110
Max. 550
—
80 – 85
80 – 110
580 – 520 {2.8 – 5.3} —
— —
80 – 85 80 – 85
80 – 110 80 – 110
— Min.70 {Min.0.7}
— —
Min. 12.0
75 – 95
90 – 110
Max. 650
—
75 – 95
90 – 110
390 – 590 {3.5 – 6.0} —
Max. 650
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
—
Min. 12.5
75 – 95
90 – 110
Max. 650
541–574 (Gross) {55.2–58.6}(Gross) — —
—
75 – 95
90 – 110
390 – 590 {3.5 – 6.0} —
Max. 650
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
—
Min. 12.5
75 – 95
90 – 110
Max. 600
541–575 (Gross) {55.2–58.6}(Gross) — —
—
75 – 95
90 – 110
390 – 590 {3.5 – 6.0} —
Max. 650
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
66.3–70.4 (Gross) — {90.2–95.7}(Gross) — 322–364 (Gross) {34.9–37.1}(Gross) — — — — 67.3–74.3 (Gross) — {90.2–99.6}(Gross) — 330–366 (Gross) {33.7–37.3}(Gross) — — — — 102–108 (Gross) — {138.9–147.1}(Gross) — 559–592 (Gross) {57.0–60.4}(Gross) — — — — 98.6–104 (Gross) {132–140}(Gross) — — — 98.6–104 (Gross) {132–140}(Gross) — — —
102 SERIES
Fuel Cooling water Lubricating oil Lubricating oil Exhaust consumption temperature temperature pressure temperature (sec/100cc) (°C) (kPa{kg/cm2}) (°C) (°C) 75 – 95
90 – 110
—
75 – 95
— —
Max. 650
Max. 650
—
12-53-4 (17)
PERFORMANCE TEST CRITERIA
TESTING AND ADJUSTING
fl This table gives the standard values using the JIS compensation factor. fl The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opened (if installed). fl The loads for the dynamometer are at an arm's length of 716 mm.
Engine model
Applicable machine
Test item
PC228USLC-1 Flywheel horsepower Max. torque High idling speed Low idling speed PC228USLC-2
Flywheel horsepower Max. torque High idling speed Low idling speed
D41E, P-6
Flywheel horsepower Max. torque High idling speed Low idling speed
Specifications
95.6 kW/2,000 rpm(Net) {128 HP/2,000 rpm}(Net) 545 Nm/1,350 rpm(Net) {55.6 kgm/1,350 rpm}(Net) 2,140 – 2,260 rpm 1,000 – 1,050 rpm
Engine Speed (rpm) 1,955 – 2,005 1,250 – 1,450 2,140 – 2,260 1,000 – 1,050
95.6 kW/2,000 rpm(Net) {128 HP/2,000 rpm}(Net) 545 Nm/1,350 rpm(Net) {55.6 kgm/1,350 rpm}(Net) 2,140 – 2,260 rpm 1,000 – 1,050 rpm
1,995 – 2,005
78.0 kW/2,400 rpm(Net) {105 HP/2,400 rpm}(Net) 461 Nm/1,300 rpm(Net) {47.0 kgm/1,300 rpm}(Net) 2,650 rpm 825 rpm
2,395 – 2,405
1,250 – 1,450
Dynamometer (N{kg}) 658 – 695 {67.1 – 70.9} 756 – 802 {77.1 – 81.8} — — 658 – 695 {67.1 – 70.9} 756 – 802 {77.1 – 81.8} — —
1,200 – 1,400 2,600 – 2,700 775 – 875
— —
2,395 – 2,405
449 – 478 {45.8 – 48.7} 566 – 606 {57.7 – 61.8} — —
S6D102E-1 WA180-3
Flywheel horsepower
WA180-3 (for CIS)
Max. torque High idling speed Low idling speed
WA180-3 (for EU)
Flywheel horsepower Max. torque High idling speed Low idling speed
WA180PT-3 Flywheel horsepower Max. torque High idling speed Low idling speed
12-53-5 (23)
81 kW/2,400 rpm(Net) {108 HP/2,400 rpm}(Net) 417 Nm/1,600 rpm(Net) {42.5 kgm/1,600 rpm}(Net) 2,600 – 2,700 rpm 750 – 800 rpm 81 kW/2,400 rpm(Net) {108 HP/2,400 rpm}(Net) 417 Nm/1,600 rpm(Net) {42.5 kgm/1,600 rpm}(Net) 2,600 – 2,700 rpm 750 – 800 rpm 81 kW/2,400 rpm(Net) {108 HP/2,400 rpm}(Net) 417 Nm/1,600 rpm(Net) {42.5 kgm/1,600 rpm}(Net) 2,600 – 2,700 rpm 750 – 800 rpm
1,500 – 1,700 2,600 – 2,700 750 – 800 2,395 – 2,405 1,500 – 1,700 2,600 – 2,700 750 – 800 2,395 – 2,405 1,500 – 1,700
449 – 478 {45.8 – 48.7} 566 – 606 {57.7 – 61.8} — — 449 – 478 {45.8 – 48.7} 566 – 606 {57.7 – 61.8} — —
102 SERIES
TESTING AND ADJUSTING
PERFORMANCE TEST CRITERIA
fl For fuel, use ASTM D975 No. 1 or No. 2. fl For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel hosepower (kW{HP})
Torque (Nm{kgm})
98.6–104.4(Gross) — {132–140} (Gross) — 541–575 (Gross) {55.2–58.6}(Gross) — — — — 98.6–104.4(Gross) — {132–140} (Gross) — 541–575 (Gross) {55.2–58.6}(Gross) — — — — 79.0–86.0 (Gross) — {105–115} (Gross) — 447–474 (Gross) {45.6–48.4}(Gross) — — — — 81–86 (Gross) {108–115}(Gross) — — — 81–86 (Gross) {108–115}(Gross) — — — 81–86 (Gross) {108–115}(Gross) — — —
102 SERIES
Fuel Cooling water Lubricating oil Lubricating oil Exhaust consumption temperature temperature pressure temperature (sec/100cc) (°C) (kPa{kg/cm2}) (°C) (°C) 75 – 95
90 – 110
Max. 600
90 – 110
340 – 590 {3.5 – 6.0} —
—
75 – 95
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
80 – 85
80 – 110
Max. 600
—
80 – 85
80 – 110
580 – 520 {2.8 – 5.3} —
— —
80 – 85 80 – 85
80 – 110 80 – 110
— Min.70 {Min.0.7}
— —
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
Max. 650
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
Max. 650
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
Max. 650
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
— 405–434 (Gross) {41.3–44.3}(Gross) — — — 405–434 (Gross) {41.3–44.3}(Gross) — — — 405–434 (Gross) {41.3–44.3}(Gross) — —
Max. 650
Max. 650
—
12-53-6 (17)
PERFORMANCE TEST CRITERIA
TESTING AND ADJUSTING
fl This table gives the standard values using the JIS compensation factor. fl The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opened (if installed). fl The loads for the dynamometer are at an arm's length of 716 mm.
Engine model
Applicable machine WA250-3
Test item
Specifications
Flywheel horsepower
92 kW/2,400 rpm(Net) {123 HP/2,400 rpm}(Net) 4 Nm/1,600 rpm(Net) {4 kgm/1,600 rpm}(Net) 2,600 – 2,700 rpm 825 – 875 rpm
Max. torque High idling speed Low idling speed WA250PT-3 Flywheel horsepower Max. torque High idling speed Low idling speed WA250L-3 (for USA)
Flywheel horsepower Max. torque
S6D102E-1 High idling speed Low idling speed GD521A-1E Flywheel horsepower Max. torque High idling speed Low idling speed JV100WA-2 Flywheel horsepower JV100WP-2 Max. torque High idling speed Low idling speed
12-53-7 (17)
92 kW/2,400 rpm(Net) {123 HP/2,400 rpm}(Net) 4 Nm/1,600 rpm(Net) {4 kgm/1,600 rpm}(Net) 2,600 – 2,700 rpm 825 – 875 rpm 92.6 kW/2,400 rpm(Net) {124 HP/2,400 rpm}(Net) 483 Nm/1,600 rpm(Net) {49.3 kgm/1,600 rpm}(Net) 2,600 – 2,700 rpm 825 – 875 rpm 104 kW/2,500 rpm(Net) {140 HP/2,500 rpm}(Net) 425 Nm/1,600 rpm(Net) {53.5 kgm/1,600 rpm}(Net) 2,650 – 2,750 rpm 775 – 825 rpm 99.3 kW/2,000 rpm(Net) {133 HP/2,000 rpm}(Net) 563 Nm/1,350 rpm(Net) {57.4 kgm/1,350 rpm}(Net) 2,140 – 2,260 rpm 975 – 1,025 rpm
Engine Speed (rpm) 2,395 – 2,405 1,500 – 1,700 2,600 – 2,700 825 – 875 2,395 – 2,405 1,500 – 1,700 2,600 – 2,700 825 – 875 2,395 – 2,405 1,500 – 1,700 2,600 – 2,700 825 – 875 2,495 – 2,505 1,500 – 1,700 2,650 – 2,750 775 – 825 1,995 – 2,005 1,250 – 1,450 2,140 – 2,260 975 – 1,025
Dynamometer (N{kg}) 510 – 537 {52.0 – 54.8} 629 – 667 {64.1 – 68.0} — — 510 – 537 {52.0 – 54.8} 629 – 667 {64.1 – 68.0} — — 535 – 568 {54.6 – 57.9} 671 – 712 {68.4 – 72.6} — — 561 – 593 {57.2 – 60.5} 720 – 762 {73.4 – 77.7} — — 682 – 721 {69.5 – 73.5} 782 – 827 {79.7 – 84.3} — —
102 SERIES
TESTING AND ADJUSTING
PERFORMANCE TEST CRITERIA
fl For fuel, use ASTM D975 No. 1 or No. 2. fl For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel hosepower (kW{HP})
Torque (Nm{kgm})
91.7–96.9 (Gross) — {124.7–131.7}(Gross) — 450–478 (Gross) {45.9–48.7}(Gross) — — — —
Max. 600
90 – 110
340 – 590 {3.5 – 6.0} —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
Max. 650
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
—
Min. 12.0
75 – 95
90 – 110
Max. 650
559–592 (Gross) {57.0–60.4}(Gross) — —
—
75 – 95
90 – 110
390 – 590 {3.5 – 6.0} —
Max. 650
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
91.7–96.9 (Gross) — {124.7–131.7}(Gross) — 450–478 (Gross) {45.9–48.7}(Gross) — — — — 96–102 (Gross) {129–137}(Gross) — — —
— —
102 SERIES
75 – 95
90 – 110
—
75 – 95
— —
— 481–510 (Gross) {49.0–52.0}(Gross) — —
105–111 (Gross) — {140.8–149.3}(Gross) — 515–546 (Gross) {52.5–55.7}(Gross) — — — — 102–108 (Gross) {137–145}(Gross) —
Fuel Cooling water Lubricating oil Lubricating oil Exhaust consumption temperature temperature pressure temperature (sec/100cc) (°C) (kPa{kg/cm2}) (°C) (°C)
Max. 650
Max. 650
Max. 650
12-53-8 (17)
PERFORMANCE TEST CRITERIA
TESTING AND ADJUSTING
fl This table gives the standard values using the JIS compensation factor. fl The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opened (if installed). fl The loads for the dynamometer are at an arm's length of 716 mm.
