125E Series: Engine

SEN00177-15
ENGINE
125E
-5
SERIES
SEN00179-15
ENGINE
1SHOP MANUAL
125E-5 Series
00 Index and foreword
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 3
125E-5 Series
SEN00179-15
Composition of shop manual
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title
Form Number
Shop Manual, contents binder, binder label and tabs ............................................................ SEN00177-15
00 Index and foreword ......................................................................................................... SEN00178-15
Index ............................................................................................................................... SEN00179-15 q
Foreword and general information .................................................................................. SEN00180-06
01 Specification.................................................................................................................... SEN00181-06
Specification and technical data...................................................................................... SEN00182-06 q
10 Structure, function and maintenance standard ............................................................... SEN00183-07
Structure, function and maintenance standard, Part 1.................................................... SEN00184-06 q
Structure, function and maintenance standard, Part 2.................................................... SEN00185-06 q
20 Standard value table ....................................................................................................... SEN00186-09
Standard service value table........................................................................................... SEN00546-09 q
30 Testing and adjusting ...................................................................................................... SEN00187-05
Testing and adjusting ...................................................................................................... SEN00547-05
40 Troubleshooting .............................................................................................................. SEN00188-04
General information on troubleshooting.......................................................................... SEN00548-03
Troubleshooting of electrical system (E-mode), Part 1 ................................................... SEN00550-01
Troubleshooting of mechanical system (S-mode)........................................................... SEN00549-02
50 Disassembly and assembly ............................................................................................ SEN00189-04
General information on disassembly and assembly ....................................................... SEN00697-03
Disassembly and assembly, Part 1 (With EGR).............................................................. SEN00698-02
Disassembly and assembly, Part 2 (EGR-less) .............................................................. SEN00699-03
Disassembly and assembly, Part 3 ................................................................................. SEN00700-00
90 Repair and replacement of parts..................................................................................... SEN05201-01
Information related to repair and replacement ................................................................ SEN05202-00
Parts related to cylinder head ......................................................................................... SEN05203-01
Parts related to cylinder block......................................................................................... SEN05204-00
125E-5 Series
SEN00179-15
Table of contents

Index ............................................................................................................................... SEN00179-15
Composition of shop manual ...................................................................................................
2
Table of contents .....................................................................................................................
3
Foreword and general information.................................................................................. SEN00180-06
Safety notice............................................................................................................................
2
How to read the shop manual..................................................................................................
7
Explanation of terms for maintenance standard ......................................................................
9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code ................................................................................................ 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data ..................................................................................... SEN00182-06
Outline .....................................................................................................................................
2
Specifications...........................................................................................................................
6
General view............................................................................................................................ 20
Weight table............................................................................................................................. 48
Engine performance curves..................................................................................................... 51
10 Structure, function and maintenance standard
Structure, function and maintenance standard, Part 1.................................................... SEN00184-06
General structure ........................................................................................................................
4
Air intake and exhaust unit ..........................................................................................................
6
Air cleaner ................................................................................................................................... 10
Turbocharger............................................................................................................................... 12
Aftercooler ................................................................................................................................... 19
EGR system ................................................................................................................................ 20
Cylinder head .............................................................................................................................. 27
Cylinder block.............................................................................................................................. 30
Cylinder liner ............................................................................................................................... 34
Main moving parts ....................................................................................................................... 35
Crankshaft ................................................................................................................................... 37
Camshaft ..................................................................................................................................... 38
Cam follower and push rod ......................................................................................................... 39
Piston, piston ring and piston pin ................................................................................................ 40
Connecting rod............................................................................................................................ 42
Flywheel and flywheel housing ................................................................................................... 43
Vibration damper ......................................................................................................................... 48
Timing gear ................................................................................................................................. 50
Valve system ............................................................................................................................... 58
Valve and valve guide ................................................................................................................. 62
Rocker arm and shaft .................................................................................................................. 64
Crosshead and guide .................................................................................................................. 65
Structure, function and maintenance standard, Part 2.................................................... SEN00185-06
Lubrication system ......................................................................................................................
4
Lubrication system diagram.....................................................................................................
4
125E-5 Series
SEN00179-15
Oil pump ..................................................................................................................................

Main relief valve.......................................................................................................................
EGR oil pump ..........................................................................................................................
Oil filter.....................................................................................................................................
Safety valve .............................................................................................................................
Oil cooler..................................................................................................................................
Fuel system .................................................................................................................................
CRI system diagram ................................................................................................................
Outline of CRI system..............................................................................................................
Fuel piping ...............................................................................................................................
Fuel filter ..................................................................................................................................
Electric priming pump ..............................................................................................................
Engine controller cooler ...........................................................................................................
Cooling system............................................................................................................................
Cooling system diagram ..........................................................................................................
Water pump .............................................................................................................................
Thermostat...............................................................................................................................
Electrical equipment ....................................................................................................................
Alternator .................................................................................................................................
Starting motor ..........................................................................................................................
Electrical intake air heater .......................................................................................................
Engine controller......................................................................................................................
8
9
10
11
13
14
16
16
18
40
42
44
45
46
46
48
50
52
52
60
64
65
20 Standard value table

Standard service value table........................................................................................... SEN00546-09
Standard service value table .......................................................................................................
2
Standard service value table for testing, adjusting, and troubleshooting .................................
2
Running-in standard and performance test standard .............................................................. 16
30 Testing and adjusting
Testing and adjusting ...................................................................................................... SEN00547-05
Testing and adjusting (With EGR) ...............................................................................................
3
Testing and adjusting tools list .................................................................................................
3
Sketches of special tools .........................................................................................................
5
Testing air boost pressure........................................................................................................
6
Testing exhaust temperature ...................................................................................................
7
Adjusting valve clearance ........................................................................................................
8
Testing compression pressure .................................................................................................
9
Testing blow-by pressure ......................................................................................................... 11
Testing engine oil pressure ...................................................................................................... 12
Measuring EGR valve and bypass valve drive pressure ......................................................... 13
Handling fuel system parts ...................................................................................................... 14
Releasing residual pressure in fuel system ............................................................................. 14
Testing fuel pressure................................................................................................................ 15
Reduced cylinder mode operation ........................................................................................... 16
No-injection cranking ............................................................................................................... 16
Testing leakage from pressure limiter and return rate from injector......................................... 17
Bleeding air from fuel circuit .................................................................................................... 20
Testing fuel system for leakage ............................................................................................... 22
Adjusting speed sensor ........................................................................................................... 23
Testing and adjusting alternator belt tension ........................................................................... 24
Handling controller voltage circuit............................................................................................ 25
Testing and adjusting (EGR-less)................................................................................................ 26
Testing and adjusting tools list ................................................................................................. 26
Sketches of special tools ......................................................................................................... 28
Testing air boost pressure........................................................................................................ 29
125E-5 Series
SEN00179-15
Testing exhaust temperature ...................................................................................................

Adjusting valve clearance........................................................................................................
Testing compression pressure.................................................................................................
Testing blow-by pressure.........................................................................................................
Testing engine oil pressure......................................................................................................
Handling fuel system parts ......................................................................................................
Releasing residual pressure in fuel system .............................................................................
Testing fuel pressure ...............................................................................................................
Reduced cylinder mode operation...........................................................................................
No-injection cranking ...............................................................................................................
Testing leakage from pressure limiter and return rate from injector ........................................
Bleeding air from fuel circuit ....................................................................................................
Testing fuel system for leakage ...............................................................................................
Adjusting speed sensor ...........................................................................................................
Testing and adjusting alternator belt tension ...........................................................................
Handling controller voltage circuit............................................................................................
30
31
32
34
35
36
36
37
38
38
39
41
43
44
45
46
40 Troubleshooting
General information on troubleshooting.......................................................................... SEN00548-03
General information on troubleshooting ......................................................................................
2
Points on troubleshooting ........................................................................................................
2
Error code and failure code table ............................................................................................
4
Information in troubleshooting table ........................................................................................
8
Troubleshooting of electrical system (E-mode), Part 1 ...............................................................
4
E-1 Code [111/CA111] ECM Critical Internal Failure................................................................
4
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error ..............................................
6
E-3 Code [122/CA122] Charge Air Press Sensor High Error ..................................................
8
E-4 Code [123/CA123] Charge Air Press Sensor Low Error ................................................... 10
E-5 Code [131/CA131] Throttle Sensor High Error ................................................................. 12
E-6 Code [132/CA132] Throttle Sensor Low Error .................................................................. 16
E-7 Code [135/CA135] Oil press. Sensor High Error .............................................................. 18
E-8 Code [141/CA141] Oil press. Sensor Low Error ............................................................... 20
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ...................................................... 22
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error ..................................................... 24
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error ................................................ 26
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error ................................................ 28
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error .......................................................... 29
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error.............................................. 30
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error............................................... 32
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error ......................................................... 34
E-17 Code [234/CA234] Eng. Overspeed ............................................................................... 36
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error.................................................... 38
E-19 Code [263/CA263] Fuel Temp. Sensor High Error .......................................................... 40
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error........................................................... 42
E-21 Code [271/CA271] PCV1 Short Error ............................................................................. 44
E-22 Code [272/CA272] PCV1 Open Error ............................................................................. 46
E-23 Code [273/CA273] PCV2 Short Error ............................................................................. 48
E-24 Code [274/CA274] PCV2 Open Error ............................................................................. 50
E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error ................................. 52
E-31 Code [342/CA342] Calibration Code Incompatibility ....................................................... 64
E-32 Code [351/CA351] INJ. Drive Circuit Error ..................................................................... 66
125E-5 Series
SEN00179-15
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error .......................................................... 68

E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error ......................................................... 70
E-35 Code [431/CA431] Idle Validation SW Low error ............................................................ 72
E-36 Code [432/CA432] Idle Validation Process error............................................................. 74
E-37 Code [441/CA441] Battery voltage low error................................................................... 74
E-38 Code [442/CA442] Battery voltage high error ................................................................. 75
Troubleshooting of electrical system (E-mode), Part 2................................................................
3
E-39 Code [449/CA449] Rail Press. Very High Error...............................................................
3
E-40 Code [451/CA451] Rail Press. Sensor High Error ..........................................................
4
E-41 Code [452/CA452] Rail Press. Sensor Low Error ...........................................................
6
E-42 Code [553/CA553] Rail Press. High Error.......................................................................
6
E-43 Code [554/CA554] Rail Press Sensor In Range Error ....................................................
7
E-44 Code [559/CA559] Rail Press. Low Error........................................................................
8
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error ............................................................ 12
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error ............................................. 14
E-47 Code [757/CA757] All Persistent Data Lost Error ........................................................... 15
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error ........................................................ 16
E-49 Code [1228/CA1228] EGR Valve Servo Error 1.............................................................. 18
E-50 Code [1625/CA1625] EGR Valve Servo Error 2.............................................................. 19
E-51 Code [1626/CA1626] Bypass Valve Solenoid Current High Error................................... 20
E-52 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error.................................... 22
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1.......................................................... 23
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2.......................................................... 24
E-55 Code [1631/CA1631] BP valve Lift Position Sensor High Error ...................................... 26
E-56 Code [1632/CA1632] BP valve Lift Position Sensor Low Error ....................................... 28
E-57 Code [1633/CA1633] KOMNET Datalink Timeout Error ................................................. 28
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error............................................... 29
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error .............................................. 30
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ............................................. 32
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error .............................................. 36
E-62 Code [2249/CA2249] Rail Press. Very Low Error ........................................................... 37
E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error................................... 38
E-64 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error.................................... 40
E-65 Code [2351/CA2351] EGR Valve Solenoid Current High Error....................................... 42
E-66 Code [2352/CA2352] EGR Valve Solenoid Current Low Error ....................................... 44
E-67 Code [2555/CA2555] Grid Heater Relay Volt. Low Error ................................................ 45
E-68 Code [2556/CA2556] Grid Heater Relay Volt. High Error ............................................... 46
E-69 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate ................................................... 48
E-70 Code [(146)/B@BCNS] Eng. Overheat ........................................................................... 48
E-71 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate ............................................ 49
Troubleshooting of mechanical system (S-mode)........................................................... SEN00549-02
Troubleshooting of mechanical system (S-mode) .......................................................................
4
Method of using troubleshooting charts...................................................................................
4
S-1 Starting performance is poor .............................................................................................
8
S-2 Engine does not start ........................................................................................................ 10
S-3 Engine does not pick up smoothly .................................................................................... 14
S-4 Engine stops during operations......................................................................................... 15
S-5 Engine does not rotate smoothly....................................................................................... 16
S-6 Engine lacks output (or lacks power) ................................................................................ 17
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 18
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 20
S-9 Oil becomes contaminated quickly.................................................................................... 21
S-10 Fuel consumption is excessive ....................................................................................... 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .............................. 23
S-12 Oil pressure drops........................................................................................................... 24
S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 25
125E-5 Series
SEN00179-15
S-14 Coolant temperature becomes too high (overheating).................................................... 27

S-15 Abnormal noise is made ................................................................................................. 28
S-16 Vibration is excessive ..................................................................................................... 29
50 Disassembly and assembly
General information on disassembly and assembly ....................................................... SEN00697-03
General information on disassembly and assembly....................................................................
2
How to read this manual..........................................................................................................
2
Coating materials list ...............................................................................................................
4
Special tools list .......................................................................................................................
7
Disassembly and assembly, Part 1 (With EGR).............................................................. SEN00698-02
Disassembly and assembly, Part 1 (With EGR) ..........................................................................
2
General disassembly of engine ...............................................................................................
2
General assembly of engine.................................................................................................... 17
Disassembly and assembly, Part 2 (EGR-less) .............................................................. SEN00699-03
Disassembly and assembly, Part 2 (EGR-less)...........................................................................
2
General disassembly of engine ...............................................................................................
2
General assembly of engine.................................................................................................... 16
Disassembly and assembly, Part 3 ................................................................................. SEN00700-00
Disassembly and assembly, Part 3 .............................................................................................
2
Removal and installation of fuel supply pump unit ..................................................................
2
Replacement of oil seal of engine mounted on machine.........................................................
4
90 Repair and replacement of parts
Information related to repair and replacement ................................................................ SEN05202-00
Flowchart .................................................................................................................................
2
Special tool table .....................................................................................................................
4
Special tool sketch...................................................................................................................
6
Parts related to cylinder head ......................................................................................... SEN05203-01
Part names related to cylinder head........................................................................................
2
Testing and inspection of cylinder head...................................................................................
3
Pressure test of cylinder head .................................................................................................
5
Replacement of valve guide ....................................................................................................
5
Replacement of valve seat insert ............................................................................................
6
Replacement of crosshead guide ............................................................................................ 13
Repair of valve by grinding ...................................................................................................... 14
Parts related to cylinder block......................................................................................... SEN05204-00
Part names related to cylinder block .......................................................................................
2
Testing and inspection of cylinder block ..................................................................................
3
Part names related to crankshaft.............................................................................................
6
Testing and inspection of crankshaft .......................................................................................
7
Part names related to connecting rod......................................................................................
8
Testing and inspection of connecting rod ................................................................................
9
Replacement of flywheel ring gear .......................................................................................... 11
Replacement of camshaft gear................................................................................................ 11
Replacement of main bearing metal cap ................................................................................. 12
Replacement of connecting rod small end bushing................................................................. 14
Replacement of cam bushing .................................................................................................. 15
Replacement of engine rear seal............................................................................................. 17
Replacement of wear sleeve (when sleeve is installed) .......................................................... 21
Repair of crankshaft by grinding .............................................................................................. 22
125E-5 Series
SEN00179-15
KOMATSU 125E-5 Series engine

Form No. SEN00179-15
2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11
SEN00180-06
ENGINE
1SHOP MANUAL
125E-5 Series
Foreword and general information

Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
125E-5 Series
SEN00180-06
Safety notice
(Rev. 2008/08)
1
Important safety notice

Proper service and repair are 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.
To prevent injury to workers, the symbol k 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.
1.
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read all the safety labels stuck to
the machine. For the locations of the
safety labels and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) 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, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 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 warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.
7)
8)
9)
If welding repairs are needed, always

have a trained and experienced welder
carry out the work. When carrying out
w elding work, alw ays wear welding
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.
Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition. Take rests in
specified safe places.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5
Prohibition of operation and handling by

unlicensed workers
6 Safety check before starting work

7
Wearing protective goggles

(for cleaning or grinding work)
Wearing shielding goggles and protectors

(for welding work)
9 Good physical condition and preparation

10
Precautions against work which you are

not used to or you are used to too much
125E-5 Series
2.
3.
SEN00180-06
Preparations for work

1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock 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.
3) When disassembling or assembling, support the machine with blocks, jacks, or
stands before starting work.
4) 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
m a c h i n e . N e v e r j u m p o n o r o ff t h e
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
6)
Precautions during work

1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
11)
125E-5 Series
7)
8)
9)
10)
12)
13)
14)
15)
16)
When removing a cover which is under

internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
When removing components, be careful
not to break or damage the electrical wiring. Damaged wiring may cause electrical
fires.
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
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
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 operated.
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. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
When assembling or installing parts,
always tighten them to the specified
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.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
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.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
SEN00180-06
4.
Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q
Do not stand under the load.
q
Do not step on the load.
2) Check the slings before starting sling
work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 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.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allowable load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular

load, apply pads to protect the wire ropes.
If the load is slippery, apply proper material to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
q
Slinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes.

12) When lifting up a load, observe the following.
q
Wind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
q
After the wire ropes are stretched,
stop the crane and check the condition of the slung load, wire ropes, and
pads.
125E-5 Series
If the load is unstable or the wire rope

or chains are twisted, lower the load
and lift it up again.
q
Do not lift up the load slantingly.
13) When lifting down a load, observe the following.
q
When lifting down a load, stop it temporarily at 30 cm above the floor, and
then lower it slowly.
q
Check that the load is stable, and
then remove the sling.
q
Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
SEN00180-06
13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
5.
6.
Precautions for using mobile crane

a Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
Precautions for using overhead hoist crane
k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immediately in an emergency.
125E-5 Series
7.
Selecting wire ropes

1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.
Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
SEN00180-06
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air conditioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recovering or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2)

a
Example of O-ring (Fitted to every joint of

hoses and tubes)
For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
Connection
1] When installing the air conditioner circuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
125E-5 Series
How to read the shop manual

q
q
q
1.
SEN00180-06
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
Materials and specifications are subject to change without notice.
Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
125E-5 Series
SEN00180-06
3.
4.
Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q
Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 )
Revisions
Revised brochures are shown in the shop manual composition table.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol
Item
Safety
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Weight of parts of component or parts. Caution necessary when

selecting hoisting wire, or when working posture is important, etc.
Tightening
torque
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during

assembly.
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
5.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
125E-5 Series
SEN00180-06
Explanation of terms for maintenance standard
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1.
Standard size and tolerance

q
To be accurate, the finishing size of parts
is a little different from one to another.
q
To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated.
q
The above size set temporarily is called
the standard size and the range of difference from the standard size is called the
tolerance.
q
The tolerance with the symbols of + or is
indicated on the right side of the standard
size.
Example:
Standard size
120
Tolerance
0.022
0.126
The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)
Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size
60
125E-5 Series
Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0
SEN00180-06
2.
Standard clearance and standard value

q
The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.
3.
Standard interference
q
When the diameter of a hole of a part
shown in the given standard size and tolerance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q
The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q
After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4.
Repair limit and allowable value or allowable dimension

q
The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q
If a part is worn to the repair limit, it must
be replaced or repaired.
q
The performance and function of a product lowers while it is used. A value which
the product can be used without causing a
problem is called the allowable value or
allowable dimension.
q
If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.
10
5.
Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q
6.
Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q
125E-5 Series
Handling of electric equipment and hydraulic component
SEN00180-06
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connecting and disconnecting the connector about
10 times.
2)
Defective crimping or soldering of connectors

The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
125E-5 Series
11
SEN00180-06
12
3)
Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be damaged, or the wiring
may be broken.
4)
High-pressure water entering connector

The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-circuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5)
Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with compressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.
125E-5 Series
3.
SEN00180-06
Removing, installing, and drying connectors and wiring harnesses

1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connectors apart.
a Never pull with one hand.
2]
q
When removing from clips

Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stoppers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3]
Action to take after removing connectors

After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.
125E-5 Series
13
SEN00180-06
2)
14
Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp
and adjust the position.
q
If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
125E-5 Series
3)
Heavy duty wire connector (DT 8-pole, 12pole)

Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizontally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
125E-5 Series
SEN00180-06
Disconnection
Connection (Example of
incomplete setting of (a))
15
SEN00180-06
4)
16
Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as follows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the compressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
125E-5 Series
4.
Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness connectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5.
Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.
125E-5 Series
SEN00180-06
17
SEN00180-06
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1.
Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2.
Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the performance should be checked with special test
equipment.
3.
Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4.
Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18
125E-5 Series
5.
Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6.
Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
125E-5 Series
SEN00180-06
19
SEN00180-06
Handling of connectors newly used for engines

a
1.
Mainly, following engines are object for following connectors.

q
95E-5
q
107E-1
q
114E-3
q
125E-5
q
140E-5
q
170E-5
q
12V140E-3
Slide lock type
(FRAMATOME-3, FRAMATOME-2)
q
95 170, 12V140 engines
q
Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE
(95 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
2.
Pull lock type (PACKARD-2)

95 170, 12V140 engines
q
Various temperature sensors
Example)
Intake air temperature sensor in
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
etc.
Disconnect the connector by pulling lock
(B) (on the wiring harness side) of connector (2) outward.
Disconnect connector (1) according to the following procedure.

1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector (1) toward you.
a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screwdriver while press lock (L2), and then
pull out connector (1) toward you.
20
125E-5 Series
3.
SEN00180-06
Push lock type

q
95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the following procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q
114 engine
107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3)
While pressing lock (D), pull out connector

(4) in the direction of the arrow.
107 engine
2)
If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
125E-5 Series
21
SEN00180-06
4)
95, 125 170, 12V140 engines

While pressing lock (E) of the connector,
pull out connector (5) in the direction of
the arrow.
Example)
Fuel pressure sensor in common rail:
PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector)

140 engine
Example)
Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
1)
Disconnect connector (6) according to the

following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring harness side.
2)
Connect the connector according to the

1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it clicks.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22
125E-5 Series
SEN00180-06
How to read electric wire code

a
The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Type
Low-voltage
wire for
automobile
Thin-cover
low-voltage
wire for
automobile
Symbol
AV
AVS
Heat-resistant low-voltAEX
age wire for
automobile
125E-5 Series
Material
Conductor
Insulator
Conductor
Annealed copper for electric appliance

Soft polyvinyl chloride
Insulator
Soft polyvinyl chloride
Conductor

Heat-resistant crosslinked
polyethylene
Insulator
Using
temperature
range (C)
Example of use
General wiring
(Nominal No. 5 and above)
30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place
23
SEN00180-06
2.
Dimensions
(Table 2)
Nominal No.
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
area (mm2)
d (approx.)
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6
CovAV
Standard
4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
5.5
5.3
4.8
7.0
7.0
6.0
8.2
8.2
8.0
10.8
10.8
8.6
11.4
11.4
9.8
13.0
13.0
10.4
13.6
13.6
12.0
16.0
16.0
13.6
17.6
17.6
108/0.80 127/0.80 169/0.80 217/0.80
f of nominal No. denotes flexible.
24
125E-5 Series
3.
SEN00180-06
Color codes table
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4)
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others
125E-5 Series
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
R
B
R
D
Y
G
L
WG
RB
YR
GW
LW
BrW
LgR
RY
YB
GR
LR
BrR
LgY
RG
YG
GY
LY
BrY
LgB
RL
YL
GB
LB
BrB
LgW
YW
GL
Gr
Br
25
SEN00180-06
Precautions when carrying out operation
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1.
q
q
q
q
q
q
q
q
q
q
Precautions when carrying out removal work

If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number
02
03
04
05
06
10
12
2)
26
Sleeve nut (elbow end)
07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234
02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234
Split flange type hoses and tubes

Nominal
number
04
05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400
07379-00500
07378-10400
07378-10500
07371-30400
07371-30500
If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
Part Number
06
08
10
12
14
16
18
20
22
24
07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430
Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14
11.5
18
16
13.5
20
18
15
22
20
17
25
22
18.5
28
24
20
30
27
07049-02734
27
22.5
34
125E-5 Series
2.
q
q
q
q
q
q
q
q
q
q
q
q
q
a
3.
SEN00180-06
Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
When using the machine for the first time after repair or long storage, follow the same procedure.
Precautions when completing the operation
1) Refilling with coolant, oil and grease
q
If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q
If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, Bleeding air.
q
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q
For the tightening torque, see Disassembly and assembly.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
125E-5 Series
27
SEN00180-06
4)
5)
28
Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly
and assembly.
125E-5 Series
SEN00180-06
Method of disassembling and connecting push-pull type coupler

k
k
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the 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.
Type 1
1.
Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2.
Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a 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. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
125E-5 Series
29
SEN00180-06
Type 2
1.
Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to disconnect it. (Fig. 8)
2.
Connection
q
Hold the tightening portion and push body
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
30
125E-5 Series
SEN00180-06
Type 3
1.
Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection
q
Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
125E-5 Series
31
SEN00180-06
Standard tightening torque table

1.
Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a
The following table applies to the bolts in Fig. A.
Thread diameter of bolt

mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
a
Tightening torque
Nm
11.8 14.7
27 34
59 74
98 123
157 196
245 309
343 427
490 608
662 829
824 1,030
1,180 1,470
1,520 1,910
1,960 2,450
2,450 3,040
2,890 3,630
kgm
1.2 1.5
2.8 3.5
6.0 7.5
10.0 12.5
16 20
25 31.5
35 43.5
50 62
67.5 84.5
84 105
120 150
155 195
200 250
250 310
295 370
The following table applies to the bolts in Fig. B.

mm
6
8
10
12
a Fig. A
Width across flats

mm
10
13
17
19
22
24
27
30
32
36
41
46
50
55
60
Width across flats

mm
10
12
14
17
Tightening torque
Nm
kgm
5.9 9.8
0.6 1.0
13.7 23.5
1.4 2.4
34.3 46.1
3.5 4.7
74.5 90.2
7.6 9.2
a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32
125E-5 Series
2.
Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm
10
12
16
3.
Width across flats

mm
14
17
22
Tightening torque
Nm
59 74
98 123
235 285
kgm
6.0 7.5
10.0 12.5
23.5 29.5
Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter
mm
14
20
24
33
42
Nominal No.
02
03,04
05,06
10,12
14
4.
SEN00180-06
Width across flats

mm
Tightening torque Nm {kgm}

Range
Target
35 63 { 3.5 6.5}
44 { 4.5}
84 132 { 8.5 13.5}
103 {10.5}
Varies depending
on type of connec- 128 186 {13.0 19.0}
157 {16.0}
tor.
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}
Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal
No.
08
10
12
14
16
18
20
24
30
33
36
42
52
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
125E-5 Series
Width across flats

mm
14
17
19
22
24
27
30
32
32
36

Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}
33
SEN00180-06
5.
Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Nominal
No. of
hose
Width
across
flats
02
19
03
04
05
06
(10)
(12)
(14)
6.
22
24
27
32
36
41
46
55
Range
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
Target
44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
Taper seal
Thread size
(mm)
14
18
22
24
30
33
36
42
Face seal
Nominal No.
Thread
Number of
diameter (mm)
threads, type of
(Reference)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer
diameter
of pipe
(mm)
Width
across
flats
(mm)
8
10
12
15 (16)
22 (20)
19
22
24 (27)
30 (32)
36

Range
Target
14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Thread diameter
Nominal No.
(mm)
Number of threads,
(Reference)
type of thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UN
25.4
1-3/16-12UN
30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Bolts and nuts
Thread size
mm
6
8
10
12
14
34
Nm
10 2
24 4
43 6
77 12
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
125E-5 Series
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size
mm
6
8
10
12
14
9.
SEN00180-06
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4
125E-5 Series
Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51
35
SEN00180-06
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 (A), and then draw a horizontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) 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 it 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.
Millimeters to inches
(A)
36
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
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
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
125E-5 Series
SEN00180-06
Millimeters to inches
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
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
1 kg = 2.2046 lb
6
7
8
9
13.23
15.43 17.64
19.84
35.27
37.48 39.68
41.89
57.32
59.53 61.73
63.93
79.37
81.57 83.78
85.98
101.41 103.62 105.82 108.03
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
130.07
152.12
174.17
196.21
218.26
Liters to U.S. Gallons
0
10
20
30
40
0
1
2
0
0.264 0.528
2.642
2.906 3.170
5.283
5.548 5.812
7.925
8.189 8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321
1.585
1.849
2.113
2.378
3.963
4.227
4.491 4.755
5.019
6.604
6.869
7.133 7.397
7.661
9.246
9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
125E-5 Series
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
37
SEN00180-06
Liters to U.K. Gallons
0
10
20
30
40
0
0
2.200
4.399
6.599
8.799
1
0.220
2.420
4.619
6.819
9.019
2
0.440
2.640
4.839
7.039
9.239
3
0.660
2.860
5.059
7.259
9.459
4
0.880
3.080
5.279
7.479
9.679
5
1.100
3.300
5.499
7.699
9.899
50
60
70
80
90
10.998
13.198
15.398
17.598
19.797
11.281
13.418
15.618
17.818
20.017
11.438
13.638
15.838
18.037
20.237
11.658
13.858
16.058
18.257
20.457
11.878
14.078
16.278
18.477
20.677
12.098
14.298
16.498
18.697
20.897
1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540 1.760
1.980
3.520
3.740 3.950
4.179
5.719
5.939 6.159
6.379
7.919
8.139 8.359
8.579
10.119 10.339 10.559 10.778
12.318
14.518
16.718
18.917
21.117
12.528
14.738
16.938
19.137
21.337
12.758
14.958
17.158
19.357
21.557
12.978
15.178
17.378
19.577
21.777
kgm to ft.lb
0
10
20
30
40
0
0
72.3
144.7
217.0
289.3
1
7.2
79.6
151.9
224.2
296.6
2
14.5
86.8
159.1
231.5
303.8
3
21.7
94.0
166.4
238.7
311.0
4
28.9
101.3
173.6
245.9
318.3
5
36.2
108.5
180.8
253.2
325.5
6
43.4
115.7
188.1
260.4
332.7
1 kgm = 7.233 ft.lb

7
8
9
50.6
57.9
65.1
123.0 130.2
137.4
195.3 202.5
209.8
267.6 274.9
282.1
340.0 347.2
354.4
50
60
70
80
90
361.7
434.0
506.3
578.6
651.0
368.9
441.2
513.5
585.9
658.2
376.1
448.5
520.8
593.1
665.4
383.4
455.7
528.0
600.3
672.7
390.6
462.9
535.2
607.6
679.9
397.8
470.2
542.5
614.8
687.1
405.1
477.4
549.7
622.0
694.4
412.3
484.6
556.9
629.3
701.6
419.5
491.8
564.2
636.5
708.8
426.8
499.1
571.4
643.7
716.1
100
110
120
130
140
723.3
730.5 737.8
745.0
752.2 759.5
766.7
773.9 781.2
788.4
795.6
802.9 810.1
817.3
824.6 831.8
839.0
846.3 853.5
860.7
868.0
875.2 882.4
889.7
896.9 904.1
911.4
918.6 925.8
933.1
940.3
947.5 954.8
962.0
969.2 976.5
983.7
990.9 998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150
160
170
180
190
1084.9
1157.3
1129.6
1301.9
1374.3
38
1092.2
1164.5
1236.8
1309.2
1381.5
1099.4
1171.7
1244.1
1316.4
1388.7
1106.6
1179.0
1251.3
1323.6
1396.0
1113.9
1186.2
1258.5
1330.9
1403.2
1121.1
1193.4
1265.8
1338.1
1410.4
1128.3
1200.7
1273.0
1345.3
1417.7
1135.6
1207.9
1280.1
1352.6
1424.9
1142.8
1215.1
1287.5
1359.8
1432.1
1150.0
1222.4
1294.7
1367.0
1439.4
125E-5 Series
SEN00180-06
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
1 kg/cm2 = 14.2233 lb/in2

7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9
50
60
70
80
90
711.2
853.4
995.6
1,138
1,280
725.4
867.6
1,010
1,152
1,294
739.6
881.8
1,024
1,166
1,309
753.8
896.1
1,038
1,181
1,323
768.1
910.3
1,053
1,195
1,337
782.3
924.5
1,067
1,209
1,351
796.5
938.7
1,081
1,223
1,365
810.7
953.0
1,095
1,237
1,380
825.0
967.2
1,109
1,252
1,394
839.2
981.4
1,124
1,266
1,408
100
110
120
130
140
1,422
1,565
1,707
1,849
1,991
1,437
1,579
1,721
1,863
2,005
1,451
1,593
1,735
1,877
2,020
1,465
1,607
1,749
1,892
2,034
1,479
1,621
1,764
1,906
2,048
1,493
1,636
1,778
1,920
2,062
1,508
1,650
1,792
1,934
2,077
1,522
1,664
1,806
1,949
2,091
1,536
1,678
1,821
1,963
2,105
1,550
1,693
1,835
1,977
2,119
150
160
170
180
190
2,134
2,276
2,418
2,560
2,702
2,148
2,290
2,432
2,574
2,717
2,162
2,304
2,446
2,589
2,731
2,176
2,318
2,460
2,603
2,745
2,190
2,333
2,475
2,617
2,759
2,205
2,347
2,489
2,631
2,773
2,219
2,361
2,503
2,646
2,788
2,233
2,375
2,518
2,660
2,802
2,247
2,389
2,532
2,674
2,816
2,262
2,404
2,546
2,688
2,830
200
210
220
230
240
2,845
2,987
3,129
3,271
3,414
2,859
3,001
3,143
3,286
3,428
2,873
3,015
3,158
3,300
3,442
2,887
3,030
3,172
3,314
3,456
2,901
3,044
3,186
3,328
3,470
2,916
3,058
3,200
3,343
3,485
2,930
3,072
3,214
3,357
3,499
2,944
3,086
3,229
3,371
3,513
2,958
3,101
3,243
3,385
3,527
2,973
3,115
3,257
3,399
3,542
125E-5 Series
39
SEN00180-06
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 (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
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
177.8
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
60
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
40
125E-5 Series
125E-5 Series
SEN00180-06
41
SEN00180-06

2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)
42
SEN00182-06
ENGINE
1SHOP MANUAL
125E-5 Series
01 Specification
Specification and technical data

Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 6
General view ...................................................................................................................................... 20
Weight table ....................................................................................................................................... 48
Engine performance curves ............................................................................................................... 51
125E-5 Series
SEN00182-06
01 Specification
Outline
1. Applicable machine
Engine
Engine serial No.
Applicable machine
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
Hydraulic excavator
PC400-8, PC400LC-8, PC400-8R, PC400LC-8R
PC450-8, PC450LC-8, PC450-8R, PC450LC-8R
SAA6D125E-5
D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
Bulldozer
WA450-6, WA470-6, WA470-6R
Wheel loader
WA480-6, WA480-6R
Wheel loader
HM250-2, HM300-2, HM300-2R
Articulated dump truck
BR580JG-1
Mobile crusher
GD755-5R
Motor grader
DCA-300SSK4 (DENYO/MQ GENERATOR)
Generator
125E-5 Series
01 Specification
SEN00182-06
2. Outline of engine (with EGR)

q
The 125E-5 engine is a high-performance and

high-efficiency engine, which passed strict
emission regulations (USA: EPA Regulations
for 2006, EU: Regulations for 2006, Japan:
Construction machinery regulations for 2006)
and attained low fuel consumption, low noise,
better exhaust gas color, and high acceleration
performance. Accordingly, this newly developed engine is suitable as a power source of
construction machinery and industrial machinery used for various purposes.
The 125E-5 engine is the successor to the

125E-3 engine. While it is an in-line 6-cylinder,
water-cooled, common rail direct injection, 4stroke diesel engine, it is equipped with the
cooled EGR system which is a new technology.
1)
The main components of the cooled EGR system are the EGR cooler of corrugated tube
type made of newly developed special stainless steel and the EGR valve driven hydraulically and controlled electronically which
KOMATSU developed by itself. The cooled
EGR system secures the optimum EGR rate
from the low-speed range to the high-speed
range to attain both clean exhaust gas and low
fuel consumption with the bypass assist circuit
consisting of the venturi system and bypass
valve which has the same function and structure as those of the EGR valve.
2)
The special EGR oil pump is employed to generate high oil pressure (1.47 MPa {15 kg/cm2})
as the drive power source of the EGR valve
driven hydraulically and controlled electronically.
3)
The 125E-5 engine is equipped with the combination filter system of high performance and
efficiency, which has been employed for the
125E-3 engine, to meet the requirements of
the EGR system and high-dispersion oil and
capture large and small particles. In addition,
the recommended sub-materials for operation
(oil and fuel) are changed to improve the reliability and durability of the engine.
4)
Since the high-pressure fuel injection system

controlled electronically is employed, less soot
is produced and the draining interval of the oil
is lengthened. (While the capacity of the oil
pan is not changed, the oil replacement interval of 500 hours is secured.)
125E-5 Series
5)
The common rail high-pressure fuel injection

system controlled electronically is employed
for the 125E-3 and after models. This system
can inject the fuel at high pressure of 120 MPa
{1,200 kg/cm2} from the low-speed range to the
high-speed range. In addition, this system can
control the form of injection most properly by
electronic control according to the speed and
load. The injection system of 125E-5 is further
improved to employ multiple injection and
increase the injection pressure up to 140 MPa
{1,400 kg/cm2}. As a result, exhaust gas of the
cleanest level in the world, good exhaust gas
color, low fuel consumption, and low noise are
realized simultaneously.
6)
As the injection pressure of the common rail

injection system employed for the 125E-3
engine and after models is increased (from
120 to 140 MPa {from 1,200 to 1,400 kg/cm2}),
the pressure resistance of the common rail,
injector, and supply pump is improved for
higher reliability.
7)
The main fuel filter of high efficiency and the

pre-fuel filter are installed as standard so that
the low grade fuel in the market (equivalent to
Class NAS13) can be used. In addition, the
delivery of the priming pump used to replace
the filters is increased for higher serviceability.
8)
The high-quality piston made of cast iron which

has been employed for the 125E-2 engine and
after models is employed. This piston has a
less coefficient of thermal expansion, a reentrant combustion chamber, and a shaker cooling gallery. As a result, clean exhaust gas,
good exhaust gas color, and low fuel consumption are attained simultaneously, and high
durability and reliability are also obtained.
9)
By using the above-mentioned high-pressure

fuel injection system controlled electronically,
the multiple injection and injection characteristics are set most properly to improve the startability and reduce the white exhaust smoke
when the temperature is low.
10) Since the engine controller is mounted on the

engine and equipped with the automatic highaltitude compensation function, the engine can
be operated at high altitude without replacing
the controller. As a result, the serviceability is
improved.
SEN00182-06
01 Specification
11) The KTR90 turbocharger newly developed and

manufactured by KOMATSU for higher reliability and higher performance is mounted. The
efficiency of the blower impeller is improved
and special manufacturing methods for higher
strength of the material are employed to obtain
higher efficiency and higher pressure ratio. As
a result, high performance is maintained from
the low-speed range to the high-speed range.
12) The copper sleeve at the injector mounting
hole of the cylinder head is eliminated.
Instead, the dry sleeve structure is employed
and the top and bottom faces of the cylinder
head are connected by casting to meet the
requirements of the high output and attain
higher reliability.
13) The cylinder block is changed partly to add the
cooled EGR system. Since its overall length,
overall width, and overall height are the same
as before, however, its compactness is maintained.
14) If only fuel containing sulfur more than 5,000
PPM (0.5%) is obtained in a district where the
emission regulations are not applied, the high
sulfur-content fuel specification without EGR
system is prepared.
125E-5 Series
01 Specification
SEN00182-06
3. Outline of engine (EGR-less)

q
The 125E-5 EGR-less engine is a high-performance and high-efficiency engine, which

attained low fuel consumption, low noise, better exhaust gas color, and high acceleration
performance. Accordingly, this newly developed engine is suitable as a power source of
construction machinery and industrial machinery used for various purposes.
The 125E-5 EGR-less engine is the successor

to the 125E-3 engine, which is an in-line 6-cylinder, water-cooled, common rail direct injection, and 4-stroke diesel engine.
1)
The 125E-5 EGR-less engine is equipped with

the combination filter system of high perform a n c e a n d e ff i c i e n c y, w h i c h h a s b e e n
employed for the 125E-3 engine, to meet the
requirements of high-dispersion oil and capture large and small particles. In addition, the
recommended sub-materials for operation (oil
and fuel) are changed to improve the reliability
and durability of the engine.
5)
The main fuel filter of high efficiency and the

pre-fuel filter are installed as standard so that
the low grade fuel in the market (equivalent to
Class NAS13) can be used. In addition, the
priming pump used for replacement of the filters is electrified for high serviceability.
6)
The high-quality piston made of cast iron which

has been employed for the 125E-2 engine and
after models is employed. This piston has a
less coefficient of thermal expansion, a reentrant combustion chamber, and a shaker cooling gallery. As a result, clean exhaust gas,
good exhaust gas color, and low fuel consumption are attained simultaneously, and high
durability and reliability are also obtained.
7)
By using the above-mentioned high-pressure

fuel injection system controlled electronically,
the multiple injection and injection characteristics are set most properly to improve the startability and reduce the white exhaust smoke
when the temperature is low.
2)
Since the high-pressure fuel injection system

controlled electronically is employed, less soot
is produced and the draining interval of the oil
is lengthened. (While the capacity of the oil
pan is not changed, the oil replacement interval of 500 hours is secured.)
8)
Since the engine controller is mounted on the

engine and equipped with the automatic highaltitude compensation function, the engine can
be operated at high altitude without replacing
the controller. As a result, the serviceability is
improved.
3)
The common rail high-pressure fuel injection

system controlled electronically is employed
for the 125E-3 and after models. This system
can inject the fuel at high pressure of 120 MPa
{1,200 kg/cm2} from the low-speed range to the
high-speed range. In addition, this system can
control the form of injection most properly by
electronic control according to the speed and
load. The injection system of 125E-5 is further
improved to employ multiple injection. As a
result, the characteristics of good exhaust gas
color, low fuel consumption and low noise are
realized simultaneously.
9)
The KTR90 turbocharger newly developed and

manufactured by KOMATSU for higher reliability and higher performance is mounted. The
efficiency of the blower impeller is improved
and special manufacturing methods for higher
strength of the material are employed to obtain
higher efficiency and higher pressure ratio. As
a result, high performance is maintained from
the low-speed range to the high-speed range.
4)
The pressure resistance of the common rail,

injector, and supply pump of the common rail
injection system employed for the 125E-3
engine and after models is improved for higher
reliability.
125E-5 Series
10) The copper sleeve at the injector mounting

hole of the cylinder head is eliminated.
Instead, the dry sleeve structure is employed
and the top and bottom faces of the cylinder
head are connected by casting to meet the
requirements of the high output and attain
higher reliability.
SEN00182-06
01 Specification
Specifications
Engine name
SAA6D125E-5
Applicable machine
PC400-7E0, PC400LC-7E0,
PC400-8, PC400LC-8
PC450-7E0, PC450LC-7E0,
PC450-8, PC450LC-8
mm
l {cc}
6 125 150
11.0 {11,040}
153624
Overall length
mm
1,713
Overall width
mm
1,001
Overall height (excluding exhaust pipe)
mm
Overall height (including exhaust pipe)
mm
1,741
Rated output
kW/rpm
{HP/rpm}
262.5 / 1,900
{352 / 1,900}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
1,422 / 1,400
{145 / 1,400}
(Gross)
No-load max. speed

(High idle speed)
rpm
1,930 (+35/-15)
No-load min. speed

(Low idle speed)
rpm
1,000 25
g/kWh
{g/HPh}
211
{157}
Dry weight
kg
1,310
Fuel injection pump

Governor
DENSO ECD-U2
Electronic control type
Quantity of lubricating oil

(Refill capacity)
46
(37)
Quantity of coolant
(for only engine)
Alternator
Starting motor
Battery
24V, 35A, 60A

24V, 7.5kW
12V, 150Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
With air-cooled aftercooler
Performance
Dimensions
Number of cylinders Bore Stroke

Total displacement
Firing order
Fuel consumption ratio at rated output
(21)
125E-5 Series
01 Specification
SEN00182-06
Engine name
SAA6D125E-5
Applicable machine
PC400-8R, PC400LC-8R
mm
l {cc}
6 125 150
11.0 {11,040}
153624
Overall length
mm
1,713
Overall width
mm
975
mm
mm
1,741
Rated output
kW/rpm
{HP/rpm}
262.5 / 1,900
{352 / 1,900}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
1,422 / 1,400
{145 / 1,400}
(Gross)
No-load max. speed

(High idle speed)
rpm
1,930 (+35/-15)
No-load min. speed

(Low idle speed)
rpm
1,000 25
g/kWh
{g/HPh}
211
{157}
Dry weight
kg
1,270
Fuel injection pump

Governor
DENSO ECD-U2

(Refill capacity)
46
(37)
Quantity of coolant
(for only engine)
Alternator
Starting motor
Battery
24V, 50A, 60A

24V, 7.5kW
12V, 150Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
Performance
Dimensions

Total displacement
Firing order
125E-5 Series
(21)
SEN00182-06
01 Specification
Engine name
SAA6D125E-5
Applicable machine
D85EX-15E0, D85PX-15E0
mm
l {cc}
6 125 150
11.0 {11,040}
153624
Overall length
mm
1,307
Overall width
mm
1,004
mm
1,711
mm
Rated output
kW/rpm
{HP/rpm}
199 / 1,900
{266 / 1,900}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
1,272 / 1,400
{130 / 1,400}
(Gross)
No-load max. speed

(High idle speed)
rpm
2,100 50
No-load min. speed

(Low idle speed)
rpm
750 (+50/0)
g/kWh
{g/HPh}
215
{160}
Dry weight
kg
1,330
Fuel injection pump

Governor
DENSO ECD-U2

(Refill capacity)
44
(38)
Quantity of coolant
(for only engine)
Alternator
Starting motor
Battery
24V, 50A
24V, 7.5kW
12V, 150Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
Performance
Dimensions

Total displacement
Firing order
(21)
125E-5 Series
01 Specification
SEN00182-06
Engine name
SAA6D125E-5
Applicable machine
D85EX-15R, D85PX-15R
mm
l {cc}
6 125 150
11.0 {11,040}
153624
Overall length
mm
1,307
Overall width
mm
1,004
mm
1,711
mm
Rated output
kW/rpm
{HP/rpm}
199 / 1,900
{266 / 1,900}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
1,272 / 1,400
{130 / 1,400}
(Gross)
No-load max. speed

(High idle speed)
rpm
2,100 50
No-load min. speed

(Low idle speed)
rpm
750 (+50/0)
g/kWh
{g/HPh}
215
{160}
Dry weight
kg
1,270
Fuel injection pump

Governor
DENSO ECD-U2

(Refill capacity)
44
(38)
Quantity of coolant
(for only engine)
Alternator
Starting motor
Battery
24V, 50A
24V, 7.5kW
12V, 150Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
Performance
Dimensions

Total displacement
Firing order
125E-5 Series
(21)
SEN00182-06
01 Specification
Engine name
SAA6D125E-5
Applicable machine
HM250-2
mm
l {cc}
6125 150
11.0 {11,040}
153624
Overall length
mm
1,681
Overall width
mm
1,010
mm
1,268
mm
Rated output
kW/rpm
{HP/rpm}
232 / 2,000
{311 / 2,000}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
1,706 / 1,400
{174 / 1,400}
(Gross)
No-load max. speed

(High idle speed)
rpm
2,100 50
No-load min. speed

(Low idle speed)
rpm
725 (+50/0)
g/kWh
{g/HPh}
218
{162}
Dry weight
kg
1,285
Fuel injection pump

Governor
DENSO ECD-U2

(Refill capacity)
44
(35)
Quantity of coolant
(for only engine)
Alternator
Starting motor
Battery
24V, 50A
24V, 7.5kW
12V, 300Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
Performance
Dimensions

Total displacement
Firing order
10
(21)
125E-5 Series
01 Specification
SEN00182-06
Engine name
SAA6D125E-5
Applicable machine
HM300-2
mm
l {cc}
6125 150
11.0 {11,040}
153624
Overall length
mm
1,681
Overall width
mm
1,010
mm
1,268
mm
Rated output
kW/rpm
{HP/rpm}
254 / 2,000
{340 / 2,000}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
1,706 / 1,400
{174 / 1,400}
(Gross)
No-load max. speed

(High idle speed)
rpm
2,220 50
No-load min. speed

(Low idle speed)
rpm
725 (+50/0)
g/kWh
{g/HPh}
215
{161}
Dry weight
kg
1,285
Fuel injection pump

Governor
DENSO ECD-U2

(Refill capacity)
44
(35)
Quantity of coolant
(for only engine)
Alternator
Starting motor
Battery
24V, 50A
24V, 7.5kW
12V, 300Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
Performance
Dimensions

Total displacement
Firing order
125E-5 Series
(21)
11
SEN00182-06
01 Specification
Engine name
SAA6D125E-5
Applicable machine
HM300-2R
mm
l {cc}
6125 150
11.0 {11,040}
153624
Overall length
mm
1,681
Overall width
mm
1,010
mm
1,263
mm
Rated output
kW/rpm
{HP/rpm}
254 / 2,000
{340 / 2,000}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
1,706 / 1,400
{174 / 1,400}
(Gross)
No-load max. speed

(High idle speed)
rpm
2,220 50
No-load min. speed

(Low idle speed)
rpm
725 (+50/0)
g/kWh
{g/HPh}
211
{157}
Dry weight
kg
1,260
Fuel injection pump

Governor
DENSO ECD-U2

(Refill capacity)
44
(35)
Quantity of coolant
(for only engine)
Alternator
Starting motor
Battery
24V, 50A
24V, 7.5kW
12V, 300Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
Performance
Dimensions

Total displacement
Firing order
12
(21)
125E-5 Series
01 Specification
SEN00182-06
Engine name
SAA6D125E-5
Applicable machine
WA450-6
WA470-6
mm
l {cc}
6 125 150
11.0 {11,040}
153624
Overall length
mm
1,713
Overall width
mm
1,001
mm
mm
1,298
Rated output
kW/rpm
{HP/rpm}
204 / 2,000
{273 / 2,000}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
1,307 / 1,450
{133 / 1,450}
(Gross)
No-load max. speed

(High idle speed)
rpm
2,170 50
No-load min. speed

(Low idle speed)
rpm
800 (+50/0)
g/kWh
{g/HPh}
216
{161}
Dry weight
kg
1,310
Fuel injection pump

Governor
DENSO ECD-U2

(Refill capacity)
46
(37)
Quantity of coolant
(for only engine)
Alternator
Starting motor
Battery
24V, 50A
24V, 7.5kW
24V, 136Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
Performance
Dimensions

Total displacement
Firing order
125E-5 Series
(21)
13
SEN00182-06
01 Specification
Engine name
SAA6D125E-5
Applicable machine
WA470-6R
mm
l {cc}
6 125 150
11.0 {11,040}
153624
Overall length
mm
1,713
Overall width
mm
1,001
mm
mm
1,298
Rated output
kW/rpm
{HP/rpm}
204 / 2,000
{273 / 2,000}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
1,307 / 1,450
{133 / 1,450}
(Gross)
No-load max. speed

(High idle speed)
rpm
2,170 50
No-load min. speed

(Low idle speed)
rpm
800 (+50/0)
g/kWh
{g/HPh}
216
{161}
Dry weight
kg
1,250
Fuel injection pump

Governor
DENSO ECD-U2

(Refill capacity)
46
(37)
Quantity of coolant
(for only engine)
Alternator
Starting motor
Battery
24V, 50A
24V, 7.5kW
24V, 136Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
Performance
Dimensions

Total displacement
Firing order
14
(21)
125E-5 Series
01 Specification
SEN00182-06
Engine name
SAA6D125E-5
Applicable machine
WA480-6
mm
l {cc}
6 125 150
11.0 {11,040}
153624
Overall length
mm
1,713
Overall width
mm
1,001
mm
mm
1,298
Rated output
kW/rpm
{HP/rpm}
224 / 2,000
{301 / 2,000}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
1,360 / 1,400
{139 / 1,400}
(Gross)
No-load max. speed

(High idle speed)
rpm
2,190 50
No-load min. speed

(Low idle speed)
rpm
800 (+50/0)
g/kWh
{g/HPh}
216
{161}
Dry weight
kg
1,310
Fuel injection pump

Governor
DENSO ECD-U2

(Refill capacity)
46
(37)
Quantity of coolant
(for only engine)
Alternator
Starting motor
Battery
24V, 50A
24V, 7.5kW
24V, 136Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
Performance
Dimensions

Total displacement
Firing order
125E-5 Series
(21)
15
SEN00182-06
01 Specification
Engine name
SAA6D125E-5
Applicable machine
WA480-6R
mm
l {cc}
6 125 150
11.0 {11,040}
153624
Overall length
mm
1,713
Overall width
mm
1,001
mm
mm
1,298
Rated output
kW/rpm
{HP/rpm}
224 / 2,000
{301 / 2,000}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
1,360 / 1,400
{139 / 1,400}
(Gross)
No-load max. speed

(High idle speed)
rpm
2,190 50
No-load min. speed

(Low idle speed)
rpm
800 (+50/0)
g/kWh
{g/HPh}
216
{161}
Dry weight
kg
1,250
Fuel injection pump

Governor
DENSO ECD-U2

(Refill capacity)
46
(37)
Quantity of coolant
(for only engine)
Alternator
Starting motor
Battery
24V, 50A
24V, 7.5kW
24V, 136Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
Performance
Dimensions

Total displacement
Firing order
16
(21)
125E-5 Series
01 Specification
SEN00182-06
Engine name
SAA6D125E-5
Applicable machine
BR580JG-1
mm
l {cc}
6 125 150
11.0 {11,040}
153624
Overall length
mm
1,713
Overall width
mm
1,001
mm
mm
1,311
Rated output
kW/rpm
{HP/rpm}
262.5 / 1,900
{352 / 1,900}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
1,422 / 1,400
{145 / 1,400}
(Gross)
No-load max. speed

(High idle speed)
rpm
1,930 (+35/-15)
No-load min. speed

(Low idle speed)
rpm
1,000 25
g/kWh
{g/HPh}
211
{157}
Dry weight
kg
1,310
Fuel injection pump

Governor
DENSO ECD-U2

(Refill capacity)
46
(37)
Quantity of coolant
(for only engine)
Alternator
Starting motor
Battery
24V, 35A
24V, 7.5kW
12V, 150Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
Performance
Dimensions

Total displacement
Firing order
125E-5 Series
(21)
17
SEN00182-06
01 Specification
Engine name
SAA6D125E-5
Applicable machine
GD755-5R
mm
l {cc}
6 125 150
11.0 {11,040}
153624
Overall length
mm
1,340
Overall width
mm
984
mm
mm
1,640
Rated output
kW/rpm
{HP/rpm}
216 / 2,000
{289.7 / 2,000}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
1,317 / 1,400
{134.3 / 1,400}
(Gross)
No-load max. speed

(High idle speed)
rpm
2,200 50
No-load min. speed

(Low idle speed)
rpm
800 (+50/0)
g/kWh
{g/HPh}
216
{161}
Dry weight
kg
1,340
Fuel injection pump

Governor
DENSO ECD-U2

(Refill capacity)
46
(37)
Quantity of coolant
(for only engine)
Alternator
Starting motor
Battery
24V, 75A
24V, 7.5kW
24V, 150Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
Performance
Dimensions

Total displacement
Firing order
18
(21)
125E-5 Series
01 Specification
SEN00182-06
Engine name
SAA6D125E-5
Applicable machine
DCA-300SSK4
(DENYO/MQ GENERATOR)
mm
l {cc}
6125 150
11.0 {11,040}
153624
Overall length
mm
1,753
Overall width
mm
1,143
mm
1,420
mm
Rated output
kW/rpm
{HP/rpm}
272 / 1,800
{365 / 1,800}
(Gross)
Max. torque
Nm/rpm
{kgm/rpm}
No-load max. speed

(High idle speed)
rpm
Max. 1,890
No-load min. speed

(Low idle speed)
rpm
750 25
g/kWh
{g/HPh}
218
{162}
Dry weight
kg
1,450
Fuel injection pump

Governor
DENSO ECD-U2

(Refill capacity)
63
(63)
Quantity of coolant
(for only engine)
53
(21)
Alternator
Starting motor
Battery
24V, 35A
24V, 7.5kW
12V, 150Ah2
Turbocharger
Air compressor
Others
KOMATSU KTR90
Performance
Dimensions

Total displacement
Firing order
125E-5 Series
19
SEN00182-06
01 Specification
General view
SAA6D125E-5 (Left side of engine)

Applicable machines: PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8, PC450-8, PC450LC-8
a
a
The shape is subject to machine models.

For the dimensions of each part, see the last page of the general view.
1.
2.
Center of crankshaft
Rear face of flywheel housing
20
125E-5 Series
01 Specification
SEN00182-06
SAA6D125E-5 (Front side of engine)

Applicable machines: PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8, PC450-8, PC450LC-8
a
a

1.
2.
Center of cylinder liner
125E-5 Series
21
SEN00182-06
01 Specification

Applicable machines: PC400-8R, PC400LC-8R, PC450-8R, PC450LC-8R
Reference: The electric priming pump switch is installed to the chassis.
a
a

1.
2.
22
125E-5 Series
01 Specification
SEN00182-06

Reference: The electric priming pump switch is installed to the chassis.
a
a

1.
2.
125E-5 Series
23
SEN00182-06
01 Specification

Reference: The manual priming pump is installed to the engine.
a
a

1.
2.
24
125E-5 Series
01 Specification
SEN00182-06
SAA6D125E-5 (Rear side of engine)

Reference: The manual priming pump is installed to the engine.
a
a

1.
2.
125E-5 Series
25
SEN00182-06
01 Specification

Applicable machines: D85EX-15E0, D85PX-15E0
a
a

1.
2.
26
125E-5 Series
01 Specification
SEN00182-06

Applicable machines: D85EX-15E0, D85PX-15E0
a
a

1.
2.
125E-5 Series
27
SEN00182-06
01 Specification

Applicable machines: D85EX-15R, D85PX-15R
a
a

1.
2.
28
125E-5 Series
01 Specification
SEN00182-06

Applicable machines: D85EX-15R, D85PX-15R
a
a

1.
2.
125E-5 Series
29
SEN00182-06
01 Specification

Applicable machine: HM250-2, HM300-2
a
a

1.
2.
30
125E-5 Series
01 Specification
SEN00182-06

a
a

1.
2.
125E-5 Series
31
SEN00182-06
01 Specification
SAA6D125E-5 (Top of engine)

a
a

1.
32
125E-5 Series
01 Specification
SEN00182-06

Applicable machine: HM300-2R
a
a

1.
2.
125E-5 Series
33
SEN00182-06
01 Specification

a
a

1.
2.
34
125E-5 Series
01 Specification
SEN00182-06

a
a

1.
125E-5 Series
35
SEN00182-06
01 Specification

Applicable machines: WA450-6, WA470-6, WA480-6
a
a

1.
2.
36
125E-5 Series
01 Specification
SEN00182-06

Applicable machines: WA450-6, WA470-6, WA480-6
a
a

1.
2.
125E-5 Series
37
SEN00182-06
01 Specification

Applicable machines: WA470-6R, WA480-6R
a
a

1.
2.
38
125E-5 Series
01 Specification
SEN00182-06

Applicable machines: WA470-6R, WA480-6R
a
a

1.
2.
125E-5 Series
39
SEN00182-06
01 Specification

Applicable machines: BR580JG-1
a
a

1.
2.
40
125E-5 Series
01 Specification
SEN00182-06

Applicable machines: BR580JG-1
a
a

1.
2.
125E-5 Series
41
SEN00182-06
01 Specification

Applicable machine: GD755-5R
a
a

1.
2.
42
125E-5 Series
01 Specification
SEN00182-06

a
a

1.
2.
125E-5 Series
43
SEN00182-06
01 Specification

a
a

1.
2.
44
125E-5 Series
01 Specification
SEN00182-06

Applicable machine: DCA-300SSK4 (DENYO/MQ GENERATOR)
a
a

1.
2.
125E-5 Series
45
SEN00182-06
01 Specification

Applicable machine: DCA-300SSK4 (DENYO/MQ GENERATOR)
a
a

1.
2.
46
125E-5 Series
01 Specification
SEN00182-06
Dimensions table
Unit: mm
Engine
Dimension of each part
Machine
1,713 1,741
438
1,001
PC400-8R
PC400LC-8R
(*1) 1,713 1,741
438
PC450-8R
PC450LC-8R
(*2) 1,484 1,744
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8
PC450-8, PC450LC-8
SAA6D125E-5
975
442
1,002
D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
1,307 1,711
387
15
15
777
949
1,004
WA450-6, WA470-6
WA480-6, WA470-6R
WA480-6R
1,334 1,638
388
25
800
935
HM250-2, HM300-2
1,681 1,268
401
178
40
530
660
1,010
718
HM300-2R
1,681 1,263
401
178
40
530
660
1,010
718
BR580JG-1
1,713 1,311
453
1,001
GD755-5R
1,340 1,640
390
35
800
984
DCA-300SSK4
1,753 1,420
371
160
750
810
1,143
a These dimensions are given for reference when the engine is set on a test bench.
*1: The electric priming pump switch is installed to the chassis.
*2: The manual priming pump is installed to the engine.
125E-5 Series
47
SEN00182-06
01 Specification
Weight table
(with EGR)
Unit: kg
No.
Item
Main parts
SAA6D125E-5
Turbocharger
KOMATSU KTR90
17
Cylinder head assembly
Cylinder head, valve,

valve spring
15
Cylinder block assembly
Cylinder block, bearing,

cap, cylinder liner
305
Front cover
48
29
Oil pan
Flywheel assembly
Flywheel housing assembly
Flywheel ring gear
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8,PC400LC-8
PC450-8,PC450LC-8
BR580JG-1
18
D85EX-15E0, D85PX-15E0
21
WA450-6, WA470-6
WA480-6
HM250-2, HM300-2
22
DCA-300SSK4
35
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8
PC450-8, PC450LC-8
BR580JG-1
49
D85EX-15E0, D85PX-15E0
55
WA450-6, WA470-6
WA480-6
27
HM250-2, HM300-2
23
DCA-300SSK4
118
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8
PC450-8, PC450LC-8
BR580JG-1
D85EX-15E0, D85PX-15E0
54
WA450-6, WA470-6,
WA480-6
HM250-2, HM300-2
47
DCA-300SSK4
64
125E-5 Series
01 Specification
SEN00182-06
Unit: kg
No.
Item
Main parts
SAA6D125E-5
Crankshaft assembly
Crankshaft, crank gear
106
Camshaft assembly
Camshaft, cam gear,

thrust plate
16
10
Piston and connecting rod

assembly
Piston, piston ring,

piston pin, connecting rod
11
Oil pump
12 Fuel supply pump
10
13 Water pump
10
14 Alternator
15 Starting motor
24V, 35A
24V, 50A
10
24V, 60A
11
24V, 75A
13
24V, 7.5kW
16
24V, 11kW
18
16 EGR oil pump
17 EGR valve
16
18 Bypass valve
16
19 EGR cooler
125E-5 Series
49
SEN00182-06
01 Specification
(EGR-less)
Unit: kg
No.
Item
Main parts
SAA6D125E-5
Turbocharger
KOMATSU KTR90
17
Cylinder head assembly
Cylinder head, valve,

valve spring
15
Cylinder block assembly
Cylinder block, bearing,

cap, cylinder liner
305
Front cover
29
Oil pan
Flywheel assembly
Flywheel ring gear
Flywheel housing assembly
18
GD755-5R
21
HM300-2R
WA470-6R, WA480-6R
22
49
55
WA470-6R, WA480-6R
27
HM300-2R
23
GD755-5R
56
GD755-5R
54
HM300-2R
WA470-6R, WA480-6R
47
Crankshaft assembly
Crankshaft, crank gear
106
Camshaft assembly
Camshaft, cam gear,

thrust plate
16
10
Piston and connecting rod

assembly
Piston, piston ring,

piston pin, connecting rod
11
Oil pump
12 Fuel supply pump
10
13 Water pump
10
14 Alternator
15 Starting motor
50
24V, 50A
10
24V, 60A
11
24V, 75A
13
24V, 7.5kW
16
24V, 11kW
18
125E-5 Series
01 Specification
SEN00182-06
Engine performance curves

Engine
SAA6D125E-5
125E-5 Series
Engine serial No.
1
Applicable machine
Page
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8, PC400-8R, PC400LC-8R
PC450-8, PC450LC-8, PC450-8R, PC450LC-8R
52
D85EX-15E0, D85EX-15R, D85PX-15E0, D85PX-15R
53
WA450-6, WA470-6, WA470-6R
54
WA480-6, WA480-6R
55
HM250-2
56
HM300-2, HM300-2R
57
BR580JG-1
58
GD755-5R
59
51
SEN00182-06
SAA6D125E-5
(Applicable machine:
01 Specification
PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0

PC400-8, PC400LC-8, PC400-8R, PC400LC-8R,
PC450-8, PC450LC-8, PC450-8R, PC450LC-8R)
Rated output: 262.5 kW {352 HP}/1,900 rpm (Gross)

Max. torque: 1,423 Nm {145 kgm}/1,400 rpm (Gross)
52
125E-5 Series
01 Specification
SEN00182-06
SAA6D125E-5
(Applicable machine: D85EX-15E0, D85EX-15R, D85PX-15E0, D85PX-15R)
Rated output: 199 kW {266 HP}/1,900 rpm (Gross)
125E-5 Series
53
SEN00182-06
01 Specification
SAA6D125E-5 (Applicable machine: WA450-6, WA470-6, WA470-6R)

54
125E-5 Series
01 Specification
SEN00182-06
SAA6D125E-5 (Applicable machine: WA480-6, WA480-6R)

125E-5 Series
55
SEN00182-06
01 Specification
SAA6D125E-5 (Applicable machine: HM250-2)

56
125E-5 Series
01 Specification
SEN00182-06
SAA6D125E-5 (Applicable machine: HM300-2, HM300-2R)

125E-5 Series
57
SEN00182-06
01 Specification
SAA6D125E-5 (Applicable machine: BR580JG-1)

Rated output: 262.5 kW {352 HP}/1,900 rpm (Gross)
58
125E-5 Series
01 Specification
SEN00182-06
SAA6D125E-5 (Applicable machine: GD755-5R)

Rated output: 216 kW {289.7 HP}/2,000 rpm (Gross)
Max. torque: 1,317 Nm {134.3 kgm}/1,400 rpm (Gross)
125E-5 Series
59
SEN00182-06

2011 KOMATSU
All Rights Reserved
60
SEN00184-06
125E-5 Series
SEN00184-05
ENGINE
Shop Manual
125E-5 Series
Machine model Serial number

125E-5 SERIES ENGINE .........
10 Structure,function and
maintenance standard
Structure, function and maintenance
standard, Part 1
General structure ........................................................................................................................................
Air intake and exhaust unit..........................................................................................................................
Air cleaner................................................................................................................................................... 10
Turbocharger .............................................................................................................................................. 12
Aftercooler................................................................................................................................................... 19
EGR system................................................................................................................................................ 20
Cylinder head.............................................................................................................................................. 27
Cylinder block ............................................................................................................................................. 30
125E-5 Series
SEN00184-06
10 Structure,function and maintenance standard
Cylinder liner ............................................................................................................................................... 34

Main moving parts....................................................................................................................................... 35
Crankshaft................................................................................................................................................... 37
Camshaft..................................................................................................................................................... 38
Cam follower and push rod ......................................................................................................................... 39
Piston, piston ring and piston pin ................................................................................................................ 40
Connecting rod............................................................................................................................................ 42
Flywheel and flywheel housing ................................................................................................................... 43
Vibration damper......................................................................................................................................... 48
Timing gear ................................................................................................................................................. 50
Valve system............................................................................................................................................... 58
Valve and valve guide ................................................................................................................................. 62
Rocker arm and shaft.................................................................................................................................. 64
Crosshead and guide .................................................................................................................................. 65
125E-5 Series
125E-5 Series
SEN00184-06
SEN00184-06
General structure
1. Cylinder block
2. Cylinder liner
3. Piston
4. Connecting rod
5. Piston pin
6. Cross head
7. Intake valve
8. Exhaust valve
9. Rocker arm shaft
10. Injector
11. Cylinder head cover
12. Camshaft
13. Ring gear
14. Flywheel
15. Rear seal
16. Flywheel housing
17. Oil pan
18. Crankshaft
19. Main bearing cap
20. Oil strainer
21. Crank gear
22. Front cover
23. Front seal
24. Crankshaft pulley
25. Vibration damper
125E-5 Series
26. Exhaust manifold

27. Turbocharger
28. Cylinder head
29. Rocker arm
30. Push rod
SEN00184-06
31. Air intake manifold

32. Common rail
33. Fuel supply pump
34. Cam follower
35. Connecting rod cap
Engine
Name: SAA6D125E-5 (with turbocharger and air-cooled aftercooler)
Type : In-line 6-cylinder, water-cooled, direct injection, 4-stroke diesel engine
125E-5 Series
SEN00184-06
Air intake and exhaust unit

A: Intake unit (Between air-cooled aftercooler and intake manifold)

1. Electrical intake air heater
2. Diffuser
3. Intake manifold
125E-5 Series
SEN00184-06
SAA6D125E-5 (Right side of engine) (with EGR)
A: To EGR cooler
B: To turbocharger
C: From bypass valve
1. Exhaust manifold (Rear)
2. Exhaust manifold (Center)
3. Exhaust manifold (Front)
125E-5 Series
SEN00184-06
SAA6D125E-5 (Right side of engine) (EGR-less)
A: To turbocharger
1. Exhaust manifold (Rear)
2. Exhaust manifold (Center)
3. Exhaust manifold (Front)
125E-5 Series
125E-5 Series
SEN00184-06
SEN00184-06
Air cleaner
FRG type (Radial seal type)
a The shape is subject to machine models.

1. Inlet
2. Outlet
3. Guide vane
4. Primary element
5. Safety element
Engine
6. Evacuator valve
7. Dust pan
8. Guide plate (Sleeve)
9. Body
10. Element
Applicable machines
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8, PC400-8R, PC400LC-8R
PC400-8, PC400LC-8, PC400-8R, PC400LC-8R
D85EX-15E0, D85PX-15R
D85PX-15E0, D85PX-15R
SAA6D125E-5
WA450-6, WA470-6, WA470-6R
WA480-6, WA480-6R
HM250-2, HM300-2, HM300-2R
BR580JG-1, GD755-5R
DCA-300SSK4
10
Type
Evacuator
valve
Number of elements
FRG
(Radial seal type)
Automatic
discharge
1 inner element
1 outer element
125E-5 Series
SEN00184-06
Structure
q The size of the body is reduced from the conventional type without changing the diameter of the
element.
q Since the inlet is set in the tangential direction,
air is given sufficient centrifugal force by the simple spiral guide vane, not by the guide plate.
Operation
q Air containing dust is sucked in vertically through
inlet (1) and the dust is separated by the centrifugal effect of guide vane (3).
q More than 99.9% of the dust is removed by primary element (4) and clean air is sucked in the
engine through safety element (5) and outlet (2).
q The dust and water separated by guide vane (3)
swirl along the inside wall of body (9) and enter
evacuator valve (6) and then are discharged out
automatically.
125E-5 Series
11
SEN00184-06
Turbocharger
(with EGR)
Model name: KTR90
12
125E-5 Series
SEN00184-06
A: Intake air inlet

B: Intake air outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
E: Oil inlet
F: Oil outlet
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model name: KOMATSU KTR90
Overall length: 268 mm
Overall width: 247 mm
Overall height: 227 mm
Weight: 17 kg
125E-5 Series
13
SEN00184-06
Unit: mm
No.
Check item
1 End play (Play in axial direction)

2 Radial play (Play in radial direction)
3
14
Clearance between blower housing and impeller
Criteria
Remedy
Standard
Repair limit
0.08 0.13
0.18
0.38 0.59
Clearance limit (Min.): 0.01
Replace thrust parts

Replace bearing
parts
Replace bearing
parts
125E-5 Series
125E-5 Series
SEN00184-06
15
SEN00184-06
(EGR-less)
Model name: KTR90
16
125E-5 Series
SEN00184-06
A: Intake air inlet

B: Intake air outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
E: Oil inlet
F: Oil outlet
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model name: KOMATSU KTR90
Overall length: 268 mm
Overall width: 247 mm
Overall height: 227 mm
Weight: 17 kg
125E-5 Series
17
SEN00184-06
Unit: mm
No.
Check item
1 End play (Play in axial direction)

2 Radial play (Play in radial direction)
3
18
Clearance between blower housing and impeller
Criteria
Remedy
Standard
Repair limit
0.08 0.13
0.18
0.38 0.59
Clearance limit (Min.): 0.01
Replace thrust parts

Replace bearing
parts
Replace bearing
parts
125E-5 Series
SEN00184-06
Aftercooler
Air-cooled type

a. Inlet/Outlet of intake air (Between turbocharger and air intake manifold)
1. Tank
2. Side support
3. Tube
4. Fin
125E-5 Series
19
SEN00184-06
EGR system
No.
1
Component part
EGR valve (driven hydraulically)
Function
q
q
q
2 Bypass valve
Controls the gas flow from the exhaust system to the air intake system.
Since the exhaust pressure (PEX) is higher than the boost pressure (PIN), the exhaust gas flows to the air intake valve.
Opens the bypass valve when the boost pressure (PIN) is higher than the exhaust
pressure (PEX).
Makes the intake air flow to the exhaust side to increase the exhaust pressure so
that the exhaust gas will be returned to the air intake side easily.
3 EGR cooler
Lowers the exhaust temperature and returns the exhaust gas to the air intake side.
4 Venturi system
Generates negative pressure with the venturi effect and takes in the exhaust gas.
Controls the EGR according to the operating condition.