Engine model
Applicable machine
Test item
PC220,LC-6 Flywheel horsepower PC250HD-1 PC250,LC-6 Max. torque High idling speed Low idling speed WA300L-3 (for USA)
Flywheel horsepower Max. torque High idling speed Low idling speed
SA6D102E-1
PC220,LC-6 Flywheel horsepower EXCEL Max. torque High idling speed Low idling speed WA320-3 Flywheel horsepower AVANCE CUSTOM Max. torque High idling speed Low idling speed DCA-125SSK Flywheel horsepower (DENYO generator) Max. torque High idling speed Low idling speed
12-53-9 (17)
Specifications
118 kW/2,100 rpm(Net) {158 HP/2,100 rpm}(Net) 618 Nm/1,400 rpm(Net) {63 kgm/1,400 rpm}(Net) 2,340 – 2,460 rpm 975 – 1,025 rpm 114 kW/2,350 rpm(Net) {153 HP/2,350 rpm}(Net) 608 Nm/1,600 rpm(Net) {62 kgm/1,600 rpm}(Net) 2,535 – 2,635 rpm 975 – 1,025 rpm 114 kW/2,100 rpm(Net) {153 HP/2,100 rpm}(Net) 588 Nm/1,400 rpm(Net) {60 kgm/1,400 rpm}(Net) 2,240 – 2,360 rpm 975 – 1,025 rpm 114 kW/2,350 rpm(Net) {153 HP/2,350 rpm}(Net) 608 Nm/1,600 rpm(Net) {62 kgm/1,600 rpm}(Net) 2,535 – 2,635 rpm 775 – 825 rpm 115.5 kW/1,800 rpm(Net) 60Hz 154.8 HP/1,800 rpm(Net) 60Hz — Max. 1,890 rpm 750 – 850 rpm
Engine Speed (rpm) 2,095 – 2,105 1,300 – 1,500 2,340 – 2,460 975 – 1,025 2,345 – 2,355 1,500 – 1,600 2,535 – 2,635 975 – 1,025 2,095 – 2,105 1,300 – 1,500
2,345 – 2,355 1,500 – 1,700
1,795 – 1,805 —
Dynamometer (N{kg}) 769 – 814 {78.4 – 83.0} 861 – 914 {87.8 – 93.2} — — 657 – 694 {67.0 – 70.8} 838 – 888 {85.5 – 90.5} — — 745 – 788 {76.0 – 80.4} 820 – 874 {83.6 – 89.1} — — 657 – 694 {67.0 – 70.8} 838 – 888 {85.5 – 90.5} — — 861 – 914 {87.8 – 93.2} — — —
102 SERIES
TESTING AND ADJUSTING
PERFORMANCE TEST CRITERIA
fl For fuel, use ASTM D975 No. 1 or No. 2. fl For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel hosepower (kW{HP}) 121–128 (Gross) {162–172}(Gross) — — — 116–123 (Gross) {155–164}(Gross) — — —
Torque (Nm{kgm})
Fuel Cooling water Lubricating oil Lubricating oil Exhaust consumption temperature temperature pressure temperature (sec/100cc) (°C) (kPa{kg/cm2}) (°C) (°C)
—
Min. 10.7
75 – 95
90 – 110
616–655 (Gross) {62.8–66.8}(Gross) — —
—
75 – 95
— —
— 600–635 (Gross) {61.2–64.8}(Gross) — —
117.4–124.3 (Gross) — {157.4–166.6}(Gross) — 586–626 (Gross) {59.8–63.8}(Gross) — — — — 115.8–122.5 (Gross) — {155.2–164.3}(Gross) — 600–635 (Gross) {61.2–64.8}(Gross) — — — —
90 – 110
390 – 590 {3.5 – 6.0} —
Max. 600 Max. 650
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147
— —
Min. 10.1
75 – 95
90 – 110
Max. 650
—
75 – 95
90 – 110
390 – 590 {3.5 – 6.0} —
Max. 650
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
75 – 95
90 – 110
Max. 600
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
75 – 95
90 – 110
Max. 650
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} —
— —
75 – 95 75 – 95
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
Max. 650
Max. 650
116.3–123.5 (Gross) {155.9–165.6}(Gross) —
—
—
70 – 90
90 – 110
340 – 490 {3.5 – 5.0} —
Max. 650
— —
— —
— —
70 – 90 70 – 90
90 – 110 80 – 110
— Min.147 {Min.1.5}
— —
102 SERIES
12-53-10 (17)
PERFORMANCE TEST CRITERIA
TESTING AND ADJUSTING
fl This table gives the standard values using the JIS compensation factor. fl The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opened (if installed). fl The loads for the dynamometer are at an arm's length of 716 mm.
102-2 Engine model
Applicable machine
Test item
Specifications
D31EX-21 D31PX-21
Flywheel horsepower
High idling speed
55.9 kW/2,000 rpm(Net) {74.9 HP/2,000 rpm}(Net) 384 Nm/1,300 rpm(Net) {39.2 kgm/1,300 rpm}(Net) 2,200 ± 50 rpm
Low idling speed
800 +50 rpm 0
Max. torque
D37EX-21 D37PX-21
Flywheel horsepower
High idling speed
63.3 kW/2,000 rpm(Net) {84.9 HP/2,000 rpm}(Net) 412 Nm/1,300 rpm(Net) {42 kgm/1,300 rpm}(Net) 2,200 ± 50 rpm
Low idling speed
800 +50 rpm 0
Max. torque
D39EX-21 D39PX-21
Flywheel horsepower
High idling speed
70 kW/2,200 rpm(Net) {94 HP/2,200 rpm}(Net) 434 Nm/1,300 rpm(Net) {44.3 kgm/1,300 rpm}(Net) 2,400 ± 50 rpm
Low idling speed
800 +50 rpm 0
Max. torque
SAA4D 102E-2
PC160LC-7
Flywheel horsepower
2,000 ± 5 1,300 ± 100 2,200 ± 50 800
+50 0
2,000 ± 5 1,300 ± 100 2,200 ± 50 800
+50 0
2,200 ± 5 1,300 ± 100 2,400 ± 50 800
+50 0
2,200 ± 5
Dynamometer (N{kg}) 361 – 384 {36.9 – 39.2} 520 – 553 {53.1 – 56.4} — — 409 – 434 {41.7 – 44.3} 548 – 602 {55.9 – 61.4} — — 436 – 462 {44.5 – 47.1} 584– 647 {59.6 – 66.0} — —
1,500 ± 100
High idling speed
82 kW/2,200 rpm(Net) {110 HP/2,200 rpm}(Net) 431 Nm/1,500 rpm(Net) {44 kgm/1,500 rpm}(Net) 2,490 ± 50 rpm
2,490 ± 50
493 – 545 {50.3 – 55.6} 577– 640 {58.9 – 65.3} —
Low idling speed
1,050 ± 50 rpm
1,050 ± 50
—
2,000 ± 5 1,300 ± 100
High idling speed
74.2 kW/2,000 rpm(Gross) {99.5 HP/2,000 rpm}(Gross) 408 Nm/1,300 rpm(Gross) {41.6 kgm/1,300 rpm}(Gross) 2,250 ± 50 rpm
2,250 ± 50
470 – 520 {48 – 53} 541 – 598 {55.2 – 61} —
Low idling speed
825 ± 50 rpm
825 ± 50
—
Max. torque
WA150-5
Engine Speed (rpm)
Flywheel horsepower Max. torque
Flywheel horsepower Max. torque High idling speed Low idling speed
12-53-21 (19)
102 SERIES
TESTING AND ADJUSTING
PERFORMANCE TEST CRITERIA
fl For fuel, use ASTM D975 No. 1 or No. 2. fl For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel hosepower (kW{HP}) 57.8–61.3 (Gross) {77.5–82.2}(Gross) —
Torque (Nm{kgm})
Fuel Cooling water Lubricating oil Lubricating oil Exhaust consumption temperature temperature pressure temperature (sec/100cc) (°C) (kPa{kg/cm2}) (°C) (°C)
—
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
380–404 (Gross) {38.8–41.2}(Gross) —
—
75 – 95
90 – 110
—
—
—
75 – 95
80 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
80 – 110
Min. 16.7
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
80 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
80 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
80 – 110
65.6–69.7 (Gross) — {87.9–93.4}(Gross) — 392–431 (Gross) {40–44} (Gross) — — —
—
72.0–76.3 (Gross) — {91.5–102.2}(Gross) — 419–464 (Gross) {42.7–47.3}(Gross) — — —
—
81.4–90.0 (Gross) — {109.1–120.6}(Gross) — 413–459 (Gross) {42.2–46.8}(Gross) — — —
—
70.5–77.9 (Gross) — {94.5–104.4}(Gross) — 388–428 (Gross) {39.5–43.7}(Gross) — — —
102 SERIES
—
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} Min.147{1.5}
Max. 650
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} Min.147{1.5}
Max. 650
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} Min.147{1.5}
Max. 650
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0}
Max. 650
Max. 650 — —
Max. 650 — —
Max. 650 — —
Max. 650 — —
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} Min.147{1.5}
Max. 650 Max. 650 — —
12-53-22 (19)
PERFORMANCE TEST CRITERIA
TESTING AND ADJUSTING
fl This table gives the standard values using the JIS compensation factor. fl The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opened (if installed). fl The loads for the dynamometer are at an arm's length of 716 mm.
Engine model
Applicable machine
Test item
Flywheel horsepower PC200-7 PC200LC-7 PC228US-3 Max. torque PC228 USLC-3 High idling speed
PC270-7 PC308 USLC-3 BR380JG-1
PC220-7 PC220LC-7
1,500 ± 100 2,200 ± 30
1,050 ± 25 rpm
1,050 ± 25
—
2,050 ± 5 1,500 ± 100
High idling speed
141 kW/2,050 rpm(Gross) {189 HP/2,050 rpm}(Gross) 740 Nm/1,500 rpm(Gross) {75.7 kgm/1,500 rpm}(Gross) 2,330 ± 50 rpm
2,330 ± 50
– – – – —
Low idling speed
1,050 ± 25 rpm
1,050 ± 25
—
2,050 ± 5 1,500 ± 100
High idling speed
134 kW/2,050 rpm(Net) {180 HP/2,050 rpm}(Net) 718 Nm/1,500 rpm}(Net) {73.3 kgm/1,500 rpm}(Gross) 2,330 +70 _ 30 rpm
_ 30 2,330 +70
871 – 962 {88.9 – 98.2} 984 – 1,088 {100.4 – 111} —
Low idling speed
1,050 ± 25 rpm
1,050 ± 25
—
2,000 ± 5 1,500 ± 100
High idling speed
125 kW/2,000 rpm(Net) {168 HP/2,000 rpm}(Net) 684 Nm/1,500 rpm}(Net) {69.8 kgm/1,500 rpm}(Net) 2,260 +80 _ 20 rpm
_ 20 2,260 +80
843 – 931 {86 – 95} 940 – 1,036 {95.9 – 105.7} —
Low idling speed
1,050 ± 25 rpm
1,050 ± 25
—
Flywheel horsepower
Flywheel horsepower Max. torque
Flywheel horsepower Max. torque
12-53-23 (19)
1,950 ± 50
Dynamometer (N{kg}) 740 – 780 {75.6 – 80.8} 810 – 890 {82.6 – 90.9} —
Max. torque
SAA6D 102E-2
Engine Speed (rpm)
107 kW/950 rpm(Net) {143 HP/950 rpm}(Net) 610 Nm/1,500 rpm(Net) {62.2 kgm/1,500 rpm}(Net) 2,200 ± 30 rpm
Low idling speed BR120T-1
Specifications
{ {
} }
102 SERIES
TESTING AND ADJUSTING
PERFORMANCE TEST CRITERIA
fl For fuel, use ASTM D975 No. 1 or No. 2. fl For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel hosepower (kW{HP})
Torque (Nm{kgm})
108–115 (Gross) — {144.9–153.8}(Gross) — 580–640 (Gross) {59.1–65.1}(Gross) — —
{
– –
Fuel Cooling water Lubricating oil Lubricating oil Exhaust consumption temperature temperature pressure temperature (sec/100cc) (kPa{kg/cm2}) (°C) (°C) (°C) Min.
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
—
—
75 – 95
80 – 110
(Gross) }(Gross) —
—
Min.
75 – 95
90 – 110
—
75 – 95
90 – 110
—
(Gross) }(Gross) —
—
75 – 95
90 – 110
—
—
—
75 – 95
80 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
80 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
80 – 110
{
– –
134–148 (Gross) — {179.6–198.6}(Gross) — 705–779 (Gross) {71.9–79.5}(Gross) — — —
—
126.5–139.7 (Gross) — {170–187}(Gross) — 673–742 (Gross) {68.7–75.7}(Gross) — — —
102 SERIES
—
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} Min.147 {1.5}
Max. 650
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} Min.147 {1.5}
Max. 650
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} Min.147 {1.5}
Max. 675
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} Min.147 {1.5}
Max. 650
Max. 650 — —
Max. 650 — — —
Max. 675 — —
Max. 650 — —
12-53-24 (19)
PERFORMANCE TEST CRITERIA
TESTING AND ADJUSTING
fl This table gives the standard values using the JIS compensation factor. fl The values in the table are the standard values for machines with the muffler installed, air cleaner installed, alternator under no load, and air compressor opened (if installed). fl The loads for the dynamometer are at an arm's length of 716 mm.
Engine model
Applicable machine
Test item
Specifications
WA200-5 WA200PT-5
Flywheel horsepower
95.2 kW/2,000 rpm(Gross) {127.7 HP/2,000 rpm}(Gross) 586 Nm/1,400 rpm(Gross) {59.8 kgm/1,400 rpm}(Gross) 2,250 ± 50 rpm
Max. torque High idling speed Low idling speed WA250-5 WA250PT-5
Flywheel horsepower Max. torque High idling speed Low idling speed
WA320-5 WA320PT-5
Flywheel horsepower Max. torque
SAA6D 102E-2
High idling speed Low idling speed GD555-3A GD555-3C
Flywheel horsepower Max. torque High idling speed Low idling speed
DCA-150ESK Flywheel horsepower (DENYO generator) Max. torque High idling speed Low idling speed
12-53-25 (21)
825 ± 50 rpm 104.1 kW/2,000 rpm(Gross) {139.5 HP/2,000 rpm}(Gross) 627 Nm/1,400 rpm(Gross) {64 kgm/1,400 rpm}(Gross) 2,250 ± 50 rpm 825 ± 50 rpm 127 kW/2,000 rpm(Gross) {170 HP/2,000 rpm}(Gross) 672 Nm/1,500 rpm(Gross) {68.5 kgm/1,500 rpm}(Gross) 2,250 ± 50 rpm 900 ± 25 rpm 124.5 kW/2,000 rpm(Gross) {167 HP/2,000 rpm}(Gross) 743 Nm/1,500 rpm(Gross) {75.7 kgm/1,500 rpm}(Gross) 2,230 ± 50 rpm 900 ± 50 rpm
Engine Speed (rpm) 2,000 ± 5 1,400 ± 100 2,250 ± 50 825 ± 50 2,000 ± 5 1,400 ± 100 2,250 ± 50 825 ± 50 2,000 ± 5 1,500 ± 100 2,250 ± 50 900 ± 25 2,000 ± 5 1,500 ± 100 2,230 ± 50 900 ± 50
113 kW/1,500 rpm(Net, 50Hz) 1,500 ± 5 {151 HP/1,500 rpm}(Net, 50Hz) 135 kW/1,800 rpm(Net, 60Hz) 1,800 ± 5 {180 HP/1,800 rpm}(Net, 60Hz) Max.1,580 rpm(50Hz) Max. 1,580 rpm (50Hz) Max.1,890 rpm(60Hz) Max. 1,890rpm (60Hz) 800 ± 50 rpm 800 ± 50 rpm
Dynamometer (N{kg}) 604 – 666 {61.6 – 67.9} 778 – 860 {79.3 – 87.7} — — 660 – 728 {67.3 – 74.3} 832 – 919 {84.9 – 93.8} — — 806 – 890 {82.2 – 90.8} 890 – 985 {90.8 – 100.5} — — 787 – 870 {80.3 – 88.7} 984 – 1,088 {100.4 – 111} — — 995 – 1,056 {101.5 – 107.8} 998 – 1,060 {101.8 – 108.2} — —
102 SERIES
TESTING AND ADJUSTING
PERFORMANCE TEST CRITERIA
fl For fuel, use ASTM D975 No. 1 or No. 2. fl For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel hosepower (kW{HP})
Torque (Nm{kgm})
90.5–100 (Gross) — {119.6–132.1}(Gross) — 557–615 (Gross) {56.8–62.8}(Gross) — —
Fuel Cooling water Lubricating oil Lubricating oil Exhaust consumption temperature temperature pressure temperature (sec/100cc) (kPa{kg/cm2}) (°C) (°C) (°C) —
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
—
—
75 – 95
80 – 110
99–109 (Gross)
—
—
75 – 95
90 – 110
—
—
75 – 95
90 – 110
—
596–659 (Gross) {60.8–67.2}(Gross) —
—
75 – 95
90 – 110
—
—
—
75 – 95
80 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
80 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
—
75 – 95
90 – 110
121–133 (Gross) — {162.2–178.3}(Gross) — 638–705 (Gross) {65.1–71.9}(Gross) — — —
—
118–131 (Gross) — {160.8–177.7}(Gross) — 705–779 (Gross) {71.9–79.5}(Gross) — —
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} Min.147 {1.5}
Max. 650 — —
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} Min.147 {1.5}
Max. 650
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} Min.147 {1.5}
Max. 675
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} Min.147 {1.5}
Max. 650
Max. 680 Max. 680
—
—
—
—
75 – 95
80 – 110
112–119 (Gross) {150–160}(Gross) 135–143 (Gross) {180–192}(Gross) —
—
Min. 13.2
75 – 95
90 – 110
—
Min. 10.7
75 – 95
90 – 110
—
—
75 – 95
90 – 110
340 – 590 {3.5 – 6.0} 340 – 590 {3.5 – 6.0} —
—
—
—
75 – 95
80 – 110
Min.147 {1.5}
102 SERIES
Max. 650
Max. 650 — —
Max. 675 — —
Max. 675 — —
—
12-53-26 (21)
TESTING AND ADJUSTING
TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP
TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP (DIAPHRAGM TYPE) Defective actuation of the feed pump is a cause of low engine output. The diaphragm type pump cannot be cleaned or reassembled. The feed pump is driven mechanically by the cam shaft lobe. Lever where or damage to the lobe will reduce the feed pump actuation capacity. The fuel system must not be actuated if the resistance at the intake side (A) is more than 100 mmHg. If the diaphragm breaks, the fuel will return through the housing breather hole (B).
The normal drop in pressure at the filter is a maximum of 21 kPa{0.2 kg/cm2}. The filter becomes clogged by the dirt in the fuel, so the drop in pressure increases. If the feed pump becomes worn, its filtering capacity will drop, and the fuel will pass through the dirty filter. This will cause a drop in the engine output. Caution: If the filter must be replaced frequently to allow the engine to display its power to the full, it means that the feed pump is worn.
Testing feed pump The output of the fuel feed pump can be tested by the following two methods. Test 1: Measure the output pressure with an in-line pressure gauge. Test 2: Measure the flow
TEST 1: TESTING OUTPUT PRESSURE Start the engine and measure the output of the fuel feed pump with an in-line pressure gauge.
Min. pressure
21kPa{0.2kg/cm2}
12-54 0
102 SERIES
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TESTING AND ADJUSTING
S6D102E-1 PC228USLC-2
WA180-3 WA180PT-3 WA180-3 (for CIS)
D41E, P-6
WA180-3 (for EU)
Standard value
Permissible value
Standard value
Permissible value
Standard value
Permissible value
Standard value
Permissible value
2,140 – 2,260 1,000 – 1,050
2,140 – 2,260 1,000 – 1,050
2,600 – 2,700 825 – 900
2,600 – 2,700 825 – 900
2,600 – 2,700 750 – 800
2,600 – 2,700 750 – 800
2,600 – 2,700 750 – 800
2,600 – 2,700 750 – 800
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
170 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Max. 2.94 {Max. 300}
7.47 {762}
Max. 6.23 {Max. 635}
6.23 {635}
Max. 2.94 {Max. 300}
7.47 {762}
Max. 2.94 {Max. 300}
7.47 {762}
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Max. 650
700
Max. 650
600
Max. 650
700
Max. 650
700
Max. 5.5
7.5
—
—
Max. 5.5
7.5
Max. 5.5
7.5
Max. 2.0
3.0
Max. 1.5
2.5
Max. 2.0
3.0
Max. 2.0
3.0
Max. 1.0
2.0
—
—
Max. 1.0
2.0
Max. 1.0
2.0
0.25 0.51
— —
0.25 0.51
— —
0.25 0.51
— —
0.25 0.51
— —
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Min. 2.41 {Min. 24.6}
2.10 {21.1}
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Max. 0.49 {Max. 50}
0.98 {100}
Max. 0.25 {Max. 26}
0.50 {51}
Max. 0.49 {Max. 50}
0.98 {100}
Max. 0.49 {Max. 50}
0.98 {100}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 206 {2.1}
280 – 520 {2.8 – 5.3}
210 {2.1}
—
—
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 206 {2.1}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 206 {2.1}
Min. 147 {Min. 1.5} Min. 98 {Min. 1.0}
78 {0.80} 69 {0.70}
Min. 100 {Min. 1.0}
70 {0.7}
—
—
Min. 147 {Min. 1.5} Min. 98 {Min. 1.0}
78 {0.80} 69 {0.70}
Min. 147 {Min. 1.5} Min. 98 {Min. 1.0}
78 {0.80} 69 {0.70}
90 – 110
120
80 – 110
120
90 – 110
120
90 – 110
120
Max. 0.5
1.0
Max. 0.5
1.0
Max. 0.5
1.0
Max. 0.5
1.0
21.6 – 22.4 {220 – 228}
18.0 {184}
24.0 – 25.0 {245 – 255}
21.0 {215}
21.6 – 22.4 {220 – 228}
18.0 {184}
21.6 – 22.4 {220 – 228}
18.0 {184}
16 – 18
16 – 18
14
—
17 – 19
17 – 19
17 – 19
17 – 19
—
—
0.10 {1.0}
0.10 {1.0}
—
—
—
—
1,690 – 1,790
1,690 – 1,790
2,300
2,300
1,630 – 1,730
1,630 – 1,730
9.5 – 12.7
11 – 15
9.5 – 12.7
9.5 – 12.7
9.5 – 12.7
11 – 15
9.5 – 12.7
11 – 15
102 SERIES
12-209 (23)
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TESTING AND ADJUSTING
102-2 SAA4D102E-2
Engine model Applicable machine model
Cooling system
Fuel system
Lubrication system
Engine proper
Intake, exhaust system
Performance
Category
item
Measurement conditions
D31EX-21, D31PX-21
D37EX-21, D37PX-21
Unit
Standard value
Permissible value
Standard value
Permissible value
Engine speed
High idling speed Low idling speed
rpm rpm
2,200 ± 50 800 +50 0
2,200 ± 50 800 +50 0
2,200 ± 50 800 +50 0
2,200 ± 50 800 +50 0
Nessary stating speed
0ºC (without starting aid) -20º (with starting aid)
rpm rpm
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Intake resistance
At all speed
Boost pressure Exhaust pressure (turbine inlet pressure) Exhaust temperature (turbine inlet temp.)
At rated flywheel horsepower
kPa {mmH2O} kPa {mmHg} kPa {mmHg}
Max. 3.72 {Max. 380} Min. 93 {Min. 700} Min. 120 {Min. 900}
7.47 {762} 81 {650} 106 {800}
Max. 3.72 {Max. 380} Min. 106 {Min. 800} Min. 120 {Min. 900}
7.47 {762} 100 {750} 106 {800}
ºC
Max. 650
700
Max. 650
700
Max. 4.5
6.0
Max. 4.0
6.0
Max. 2.0
3.0
Max. 2.0
3.0
Max. 1.0
2.0
Max. 1.0
2.0
mm mm
0.25 0.51
— —
0.25 0.51
— —
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Min. 2.41 {Min. 24.6}
1.69 {17.2}
At rated flywheel horsepower All speed (20ºC) Quick acceleration (low idle → high idle)
Exhaust gas color
At rated flywheel horsepower
Bosch index
High idling speed Valve clearance (When engine is hot or cold)
Intake valve Exhaust valve
Compression pressure (SAE30 or SAE15W-40)
Oil temperature: 40 – 60ºC (engine speed)
MPa {kg/cm2} (rpm)
Blow-by pressure (SAE30 or SAE15W-40)
At rated flywheel horsepower (water temp. : Min. 70ºC)
kPa {mmH2O}
Max. 0.49 {Max. 50}
0.98 {100}
Max. 0.49 {Max. 50}
0.98 {100}
At rated flywheel horsepower SAE 30 or SAE15 W–40 oil
kPa {kg/cm2} kPa {kg/cm2}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 206 {2.1}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 206 {2.1}
kPa {kg/cm2} kPa {kg/cm2}
Min. 147 {Min. 1.5} Min. 98 {Min. 1.0}
78 {0.80} 69 {0.70}
Min. 147 {Min. 1.5} Min. 98 {Min. 1.0}
78 {0.80} 69 {0.70}
Oil pressure (oil temperature : Min. 80ºC)
SAE10W oil At low idling SAE 30 or SAE15 W–40 oil SAE 10W oil
Oil temperature
All speed (Oil in oil pan)
ºC
90 – 110
120
90 – 110
120
Oil consumption ratio
At continuous rated horsepower (Ratio for fuel consumption)
%
Max. 0.2
0.6
Max. 0.2
0.6
Fuel injection pressure
Nozzle tester
MPa {kg/cm2}
22 0 +15 {224 0 }
18.0 {184}
22 0 +15 {224 0 }
Fuel injection timing
B. T. D. C
degree
Radiator pressure valve
Opening pressure (Differential pressure)
kPa {kg/cm2}
—
—
—
—
Fan speed
At rated engine speed
rpm
1,660 ± 50
1,660 ± 50
1,660 ± 50
1,660 ± 50
Fan belt tension
Deflection when pushed with a force of 60N {6 kg}
mm
(Auto-tension)
—
(Auto-tension)
—
12-220 (19)
+1.4
+1.4
—
18.0 {184} —
102 SERIES
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TESTING AND ADJUSTING
SAA4D102E-2 WA150-5 Standard value
Permissible value
2,250 ± 50 825 ± 50
2,250 ± 50 825 ± 50
Min. 170 Min. 120
Min. 170 Min. 120
Max. 3.72 {Max. 380} Min. 106 {Min. 800} Min. 120 {Min. 900} Max. 650
7.47 {762} 93 {700} 106 {800} 700
Max. 4.0
6.0
Max. 1.5
2.5
Max. 0.5
1.5
0.25 0.51
— —
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Max. 0.49 {Max. 50}
0.98 {100}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 210 {2.1}
Min. 147 {Min. 1.5} Min. 98 {Min. 1.0}
78 {0.80} 69 {0.70}
90 – 110
120
Max. 0.2
0.6
+1.4
22 0 +15 {224 0 }
18.0 {184}
11 ± 1
—
—
—
—
—
(Auto-tensioner)
—
102 SERIES
Standard value
Permissible value
Standard value
Permissible value
Standard value
Permissible value
12-221 (19)
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TESTING AND ADJUSTING
102-2 SAA4D102E-2
Engine model Applicable machine model
Cooling system
Fuel system
Lubrication system
Engine proper
Intake, exhaust system
Performance
Category
item
Measurement conditions
D39EX-21, D39PX-21 Unit
Standard value
Permissible value
Engine speed
High idling speed Low idling speed
rpm rpm
2,400 ± 50 800 +50 0
2,400 ± 50 800 +50 0
Nessary stating speed
0ºC (without starting aid) -20º (with starting aid)
rpm rpm
Min. 170 Min. 120
Min. 170 Min. 120
Intake resistance
At all speed
Boost pressure Exhaust pressure (turbine inlet pressure) Exhaust temperature (turbine inlet temp.)