Troubleshoots the system.
5 Each sensor
Features
q The exhaust gas is kept clean by sensing each
part of the EGR circuit and controlling the EGR
rate according to the operating condition.
q Since the EGR circuit is monitored and troubleshooted, a serious trouble is prevented.
20
125E-5 Series
125E-5 Series
SEN00184-06
21
SEN00184-06
a The above illustration shows the engine for HM300-2.
22
125E-5 Series
SEN00184-06
1. EGR valve
2. Bypass valve
3. EGR cooler
4. Venturi system
5. EGR valve position sensor
6. Bypass valve position sensor
7. Bypass piping
8. EGR piping
9. EGR oil pump
Operation
q The engine controller outputs signals for opening EGR valve (1) most properly according to the
load on the engine to attain both clean exhaust
gas and low fuel consumption.
q If EGR valve (1) opens, a part of the exhaust gas
(EGR gas) flows from the exhaust manifold
through EGR piping (8) to EGR cooler (3).
q The exhaust gas cooled by EGR cooler (3) flows
through EGR valve (1) and mixes with the intake
air in venturi system (4), and then flows in the air
intake manifold.
q In the operating range where the boost pressure
is higher than the exhaust pressure on the high
load side, the EGR gas does not flow to the air
intake side easily. At this time, the engine controller opens bypass valve (2).
q If bypass valve (2) opens, the intake air flows
through bypass piping (7). As a result, the exhaust pressure rises and more EGR gas mixes
with the intake air.
125E-5 Series
23
SEN00184-06
EGR valve and bypass valve
A: Oil inlet
B: Oil outlet
C: EGR gas passage (EGR valve)
D: Boost air passage (Bypass valve)
1. Stick prevention device

2. Oil pressure control valve
3. Solenoid
4. Position sensor
5. Hydraulic piston
6. Spring
7. Valve
Function
q The EGR valve controls the EGR gas.
q This valve is driven hydraulically and its opening
ratio is controlled electronically.
Operation
The oil pressure (engine oil) of 1.47 MPa {15
kg/cm2} supplied to oil inlet (A) is reduced by oil
pressure control valve (2).
q Hydraulic piston (5) generates pressing force
from the reduced oil pressure.
q The control oil pressure can be changed with the
drive current of solenoid (3).
24
q
q
Valve (7) is closed by spring (6) but pushed open

by hydraulic piston (5) to an opening ratio in proportion to the control oil pressure.
The valve opening ratio is sensed with position
sensor (4) installed to hydraulic piston (5) and
set to the specified opening ratio by controlling
the solenoid current.
The bypass valve assists the EGR gas by increasing the exhaust pressure.
The structure and operation of the EGR bypass
valve are the same as those of the EGR valve.
125E-5 Series
SEN00184-06
EGR cooler
A: EGR gas inlet

B: EGR gas outlet
C: Coolant inlet
D: Coolant outlet
E: Air bleeder
1. Heat exchange tube (Corrugated tube)

Function
q The EGR cooler cools the high-temperature
EGR gas taken out of the exhaust gas to increase the gas density, or the EGR efficiency.
Structure
The EGR cooler is a multi-tube heat exchanger.
When the high-temperature EGR gas flows
through heat exchange tube (1), it is cooled by
the coolant flowing outside of the tube.
q Heat exchange tube (1) is made of corrosion-resistant stainless steel and corrugated to increase the cooling efficiency.
q
125E-5 Series
25
SEN00184-06
Venturi system
A: Air inlet
B: EGR gas inlet
1. Venturi nozzle
2. Throat
3. Diffuser
Structure
q The EGR gas and intake air mix together in the
venturi system.
q The venturi system consists of throat (2), venturi
nozzle (1), and diffuser (3).
Operation
The boost pressure increased by the turbocharger is set negative temporarily with the venturi effect of the throat to take the EGR gas into
the intake air through venturi nozzle (1).
q When the mixture of the EGR gas and intake air
flows through diffuser (3), its pressure is increased again to the normal level and then it
flows in the intake manifold.
q
26
125E-5 Series
SEN00184-06
Cylinder head
1. Coolant air tube

2. Cylinder head bolt
3. Injector
4. Fuel spill tube
5. Valve guide
6. Cylinder head
7. Cylinder head cover
8. Valve seat insert
9. Rocker arm housing
125E-5 Series
27
SEN00184-06

Cylinder head
q Direct injection type
q 4-valve type
q Overhead injector (Common rail system specification)
q Split-type 1-cylinder, 1-head
Valve seat
Valve seat inserts are press fitted to both intake and exhaust valves
Head cover
Float-type seal
28
125E-5 Series
SEN00184-06
a Order of tightening cylinder head mounting bolts

a Tighten the cylinder head mounting bolts in the order of (1) ? (7).
Unit: mm
No.
1
Check item
Criteria
Tolerance
Repair limit
00.06
0.09
Engine
Standard
SAA6D125E - 5
3.203.90
Strain of cylinder head mounting

surface
2 Projection of nozzle
Bolt
Tightening torque of cylinder head

mounting bolt
(apply molybdenum disulfide or
engine oil to underside of bolt
head.)
Procedure
1st stage
(1)(6)
2nd stage
3rd stage
(7)
Tightening torque of injector mounting bolt
Tightening torque of rocker arm

housing mounting bolt
125E-5 Series
Remedy
Correct by grinding
or replace
Replace nozzle
sleeve
Target (Nm {kgm}) Range (Nm {kgm})

88.2107.8
98 {10}
{911}
166.6176.4
Tighten in order
176.4 {18}
{1718}
shown above
Retighten 120
90120
68.6 {7}
58.873.5 {67.5}
Target (Nm {kgm})
Range (Nm {kgm})
66 {6.75}
58.873.5 {6.07.5}
66 {6.75}
58.873.5 {6.07.5}
Tighten
29
SEN00184-06
Cylinder block
1. Cylinder block
2. Cylinder liner
3. Clevis seal
4. Liner ring (Ethylene-propylene rubber)
5. Liner ring (Silicone rubber)
6. Front seal
7. Front cover
8. Main cap bolt
9. Main bearing cap
10. Main bearing
11. Thrust bearing
12. Piston cooling nozzle
30
125E-5 Series
SEN00184-06
Cylinder block
q Crankshaft section: 7 bearings
q Camshaft section: 7 bearings
Front seal
Single lip with dust seal
Piston cooling
With piston cooling nozzle
Cylinder liner
Wet type
q Machining on inside: Plateau honing
Soft nitriding process
q
Liner ring
Upper: Clevis seal
q Middle: O-ring (Ethylene-propylene rubber)
q Lower: O-ring (Silicone rubber)
q
125E-5 Series
31
SEN00184-06
Unit: mm
No.
1
Check item
Strain of cylinder head mounting
surface
Diameter of main bearing mounting hole
Criteria
Tolerance
Repair limit
0 0.080
0.12
Standard size
Tolerance
+0.015
-0.010
116
Roundness of mounting hole

3
Standard size
Diameter of cam bushing mounting

hole
110
32
Tolerance
+0.040
+0.010
Standard size
63
Standard size
5 Inside diameter of cam bushing
Correct by grinding
or replace
Replace main bearing cap
Repair limit: 0.005
Thickness of main bearing
3 Inside diameter of main bearing
Remedy
60
Tolerance
+0.070
0
-0.005
-0.020
Repair limit
110.15
Tolerance
+0.030
0
Repair limit
60.30
Replace bearing
Replace main bearing
Correct or replace
cylinder block
Replace cam bushing
125E-5 Series
SEN00184-06
Unit: mm
No.
Check item
Tightening torque of main cap

(apply engine oil to threads)
Tightening torque for oil pan mounting bolt
Tightening torque for crankshaft

pulley mounting bolt
Criteria
Remedy
Procedure
1st stage
2nd stage
3rd stage
Target (Nm {kgm})

98 {10}
196 {20}
Retighten 90
Range (Nm {kgm})

88 108 {9 11}
191 201 {19.5 20.5}
Retighten 90(+30/0)
54 {5.5}
34 73 {3.5 7.5}
M16 (5 pieces)
274 {28}
245 309 {25 31.5}
M14 (1 piece)
176 {18}
157 196 {16 20}
Tighten
Level difference between underside
9 surfaces of cylinder block and flywheel housing

Level difference between underside
10 surfaces of cylinder block and front
cover
125E-5 Series
Repair limit: 0.35

Correct by reassembling
Repair limit: 0.28
33
SEN00184-06
Cylinder liner
Unit: mm
No.
Check item
1 Projection of cylinder liner

Inside diameter of cylinder liner
(unit)
Criteria
Remedy
Permissible range: 0.07 0.15
Replace cylinder liner or

cylinder block
Rank
Standard size
125
125
Roundness of inside of cylinder

liner (unit)
Cylindricality of inside of cylinder
liner (unit)
Outside diameter of cylinder liner

(at counterbore portion) (unit)
4
Interference of cylinder liner and
block (at bottom of counterbore)

(at O-ring)
Clearance between cylinder liner
and block (at O-ring)
34
Repair limit
125.20
125.20
Replace cylinder liner
(Spare liner is supplied
only for rank B)
Repair limit: 0.08

Repair limit: 0.08
Standard size
Tolerance
153
0.025
Interference of cylinder liner and

block (at counterbore portion)
(at bottom of counterbore)
Tolerance
+0.020
0
+0.040
+0.021
Standard clearance: 0 0.113

Standard size
Standard interference
Tolerance
+0.090
+0.040
Interference limit
0.010.12
0.01
Standard size
Tolerance
+0.386
+0.361
145
141
Standard clearance: 0.014 0.079

block
block
block
125E-5 Series
SEN00184-06
Main moving parts

a. Re-entrant combustion chamber
1. Piston (FCD piston)
2. Connecting rod bushing
3. Piston pin
4. Crankshaft
5. Crank gear (Number of teeth: 33)
6. Connecting rod cap
125E-5 Series
7. Connecting rod bearing

8. Connecting rod
9. Connecting rod cap bolt
10. Top ring
11. Second ring
12. Oil ring
35
SEN00184-06
Specifications
Crankshaft: Closed die forging
: Journal, fillet Induction hardening
Piston rings
Piston: Special thin ductile cast iron (FCD piston)

: Re-entrant combustion chamber
Connecting rod lubricating oil hole: Made
Piston cooling from connecting rod end: Applied
Features of FCD piston
q The FCD piston has high heat resistance.
q The FCD piston has low thermal expansion factor and the clearance between the liner and it
can be reduced.
q Since the FCD piston has high strength, the top
ring can be installed to a higher place, and the
loss area of the combustion chamber can be reduced.
q The exhaust sound is low and the exhaust gas
color is better.
q The output can be heightened.
36
Top ring (1): Double-side keystone, inner cut, barrel

face, hard chromium-plated
Second ring (2): Keystone, inner cut, taper face,
hard chromium-plated
Oil ring (3): With coil expander and nitrided surface
125E-5 Series
SEN00184-06
Crankshaft
Unit: mm
No.
Check item
1 End play
Criteria
Standard value
Repair limit
0.140 0.315
0.50
Standard size
Outside diameter of main journal
Roundness
Clearance of crankshaft pin journal
4 Bend of crankshaft
125E-5 Series
Repair limit
110
109.88
0.25 U.S.
109.75
109.63
0.50 U.S.
109.50
0.75 U.S.
109.25
109.13
1.00 U.S.
109.00
108.88
-0.050
-0.070
109.38
Standard
Repair limit
0 0.010
0.020
Standard clearance
Clearance limit
0.062 0.106
0.27
Standard size
Outside diameter of crank pin journal
Tolerance
Replace thrust bearing or use oversize

bearing
S.T.D.
Roundness
Clearance of main journal
Remedy
Tolerance
Use undersize journal or replace
Replace main bearing
Repair limit
S.T.D.
80
79.88
0.25 U.S.
79.75
79.63
0.50 U.S.
79.50
0.75 U.S.
79.25
79.13
1.00 U.S.
79.00
78.88
-0.050
-0.070
79.38
Standard
Repair limit
0 0.010
0.020
Standard clearance
Clearance limit
0.046 0.090
0.24
Standard
Repair limit
0 0.09
0.20
Use undersize journal or replace
Replace connecting
rod bearing
Use undersize
crank-shaft or
replace
37
SEN00184-06
Camshaft
Unit: mm
No.
Check item
1 End play
Outside diameter of camshaft journal
2
Clearance of camshaft journal
3 Bend of camshaft
Criteria
Standard
Repair limit
0.15 0.35
0.50
Standard size
Standard clearance
Tolerance
-0.080
-0.110
Clearance limit
0.080 0.180
0.28
60
38
Replace thrust plate
Replace
Replace cam bushing
Repair limit: 0.03 (Overall swing of indicator)

Standard size
4 Height of cam
Remedy
52
Tolerance
+0.395
+0.195
Repair limit
Replace
51.73
125E-5 Series
SEN00184-06
Cam follower and push rod
Unit: mm
No.
Check item
Criteria
Standard size
Diameter of cam follower shaft
1
Diameter of cam follower shaft hole
2 Outside diameter of cam roller
Tolerance
-0.040
-0.050
+0.020
0
-0.250
-0.280
-0.262
-0.287
-0.364
-0.376
19.8
19.8
32
Inside diameter of cam roller
13
Diameter of cam roller pin
13
Remedy
Repair limit
19.73
31.70
12.78
Replace
12.62
Standard size
4 Radius of push rod ball end

5 Radius of push rod socket end
6 Bend of push rod
Tightening torque of cam follower

shaft mounting bolt
125E-5 Series
Tolerance
0
12.7
-0.20
0
12.7
-0.20
51 7.4 Nm {5.25 0.75 kgm}
Tighten
39
SEN00184-06
Piston, piston ring and piston pin
40
125E-5 Series
SEN00184-06
Unit: mm
No.
Check item
Outside diameter of piston
Thickness of piston ring
Width of piston ring groove
24
Clearance between piston ring and
piston ring groove
Closed gap of piston ring
Criteria
Rank
Standard size
A or S
125
B or L
125
No.
Measuring point
Tolerance
-0.090
-0.105
-0.075
-0.090
Standard size
No. 1 ring
2.42
No. 2 ring
2.4
Oil ring
No. 1 ring
No. 2 ring
Oil ring
+0.040
+0.020
No.
Measuring point
Standard clearance
Clearance limit
No. 1 ring
Diameter of piston pin hole

Clearance between piston pin and
piston
Weight of piston
Repair limit
124.80
124.80
Tolerance
-0.005
-0.025
-0.010
-0.030
-0.010
-0.030
No. 2 ring
Oil ring
0.030 0.070
0.15
No. 1 ring
0.37 0.47
2.0
No. 2 ring
1.10 1.20
2.0
Oil ring
0.23 0.35
1.0
Standard clearance
Tolerance
0
-0.006
+0.045
+0.035
Clearance limit
0.035 0.051
0.063
48
48
Replace piston
(Spare piston is
supplied for only
rank A or S)
Replace piston ring
*1 Check with groove wear gauge

(When new ring is installed, clearance is 0.15)
Replace piston
Check with groove wear gauge
Standard size
Outside diameter of piston pin
Remedy
3,000g, Permissible range: 60 g
Replace piston or
piston ring
Replace piston ring

or cylinder liner
Replace piston pin

Replace piston
Replace piston or
piston pin
Replace piston
a *1: Part No. (Groove wear gauge) 795-901-1130
125E-5 Series
41
SEN00184-06
Connecting rod
Unit: mm
No.
Check item
Inside diameter of connecting rod
small end bushing
1
Clearance between connecting rod
small end bushing and piston pin
Diameter of connecting rod small

end bushing mounting hole
Inside diameter of connecting rod
3 large end bearing

(crank pin journal)
Diameter of connecting rod large

end bearing mounting hole
Thickness of connecting rod bearing
Parallelism and twist of connecting

rod
Tightening torque of connecting rod

cap mounting bolt
(Apply engine oil to bolt threads
and nut seat)
Weight of connecting rod
Criteria
Standard size
Tolerance
+0.041
+0.025
48
Remedy
Repair limit
48.08
Standard clearance
Clearance limit
0.025 0.047
0.10
Standard size
Tolerance
+0.030
0
Repair limit
53
Standard size
Tolerance
+0.020
80
80.12
-0.010
+0.022
85
-0.004
Before measuring, tighten connecting rod cap mounting bolt to specified torque.
+0.005
2.5
-0.004
Item
Standard
Repair limit
Parallelism a
0 0.20
0.25
Twist b
0 0.30
0.35
Dimension c
240
Procedure
Target (Nm {kgm})
Range (Nm {kgm})
1st stage
98 {10}
93 103 {9.5 10.5}
2nd stage
Retighten 90
Retighten 90 (+30/0)
Permissible range: Dispersion of weight of connecting rods in 1

engine must not exceed 140 g.
Replace bushing
(Spare is half
worked)
Replace bushing or
piston pin
Replace connecting rod
Replace bearing

Replace bearing
Retighten
Replace
a Do not use a connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on its head.
42
125E-5 Series
SEN00184-06
Flywheel and flywheel housing

Without PTO

1. Flywheel housing
2. Ring gear
3. Flywheel
4. Rear seal
125E-5 Series
Applicable machine
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8,
PC450-8, PC450LC-8,
D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
BR580JG-1, GD755-5R
WA450-6, WA470-6,
WA470-6R
WA480-6, WA480-6R
HM250-2
HM300-2, HM300-2R
Number of
teeth of ring
gear
Number of
internal
teeth of flywheel
148
137
43
SEN00184-06
a Tighten the flywheel mounting bolts with an impact wrench in the 1st stage and then tighten
them with a torque wrench in the 2nd stage.
A: Tightening order of flywheel mounting bolts
B: Tightening order of flywheel housing mounting
bolts
44
125E-5 Series
SEN00184-06
Unit: mm
No.
Check item
Criteria
1 Face runout of flywheel housing
Repair limit: 0.35
2 Radial runout of flywheel housing
Repair limit: 0.30

Bolt
Tightening torque of flywheel housing mounting bolt
Procedure
Target (Nm {kgm})
Range (Nm {kgm})
1st stage
191 {19.5}
147 235 {15 24}
2nd stage
279 {28.5}
245 309 {25 31.5}
69 {7}
59 74 {6 7.5}
4 Facial runout of flywheel
Repair limit: 0.20
5 Radial runout of flywheel
Repair limit: 0.15
M16
M10
Tightening torque for flywheel

mounting bolt (Apply engine oil to
threads)
Remedy
Tighten
Procedure
Target (Nm {kgm})
Range (Nm {kgm})
1st stage
147 {15}
127 167 {13 17}
2nd stage
289 {29.5}
270 309 {27.5 31.5}
Tighten
a Do not use a flywheel mounting bolt more than 5

times.
Each time the bolt is used, make a punch mark
on its head.
125E-5 Series
45
SEN00184-06
DCA-300SSK4 (DENYO/MQ GENERATOR)

a Tighten the flywheel mounting bolts with an impact wrench in the 1st stage and then tighten
them with a torque wrench in the 2nd stage.
46
125E-5 Series
SEN00184-06
A: Tightening order of flywheel mounting bolts

B: Tightening order of flywheel housing mounting
bolts
1. Flywheel housing
2. Seal
3. Flywheel
Applicable machine
DCA-300SSK4
Number of
teeth of
ring gear
Number of
internal teeth
of flywheel
178
Unit: mm
No.
Check item
Criteria
Facial runout of flywheel housing
Repair limit: 0.25
Radial runout of flywheel housing
Repair limit: 0.25

Bolt
Tightening torque of flywheel housing mounting bolt
Remedy
Procedure
Target (Nm {kgm})
Range (Nm {kgm})
1st stage
191 {19.5}
147 235 {15 24}
2nd stage
279 {28.5}
245 309 {25 31.5}
69 {7}
59 74 {6 7.5}
M16
M10
Tighten
Facial runout of flywheel
Repair limit: 0.28
Radial runout of flywheel
Repair limit: 0.13
Tightening torque for flywheel

mounting bolt (Apply engine oil to
threads)
Procedure
Target (Nm {kgm})
Range (Nm {kgm})
1st stage
147 {15}
127 167 {13 17}
2nd stage
289 {29.5}
270 309 {27.5 31.5}
Tighten
a Do not use a flywheel mounting bolt more than 5

times.
Each time the bolt is used, make a punch mark
on its head.
125E-5 Series
47
SEN00184-06
Vibration damper

1. Vibration damper
2. Pin
3. Crankshaft pulley
4. Crankshaft pulley mounting bolt
5. Vibration damper mounting bolt
48
125E-5 Series
SEN00184-06
Unit: mm
No.
Check item
1 Outside check
Criteria
Rubber parts must be free from cracking and flaking.
2 Radial runout of damper
Repair limit: 0.80
3 Facial runout of damper
Repair limit: 0.80
Tightening torque of vibration

damper mounting bolt
125E-5 Series
Remedy
Replace
Bolt
Target (Nm {kgm})
Range (Nm {kgm})
M12
111 {11.3}
98 213 {10 12.5}
Tighten
49
SEN00184-06
Timing gear
(with EGR)

1. Cylinder block
2. Water pump drive gear (Number of teeth: 22)
3. Main idler gear (Number of teeth: 57)
4. EGR oil pump drive gear (Number of teeth: 20)
5. Main idler gear, small (Number of teeth: 38)
6. Oil pump drive gear (Number of teeth: 21)
50
7. Oil pump idler gear (Number of teeth: 25)

8. Injection drive gear (Number of teeth: 44)
9. Timing gear cover
10. Camshaft gear (Number of teeth: 44)
11. Crankshaft gear (Number of teeth: 33)
12. Crankshaft
A.B.C: Timing gear mating marks
125E-5 Series
125E-5 Series
SEN00184-06
51
SEN00184-06
Unit: mm
No.
Check item
Criteria
Position
Backlash of each gear
1
2
Clearance between main idler gear

bushing and shaft
Clearance between oil pump idler
gear bushing and shaft
3 End play of main idler gear

4 End play of oil pump idler gear
52
Check parts
Remedy
Standard
Crank gear and main idler gear (large) 0.116 0.359
Main idler gear (small) and cam gear
0.105 0.325
Cam gear and fuel supply pump gear
0.105 0.325
Main idler gear (large) and water

a
pump gear
Main idler gear (large) and oil pump
b
idler gear
Oil pump idler gear and oil pump drive
c
gear
Tolerance
Standard size
Shaft
Hole
+0.165
+0.115
47.5
+0.140
+0.100
-0.025
+0.065
35
-0.040
0
Standard
Repair limit
Replace
0.6
0.076 0.366
0.105 0.337
0.082 0.389
Standard
clearance
Clearance
limit
0.025 0.060
0.20
0.025 0.105
0.20
Replace
bushing
Repair limit
0.05 0.17
0.4
0.05 0.21
0.4
Replace
thrust bearing
125E-5 Series
125E-5 Series
SEN00184-06
53
SEN00184-06
(EGR-less)

1. Cylinder block
2. Water pump drive gear (Number of teeth: 22)
3. Main idler gear (Number of teeth: 57)
4. Main idler gear, small (Number of teeth: 38)
5. Oil pump drive gear (Number of teeth: 21)
6. Oil pump idler gear (Number of teeth: 25)
54
7. Injection drive gear (Number of teeth: 44)

8. Timing gear cover
9. Camshaft gear (Number of teeth: 44)
10. Crankshaft gear (Number of teeth: 33)
11. Crankshaft
A.B.C: Timing gear mating marks
125E-5 Series
125E-5 Series
SEN00184-06
55
SEN00184-06
Unit: mm
No.
Check item
Criteria
Position
Backlash of each gear
1
2
Clearance between main idler gear

bushing and shaft
Clearance between oil pump idler
gear bushing and shaft
3 End play of main idler gear

4 End play of oil pump idler gear
56
Check parts
Remedy
Standard
Crank gear and main idler gear (large) 0.116 - 0.359
Main idler gear (small) and cam gear
0.105 - 0.325
Cam gear and fuel supply pump gear
0.105 - 0.325
Main idler gear (large) and water

a
pump gear
Main idler gear (large) and oil pump
b
idler gear
Oil pump idler gear and oil pump drive
c
gear
Tolerance
Standard size
Shaft
Hole
+0.165
+0.115
47.5
+0.140
+0.100
-0.025
+0.065
35
-0.040
0
Standard
Repair limit
Replace
0.6
0.076 - 0.366
0.105 - 0.337
0.082 - 0.389
Standard
clearance
Clearance
limit
0.025 - 0.060
0.20
0.025 - 0.105
0.20
Replace
bushing
Repair limit
0.05 - 0.17
0.4
0.05 - 0.21
0.4
Replace
thrust bearing
125E-5 Series
125E-5 Series
SEN00184-06
57
SEN00184-06
Valve system
1. Rocker arm shaft

2. Cam roller
3. Cam roller pin
4. Camshaft
5. Cam gear (Number of teeth: 44)
6. Adjustment screw
7. Locknut
8. Cross head
9. Valve seat (upper)
10. Intake valve
58
11. Valve spring

12. Valve spring seat (lower) (both IN and EX)
13. Adjustment screw
14. Locknut
15. Rocker arm
16. Push rod
17. Cam follower
18. Valve cotter
19. Exhaust valve
20. Valve stem seal (both IN and EX)
125E-5 Series
SEN00184-06
A: No.1 cylinder intake side

B: No.1 cylinder exhaust side
Camshaft: Closed die forging
Journal and cam sections: Induction hardening
125E-5 Series
59
SEN00184-06
Parts related to valves

Part
Cross head
Valve
Valve spring
(Color code)
Valve spring seat
(lower)
Valve rotator
Valve guide
Valve stem seal
IN
6150-42-5610
6150-42-4110
6251-41-4450
( Light blue )
EX
6150-42-5610
6150-42-4210
6251-41-4450
( Light blue )
6150-41-4430 6150-41-4430
6150-11-1370 6150-11-1370
6150-41-4570 6150-41-4570
Valve timing
60
125E-5 Series
125E-5 Series
SEN00184-06
61
SEN00184-06
Valve and valve guide
Unit: mm
No.
Check item
1 Sinking distance of valve
2 Thickness of valve lip
3 Valve seat angle
Diameter of valve stem
Inside diameter of valve guide
4
Clearance between valve guide
and stem
Bend of valve stem
62
Criteria
Remedy
Valve
Standard size
Tolerance
Repair limit
Intake
1.88
0.10
2.51
Exhaust
1.20
0.10
1.90
Valve
Standard size
Repair limit
Intake
2.10
1.7
Exhaust
1.50
1.2
Intake
Exhaust
Standard
30 15L
45 15L
Valve
Standard size
Intake
Exhaust
Tolerance
-0.045
-0.065
-0.050
-0.070
+0.015
-0.003
+0.009
-0.011
Clearance limit
Before head is
press fitted
After head is
press fitted
Valve
Intake/Exhaust
9
valve
Intake/Exhaust
9
valve
Standard clearance
Intake
0.034 ? 0.074
0.22
Exhaust
0.039 ? 0.079
0.24
Repair limit: 0.01 (Overall swing of indicator in 100 mm)
Replace valve or
valve seat
Replace valve
Correct or replace
valve or valve seat
Replace valve
Replace valve
guide
Replace valve or
valve guide
Replace
125E-5 Series
SEN00184-06
Unit: mm
No.
Check item
Criteria
5 Driving height of valve guide
Free length of valve spring
6
Installed load of valve spring
Perpendicularity of valve spring
125E-5 Series
Remedy
Standard
Tolerance
22
0.2
Correct
Valve
Color code
Standard size
Repair limit
Intake
Light blue
76.2
Exhaust
Light blue
76.2
Valve
Color code
Installed
length
Intake
Light blue
56.0
Exhaust
Light blue
56.0
Standard load Allowable load

Replace valve
(N {kg})
(N {kg})
spring
519.8 26
468 {47.7}
{53.0 2.7}
519.8 26
468 {47.7}
{53.0 2.7}
Repair limit: 2 (both sides)
63
SEN00184-06
Rocker arm and shaft
Unit: mm
No.
Check item
Criteria
Standard size
Standard clearance
Tolerance
-0.053
-0.066
+0.033
-0.027
Clearance limit
0.026 0.099
0.13
Diameter of rocker arm shaft
28.6
Diameter of rocker arm shaft hole
1
Clearance between rocker arm
shaft and rocker arm
Bend of rocker arm shaft
Tightening torque of locknut of

rocker arm adjustment screw
Valve clearance
(Both when hot and cold)
28.6

Target (Nm {kg})
Range (Nm {kg})
59 {6.0}
53 65 {5.4 6.6}
Valve
Standard
Intake side
0.33
Replace rocker arm

and shaft
Replace rocker arm
Replace rocker arm
or rocker arm shaft
Replace rocker arm
shaft
Tighten
Tolerance
0.02
Exhaust side
64
Remedy
Adjust
0.71
125E-5 Series
SEN00184-06
Crosshead and guide
Unit: mm
No.
Check item
Criteria
Standard size
Inside diameter of crosshead
1
Outside diameter of crosshead
guide
2 Projection of crosshead guide
125E-5 Series
11
11
45.5
Remedy
Tolerance
+0.075
+0.025
+0.011
0
Repair limit
0.25
11.18
Replace
10.95
Correct
65
SEN00184-06

Form Number : SEN00184-06
2011 KOMATSU
All Rights Reserved
66
SEN00185-06
ENGINE
1SHOP MANUAL
125E-5 Series
10 Structure, function and

maintenance standard
Structure, function and maintenance

standard, Part 2
Lubrication system .......................................................................................................................................... 4
Lubrication system diagram ................................................................................................................. 4
Oil pump............................................................................................................................................... 8
Main relief valve ................................................................................................................................... 9
EGR oil pump..................................................................................................................................... 10
Oil filter ................................................................................................................................................11
Safety valve........................................................................................................................................ 13
Oil cooler ............................................................................................................................................ 14
Fuel system................................................................................................................................................... 16
CRI system diagram........................................................................................................................... 16
Outline of CRI system ........................................................................................................................ 18
125E-5 Series
SEN00185-06
Fuel piping.......................................................................................................................................... 40
Fuel filter............................................................................................................................................. 42
Electric priming pump......................................................................................................................... 44
Engine controller cooler...................................................................................................................... 45
Cooling system.............................................................................................................................................. 46
Cooling system diagram..................................................................................................................... 46
Water pump ........................................................................................................................................ 48
Thermostat ......................................................................................................................................... 50
Electrical equipment...................................................................................................................................... 52
Alternator............................................................................................................................................ 52
Starting motor ..................................................................................................................................... 60
Electrical intake air heater .................................................................................................................. 64
Engine controller ................................................................................................................................ 65
125E-5 Series
125E-5 Series
SEN00185-06
SEN00185-06
Lubrication system
Lubrication system diagram
(with EGR)
The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
125E-5 Series
SEN00185-06
W: Coolant
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Oil pan
Oil strainer
Oil pump
Oil pump relief valve
Oil cooler
Thermo-valve
Oil filter
Safety valve
Crankshaft
Piston cooling nozzle
Piston
Camshaft
Cam follower
Rocker arm
Air intake valve and exhaust valve
Timing gear
Turbocharger
Fuel supply pump
EGR oil pump
EGR oil pump relief valve
EGR valve
Bypass valve
Main gallery
Oil filter clogging switch (for DCA-300SSK4)
125E-5 Series
SEN00185-06
(EGR-less)
The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
125E-5 Series
SEN00185-06
W: Coolant
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Oil pan
Oil strainer
Oil pump
Oil pump relief valve
Oil cooler
Thermo-valve
Oil filter
Safety valve
Crankshaft
Piston
Camshaft
Cam follower
Rocker arm
Air intake valve and exhaust valve
Timing gear
Turbocharger
Fuel supply pump
Main gallery
125E-5 Series
SEN00185-06
Oil pump
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Oil pump drive gear (Number of teeth: 21)

Bushing
Pump cover
Drive gear
Pump body
Drive shaft
Main relief valve
Valve spring
Retainer
Drive shaft
Bushing
Driven gear
Oil pump gear

Type: Gear pump
Speed: Engine speed 1.571
Main relief valve
Cracking pressure:
0.65 0.8 MPa {6.63 8.16 kg/cm2}
125E-5 Series
Main relief valve
SEN00185-06
Unit: mm
No.
1
Check item
Cracking pressure of
relief valve
125E-5 Series
Criteria
Standard: 0.65 0.8 MPa {6.63 8.16 kg/cm2}
Remedy
Correct or
replace spring
SEN00185-06
EGR oil pump
A:
B:
C:
From main gallery

To EGR valve and bypass valve
Rotation direction
1.
2.
3.
4.
5.
6.
7.
Pump cover
Driven gear
Pump body
Drive gear
Pump drive gear (Number of teeth: 20)
Main relief valve
Main valve spring
10
Specifications
Oil pump
Type: Gear pump
Main relief valve
Cracking pressure:
1.43 0.1 MPa {14.6 1.0 kg/cm2}
125E-5 Series
Oil filter
SEN00185-06
Remote mount type
A:
B:
Oil inlet
Oil outlet
1.
2.
3.
Safety valve
Filter head
Cartridge
125E-5 Series
Specifications
Oil filter
Filtration area: 0.44 m2 (Full-flow)
Safety valve
Cracking pressure: 343 19 kPa {3.5 0.2 kg/cm2}
11
SEN00185-06
Remote mount type (for DCA-300SSK4)
A:
B:
Oil inlet
Oil outlet
1.
2.
3.
4.
Safety valve
Filter head
Cartridge
Clogging switch
Specifications
Oil filter
Filtration area: 0.44 m2 (Full-flow)
Safety valve
Cracking pressure: 343 19 kPa {3.5 0.2 kg/cm2}
Clogging switch
Operating pressure: 147
12
+39
0
kPa {1.5
+0.4
0
kg/cm2}
125E-5 Series
Safety valve
1.
2.
3.
4.
SEN00185-06
Safety valve
Filter head
Spring
Cap
Unit: mm
No.
1
Check item
Cracking pressure of safety
valve
125E-5 Series
Criteria
Standard: 343 19 kPa {3.5 0.2 kg/cm2}
Remedy
Replace
13
SEN00185-06
Oil cooler
a.
b.
c.
d.
Water drain
Oil inlet
To each part of engine (Oil)
Water inlet
1.
2.
3.
4.
5.
Thermostat cover
Thermostat (Thermo-valve)
Cooler cover
Cooler element
Strainer
Oil cooler thermostat (Thermo-valve)

Opening temperature:
71C 1.5C
Full opening temperature: 85C
Full opening lift:
Min. 8 mm
Oil cooler
Heat dissipation surface: 0.575 m2
Unit: mm
No.
Check item
Full opening lift of thermostat SAA6D125E-5
14
Criteria
Min. 8 mm
(Check after soaking in oil tank at 85C for 4 5 minutes)
Opening and closing of ther- When valve full open (at 85C) is soaked in oil tank at full closing temperamostat
ture (71C), it must close fully in 4 5 minutes.
Remedy
Replace
125E-5 Series
125E-5 Series
SEN00185-06
15
SEN00185-06
Fuel system
CRI system diagram
(with EGR)
CRI is an abbreviation for Common Rail Injection. Hereinafter, the common rail injection is referred to
as the CRI.
1.
2.
Fuel tank
Fuel supply pump assembly
2A. PCV
2B. High pressure pump
2C. Priming pump
2D. Feed pump
2E. Bypass valve
2F. G speed sensor
16
3.
4.
5.
6.
7.
8.
9.
10.
Fuel filter
Overflow valve
Common rail
Pressure limiter
Flow damper
Injector assembly
Engine controller
NE speed sensor
11. Large-capacity priming pump

12. Check valve
13. Pre-fuel filter
125E-5 Series
SEN00185-06
(EGR-less)
CRI is an abbreviation for Common Rail Injection. Hereinafter, the common rail injection is referred to
as the CRI.
1.
2.
Fuel tank
Fuel supply pump assembly
2A. PCV
2B. High pressure pump
2C. Priming pump
2D. Feed pump
2E. Bypass valve
2F. G speed sensor
125E-5 Series
3.
4.
5.
6.
7.
8.
9.
10.
Fuel filter
Overflow valve
Common rail
Pressure limiter
Flow damper
Injector assembly
Engine controller
NE speed sensor
11. Electric priming pump

12. Water separator
13. Pre-fuel filter
17
SEN00185-06
Outline of CRI system

Outline
q
The CRI system checks the condition of the
engine (engine speed, accelerator angle, coolant temperature, etc.) with sensors.
q
The microcomputer of the CRI system controls
the fuel injection rate, fuel injection timing, fuel
injection pressure, etc. totally to operate the
engine under the best condition.
q
The CRI system has a diagnosis function and
an alarm function, with which the computer of
the system checks the main component parts
and notifies the operator of detected failures.
q
In addition, the CRI system has a failsafe function which stops the engine when a certain
parts fail and a backup function which continues the operation by changing the control
method in such a case.
1
1. Fuel system
Configuration
The CRI system is divided by the function into
the fuel system and control system.
18
The fuel system distributes the high-pressure

fuel supplied by the fuel supply pump to the
cylinders through the common rail.
The solenoid valve in the injector opens and
closes the nozzle needle valve to start and finish injection.
125E-5 Series
SEN00185-06
2. Control system
Parts marked with * (2 places) are installed to only the engines with EGR.
The engine controller calculates and controls

the energizing timing and energizing period of
the injector with the signals from the sensors
installed to the machine to inject proper quantity of fuel in proper timing.
The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.
125E-5 Series
19
SEN00185-06
Structure and operation of CRI system
20
The CRI system consists of the fuel supply

pump, common rail, injector, engine controller
to control them, and sensors.
The fuel supply pump generates fuel pressure
in the common rail. The fuel pressure is controlled by the fuel discharge rate of the supply
pump.
The discharge rate is controlled by turning on
and off the PCV (pressure control valve) of the
fuel supply pump according to the electric signals from the engine controller.
The common rail receives the pressurized fuel
from the fuel supply pump and distributes it to
the cylinders.
The fuel pressure is sensed by the common
rail fuel pressure sensor installed to the common rail.
A feedback control is applied so that the actual
fuel pressure will match to the command pressure set according to the engine speed and the
load on the engine.
The fuel pressure in the common rail is applied
to the nozzle side of the injector and to the
control chamber through the fuel injection pipe
of each cylinder.
The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve).
If the TWV is turned on (energized), the fuel

circuit is so changed that the high-pressure
fuel in the control chamber will flow through the
orifice. As a result, the needle valve is raised
to start fuel injection by the nozzle cracking
pressure of the high-pressure fuel on the nozzle side.
If the TWV is turned off (de-energized), the fuel
circuit is so changed that the high-pressure
fuel will be applied to the control chamber
through the orifice. As a result, the needle
valve lowers and finishes fuel injection.
Accordingly, the fuel injection timing and fuel
injection rate are controlled respectively by the
timing to turn on the TWV and the length of the
turn-on time of the TWV.
125E-5 Series
SEN00185-06
Structure and operation of component parts
1. Fuel supply pump
1.
2.
3.
4.
5.
3-head cam
Overflow valve
Drive gear
No. 1 high-pressure pump
PCV (Pressure control valve)
Outline
q
The fuel supply pump consists of priming
pump (7), feed pump (8), and high-pressure
pumps (4) and (6).
q
The function of the fuel supply pump is to generate common rail fuel pressure by controlling
the fuel delivery.
Structure
High-pressure pumps (4) and (6) have the
pressure feed systems similar to those of the
conventional in-line fuel injection pump and the
PCVs (pressure control valves) for each cylinder to control the fuel delivery.
q
By employing the 3-head cam, the necessary
number of the cylinders of high-pressure
pumps (4) and (6) is reduced to 1/3 of the
engine cylinders.
q
125E-5 Series
6.
7.
8.
9.
No. 2 high-pressure pump

Priming pump
Feed pump
Gear for Bkup speed sensor (G sensor)
Since the number of the times of feeding fuel

to the common rail is the same as the number
of the times of fuel injection, the common rail
fuel pressure is smooth and stable.
The fuel fed by high-pressure pumps (4) and
(6) to the common rail is divided as follows.
No. 1 high-pressure pump (on the drive gear
side) (4) compensates for drop in the common
rail fuel pressure caused by fuel injection into
the No. 1, 3, and 5 cylinders.
No. 2 high-pressure pump (on the feed pump
side) (6) compensates for drop in the common
rail fuel pressure caused by fuel injection into
the No. 2, 4, and 6 cylinders.
q
q
21
SEN00185-06
Operation
22
(A): During the lowering stroke of the plunger,

the PCV is open and the low-pressure fuel
is sucked in the plunger chamber through
the PCV.
(B): While the PCV is not energized and is
open after the plunger starts the rising
stroke, the sucked fuel is returned through
the PCV without being pressurized.
(C): If the PCV is energized and closed in the
timing for the necessary delivery, the return
passage is closed and the pressure in the
plunger chamber rises. Accordingly, the
fuel is fed through the delivery valve (check
valve) to the common rail. That is, the
quantity of the fuel corresponding to the
plunger lift after the PCV is closed is the
delivery. The delivery is changed and the
common rail fuel pressure is controlled by
changing the opening timing of the PCV.
(D): After the cam passes the maximum lift
point, the plunger starts the lowering
stroke and the pressure in it lowers. At
this time, the delivery valve closes to stop
feeding the fuel. Since the PCV is deenergized, it opens and the low-pressure
fuel is sucked in the plunger chamber, or
the state of (A) starts again.
125E-5 Series
1)
q
PCV (Pressure control valve)