At rated flywheel horsepower At rated flywheel horsepower All speed (20ºC)
kPa Max. 3.72 {mmH2O} {Max. 380} kPa Min. 133 {mmHg} {Min. 1,000} kPa Min. 153 {mmHg} {Min. 1,150} ºC
700
Max. 4.0
6.0
Exhaust gas color
At rated flywheel horsepower
Max. 2.0
3.0
Max. 1.0
2.0
mm mm
0.25 0.51
— —
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Bosch index
High idling speed Valve clearance (When engine is hot or cold)
Intake valve Exhaust valve
Compression pressure (SAE30 or SAE15W-40)
Oil temperature: 40 – 60ºC (engine speed)
MPa {kg/cm2} (rpm)
Blow-by pressure (SAE30 or SAE15W-40)
At rated flywheel horsepower (water temp. : Min. 70ºC)
kPa {mmH2O}
Max. 0.49 {Max. 50}
0.98 {100}
At rated flywheel horsepower SAE 30 or SAE15 W–40 oil
kPa {kg/cm2} kPa {kg/cm2}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 206 {2.1}
kPa {kg/cm2} kPa {kg/cm2}
Min. 147 {Min. 1.5} Min. 98 {Min. 1.0}
78 {0.80} 69 {0.70}
Oil pressure (oil temperature : Min. 80ºC)
SAE10W oil At low idling SAE 30 or SAE15 W–40 oil SAE 10W oil
Oil temperature
All speed (Oil in oil pan)
ºC
90 – 110
120
Oil consumption ratio
At continuous rated horsepower (Ratio for fuel consumption)
%
Max. 0.2
0.6
Fuel injection pressure
Nozzle tester
MPa {kg/cm2}
22 0 +15 {224 0 }
18.0 {184}
Fuel injection timing
B. T. D. C
degree
13 ± 1
—
Radiator pressure valve
Opening pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated engine speed
rpm
1,825 ± 55
—
Fan belt tension
Deflection when pushed with a force of 60N {6 kg}
mm
(Auto-tension)
—
12-221-1 (19)
+1.4
Permissible value
7.47 {762} 127 {950} 147 {1,100}
Max. 650
Quick acceleration (low idle → high idle)
Standard value
102 SERIES
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TESTING AND ADJUSTING
SAA4D102E-2 PC160LC-7
SAA6D102E-2 PC200-7, PC200LC-7
PC228US-3, PC228USLC-3
PC270-7, PC308USLC-3, BR380JG-1
Standard value
Permissible value
Standard value
Permissible value
Standard value
Permissible value
Standard value
2,490 ± 50 1,050 ± 50
2,490 ± 50 1,050 ± 50
2,200 ± 30 1,050 ± 25
2,200 ± 30 1,050 ± 25
2,200 ± 30 1,050 ± 25
2,200 ± 30 1,050 ± 25
2,330 _ 30
2,330 _ 30
1,050 ± 25
1,050 ± 25
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Max. 3.72 {Max. 380} Min. 120 {Min. 900} Min. 133 {Min. 1,000} Max. 650
7.47 {762} 113 {850} 127 {950} 700
Max. 3.72 {Max. 380} Min. 126 {Min. 950} Min. 120 {Min. 900}
7.47 {762} 113 {850} 106 {800}
Max. 3.72 {Max. 380} Min. 126 {Min. 950} Min. 120 {Min. 900}
7.47 {762} 113 {850} 106 {800}
Max. 3.72 {Max. 380} Min. 146 {Min. 1,100} Min. 133 {Min. 1,000}
7.47 {762} 133 {1,000} 120 {900}
Max. 650
700
Max. 650
700
Max. 675
700
Max. 4.5
6.5
Max. 5.5
7.5
Max. 5.5
7.5
Max. 5.5
7.5
Max. 1.5
2.5
Max. 21.5
2.5
Max. 21.5
2.5
Max. 1.5
2.5
Max. 1.0
2.0
Max. 0.5
1.5
Max. 0.5
1.5
Max. 0.5
1.5
0.25 0.51
— —
0.25 0.51
— —
0.25 0.51
— —
0.25 0.51
— —
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Max. 0.49 {Max. 50}
0.98 {100}
Max. 1.2 {Max. 123}
5.1 {520}
Max. 0.49 {Max. 50}
0.98 {100}
Max. 0.49 {Max. 50}
0.98 {100}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 206 {2.1}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 210 {2.1}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 210 {2.1}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 210 {2.1}
Min. 147 {Min. 1.5} Min. 98 {Min. 1.0}
78 {0.80} 69 {0.70}
Min. 150 {Min. 1.5} Min. 100 {Min. 1.0}
80 {0.80} 70 {0.70}
Min. 150 {Min. 1.5} Min. 100 {Min. 1.0}
80 {0.80} 70 {0.70}
Min. 150 {Min. 1.5} Min. 100 {Min. 1.0}
80 {0.80} 70 {0.70}
90 – 110
120
90 – 110
120
90 – 110
120
90 – 110
120
Max. 0.2
0.6
Max. 0.2
0.6
Max. 0.2
0.6
Max. 0.2
0.6
22 0 +15 {224 0 }
18.0 {184}
22 0 +15 {224 0 }
18.0 {184}
22 0 +15 {224 0 }
18.0 {184}
22 0 +15 {224 0 }
18.0 {184}
11 ± 1
—
11 ± 1
—
11 ± 1
—
11.5± 1
—
—
—
—
—
—
—
—
—
2,024 ± 60
2,024 ± 60
1,690 ± 50
1,690 ± 50
1,690 ± 50
1,690 ± 50
2,110 ± 50
2,110 ± 50
(Auto-tensioner)
—
(Auto-tensioner)
—
(Auto-tensioner)
—
(Auto-tensioner)
—
+1.4
102 SERIES
+1.4
+1.4
+70
+1.4
Permissible value +70
12-221-2 (22)
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TESTING AND ADJUSTING
SAA6D102E-2
Engine model
WA200-5, WA200PT-5
Applicable machine model
Engine proper
Intake, exhaust system
Performance
Category
item
Measurement conditions
Lubrication system Fuel system
Unit
Standard value
Permissible value
Standard value
Permissible vaalue
Engine speed
High idling speed Low idling speed
rpm rpm
2,250 ± 50 825 ± 50
2,250 ± 50 825 ± 50
2,250 ± 50 825 ± 50
2,250 ± 50 825 ± 50
Nessary stating speed
0ºC (without starting aid) -20º (with starting aid)
rpm rpm
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Intake resistance
At all speed
Boost pressure Exhaust pressure (turbine inlet pressure) Exhaust temperature (turbine inlet temp.)
At rated flywheel horsepower
kPa {mmH2O} kPa {mmHg} kPa {mmHg}
Max. 3.72 {Max. 380} Min. 93 {Min. 700} Min. 93 {Min. 700}
7.47 {762} 80 {600} 80 {600}
Max. 3.72 {Max. 380} Min. 120 {Min. 900} Min. 120 {Min. 900}
7.47 {762} 106 {800} 106 {800}
ºC
Max. 650
700
Max. 650
700
Max. 5.5
7.5
Max. 5.5
7.5
Max. 2.0
3.0
Max. 1.5
3.0
Max. 0.5
1.5
Max. 0.5
1.5
mm mm
0.25 0.51
— —
0.25 0.51
— —
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Min. 2.41 {Min. 24.6}
1.69 {17.2}
At rated flywheel horsepower All speed (20ºC) Quick acceleration (low idle → high idle)
Exhaust gas color
At rated flywheel horsepower
Bosch index
High idling speed Valve clearance (When engine is hot or cold)
Intake valve Exhaust valve
Compression pressure (SAE30 or SAE15W-40)
Oil temperature: 40 – 60ºC (engine speed)
MPa {kg/cm2} (rpm)
Blow-by pressure (SAE30 or SAE15W-40)
At rated flywheel horsepower (water temp. : Min. 70ºC)
kPa {mmH2O}
Max. 0.49 {Max. 50}
0.98 {100}
Max. 0.49 {Max. 50}
0.98 {100}
kPa {kg/cm2} kPa {kg/cm2}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 210 {2.1}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 210 {2.1}
kPa {kg/cm2} kPa {kg`/cm2}
Min. 150 {Min. 1.5} Min. 100 {Min. 1.0}
80 {0.80} 70 {0.70}
Min. 150 {Min. 1.5} Min. 70 {Min. 0.70}
80 {0.80} 70 {0.70}
At rated flywheel horsepower SAE 30 or SAE15 W–40 oil
Cooling system
WA250-5, WA250PT-5
Oil pressure (oil temperature : Min. 80ºC)
SAE10W oil At low idling SAE 30 or SAE15 W–40 oil SAE 10W oil
Oil temperature
All speed (Oil in oil pan)
ºC
90 – 110
120
90 – 110
120
Oil consumption ratio
At continuous rated horsepower (Ratio for fuel consumption)
%
Max. 0.2
0.6
Max. 0.2
0.6
Fuel injection pressure
Nozzle tester
MPa {kg/cm2}
22 0 +15 {224 0 }
18.0 {184}
22 0 +15 {224 0 }
18.0 {184}
Fuel injection timing
B. T. D. C
degree
11 ± 1
—
10 ± 1
—
Radiator pressure valve
Opening pressure (Differential pressure)
kPa {kg/cm2}
—
—
—
—
Fan speed
At rated engine speed
rpm
—
—
—
—
Fan belt tension
Deflection when pushed with a force of 60N {6 kg}
mm
(Auto-tension)
—
(Auto-tension)
—
12-222 (21)
+1.4
+1.4
102 SERIES
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TESTING AND ADJUSTING
SAA6D102E-2 WA320-5, WA320PT-5
GD555-3A, GD555-3C
BR120T-1
PC220-7, PC220LC-7
Standard value
Permissible value
Standard value
Permissible value
Standard value
Permissible value
Standard value
Permissible value
2,250 ± 50 900 ± 25
2,250 ± 50 900 ± 25
2,330 ± 50 1,050 ± 25
2,330 ± 50 1,050 ± 25
2,230 ± 50 850 ± 50
2,230 ± 50 850 ± 50
2,260 _ 20 1,050 ± 25
+80
2,260 _ 20 850 ± 50
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Min. 170 Min. 120
Max. 3.72 {Max. 380} Min. 120 {Min. 900} Min. 126 {Min. 950} Max. 675
7.47 {762} 106 {800} 113 {850} 700
Max. 4.5
6.5
Max. 5.5
Max. 2.0
3.0
Max. 0.5
+80
Max. 3.72 {Max. 380} Min. 146 {Min. 1,100} Min. 133 {Min. 1,000}
7.47 {762} 133 {1,000} 120 {900}
Max. 3.72 {Max. 380} Min. 146 {Min. 1,100} Min. 140 {Min. 1,050}
7.47 {762} 133 {1,000} 127 {950}
Max. 3.72 {Max. 380} Min. 140 {Min. 1,050} Min. 133 {Min. 1,000}
7.47 {762} 133 {1,000} 120 {900}
Max. 650
700
Max. 675
700
Max. 650
700
7.5
Max. 4.5
5.5
Max. 5.5
7.5
Max. 1.5
2.5
Max. 1.5
2.5
Max. 1.5
2.5
1.5
Max. 0.5
1.5
Max. 1.0
2.0
Max. 0.5
1.5
0.25 0.51
— —
0.25 0.51
— —
0.25 0.51
— —
0.25 0.51
— —
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Max. 0.49 {Max. 50}
0.98 {100}
Max. 0.49 {Max. 50}
0.98 {100}
Max. 0.49 {Max. 50}
0.98 {100}
Max. 0.49 {Max. 50}
0.98 {100}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 210 {2.1}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 210 {2.1}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 210 {2.1}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 210 {2.1}
Min. 150 {Min. 1.5} Min. 100 {Min. 1.0}
80 {0.80} 70 {0.70}
Min. 150 {Min. 1.5} Min. 100 {Min. 1.0}
80 {0.80} 70 {0.70}
Min. 150 {Min. 1.5} Min. 100 {Min. 1.0}
80 {0.80} 70 {0.70}
Min. 150 {Min. 1.5} Min. 100 {Min. 1.0}
80 {0.80} 70 {0.70}
90 – 110
120
90 – 110
120
90 – 110
120
90 – 110
120
Max. 0.2
0.6
Max. 0.2
0.6
Max. 0.2
0.6
Max. 0.2
0.6
22 0 +15 {224 0 }
18.0 {184}
22 +1.4 0 {224 +15 0 }
18.0 {184}
22 0 +15 {224 0 }
18.0 {184}
22 +1.4 0 {224 +15 0 }
18.0 {184}
11 ± 1
—
13 ± 1
—
10 ± 0.5
—
11 ± 1
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
2,060 ± 50
2,060 ± 50
(Auto-tension)
—
(Auto-tension)
—
(Auto-tension)
—
+1.4
102 SERIES
+1.4
(Auto-tension)
—
12-223 (20)
STANDARD VALUE TABLE FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TESTING AND ADJUSTING
SAA6D102E-2
Engine model
DCA-150ESK (DENYO generator)
Applicable machine model
Cooling system
Fuel system
Lubrication system
Engine proper
Intake, exhaust system
Performance
Category
item
Measurement conditions
Unit
Standard value
Permissible value Max. 1,580 Max. 1,890 800 ± 50
High idling speed
rpm
Low idling speed
rpm
Max. 1,580 Max. 1,890 800 ± 50
Nessary stating speed
0ºC (without starting aid) -20º (with starting aid)
rpm rpm
Min. 170 Min. 120
Min. 170 Min. 120
Intake resistance
At all speed
Boost pressure Exhaust pressure (turbine inlet pressure) Exhaust temperature (turbine inlet temp.)
At rated flywheel horsepower
kPa {mmH2O} kPa {mmHg} kPa {mmHg} ºC
Max. 3.72 {Max. 380} — — — — Max. 680
7.47 {762} — — — — 700
—
—
Max. 1.5
2.5
Max. 0.5
1.5
mm mm
0.25 0.51
— —
Min. 2.41 {Min. 24.6}
1.69 {17.2}
Engine speed
At rated flywheel horsepower All speed (20ºC) Quick acceleration (low idle → high idle)
Exhaust gas color
At rated flywheel horsepower
Bosch index
High idling speed Valve clearance (When engine is hot or cold)
Intake valve Exhaust valve
Compression pressure (SAE30 or SAE15W-40)
Oil temperature: 40 – 60ºC (engine speed)
MPa {kg/cm2} (rpm)
Blow-by pressure (SAE30 or SAE15W-40)
At rated flywheel horsepower (water temp. : Min. 70ºC)
kPa {mmH2O}
Max. 0.49 {Max. 50}
0.98 {100}
At rated flywheel horsepower SAE 30 or SAE15 W–40 oil SAE10W oil
kPa {kg/cm2} kPa {kg/cm2}
340 – 590 {3.5 – 6.0} 290 – 540 {3.0 – 5.5}
245 {2.5} 210 {2.1}
At low idling SAE 30 or SAE15 W–40 oil
kPa {kg/cm2}
Min. 150 {Min. 1.5}
80 {0.80}
SAE 10W oil
kPa {kg`/cm2}
Min. 100 {Min. 1.0}
70 {0.70}
Oil pressure (oil temperature : Min. 80ºC)
Oil temperature
All speed (Oil in oil pan)
ºC
90 – 110
120
Oil consumption ratio
At continuous rated horsepower (Ratio for fuel consumption)
%
Max. 0.5
1.0
+1.4 0 +15 0
Fuel injection pressure
Nozzle tester
MPa {kg/cm2}
22 {224
Fuel injection timing
B. T. D. C
degree
10.0 ± 1
—
Radiator pressure valve
Opening pressure (Differential pressure)
kPa {kg/cm2}
—
—
Fan speed
At rated engine speed
rpm
1,440 ± 40 (50Hz) 1,440 ± 40 (50Hz) 1,730 ± 50 (60Hz) 1,730 ± 50 (60Hz)
Fan belt tension
Deflection when pushed with a force of 60N {6 kg}
mm
(Auto-tension)
12-223-1 (21)
}
18.0 {184}
—
102 SERIES
TROUBLESHOOTING
S-1
S-1 Starting performance is poor (Starting always takes time) General causes why exhaust smoke comes out but engine takes time to start Defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel (At ambient temperature of -10ºC or below, ASTM D975 No. 2 diesel fuel is used)
Causes
n pi ston Defe ring , cyl ctive inde cont Clog r act o ged f val a i r ve, v clea Clog ner ged elem alve sea fuel t Clog ent filte ged r, st rain feed e Elec r p ump trica gau l int ze fi ake lter air h eate r
• • • •
fl Battery charging rate Ambient temperature
Charging rate
20°C 0°C –10°C
90 %
80 %
75 %
70 %
1.28 1.29 1.30
1.26 1.27 1.28
1.24 1.25 1.26
1.23 1.24 1.25
1.22 1.23 1.24
The specific gravity should exceed the value for the charging rate of 70% in the above table. In cold areas the specific gravity must exceed the value for the charging rate of 75% in the above table.
•
Wor
•
100 %
Questions
Confirm recent repair history Degree of use of machine
Operated for long period
Ease of starting
Gradually became worse Starts when warm
Indicator lamp does not light up Engine oil must be added more frequently Replacement of filters has not been carried out according to operation Manual Non-specified fuel has being used Dust indicator lamp is red Battery charge lamp is ON Starting motor cranks engine slowly When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Check items
Engine does not pick up smoothly, and combustion is irregular Blow-by gas is excessive Timing lock on fuel injection pump does not match Mud is stuck to fuel tank cap When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump piping sleeve nut is loosened 2) Little fuel comes out even when fuel filter air bleed plug is loosened Leakage from fuel piping There is hunting from engine (rotation is irregular) When compression pressure is measured, it is found to be low When air cleaner element is inspected directly, it is found to be clogged
Troubleshooting
When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged Heater mount does not become warm Is voltage 26–30V between alternator terminal B and terminal E with engine at low idling?
Yes No
Either specific gravity of electrolyte or voltage of battery is low Speed does not change when operation of certain cylinders is stopped When control rack is pushed, it is found to be heavy or does not return (check after removing fuel injection pump)
12-256 (17)
ª Use a test stand
Replace
Clean
Clean
Clean
Correct
Remedy
Replace
When fuel tank cap is inspected directly, it is found to be clogged
102 SERIES
102 SERIES
Replace
Replace
Clean
Correct
Replace
ªAdjust
Replace
Replace
Replace
Replace Defe ctive regu Defe lato ctive r a ltern Defe ator ctive or d Defe eter ctive iora ted injec Defe batt tion tive ery nozz injec le Defe tion tive timi injec ng Leak tion age, p ump clog (rac Clog ging k, pl ged , air ung a i i n r er st brea fuel Defe uck) ther pipi ctive ng h o f e l e in ed p Defe fuel ump ctive tank boo st co mpe nsat or c ance l
TROUBLESHOOTING S-1
Causes
12-257
(17)
S-7
TROUBLESHOOTING
S-7 Exhaust smoke is black (Incomplete combustion) General causes why exhaust smoke is black Insufficient intake of air Improper condition of fuel injection Excessive injection of fuel
Causes Seiz ed t urbo Clog cha rger ged , int air c Wor erfe lean renc n pi er e ston e lem Clog ent ring ged , cyl i i nde njec Imp r tion rope noz r inj zle, Defe ecti o ctiv n tim defecti e in ve s ing Imp ject pray i rope on p r u v m a Cru p l v ( e e she xces clea d, c ranc sive logg Lea e inje ed m kag ctio e of u n) f fler air b Defe e ctiv twe e en t con Defe urbo tact ctiv cha of v e in rger alve ject and and ion hea pum valv d e se p (ra at ck, p lung er s eize d)
• • •
Confirm recent repair history Degree of use of machine Operated for long period
Questions
Suddenly became black Color of exhaust gas
Gradually became black Blue under light load
Engine oil must be added more frequently Power was lost
Suddenly Gradually
Non-specified fuel is being used Noise of interference is heard from around turbocharger Dust indicator lamp is red Blow-by gas is excessive
Check items
Engine pickup is poor and combustion is irregular When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low Timing lock on fuel injection pump does not match Seal on injection pump has come off Clanging sound is heard from around cylinder head Exhaust noise is abnormal Muffler is crushed Leakage of air between turbocharger and head, loose clamp When turbocharger is rotated by hand, it is found to be heavy When air cleaner element is inspected directly, it is found to be clogged Troubleshooting
When compression pressure is measured, it is found to be low Speed does not change when operation of certain cylinders is stopped When check is made using delivery method, injection timing is found to be incorrect Injection pump test shows that injection amount is incorrect When valve clearance is checked directly it is found to be outside standard value When muffler is removed, exhaust color returns to normal
102 SERIES
Replace
Replace
Correct
Replace
Adjust
Adjust
Adjust
Replace
Replace
Clean
Remedy
Replace
When control rack is pushed, it is found to be heavy, or does not return
12-265 (19)
TROUBLESHOOTING
S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive Abnormal combustion of oil External leakage of oil Wear of lubrication system
Bro
• • •
Causes
ken pist on r Wor ing n pi ston Clog ring ged , cyl inde brea Lea r (lin ther kag er le or b e fro ss e reat Lea mo ngin her kag il fil h e) e fro ose ter o mo Lea r o i l co il pi kag ping e fro oler mo Lea kag il dr e fro ain plug mo Bro ken il pa oil c n or oole Wor cylin r n se der al a hea t tur Wor d bine n se a e l n at b d Wor low n, b er e roke nd n re Dus Turb ar s t su eal, cked och seal arge Wor in fr surf r n va om ace inta lve (ste ke s m, g yste uide m ), br oke n se al
fl Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling)
Confirm recent repair history Degree of use of machine Operated for long period
Questions
Oil consumption suddenly increased Engine oil must be added more frequently Engine oil becomes contaminated quickly Exhaust smoke is blue under light load Amount of blow-by gas
Excessive None
Area around engine is dirty with oil Check items
There is oil in engine cooling water When exhaust pipe is removed, inside is found to be dirty with oil When turbocharger air supply pipe is removed, inside is found to be dirty with oil Oil level in clutch or TORQFLOW transmission damper chamber rises Clamps for intake system are loose
Troubleshooting
When compression pressure is measured, it is found to be low When breather element is inspected, it is found to be clogged with dirty oil There is external leakage of oil from engine Pressure-tightness test of oil cooler shows there is leakage Excessive play of turbocharger shaft Inspect rear seal directly When intake manifold is removed, dust is found inside
12-266 0
Correct
Correct
Correct
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Replace
Remedy
Replace
When intake manifold is removed, inside is found to be dirty with oil
102 SERIES
DISASSEMBLY AND ASSEMBLY
13 DISASSEMBLY AND ASSEMBLY Special tool list ............................................... 13- 6 Special tools for disassembly and assembly ........................................... 13- 6 Special tools for engine ............................. 13- 8 Special tools for fuel system ..................... 13-10 Outline of disassembly and assembly of engine ....................................................... 13-12 Outline ........................................................ 13-12 Disassembly ............................................... 13-12 Assembly .................................................... 13-12 Disassembly of engine ................................... 13-13 Steam cleaning of engine ......................... 13-13 Removal of starting motor ........................ 13-13 Weight of engine ........................................ 13-13 Installation to engine stand ....................... 13-13 Draining oil ................................................. 13-14 Removal of rear lifting bracket ................. 13-14 Removal of belt .......................................... 13-14 Removal of fan pulley ................................ 13-15 Removal of vibration damper, crankshaft pulley ...................................... 13-15 Removal of belt tensioner ......................... 13-15 Removal of fan hub ................................... 13-16 Removal of alternator ................................ 13-16 Removal of thermostat .............................. 13-17 Removal of turbocharger (engine with turbocharger) ..................... 13-17 Removal of exhaust manifold ................... 13-19 Removal of fuel filter ................................. 13-19 Removal of fuel filter head ........................ 13-20 Removal of fuel piping .............................. 13-20 Removal of dipstick ................................... 13-22 Removal of intake manifold cover ............ 13-22 Removal of after cooler (engine with after cooler) ........................ 13-23 Removal of cylinder head cover ............... 13-23 Removal of fuel injection nozzle ............... 13-23 Removal of rocker lever ............................ 13-24 Removal of push rod ................................. 13-25 Removal of cylinder head ......................... 13-25 Removal of front cover .............................. 13-25 Removal of water pump ............................ 13-26 Removal of flywheel .................................. 13-26 Removal of flywheel housing ................... 13-27 Removal of components (compressor, hydraulic pump, etc.) ........ 13-27 102 SERIES
Removal of fuel injection pump (Bosch A, Zexle A) .................................. 13-27 Removal of feed pump (engine mount type) .............................. 13-30 Removal of tappet cover ......................... 13-30 Removal of oil filler .................................. 13-30 Removal of coolant heater (If applicable) .......................................... 13-30 Removal of oil cooler ............................... 13-31 Removal of water inlet ............................ 13-31 Removal of oil pan heater (If applicable) .......................................... 13-31 Removal of oil pan ................................ 13-31-1 Removal of oil pan suction tube .......... 13-31-1 Removal of rear seal cover ..................... 13-32 Removal of camshaft ............................... 13-32 Removal of tappet .................................... 13-34 Removal of oil pump ............................... 13-34 Removal of timing pin housing .............. 13-35 Removal of gear housing ........................ 13-35 Removal of balancer ................................ 13-36 Removal of piston connecting rod ......... 13-38 Removal of crankshaft ............................. 13-40 Removal of turbocharger lubrication drain tube ............................ 13-42 Removal of cylinder block from engine stand .................................. 13-42 Assembly of engine ..................................... 13-43 Preparation for assembly of cylinder block ..................................... 13-43 Installation of tappet ................................ 13-43 Installation of crankshaft ......................... 13-44 Installation of piston and connecting rod assemblies ................... 13-48 Installation of piston and connecting rod assembly ...................... 13-48 Installation of gear housing .................... 13-52 Installation of oil pump ........................... 13-53 Installation of camshaft ........................... 13-54 Installation of timing pin ......................... 13-57 Installation of balancer ............................ 13-60 Installation of rear oil seal ....................... 13-64 Installation of oil pan suction tube ......... 13-65 Installation of oil pan ............................... 13-66 Installation of oil pan heater (If applicable) .......................................... 13-67
13-1 (23)
DISASSEMBLY AND ASSEMBLY Installation of oil cooler ........................... 13-67 Installation of coolant heater (If applicable) ....................................... 13-67-1 Installation of oil filler port ................... 13-67-1 Installation of feed pump ........................ 13-68 Installation of tappet cover ..................... 13-68 Installation of fuel injection pump (Bosch A, Zexel A) .................................. 13-69 Installation of components (compressor, hydraulic pump, etc.) ...... 13-74 Installation of flywheel housing ............. 13-74 Installation of flywheel ............................ 13-75 Installation of water pump ...................... 13-76 Installation of front cover ........................ 13-76 Installation of cylinder head .................... 13-78 Installation of push rod ........................... 13-79 Installation of rocker lever ....................... 13-79 Tightening of cylinder head .................... 13-81 Adjusting valve clearance ....................... 13-83 Installation of fuel injection nozzle ......... 13-85 Installation of cylinder head cover ......... 13-86 Installation of intake manifold cover ...... 13-86 Installation of fuel filter head .................. 13-88 Installation of exhaust manifold ............. 13-89 Installation of turbocharger (engine with turbocharger) ................... 13-90 Installation of thermostat ........................ 13-93 Installation of crankshaft pulley, vibration damper ................................... 13-94 Installation of fan hub .............................. 13-94 Installation of belt tensioner ................... 13-94 Installation of water inlet ......................... 13-95 Installation of alternator .......................... 13-95 Installation of belt .................................... 13-96 Installation of oil filter .............................. 13-97 Removal of engine from engine stand ... 13-97 Installation of starting motor .................. 13-97 Intake group .................................................. 13-98 Disassembly and assembly drawing ...... 13-98 Outline .................................................... 13-100 Replacement of turbocharger (engine with turbocharger) ...................... 13-101 Removal .................................................. 13-101 Installation .............................................. 13-102 Cleaning and inspection ........................ 13-104 Replacement of aftercooler, gasket (engine with aftercooler) ..................... 13-106 Removal .................................................. 13-106 Cleaning .................................................. 13-106 Installation .............................................. 13-107 Cleaning and inspection ........................ 13-108 Assembly ................................................ 13-108 Replacement of intake connector ............. 13-109 Removal and installation ....................... 13-109 Air connector .............................................. 13-109 Cleaning .................................................. 13-109 Inspection ............................................... 13-109 Replacement of intake manifold cover, gasket ............................. 13-109