The PCV adjusts the fuel delivery from the fuel
supply pump to adjust the common rail fuel
pressure. The delivery from the fuel supply
pump to the common rail is decided by the timing of energizing the PCV.
SEN00185-06
2)
q
q
q
125E-5 Series
Feed pump
The feed pump built in the fuel supply pump
assembly draws the fuel from the fuel tank and
sends it through the fuel filter to the high-pressure pump chamber.
The outer and inner rotors of the feed pump
are rotated by the camshaft.
The fuel is sucked in on the suction side and
discharged on the delivery side according to
the increase and decrease of the spaces
between the outer and inner rotors.
23
SEN00185-06
2. Common rail
Structure
q
Common rail (4) distributes the high-pressure
fuel from the high-pressure pump to the injectors of the cylinders.
q
Common rail (4) is equipped with common rail
fuel pressure sensor (2), flow dampers (1), and
pressure limiter (3).
q
The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
the injectors.
q
The piping of the pressure limiter (3) is
returned to the fuel tank.
1)
Operation
When fuel is not injected
q
Piston (2) is in contact with stopper (1) (initial
position).
q
The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
When fuel is injected
q
The fuel pressure is applied to piston (2),
which compresses spring (3) and moves to the
right.
q
The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
When fuel is stopped
q
If the fuel flows out abnormally because of a
burst of the piping, etc., piston (2) moves to the
right stroke end.
q
The tip of piston (2) contacts seat (b) to stop
the fuel.
q
Once the fuel is stopped, piston (2) does not
return to the initial position until the engine is
stopped.
Flow damper
Function
q
The flow dampers damp the pressure pulses in
the high pressure piping and supply the fuel to
the injectors with stable pressure.
q
If excessive fuel flows out, the flow dampers
block the fuel passage to prevent abnormal
outflow of the fuel.
q
If the fuel flows out abnormally, high pressure
is applied to the piston, which moves to the
right until it reaches the seat to stop the fuel.
24
125E-5 Series
2)
q
1.
2.
3.
4.
5.
Pressure limiter
If abnormally high pressure is generated, the
pressure limiter opens to release that pressure.
If the common rail fuel pressure reaches about
200 MPa {2,040 kg/cm2}, the pressure limiter
operates (opens).
If the common rail fuel pressure lowers to 30
MPa {310 kg/cm2}, the pressure limiter resets
itself (closes) to maintain the pressure.
Under the normal condition, the pressure limiter does not reset itself (close) until the engine
is stopped.
SEN00185-06
3)
q
Common rail fuel pressure sensor

The common rail fuel pressure sensor is
installed to the common rail to sense the fuel
pressure.
This sensor is a semiconductor pressure sensor, which utilizes the phenomenon that the
electric resistance of silicon changes according
to pressure applied to it.
Ball
Housing
Spring
Body
Guide
125E-5 Series
25
SEN00185-06
3. Injector
Outline
q
The function of the injector is to inject the highpressure fuel from the common rail into each
combustion chamber of the engine in the optimum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q
The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q
The orifice limits the opening speed of the nozzle and controls the fuel injection rate.
q
The hydraulic piston transmits the force generated by the pressure in the control chamber to
the needle valve of the nozzle.
q
The nozzle sprays the fuel.
26
125E-5 Series
SEN00185-06
Structure
1.
2.
3.
4.
5.
6.
Inlet connector
Terminal
Upper body
Solenoid
Valve body
Orifice (out)
The injector consists of the nozzle section, orifice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve section.
125E-5 Series
7.
8.
9.
10.
11.
12.
Orifice (in)
Pressure control chamber
Control piston
Spring
Pressure pin
Nozzle assembly
27
SEN00185-06
A:
B:
No fuel injection
Start of fuel injection
C:
D:
Finish of fuel injection

From common rail
1.
2.
3.
4.
Nozzle
Control piston
Orifice (in)
Orifice (out)
5.
6.
7.
8.
Valve body
Solenoid
Spring
Pressure control chamber
3)
Finish of fuel injection (C)

If solenoid (6) is de-energized, valve body (5)
is lowered by spring (7) and the fuel passage is
closed.
At this time, the high-pressure fuel in the common rail is applied to pressure control chamber
(8) suddenly and nozzle (1) is closed quickly,
fuel injection is finished sharply.
Operation
1)
q
q
2)
q
q
q
28
No fuel injection (A)

While solenoid (6) is not energized, valve body
(5) is pressed down by spring (7).
Since the high-pressure fuel is applied from
the common rail to pressure control chamber
(8), nozzle (1) is closed and the fuel is not
injected.
Start of fuel injection (B)

If solenoid (6) is energized, valve body (5) is
pulled up by the electromagnetic force and the
fuel passage is opened.
Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and fuel injection pump starts.
The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
If solenoid (6) is kept energized, the fuel injection rate is increased to the maximum.
125E-5 Series
SEN00185-06
Electric circuit diagram
Since high voltage (118 V) is applied to the

wiring harnesses connected to the engine
controller, COMMON 1 and COMMON 2 of
the supply pump, and TWV #1 #6 of the
injector, take care not get an electric shock.
125E-5 Series
29
SEN00185-06
Various controls
Parts marked with * (3 places) are installed to only the engines with EGR.
The CRI system controls the fuel injection rate

and fuel injection timing more properly than the
mechanical governor or timer of the conventional fuel injection pump.
For the control of the system, calculations necessary to the engine controller are performed
from the signals sent from the sensors
installed to the engine and machine.
The energizing timing and energizing period of
the injector are so controlled that the optimum
quantity of fuel will be injected in the optimum
timing.
2. Fuel injection timing control function

q
3. Fuel injection pressure control function

(Common rail fuel pressure control function)
q
1. Fuel injection rate control function

q
30
The fuel injection rate control function is

employed instead of the function of the conventional governor. It controls the fuel injection
according to the signals of engine speed and
accelerator angle so that the fuel injection rate
will be most proper.
The fuel injection timing control function is

employed instead of the function of the conventional timer. It controls the fuel injection
timing most properly from the engine speed
and fuel injection rate.
The fuel injection pressure control function

(common rail fuel pressure control function) is
a function of measuring the fuel pressure with
the common rail fuel pressure sensor and
feeding it back to the engine controller to control the delivery of the fuel supply pump.
This function performs pressure feedback control so that the fuel injection pressure will be
the same as the optimum value (command
value) set according to the engine speed and
fuel injection rate.
125E-5 Series
125E-5 Series
SEN00185-06
31
SEN00185-06
4. Various sensors
a
a
a
32
Nos. 1 13 in the above illustration correspond to title Nos. 1) 13).

The above illustration shows the engine for HM300-2.
Parts *1, *3 and *4 are installed to only the engines with EGR.
125E-5 Series
125E-5 Series
SEN00185-06
33
SEN00185-06
1)
q
34
EGR inlet pressure sensor (with EGR)

(Applicable machine: HM300-2)
This sensor is used to sense the EGR pressure.
2)
q
Atmospheric pressure sensor

This sensor is used to correct altitude.
The following graph shows the output characteristics of the EGR inlet pressure sensor.
A:
B:
Pressure inlet
Mounting screw: M5
Tightening torque: 4.5 0.5 Nm {0.46 0.05 kgm}
The following graph shows the output characteristics of the atmospheric pressure sensor.
125E-5 Series
SEN00185-06
3)
EGR valve position sensor (with EGR)
4)
q
Bypass valve position sensor (Applicable machine: HM300-2) (with EGR)

These sensors sense the opening and closing positions of the EGR valve and bypass valve.
1.
EGR and bypass valve position sensors
The following graph shows the output characteristics of the position sensor.
125E-5 Series
35
SEN00185-06
5)
Common rail pressure sensor
6)
NE speed sensor (Crank angle sensor)

If the signal hole made on the flywheel passes
the sensor, the magnetic line of force changes.
If the magnetic line of force changes, the output of the Hall element sensor changes linearly
and it is converted into pulse of 0 5 V by the
wave form shaping circuit in the sensor, and
then output.
7)
q
q
q
36
Fuel temperature sensor

The fuel temperature sensor senses the fuel
temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the
temperature.
The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the computer and the resistance of the thermistor.
8)
Engine controller
9)
Oil pressure sensor
125E-5 Series
10) Bkup speed sensor (G sensor)

(Cylinder No. sensor)
q
Similarly to the NE speed sensor, this sensor
utilizes the pulses of 0 5 V generated by the
change of the magnetic line of force crossing
the sensor unit.
q
The disc gear installed to the central part of the
camshaft of the high-pressure pump has teeth
(cut parts) around it at intervals of 120C.
q
In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are generated every 2 revolutions of the engine.
q
The standard pulse of the No. 1 cylinder is recognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
125E-5 Series
SEN00185-06
11) Charge pressure sensor

q
This sensor is used to sense the charge pressure (boost pressure).
A:
Mounting screw: M6
Tightening torque: 5.5 0.5 Nm {0.56 0.05 kgm}
1.
2.
Sensor
O-ring
The following graph shows the output characteristics of the charge pressure sensor.
37
SEN00185-06
12) Charge temperature sensor

q
The charge temperature sensor senses the
intake air temperature (boost temperature) and
sends it to the engine controller.
q
The sensor unit is a thermistor the resistance
of which changes according to the temperature. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
38
13) Coolant temperature sensor

q
The coolant temperature sensor senses the
coolant temperature and sends it to the engine
controller.
q
The sensor unit is a thermistor the resistance
of which changes according to the temperature. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.
125E-5 Series
125E-5 Series
SEN00185-06
39
SEN00185-06
Fuel piping
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Fuel injection pipe (No. 1 cylinder)

Fuel return pipe
Common rail
Priming pump
Feed pump
Oil inlet pipe (for pump lubricating oil)
High pressure pump
Fuel supply pump drive gear
(Number of teeth: 44)
14. Overflow valve
15. PCV
40
125E-5 Series
SEN00185-06
A:
B:
C:
D:
E:
Fuel inlet
To fuel filter
From fuel filter
To injector
Fuel return (between overflow valve and fuel
tank)
F: Fuel return (between injector and fuel tank)
G: Engine oil (to fuel supply pump)
Specifications
Fuel supply pump
Manufacturer:
DENSO CORPORATION
Model:
DENSO ECD-U2
Lubrication method: Forced lubrication with engine oil
125E-5 Series
41
SEN00185-06
Fuel filter
Main fuel filter
A:
B:
Fuel inlet
Fuel outlet
1.
2.
3.
Air bleeding plug

Filter head
Cartridge
Specifications
Filtration area: 1.0 m2
42
125E-5 Series
SEN00185-06
Pre-fuel filter
A: Fuel inlet
B: Fuel outlet
1. Air bleeding plug
2. Filter head
3. Cartridge
Specifications
Filtration area: 1.06 m2
125E-5 Series
43
SEN00185-06
Electric priming pump
A:
B:
Fuel IN
Fuel OUT
1.
2.
Connector
Vibration prevention rubber
44
125E-5 Series
Engine controller cooler
SEN00185-06
A:
B:
Fuel IN (From feed pump of fuel supply pump)

Fuel OUT (Main fuel filter)
1.
2.
Engine controller
Engine controller cooler
Outline
q
The fuel is circulated as refrigerant through
engine controller cooler (2) to prevent engine
controller (1) from overheating.
q
The fuel is not circuited in some applicable
machines.
125E-5 Series
45
SEN00185-06
Cooling system
Cooling system diagram
1
1
(with EGR)
A:
B:
C:
D:
Oil inlet
Oil outlet
Exhaust gas inlet
Exhaust gas outlet
1.
2.
3.
4.
5.
6.
Radiator
Thermostat
Water pump
Coolant temperature gauge
Water manifold (made one with cylinder block)
Corrosion resistor
46
7.
8.
9.
10.
11.
12.
13.
Cylinder head
Cylinder liner
Piston
Cylinder block
Oil cooler
Air compressor
EGR cooler
125E-5 Series
SEN00185-06
(EGR-less)
A:
B:
C:
D:
Oil inlet
Oil outlet
Exhaust gas inlet
Exhaust gas outlet
125E-5 Series
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Radiator
Thermostat
Water pump
Coolant temperature gauge
Water manifold (made one with cylinder block)
Corrosion resistor
Cylinder head
Cylinder liner
Piston
Cylinder block
Oil cooler
Air compressor
47
SEN00185-06
Water pump
Mounting
A:
B:
C:
D:
E:
F:
To radiator (Coolant)
From each part of engine (Coolant)
To each part of engine through oil cooler
(Coolant)
From radiator (Coolant)
From oil pump (Oil)
To each part of engine (Oil)
a.
b.
c.
Cab heater take-out opening

Coolant temperature gauge pickup port
Water drain valve
48
1.
2.
3.
4.
5.
Thermostat
Housing cover
Thermostat housing
Water pump
Oil cooler
125E-5 Series
a.
b.
c.
From thermostat
From radiator
To each part of engine
1.
2.
3.
4.
5.
6.
7.
Water pump drive gear (Number of teeth: 22)

Pump shaft
Ball bearing
Pump body
Water seal
Impeller
Pump cover
SEN00185-06
Water pump
Type: Centrifugal, gear-driven
Unit: mm
No.
Check item
Interference of impeller
and shaft
Interference of drive gear

and shaft
10
Clearance between impeller and body
11
Wear of water seal ring
125E-5 Series
Criteria
Standard size
Remedy
Tolerance
Shaft
Hole
15.9
+0.018
+0.005
0.020
0.050
20.0
+0.015
+0.002
0.023
0.053
Standard inter- Replace

ference
Usually, impeller needs to be
replaced (Outside diameter of
0.025 0.068 shaft changes little)
0.025 0.068
Standard clearance: 0.30 1.10 (including end play)
Replace (Usually, gear needs to

be replaced)
Replace
Limits of size: 1.5
49
SEN00185-06
Thermostat
Mounting
a.
b.
To radiator
To water pump
1.
2.
Thermostat
Thermostat housing
50
125E-5 Series
A:
B:
When cold (Fully closed)

When hot (Fully open)
a.
b.
c.
To water pump (bypass)

To radiator
From engine
1.
2.
3.
4.
5.
6.
7.
SEN00185-06
Thermostat
Seal
Valve
Body
Piston
Heat sensing portion
Inflating portion
8.
9.
Sleeve
Flange
Function of thermostat (before

installed)
Opening temperature:
76.5C
Full opening temperature: 90C
Valve lift:
Min. 10 mm
Unit: mm
No.
1
Check item
Criteria
Remedy
Full opening lift of thermostat
Min. 10 mm (Check after soaking in oil tank at 90C for 4 5 minutes.)
Opening and closing of

thermostat
When valve full open (at 90C) is soaked in oil tank at full closing temper- Replace
ature (71C) , it must close fully in 4 5 minutes.
125E-5 Series
51
SEN00185-06
Electrical equipment
Alternator
1
1
1. Alternator with built-in regulator (Open type, 35 A)
1.
2.
3.
4.
5.
Alternator
Alternator pulley
Terminal B
Terminal R
Terminal E
6.
Internal electric circuit diagram

6A. Initial excitation resistor
6B. Regulator
6C. Field coil
Pulley
Engine
Applicable machine
Type
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0 Open type (brushless),
SAA6D125E-5 BR580JG-1
manufactured by NIKKO
DCA-300SSK4
DENKI
52
Specification Number Outside

diameter
of stages
(mm)
24V, 35A
93
Weight
(kg)
8.0
125E-5 Series
SEN00185-06
1.
2.
3.
4.
5.
Alternator
Alternator pulley
Terminal B
Terminal R
Terminal E
6.

6A. Initial excitation resistor
6B. Regulator
6C. Field coil
Pulley
Engine
Applicable machine
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8,
PC450-8, PC450LC-8,
SAA6D125E-5 D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
WA450-6, WA470-6,
WA470-6R
WA480-6, WA480-6R
HM250-2, HM300-2,
HM300-2R
125E-5 Series
Type
Open type (brushless),

manufactured by NIKKO
DENKI

diameter
of stages
(mm)
24V, 50A
75
Weight
(kg)
10
53
SEN00185-06
a.
Load
1.
2.
3.
4.
Alternator
Alternator pulley
Terminal B
Terminal R
5.
6.
Terminal E
6A. Field coil
6B. Primary energized resistance
6C. Regulator
Pulley
Engine
Applicable machine
Type
PC400-8, PC400LC-8
Open type, manufactured by
PC450-8, PC450LC-8
SAA6D125E-5
PC400-8R, PC400LC-8R NIKKO DENKI
54

diameter
of stages
(mm)
24V, 60A
85
Weight
(kg)
11
125E-5 Series
SEN00185-06
a.
Load
1.
2.
3.
4.
5.
6.
Alternator
Alternator pulley
Terminal R
Terminal E
Terminal B
6A. Alternator
6B. Regulator
Engine
Applicable machine
D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
HM250-2, HM300-2,
HM300-2R
SAA6D125E-5
WA450-6, WA470-6,
WA480-6
WA470-6R, WA480-6R
GD755-5R
125E-5 Series
Type
Open type, manufactured

by SAWAFUJI DENKI
Pulley
diameter
of stages
(mm)
24V, 75A
95
Weight
(kg)
13
55
SEN00185-06
Alternator mounting
SAA6D125E-5 (D85EX-15E0, D85EX-15R, D85PX-15E0, D85PX-15R, WA450-6, WA470-6, WA480-6,
WA470-6R, WA480-6R, GD755-5R)
1.
2.
3.
4.
Alternator pulley
Alternator drive belt
Crankshaft pulley
Adjustment bolt
56
125E-5 Series
SEN00185-06
SAA6D125E-5 (PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0, PC400-8, PC400LC-8, PC450-8,

PC450LC-8, PC400-8R, PC400LC-8R, PC450-8R, PC450LC-8R, BR580JG-1)
1.
2.
3.
4.
Alternator pulley
Crankshaft pulley
Adjustment bolt
125E-5 Series
57
SEN00185-06
SAA6D125E-5 [DCA-300SSK4 (DENYO/MQ GENERATOR)]
1.
2.
3.
4.
Alternator pulley
Crankshaft pulley
Adjustment bolt
58
125E-5 Series
125E-5 Series
SEN00185-06
59
SEN00185-06
Starting motor
Starting motor with built-in safety relay (7.5 kW)
60
125E-5 Series
1.
2.
3.
4.
5.
6.
SEN00185-06
Pinion gear
Starting motor (body)
Magnetic switch
External electric circuit diagram [2P connector (male)]
4A. Safety relay
4B. Starting motor
External electric circuit diagram [3P connector (male)]
5A. Safety relay
5B. Starting motor
Specifications of connector
Type A: 2P connector (male)
Type B: 2P dust-proof connector (male)
Type C: 3P dust-proof connector (male)
Type D: 2P connector (male)
B, C, R, S, E: Terminals
Engine
Applicable
machine
Type
Specification
Number of
pinion teeth
Weight (kg)
Type of
connector
SAA6D125E-5
All machines
Waterproof, oilproof, manufactured

by NIKKO DENKI
24V, 7.5kW
12
20
125E-5 Series
61
SEN00185-06
Starting motor with built-in safety relay (11 kW)
62
125E-5 Series
1.
2.
3.
4.
5.
SEN00185-06
Pinion gear
Starting motor (body)
Magnetic switch
External electric circuit diagram
4A. Safety relay
4B. Starting motor
Specifications of connector
Type A: 2P connector (male)
Type B: Dust-proof connector (male)
B, C, R, S, E: Terminals
Engine
Applicable
machine
Type
Specification
Number of
pinion teeth
Weight (kg)
Type of
connector
SAA6D125E-5
All machines
(if equipped)
Waterproof, oilproof, manufactured

by NIKKO DENKI
24V, 11kW
12
18
125E-5 Series
63
SEN00185-06
Electrical intake air heater
SAA6D125E-5
1.
2.
3.
4.
Terminal
Body
Heater coil
Electric circuit diagram
Electrical intake air heater

Rated voltage: 22 V (DC)
Rated current: 111 A
64
125E-5 Series
Engine controller
SEN00185-06
Features
Mounting of engine controller on engine
q
Since the engine controller is mounted on the
engine, the operator can service it easily in the
field.
q
The engine controller cooler (if equipped) is
prepared to cool the engine controller with the
fuel to secure the reliability of the mounted
engine controller.
q
Vibrations are damped by the vibration-proof
rubber.
Unified specifications of engine controller
q
Engine controller CM850 developed by the
cooperation between KOMATSU and CUMMINS is employed.
125E-5 Series
65
SEN00185-06

2011 KOMATSU
All Rights Reserved
66
SEN00546-09
ENGINE
1SHOP MANUAL
125E-5 Series
Standard service value table

Standard service value table ........................................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ............................................. 2
Running-in standard and performance test standard ......................................................................... 16
125E-5 Series
SEN00546-09
Standard service value table
Cooling system
Lubrication system
Body
Air intake and exhaust system
Performance Category
Standard service value table for testing, adjusting, and troubleshooting
Engine
SAA6D125E-5
Machine model
D85EX-15E0
D85PX-15E0
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
2,100 50
2,100 50
Low idle
rpm
750 (+50/0)
750 (+50/0)
rpm
Min. 100
rpm
Min. 85
Item
Speed
Measurement conditions
Necessary speed for At 0C (Without starting aid)

starting
At 20C (With starting aid)
Air intake resistance
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 93
{Min. 700}
73
{550}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 113
{Min. 850}
93
{700}
650
700
At sudden acceleration (Low o High)
%
(Bosch
index)
Max. 25
{Max. 2.5}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust valve
mm
0.71
Exhaust temperature Whole speed range (20C)
Exhaust gas color
Valve clearance
EGR valve and
bypass valve drive
pressure
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}
Compression pressure
Engine oil temperature: 40 60C

Engine speed: 200 250 rpm
MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
Engine coolant temperature: Min. 70C
kPa
{mmH2O}
Max. 1.47
{Max. 150}
2.94
{300}
At rated output
Engine oil temperature:
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
At low idle
Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
Engine oil temperature
Whole speed range (In oil pan)
90 110
120
Oil consumption
Ratio to fuel consumption at continuous

rated output
Max. 0.15
0.3
Function of radiator
pressure valve
Cracking pressure (Differential pressure)
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension
Deflection under finger pressure of 98 N

{10 kg}
mm
Alternator belt tension
Deflection under finger pressure of 58.8 N

{6 kg}
mm
13 16
13 16
125E-5 Series
Body
Lubrication system
Engine
SAA6D125E-5
Machine model
D85EX-15R
D85PX-15R
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
2,100 50
2,100 50
Low idle
rpm
750 (+50/0)
750 (+50/0)
rpm
Min. 100
rpm
Min. 85
Item
Speed

starting
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 80
{Min. 600}
67
{500}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 87
{Min. 650}
73
{550}
650
700
%
(Bosch
index)
Max. 40
{Max. 4.0}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust gas color
Valve clearance
Cooling system
SEN00546-09
mm
0.71

MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
kPa
{mmH2O}
Max. 1.47
{Max. 150}
2.94
{300}
At rated output
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
Exhaust valve
At low idle
Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
90 110
120
Oil consumption

rated output
Max. 0.15
0.3
pressure valve
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{6 kg}
mm
13 16
13 16
125E-5 Series
Cooling system
Lubrication system
Body
SEN00546-09
Engine
SAA6D125E-5
Machine model
PC400, 400LC-7E0,
PC400, 400LC-8
PC450, 450LC-7E0,
PC450, 450LC-8
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
1,930 50
1,930 50
Low idle
rpm
1,000 25
1,000 25
rpm
Min. 100
rpm
Min. 85
Item
Speed

starting
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 140
{Min. 1,050}
113
{850}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 167
{Min. 1,250}
140
{1,050}
Max. 700
700
%
(Bosch
index)
Max. 25
{Max. 2.5}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust gas color
Valve clearance
Exhaust valve
mm
0.71
Min. 1.18
{Min. 12}
EGR valve and

bypass valve drive
pressure
At low idle
MPa
{kg/cm2}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
kPa
{mmH2O}
Max. 1.47
{Max. 150}
2.94
{300}
At rated output
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
At low idle
Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
90 110
120
Oil consumption

rated output
Max. 0.15
0.3
pressure valve
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{6 kg}
mm
13 16
13 16
125E-5 Series
Body
Lubrication system
Engine
SAA6D125E-5
Machine model
PC400, 400LC-8R
PC450, 450LC-8R
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
1,930 (+35/-15)
1,930 (+35/-15)
Low idle
rpm
1,000 25
1,000 25
rpm
Min. 100
rpm
Min. 85
Item
Speed

starting
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 127
{Min. 950}
107
{800}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 153
{Min. 1,150}
127
{950}
Max. 700
700
%
(Bosch
index)
Max. 40
{Max. 4.0}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust gas color
Valve clearance
Cooling system
SEN00546-09
mm
0.71

MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
kPa
{mmH2O}
Max. 1.47
{Max. 150}
2.94
{300}
At rated output
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
Exhaust valve
At low idle
Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
90 110
120
Oil consumption

rated output
Max. 0.15
0.3
pressure valve
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{6 kg}
mm
13 16
13 16
125E-5 Series
Cooling system
Lubrication system
Body
SEN00546-09
Engine
SAA6D125E-5
Machine model
HM250-2
Item
Speed
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
2,100 50
2,100 50
Low idle
rpm
725 (+50/0)
725 (+50/0)
rpm
Min. 100
rpm
Min. 85

starting
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 127
{Min. 950}
100
{750}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 140
{Min. 1,050}
113
{850}
Max. 700
700
%
(Bosch
index)
Max. 25
{Max. 2.5}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust valve
mm
0.71
Exhaust gas color
Valve clearance
EGR valve and
bypass valve drive
pressure
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
kPa
{mmH2O}
Max. 1.47
{Max. 150}
2.94
{300}
At rated output
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
At low idle
Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
90 110
120
Oil consumption

rated output
Max. 0.15
0.3
pressure valve
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{6 kg}
mm
13 16
13 16
125E-5 Series
Cooling system
Lubrication system
Body
SEN00546-09
Engine
SAA6D125E-5
Machine model
HM300-2
Item
Speed
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
2,220 50
2,220 50
Low idle
rpm
725 (+50/0)
725 (+50/0)
rpm
Min. 100
rpm
Min. 85

starting
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 133
{Min. 1,000}
107
{800}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 147
{Min. 1,100}
120
{900}
Max. 700
700
%
(Bosch
index)
Max. 25
{Max. 2.5}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust valve
mm
0.71
Exhaust gas color
Valve clearance
EGR valve and
bypass valve drive
pressure
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
kPa
{mmH2O}
Max. 1.47
{Max. 150}
2.94
{300}
At rated output
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
At low idle
Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
90 110
120
Oil consumption

rated output
Max. 0.15
0.3
pressure valve
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{6 kg}
mm
13 16
13 16
125E-5 Series
SEN00546-09
Body
Lubrication system
Cooling system
Engine
SAA6D125E-5
Machine model
HM300-2R
Item
Speed
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
2,220 50
2,220 50
Low idle
rpm
725 (+50/0)
725 (+50/0)
rpm
Min. 100
rpm
Min. 85

starting
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 113
{Min. 850}
93
{700}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 120
{Min. 900}
100
{750}
Max. 700
700
%
(Bosch
index)
Max. 40
{Max. 4.0}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust valve
mm
0.71
Exhaust gas color
Valve clearance

MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
kPa
{mmH2O}
Max. 1.47
{Max. 150}
2.94
{300}
At rated output
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
At low idle
Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
90 110
120
Oil consumption

rated output
Max. 0.15
0.3
pressure valve
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{6 kg}
mm
13 16
13 16
125E-5 Series
Cooling system
Lubrication system
Body
SEN00546-09
Engine
SAA6D125E-5
Machine model
WA450-6, WA480-6
Item
Speed
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
2,170 50
2,170 50
Low idle
rpm
800 (+50/0)
800 (+50/0)
rpm
Min. 100
rpm
Min. 85

starting
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 100
{Min. 750}
80
{600}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 113
{Min. 850}
93
{700}
Max. 650
650
%
(Bosch
index)
Max. 25
{Max. 2.5}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust valve
mm
0.71
Exhaust gas color
Valve clearance
EGR valve and
bypass valve drive
pressure
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
kPa
{mmH2O}
Max. 1.47
{Max. 150}
2.94
{300}
At rated output
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
At low idle
Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
90 110
120
Oil consumption

rated output
Max. 0.15
0.3
pressure valve
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{6 kg}
mm
13 16
13 16
125E-5 Series
SEN00546-09
Body
Lubrication system
Cooling system
Engine
SAA6D125E-5
Machine model
WA470-6R
Item
Speed
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
2,170 50
2,170 50
Low idle
rpm
800 (+50/0)
800 (+50/0)
rpm
Min. 100
rpm
Min. 85

starting
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 107
{Min. 800}
87
{650}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 127
{Min. 950}
107
{800}
Max. 650
650
%
(Bosch
index)
Max. 25
{Max. 2.5}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust valve
mm
0.71
Exhaust gas color
Valve clearance
10

MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
kPa
{mmH2O}
Max. 1.47
{Max. 150}
2.94
{300}
At rated output
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
At low idle
Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
90 110
120
Oil consumption

rated output
Max. 0.15
0.3
pressure valve
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{6 kg}
mm
13 16
13 16
125E-5 Series
Cooling system
Lubrication system
Body
SEN00546-09
Engine
SAA6D125E-5
Machine model
WA480-6
Item
Speed
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
2,190 50
2,190 50
Low idle
rpm
800 (+50/0)
800 (+50/0)
rpm
Min. 100
rpm
Min. 85

starting
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 113
{Min. 850}
93
{700}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 133
{Min. 1,000}
113
{850}
Max. 700
700
%
(Bosch
index)
Max. 25
{Max. 2.5}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust valve
mm
0.71
Exhaust gas color
Valve clearance
EGR valve and
bypass valve drive
pressure
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
kPa
{mmH2O}
Max. 1.47
{Max. 150}
2.94
{300}
At rated output
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
At low idle
Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
90 110
120
Oil consumption

rated output
Max. 0.15
0.3
pressure valve
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{6 kg}
mm
13 16
13 16
125E-5 Series
11
SEN00546-09
Body
Lubrication system
Cooling system
Engine
SAA6D125E-5
Machine model
WA480-6R
Item
Speed
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
2,190 50
2,190 50
Low idle
rpm
800 (+50/0)
800 (+50/0)
rpm
Min. 100
rpm
Min. 85

starting
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 113
{Min. 850}
93
{700}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 133
{Min. 1,000}
113
{850}
Max. 700
700
%
(Bosch
index)
Max. 25
{Max. 2.5}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust valve
mm
0.71
Exhaust gas color
Valve clearance
12

MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
kPa
{mmH2O}
Max. 1.47
{Max. 150}
2.94
{300}
At rated output
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
At low idle
Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
90 110
120
Oil consumption

rated output
Max. 0.15
0.3
pressure valve
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{6 kg}
mm
13 16
13 16
125E-5 Series
Cooling system
Lubrication system
Body
SEN00546-09
Engine
SAA6D125E-5
Machine model
BR580JG-1
Item
Speed
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
1,930 50
1,930 50
Low idle
rpm
1,000 25
1,000 25
rpm
Min. 100
rpm
Min. 85

starting
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 140
{Min. 1,050}
113
{850}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 167
{Min. 1,250}
140
{1,050}
Max. 700
700
%
(Bosch
index)
Max. 25
{Max. 2.5}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust valve
mm
0.71
Exhaust gas color
Valve clearance
EGR valve and
bypass valve drive
pressure
At low idle
MPa
{kg/cm2}
Min. 1.18
{Min. 12}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
kPa
{mmH2O}
Max. 1.47
{Max. 150}
2.94
{300}
At rated output
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
At low idle
Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
90 110
120
Oil consumption

rated output
Max. 0.15
0.3
pressure valve
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{6 kg}
mm
13 16
13 16
125E-5 Series
13
SEN00546-09
Body
Lubrication system
Cooling system
Engine
SAA6D125E-5
Machine model
GD755-5R
Item
Speed
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
2,200 50
2,200 50
Low idle
rpm
800 (+50/0)
800 (+50/0)
rpm
Min. 100
rpm
Min. 85

starting
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 113
{Min. 850}
93
{700}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 133
{Min. 1,000}
113
{850}
Max. 700
700
%
(Bosch
index)
Max. 25
{Max. 2.5}
At rated output
Bosch
index
Max. 1.5
At high idle
Bosch
index
Max. 1.0
Intake valve
mm
0.33
Exhaust valve
mm
0.71
Exhaust gas color
Valve clearance
14

MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
kPa
{mmH2O}
Max. 1.47
{Max. 150}
2.94
{300}
At rated output
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
At low idle
Min. 80C
SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH
90 110
120
Oil consumption

rated output
Max. 0.15
0.3
pressure valve
kPa
{kg/cm2}
Fan speed
At rated speed
rpm
Fan belt tension

{10 kg}
mm

{6 kg}
mm
13 16
13 16
125E-5 Series
Cooling system
Lubrication system
Body
SEN00546-09
Engine
SAA6D125E-5
Machine model
DCA-300SSK4
Unit
Standard value
for new machine
Judgement
criteria
High idle
rpm
1,890 50
1,890 50
Low idle
rpm
750 25
750 25
rpm
Min. 100
rpm
Min. 85
Item
Speed

starting
Whole speed range
kPa
{mmH2O}
Max. 3.73
{Max. 380}
7.47
{762}
Air boost pressure
At rated output
kPa
{mmHg}
Min. 173
{Min. 1,300}
140
{1,050}
Exhaust pressure
At rated output
kPa
{mmHg}
Min. 173
{Min. 1,300}
140
{1,050}
Max. 700
700

Exhaust gas color
Valve clearance
At rated output
Max. 10
At high idle
Max. 10
Intake valve
mm
0.33
Exhaust valve
mm
0.71
Min. 1.18
{Min. 12}
EGR valve and

bypass valve drive
pressure
At low idle
MPa
{kg/cm2}
At high idle
MPa
{kg/cm2}
Min. 1.43
{Min. 14.6}

MPa
{kg/cm2}
Min. 2.9
{Min. 30}
2.0
{20}
Blow-by pressure
At rated output
kPa
{mmH2O}
Max. 1.67
{Max. 170}
2.94
{300}
At rated output
Min. 80C
MPa
{kg/cm2}
0.29 0.69
{3.0 7.0}
0.18
{1.8}
MPa
{kg/cm2}
Min. 0.08
{Min. 0.8}
0.05
{0.5}
Engine oil pressure
At low idle
Min. 80C
SAE10W30DH
SAE15W40DH
SAE30DH
90 110
120
Oil consumption

rated output
Max. 0.15
0.3
pressure valve
kPa
{kg/cm2}
0.069
{0.7}
Fan speed
At rated speed
rpm
1,543
Fan/alternator belt
tension

{10 kg}
mm
10 13

{6 kg}
mm
10 15
125E-5 Series
15
SEN00546-09
Running-in standard and performance test standard
Running-in standard
Engine
SAA6D125E-5
Machine model
D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
Procedure
Item
Running time
min.
Speed
rpm
750
950
1,140
1,425
1,900
Dynamometer
load
N {kg}
0 {0}
275 {28}
697 {71}
1,115 {114}
1,394 {142}
Output
kW {HP}
0 {0}
20 {26.6}
60 {80}
119 {160}
199 {266}
a
a
This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard

Engine
SAA6D125E-5
Machine model
D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
Test item
Rated output
Max. torque
Max. speed at no
load
Min. speed at no
load
Specification
value
(Gross value)
Speed
rpm
1,900
1,400
2,100 50
750 (+50/0)
Dynamometer
load
N
{kg}
1,354 1,432
{138 146}
1,727 1,834
{176 187}
Output
(Gross value)
kW
{HP}
199
{266}
Torque
(Gross value)
Nm
{kgm}
1,272
{130}
Fuel consumption sec/300cc

Coolant
temperature
80 90
80 90
80 90
80 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
kPa
{kg/cm2}
290 690
{3.0 7.0}
190 540
{2.0 5.5}
290 690
{3.0 7.0}
Min. 80
{Min. 0.8}
Exhaust
temperature
Max. 650
Max. 650
a
a
a
a
a
a
16
This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
Use ASTM No. 1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.
125E-5 Series
SEN00546-09
Running-in standard
Engine
SAA6D125E-5
Machine model
PC400, 400LC-7E0, PC400, 400LC-8, PC400, 400LC-8R

PC450, 450LC-7E0, PC450, 450LC-8, PC450, 450LC-8R
Procedure
Item
a
a
Running time
min.
Speed
rpm
1,000
1,000
1,200
1,500
1,900
Dynamometer
load
N {kg}
0 {0}
353 {36}
875 {89}
1,400 {143}
1,893 {193}
Output
kW {HP}
0 {0}
26 {35.5}
79 {106}
157 {211}
262.5 {352}

Engine
SAA6D125E-5
Machine model
PC400, 400LC-7E0, PC400, 400LC-8, PC400, 400LC-8R

PC450, 450LC-7E0, PC450, 450LC-8, PC450, 450LC-8R
Test item
a
a
a
a
Max. torque
Max. speed at no
load
Min. speed at no
load
Specification
value
(Gross value)
Speed
rpm
1,900
1,400
1,930 50
1,000 25
Dynamometer
load
N
{kg}
1,785 1,900
{182 194}
1,920 2,050
{196 209}
Output
(Gross value)
kW
{HP}
262.5
{352}
Torque
(Gross value)
Nm
{kgm}
1,422
{145}
a
a
Rated output
Coolant
temperature
80 90
80 90
80 90
80 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
kPa
{kg/cm2}
290 690
{3.0 7.0}
190 540
{2.0 5.5}
290 690
{3.0 7.0}
Min. 80
{Min. 0.8}
Exhaust
temperature
Max. 700
Max. 700
125E-5 Series
17
SEN00546-09
Running-in standard
Engine
SAA6D125E-5
Machine model
HM250-2
Procedure
Item
Running time
min.
Speed
rpm
725
1,000
1,200
1,500
2,000
Dynamometer
load
N {kg}
0 {0}
307 {31}
774 {79}
1,238 {126}
1,547 {158}
Output
kW {HP}
0 {0}
23 {31}
70 {94}
139 {186}
232 {311}
a
a

Engine
SAA6D125E-5
Machine model
HM250-2
Test item
Rated output
Max. torque
Max. speed at no
load
Min. speed at no
load
Specification
value
(Gross value)
Speed
rpm
2,000
1,400
2,100 50
725 (+50/0)
Dynamometer
load
N
{kg}
1,500 1,593
{153 162}
2,320 2,450
{236 250}
Output
(Gross value)
kW
{HP}
232
{311}
Torque
(Gross value)
Nm
{kgm}
1,706
{174}