13-2 (23)
Removal .................................................. 13-110 Cleaning .................................................. 13-110 Installation .............................................. 13-110 Air crossover tube ...................................... 13-111 Cleaning .................................................. 13-111 Inspection ............................................... 13-111 Exhaust group ............................................ 13-112 Disassembly and assembly drawing .... 13-112 Outline of exhaust manifold ................. 13-113 Replacement of exhaust manifold, gasket ....................................... 13-114 Removal .................................................. 13-114 Cleaning and inspection ........................ 13-114 Installation .............................................. 13-114 Replacement of exhaust manifold .......... 13-115 Removal .................................................. 13-115 Cleaning .................................................. 13-115 Installation .............................................. 13-116 Inspection ............................................... 13-116 Replacement of turbocharger ................... 13-117 Removal .................................................. 13-117 Installation .............................................. 13-118 Turbocharger mounting stud (engine with turbocharger) ...................... 13-121 Replacement ........................................... 13-121 Cylinder block group .................................. 13-122 Disassembly and assembly drawing .... 13-122 Outline of cylinder block group ............ 13-125 Outline of camshaft ............................... 13-125 Outline of crankshaft ............................. 13-125 Outline of cylinder block ....................... 13-125 Outline of oil seal ................................... 13-125 Replacement of front oil seal .................. 13-126 Removal .................................................. 13-126 Cleaning and inspection ........................ 13-127 Installation .............................................. 13-127 Replacement of rear oil seal .................... 13-129 Outline of piston .................................... 13-131 Outline of vibration damper .................. 13-131 Check list for cylinder block group ....... 13-132 Cylinder block ............................................. 13-133 Inspection before disassembly ............. 13-133 Disassembly of cylinder block .............. 13-133 Cleaning of cylinder block ..................... 13-135 Inspection of cylinder block .................. 13-138 Removal of glaze from cylinder bore ..... 13-140 Disassembly ........................................... 13-140 Inspection ............................................... 13-141 Removal of glaze .................................... 13-141 Cleaning .................................................. 13-144 Assembly ................................................ 13-145 Removal of glaze from cylinder block ...... 13-146 Replacement of plug ................................ 13-149 Removal .................................................. 13-149 Cleaning and inspection ........................ 13-149 Installation .............................................. 13-150 Replacement of cap .................................. 13-150 Removal .................................................. 13-150 Cleaning .................................................. 13-151 102 SERIES
DISASSEMBLY AND ASSEMBLY Installation .............................................. 13-151 Installation of cup plug .......................... 13-152 Installation of cap and plug ..................... 13-154 Installation of camshaft cup .................. 13-156 Installation of camshaft bushing .......... 13-157 Replacement of dipstick tube ................ 13-158 Storing cylinder block ............................ 13-159 Crankshaft ................................................... 13-159 Replacement of main bearing ............... 13-160 Cleaning of crankshaft ........................... 13-165 Installation of crankshaft ....................... 13-165 Replacement of crankshaft gear ........... 13-166 Replacement of camshaft and tappet .. 13-168 Removal of camshaft ............................. 13-168 Removal of tappet .................................. 13-169 Inspection of tappet ............................... 13-171 Standards for pitting when reusing ..... 13-173 Standard for deterioration (breakage) of tip ...................................................... 13-174 Inspection of camshaft bore ................. 13-177 Replacement of camshaft bushing ......... 13-177 Installation of tappet .............................. 13-178 Installation of camshaft ......................... 13-181 Cleaning of camshaft ............................... 13-183 Inspection of camshaft, gear ................. 13-184 Replacement of camshaft, gear ................ 13-186 Cleaning and inspection ........................ 13-187 Installation .............................................. 13-188 Replacement of timing pin ........................ 13-190 Replacement of gear housing, gasket ...... 13-191 Removal .................................................. 13-191 Cleaning and inspection ........................ 13-192 Repair of oil pan gasket ......................... 13-192 Installation .............................................. 13-193 Repositioning of timing pin .................. 13-196 Replacement of camshaft gear ............... 13-201 Removal .................................................. 13-201 Installation (shrink-fitting method) ....... 13-202 Installation (method using special tool) ................ 13-203 Installation of camshaft mounting bolts ..................................... 13-205 Replacement of vibration damper, crankshaft pulley ...................................... 13-206 Removal .................................................. 13-206 Inspection of rubber damper ................ 13-206 Installation .............................................. 13-207 Inspection of viscous damper ............... 13-207 Vibration damper (rubber type) ............ 13-209 Cleaning and inspection ........................ 13-209 Piston, pin, connecting rod ........................ 13-211 Replacement of piston and ring ........... 13-211 Removal of piston connecting rod ....... 13-212 Disassembly of piston connecting rod ..................................... 13-214 Cleaning of piston, pin, connecting rod ..................................... 13-214 Inspection of piston ............................... 13-215 Inspection of piston pin ......................... 13-216 102 SERIES
Assembly of piston connecting rod ..... 13-217 Inspection of piston ring gap ................ 13-218 Installation of piston ring ...................... 13-219 Installation of piston connecting rod ... 13-220 Replacement of connecting rod .............. 13-224 Removal .................................................. 13-224 Cleaning and inspection ........................ 13-225 Installation .............................................. 13-227 Replacement of connecting rod bearing ........................................... 13-228 Removal .................................................. 13-228 Cleaning and inspection ........................ 13-230 Installation .............................................. 13-231 Disassembly of piston connecting rod ..................................... 13-234 Cleaning of piston, pin, connecting rod ..................................... 13-235 Inspection of piston ............................... 13-236 Inspection of piston pin ......................... 13-237 Inspection of connecting rod ................ 13-237 Inspection of connecting rod bearing clearance .......................... 13-237 Assembly of piston connecting rod ..... 13-238 Inspection of piston ring end gap ......... 13-239 Installation of piston ring ...................... 13-240 Balancer ...................................................... 13-241 Disassembly ........................................... 13-241 Assembly ................................................ 13-244 Gear housing .............................................. 13-251 Replacement of gear cover ...................... 13-251 Removal .................................................. 13-251 Cleaning and inspection ........................ 13-252 Installation .............................................. 13-252 Installation of gear cover ....................... 13-254 Inspection of gear housing and timing pin ...................................... 13-256 Disassembly of gear housing ............... 13-256 Replacement of fuel injection pump mounting stud ........................... 13-257 Replacement of engine name plate ...... 13-257 Cylinder head .............................................. 13-260 Disassembly and assembly drawing .... 13-260 Outline ....................................................... 13-262 Replacement of cylinder head ................. 13-263 Removal .................................................. 13-263 Inspection before disassembly of cylinder head ................................... 13-266 Disassembly of cylinder head ............... 13-267 Cleaning of cylinder head ..................... 13-268 Inspection of valve ................................. 13-270 Inspection of valve guide ...................... 13-271 Inspection of cylinder deck ................... 13-271 Inspection of valve seat ......................... 13-272 Standards for cracks in cylinder head when reusing .............................. 13-272 Replacement of valve spring ................ 13-273 Assembly of cylinder head .................... 13-273 Installation of cylinder head .................. 13-274 Adjusting valve clearance ..................... 13-278
13-3 (23)
DISASSEMBLY AND ASSEMBLY
Installation of themostat ....................... 13-279 Installation of fan hub ............................ 13-279 Installation of belt tensioner ................. 13-280 Installation of alternator ........................ 13-280 Installation of drive belt ......................... 13-281 Inspection before disassembly ............. 13-281 Disassembly of cylinder head ............... 13-282 Cleaning of cylinder head ..................... 13-283 Inspection of valve ................................. 13-285 Inspection of valve guide ...................... 13-286 Inspection of cylinder head combustion deck .................................. 13-286 Inspection valve seat ............................. 13-287 Standards for cracks in cylinder head when reusing ........... 13-287 Replacement of valve spring ................ 13-288 Replacement of cap ............................... 13-288 Polishing valve ....................................... 13-290 Polishing valve seat ............................... 13-291 Calculating grinding depth and measuring depth of valve ................... 13-292 Assembly of cylinder head .................... 13-296 Rocker lever ................................................ 13-298 Disassembly and assembly drawing .... 13-298 Outline .................................................... 13-300 Replacement of rocker lever and push rod ........................................ 13-301 Removal .................................................. 13-301 Disassembly of rocker lever .................. 13-302 Cleaning of rocker lever ........................ 13-303 Inspection of rocker lever ...................... 13-303 Assembly of rocker lever ....................... 13-304 Installation of rocker lever ..................... 13-305 Disassembly of rocker lever .................. 13-307 Cleaning of rocker lever, rocker lever shaft ................................. 13-308 Inspection of rocker lever ...................... 13-308 Inspection of rocker lever shaft ............ 13-309 Assembly of rocker lever ....................... 13-309 Tappets and push rods ............................... 13-311 Disassembly and assembly drawing .... 13-311 Outline .................................................... 13-312 Cleaning of push rod ................................ 13-313 Inspection of push rod ........................... 13-313 Installation of push rod ......................... 13-313 Inspection of tappet ............................... 13-314 Engine mount group .................................. 13-316 Outline of flywheel housing .................. 13-316 Outline of flywheel, ring gear ............... 13-316 Outline of front support ......................... 13-316 Flywheel, ring gear ..................................... 13-317 Inspection of flywheel, ring gear .......... 13-317 Replacement of flywheel, ring gear ..... 13-317 Flywheel housing ....................................... 13-319 Replacement of rear oil seal .................... 13-319 Removal .................................................. 13-319 Cleaning and inspection ........................ 13-321
13-4 (23)