Coolant
temperature
80 90
80 90
80 90
80 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
kPa
{kg/cm2}
290 690
{3.0 7.0}
190 540
{2.0 5.5}
290 690
{3.0 7.0}
Min. 80
{Min. 0.8}
Exhaust
temperature
Max. 700
Max. 750
a
a
a
a
a
a
18
125E-5 Series
SEN00546-09
Running-in standard
Engine
SAA6D125E-5
Machine model
HM300-2, HM300-2R
Procedure
Item
a
a
Running time
min.
Speed
rpm
725
1,000
1,200
1,500
2,000
Dynamometer
load
N {kg}
0 {0}
343 {35}
850 {87}
1,354 {138}
1,692 {173}
Output
kW {HP}
0 {0}
26 {34.5}
76 {103}
152 {204}
254 {340}

Engine
SAA6D125E-5
Machine model
HM300-2, HM300-2R
Test item
a
a
a
a
Max. torque
Max. speed at no
load
Min. speed at no
load
Specification
value
(Gross value)
Speed
rpm
2,000
1,400
2,220 50
725 (+50/0)
Dynamometer
load
N
{kg}
1,650 1,750
{168 178}
2,320 2,450
{236 250}
Output
(Gross value)
kW
{HP}
254
{340}
Torque
(Gross value)
Nm
{kgm}
1,706
{174}
a
a
Rated output
Coolant
temperature
80 90
80 90
80 90
80 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
kPa
{kg/cm2}
290 690
{3.0 7.0}
190 540
{2.0 5.5}
290 690
{3.0 7.0}
Min. 80
{Min. 0.8}
Exhaust
temperature
Max. 700
Max. 750
125E-5 Series
19
SEN00546-09
Running-in standard
Engine
SAA6D125E-5
Machine model
WA450-6
WA470-6, WA470-6R
Procedure
Item
Running time
min.
Speed
rpm
800
1,000
1,200
1,500
2,000
Dynamometer
load
N {kg}
0 {0}
275 {28}
677 {69}
1,079 {110}
1,353 {138}
Output
kW {HP}
0 {0}
21 {27.6}
61 {82}
121 {163}
203 {272}
a
a

Engine
SAA6D125E-5
Machine model
WA450-6
WA470-6, WA470-6R
Test item
Rated output
Max. torque
Max. speed at no
load
Min. speed at no
load
Specification
value
(Gross value)
Speed
rpm
2,000
1,450
2,170 50
800 (+50/0)
Dynamometer
load
N
{kg}
1,319 1,400
{135 143}
1,267 1,345
{129 137}
Output
(Gross value)
kW
{HP}
204
{273}
Torque
(Gross value)
Nm
{kgm}
1,307
{133}

Coolant
temperature
80 90
80 90
80 90
80 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
kPa
{kg/cm2}
290 690
{3.0 7.0}
190 540
{2.0 5.5}
290 690
{3.0 7.0}
Min. 80
{Min. 0.8}
Exhaust
temperature
Max. 650
Max. 650
a
a
a
a
a
a
20
125E-5 Series
SEN00546-09
Running-in standard
Engine
SAA6D125E-5
Machine model
WA480-6, WA480-6R
Procedure
Item
a
a
Running time
min.
Speed
rpm
800
1,000
1,200
1,500
2,000
Dynamometer
load
N {kg}
0 {0}
294 {30}
735 {75}
1,196 {122}
1,491 {152}
Output
kW {HP}
0 {0}
22 {29.6}
66 {89}
135 {180}
224 {300}

Engine
SAA6D125E-5
Machine model
WA480-6, WA480-6R
Test item
a
a
a
a
Max. torque
Max. speed at no
load
Min. speed at no
load
Specification
value
(Gross value)
Speed
rpm
2,000
1,400
2,190 50
800 (+50/0)
Dynamometer
load
N
{kg}
1,450 1,541
{148 157}
1,843 1,956
{188 200}
Output
(Gross value)
kW
{HP}
224
{301}
Torque
(Gross value)
Nm
{kgm}
1,360
{139}
a
a
Rated output
Coolant
temperature
80 90
80 90
80 90
80 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
kPa
{kg/cm2}
290 690
{3.0 7.0}
190 540
{2.0 5.5}
290 690
{3.0 7.0}
Min. 80
{Min. 0.8}
Exhaust
temperature
Max. 700
Max. 700
125E-5 Series
21
SEN00546-09
Running-in standard
Engine
SAA6D125E-5
Machine model
BR580JG-1
Procedure
Item
Running time
min.
Speed
rpm
1,000
1,000
1,200
1,500
1,900
Dynamometer
load
N {kg}
0 {0}
353 {36}
875 {89}
1,400 {143}
1,893 {193}
Output
kW {HP}
0 {0}
26 {35.5}
79 {106}
157 {211}
262.5 {352}
a
a

Engine
SAA6D125E-5
Machine model
BR580JG-1
Test item
Rated output
Max. torque
Max. speed at no
load
Min. speed at no
load
Specification
value
(Gross value)
Speed
rpm
1,900
1,400
1,930 50
1,000 25
Dynamometer
load
N
{kg}
1,785 1,900
{182 194}
1,920 2,050
{196 209}
Output
(Gross value)
kW
{HP}
262.5
{352}
Torque
(Gross value)
Nm
{kgm}
1,422
{145}

Coolant
temperature
80 90
80 90
80 90
80 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
kPa
{kg/cm2}
290 690
{3.0 7.0}
190 540
{2.0 5.5}
290 690
{3.0 7.0}
Min. 80
{Min. 0.8}
Exhaust
temperature
Max. 700
Max. 700
a
a
a
a
a
a
22
125E-5 Series
SEN00546-09
Running-in standard
Engine
SAA6D125E-5
Machine model
GD755-5R
Procedure
Item
a
a
Running time
min.
Speed
rpm
800
1,000
1,200
1,500
2,000
Dynamometer
load
N {kg}
0 {0}
288 {29}
720 {73}
1,152 {117}
1,440 {147}
Output
kW {HP}
0 {0}
21.6 {29.0}
64.8 {86.9}
129.6 {173.8}
216 {289.7}

Engine
SAA6D125E-5
Machine model
GD755-5R
Test item
a
a
a
a
Max. torque
Max. speed at no
load
Min. speed at no
load
Specification
value
(Gross value)
Speed
rpm
2,000
1,400
2,200 50
800 (+50/0)
Dynamometer
load
N
{kg}
1,397 1,483
{142.5 151.3}
1,784 1,894
{181.9 193.1}
Output
(Gross value)
kW
{HP}
216
{289.7}
Torque
(Gross value)
Nm
{kgm}
1,317
{134.3}
a
a
Rated output
Coolant
temperature
80 90
80 90
80 90
80 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
kPa
{kg/cm2}
290 690
{3.0 7.0}
190 540
{2.0 5.5}
290 690
{3.0 7.0}
Min. 80
{Min. 0.8}
Exhaust
temperature
Max. 700
Max. 700
125E-5 Series
23
SEN00546-09
Running-in standard
Engine
SAA6D125E-5
Machine model
DCA-300SSK4
Procedure
Item
Running time
min.
Speed
rpm
750
1,500
1,500
1,500
1,800
Dynamometer
load
N {kg}
0 {0}
366 {37}
970 {99}
1,568 {160}
2,019 {206}
Output
kW {HP}
0 {0}
41 {56}
109 {148}
177 {240}
277 {370}
a
a

Engine
SAA6D125E-5
Machine model
DCA-300SSK4
Test item
Rated output
Max. output
Max. speed at no
load
Min. speed at no
load
Specification
value
(Gross value)
kW
{HP}
272 7.36
{365 10}
313 9.56
{420 13}
Speed
rpm
1,800
1,800
Max. 1,890
750 25
Dynamometer
load
N
{kg}
1,960 2,068
{200 211}
2,244 2,391
{229 244}
Output
(Gross value)
kW
{HP}
272
{370}
Torque
(Gross value)
Nm
{kgm}

Coolant
temperature
80 90
80 90
80 90
80 90
Lubricating oil
temperature
90 110
90 110
90 110
90 110
Lubricating oil
pressure
kPa
{kg/cm2}
290 690
{3.0 7.0}
190 540
{2.0 5.5}
290 690
{3.0 7.0}
Min. 80
{Min. 0.8}
Exhaust
temperature
Max. 700
Max. 750
a
a
a
a
a
a
24
125E-5 Series
125E-5 Series
SEN00546-09
25
SEN00546-09

2011 KOMATSU
All Rights Reserved
26
SEN00547-05
ENGINE
1SHOP MANUAL
125E-5 Series
Testing and adjusting

Testing and adjusting (With EGR)................................................................................................................... 3
Testing and adjusting tools list ............................................................................................................. 3
Sketches of special tools...................................................................................................................... 5
Testing air boost pressure .................................................................................................................... 6
Testing exhaust temperature................................................................................................................ 7
Adjusting valve clearance .................................................................................................................... 8
Testing compression pressure ............................................................................................................. 9
Testing blow-by pressure ....................................................................................................................11
Testing engine oil pressure ................................................................................................................ 12
Measuring EGR valve and bypass valve drive pressure.................................................................... 13
Handling fuel system parts ................................................................................................................. 14
Releasing residual pressure in fuel system........................................................................................ 14
Testing fuel pressure .......................................................................................................................... 15
Reduced cylinder mode operation ..................................................................................................... 16
No-injection cranking.......................................................................................................................... 16
Testing leakage from pressure limiter and return rate from injector ................................................... 17
125E-5 Series
SEN00547-05
Bleeding air from fuel circuit ............................................................................................................... 20

Testing fuel system for leakage .......................................................................................................... 22
Adjusting speed sensor ...................................................................................................................... 23
Testing and adjusting alternator belt tension ...................................................................................... 24
Handling controller voltage circuit ...................................................................................................... 25
Testing and adjusting (EGR-less).................................................................................................................. 26
Testing and adjusting tools list............................................................................................................ 26
Sketches of special tools.................................................................................................................... 28
Testing air boost pressure .................................................................................................................. 29
Testing exhaust temperature .............................................................................................................. 30
Adjusting valve clearance................................................................................................................... 31
Testing compression pressure............................................................................................................ 32
Testing blow-by pressure.................................................................................................................... 34
Testing engine oil pressure................................................................................................................. 35
Handling fuel system parts ................................................................................................................. 36
Releasing residual pressure in fuel system........................................................................................ 36
Testing fuel pressure .......................................................................................................................... 37
Reduced cylinder mode operation...................................................................................................... 38
No-injection cranking.......................................................................................................................... 38
Testing leakage from pressure limiter and return rate from injector ................................................... 39
Bleeding air from fuel circuit ............................................................................................................... 41
Testing fuel system for leakage .......................................................................................................... 43
Adjusting speed sensor ...................................................................................................................... 44
Testing and adjusting alternator belt tension ...................................................................................... 45
Handling controller voltage circuit ...................................................................................................... 46
125E-5 Series
SEN00547-05
Testing and adjusting (With EGR)
Testing and adjusting tools list 1

Testing and adjusting item
Symbol
Testing air boost pressure
Testing exhaust
temperature
Adjusting valve clearance
Q'ty
Remarks
799-201-2202 Boost gauge kit
101 200 kPa {760 1,500 mmHg}
799-401-2220 Hose
I-coupler type (if necessary)
799-101-1502 Digital thermometer
99.9 1,299C
Commercially
Feeler gauge
available
Intake: 0.33 mm
Exhaust: 0.71 mm
795-502-1590 Compression gauge
0 7 MPa {0 70 kg/cm2}
795-471-1420 Adapter
6217-71-6112 Gasket
799-201-1504 Blow-by checker
0 5 kPa {0 500 mmH2O}
799-101-5002 Hydraulic tester
Pressure gauge: 2.5, 6, 40, 60 MPa

{25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
Pressure gauge: 60 MPa {600 kg/cm2}

{25, 60, 400, 600 kg/cm2}
799-401-2320 Gauge
795-471-1450 Adapter
07005-00812 Gasket
6151-51-8490 Spacer
Inside diameter: 14 mm
6206-71-1770 Joint
Inside diameter of joint: 10 mm
Commercially
Hose
available
5 mm x 2 3 m
Commercially
Hose
available
15 mm x 2 3 m
Commercially
Measuring cylinder
available
Commercially
Stopwatch
available
1
Testing compression
pressure
Testing blow-by pressure
Testing oil pressure
2
E
1
2
1
Testing fuel pressure
2
3
Testing leakage from

pressure limiter and return H 4
rate from injector
125E-5 Series
Part No.
Part name
For 125E-5
8 x 1.25 mm o R1/8
SEN00547-05
Troubleshooting for
controllers,
sensors, and actuators
Removal and installation

of engine coolant
temperature sensor
Symbol
Part No.
Part name
Remarks
799-601-4130 T-adapter
For Ne sensor
799-601-4330 Socket
For Bkup sensor
799-601-4240 Socket
For atmospheric pressure sensor
799-601-4250 Socket
For boost pressure sensor
799-601-4180 T-adapter
For EGR gas sensor
799-601-9420 T-adapter
For common rail pressure
799-601-4150 T-adapter
For oil pressure sensor
795-799-5540 T-adapter
For boost temperature sensor
795-799-5530 T-adapter
For coolant temperature sensor

For fuel temperature sensor
799-601-9020 T-adapter
For EGR valve solenoid

For bypass valve solenoid
799-601-9030 T-adapter
For EGR valve solenoid

For bypass valve stroke sensor
799-601-9430 T-adapter
For supply pump PCV
799-601-9020 T-adapter
For injector
799-601-4260 T-adapter
For controller (4-pole)
799-601-4210 T-adapter
799-601-4220 T-adapter
799-601-9320 T-box
799-601-9310 Plate
799-601-4350 T-box
For 60-pole type
Commercially
Socket
available
For 24-pole type
21 mm deep socket
(MITOLOY 4ML-21 or equivalent)
Applicable engine serial No.:
560001 - 564999
19 mm deep socket
565000 and up
795T-981-1010 Socket
Q'ty
125E-5 Series
Sketches of special tools
SEN00547-05
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
125E-5 Series
SEN00547-05

a
Testing tools for air boost pressure
Symbol
A
k
a
1.
Part No.
Part name
799-201-2202
Boost gauge kit
799-401-2220
Hose
Be careful not to touch any hot part when

removing or installing the testing tools.
The test point is subject to machine models.
Remove one air boost pressure pickup plug
(1).
a You may check at either front or rear plug.
2.
Install nipple [1] of boost gauge kit A and connect it to gauge [2].
3.
Run the engine at the rated output and test the

air boost pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.
4.
After finishing testing, remove the testing tools

and return the removed parts.
125E-5 Series
SEN00547-05
Testing exhaust temperature

a
Testing tools for exhaust temperature
Symbol
Part No.
799-101-1502
a
1.
Part name
Digital thermometer
Remove and install the testing tools after

the exhaust manifold temperature has lowered.
Remove exhaust temperature pickup plug (1)
from the side face of the center of the exhaust
manifold.
4.
2.
Install sensor [1] of digital thermometer B and

connect it to thermometer [2].
3.
Run the engine and test the exhaust temperature in the whole speed range.
machine.
125E-5 Series

3 Exhaust temperature pickup plug:
3.9 6.9 Nm {0.4 0.7 kgm}
SEN00547-05

a
Part No.
Commercially
available
2.
3.
While fixing adjustment screw (3), loosen locknut (4).

a After setting the No. 1 cylinder to the compression top dead center, adjust the valve
clearance of the No. 1 cylinder.
4.
Insert feeler gauge C in the clearance between

rocker arm (5) and crosshead (6) and adjust
the valve clearance with adjustment screw (3).
a With the feeler gauge inserted, turn the
adjustment screw to a degree that you can
move the feeler gauge lightly.
a Valve clearance
Intake valve: 0.33 mm
Exhaust valve: 0.71 mm
5.
While fixing adjustment screw (3), tighten locknut (4).

3 Locknut:
58.8 73.5 Nm {6.0 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.
6.
After adjusting the No. 1 cylinder, rotate the

crankshaft forward by 120 and adjust the
clearance of each cylinder according to the firing order.
a Firing order: 1-5-3-6-2-4
7.
After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}
Adjusting tools for valve clearance
Symbol
1.
Part name
Feeler gauge
Remove 6 cylinder head covers (1).
Rotate the crankshaft forward to bring the

stamped 1.6TOP line (a) of the damper to
pointer (2) and set the No. 1 cylinder to the
compression top dead center.
a Rotate the crankshaft with the mounting
bolt of the crankshaft pulley (width across
flats: 24 mm), and be sure to rotate it only
forward to prevent the bolt from loosening.
a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, rotate the crankshaft
one more turn.
125E-5 Series
SEN00547-05
Testing compression pressure

a
Testing tools for compression pressure
Symbol
1
D
k
1.
Part No.
Pass a wire, etc. under the fuel path projected sideways and pull up the injector
(Do not pry the injector top up).
Part name
795-502-1590
Compression gauge
795-471-1420
Adapter
6217-71-6112
Gasket
When measuring the compression pressure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
Measure the compression pressure after the
engine is warmed up
(Engine oil temperature: 40 60C).
Remove cylinder head cover (1) of the cylinder
to be tested for compression pressure.
2.
Bring the cylinder to be tested to the compression top dead center and remove rocker arm
assembly (2).
a See "Adjusting valve clearance".
3.
Disconnect fuel high-pressure tube (3) and

injector wiring harness (4) and remove injector
(5).
a Before disconnecting the fuel high-pressure tube, loosen all center clamps.
a Disconnect the terminal of the injector wiring harness on the injector side and the
bracket on the rocker housing side and
pull them outside the rocker arm housing
(Loosen the 2 terminal nuts alternately).
125E-5 Series
4.
Install adapter D2 to the mounting hole on the

injector and the compression gauge D1.
a Fit the gasket to the adapter end without
fail
a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
5.
Install rocker arm assembly (2) and adjust the

valve clearance.
3 Rocker arm assembly mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
SEN00547-05
6.
Connect the INSITE (bench test tool) to the

engine and set the engine in the no-injection
cranking mode.
k If the engine is not set in the no-injection cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.
7.
Rotate the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
8.

a Install the injector, injector wiring harness,
and fuel high-pressure tube according to
the following procedure.
1) Install the O-ring and gasket to injector
(11).
2) Fit holder (12) to injector (11) to temporarily assemble them as a unit to the cylinder head.
3) Fit mounting bolt (13) to spherical washer
(14) to tighten them to the cylinder head.
2 Spherical part of washer:
Engine oil (SAE30DH)
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
4) Install wiring harness (15) to the rocker
arm housing and fix it with mounting bolt
(16).
5) Insert wiring harness (15) into holder (17).
6) Alternately tighten 2 nuts at wiring harness
(15) end to injector (11).
3 Nut: 2.0 2.4 Nm {0.2 0.24 kgm}
7) Tighten tube (18) to injector (11).
3 Sleeve nut:
39.2 49.0 Nm {4 5 kgm}
8) Tighten the clamping bolt of the fuel piping.
3 Clamping bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
10

3
Rocker arm assembly mounting

bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
Adjust the valve clearance.

For
details, see "Adjusting valve clearance".
Cylinder head cover mounting bolt:

9.8 1 Nm {1.0 0.1 kgm}
125E-5 Series
SEN00547-05

a
Testing tool for blow-by pressure
Symbol
Part No.
799-201-1504
Part name
Blow-by checker
1.
Install nozzle [1] of blow-by checker E to the

end of breather hose (1).
2.
Connect hose [2], and then connect it to gauge

[3].
3.

blow-by pressure.
machine.
4.

125E-5 Series
11
SEN00547-05
Testing engine oil pressure

a
Testing tools for engine oil pressure
Symbol
F
1
2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
799-401-2320
Hydraulic tester
1.
Remove oil pressure pickup plug (1) from the

cylinder block.
4.
2.
Connect nipple [1] of hydraulic tester F1 and

connect it to hydraulic tester F2.
3.
Run the engine at the rated output and low idle

and test the oil pressure.
machine.
12

125E-5 Series
SEN00547-05
Measuring EGR valve and bypass

valve drive pressure
1
a
Part No.
4.
Start the engine and measure the oil pressure

at low idle and high idle.
a When measuring without removing the
engine from the machine, measure under
the condition described in the shield
machine for the machine.
5.
After finishing measurement, remove the measuring instruments and return the removed
parts.
q
Replace the removed plug with new one.
When reusing it, remove the sticking gasket sealant from it with a wire brush and
apply new adhesive or gasket sealant to it
before installing.
2 Plug:
Adhesive (LT-2) or Gasket sealant (LG-4)
3 Plug: 16.7 37.2 Nm {1.7 3.8 kgm}
Part name
799-101-5002
Hydraulic tester
790-261-1204
The measuring points may be different from

the following explanation, depending on each
applicable machine.
1.
Remove either of oil pressure pickup plugs (2)

of timing gear cover (1).
Reference: When measuring without removing the engine from the machine, if it is difficult
to remove the pickup plug, remove or move the
following parts.
q
Remove the belt cover.
q
Remove the air conditioner compressor
belt.
q
Move the air conditioner compressor so
that it will not be an obstacle to the work.
2.
Connect hydraulic tester [1] to the nipple.
Measuring instruments for EGR valve and

bypass valve drive pressure
Symbol
F
3.
Install nipple (Component of tool F1: 790-3011190) to the oil pressure pickup hole.
125E-5 Series
13
SEN00547-05
Handling fuel system parts

a
14
Precautions for testing and maintaining fuel

system
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a
trouble.
When testing and maintaining the fuel system,
take care more than the past. If dust, etc.
sticks to any part, wash that part thoroughly
with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge.
Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzle, it
employs a high-efficiency special filter to prevent foreign matter from entering it.
If a filter other than the genuine one is used,
the fuel system may have a trouble. Accordingly, never use such a filter.
Releasing residual pressure in

fuel system
a
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit:
Feed pump Fuel filter Supply pump
High-pressure circuit:
Supply pump Common rail Injector
The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit must be released completely. Accordingly,
observe the following.
Before testing the fuel system or removing
its parts, wait at least 30 seconds after
stopping the engine until the residual pressure in the fuel circuit is released. (Do not
start the work just after stopping the engine
since there is residual pressure.)
125E-5 Series
SEN00547-05

a
1
2
3
a
k
1.
3.
Testing tools for fuel pressure
Symbol
Part No.
799-101-5002
Part name
Hydraulic tester
790-261-1204
799-401-2320
Gauge
795-471-1450
Adapter
07005-00812
Gasket
Engine speed
Fuel pressure
High idle
0.15 0.3 MPa

{1.5 3 kg/cm2}
Test only the fuel pressure in the low-pressure

circuit from the feed pump through the fuel filter to the supply pump.
Since the pressure in the high-pressure circuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
Remove fuel pressure pickup plug (1) from the
fuel filter head.
4.
2.
Run the engine at high idle and measure the

fuel pressure.
a If the fuel pressure is in the following
range, it is normal.

Install adapter G3 and nipple [1] of hydraulic

tester G1 and connect it to gauge G2.
125E-5 Series
15
SEN00547-05
Reduced cylinder mode operation1
No-injection cranking
1.
2.
3.
16
Reduced cylinder mode operation means to

run the engine with the fuel injectors of 1 or
more cylinders disabled electrically to reduce
the number of effective cylinders. The purposes and effects of this operation are as follows.
This operation is used to find out a cylinder
which does not output power normally (or,
combustion in it is abnormal).
When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects.
The possible defects are as follows.
q
Leakage from the cylinder head gasket
q
Defective injection
q
Defective piston, piston ring, or cylinder
liner
q
Defective valve mechanism (Moving valve
system)
q
Defect in electrical system
controls the injector of each cylinder electronically, the operator can perform the reduced
cylinder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode operation with the engine mounted on the
machine or connected to INSITE (bench
test tool).
a Before performing, see "Testing method"
in the shop manual for the machine or
INSITE (bench test tool).
a
a
No-injection cranking means to crank the

engine with the starting motor while all the
injections are stopped electrically. The purpose and effect of this operation are as follows.
Before the engine is started after it or the
engine unit has been stored for a long period,
the no-injection cranking is performed to lubricate the engine parts and protect them from
seizure.
Perform the no-injection operation with the
engine mounted on the machine or connected
to INSITE (bench test tool).
Before performing, see "Testing method" in the
shop manual for the machine or INSITE
(bench test tool).
125E-5 Series
SEN00547-05
Testing leakage from pressure limiter and return rate from injector
The locations of the fuel circuit parts are subject to machine models (The figure shows the
engine for PC400/400LC-7E0 and PC450/
450LC-7E0).
Testing tools for leakage from pressure limiter
and return rate from injector
Symbol
Part No.
Preparation work
1) Remove tube (3) between common rail (1)
and return block (2).
Part name
6151-51-8490
Spacer
6206-71-1770
Joint
Commercially available
Hose
Hose
Measuring cylinder
Stopwatch
Prepare a pan of about 20 l to receive the fuel

flowing out during the test.
125E-5 Series
1.
2)
Insert spacer H1 on return block (2) side

and tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the spacer.
17
SEN00547-05
3)
4)
Insert joint H2 on common rail (1) side and

tighten the removed joint bolt again.
of the joint.
Connect test hose H3 to the end of joint
H2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
5)
3.
2.
18
Testing leakage from pressure limiter

1) Lay test hose H3 so that it will not slacken
and put its end in the pan.
2) Connect INSITE (bench test tool) to the
engine and set it so that it can check the
engine speed.
q
Or set on the machine so that it can
check the engine speed.
3) Start the engine and run it at the rated output.
4) After the engine speed is stabilized, test
the leakage in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure limiter is in the following range, it is normal.
Engine speed
Leakage
(cc/min)
At rated output
Max. 10
After finishing testing, stop the engine.
Testing return rate from injector

a Keep the hose on the pressure limiter side
connected and keep its end in the pan
while testing the return rate from the injector.
1) Disconnect fuel return hose (4) from return
block (2).
a Stop the fuel return hose with a plug,
etc. and fix it to the fuel tank.
Plug: 07376-70315
2)
3)
Connect test hose H4 to the return block

(2) side.
from coming off.
Lay test hose H4 so that it will not slacken
125E-5 Series
SEN00547-05
4.
Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
4)
5)
6)
Connect INSITE (bench test tool) to the

engine speed.
q
Run the engine at the rated output.
After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder H5.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injector is in the following range, it is normal.
Rated output speed
(rpm)
7)
Return (Spill) limit

(cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
125E-5 Series
19
SEN00547-05
Bleeding air from fuel circuit
a
a
1.
20
If fuel is used up or if a fuel circuit part is

removed and installed, bleed air from the fuel
circuit according to the following procedure.
The locations of the fuel circuit parts are subject to machine models (The figure shows the
engine for PC400/400LC-7E0 and PC450/
450LC-7E0).
Remove fuel pre-fuel filter (1) and fill it with
fuel.
a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the pre-fuel filter, and
then add fuel through part (b) (holes
around the central hole).
a After filling the pre-fuel filter with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the pre-fuel filter but fill it with the
fuel by operating priming pump (4).
a Do not add fuel to fuel main filter (2) externally.
125E-5 Series
2.
Install pre-fuel filter (1) to the filter head.

a Apply engine oil thinly over the packing on
the pre-fuel filter side.
a After the packing of the pre-fuel filter
touches the sealing face of the filter head,
tighten the fuel filter 3/4 turns.
3.
Remove air bleeding plug (4) of the fuel main

filter and operate priming pump (4).
a Operate the priming pump until the fuel
flows out of the plug hole and install the
plug.
3 Air bleeding plug:
7.8 9.8 Nm {0.8 1.0 kgm}
4.
Loosen air bleeding plug (5) of the fuel main filter (2) and operate priming pump (4).
flows out of the plug hole and install the
plug.
3 Air bleeding plug:
7.8 9.8 Nm {0.8 1.0 kgm}
125E-5 Series
SEN00547-05
5.
Loosen air bleeder (6) of the fuel supply pump

and operate priming pump (4) 90 100 times.
flows out of the air bleeder and tighten the
air bleeder. Then, operate the priming
pump several times more until it becomes
heavy.
3 Air bleeder:
4.9 6.9 Nm {0.5 0.7 kgm}
6.
Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 3.
21
SEN00547-05
Testing fuel system for leakage 1

k
Very high pressure is generated in the

high-pressure circuit of the fuel system. If
fuel leaks while the engine is running, it is
dangerous since it can catch fire.
After testing the fuel system or removing
its parts, test it for fuel leakage according
to the following procedure.
Clean and degrease the engine and the parts
around it in advance so that you can test it easily for fuel leakage.
1.
Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2.
Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3.
Inspect the fuel piping and devices for fuel

leakage.
a Inspect mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4.
Run the engine at low idle.
5.

leakage.
for fuel leakage.
6.
Run the engine at high idle.
7.

leakage.
for fuel leakage.
8.
Run the engine at high idle and load it.

a When testing the engine mounted on the
machine, stall the torque converter or
relieve the oil from the hydraulic pump.
22
9.

leakage.
for fuel leakage.
a If no fuel leakage is detected, inspection is
completed.
125E-5 Series
Adjusting speed sensor

a
a
SEN00547-05
The Ne speed sensor and Bkup speed sensor

for the common rail fuel injection system cannot be adjusted.
Adjust speed sensor (1), which detects the signal of the flywheel ring gear to use it for the
electronic system on the machine side, according to the following procedure.
1.
Remove speed sensor (1) and check that its tip

is free from steel chips and flaws, and then
install it again temporarily.
2 Threads: Gasket sealant (LG-6)
2.
Screw in sensor (1) until its tip touches the

tooth tip of flywheel ring gear (2).
3.
Return sensor (1) by 1/2 2/3 turns.

a Adjust clearance (a) between the sensor
tip and gear tooth tip to 0.75 1.00 mm.
4.
While fixing sensor (1), tighten nut (3).

3 Nut: 69 74 Nm {7.0 7.5 kgm}
125E-5 Series
23
SEN00547-05
Testing and adjusting alternator

belt tension
1
Separately installed fan type
Testing
Press the intermediate point of the belt between
alternator pulley and crankshaft pulley with a finger
and measure deflection (a) of the belt.
a Pressing force: Approx. 58.8 N {Approx. 6 kg}
a Deflection (a): 13 16 mm
Simultaneous fan drive type

Testing
alternator pulley and fan pulley with a finger and
measure deflection (a) of the belt.
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
Adjusting
a The figure shows an example. The number of
the belt may be different and locknut (1) may
not be used depending on each model.
1.
Loosen locknut (1) and loosen rocknut (2) and

bolts (3) and (4).
2.
Move alternator (6) with adjustment nut (5) to

adjust the tension of belt (7).
3.
Tighten bolts (4) and (3) and tighten locknut

(2), and then tighten locknut (1).
3 Bolt (4): 107.8 147 Nm {11 15 kgm}
3 Bolt (3): 28.4 32.4 Nm {2.9 3.3 kgm}
a After adjusting, test the belt tension again.
24
1.
Loosen locknut (1) and bolts (2) and (3).
2.

3.

(1).
3 Bolt (3): 107.8 147 Nm {11 15 kgm}
3 Bolt (2): 28.4 38.2 Nm {2.9 3.9 kgm}
125E-5 Series
SEN00547-05
Handling controller voltage circuit1

1.
When disconnecting or connecting a connector

between the engine controller and engine, be
sure to turn the starting switch OFF.
2.
If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
125E-5 Series
25
SEN00547-05
Testing and adjusting (EGR-less)
Testing and adjusting tools list 1

Symbol
Testing exhaust
temperature
Q'ty
Remarks
799-201-2202 Boost gauge kit
101 200 kPa {760 1,500 mmHg}
799-401-2220 Hose
I-coupler type (if necessary)
799-101-1502 Digital thermometer
99.9 1,299C
Commercially
Feeler gauge
available
Intake: 0.33 mm
Exhaust: 0.71 mm
795-502-1590 Compression gauge
0 7 MPa {0 70 kg/cm2}
795-471-1420 Adapter
6217-71-6112 Gasket
799-201-1504 Blow-by checker
0 5 kPa {0 500 mmH2O}

{25, 60, 400, 600 kg/cm2}

{25, 60, 400, 600 kg/cm2}
799-401-2320 Gauge
795-471-1450 Adapter
07005-00812 Gasket
6151-51-8490 Spacer
Inside diameter: 14 mm
6206-71-1770 Joint
Inside diameter of joint: 10 mm
Commercially
Hose
available
5 mm x 2 3 m
Commercially
Hose
available
15 mm x 2 3 m
Commercially
Measuring cylinder
available
Commercially
Stopwatch
available
1
Testing compression
pressure
Testing oil pressure
2
E
1
2
1
2
3
Testing leakage from

pressure limiter and return H 4
rate from injector
26
Part No.
Part name
For 125E-5
8 x 1.25 mm o R1/8
125E-5 Series
Troubleshooting for
controllers,
sensors, and actuators
Removal and installation

of engine coolant
temperature sensor
SEN00547-05
Symbol
Part No.
Part name
Remarks
799-601-4130 T-adapter
For Ne sensor
799-601-4330 Socket
For Bkup sensor
799-601-4240 Socket
For atmospheric pressure sensor
799-601-4250 Socket
For boost pressure sensor
799-601-9420 T-adapter
For common rail pressure
799-601-4150 T-adapter
For oil pressure sensor
795-799-5540 T-adapter
For boost temperature sensor
795-799-5530 T-adapter
799-601-9430 T-adapter
For supply pump PCV
799-601-9020 T-adapter
For injector
799-601-4260 T-adapter
799-601-4210 T-adapter
799-601-4220 T-adapter
799-601-9320 T-box
799-601-9310 Plate
799-601-4350 T-box
For 60-pole type
Commercially
Socket
available
For coolant temperature sensor

For fuel temperature sensor
For 24-pole type
21 mm deep socket
560001 - 564999
19 mm deep socket
565000 and up
795T-981-1010 Socket
125E-5 Series
Q'ty
27
SEN00547-05
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Socket
28
125E-5 Series
SEN00547-05

a
Testing tools for air boost pressure
Symbol
A
k
a
1.
Part No.
Part name
799-201-2202
Boost gauge kit
799-401-2220
Hose
Be careful not to touch any hot part when

removing or installing the testing tools.
Remove one air boost pressure pickup plug
(1).
a You may check at either front or rear plug.
2.
Install nipple [1] of boost gauge kit A and connect it to gauge [2].
3.

air boost pressure.
machine.
125E-5 Series
4.

29
SEN00547-05
Testing exhaust temperature

a
Testing tools for exhaust temperature
Symbol
Part No.
799-101-1502
a
1.
Part name
Digital thermometer
Remove and install the testing tools after

the exhaust manifold temperature has lowered.
Remove exhaust temperature pickup plug (1)
from the side face of the center of the exhaust
manifold.
4.
2.
Install sensor [1] of digital thermometer B and

connect it to thermometer [2].
3.
Run the engine and test the exhaust temperature in the whole speed range.
machine.
30

3 Exhaust temperature pickup plug:
3.9 6.9 Nm {0.4 0.7 kgm}
125E-5 Series
SEN00547-05

a
Part No.
Commercially
available
2.
3.
While fixing adjustment screw (3), loosen locknut (4).

a After setting the No. 1 cylinder to the compression top dead center, adjust the valve
clearance of the No. 1 cylinder.
4.
Insert feeler gauge C in the clearance between

rocker arm (5) and crosshead (6) and adjust
the valve clearance with adjustment screw (3).
a With the feeler gauge inserted, turn the
adjustment screw to a degree that you can
move the feeler gauge lightly.
a Valve clearance
Intake valve: 0.33 mm
Exhaust valve: 0.71 mm
5.
While fixing adjustment screw (3), tighten locknut (4).

3 Locknut:
58.8 73.5 Nm {6.0 7.5 kgm}
6.
After adjusting the No. 1 cylinder, rotate the

crankshaft forward by 120 and adjust the
clearance of each cylinder according to the firing order.
a Firing order: 1-5-3-6-2-4
7.
After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}
Adjusting tools for valve clearance
Symbol
1.
Part name
Feeler gauge
Remove 6 cylinder head covers (1).
Rotate the crankshaft forward to bring the

stamped 1.6TOP line (a) of the damper to
pointer (2) and set the No. 1 cylinder to the
compression top dead center.
a Rotate the crankshaft with the mounting
bolt of the crankshaft pulley (width across
flats: 24 mm), and be sure to rotate it only
forward to prevent the bolt from loosening.
a When the No. 1 cylinder is at the compression top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, rotate the crankshaft
one more turn.
125E-5 Series
31
SEN00547-05
Testing compression pressure

a
Testing tools for compression pressure
Symbol
1
D
k
1.
Part No.
Pass a wire, etc. under the fuel path projected sideways and pull up the injector
(Do not pry the injector top up).
Part name
795-502-1590
Compression gauge
795-471-1420
Adapter
6217-71-6112
Gasket
When measuring the compression pressure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
Measure the compression pressure after the
engine is warmed up
(Engine oil temperature: 40 60C).
Remove cylinder head cover (1) of the cylinder
to be tested for compression pressure.
2.
Bring the cylinder to be tested to the compression top dead center and remove rocker arm
assembly (2).
3.
Disconnect fuel high-pressure tube (3) and

injector wiring harness (4) and remove injector
(5).
a Before disconnecting the fuel high-pressure tube, loosen all center clamps.
a Disconnect the terminal of the injector wiring harness on the injector side and the
bracket on the rocker housing side and
pull them outside the rocker arm housing
(Loosen the 2 terminal nuts alternately).
32
4.
Install adapter D2 to the mounting hole on the

injector and the compression gauge D1.
a Fit the gasket to the adapter end without
fail
a Fix the adapter with the injector holder.
58.8 73.5 Nm {6.0 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
5.
Install rocker arm assembly (2) and adjust the

valve clearance.
3 Rocker arm assembly mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
125E-5 Series
6.
Connect the INSITE (bench test tool) to the

engine and set the engine in the no-injection
cranking mode.
a When inspecting with the engine mounted
on the machine, set the engine in the noinjection cranking mode by operating the
monitor panel.
k If the engine is not set in the no-injection cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.
7.
Rotate the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
8.

a Install the injector, injector wiring harness,
and fuel high-pressure tube according to
1) Install the O-ring and gasket to injector
(11).
2) Fit holder (12) to injector (11) to temporarily assemble them as a unit to the cylinder head.
3) Fit mounting bolt (13) to spherical washer
(14) to tighten them to the cylinder head.
Engine oil (SAE30DH)
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
4) Install wiring harness (15) to the rocker
arm housing and fix it with mounting bolt
(16).
5) Insert wiring harness (15) into holder (17).
6) Alternately tighten 2 nuts at wiring harness
(15) end to injector (11).
3 Nut: 2.0 2.4 Nm {0.2 0.24 kgm}
7) Tighten tube (18) to injector (11).
3 Sleeve nut:
39.2 49.0 Nm {4 5 kgm}
8) Tighten the clamping bolt of the fuel piping.
3 Clamping bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
125E-5 Series
SEN00547-05
Rocker arm assembly mounting

bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
Adjust the valve clearance.

For
details, see "Adjusting valve clearance".
Cylinder head cover mounting bolt:

9.8 1 Nm {1.0 0.1 kgm}
33
SEN00547-05

a
Testing tool for blow-by pressure
Symbol
Part No.
799-201-1504
Part name
Blow-by checker
1.
Install nozzle [1] of blow-by checker E to the

end of breather hose (1).
2.
Connect hose [2], and then connect it to gauge

[3].
3.

blow-by pressure.
machine.
4.

34
125E-5 Series
SEN00547-05
Testing engine oil pressure

a
Testing tools for engine oil pressure
Symbol
F
1
2
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
799-401-2320
Hydraulic tester
1.
Remove oil pressure pickup plug (1) from the

cylinder block.
4.
2.
Connect nipple [1] of hydraulic tester F1 and

connect it to hydraulic tester F2.
3.
Run the engine at the rated output and low idle

and test the oil pressure.
machine.
125E-5 Series

35
SEN00547-05
Handling fuel system parts

a
36
Precautions for testing and maintaining fuel

system
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a
trouble.
When testing and maintaining the fuel system,
take care more than the past. If dust, etc.
sticks to any part, wash that part thoroughly
with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter
cartridge.
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzle, it
employs a high-efficiency special filter to prevent foreign matter from entering it.
If a filter other than the genuine one is used,
the fuel system may have a trouble. Accordingly, never use such a filter.
Releasing residual pressure in

fuel system
a
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit:
Feed pump Fuel filter Supply pump
High-pressure circuit:
Supply pump Common rail Injector
The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit must be released completely. Accordingly,
observe the following.
Before testing the fuel system or removing
its parts, wait at least 30 seconds after
stopping the engine until the residual pressure in the fuel circuit is released. (Do not
start the work just after stopping the engine
since there is residual pressure.)
125E-5 Series
SEN00547-05

a
1
2
3
a
k
1.
3.
Testing tools for fuel pressure
Symbol
Part No.
799-101-5002
Part name
Hydraulic tester
790-261-1204
799-401-2320
Gauge
795-471-1450
Adapter
07005-00812
Gasket
Engine speed
Fuel pressure
High idle
0.15 0.3 MPa

{1.5 3 kg/cm2}
Test only the fuel pressure in the low-pressure

circuit from the feed pump through the fuel filter to the supply pump.
Since the pressure in the high-pressure circuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
Remove fuel pressure pickup plug (1) from the
fuel filter head.
4.
2.
Run the engine at high idle and measure the

fuel pressure.
a If the fuel pressure is in the following
range, it is normal.

Install adapter G3 and nipple [1] of hydraulic

tester G1 and connect it to gauge G2.
125E-5 Series
37
SEN00547-05
Reduced cylinder mode operation1
No-injection cranking
1.
2.
3.
38
Reduced cylinder mode operation means to

run the engine with the fuel injectors of 1 or
more cylinders disabled electrically to reduce
the number of effective cylinders. The purposes and effects of this operation are as follows.
This operation is used to find out a cylinder
which does not output power normally (or,
combustion in it is abnormal).
When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects.
The possible defects are as follows.
q
Leakage from the cylinder head gasket
q
Defective injection
q
Defective piston, piston ring, or cylinder
liner
q
Defective valve mechanism (Moving valve
system)
q
Defect in electrical system
controls the injector of each cylinder electronically, the operator can perform the reduced
cylinder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode operation with the engine mounted on the
machine or connected to INSITE (bench
test tool).
a Before performing, see "Testing method"
in the shop manual for the machine or
INSITE (bench test tool).
a
a
No-injection cranking means to crank the

engine with the starting motor while all the
injections are stopped electrically. The purpose and effect of this operation are as follows.
Before the engine is started after it or the
engine unit has been stored for a long period,
the no-injection cranking is performed to lubricate the engine parts and protect them from
seizure.
Perform the no-injection operation with the
engine mounted on the machine or connected
to INSITE (bench test tool).
Before performing, see "Testing method" in the
shop manual for the machine or INSITE
(bench test tool).
125E-5 Series
SEN00547-05
Testing leakage from pressure

limiter and return rate from
injector
a
a
The locations of the fuel circuit parts are subject to machine models.
Testing tools for leakage from pressure limiter
and return rate from injector
Symbol
Part No.
Part name
6151-51-8490
Spacer
6206-71-1770
Joint
Hose
Hose
Measuring cylinder
Stopwatch
Prepare a pan of about 20 l to receive the fuel

flowing out during the test.
1.
Preparation work
1) Remove tube (3) between common rail (1)
and return block (2).
2)
3)
4)
Insert spacer H1 on return block (2) side

and tighten the removed joint bolt again.
of the spacer.
Insert joint H2 on common rail (1) side and
tighten the removed joint bolt again.
of the joint.
Connect test hose H3 to the end of joint
H2.
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
125E-5 Series
2.
Testing leakage from pressure limiter

1) Lay test hose H3 so that it will not slacken
2) Connect INSITE (bench test tool) to the
engine speed.
q
3) Start the engine and run it at the rated output.
4) After the engine speed is stabilized, test
the leakage in 1 minute with measuring
cylinder H5.
a If the leakage from the pressure limiter is in the following range, it is normal.
5)
Engine speed
Leakage
(cc/min)
At rated output
Max. 10
39
SEN00547-05
3.
Testing return rate from injector

a Keep the hose on the pressure limiter side
connected and keep its end in the pan while
testing the return rate from the injector.
1) Disconnect fuel return hose (4) from return
block (2).
a Stop the fuel return hose with a plug,
etc. and fix it to the fuel tank.
Plug: 07376-70315
2)
3)
6)
4.
5)
40
Rated output speed

(rpm)
Return (Spill) limit

(cc/min)
1,600
960
1,700
1,020
1,800
1,080
1,900
1,140
2,000
1,200
Connect test hose H4 to the return block

(2) side.
from coming off.
Lay test hose H4 so that it will not slacken
7)
4)
After the engine speed is stabilized, test

the return rate in 1 minute with measuring
cylinder H5.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injector is in the following range, it is normal.
Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
Connect INSITE (bench test tool) to the

engine speed.
q
Run the engine at the rated output.
125E-5 Series
Bleeding air from fuel circuit
SEN00547-05
4.
Reference: The electric priming pump switch is

installed to the chassis.
a
a
Turn ON switch (3) of electric priming pump

(2) installed to the chassis.
a The electric priming pump operates and
lamp (4) blinks.
Manual priming pump is set for some models.

(See the"with EGR")
Bleed air from the fuel circuit in the following
cases according to this procedure.
q
When the fuel filter is replaced
q
When fuel is used up
q
When the engine is started for the first
time after the fuel piping or supply pump is
replaced
If the fuel filter was replaced, do not fill the
main filter and prefilter with the fuel.
1.
Turn the starting switch to the OFF position.
2.
Check that the fuel valve on the fuel tank side

is open.
3.
Turn lever (1) of the air bleeding piping to the

parallel position with the piping to open the circuit valve.
a
a
k
The electric priming pump has a timer in it

to start and stop itself automatically (See
the following figure).
The electric priming pump stops while the
lamp is blinking. This phenomenon is not
abnormal, however.
If the switch is turned to the OFF position
while the lamp is blinking, the lamp goes
off and the electric priming pump stops.
While the electric priming pump is
operating, pressure is applied to the
fuel circuit. Do not loosen the air
bleeding plug at this time, since the
fuel may spout out.
Reference: The operating procedure sticker is

stuck near the air bleeding piping lever.
125E-5 Series
5.
After the specified time (approx. 7 minutes),

lamp (4) goes off and the electric priming pump
stops automatically.
a If only the fuel filter was replaced, the air
bleeding work is completed now.
6.
If the fuel was used up or the fuel piping or

supply pump was replaced and there is not fuel
in the fuel circuit, turn switch (3) ON after the
electric priming pump stops automatically.
41
SEN00547-05
7.
When lamp (4) goes off, the air bleeding work

is completed.
8.
Turn lever (1) of the air bleeding piping to the

cross position with the piping to close the circuit valve.
9.
Start the engine with the starting motor.

a Do not operate the starting motor continuously for more than 20 seconds.
q
After starting the engine, run it at low
idle for about 5 minutes to bleed all air
from the fuel circuit.
q
Stop the engine and check that the air
bleeding valve is closed.
10. If the engine does not start, try to start it again
according to the following procedure.
k When starting the engine, check that there
is no person around it.
a Carry out the work with the air bleeding
valve closed. (Do not open the air bleeding valve after step 7.)
a After the engine fails to start, wait for
about 2 minutes before trying to start
again.
1) Turn the electric priming pump switch ON.
2) While the electric priming pump is operating, crank the engine.
q
If the engine does not start, repeat the
above operation.
a Do not operate the starting motor continuously for more than 20 seconds.
a If the engine fails to start, wait for about 2
minutes and try to start again.
3) After starting the engine, run it at low idle
for about 5 minutes to bleed all air from
the fuel circuit.
4) Stop the engine and check that the air
bleeding valve is closed.
5) After the above operation, start the engine
normally.
42
125E-5 Series
Testing fuel system for leakage 1

k
Very high pressure is generated in the

high-pressure circuit of the fuel system. If
fuel leaks while the engine is running, it is
dangerous since it can catch fire.
After testing the fuel system or removing
its parts, test it for fuel leakage according
to the following procedure.
Clean and degrease the engine and the parts
around it in advance so that you can test it easily for fuel leakage.
1.
Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2.
Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3.

leakage.
for fuel leakage.
4.
5.

leakage.
for fuel leakage.
6.
7.

leakage.
for fuel leakage.
8.

a When testing the engine mounted on the
relieve the oil from the hydraulic pump.
125E-5 Series
SEN00547-05
9.

leakage.
for fuel leakage.
a If no fuel leakage is detected, inspection is
completed.
43
SEN00547-05
Adjusting speed sensor

a
a
The Ne speed sensor and Bkup speed sensor

for the common rail fuel injection system cannot be adjusted.
Adjust speed sensor (1), which detects the signal of the flywheel ring gear to use it for the
electronic system on the machine side, according to the following procedure.
1.
Remove speed sensor (1) and check that its tip

is free from steel chips and flaws, and then
install it again temporarily.
2 Threads: Gasket sealant (LG-6)
2.
Screw in sensor (1) until its tip touches the

tooth tip of flywheel ring gear (2).
3.
Return sensor (1) by 1/2 2/3 turns.

a Adjust clearance (a) between the sensor
tip and gear tooth tip to 0.75 1.00 mm.
4.
While fixing sensor (1), tighten nut (3).

3 Nut: 69 74 Nm {7.0 7.5 kgm}
44
125E-5 Series
Testing and adjusting alternator

belt tension
1
Separately installed fan type
Testing
alternator pulley and crankshaft pulley with a finger
and measure deflection (a) of the belt.
SEN00547-05
Simultaneous fan drive type

Testing
alternator pulley and fan pulley with a finger and
measure deflection (a) of the belt.
Adjusting
Adjusting
a The figure shows an example. The number of
the belt may be different and locknut (1) may
not be used depending on each model.
1.
Loosen locknut (1) and loosen rocknut (2) and

bolts (3) and (4).
2.

3.

(2), and then tighten locknut (1).
3 Bolt (4): 107.8 147 Nm {11 15 kgm}
3 Bolt (3): 28.4 32.4 Nm {2.9 3.3 kgm}
125E-5 Series
1.
Loosen locknut (1) and bolts (2) and (3).
2.

3.

(1).
3 Bolt (3): 107.8 147 Nm {11 15 kgm}
3 Bolt (2): 28.4 38.2 Nm {2.9 3.9 kgm}
45
SEN00547-05
Handling controller voltage circuit1

1.
When disconnecting or connecting a connector

between the engine controller and engine, be
sure to turn the starting switch OFF.
2.
If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
46
125E-5 Series
125E-5 Series
SEN00547-05
47
SEN00547-05

2010 KOMATSU
All Rights Reserved
48
SEN00548-03
ENGINE
1SHOP MANUAL
125E-5 Series
40 Troubleshooting
General information on troubleshooting

General information on troubleshooting.......................................................................................................... 2
Points on troubleshooting..................................................................................................................... 2
Error code and failure code table ......................................................................................................... 4
Information in troubleshooting table ..................................................................................................... 8
125E-5 Series
SEN00548-03
40 Troubleshooting
General information on troubleshooting

Points on troubleshooting
k
k
k
k
k
k
When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so be sure to wait for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1.
2.
When carrying out troubleshooting, do not

hurry to disassemble the components.
If components are disassembled immediately
after any failure occurs:
q
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q
It will become impossible to find the cause
of the failure.
It will also cause a waste of manhours, parts,
or oil or grease, and at the same time, will also
lose the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough
prior investigation and to carry out troubleshooting in accordance with the fixed procedure.
Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly, or were
there problems with the machine condition
before this?
4) Under what conditions did the failure
occur?
5) Had any repairs been carried out before
the failure? When were these repairs carried out?
6) Has the same kind of failure occurred
before?
3.
Check before troubleshooting

1) Check for symptoms of any abnormality in
the machine and engine.
2) Be sure to check the CHECKS BEFORE
STARTING items.
3) Check other inspection items, if necessary.
4) Some other maintenance items can be
checked externally, so check any item that
is considered to be necessary.
5) Check the controller for display of an error.
4.
Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
as a problem with the method of operation, etc.
a When operating the machine or engine to
reenact the troubleshooting symptoms, do
not carry out any investigation or measurement that may make the problem
worse.
5.
Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the causes
of failure, then use the troubleshooting matrix
to locate the position of the failure exactly.
a The basic procedure for troubleshooting is
as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
125E-5 Series
40 Troubleshooting
6.
SEN00548-03
Measures to remove root cause of failure

Even if the failure is repaired, if the root cause
of the failure is not repaired, the same failure
will occur again. To prevent this, always investigate why the problem occurred. Then,
remove the root cause.
125E-5 Series
SEN00548-03
40 Troubleshooting
Error code and failure code table
(for construction equipment)
INSITE
error code
Machine failure
code
111
CA111
ECM Critical Internal Failure
115
CA115
Eng. Ne and Bkup Speed Sensor Error
Failure phenomenon
122
CA122
Charge Air Press Sensor High Error
123
CA123
Charge Air Press Sensor Low Error
131
CA131
Throttle Sensor High Error
132
CA132
Throttle Sensor Low Error
135
CA135
Oil Press. Sensor High Error
141
CA141
Oil Press. Sensor Low Error
144
CA144
Coolant Temp. Sensor High Error
145
CA145
Coolant Temp. Sensor Low Error
153
CA153
Charge Air Temp. Sensor High Error
154
CA154
Charge Air Temp. Sensor Low Error
187
CA187
Sensor Sup. 2 Volt. Low Error
221
CA221
Ambient Air Press. Sensor High Error
222
CA222
Ambient Air Press. Sensor Low Error
227
CA227
Sensor Sup. 2 Volt. High Error
234
CA234
Eng. Overspeed
238
CA238
Ne Speed Sensor Sup. Volt. Error
263
CA263
Fuel Temp. Sensor High Error
265
CA265
Fuel Temp. Sensor Low Error
271
CA271
PCV1 Short Error
272
CA272
PCV1 Open Error
273
CA273
PCV2 Short Error
274
CA274
PCV2 Open Error
322
CA322
Injector #1 (L/B #1) System Open/Short Error
323
CA323
324
CA324
325
CA325
331
CA331
332
CA332
342
CA342
Calibration Code Incompatibility
351
CA351
INJ. Drive Circuit Error
352
CA352
386
CA386
431
CA431
Idle Validation SW Low error
432
CA432
Idle Validation Process error
441
CA441
Battery voltage low error
442
CA442
Battery voltage high error
Reference
document No.
Troubleshooting of electrical
system (E-mode), Part 1
SEN00550-01
125E-5 Series
40 Troubleshooting
SEN00548-03
INSITE
error code
Machine failure
code
449
CA449
Rail Press. Very High Error
451
CA451
Rail Press. Sensor High Error
452
CA452
Rail Press. Sensor Low Error
553
CA553
Rail Press. High Error
554
CA554
Rail Press Sensor In Range Error
559
CA559
Rail Press. Low Error
689
CA689
Eng. Ne Speed Sensor Error
731
CA731
Eng. Bkup Speed Sensor Phase Error
757
CA757
All Persistent Data Lost Error
778
CA778
Eng. Bkup Speed Sensor Error
1228
CA1228
EGR Valve Servo Error 1 ["with EGR" only]
a
a
Failure phenomenon
Reference
document No.
1625
CA1625
EGR Valve Servo Error 2 ["with EGR" only]
1626
CA1626
Bypass Valve Solenoid Current High Error ["with EGR" only]
1627
CA1627
Bypass Valve Solenoid Current Low Error ["with EGR" only]
1628
CA1628
Bypass Valve Servo Error 1 ["with EGR" only]
1629
CA1629
Bypass Valve Servo Error 2 ["with EGR" only]
1631
CA1631
1632
CA1632
BP valve Lift Position Sensor High Error ["with EGR" only] system (E-mode), Part 2
BP valve Lift Position Sensor Low Error ["with EGR" only] SEN00551-01
1633
CA1633
KOMNET Datalink Timeout Error
1642
CA1642
EGR Inlet Press Sensor Low Error ["with EGR" only]
1653
CA1653
EGR Inlet Press Sensor High Error ["with EGR" only]
2185
CA2185
Throttle Sens. Sup. Volt. High Error
2186
CA2186
Throttle Sens. Sup. Volt. Low Error
2249
CA2249
Rail Press. Very Low Error
2271
CA2271
EGR Valve Lift Position Sensor High Error ["with EGR" only]
2272
CA2272
EGR Valve Lift Position Sensor Low Error ["with EGR" only]
2351
CA2351
EGR Valve Solenoid Current High Error ["with EGR" only]
2352
CA2352
EGR Valve Solenoid Current Low Error ["with EGR" only]
2555
CA2555
Grid Heater Relay Volt. Low Error
2556
CA2556
Grid Heater Relay Volt. High Error
(143)
B@BAZG
Eng. Oil press. Torque Derate
(146)
B@BCNS
Eng. Overheat
(415)
B@BAZG
Eng. Oil press. Low Speed Derate
INSITE error code:

An error code of 3 or 4 digits displayed on the INSITE (bench test tool) when the occurrence condition of
the failure is confirmed with the INSITE.
Machine failure code:
An error code of 5 or 6 digits displayed on the machine monitor when the occurrence condition of the
failure is confirmed with the machine monitor, etc. on the machine side.
125E-5 Series
SEN00548-03
40 Troubleshooting
(for Generator)
Machine failure
code
Failure phenomenon
A8
Speed Adj. Vol. High (Isochronous) A8
A9
Speed Adj. Vol. Low (Isochronous) A9
AA
Speed Adj. Vol. High (Droop) AA
AB
Speed Adj. Vol. Low (Droop) AB
AF
KOMNET Error (CR710) AF
b6
Droop Rate Adj. Vol. High b6
b7
Droop Rate Adj. Vol. Low b7
b8
Low Idle Speed Adj. Vol. High b8
b9
Low Idle Speed Adj. Vol. Low b9
bc
Speed Adj. Vol. High (Default) bc
bd
Speed Adj. Vol. Low (Default) bd
bE
Ramptime Adj. Vol. High bE
bF
Ramptime Adj. Vol. Low bF
CA111
ECM Critical Internal Failure CA111
CA115
Ne, Bkup Speed Sensor Error CA115
CA122
Charge Air Press Sensor High CA122
CA123
Charge Air Press Sensor Low CA123
CA135
Oil Press. Sensor High CA135
CA141
Oil Press. Sensor Low CA141
CA144
Coolant Temp. Sensor High CA144
CA145
Coolant Temp. Sensor Low CA145
CA153
Charge Air Temp. Sensor High CA153
CA154
Charge Air Temp. Sensor Low CA154
CA187
Sensor Sup. 2 Volt. Low CA187
CA221
Ambient Air Press. Sensor High CA221
CA222
Ambient Air Press. Sensor Low CA222
CA227
Sensor Sup. 2 Volt. High CA227
CA234
Eng. Overspeed CA234
CA238
Ne Speed Sensor Sup. Volt. Error CA238
CA263
Fuel Temp. Sensor High CA263
CA265
Fuel Temp. Sensor Low CA265
CA271
IMV/PCV1 Short CA271
CA272
IMV/PCV1 Open CA272
CA273
PCV2 Short CA273
CA274
PCV2 Open CA274
CA322
Injector #1 Open/Short CA322
CA323
CA324
CA325
CA331
CA332
CA342
Calibration Code Incompatibility CA342
CA351
INJ. Drive Circuit Error CA351
CA352
Sensor Sup. 1 Volt. Low CA352
Reference
document No.
SEN00550-01
125E-5 Series
40 Troubleshooting
Machine failure
code
SEN00548-03
Failure phenomenon
CA386
Sensor Sup. 1 Volt. High CA386
CA441
Battery Voltage Low CA441
CA442
Battery Voltage High CA442
CA449
Rail Press. Very High CA449
CA451
Rail Press. Sensor High CA451
CA452
Rail Press. Sensor Low CA452
CA553
Rail Press. High CA553
CA559
Rail Press. Low CA559
CA689
Ne Speed Sensor Error CA689
CA731
Bkup Speed Sensor Phase CA731
CA757
All Data Lost CA757
CA778
Bkup Speed Sensor Error CA778
CA1228
EGR Valve Servo Error 1 CA1228
CA1625
EGR Valve Servo Error 2 CA1625
CA1626
Bypass Valve Solenoid Current High CA1626
CA1627
Bypass Valve Solenoid Current Low CA1627
CA1628
Bypass Valve Servo Error 1 CA1628
CA1629
Bypass Valve Servo Error 2 CA1629
CA1631
BP Valve Lift Position High CA1631
CA1632
BP Valve Lift Position Low CA1632
CA1633
KOMNET Error CA1633
CA1642
EGR Inlet Press Sensor Low CA1642
CA1653
EGR Inlet Press Sensor High CA1653
CA2185
Throttle Sensor Sup. Volt. High CA2185
CA2186
Throttle Sensor Sup. Volt. Low CA2186
CA2249
Rail Press. Very Low CA2249
CA2271
EGR Valve Lift Position High CA2271
CA2272
EGR Valve Lift Position Low CA2272
CA2341
Eng. Overspeed CA2341
CA2351
EGR Valve Solenoid Current High CA2351
CA2352
EGR Valve Solenoid Current Low CA2352
CA2555
Heater Relay Volt. Low CA2555
CA2556
Heater Relay Volt. High CA2556
CA143
Oil Press. Low CA143
CA146
Eng. Overheat CA146
125E-5 Series
Reference
document No.
SEN00550-01
SEN00551-01
SEN00548-03
40 Troubleshooting
Information in troubleshooting table

a
The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Error code
Failure code
Display on
INSITE
Display on applicable machine
Contents of
trouble
Trouble
Problem that appears on engine
Contents of trouble detected by engine controller
Action of
controller
Action taken by engine controller to protect system or devices when engine controller detects
trouble
Problem that
appears on
machine
Problem that appears on engine as result of action taken by engine controller (shown above)
Related
information
Information related to detected trouble or troubleshooting
Causes
Standard value in normal state/Remarks on troubleshooting

<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
2
Possible causes
and standard
value in normal
state
<Troubles in wiring harness>

Disconnection
Connector is connected imperfectly or wiring harness is
broken.
Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
Hot short
Wiring harness which is not connected to power source
(24 V) circuit is in contact with power source (24 V) circuit.
Short circuit
Independent wiring harnesses are in contact with each
other abnormally.
Possible causes of trouble

(Given numbers are reference
numbers, which do not indicate <Precautions for troubleshooting>
(1) Method of indicating connector No. and handling of Tpriority)
adapter
Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified.
3
If connector No. has no marks of male and female,
disconnect connector and insert T-adapters in both
male side and female side.
If connector No. has marks of male and female,
disconnect connector and connect T-adapter to only
male side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester
as explained below for troubleshooting, unless otherwise
specified.
4
Connect positive (+) lead to pin No. or wiring harness
entered on front side.
Connect negative () lead to pin No. or wiring harness
entered on rear side.
125E-5 Series
40 Troubleshooting
SEN00548-03
Related circuit diagram
This drawing is a part of the electric circuit diagram related

to troubleshooting.
Connector No.: Indicates (Model Number of pins) and
(Color).
Connector No. and pin No. from each branching/merging point: Shows the ends of branch or source of merging
within the parts of the same wiring harness.
Arrow (): Roughly shows the location on the machine.
125E-5 Series
SEN00548-03

2007 KOMATSU
All Rights Reserved
10
SEN00550-01
ENGINE
1SHOP MANUAL
125E-5 Series
40 Troubleshooting
Troubleshooting of electrical system

(E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 4
E-1 Code [111/CA111] ECM Critical Internal Failure ............................................................................ 4
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error........................................................... 6
E-3 Code [122/CA122] Charge Air Press Sensor High Error ............................................................... 8
E-4 Code [123/CA123] Charge Air Press Sensor Low Error.............................................................. 10
E-5 Code [131/CA131] Throttle Sensor High Error ............................................................................ 12
E-6 Code [132/CA132] Throttle Sensor Low Error............................................................................. 16
E-7 Code [135/CA135] Oil press. Sensor High Error ......................................................................... 18
E-8 Code [141/CA141] Oil press. Sensor Low Error.......................................................................... 20
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ................................................................. 22
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error................................................................ 24
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error........................................................... 26
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error ........................................................... 28
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error..................................................................... 29
125E-5 Series
SEN00550-01
40 Troubleshooting
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error......................................................... 30

E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error ......................................................... 32
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error .................................................................... 34
E-17 Code [234/CA234] Eng. Overspeed .......................................................................................... 36
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error............................................................... 38
E-19 Code [263/CA263] Fuel Temp. Sensor High Error..................................................................... 40
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error ..................................................................... 42
E-21 Code [271/CA271] PCV1 Short Error ........................................................................................ 44
E-22 Code [272/CA272] PCV1 Open Error ........................................................................................ 46
E-23 Code [273/CA273] PCV2 Short Error ........................................................................................ 48
E-24 Code [274/CA274] PCV2 Open Error ........................................................................................ 50
E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error ............................................ 52
E-31 Code [342/CA342] Calibration Code Incompatibility.................................................................. 64
E-32 Code [351/CA351] INJ. Drive Circuit Error ................................................................................ 66
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error..................................................................... 68
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error .................................................................... 70
E-35 Code [431/CA431] Idle Validation SW Low error ....................................................................... 72
E-36 Code [432/CA432] Idle Validation Process error ....................................................................... 74
E-37 Code [441/CA441] Battery voltage low error ............................................................................. 74
E-38 Code [442/CA442] Battery voltage high error............................................................................ 75
125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00550-01
SEN00550-01
40 Troubleshooting
Troubleshooting of electrical system (E-mode), Part 1
E-1 Code [111/CA111] ECM Critical Internal Failure
Error code
Failure code
111
CA111
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
ECM Critical Internal Failure
Abnormality occurred in controller.

None in particular.
Engine runs normally but it may stop during operation or may not be able to start.
Different machine models may have different connector Nos.
Cause
1 Defective fuse

Check fuse or circuit breaker on machine side directly for defect.
(If fuse is broken or circuit breaker is turned OFF, circuit probably
has ground fault.)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between E03 (female) (3),
2
or defective contact in connec- (4) battery (+)
tor)
Wiring harness between E03 (female) (1),
(2) chassis ground
Resistance
Max. 1 z
Resistance
Max. 1 z
3
Ground fault in wiring harness Wiring harness between E03 (female) (3),
(Short circuit with GND circuit) (4) battery (+) and chassis ground
Resistance
Min.
1 Mz

(2) chassis ground
Resistance
Min.
1 Mz
a Prepare with starting switch OFF, then turn starting switch ON

and carry out troubleshooting.
4 Defective engine controller
E03
Voltage
Between (3), (4) (1), (2)
20 30 V
125E-5 Series
40 Troubleshooting
SEN00550-01
Circuit diagram related to controller power supply
125E-5 Series
SEN00550-01
40 Troubleshooting
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error

Error code
Failure code
115
CA115
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Eng. Ne and Bkup Speed Sensor Error
Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
None in particular.
Engine cannot be started (if engine has been stopped).
Engine stops (if engine has been running).
Related
information
Causes
Possible causes
and standard
value in normal
state
Defective Ne speed sensor

system
Carry out troubleshooting for code [689/CA689].
Defective Bkup speed sensor

system
Carry out troubleshooting for code [778/CA778].
Defective mount of Ne speed

sensor
Check mount of Ne speed sensor directly for defect (defective

installation of sensor, internal of flywheel, etc.)
Defective mount of Bkup

speed sensor
Check mount of Bkup speed sensor directly for defect (defective

installation of sensor, internal of supply pump, etc.)
Defective connection (Wrong

connection)
Check Ne speed sensor and Bkup speed sensor directly for

defective connection (wrong connection).
If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)
125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00550-01
SEN00550-01
40 Troubleshooting
E-3 Code [122/CA122] Charge Air Press Sensor High Error

Error code
Failure code
122
CA122
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Charge Air Press Sensor High Error
Signal voltage in charge pressure sensor circuit is abnormally high.

Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
Acceleration performance of engine drops.
Causes
1
Defective sensor power supply If code [187/CA187] or [227/CA227] is indicated, carry out trousystem
bleshooting for it first.
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
Defective charge pressure

2 sensor
(Internal trouble)
Possible causes
and standard
value in normal
state
PIM
Between (1) (3)
Voltage
Power supply
4.75 5.25V
Sensor voltage is measured with wiring harness connected.

Accordingly, if voltage is abnormal, check wiring harness and
controller, too, for another cause of trouble, and then judge.
Disconnection in wiring harness

3
(Disconnection in wiring or
defective contact in connector)
Wiring harness between ENG (female)

(37) PIM (female) (1) and chassis ground
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z

Ground fault in wiring harness (37) PIM (female) (1)
4
(Short circuit with GND circuit) Wiring harness between ENG (female)
(44) PIM (female) (2)
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz

(47) PIM (female) (3)
Resistance
Min.
1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
Causes

Possible causes
and standard
value in normal
state
Short circuit in wiring harness

(With another wiring harness)

(37) PIM (female) (1) and wiring harness
between ENG (female) (44) PIM (female)
(2)
Resistance
Min.
1 Mz

(3)
Resistance
Min.
1 Mz

(3)
Resistance
Min.
1 Mz

or start engine and carry out troubleshooting.
ENG
Between (37) (47)
Voltage
Power supply
4.75 5.25V
Circuit diagram related to charge pressure sensor
Remarks: The figure shows with EGR for an example.

Following connectors apply to only with EGR.
<Applied connector>
q
BP
q
EGR
q
PEVA
q
SEGR
q
SBP
125E-5 Series
SEN00550-01
40 Troubleshooting
E-4 Code [123/CA123] Charge Air Press Sensor Low Error

Error code
Failure code
123
CA123
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Charge Air Press Sensor Low Error
Signal voltage in charge pressure sensor circuit is abnormally low.

Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
Acceleration performance of engine drops.
Related
information
Possible causes
and standard
value in normal
state
10
Cause

Carry out troubleshooting for E-3 Code [122/CA122].
125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00550-01
11
SEN00550-01
40 Troubleshooting
E-5 Code [131/CA131] Throttle Sensor High Error
Throttle sensor of accelerator pedal type (Case of HM300-2)

Error code
Failure code
131
CA131
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signal voltage in throttle sensor circuit is abnormally high.

Sets throttle angle with signal other than throttle sensor signal and continues operation
(depending on each model)
Different problems occur on different machine models.
Causes
1
Defective sensor power supply If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
system
troubleshooting for it first.
AS1
Accelerator pedal
Voltage
Between (1) (3)
All range
(Power supply)
4.75 5.25V
Released
(13 2% of source
voltage)
Pressed
(77 2% of source
voltage)
Defective accelerator pedal

(Internal trouble)
Between (2) (3)

Possible causes
and standard
value in normal
state
3
Wiring harness between E02 (female) (22)

AS1 (female) (1)
Resistance
Max. 1 z

AS1 (female) (2)
Resistance
Max. 1 z

AS1 (female) (3)
Resistance
Max. 1 z
12

Ground fault in wiring harness AS1 (female) (1) and chassis ground
4
(Short circuit with GND circuit) Wiring harness between E02 (female) (9)
AS1 (female) (2) and chassis ground
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz

Resistance
Min.
1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
Causes

Possible causes
and standard
value in normal
state
E02
Accelerator pedal
Voltage
Between (22) (23)
All range
(Power supply)
4.75 5.25V
Released
(13 2% of source
voltage)
Pressed
(77 2% of source
voltage)
Between (9) (23)
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HM300-2)
125E-5 Series
13
SEN00550-01
40 Troubleshooting
Throttle sensor of fuel control dial type (Case of PC400/400LC/450/450LC-7)

Error code
Failure code
131
CA131
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signal voltage in throttle sensor circuit is abnormally high.

Causes
Defective sensor power supply If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
1
system
troubleshooting for it first.
2
Defective fuel control dial

(Internal trouble)
P20 (male)
Resistance
Between (1) (3)
4.0 6.0 kz
Between (2) (1)
0.25 5.0 kz
Between (2) (3)
0.25 5.0 kz
Possible causes
and standard
value in normal
state

3

P20 (female) (1)
Resistance
Max. 1 z

P20 (female) (2)
Resistance
Max. 1 z

P20 (female) (3)
Resistance
Max. 1 z
Ground fault in wiring harness P20 (female) (1) and chassis ground
4
P20 (female) (2) and chassis ground
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz

Resistance
Min.
1 Mz

14
E02
Voltage
Between (22) (23)
Power supply
4.75 5.25V
Between (9) (23)
Signal
0.5 4.5V
125E-5 Series
40 Troubleshooting
SEN00550-01
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC400/400LC/450/450LC-7)
125E-5 Series
15
SEN00550-01
40 Troubleshooting
E-6 Code [132/CA132] Throttle Sensor Low Error

Error code
Failure code
132
CA132
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Throttle Sensor Low Error
Signal voltage in throttle sensor circuit is abnormally low.

Sets throttle angle with signal other than throttle signal and continues operation (depending on each
model).
Related
information
Possible causes
and standard
value in normal
state
16
Cause

125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00550-01
17
SEN00550-01
40 Troubleshooting
E-7 Code [135/CA135] Oil press. Sensor High Error

Error code
Failure code
135
CA135
Contents of
trouble
Action of
controller
Trouble
Oil press. Sensor High Error
Signal voltage in oil pressure sensor circuit is abnormally high.

Sets oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Problem that
appears on
machine
Related
information
Causes
1
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
Defective oil pressure sensor

(Internal trouble)
POIL
Between (1) (2)
Voltage
Power supply
4.75 5.25V

Possible causes
and standard
value in normal
state

(37) POIL (female) (1) and chassis
ground

3
defective contact in connector) (47) POIL (female) (2) and chassis
ground
(13) POIL (female) (3) and chassis
ground
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
18

Ground fault in wiring harness (37) POIL (female) (1)
4
(47) POIL (female) (2)
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz

(13) POIL (female) (3)
Resistance
Min.
1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
Causes

Possible causes
and standard
value in normal
state


(37) POIL (female) (1) and wiring harness between ENG (female) (47) POIL
(female) (2)
Resistance
Min.
1 Mz

(female) (3)
Resistance
Min.
1 Mz

(female) (3)
Resistance
Min.
1 Mz

ENG
Between (37) (47)
Voltage
Power supply
4.75 5.25V
Circuit diagram related to oil pressure sensor

<Applied connector>
q
BP
q
EGR
q
PEVA
q
SEGR
q
SBP
125E-5 Series
19
SEN00550-01
40 Troubleshooting
E-8 Code [141/CA141] Oil press. Sensor Low Error

Error code
Failure code
141
CA141
Contents of
trouble
Action of
controller
Trouble
Oil press. Sensor Low Error
Signal voltage in oil pressure sensor circuit is abnormally low.

Sets oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
20
Cause

125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00550-01
21
SEN00550-01
40 Troubleshooting
E-9 Code [144/CA144] Coolant Temp. Sensor High Error

Error code
Failure code
144
CA144
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Coolant Temp. Sensor High Error
Signal voltage in coolant temperature sensor circuit is abnormally high.

Fixes coolant temperature (90C) and continues operation.
Engine starting performance decreases during low temperature.
Cause
Defective coolant temperature
1
sensor (Internal trouble)
TWTR (male)
Coolant temperature
Resistance
Between (A) (B)
10 100C
0.6 20 kz
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female)
2
or defective contact in connec- (15) TWTR (female) (A)
tor)
(38) TWTR (female) (B)
Resistance
Max. 1 z
Resistance
Max. 1 z
Ground fault in wiring harness

(15) TWTR (female) (A) and chassis
ground
Resistance
Min.
1 Mz
22
ENG (female)
Coolant temperature
Resistance
Between (15) (38)
10 100C
0.6 20 kz
125E-5 Series
40 Troubleshooting
SEN00550-01
Circuit diagram related to coolant temperature sensor

<Applied connector>
q
BP
q
EGR
q
PEVA
q
SEGR
q
SBP
125E-5 Series
23
SEN00550-01
40 Troubleshooting
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error

Error code
Failure code
145
CA145
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Coolant Temp. Sensor Low Error
Signal voltage in coolant temperature sensor circuit is abnormally low.

Fixes coolant temperature (90C) and continues operation.
Related
information
Possible causes
and standard
value in normal
state
24
Cause

Carry out troubleshooting E-9 Code [144/CA144].
125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00550-01
25
SEN00550-01
40 Troubleshooting
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error

Error code
Failure code
153
CA153
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Charge Air Temp. Sensor High Error
Signal voltage in charge temperature sensor circuit is abnormally high.

Fixes charge temperature (intake air temperature) (70C) and continues operation.
Cause

Defective charge temperature

1
TIM (male)
Intake air temperature
Resistance
Between (A) (B)
10 100C
0.5 20 kz
Between (A)
chassis ground
All range
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
or defective contact in connec- (23) TIM (female) (A)
tor)
(47) TIM (female) (B)
Resistance
Max. 1 z
Resistance
Max. 1 z
3
ResisMin.
(23) TIM (female) (A) and chassis ground tance
1 Mz
4
26
Defective engine controller
ENG (female)
Intake air temperature
Resistance
Between (23) (47)
10 100C
0.5 20 kz
125E-5 Series
40 Troubleshooting
SEN00550-01
Circuit diagram related to charge temperature sensor

<Applied connector>
q
BP
q
EGR
q
PEVA
q
SEGR
q
SBP
125E-5 Series
27
SEN00550-01
40 Troubleshooting
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error

Error code
Failure code
154
CA154
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Charge Air Temp. Sensor Low Error
Signal voltage in charge temperature sensor circuit is abnormally low.