Installation ............................................ 13-321 Replacement of flywheel housing ........ 13-324 Removal ................................................ 13-324 Cleaning and inspection ...................... 13-325 Installation (dry clutch specification) ................... 13-326 Inspection of radial runout of flywheel housing ........................... 13-327 Inspection of face runout of flywheel housing ........................... 13-329 Installation (wet clutch specification) . 13-330 Inspection ............................................. 13-332 Installation ............................................ 13-333 Front support ............................................ 13-334 Cleaning and inspection ...................... 13-334 Removal of engine ................................... 13-335 Inspection of engine mount .................... 13-337 Installation of engine ............................... 13-338 Oil pan and suction tube .......................... 13-342 Disassembly and assembly drawing ... 13-342 Replacement of oil pan, suction tube, gasket ............................... 13-343 Cleaning and inspection ...................... 13-345 Regulator valve ......................................... 13-346 Replacement of regulator valve, spring ................................................. 13-346 Cleaning and inspection ...................... 13-346 Oil filter bypass valve ............................... 13-349 Replacement ......................................... 13-349 Oil cooler ................................................... 13-350 Disassembly and assembly drawing ... 13-350 Replacement of oil cooler core, gasket .................................................. 13-351 Cleaning ................................................ 13-353 Inspection ............................................. 13-354 Oil pump ................................................... 13-355 Disassembly and assembly drawing ... 13-355 Replacement of oil pump .................... 13-356 Cleaning and inspection ...................... 13-357 Installation of oil pump ....................... 13-360 Inspection ............................................. 13-361 Fuel injection pump group ...................... 13-365 Disassembly and assembly drawing ... 13-365 Fuel injection nozzle group ...................... 13-366 Disassembly ......................................... 13-367 Cleaning and inspection ...................... 13-368 Assembly .............................................. 13-370 Feed pump (cylinder block mount type) ................... 13-373 Replacement of feed pump (diaphragm type) ............................... 13-373 Replacement, assembly of feed pump (piston type) .......................................... 13-375 Removal ................................................ 13-375 Cleaning ................................................ 13-376 Assembly .............................................. 13-376 Installation ............................................ 13-377 102 SERIES
DISASSEMBLY AND ASSEMBLY
Cleaning and inspection ...................... 13-377 Assembly (piston type) ........................ 13-379 Cleaning ................................................ 13-379 Assembly .............................................. 13-380 Replacement of fuel filter ........................ 13-380 Fuel piping ................................................ 13-382 Replacement of high-pressure fuel piping (Bosch VE, Lucas CAV) ..... 13-382 Replacement of fuel supply piping (Bosch VE, Lucas CAV) ...................... 13-383 Cleaning and inspection of high-pressure fuel piping .............. 13-385 Replacement of fuel return piping (Bosch VE, Lucas CAV) ...................... 13-386 Cleaning and inspection of fuel drain piping ............................ 13-388 Replacement of low-pressure fuel piping (Bosch VE, Lucas CAV) ... 13-388 Cleaning and inspection of low-pressure fuel piping ............... 13-389 Replacement of air-fuel ratio control tube (Bosch VE) ............ 13-390 Water pump .............................................. 13-391 Disassembly and assembly drawing ... 13-391 Replacement of water pump ............... 13-392 Inspection ............................................. 13-393 Fan hub ..................................................... 13-393 Replacement of fan pulley .................. 13-393 Replacement of fan hub ...................... 13-394 Inspection ............................................. 13-394 Disassembly ......................................... 13-395 Assembly .............................................. 13-396 Belt tensioner ............................................ 13-398 Disassembly and assembly drawing ... 13-398 Replacement of belt ............................. 13-399 Replacement of belt tensioner ............ 13-399 Inspection ............................................. 13-399 Thermostat ................................................ 13-400 Disassembly and assembly drawing ... 13-400 Replacement of thermostat ................. 13-401 Inspection ............................................. 13-402 Fan ............................................................. 13-404 Coolant ...................................................... 13-404 Accessory drive adapter .......................... 13-406 Disassembly and assembly drawing ... 13-406 Cleaning ................................................ 13-407 Inspection ............................................. 13-407 Disassembly ......................................... 13-407 Assembly .............................................. 13-408 Disassembly of unloader valve, cylinder head ...................................... 13-410 Cleaning ................................................ 13-411 Inspection ............................................. 13-412 Assembly .............................................. 13-416 Replacement air compressor .............. 13-419 Removal ................................................ 13-419 Inspection ............................................. 13-420 102 SERIES
Installation ............................................ 13-422 Cleaning and inspection ...................... 13-424 Inspection ............................................. 13-424 Alternator .................................................. 13-425 Replacement of alternator ................... 13-425 Inspection ............................................. 13-426 Starting motor .......................................... 13-426 Inspection ............................................. 13-427
13-5 (23)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF ENGINE
DISASSEMBLY OF ENGINE STEAM CLEANING OF ENGINE Warning: When cleaning with steam, wear protective clothing, safety glasses, and face shield. Hot steam may cause serious burns. Caution: Fit covers to the openings of the engine and to the electrical components, and be careful not to get water on these parts. Use steam to clean off any excessive dirt on the outside of the engine.
REMOVAL OF STARTING MOTOR 10 mm Remove the starting motor.
WEIGHT OF ENGINE (REFERENCE VALUE NOT INCLUDING AUXILIARIES SUCH AS MUFFLER) 3822512 Engine lifting equipment
0 4D102 engine (wet): 325 - 350 kg 0 6D102 engine (wet): 410 - 440 kg
INSTALLATION TO ENGINE STAND 18 mm, engine rebuilding stand, adapter (795799-1160) Install the engine to the rebuilding stand. 3 : 77 Nm{7.9 kg} Installation hardware: M12 x 1.75
102 SERIES
13-13 2
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF ENGINE
DRAINING OIL 22 mm Remove the drain plug. A drain pan with a 30 liter capacity is sufficient.
REMOVAL OF REAR LIFTING BRACKET 18 mm Remove the rear lifting bracket from the cylinder head.
REMOVAL OF BELT If excessive force is applied to the tensioner in the opposite direction from winding in or when the tensioner has been wound in to the normal stop position, there is danger that the tensioner arm may break. Warning : Make sure that the wrench is secured at the portion square hole before rotating it. (The spring of the tensioner is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) : After removing the drive belt, return the tensioner slowly with care. : Be careful not to get your fingers caught between the pulley and drive belt during work. Caution: Do not put your hand near the path of the tensioner when it is under the force of the spring. Loosen the tension with a 1/2 inch or 3/8 inch square headed wrench, then remove the drive belt. Operating hint: Remove the drive belt after loosening the vibration damper crankshaft and hub pulley mounting bolt.
13-14 (21)
102 SERIES
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF ENGINE
REMOVAL OF FEED PUMP (ENGINE MOUNT TYPE) 10 mm Remove the fuel feed pump, spacer, and gasket. Caution: For details of the procedure for testing the fuel feed pump, see Component.
REMOVAL OF TAPPET COVER 10 mm Remove the tappet cover and gasket.
REMOVAL OF OIL FILLER 18 mm If it is installed, remove the mounting bolts, side oil filler assembly, and rectangular ring seal. On some engines, the oil drain connection for the air compressor is also installed at this position. Remove the connection and the rectangular ring seal.
REMOVAL OF COOLANT HEATER (IF APPLICABLE) Remove the coolant heater from the block.
13-30 (23)
102 SERIES
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF ENGINE
REMOVAL OF OIL COOLER 90 - 95 mm {3-1/2 - 3-7/8 in} filter wrench Remove the oil filter cartridge.
10 mm Remove the mounting bolts, oil cooler cover, cover gasket, oil cooler, and cooler gasket. Caution: For details of the procedure for inspection, see Component.
REMOVAL OF WATER INLET 13 mm Remove the coolant inlet port connection and rectangular ring seal.
REMOVAL OF OIL PAN HEATER (IF APPLICABLE) Remove the heater element.
102 SERIES
13-31 (23)
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF ENGINE
REMOVAL OF OIL PAN 10 mm Rotate the engine on the stand and remove the oil pan.
REMOVAL OF OIL PAN SUCTION TUBE 10 mm Remove the suction tube and gasket.
13-31-1 (23)
102 SERIES
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF ENGINE
22 mm Install the drain plug and a new sealing washer. 3 : 102-1: 80 Nm {8.2 kgm} 102-2: 59 Nm {6 kgm}
INSTALLATION OF OIL PAN HEATER (IF APPLICABLE) Install the heater element. 3 : 80 Nm {8.2 kgm}
INSTALLATION OF OIL COOLER Caution: When installing a new element, always remove the transportation plug. Insert two mounting bolts from the oil cooler cover. Assemble the cooler cover gasket, oil cooler gasket, and oil cooler cover.
10 mm Install the assembly to the cylinder block. 3: 24 Nm {2.4 kgm}
102 SERIES
13-67 (23)
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF ENGINE
INSTALLATION OF COOLANT HEATER (IF APPLICABLE) Apply pipe sealant (part number 3375066 or the equivalent) to threads of the coolant heater. Install the coolant heater. 3 : 55 Nm {5.6 kgm}
INSTALLATION OF OIL FILLER PORT 15 mm If it is installed to the side, install the chamfered oil filler port assembly and O-ring. 3: 43 Nm {4.4 kgm}
13-67-1 (23)
102 SERIES
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF ENGINE
13 mm Set the belt tensioner on the bracket and secure it with the mounting bolts. 3: 43 Nm {4.4 kgm} Caution: There are also tensioners that are tightened by bolts to the bracket at two places. Install to the specified position.
INSTALLATION OF WATER INLET Caution: Do not tighten at this point. Avoid radial misalignment and overload on the bottom support mounting gear on the alternator. Leave the mounting bolts loosened until the alternator parts are installed. Install the cooling water inlet port connection and sealing ring.
INSTALLATION OF ALTERNATOR 10 mm Assemble the alternator bracket to the thermostat housing. 3: 24 Nm {2.4 kgm}
Set the alternator on the bracket, and secure with the mounting bolts and spacers. Do not tighten at this point.
102 SERIES
13-95 2
DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF ENGINE
Caution: Do not tighten at this point. Avoid radial runout and overload on the bottom support mounting lug of the alternator. Leave the mounting bolts loosened until the alternator parts are installed. Install the alternator link.
Check the alternator pulley visually or use a straight edge to check if the center is aligned with the other pulleys and that it is parallel to the front face of the block. After assembling all parts, tighten the mounting bolts in the following order. 1. Alternator bracket mounting bolts for alternator 2. Alternator mounting bolts for bottom brace 3. Cooling water inlet port mounting bolts for alternator 4. Block mounting bolts for cooling water inlet port Caution: The size of the wrench and the torque value depend on the alternator manufacturer and the model. For details of the torque value, see Engine Components.
INSTALLATION OF BELT 3/8 inch square drive Raise the tensioner and install the belt. Warning : Make sure that the wrench is secured at the portion square hole before rotating it. (The spring of the tensioner is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) : After removing the drive belt, return the tensioner slowly with care. : Be careful not to get your fingers caught between the pulley and drive belt during work. Operating hint: If it is difficult to install the drive belt (the belt may be too short), set the belt on top of the grooved pulley and support the tensioner while sliding the belt over the water pump pulley.
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102 SERIES
DISASSEMBLY AND ASSEMBLY
CYLINDER BLOCK GROUP
OUTLINE OF CYLINDER BLOCK GROUP There are two types of engines in the 102 series: the 4-cylinder engine and the 6-cylinder engine. Most of the parts are common for both the 4-cylinder engine and 6-cylinder engine (for example, pistons, rings, connecting rods, water pump) Generally speaking, the parts that are different for the 4-cylinder engine and 6-cylinder engine are the parts that differ because of the different number of cylinders (for example, crankshaft, block casting, cylinder head)
OUTLINE OF CAMSHAFT
OUTLINE OF OIL SEAL The crankshaft seals on the 102 series engines all are of the Teflon lay-down lip (scroll) type. With this type of seal, there is no spring behind the sealing lip. The seal lip is a thin but sturdy Teflon piece. Dry the Teflon seal before installing it. Do not add oil to the seal lip or shaft. If the shaft is rotated 2 or 3 turns, a thin film of Teflon will flow out from the seal lip to the shaft. If the shaft or seal are not cleaned and dry, there will be no flow of Teflon and this will result in leakage from the seal.
The end clearance of the camshaft is determined by the clearance between the camshaft and the thrust plate. Replace the camshaft if it is worn or if the fuel feed pump lobe or valve lobe are worn. We do not recommend grinding of the camshaft lobe.
OUTLINE OF CRANKSHAFT The crankshaft is a balanced, forged steel unit with hardening treatment given for the whole thickness. The crankshaft for the 4-cylinder engine has 5 main bearing journals and the crankshaft for the 6-cylinder engine has 7 main bearing journals. Except for the No. 4 journal, which has an upper bearing shell with a flange, all the other upper main bearing shells are the same. The upper bearing flange controls the end thrust of the crankshaft. When carrying out maintenance, an oversize main bearing, thrust bearing, and connecting rod bearing can be used. If any part requires grinding, we recommend that all the main bearings or connecting rod journals should be ground.
OUTLINE OF CYLINDER BLOCK The oil cooler, thermostat seat, coolant bypass line, water pump volute, oil pump housing, water pump inlet port, and bore type piston cylinder are installed to the cylinder block. Space is provided between the cylinders for use when maintenance is required and room is left to make it possible to use a dry liner.
102 SERIES
13-125 2
DISASSEMBLY AND ASSEMBLY
CYLINDER BLOCK GROUP
REPLACEMENT OF FRONT OIL SEAL REMOVAL Remove the drive belt. Warning : Make sure that the wrench is secured at the portion square hole before rotating it. (The spring of the tensioner is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) : After removing the drive belt, return the tensioner slowly with care. : Be careful not to get your fingers caught between the pulley and drive belt during work. Caution: If the crankshaft pulley is loosened before the belt is removed, the belt can be removed easily.
15 mm Remove the crankshaft pulley.
Remove the front cover. For details of the procedure.