Fixes charge temperature (intake air temperature) (70C) and continues operation.
Related
information
Possible causes
and standard
value in normal
state
28
Cause

125E-5 Series
40 Troubleshooting
SEN00550-01
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error

Error code
Failure code
187
CA187
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.

Operates Bkup speed sensor with signals of Ne speed sensor.
Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Sets EGR inlet pressure sensor to default value (102 kPa {1.04 kg/cm2}) and continues operation.
["with EGR" only]
Limits output of EGR valve lift sensor and closes EGR valve and bypass valve ["with EGR" only].
Limits output of bypass valve lift sensor and closes EGR valve and bypass valve ["with EGR" only].
Output drops.
Related
information
Possible causes
and standard
value in normal
state
125E-5 Series
Causes

29
SEN00550-01
40 Troubleshooting
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error

Error code
Failure code
221
CA221
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Ambient Air Press. Sensor High Error
Signal voltage in atmospheric pressure sensor circuit is abnormally high.

Output drops.
Causes
1
PAMB
Defective atmospheric pres2 sure sensor

(Internal trouble)
Voltage
Between (1) (3)
Power supply
4.75 5.25V
Between (2) (3)
Signal
0.3 4.7V

Possible causes
and standard
value in normal
state

3

(37) PAMB (female) (1)
Resistance
Max. 1 z
Wiring harness between ENG (female) (3)

PAMB (female) (2)
Resistance
Max. 1 z

(38) PAMB (female) (3)
Resistance
Max. 1 z
(37) PAMB (female) (1) and chassis
Ground fault in wiring harness ground
4
(Short circuit with GND circuit) Wiring harness between ENG (female) (3)
PAMB (female) (2) and chassis ground
(38) PAMB (female) (3) and chassis
ground
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz
5
30


(37) PAMB (female) (1) and wiring harness between ENG (female) (3) PAMB
(female) (2)
Resistance
Min.
1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
Causes
5
Possible causes
and standard
value in normal
state


(37) PAMB (female) (1) and wiring harness between ENG (female) (38) PAMB
(female) (3)
Resistance
Min.
1 Mz

PAMB (female) (2) and wiring harness
between ENG (female) (38) PAMB
(female) (3)
Resistance
Min.
1 Mz

ENG
Voltage
Between (37) (38)
4.75 5.25V
Between (3) (38)
0.3 4.7V
Circuit diagram related to atmospheric pressure sensor

<Applied connector>
q
BP
q
EGR
q
PEVA
q
SEGR
q
SBP
125E-5 Series
31
SEN00550-01
40 Troubleshooting
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error

Error code
Failure code
222
CA222
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Ambient Air Press. Sensor Low Error
Signal voltage in atmospheric pressure sensor circuit is abnormally low.

Sets oil pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Output drops.
Related
information
Possible causes
and standard
value in normal
state
32
Causes

125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00550-01
33
SEN00550-01
40 Troubleshooting
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error

Error code
Failure code
227
CA227
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.

Operates Bkup speed sensor with signals of Ne speed sensor.
Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Sets EGR inlet pressure sensor to default value (102 kPa {1.04 kg/cm2}) and continues operation.
["with EGR" only]
Limits output of EGR valve lift sensor and closes EGR valve and bypass valve ["with EGR" only].
Limits output of bypass valve lift sensor and closes EGR valve and bypass valve ["with EGR" only].
Output drops.
Causes
1 Defective related system

If another failure code is indicated, carry out troubleshooting for
it.
Possible causes
and standard
value in normal
state
Disconnect devices
Defective sensor (Internal trou- at right in order. If
error code disap2 ble)
pears when a device
(*: "With EGR" only)
is disconnected, that
device has a defect
in it.
(*: "with EGR" only)
Bkup speed sensor
G connector
Oil pressure sensor
POIL connector
Atmospheric
pressure sensor
PAMB connector
Charge pressure
sensor
PIM connector
EGR inlet pressure

sensor (*)
PEVA connector
EGR valve lift

sensor (*)
SEGR connector
Bypass valve lift

sensor (*)
SBP connector

3
(37) each sensor (female)
defective contact in connector) Wiring harness between ENG (female)
Resistance
Max. 1 z
Resistance
Max. 1 z
34

Ground fault in wiring harness (37) each sensor (female) and chassis
4
(Short circuit with GND circuit) ground
Resistance
Min.
1 Mz

(47) each sensor (female) and chassis
ground
Resistance
Min.
1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
Causes

Possible causes
and standard
value in normal
state


(37) each sensor (female) and
Resistance
Min.
1 Mz

6
ENG
Voltage
Between (37) (47)
4.75 5.25V
Circuit diagram related to sensor power supply 2 (5 V)
Remarks: The figure shows with EGR for an example. Following connectors apply to only with EGR.
Applied connector: BP, EGR, PEVA, SEGR, SBP
125E-5 Series
35
SEN00550-01
40 Troubleshooting
E-17 Code [234/CA234] Eng. Overspeed

Error code
Failure code
234
CA234
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Eng. Overspeed
Engine speed is above operating range.

Limits fuel injection rate until engine speed lowers to operating range.
Engine speed fluctuates.
Related
information
Cause
Possible causes
and standard
value in normal
state
36

it.
2 Improper way of use
Way of use may be improper. Teach proper way of use to operator.
If causes 1 and 2 are not detected, engine controller may be

defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00550-01
37
SEN00550-01
40 Troubleshooting
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error

Error code
Failure code
238
CA238
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Ne Speed Sensor Sup. Volt. Error
Abnormality occurred in Ne speed sensor power supply (5 V) circuit.

Controls Ne speed sensor with signals of Bkup speed sensor.
Running engine stops (when Bkup speed sensor is also abnormal).
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Cause

Possible causes
and standard
value in normal
state
Defective Ne speed sensor

(Internal trouble)
Disconnect devices
at right in order. If
error code disappears when a device
device has a defect
in it.
Ne speed sensor
NE connector
Resis2
Max. 1 z
or defective contact in connec- (16) NE (female) (1)
tance
tor)
ResisMax. 1 z
(48) NE (female) (2)
tance
3
Ground fault in wiring harness Wiring harness between ENG (female)

(Short circuit with GND circuit) (16) NE (female) (1) and chassis ground
Resistance
Min.
1 Mz

(48) NE (female) (2) and chassis ground
Resistance
Min.
1 Mz

(with another wiring harness)
(16) NE (female) (1) and between ENG
(female) (48) NE (female) (2)
Resistance
Min.
1 Mz

38
ENG
Voltage
Between (16) (48)
4.75 5.25 V
125E-5 Series
40 Troubleshooting
SEN00550-01
Circuit diagram related to Ne speed sensor power supply
125E-5 Series
39
SEN00550-01
40 Troubleshooting
E-19 Code [263/CA263] Fuel Temp. Sensor High Error

Error code
Failure code
263
CA263
Contents of
trouble
Action of
controller
Trouble
Fuel Temp. Sensor High Error
Signal voltage in fuel temperature sensor circuit is abnormally high.

Uses coolant temperature sensor instead of fuel temperature sensor for correction of injection rate.
Fixes fuel temperature (95C) and continues operation, if coolant temperature sensor is also defective.
Problem that
appears on
machine
Related
information
Causes
Defective fuel temperature
1 sensor
(Internal trouble)
Possible causes
and standard
value in normal
state

TFUEL (male)
Fuel temperature
Resistance
Between (A) (B)
10 100C
0.6 20 kz
Resis2
Max. 1 z
(30) TFUEL (female) (A)
tance
ResisMax. 1 z
(47) TFUEL (female) (B)
tance
3

(30) TFUEL (female) (A) and chassis
(Short circuit with GND circuit)
ground
Resistance
Min.
1 Mz
4
40
ENG (female)
Fuel temperature
Resistance
Between (30) (47)
10 100C
0.6 20 kz
125E-5 Series
40 Troubleshooting
SEN00550-01
Circuit diagram related to fuel temperature sensor

<Applied connector>
q
BP
q
EGR
q
PEVA
q
SEGR
q
SBP
125E-5 Series
41
SEN00550-01
40 Troubleshooting
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error

Error code
Failure code
265
CA265
Contents of
trouble
Action of
controller
Trouble
Fuel Temp. Sensor Low Error
Signal voltage in fuel temperature sensor circuit is abnormally low.

Uses coolant temperature sensor instead of fuel temperature sensor for correction of injection rate.
Fixes fuel temperature (95C) and continues operation, if coolant temperature sensor is also defective.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
42
Causes

125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00550-01
43
SEN00550-01
40 Troubleshooting
E-21 Code [271/CA271] PCV1 Short Error

Error code
Failure code
271
CA271
Contents of
trouble
Action of
controller
Trouble
PCV1 Short Error
There is short circuit in PCV1 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
While engine is running normally, pulse voltage of about 24 V is applied to PCV (1). This pulse voltage cannot be measured with circuit tester.
Causes

Defective supply pump PCV1

(Internal trouble)
PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Between (1), (2) chassis

ground
Min. 1 Mz
2
Ground fault in wiring harness Wiring harness between ENG (female) (4)
(Short circuit with GND circuit) PCV1 (female) (1)
Resistance
Min.
1 Mz

PCV1 (female) (2)
Resistance
Min.
1 Mz
Possible causes
and standard
value in normal
state

3
Hot short (Short circuit with

24V circuit) in wiring harness

PCV1 (female) (1) and chassis ground
Voltage
Max. 1V

Voltage
Max. 1V
4
44
ENG (female)
Resistance
Between (4) (5)
2.3 5.3 z

ground
Min. 1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
Circuit diagram related to supply pump PCV1
125E-5 Series
45
SEN00550-01
40 Troubleshooting
E-22 Code [272/CA272] PCV1 Open Error

Error code
Failure code
272
CA272
Contents of
trouble
Action of
controller
Trouble
PCV1 Open Error
There is disconnection in PCV1 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Causes


(Internal disconnection)
PCV1 (male)
Resistance
Between (1) (2)
2.3 5.3 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state

2
PCV1 (female) (1)
defective contact in connector) Wiring harness between ENG (female) (5)
PCV1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
3
(Short circuit with GND circuit) PCV1 (female) (1) and chassis ground
Resistance
Min.
1 Mz

Resistance
Min.
1 Mz
4
46
ENG (female)
Resistance
Between (4) (5)
2.3 5.3 z
Between (4) (5) chassis

ground
Min. 1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
125E-5 Series
47
SEN00550-01
40 Troubleshooting
E-23 Code [273/CA273] PCV2 Short Error

Error code
Failure code
273
CA273
Contents of
trouble
Action of
controller
Trouble
PCV2 Short Error
There is short circuit in PCV2 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Causes


(Internal trouble)
PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z

ground
Min. 1 Mz
2
(Short circuit with GND circuit) PCV2 (female) (1) and chassis ground
Possible causes
and standard
value in normal
state

(10) PCV2 (female) (2)
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz

3


Voltage
Max. 1V

(10) PCV2 (female) (2) and chassis
ground
Voltage
Max. 1V
48
ENG (female)
Resistance
Between (9) (10)
2.3 5.3 z

ground
Min. 1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
125E-5 Series
49
SEN00550-01
40 Troubleshooting
E-24 Code [274/CA274] PCV2 Open Error

Error code
Failure code
274
CA274
Contents of
trouble
Action of
controller
Trouble
PCV2 Open Error
There is disconnection in PCV2 circuit of supply pump.

None in particular.
Problem that
appears on
machine
Related
information
Causes
1
(Internal disconnection)
Possible causes
and standard
value in normal
state

PCV2 (male)
Resistance
Between (1) (2)
2.3 5.3 z
Resis2
Max. 1 z
PCV2 (female) (1)
tance
ResisMax. 1 z
(10) PCV2 (female) (2)
tance
3

(10) PCV2 (female) (2) and chassis
ground
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz
4
50
ENG (female)
Resistance
Between (9) (10)
2.3 5.3 z

ground
Min. 1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
125E-5 Series
51
SEN00550-01
40 Troubleshooting
E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error 1

Error code
Failure code
322
CA322
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
There is disconnection or short circuit in injector #1 circuit.

None in particular.
Output drops.
Rotation is unstable.
While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester.
Causes

Defective injector #1
(Internal trouble)
CN1 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state

2
(45) CN1 (female) (1)
(53) CN1 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
Ground fault in wiring harness (45) CN1 (female) (1) and chassis
3
Resistance
Min.
1 Mz

(53) CN1 (female) (2) and chassis
ground
Resistance
Min.
1 Mz
Defective injector or wiring

harness of another cylinder
If failure code of another cylinder is displayed, carry out troubleshooting for it, too.
52
ENG (female)
Resistance
Between (45) (53)
0.4 1.1 z

ground
Min. 1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
Circuit diagram related to injector #1
125E-5 Series
53
SEN00550-01
40 Troubleshooting

Error code
Failure code
323
CA323
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

None in particular.
Output drops.
Cause

Defective injector #5 (Internal

trouble)
CN5 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
or defective contact in connec- (46) CN5 (female) (1)
tor)
(60) CN5 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
3
Resistance
Min.
1 Mz

ground
Resistance
Min.
1 Mz

54
ENG (female)
Resistance
Between (46) (60)
0.4 1.1 z

ground
Min. 1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
125E-5 Series
55
SEN00550-01
40 Troubleshooting

Error code
Failure code
324
CA324
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

None in particular.
Output drops.
Cause


trouble)
CN3 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
tor)
(52) CN3 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
3
Resistance
Min.
1 Mz

ground
Resistance
Min.
1 Mz

56
ENG (female)
Resistance
Between (55) (52)
0.4 1.1 z

ground
Min. 1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
125E-5 Series
57
SEN00550-01
40 Troubleshooting

Error code
Failure code
325
CA325
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

None in particular.
Output drops.
Cause


trouble)
CN6 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
tor)
(59) CN6 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
3
Resistance
Min.
1 Mz

ground
Resistance
Min.
1 Mz

58
ENG (female)
Resistance
Between (57) (59)
0.4 1.1 z

ground
Min. 1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
125E-5 Series
59
SEN00550-01
40 Troubleshooting

Error code
Failure code
331
CA331
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

None in particular.
Output drops.
Cause


trouble)
CN2 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
tor)
(51) CN2 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
3
Resistance
Min.
1 Mz

ground
Resistance
Min.
1 Mz

60
ENG (female)
Resistance
Between (54) (51)
0.4 1.1 z

ground
Min. 1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
125E-5 Series
61
SEN00550-01
40 Troubleshooting

Error code
Failure code
332
CA332
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

None in particular.
Output drops.
Cause


trouble)
CN4 (male)
Resistance
Between (1) (2)
0.4 1.1 z

ground
Min. 1 Mz
Possible causes
and standard
value in normal
state
2
tor)
(58) CN4 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
3
Resistance
Min.
1 Mz

ground
Resistance
Min.
1 Mz

62
ENG (female)
Resistance
Between (56) (58)
0.4 1.1 z

ground
Min. 1 Mz
125E-5 Series
40 Troubleshooting
SEN00550-01
125E-5 Series
63
SEN00550-01
40 Troubleshooting
E-31 Code [342/CA342] Calibration Code Incompatibility

Error code
Failure code
342
CA342
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Calibration Code Incompatibility
Matching error occurred in engine controller data.

None in particular.
Engine continues operation normally, but it may stop during operation or may not be able to start.
Related
information
Possible causes
and standard
value in normal
state
64
Cause

125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00550-01
65
SEN00550-01
40 Troubleshooting
E-32 Code [351/CA351] INJ. Drive Circuit Error

Error code
Failure code
351
CA351
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
INJ. Drive Circuit Error
Abnormality occurred in injector drive circuit.

Limits output and continues operation (Limits common rail pressure).
Output drops.
Cause
Possible causes
and standard
value in normal
state
If another failure code (code of abnormality in injector system) is

indicated, carry out troubleshooting for it.
2 Defective fuse
Check fuse or circuit breaker on machine side directly for defect.

(If fuse is broken or circuit breaker is turned OFF, circuit probably
has ground fault.)
Disconnection in wiring harness (Disconnection in wiring Wiring harness between E03 (female) (3),
Resis3
Max. 1 z
or defective contact in connec- (4) battery (+)
tance
tor)
ResisMax. 1 z
(2) chassis ground
tance
4
Ground fault in wiring harness Wiring harness between E03 (female) (3),
(Short circuit with GND circuit) (4) battery (+) and chassis ground
Resistance
Min.
1 Mz

(2) chassis ground
Resistance
Min.
1 Mz

66
E03
Voltage
Between (3), (4) (1), (2)
20 30 V
125E-5 Series
40 Troubleshooting
SEN00550-01
Circuit diagram related to controller power supply
125E-5 Series
67
SEN00550-01
40 Troubleshooting
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error

Error code
Failure code
352
CA352
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low.

Limits output of common rail pressure sensor and continues operation (Limits common rail pressure).
Output drops.
Related
information
Possible causes
and standard
value in normal
state
68
Causes

125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00550-01
69
SEN00550-01
40 Troubleshooting
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error

Error code
Failure code
386
CA386
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high.

Limits output of common rail pressure sensor and continues operation (Limits common rail pressure).
Output drops.
Causes

it.
Disconnect devices
Defective sensor (Internal trou- at right in order. If
2
error code disapble)
pears when a device
device has a defect
in it.
Common rail pressure sensor
PFUEL connector
Possible causes
and standard
value in normal
state

3
(33) PFUEL (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z
Ground fault in wiring harness (33) PFUEL (female) (1) and chassis
4
Wiring harness between CE01 (female)
(47) PFUEL (female) (3) and chassis
ground
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz
5


(33) PFUEL (female) (1) and
wiring harness between ENG (female) (47)
PFUEL (female) (3)
Resistance
Min.
1 Mz

6
70
ENG
Voltage
Between (33) (47)
4.75 5.25V
125E-5 Series
40 Troubleshooting
SEN00550-01
Circuit diagram related to sensor power supply 1 (5 V)

<Applied connector>
q
BP
q
EGR
q
PEVA
q
SEGR
q
SBP
125E-5 Series
71
SEN00550-01
40 Troubleshooting
E-35 Code [431/CA431] Idle Validation SW Low error

Error code
Failure code
431
CA431
Contents of
trouble
Action of
controller
Trouble
Idle Validation SW Low error
Abnormality occurred in idle validation switch circuit

Sets throttle angle to certain value and continues operation (depending on each model).
Problem that
appears on
machine
Related
information
Causes


(Internal trouble)
AS1
Signal name
Between (5) (4)
Signal 1
Between (6) (4)
Signal 2
Voltage
See Fig. 1

2
Possible causes
and standard
value in normal
state

AS1 (female) (4)
Resistance
Max. 1 z

AS1 (female) (5)
Resistance
Max. 1 z

AS1 (female) (6)
Resistance
Max. 1 z
Ground fault in wiring harness AS1 (female) (4) and chassis ground
3
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz

Resistance
Min.
1 Mz

4 24V circuit)
in wiring harness
72

Voltage
Max. 1V

Voltage
Max. 1V

Voltage
Max. 1V
125E-5 Series
40 Troubleshooting
SEN00550-01
Causes
Possible causes
and standard
value in normal
state

E02
Signal name
Between (11) (32)
Signal 1
Between (1) (32)
Signal 2
Voltage
See Fig. 1
Fig. 1
Pedal: Stroke of accelerator pedal
Output voltage: Output voltage (%)
Sig1: Signal voltage of throttle sensor
Sig2: Signal voltage of idle validation switch 1
Sig3: Signal voltage of idle validation switch 2
Lo: Switch circuit closed
Hi: Switch circuit open
Switch gap: Area where signals of Switch 1 and
Switch 2 overlap
125E-5 Series
73
SEN00550-01
40 Troubleshooting
E-36 Code [432/CA432] Idle Validation Process error

Error code
Failure code
432
CA432
Contents of
trouble
Action of
controller
Trouble
Idle Validation Process error
Abnormality occurred in processing of idle validation switch circuit.

Sets throttle angle to certain value and continues operation (depending on each model).
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Cause

E-37 Code [441/CA441] Battery voltage low error

Error code
Failure code
441
CA441
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Battery voltage low error
Power supply voltage is abnormally low.

None in particular.
Related
information
Possible causes
and standard
value in normal
state
74
Cause

125E-5 Series
40 Troubleshooting
SEN00550-01
E-38 Code [442/CA442] Battery voltage high error

Error code
Failure code
442
CA442
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Battery voltage high error
Power supply voltage is abnormally high.

None in particular.
Related
information
Possible causes
and standard
value in normal
state
125E-5 Series
Cause

75
SEN00550-01

2007 KOMATSU
All Rights Reserved
76
SEN00551-01
ENGINE
1SHOP MANUAL
125E-5 Series
40 Troubleshooting
Troubleshooting of electrical system

(E-mode), Part 2
Troubleshooting of electrical system (E-mode), Part 2 ................................................................................... 3
E-39 Code [449/CA449] Rail Press. Very High Error ........................................................................... 3
E-40 Code [451/CA451] Rail Press. Sensor High Error ....................................................................... 4
E-41 Code [452/CA452] Rail Press. Sensor Low Error........................................................................ 6
E-42 Code [553/CA553] Rail Press. High Error ................................................................................... 6
E-43 Code [554/CA554] Rail Press Sensor In Range Error................................................................. 7
E-44 Code [559/CA559] Rail Press. Low Error .................................................................................... 8
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error ...................................................................... 12
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error........................................................ 14
E-47 Code [757/CA757] All Persistent Data Lost Error...................................................................... 15
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error................................................................... 16
E-49 Code [1228/CA1228] EGR Valve Servo Error 1 ........................................................................ 18
E-50 Code [1625/CA1625] EGR Valve Servo Error 2 ........................................................................ 19
E-51 Code [1626/CA1626] Bypass Valve Solenoid Current High Error ............................................. 20
125E-5 Series
SEN00551-01
40 Troubleshooting
E-52 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error .............................................. 22
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1 .................................................................... 23
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2 .................................................................... 24
E-55 Code [1631/CA1631] BP valve Lift Position Sensor High Error................................................. 26
E-56 Code [1632/CA1632] BP valve Lift Position Sensor Low Error ................................................. 28
E-57 Code [1633/CA1633] KOMNET Datalink Timeout Error ............................................................ 28
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error ......................................................... 29
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error......................................................... 30
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ........................................................ 32
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error......................................................... 36
E-62 Code [2249/CA2249] Rail Press. Very Low Error ...................................................................... 37
E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error ............................................. 38
E-64 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error .............................................. 40
E-65 Code [2351/CA2351] EGR Valve Solenoid Current High Error ................................................. 42
E-66 Code [2352/CA2352] EGR Valve Solenoid Current Low Error .................................................. 44
E-67 Code [2555/CA2555] Grid Heater Relay Volt. Low Error........................................................... 45
E-68 Code [2556/CA2556] Grid Heater Relay Volt. High Error .......................................................... 46
E-69 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate.............................................................. 48
E-70 Code [(146)/B@BCNS] Eng. Overheat...................................................................................... 48
E-71 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate....................................................... 49
125E-5 Series
40 Troubleshooting
SEN00551-01
Troubleshooting of electrical system (E-mode), Part 2
E-39 Code [449/CA449] Rail Press. Very High Error
Error code
Failure code
449
CA449
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Rail Press. Very High Error
Common rail pressure sensor circuit detected abnormally high pressure (level 2).
Output drops.
Related
information
Possible causes
and standard
value in normal
state
125E-5 Series
Causes

SEN00551-01
40 Troubleshooting
E-40 Code [451/CA451] Rail Press. Sensor High Error

Error code
Failure code
451
CA451
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Rail Press. Sensor High Error
Signal voltage in common rail pressure sensor circuit is abnormally high.

Output drops.
Causes
1
PFUEL
Defective common rail pres2 sure sensor

(Internal trouble)
Voltage
Between (1) (3)
Power supply
4.75 5.25V
Between (2) (3)
Signal
0.25 4.6V

Possible causes
and standard
value in normal
state

3

Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
ground
Resistance
Min.
1 Mz

ground
Resistance
Min.
1 Mz

ground
Resistance
Min.
1 Mz
125E-5 Series
40 Troubleshooting
SEN00551-01
Causes

5
Possible causes
and standard
value in normal
state


PFUEL (female) (2)
Resistance
Min.
1 Mz

PFUEL (female) (3)
Resistance
Min.
1 Mz

PFUEL (female) (3)
Resistance
Min.
1 Mz

ENG
Voltage
Between (33) (47)
4.75 5.25V
Between (25) (47)
0.25 4.6V
Circuit diagram related to common rail pressure sensor

<Applied connector>
q
BP
q
EGR
q
PEVA
q
SEGR
q
SBP
125E-5 Series
SEN00551-01
40 Troubleshooting
E-41 Code [452/CA452] Rail Press. Sensor Low Error

Error code
Failure code
452
CA452
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Rail Press. Sensor Low Error
Signal voltage in common rail pressure sensor circuit is abnormally low.

Output drops.
Related
information
Possible causes
and standard
value in normal
state
Cause

E-42 Code [553/CA553] Rail Press. High Error

Error code
Failure code
553
CA553
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Rail Press. High Error
Common rail pressure sensor circuit detected abnormally high pressure (level 1).
None in particular.
Output drops.
Related
information
Causes
Possible causes
and standard
value in normal
state

it.
2 Use of improper fuel
Check fuel used directly

(for high viscosity).
Defective electrical system of

common rail pressure sensor
Common rail pressure sensor may have electric trouble. Carry

out troubleshooting for code [451/CA451] (E-40).
Defective mechanical system

4 of common rail pressure sensor
Check mechanical system of common rail pressure sensor

directly.
5 Defective overflow valve
Check overflow valve directly for broken spring, worn seat, and
stuck ball.
6 Clogging of overflow piping
Check overflow piping directly for clogging.
7 Defective pressure limiter
Check pressure limiter directly for mechanical defect.
125E-5 Series
40 Troubleshooting
SEN00551-01
E-43 Code [554/CA554] Rail Press Sensor In Range Error

Error code
Failure code
554
CA554
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Rail Press Sensor In Range Error
In-range error occurred in common rail pressure sensor circuit.

Output drops.
Related
information
Possible causes
and standard
value in normal
state
125E-5 Series
Causes

SEN00551-01
40 Troubleshooting
E-44 Code [559/CA559] Rail Press. Low Error

Error code
Failure code
559
CA559
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Rail Press. Low Error
Supply pump does not feed fuel (level 1).

Limits common rail pressure.
Output drops.
Related
information
Causes

it.
2 Use of improper fuel
Check fuel used directly (for high viscosity).
Defective low-pressure circuit

device
4 Clogging of filter or strainer
Possible causes
and standard
value in normal
state
a For contents of troubleshooting, see Note 1. For check of pressure in fuel low-pressure circuit, see Testing and adjusting,
"Testing fuel pressure".
Pressure in fuel low-pressure circuit
(At high idle or equivalent to rated load
(stall))
Min. 0.15 MPa

{Min. 1.5 kg/cm2}
a For contents of troubleshooting, see Note 2.
Defective electrical system of

supply pump PCV
Supply pump PCV may have electric trouble. Carry out troubleshooting for following codes [271/CA271] (E-21), [272/CA272]
(E-22), [273/CA273] (E-23),[274/CA274] (E-24).
Defective common rail pressure sensor
Common rail pressure sensor may be defective. Check wiring

harness for damage.
7 Defective pressure limiter
a For testing of leakage from pressure limiter, see Testing and

adjusting, "Testing leakage from pressure limiter and return
rate from injector".
Leakage from pressure limiter
(At equivalent to rated operation by models)
Max. 10 cc/min
a For testing of return rate (spill) from injector, see Testing and
adjusting, "Testing leakage from pressure limiter and return
rate from injector".
Speed at rated operation
(at stall)
8 Defective injector
9 Defective supply pump
Return (Spill) limit from injector
1,600 rpm
960 cc/min
1,700 rpm
1,020 cc/min
1,800 rpm
1,080 cc/min
1,900 rpm
1,140 cc/min
2,000 rpm
1,200 cc/min
If causes 1 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached Check sheet for nopressure feed.
125E-5 Series
40 Troubleshooting
SEN00551-01
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q
Overflow valve (1): Spring is seen through both holes.
q
Bypass valve (2): Spring is seen through hole on nut side.
q
Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
125E-5 Series
SEN00551-01
40 Troubleshooting
Check sheet for no-pressure feed

Model
Machine serial No.
Work No.
#
Date of check
Engine
Engine serial No.
Worker's name
A. Visual check
Good NG
Fuel leakage to outside
Clogging of fuel tank breather
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function)
3
Service meter
Check of error/failure code
Good NG
Check of monitoring information

Code
*1
*2
Unit
Standard value
(Reference value)
Low idle
rpm
<By models>
High idle
rpm
<By models>
Equivalent to rating <By models>
rpm
<By models>
Displayed item
Engine speed
Throttle opening
Checking condition
Measured value
Good NG
Low idle
High idle
100
*3
Fuel injection command
mm3
*4
Common rail pressure

command
MPa
*5
Common rail fuel

pressure
MPa
*6
Fuel injection timing

command
Low idle
CA
High idle
CA
CA
*7
Boost pressure
kPa
*8
Engine coolant
temperature
Low idle
*9
Fuel temperature
Low idle
Unit
Standard value
(Reference value)
Check of reduced cylinder mode operation (Engine speed)

Function
5
*10
Reduced cylinder
Measured value
No. 1 cylinder
Low idle
rpm
Low idle
rpm
No. 3 cylinder
Low idle
rpm
No. 4 cylinder
Low idle
rpm
No. 5 cylinder
Low idle
rpm
No. 6 cylinder
Low idle
rpm
Checking condition
Unit
Standard value
(Reference value)
High idle or equivalent to rated load

(stall)
MPa
{kg/cm2}
Min. 0.15 {Min. 1.5}
Fuel low-pressure circuit pressure
Measured value
D. Check of strainers and filters

7
Good NG
No. 2 cylinder
C. Check of fuel circuit pressure

6
Checking condition
Good NG
Good NG
Visual check of strainers
Visual check of gauze filter
Visual check of fuel filter
10 Visual check of bypass valve

E.Check of leakage and return rate
11 Leakage through pressure limiter
12 Return rate from injector
10
Checking condition
Unit
Standard value
(Reference value)
cc/min
Max. 10

1,600 rpm
cc/min
960

1,700 rpm
cc/min
1,020

1,800 rpm
cc/min
1,080

1,900 rpm
cc/min
1,140

2,000 rpm
cc/min
1,200
Measured value
Good NG
Speed:
Return rate:
125E-5 Series
40 Troubleshooting
SEN00551-01
*1 *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
125E-5 Series
11
SEN00551-01
40 Troubleshooting
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error

Error code
Failure code
689
CA689
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Eng. Ne Speed Sensor Error
Abnormality occurred in engine Ne speed sensor circuit.

Operates with signals of Bkup speed sensor.
Running engine stops (when Bkup speed sensor is also abnormal).
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Causes
1
Defective sensor power supply If code [238/CA238] is indicated, carry out troubleshooting for it
system
first.

2

Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
Ground fault in wiring harness (16) NE (female) (1) and chassis ground
3
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz

Resistance
Min.
1 Mz
Possible causes
and standard
value in normal
state
12


(16) NE (female) (1) and
NE (female) (2)
Resistance
Min.
1 Mz

NE (female) (3)
Resistance
Min.
1 Mz

NE (female) (3)
Resistance
Min.
1 Mz
Check Ne speed sensor directly for defective mount (defective

Defective mount of sensor or
clearance) or check rotation sensing part (flywheel) directly for
defective rotation sensing part
defect.
Defective engine Ne speed

sensor
If causes 1 5 are not detected, engine Ne speed sensor may be

defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
125E-5 Series
40 Troubleshooting
Possible causes
and standard
value in normal
state
SEN00551-01
Causes

Circuit diagram related to engine Ne speed sensor
125E-5 Series
13
SEN00551-01
40 Troubleshooting
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error

Error code
Failure code
731
CA731
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Eng. Bkup Speed Sensor Phase Error
Engine Bkup sensor circuit detected abnormality in phase.

Controls with signals of engine Ne speed sensor.
Running engine stops (when Ne speed sensor is also abnormal).
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Related
information
Cause
Possible causes
and standard
value in normal
state
14
Defective engine Ne speed

sensor system
Engine Ne speed sensor may be defective. Carry out troubleshooting for [689/CA698] (E-45).
Defective engine Bkup speed

sensor system
Engine Bkup speed sensor may be defective. Carry out troubleshooting for [778/CA778] (E-48).
125E-5 Series
40 Troubleshooting
SEN00551-01
E-47 Code [757/CA757] All Persistent Data Lost Error

Error code
Failure code
757
CA757
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
All Persistent Data Lost Error
All data in engine controller are lost.

None in particular.
Related
information
Possible causes
and standard
value in normal
state
125E-5 Series
Cause

15
SEN00551-01
40 Troubleshooting
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error

Error code
Failure code
778
CA778
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Eng. Bkup Speed Sensor Error
Abnormality occurred in engine Bkup speed sensor circuit.

Operates with signals of Ne speed sensor.
Running engine stops (when Ne speed sensor is also abnormal).
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Causes
1

2

(37) G (female) (1)
Resistance
Max. 1 z

(47) G (female) (2)
Resistance
Max. 1 z

(26) G (female) (3)
Resistance
Max. 1 z
Ground fault in wiring harness (37) G (female) (1) and chassis ground
3
(47) G (female) (2) and chassis ground
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz

(26) G (female) (3) and chassis ground
Resistance
Min.
1 Mz
Possible causes
and standard
value in normal
state

Resistance
Min.
1 Mz

(37) G (female) (1) and between ENG
(female) (26) G (female) (3)
Resistance
Min.
1 Mz

Resistance
Min.
1 Mz
Check Bkup speed sensor directly for defective mount (defective

Defective mount of sensor or
clearance) or check rotation sensing part (in supply pump)
defective rotation sensing part
directly for defect.
Defective engine Bkup speed

sensor
16

If causes 1 5 are not detected, engine Bkup speed sensor may

be defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
125E-5 Series
40 Troubleshooting
SEN00551-01
Circuit diagram related to engine Bkup speed sensor

<Applied connector>
q
BP
q
EGR
q
PEVA
q
SEGR
q
SBP
125E-5 Series
17
SEN00551-01
40 Troubleshooting
E-49 Code [1228/CA1228] EGR Valve Servo Error 1

a
This code applies to only with EGR.

Error code
Failure code
1228
CA1228
Contents of
trouble
Action of
controller
Trouble
EGR Valve Servo Error 1
Abnormality (level 1) occurred in EGR valve servo.

Performs open control.
Problem that
appears on
machine
Related
information
Causes

it.
a For measurement of EGR valve drive pressure, see Testing
and adjusting, Measuring EGR valve and bypass valve drive
pressure.
Improper EGR valve drive

pressure
Engine speed
EGR valve drive pressure
Low idle
1.18 MPa {12 kg/cm2}
High idle
1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and 4.

a For check of engine oil pressure, see Testing and adjusting,
Testing engine oil pressure.
Possible causes
and standard
value in normal
state
Defective engine oil pressure

system (main circuit)
Engine speed
Engine oil pressure
Low idle
0.08 MPa {0.8 kg/cm2}
High idle
0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting for

mechanical system (S-12 Oil pressure lowers).
18
Defective oil pump for EGR

valve
Check oil pump and relief valve for EGR valve circuit directly.
Defective oil feed piping for

EGR valve
Check oil feed piping for EGR valve circuit directly.
Defective oil return piping for

EGR valve
Check oil return piping for EGR valve circuit directly.
7 Defective EGR valve
Check mechanical section of EGR valve directly.
125E-5 Series
40 Troubleshooting
SEN00551-01
E-50 Code [1625/CA1625] EGR Valve Servo Error 2

a

Error code
Failure code
1625
CA1625
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
EGR Valve Servo Error 2
Abnormality (level 2) occurred in EGR valve servo.

Limits output and continues operation.
Closes EGR valve and bypass valve.
Output drops.
Related
information
Possible causes
and standard
value in normal
state
125E-5 Series
Causes

19
SEN00551-01
40 Troubleshooting
E-51 Code [1626/CA1626] Bypass Valve Solenoid Current High Error

a

Error code
Failure code
1626
CA1626
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Bypass Valve Solenoid Current High Error
There is short circuit in drive circuit of bypass valve solenoid.

Output drops.
Cause
Defective bypass valve solenoid (Internal trouble)

BP (male)
Resistance
Between (1) (2)
10 21 z
2
or defective contact in connec- (31) BP (female) (1)
tor)
BP (female) (2)
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
3
Ground fault in wiring harness Wiring harness between ENG (female)

(Short circuit with GND circuit) (31) BP (female) (1) and chassis ground
Resistance
Min.
1 Mz

BP (female) (2) and chassis ground
Resistance
Min.
1 Mz

4


(31) BP (female) (1) and chassis ground
Voltage
Max. 1 V

BP (female) (2) and chassis ground
Voltage
Max. 1 V
20
ENG (female)
Resistance
Between (31) (11)
10 21 z
125E-5 Series
40 Troubleshooting
SEN00551-01
Circuit diagram related to bypass valve solenoid & lift sensor
125E-5 Series
21
SEN00551-01
40 Troubleshooting
E-52 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error

a
[with EGR only]

Error code
Failure code
1627
CA1627
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Bypass Valve Solenoid Current Low Error
There is disconnection in drive circuit of bypass valve solenoid.

Output drops.
Related
information
Possible causes
and standard
value in normal
state
22
Cause

125E-5 Series
40 Troubleshooting
SEN00551-01
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1

a

Error code
Failure code
1628
CA1628
Contents of
trouble
Action of
controller
Trouble
Bypass Valve Servo Error 1
Abnormality (level 1) occurred in bypass valve servo.