Remove the oil seal from the gear cover. Support the gear cover, set the oil seal facing to the front, and push out from the rear of the cover.
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102 SERIES
DISASSEMBLY AND ASSEMBLY
CYLINDER BLOCK GROUP
Install the drive belt. Warning : Make sure that the wrench is secured at the portion square hole before rotating it. (The spring of the tensioner is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) : After removing the drive belt, return the tensioner slowly with care. : Be careful not to get your fingers caught between the pulley and drive belt during work. Tighten the crankshaft pulley mounting bolts. 3: 125 Nm {12.7 kgm}
REPLACEMENT OF REAR OIL SEAL Preparatory work: • Remove the transmission. • Remove the flywheel.
1/8 inch drill Make 2 holes 180 x apart in the seal carrier.
102 SERIES
13-129 (21)
DISASSEMBLY AND ASSEMBLY
CYLINDER BLOCK GROUP
No. 10 sheet metal screw, slide hammer dent puller Remove the rear seal.
Caution: To prevent leakage from the seal, make sure that there is absolutely no oil on the crankshaft seal lip or seal surface. Clean the crankshaft seal surface and dry it.
Install the seal pilot (included in the replacement kit) to the crankshaft. Push the seal against the pilot and crankshaft. Remove the seal pilot.
Using the alignment tool, install the seal to the proper depth in the housing. Tap with a hammer to knock the seal into the housing to a point where the alignment tool contacts the housing. Tap the tool at the 12 o’clock, 3 o’clock, 6 o’clock, and 9 o’clock positions to push the seal in uniformly. Be careful not to bend the seal carrier.
13-130 2
102 SERIES
DISASSEMBLY AND ASSEMBLY
REPLACEMENT OF GEAR HOUSING, GASKET
Disassemble the camshaft gear installer, and remove the camshaft retainer.
INSTALLATION OF CAMSHAFT MOUNTING BOLTS Check that the gear is seated in front of the camshaft shoulder. Using a 0.001 inch clearance gauge, check if the clearance gauge can be inserted between the camshaft gear and camshaft gear shoulder. If the clearance gauge can be inserted, the camshaft gear is not properly seated.
Insert the camshaft mounting bolt in the gear retainer, then insert the mounting bolt and retainer assembly to the camshaft.
Tighten the camshaft mounting bolt to 27 Nm {2.8 kgm}.
102 SERIES
13-205 2
DISASSEMBLY AND ASSEMBLY
REPLACEMENT OF GEAR HOUSING, GASKET REPLACEMENT OF VIBRATION DAMPER, CRANKSHAFT PULLEY
After tightening the camshaft, tighten the mounting bolt a further 180º.
REPLACEMENT OF VIBRATION DAMPER, CRANKSHAFT PULLEY REMOVAL Remove the drive belt. Warning : Make sure that the wrench is secured at the portion square hole before rotating it. (The spring of the tensioner is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) : After removing the drive belt, return the tensioner slowly with care. : Be careful not to get your fingers caught between the pulley and drive belt during work. 15 mm Remove crankshaft pulley and vibration damper. (On the 6-cylinder engine, the vibration damper forms one unit with the crankshaft pulley.)
INSPECTION OF RUBBER DAMPER Check index line (A) of inertia material (C) and damper hub (B). If the alignment of both lines is more than 1.59 mm apart, replace the damper. Check vibration damper hub (B) for cracks. If there are any cracks in the hub, replace the damper.
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102 SERIES
DISASSEMBLY AND ASSEMBLY
REPLACEMENT OF VIBRATION DAMPER, CRANKSHAFT PULLEY
INSTALLATION Check for deterioration of the rubber. If the rubber is damaged or missing, or the elastic material is more than 3.18 mm {1/8 in} lower than the metal surface, replace the damper. Caution: Check the forward movement of the damper ring at the hub. If there is any movement, replace the damper.
INSPECTION OF VISCOUS DAMPER Check the mounting web for cracks. Check for dents or swelling in the surface of the housing. If such defects are found, replace the damper. See this section for details of the replacement procedure.
Remove the viscous damper. See this section for details of the replacement procedure. Clean the damper with detergent.
The viscous damper is filled with silicon liquid. After many hours of use, the silicon liquid will become thicker and will expand. When judging if the damper thickness is correct, remove the paint from the damper in 4 places on either side of the damper. Measure the damper thickness at the 4 places and note down the measurement. Measure the thickness at 3.175 mm from the outside of the damper. If the thickness varies by more than 0.25 mm, replace the damper.
102 SERIES
13-207 2
DISASSEMBLY AND ASSEMBLY
REPLACEMENT OF VIBRATION DAMPER, CRANKSHAFT PULLEY
Spray developer type SKD-NF or the equivalent into the damper to carry out a color check. Put the damper in an oven (set with the rolled lip at the bottom) and heat for 2 hours at 93 ºC.
Caution: Wear protective gloves to prevent burns when handling the heated parts. Remove the damper from the oven and inspect for leakage of fluid. If there is any leakage, replace the damper. See this section for details of the replacement procedure.
15 mm Install the crankshaft pulley and viscous damper. At this point, do not tighten the mounting bolts to the specified tightening torque. Install the drive belt.
Install the drive belt. Warning : Make sure that the wrench is secured at the portion square hole before rotating it. (The spring of the tensioner is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) : After removing the drive belt, return the tensioner slowly with care. : Be careful not to get your fingers caught between the pulley and drive belt during work.
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102 SERIES
DISASSEMBLY AND ASSEMBLY
REPLACEMENT OF VIBRATION DAMPER, CRANKSHAFT PULLEY
Tighten the mounting bolts of the crankshaft pulley and viscous damper. 3: 125 Nm {12.7 kgm}
102 SERIES
13-208-1 (21)
DISASSEMBLY AND ASSEMBLY
GEAR COVER
GEAR COVER REPLACEMENT OF GEAR COVER REMOVAL Remove the drive belt. Warning : Make sure that the wrench is secured at the portion square hole before rotating it. (The spring of the tensioner is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) : After removing the drive belt, return the tensioner slowly with care. : Be careful not to get your fingers caught between the pulley and drive belt during work.
15 mm Remove the crankshaft pulley.
10 mm If necessary, remove the hub pulley.
10 mm Remove the front gear cover.
102 SERIES
13-251 (21)
DISASSEMBLY AND ASSEMBLY
GEAR COVER
CLEANING AND INSPECTION Clean the gear cover and gear housing gasket surface.
Check the gear cover for cracks or damage.
Caution: Before installing the gear cover, clean and dry the crankshaft, and remove all oil and grease. If the seal surface is not properly cleaned, it will cause oil leakage.
INSTALLATION Install a new seal to the gear cover.
13-252 2
102 SERIES
DISASSEMBLY AND ASSEMBLY
GEAR COVER
Coat only the cover side of the front cover gasket thinly with a bead of Three Bond. Caution: At this point, do not remove the plastic seal pilot tool from the oil seal. Using the plastic seal pilot tool, guide the seal on to the crankshaft. Install the gasket and front cover to the engine.
Tighten the front cover mounting bolts. Remove the plastic seal pilot tool from the crankshaft. 3: 24 Nm {2.4 kgm}
15 mm Install the crankshaft pulley. At this point, do not tighten the mounting bolts to the specified torque.
Install the drive belt. Warning : Make sure that the wrench is secured at the portion square hole before rotating it. (The spring of the tensioner is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) : After removing the drive belt, return the tensioner slowly with care. : Be careful not to get your fingers caught between the pulley and drive belt during work. 102 SERIES
13-253 (21)
DISASSEMBLY AND ASSEMBLY
GEAR COVER
Tighten the crankshaft pulley mounting bolts. 3: 125 Nm {12.7 kgm}
INSTALLATION OF GEAR COVER Lubricate the front gear train with clean oil.
Caution: If the seal lip and crankshaft seal surface are not dry and completely free of oil, it will cause oil leakage. Clean the crankshaft front seal mounting surface. Caution: When removing and installing the gear cover, always replace the front seal.
10 mm Coat only the front cover side of the gasket thinly with Three Bond. Caution: At this point, do not remove the plastic seal pilot tool from the oil seal. Using the plastic seal pilot tool, guide the seal on to the crankshaft. Install the gasket and front cover.
13-254 2
102 SERIES
DISASSEMBLY AND ASSEMBLY
GEAR COVER
Tighten the front cover mounting bolts. Remove the pilot from the crankshaft. 3: 24 Nm {2.4 kgm}
Install the front cover access cap and seal.
15 mm Install the crankshaft pulley or vibration damper. At this point, tighten the mounting bolts partially.
1/2 inch square head drive Raise the belt tensioner and install the belt. Warning : Make sure that the wrench is secured at the portion square hole before rotating it. (The spring of the tensioner is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) : After removing the drive belt, return the tensioner slowly with care. : Be careful not to get your fingers caught between the pulley and drive belt during work. 102 SERIES
13-255 (21)
DISASSEMBLY AND ASSEMBLY
GEAR COVER
15 mm Tighten the crankshaft pulley. 3: 125 Nm {12.7 kgm}
INSPECTION OF GEAR HOUSING AND TIMING PIN Check the gear housing visually for cracks or damage. Check the seal surface.
Check the timing pin housing and pin for damage.
DISASSEMBLY OF GEAR HOUSING If there is no damage or leakage, or the gear housing is not replaced, do not remove the timing pin housing.
13-256 2
102 SERIES
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
REPLACEMENT OF CYLINDER HEAD REMOVAL Preparatory work: • Drain the coolant. • Remove the coolant and heater hoses.
Remove the turbocharger and exhaust manifold.
Remove the injectors and fuel line.
Remove the rocker lever and push tube.
102 SERIES
13-263 2
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
10 mm Remove the intake manifold cover and intake heater (when installed). When installing, be sure that the manifold cover is facing in the correct direction.
3/8 inch square drive Remove the drive belt. Warning : Make sure that the wrench is secured at the portion square hole before rotating it. (The spring of the tensioner is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) : After removing the drive belt, return the tensioner slowly with care. : Be careful not to get your fingers caught between the pulley and drive belt during work. 13 mm Remove the belt tensioner.
5 mm hexagon wrench Remove the belt tensioner bracket.
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102 SERIES
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
Tighten the mounting bolts in the following order. 1. Alternator bracket mounting bolts for alternator 2. Alternator mounting bolts for bottom brace 3. Cooling water inlet port mounting bolts for alternator 4. Block mounting bolts for cooling water inlet port Caution: The size of the wrench and the torque value depend on the alternator manufacturer and the model. For details of the torque value, see Engine Components.
INSTALLATION OF DRIVE BELT 3/8 inch square drive Raise the tensioner and install the belt. Warning : Make sure that the wrench is secured at the portion square hole before rotating it. (The spring of the tensioner is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) : After removing the drive belt, return the tensioner slowly with care. : Be careful not to get your fingers caught between the pulley and drive belt during work. Operating hint: If it is difficult to install the drive belt (the belt may be too short), fit the belt on the grooved pulley and raise the tensioner while sliding the belt over the water pump pulley.
INSPECTION BEFORE DISASSEMBLY Wash the cylinder head with detergent.
Check visually for damage which makes it impossible to reuse the cylinder head. Check for damage and cracks in the combustion surface that will cause loss of sealing.
102 SERIES
13-281 (21)
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD
DISASSEMBLY OF CYLINDER HEAD Make marks on the valves to distinguish the position.
Compress the valve spring and remove the valve stem collet.
Remove the valve spring, then remove the retainer and spring.
Remove the other collets, retainers, springs, and valves. When measuring, keep the valves on the labeled rack in sets with their companion seat.
13-282 2
102 SERIES
DISASSEMBLY AND ASSEMBLY
BELT TENSIONER
REPLACEMENT OF BELT 3/8-inch square head Raise the tensioner and remove the belt. Warning : Make sure that the wrench is secured at the portion square hole before rotating it. (The spring of the tensioner is strong. If the wrench is loosely inserted, the wrench may accidentally come off while being rotated and it is extremely dangerous.) : After removing the drive belt, return the tensioner slowly with care. : Be careful not to get your fingers caught between the pulley and drive belt during work. Caution: The belt tensioner is a spring type, so separate it from the drive belt and rotate it. If the direction of rotation is mistaken, the belt tensioner may be damaged.
REPLACEMENT OF BELT TENSIONER Preparatory work: • Remove the belt. 15 mm Remove the mounting bolts, then replace the tensioner. 3: 43 Nm {4.4 kgm}
INSPECTION Check that there is no excessive wear and enlargement of the hole at the tensioner pivot tube portion. If the tensioner is excessively worn, replace it.
Rotate the bearing and check that there is no rough portion and that it rotates freely.
102 SERIES
13-399 (21)
THERMOSTAT
DISASSEMBLY AND ASSEMBLY
THERMOSTAT DISASSEMBLY AND ASSEMBLY DRAWING
Index No. 1 2 3 4 5 6
13-400 0
Part Name Thermostat housing Thermostat housing gasket Hexagonal mounting bolt Hexagonal mounting bolt Lifting bracket Thermostat cooling water
Q’ty 1 1 1 2 1 1
Remarks
M8-1.25 x 35 M8-1.25 x 70 M12-1.75 x 70
102 SERIES