Performs open control.
Problem that
appears on
machine
Related
information
Causes

it.
a For measurement of bypass valve drive pressure, see Testing
and adjusting, Measuring EGR valve and bypass valve drive
pressure.
Improper bypass valve drive

pressure
Engine speed
Bypass valve drive pressure
Low idle
1.18 MPa {12 kg/cm2}
High idle
1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check causes 3 and 4.

a For check of engine oil pressure, see Testing and adjusting,
"Testing engine oil pressure".
Possible causes
and standard
value in normal
state
Defective engine oil pressure

system (main circuit)
Engine speed
Engine oil pressure
Low idle
0.08 MPa {0.8 kg/cm2}
High idle
0.21 MPa {2.1 kg/cm2}
If engine oil pressure is abnormal, carry out troubleshooting for

mechanical system (S-12 Oil pressure lowers).
125E-5 Series
Defective oil pump for bypass

valve
Check oil pump and relief valve for bypass valve circuit directly.
Defective oil feed piping for

bypass valve
Check oil feed piping for bypass valve circuit directly.
Defective oil return piping for

bypass valve
Check oil return piping for bypass valve circuit directly.
7 Defective bypass valve
Check mechanical section of bypass valve directly.
23
SEN00551-01
40 Troubleshooting
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2

a

Error code
Failure code
1629
CA1629
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Bypass Valve Servo Error 2
Abnormality (level 2) occurred in bypass valve servo.

Output drops.
Related
information
Possible causes
and standard
value in normal
state
24
Causes

125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00551-01
25
SEN00551-01
40 Troubleshooting
E-55 Code [1631/CA1631] BP valve Lift Position Sensor High Error

a

Error code
Failure code
1631
CA1631
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
BP valve Lift Position Sensor High Error
Signal voltage in bypass valve lift sensor circuit is abnormally high.

Output drops.
Causes
If code [187/CA187] or [227/CA227] is indicated, carry out trou1 Defective sensor power supply
SBP
Between (1) (2)
Voltage
Power supply
4.75 5.25V

Defective bypass valve lift sen- Accordingly, if voltage is abnormal, check wiring harness and
2
sor (Internal trouble)
(keep engine stopped, however) and carry out troubleshooting.
SBP
Possible causes
and standard
value in normal
state
Voltage
Between (3) (2)
Signal
0.8 1.2V
Between (4) (2)
Signal
0.8 1.2V
Disconnection in wiring harWiring harness between ENG (female)
ness
(37) SBP (female) (1)
3 (Disconnection in wiring or
(38) SBP (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

(29) SBP (female) (3), (4)
Resistance
Max. 1 z
(37) SBP (female) (1) and chassis
ground

(38) SBP (female) (2) and chassis
ground
(29) SBP (female) (3), (4) and chassis
ground
26
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz
125E-5 Series
40 Troubleshooting
SEN00551-01
Causes

Possible causes
and standard
value in normal
state


(37) SBP (female) (1) and
SBP (female) (2)
Resistance
Min.
1 Mz

SBP (female) (3), (4)
Resistance
Min.
1 Mz

SBP (female) (3), (4)
Resistance
Min.
1 Mz

ENG
Voltage
Between (37) (38)
4.75 5.25V
Circuit diagram related to bypass valve solenoid & lift sensor
125E-5 Series
27
SEN00551-01
40 Troubleshooting
E-56 Code [1632/CA1632] BP valve Lift Position Sensor Low Error

a

Error code
Failure code
1632
CA1632
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
BP valve Lift Position Sensor Low Error
Signal voltage in bypass valve lift sensor circuit is abnormally low.

Output drops.
Related
information
Possible causes
and standard
value in normal
state
Cause

E-57 Code [1633/CA1633] KOMNET Datalink Timeout Error

Error code
Failure code
1633
CA1633
Trouble
KOMNET Datalink Timeout Error
Contents of
trouble
Abnormality occurred in circuit of KOMNET communication with machine.
Action of
controller
Operates in default mode or maintains condition when abnormality occurs.
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
28
Cause
Carry out troubleshooting on

1
machine side
This fault is detected and indicated when KOMNET communication with machine monitor or controller on the machine side is
abnormal. Accordingly, contents of troubleshooting depends on
machine model. See Shop manual for machine.
125E-5 Series
40 Troubleshooting
SEN00551-01
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error

a

Error code
Failure code
1642
CA1642
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
EGR Inlet Press Sensor Low Error
Signal voltage in EGR inlet pressure sensor circuit is abnormally low.

Sets EGR inlet pressure to default value (102 kPa {10.4 kg/cm2}) and continues operation.
Output drops.
Related
information
Possible causes
and standard
value in normal
state
125E-5 Series
Cause

29
SEN00551-01
40 Troubleshooting
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error

a

Error code
Failure code
1653
CA1653
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
EGR Inlet Press Sensor High Error
Signal voltage in EGR inlet pressure sensor circuit is abnormally high.

Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
Output drops.
Cause
Defective EGR inlet pressure
2
PEVA
Between (1) (2)
Voltage
Power supply
4.75 5.25 V

Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring

3
or defective contact in connector)

(37) PEVA (female) (1)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
(37) PEVA (female) (1) and chassis
ground
30
Resistance
Min.
1 Mz

ground
Resistance
Min.
1 Mz

ground
Resistance
Min.
1 Mz
125E-5 Series
40 Troubleshooting
SEN00551-01
Cause

Possible causes
and standard
value in normal
state


(37) PEVA (female) (1) and between
ENG (female) (47) PEVA (female) (2)
Resistance
Min.
1 Mz

Resistance
Min.
1 Mz

Resistance
Min.
1 Mz

ENG
Voltage
Between (37) (47)
4.75 5.25 V
Circuit diagram related to EGR inlet pressure sensor
125E-5 Series
31
SEN00551-01
40 Troubleshooting
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error

Error code
Failure code
2185
CA2185
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.

Causes


1
(Internal trouble)
Disconnect devices
device has a defect
in it.
Accelerator pedal
AS1 connector
Possible causes
and standard
value in normal
state

2
AS1 (female) (1)
defective contact in connector) Wiring harness between E02 (female) (23)
AS1 (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z
3
Ground fault in wiring harness Wiring harness between E02 (female) (22)
(Short circuit with GND circuit) AS1 (female) (1) and chassis ground
Resistance
Min.
1 Mz

Resistance
Min.
1 Mz
4


AS1 (female) (1) and
wiring harness between E02 (female) (23)
AS1 (female) (3)
Resistance
Min.
1 Mz

32
E02
Voltage
Between (22) (23)
4.75 5.25V
125E-5 Series
40 Troubleshooting
SEN00551-01
125E-5 Series
33
SEN00551-01
40 Troubleshooting
Throttle sensor of fuel control dial type (Case of PC400/400LC/450/450LC-7E0)

Error code
Failure code
2185
CA2185
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.

Sets throttle angle with signal other than throttle sensor signal and continues operation (depending
on each model).
Depends on machine model.
Cause

Defective fuel control dial

1
(Internal trouble)
Disconnect devices
device has a defect
in it.
Fuel control dial
P20 connector
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between E02 (female) (22)
2
or defective contact in connec- P20 (female) (1)
tor)
P20 (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z
3
(Short circuit with GND circuit) P20 (female) (1) and chassis ground
Resistance
Min.
1 Mz

Resistance
Min.
1 Mz

P20 (female) (1) and between E02
(female) (23) P20 (female) (3)
Resistance
Min.
1 Mz

34
E02
Voltage
Between (22) (23)
4.75 5.25 V
125E-5 Series
40 Troubleshooting
SEN00551-01
Circuit diagram related to throttle sensor of fuel control dial type

(Case of PC400/400LC/450/450LC-7E0)
125E-5 Series
35
SEN00551-01
40 Troubleshooting
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error

Error code
Failure code
2186
CA2186
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Throttle Sens. Sup. Volt. Low Error
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low.

Sets throttle angle with signal other than throttle sensor signal and continues operation (depending
on each model).
Depends on machine model.
Related
information
Possible causes
and standard
value in normal
state
36
Cause

125E-5 Series
40 Troubleshooting
SEN00551-01
E-62 Code [2249/CA2249] Rail Press. Very Low Error

Error code
Failure code
2249
CA2249
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Rail Press. Very Low Error
Supply pump does not feed fuel (level 2).

Limits common rail pressure.
Output drops.
Related
information
Possible causes
and standard
value in normal
state
125E-5 Series
Cause

37
SEN00551-01
40 Troubleshooting
E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error 1
a

Error code
Failure code
2271
CA2271
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
EGR Valve Lift Position Sensor High Error
Signal voltage in EGR valve lift sensor circuit is abnormally high.

Output drops.
Cause
SEGR
Between (1) (2)
Voltage
Power supply
4.75 5.25 V

Defective EGR valve lift sensor Accordingly, if voltage is abnormal, check wiring harness and
2
(Internal trouble)
(keep engine stopped, however) and carry out troubleshooting.
SEGR
Possible causes
and standard
value in normal
state
Voltage
Between (3) (2)
Signal
0.8 1.2 V
Between (4) (2)
Signal
0.8 1.2 V
(37) SEGR (female) (1) and chassis
ground
Disconnection in wiring harness (Disconnection in wiring

3
or defective contact in connec- Wiring harness between ENG (female)
(47) SEGR (female) (2) and chassis
tor)
ground
(19) SEGR (female) (3), (4) and chassis
ground
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
38

Ground fault in wiring harness (37) SEGR (female) (1)
4
(47) SEGR (female) (2)
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz

(19) SEGR (female) (3), (4)
Resistance
Min.
1 Mz
125E-5 Series
40 Troubleshooting
SEN00551-01
Cause

Possible causes
and standard
value in normal
state


(37) SEGR (female) (1) and between
ENG (female) (47) SEGR (female) (2)
Resistance
Min.
1 Mz

ENG (female) (19) SEGR (female) (3),
(4)
Resistance
Min.
1 Mz

ENG (female) (19) SEGR (female) (3),
(4)
Resistance
Min.
1 Mz

ENG
Voltage
Between (37) (47)
4.75 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
Apply wiring harness joint JM04 to only a bypass valve-fitted engine.
125E-5 Series
39
SEN00551-01
40 Troubleshooting
E-64 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error
a

Error code
Failure code
2272
CA2272
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
EGR Valve Lift Position Sensor Low Error
Signal voltage in EGR valve lift sensor circuit is abnormally low.

Output drops.
Related
information
Possible causes
and standard
value in normal
state
40
Cause

125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00551-01
41
SEN00551-01
40 Troubleshooting
E-65 Code [2351/CA2351] EGR Valve Solenoid Current High Error

a

Error code
Failure code
2351
CA2351
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
EGR Valve Solenoid Current High Error
There is short circuit in drive circuit of EGR valve solenoid.

Output drops.
Cause
Defective EGR valve solenoid
1
(Internal trouble)
EGR (male)
Resistance
Between (1) (2)
10 21 z
2
or defective contact in connec- (22) EGR (female) (1)
tor)
EGR (female) (2)
Possible causes
and standard
value in normal
state
Resistance
Max. 1 z
Resistance
Max. 1 z
3

(22) EGR (female) (1) and chassis
ground
EGR (female) (2) and chassis ground
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz

4


(22) EGR (female) (1) and chassis
ground
Voltage
Max. 1 V

EGR (female) (2) and chassis ground
Voltage
Max. 1 V
42
ENG (female)
Resistance
Between (22) (11)
10 21 z
125E-5 Series
40 Troubleshooting
SEN00551-01
Circuit diagram related to EGR valve solenoid & lift sensor
Apply wiring harness joint JM04 to only a bypass valve-fitted engine.
125E-5 Series
43
SEN00551-01
40 Troubleshooting
E-66 Code [2352/CA2352] EGR Valve Solenoid Current Low Error

a

Error code
Failure code
2352
CA2352
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
EGR Valve Solenoid Current Low Error
There is disconnection in drive current of EGR valve solenoid.

Output drops.
Related
information
Possible causes
and standard
value in normal
state
44
Cause

125E-5 Series
40 Troubleshooting
SEN00551-01
E-67 Code [2555/CA2555] Grid Heater Relay Volt. Low Error

Error code
Failure code
2555
CA2555
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Grid Heater Relay Volt. Low Error
There is disconnection in intake air heater relay.

None in particular.
Engine does not start easily at low temperature.
Related
information
Possible causes
and standard
value in normal
state
125E-5 Series
Cause

45
SEN00551-01
40 Troubleshooting
E-68 Code [2556/CA2556] Grid Heater Relay Volt. High Error

Error code
Failure code
2556
CA2556
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Grid Heater Relay Volt. High Error
There is short circuit in intake air heater relay.

None in particular.
Engine does not start easily at low temperature.

Condition for driving heater relay depends on machine.
Cause
Defective intake air heater

relay (Internal trouble)

R18 (male)
Resistance
Between (1) (2)
200 400 z
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between E02 (female) (40)
2
or defective contact in connec- R18 (female) (1)
tor)
R18 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z
3
(Short circuit with GND circuit) R18 (female) (1) and chassis ground
Resistance
Min.
1 Mz

R18 (female) (2) and chassis ground
Resistance
Min.
1 Mz

E02
Between (40) (42)
46
Heater relay
Voltage
Under operating
condition
Max. 1 V
Under stopping condition
20 30 V
125E-5 Series
40 Troubleshooting
SEN00551-01
Circuit diagram related to intake air heater (Case of PC400/400LC/450/450LC-7E0)
125E-5 Series
47
SEN00551-01
40 Troubleshooting
E-69 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate

Error code
Failure code
(143)
B@BAZG
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Eng. Oil press. Torque Derate
Engine oil pressure is below operating range.

Limits output and continues operation (Limits fuel injection rate and engine speed).
Output drops.
Related
information
Possible causes
and standard
value in normal
state
Causes
1

machine side
This fault is indicated on only machine side when detected.

Accordingly, contents of troubleshooting depends on machine
model. See Shop manual for machine.
E-70 Code [(146)/B@BCNS] Eng. Overheat

Error code
Failure code
(146)
B@BCNS
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Eng. Overheat
Engine coolant temperature is above operating range.

Output drops.
Related
information
Possible causes
and standard
value in normal
state
48
Causes
1

machine side

125E-5 Series
40 Troubleshooting
SEN00551-01
E-71 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate

Error code
Failure code
(415)
B@BAZG
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Trouble
Eng. Oil press. Low Speed Derate
Engine oil pressure is below operating range.

Limits output and continues operation (Limits fuel injection rate and engine speed).
Output drops.
Related
information
Possible causes
and standard
value in normal
state
125E-5 Series
Causes
1

machine side

49
SEN00551-01

2007 KOMATSU
All Rights Reserved
50
SEN00549-02
ENGINE
1SHOP MANUAL
125E-5 Series
40 Troubleshooting
Troubleshooting of mechanical system

(S-mode)
Troubleshooting of mechanical system (S-mode)........................................................................................... 4
Method of using troubleshooting charts ............................................................................................... 4
S-1 Starting performance is poor ......................................................................................................... 8
S-2 Engine does not start................................................................................................................... 10
S-3 Engine does not pick up smoothly............................................................................................... 14
S-4 Engine stops during operations ................................................................................................... 15
S-5 Engine does not rotate smoothly ................................................................................................. 16
S-6 Engine lacks output (or lacks power)........................................................................................... 17
S-7 Exhaust smoke is black (incomplete combustion) ....................................................................... 18
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 20
S-9 Oil becomes contaminated quickly .............................................................................................. 21
S-10 Fuel consumption is excessive.................................................................................................. 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 23
S-12 Oil pressure drops ..................................................................................................................... 24
125E-5 Series
SEN00549-02
40 Troubleshooting
S-13 Oil level rises (Entry of coolant or fuel) ...................................................................................... 25

S-14 Coolant temperature becomes too high (overheating) .............................................................. 27
S-15 Abnormal noise is made ............................................................................................................ 28
S-16 Vibration is excessive ................................................................................................................ 29
125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00549-02
SEN00549-02
40 Troubleshooting
Troubleshooting of mechanical system (S-mode)
Method of using troubleshooting charts
The troubleshooting chart consists of the questions, check items, causes, and troubleshooting blocks.
The questions and check items are used to pinpoint high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the
most probable one to make final confirmation according to the troubleshooting procedure.
Questions:
Items to be drawn from the user or operator. They correspond to A and B in the chart on the right.
The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their
level.
Check items:
Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the
right.
Causes:
Items to be narrowed from the questions and check items.
The serviceman narrows down the probable causes from A, B, and C.
Troubleshooting:
Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable
one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the causes, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
125E-5 Series
40 Troubleshooting
125E-5 Series
SEN00549-02
SEN00549-02
40 Troubleshooting
<Example of troubleshooting> Exhaust smoke is black

Let us assume that when Color of exhaust gas is black occurs, the relevant items of [questions] and [check
items] are the following 3 symptoms: [Color of exhaust gas gradually became black], [Power was lost gradually], and [Air cleaner clogging caution lamp is flashing].
125E-5 Series
40 Troubleshooting
SEN00549-02
6 items of [causes] have causal relationship with these 3 items of [questions] and [check items].
Let us explain the method of using this causal relationship in Step 1 to Step 3 in the figure below to narrow
the [causes] to lead to [troubleshooting].
125E-5 Series
SEN00549-02
40 Troubleshooting
S-1 Starting performance is poor
General causes why starting performance is poor

q
Defective electrical system
q
Insufficient supply of fuel
q
Insufficient intake of air
q
Improper selection of fuel
q
Coolant in exhaust pipe ("with EGR" only)
a The common rail fuel injection system (CRI) controls
the fuel injection timing electrically. Accordingly, even
if the starting operation is carried out, the engine may
not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble,
however.
Clogged air cleaner element

Cracked EGR cooler
(Coolant in exhaust pipe) ["with EGR" only]
Defective contact of valve and valve seat
Worn piston ring, cylinder
Clogged air breather hole of fuel tank cap
Leaking or clogged fuel piping, entry of air
Clogged fuel filter, element
Clogged feed pump gauze filter
Stuck, seized supply pump plunger
Defective injector
Defective intake air heater system
Defective alternator (regulator section)
Defective alternator (generator section)
Defective or deteriorated battery
Causes
Confirm recent repair history
Questions
Degree of use
of machine
E E
Operated for long period
Starting perfor- Became worse gradually

mance
Engine starts easily when warm
E E
w w
Q Q
w
Non-specified fuel is being used
Q Q Q Q
Replacement of filters has not been carried out according to Operation and Mainw
tenance Manual
w w Q Q
w
Oil must be added more frequently

When engine is preheated or when temperature is low, preheating monitor does
not indicate normally (if monitor is installed)
w
w w
During operation, charge level monitor indicates abnormal charge (if monitor is installed)
Dust indicator is red (if indicator is installed)
Air breather hole of fuel tank cap is clogged

Fuel is leaking from fuel piping
When priming pump is operated, it makes no reaction or it is heavy
w Q Q
w
Q Q
Engine does not pick up smoothly and combustion is irregular
w
Q w Q Q
There is hunting from engine (rotation is irregular)

w
q
When EGR cooler outlet gas piping is removed, coolant containing antifreeze
flows out (*1) ["with EGR" only]
q
q q
When compression pressure is measured, it is found to be low
When air is bled from fuel system, air comes out
Inspect fuel filter, element directly
Inspect feed pump gauze filter directly

Carry out troubleshooting according to No-pressure feed by supply pump (*2) in
E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change
q
q
When starting switch is turned to HEAT, intake air heater mount does not become warm
Is voltage 20 30 V between alternator terminal B and terminal E with Yes

engine at low idle?
No
q
q
Replace
Remedy
Clean
When specific gravity of electrolyte and voltage of battery are measured, they are low
Correct
Replace
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Replace
Replace
Replace
Check items
If spill hose from injector is disconnected, little fuel spills
When exhaust manifold is touched immediately after starting engine, temperature

of some cylinders is low
Inspect air cleaner directly
Troubleshooting
w
w w
If air bleeding plug of fuel filter is removed, fuel does not flow out
Blow-by gas is excessive
Starting motor cranks engine slowly

While engine is
cranked with
starting motor,
125E-5 Series
40 Troubleshooting
SEN00549-02
*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler
outlet gas piping and check that the coolant
flows out. A little condensate produced from
cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.
*2: Code [559/CA559] and code [2249/CA2249] in

E-mode
125E-5 Series
SEN00549-02
40 Troubleshooting
S-2 Engine does not start
Degree of use of machine
Condition of horn when

starting switch is turned ON Horn volume is low
Battery electrolyte is low
w
Q
When starting switch is turned to START, starting pinion does not move out
Q
Q
Speed of rotation is low

When starting switch is
turned to START, starting
pinion moves out, but
Defective steering circuit wiring
When starting switch is turned ON, there is no operating sound from battery relay
w
w
Makes grating noise
w
w
Soon disengages again

w
Makes rattling noise and does not turn

When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1)
["with EGR" only].
Q w
q
q
Inspect flywheel ring gear directly
There is not voltage (20 30 V) between battery relay terminal
B and terminal E
When terminal B and terminal C of starting switch are conTurn starting switch OFF,
nected, engine starts
connect cord, and carry out
When terminal B and terminal C at safety relay outlet are controubleshooting at ON
nected, engine starts
q
q
Even if terminal B and terminal C at safety relay outlet are connected, engine does not start
Replace
Replace
Replace
Correct
Replace
Replace
q
Replace
Remedy
10
Defective starting motor (motor section)
Defective starting motor (safety relay section)
Defective starting switch
E E
Horn does not sound
Carry out troubleshooting

on applicable machine side
Check items
Defective battery relay
Battery terminal is loose
Troubleshooting
Defective connection of battery terminal
Defective or deteriorated battery
Broken flywheel ring gear
Cracked EGR cooler

(Coolant in exhaust pipe) ["with EGR" only]
Causes
Replace
Questions
a) Engine does not turn

General causes why engine does not turn
q
Internal parts of engine seized
o See S-4 Engine stops during operations
q
Water hammer caused by coolant which entered cylinder
q
Defective electrical system
q
Problem in drive devices on applicable machine side
o Requires troubleshooting on applicable machine side.
125E-5 Series
40 Troubleshooting
SEN00549-02

125E-5 Series
11
SEN00549-02
40 Troubleshooting
b) Engine turns but no exhaust smoke comes out

General causes why engine turns but no exhaust smoke
comes out
q
Fuel is not being supplied
q
Supply of fuel is extremely small
q
Improper selection of fuel (particularly in winter)
Defective fuel injector
Defective operation of flow damper
Defective operation of overflow valve (Does not close)
Wrong connection of supply pump PCV
Defective supply pump PCV
Broken supply pump shaft, key
Seized, abnormally worn feed pump
Clogged fuel filter element
Insufficient fuel in tank
Use of improper fuel
Causes
E E E
w Q w w w
Exhaust smoke suddenly stopped coming out (when starting again)

Replacement of filters has not been carried out according to Operation and
Maintenance Manual
Q Q Q
Q Q

Rust and water are found when fuel tank is drained
w
When fuel filter is removed, there is not fuel in it

Check items
When fuel tank is inspected, it is found to be empty
w Q Q
If air bleeding plug of fuel filter is removed, fuel does not

While engine is
cranked with starting flow out
motor,
w Q
w w w w
q q
Inspect fuel filter directly

Troubleshooting
w w
E E
Inspect feed pump directly

Carry out troubleshooting according to No-pressure feed by supply pump (*1)
in E-mode
Carry out troubleshooting according to Abnormality in PCV1 (*2) or Abnormality
in PCV2 (*3) in E-mode
q
q
q
Inspect overflow valve directly
q q
Correct
Replace
Replace
Replace
Replace
Replace
Clean
Replace
Correct
Correct
Add
Remedy
Replace
Engine can be started in reduced cylinder mode
Replace
Degree of use of
machine
Replace
Questions
*1: Code [559/CA559] and code [2249/CA2249] in E-mode

12
125E-5 Series
40 Troubleshooting
SEN00549-02
c) Exhaust smoke comes out but engine does not start

(fuel is being injected)
General causes why exhaust smoke comes out but engine
does not start
q
Lack of rotating force due to defective electrical system
q
q
q
Defective intake air heater system
Defective coolant temperature sensor, wiring harness
Defective, deteriorated battery
Clogged injector, defective spray
Clogged fuel filter, strainer
Leaking or clogged fuel system, entry of air
Worn piston ring, cylinder liner
Worn dynamic valve system (Valve, rocker lever, etc.)
Causes

E
E E
Suddenly failed to start
E
w
Q Q

Replacement of filters has not been carried out according to Operation and Maintew
nance Manual
w w
w

When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed)
w
w
w w

w
When fuel filter is removed, there is not fuel in it

w Q Q
w
Check items
Starting motor cranks engine slowly

w
When engine is cranked, abnormal sound is generated around cylinder head

If air bleeding plug of fuel filter is removed, fuel does not flow
While engine is
cranked with starting out
motor,
When exhaust manifold is touched immediately after starting engine, temperature of

some cylinders is low
w
q
Inspect dynamic valve system directly

Troubleshooting
w w
Inspect fuel filter, strainer directly

Carry out troubleshooting according to No-pressure feed by supply pump (*1) in Emode
q
q
When injector unit is tested, spray condition is bad
Coolant temperature gauge does not indicate normally (if coolant temperature
gauge is installed)
q
q
Replace
Replace
Replace
Replace
Clean
Clean
Correct
Clean
Replace
Replace
Clean
Remedy
Replace
When starting switch is turned to HEAT, intake air heater mount does not become warm
Replace
Questions
Degree of use of
machine

125E-5 Series
13
SEN00549-02
40 Troubleshooting
S-3 Engine does not pick up smoothly
General causes why engine does not pick up smoothly

q
q
Defective condition of fuel spray
q
q
Controller is controlling in derate mode
(limiting injection rate (output) because of an error in
electrical system)
q
EGR valve is stuck open ["with EGR" only]
(There is much EGR gas and intake of air is insufficient)
Clogged injector, defective spray
Defective EGR valve or bypass valve

["with EGR" only]
E
Defective operation of flow damper

(Large leakage from injector)

E

Improper valve clearance
Seized turbocharger, interference of turbocharger
Causes
Engine pick-up suddenly became worse
E E
Q Q
Q
w w w

Maintenance Manual
w w
w

w
w w

w Q Q
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Color of exhaust gas
Blue under light load

w
Black
When engine is cranked, interference sound is generated around turbocharger

High idle speed under no load is normal, but speed suddenly drops when load is
applied
w w
Q w
w w

q

Carry out troubleshooting according to Abnormality in EGR valve servo (*1) in
E-mode or Abnormality in bypass valve servo (*1) in E-mode ["with EGR" only]
Troubleshooting
q
q
q
q
Inspect valve clearance directly
When turbocharger is rotated by hand, it is found to be heavy

in E-mode
Replace
Adjust
Replace
Replace
Clean
Correct
Clean
Clean
Replace
Replace
Remedy
Clean
does not change
q
Replace
Replace
Questions
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in
E-mode
14
125E-5 Series
40 Troubleshooting
SEN00549-02
S-4 Engine stops during operations
General causes why engine stops during operations

q
Seized parts inside engine
q
q
There is overheating
q
Problem in drive devices on applicable machine
side
o Requires troubleshooting on applicable
machine side.
Problem in drive devices on applicable machine side
Broken dynamic valve system (valve, rocker arm, etc.)

Broken, seized piston, connecting rod
Broken, seized crankshaft bearing
Broken, seized gear train
Leaking, clogged fuel piping
Broken, seized feed pump
Broken supply pump shaft, key
Broken auxiliary equipment (pump, compressor, etc.)
Defective engine controller power supply wiring
Defective starting switch wiring
Causes

E E
Degree of use of machine Operated for long period
Questions
Abnormal noise was heard and engine

stopped suddenly
Condition when engine
stopped
w w w w
w Q
Engine overheated and stopped
Q
w
Q Q
Q Q
There was hunting and engine stopped
w Q
Q Q Q
Q Q
Q Q Q
Replacement of filters has not been carried out according to Operation

and Maintenance Manual
w w
Fuel level monitor indicates low level (if monitor is installed)
w Q Q
w w

w w w
Metal particles are found when oil is drained
w w
Does not turn at all

When engine is cranked
by hand
Engine stopped slowly
Check items
Q w Q w
Turns in opposite direction
Moves by amount of gear backlash
w
w
Supply pump shaft does not turn
Engine turns, but stops when load is applied to machine

q
Inspect piston, connecting rod directly
Inspect gear train directly
Inspect feed pump directly

Carry out troubleshooting according to No-pressure feed by supply
pump (*1) in E-mode
Engine rotates when pump auxiliary equipment (pump, compressor, etc.)
is removed
q q
q
q
Inspect controller power supply wiring
Inspect starting switch wiring

Remedy
Replace
Replace
Replace
Replace
Add
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Replace
Correct
Correct
Troubleshooting

Inspect crankshaft bearing directly

125E-5 Series
15
SEN00549-02
40 Troubleshooting
S-5 Engine does not rotate smoothly
General causes why engine does not rotate smoothly

q
Air in fuel system
q
Defective speed sensor
(Error at degree that it is not indicated)
q
Defective EGR valve ["with EGR" only]
q
Defective bypass valve ["with EGR" only]
Defective Bkup speed sensor, wiring harness
Defective Ne speed sensor, wiring harness
Clogged injector, defective spray (dirt in injector)
Defective operation of flow damper (Large leakage from injector)
Defective operation of bypass valve ["with EGR" only]
Defective operation of EGR valve ["with EGR" only]
Low setting of low idle speed
Causes
Condition of hunting
E E

Occurs at a certain speed range
Q Q Q
Occurs at low idle
E E
Q Q
Q Q Q Q Q Q Q
Q Q
Occurs even when speed is raised
Q Q
Occurs on slopes
Q Q
Replacement of filters has not been carried out according to Operation and Maintenance Manual
w w
w
Check items
Q Q

w Q Q
Troubleshooting
Carry out troubleshooting according to Abnormality in EGR valve servo (*1) in E-mode
["with EGR" only]
Carry out troubleshooting according to Abnormality in bypass valve servo (*2) in Emode ["with EGR" only]
q
q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
q q
Carry out troubleshooting according to Abnormality in engine Ne speed sensor (*3) in

E-mode
Carry out troubleshooting according to Abnormality in engine Bkup speed sensor (*4)
in E-mode
*1: Code
*2: Code
*3: Code
*4: Code
16
Correct
Replace
Replace
Replace
Replace
Correct
Clean
Add
Replace
Replace
Correct
Remedy
q
Correct
Questions
[1228/CA1228] and code [1625/CA1625] in E-mode

[1628/CA1628] and code [1629/CA1629] in E-mode
[689/CA689] in E-mode
[778/CA778] in E-mode
125E-5 Series
40 Troubleshooting
SEN00549-02
S-6 Engine lacks output (or lacks power)

General causes why engine lacks output
q
q
q
Defective spray condition of fuel
q
q
o See S-14 Coolant temperature becomes
too high (Overheating)
q
Controller is controlling in derate mode
(limiting injection rate (output) because of an
error in electrical system)
1
Defective charge pressure sensor, wiring harness
Defective fuel temperature sensor, wiring harness
Defective installation of charge pressure sensor

(air leakage)
Defective drive of injector (signal, solenoid)
Clogged injector, defective spray (dirt in injector)
Leaking, clogged fuel piping
Air leakage from air intake piping
Causes
Power was lost
E E
Q Q
Suddenly
Gradually
Q Q

Maintenance Manual
w
Q Q Q

w
Output becomes insufficient after short stop of operation

Color of exhaust gas color
w w w
Black
Check items
w
w
High idle speed is too low

High idle speed under no load is normal, but speed suddenly drops when load is
applied
w w Q
w
Q Q
w
Inspect air intake piping directly
q q q
When boost pressure is measured, it is found to be low
q
q

Troubleshooting
Q Q Q Q

in E-mode
does not change
q q
q
Inspect charge pressure sensor mount directly

Carry out troubleshooting according to Abnormality in charge pressure sensor
(*2) in E-mode
Carry out troubleshooting according to Abnormality in fuel temperature sensor

(*3) in E-mode
Replace
Correct
Replace
Replace
Replace
Clean
Correct
Replace
Clean
Replace
Adjust
Replace
Replace
Clean
Correct
Remedy
q
Replace
Questions

125E-5 Series
17
SEN00549-02
40 Troubleshooting
S-7 Exhaust smoke is black (incomplete combustion)
Improper fuel injection pressure
Improper injection timing
Clogged fuel spill piping (on cylinder head side)
Abnormally worn injector
Clogged, seized injector
Crushed, clogged muffler
Leakage of air between turbocharger and cylinder head
EGR gas piping is clogged ["with EGR" only]
Defective EGR valve or bypass valve ["with EGR" only]
Causes
General causes why exhaust smoke is black

q
q
Excessive injection of fuel
q
Defective condition of fuel injection
q
q
o See S-14 Coolant temperature becomes too high
(Overheating)
q
Controller is controlling in derate mode (limiting
injection rate (output) because of an error in electrical system)
q
EGR valve is stuck open ["with EGR" only] (There is
much EGR gas and intake of air is insufficient)
q
EGR gas piping is clogged ["with EGR" only] (Entry
of exhaust gas into air intake at acceleration or
deceleration)

Suddenly became black

Gradually became black
color
w Q Q
Q Q
Q Q
w
Q Q

w

Power was lost
Suddenly
Gradually
Q Q
Q
Muffler is crushed
w
Air leaks between turbocharger and cylinder head, clamp is loosened
Q Q Q
Engine is operated in low-temperature mode at normal temperature
Check items
When exhaust manifold is touched immediately after starting engine, temperature of

some cylinders is low
Q w
w

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively)
Q Q
Exhaust noise is abnormal
Q Q
Q Q Q
Q w
w
w
If spill hose from injector is disconnected, abnormally much fuel spills

q
When turbocharger is rotated by hand, it is fount to be heavy
Troubleshooting
Carry out troubleshooting according to Abnormality in EGR valve servo (*1) in Emode or Abnormality in bypass valve servo (*1) in E-mode ["with EGR" only]
q
q
Inspect EGR gas piping directly (*2) ["with EGR" only]
q
q
When muffler is removed, exhaust color improves

Carry out troubleshooting according to No-pressure feed by supply pump (*3) in Emode
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change
q
q
q
Inspect fuel spill piping (on cylinder head side) directly

Carry out troubleshooting according to Abnormality in coolant temperature sensor
(*4) in E-mode
18
Adjust
Adjust
Correct
Replace
Replace
Replace
Replace
Replace
Adjust
Correct
Replace
Replace
Replace
Clean
Replace
Remedy
q
Replace
Questions
Degree of use of
machine
125E-5 Series
40 Troubleshooting
SEN00549-02
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in Emode
*2: EGR gas piping
Remove EGR gas piping (1) and confirm for internal clogging

125E-5 Series
19
SEN00549-02
40 Troubleshooting
S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive
q
Abnormal consumption of oil
q
Long-time operation of engine at low idle or high
idle (Do not run engine at idle for more than 20
minutes continuously)
q
External leakage of oil
q
Wear of parts in lubrication system
Oil leakage from oil pan, cylinder head, etc.
Oil leakage from oil drain plug
Oil leakage from oil piping
Oil leakage from oil filter
Oil leakage from oil cooler
Broken oil cooler
Worn, damaged rear oil seal
Broken piston ring
Clogged breather, breather hose
Oil leakage from EGR valve stem ["with EGR" only]
Turbocharger
Worn seal at blower side
Worn seal at turbine side
Worn, damaged valve (stem, guide, seal)
Dust sucked in from intake system
Causes
E E E E
E
w
Oil consumption suddenly increased

Q
Q
w
Q Q w
Oil becomes contaminated quickly
w w w w w
Outside of engine is dirty with oil

w
There are loose piping clamps in intake system
w
Q w
Inside of turbocharger exhaust outlet pipe is dirty with oil
There is oil in coolant

w
Oil level in clutch chamber or damper chamber is high

Q
Exhaust smoke is blue under light load
None
q
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty abnormally

Troubleshooting
w w
q q
Excessive play of turbocharger shaft

When EGR valve is removed, exhaust port is found to be dirty with oil ["with
EGR" only]
q
q
Inspect breather and breather hose directly
q q
Inspect rear oil seal directly
q q
Pressure-tightness test of oil cooler shows there is leakage
q q q q
20
Replace
Replace
Replace
Replace
Replace
Clean
Replace
Replace
Replace
Correct
Remedy
Replace
There is external leakage of oil from engine
Correct
Amount of blow-by gas
w w
Q Q Q
Excessive
Correct
Check items
Inside of turbocharger intake outlet pipe is dirty with oil
Correct
Degree of use of
machine
Correct
Questions
125E-5 Series
40 Troubleshooting
SEN00549-02
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly

q
Entry of exhaust gas into oil due to internal wear
q
Clogging of lubrication passage
q
q
Use of improper oil
q
Operation under excessive load
Exhaust smoke is bad
Clogged turbocharger lubrication drain tube
Defective oil filter safety valve
Clogged oil filter
Clogged oil cooler
Clogged breather, breather hose
Worn valve, valve guide
Worn EGR valve guide ["with EGR" only]
Defective seal at turbocharger turbine side
Causes
E E E E

Q
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging
(if monitor is installed)
w Q
Metal particles are found when oil filter is drained
Q Q
Inside of exhaust pipe is dirty with oil
w
w

Amount of blow-by gas
Black
Q
Excessive
None
q
Excessive play of turbocharger shaft

Troubleshooting
Q w
When EGR valve is removed, exhaust port is found to be dirty with oil ["with EGR" only]
q q
See S-7.
Check items
Engine oil temperature rises quickly
Inspect breather and breather hose directly
Inspect oil cooler directly
Inspect oil filter directly
Spring of oil filter safety valve is hitched or broken
125E-5 Series
Replace
Replace
Replace
Clean
Replace
Replace
Replace
Remedy
Replace
Inspect turbocharger lubrication drain tube directly
Clean
Questions
21
SEN00549-02
40 Troubleshooting
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

q
Leakage of fuel
q
Defective condition of fuel injection (fuel pressure, injection timing)
q
Excessive injection of fuel
Improper injection timing
Defective operation of injector
Defective spray by injector
Defective common rail pressure
Defective supply pump plunger
Defective feed pump oil seal
Fuel leakage from fuel filter, piping, etc.
Fuel leakage inside head cover
Causes
E E
More than for other machines of same model

Condition of fuel
consumption
Gradually increased
Q Q
Suddenly increased
There is external leakage of fuel from engine
Combustion is irregular
w
w w
Q
Low idle speed is high
Torque converter stall speed or pump relief speed is high

Color of exhaust
gas
Q Q
Black
Q Q
White
Remove and inspect head cover directly
Inspect feed pump oil seal directly
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in E-mode
q q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
If spill hose from injector is disconnected, much fuel spills
Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) in E-mode
Correct
Replace
Replace
Correct
Correct
Remedy
q
Replace
Confirm with INSITE or with monitoring function on applicable machine side
Replace
Check items
Engine oil level rises and oil smells of diesel fuel
Troubleshooting
Q Q Q
Q
Correct
Degree of use of
machine
Replace
Questions

22
125E-5 Series
40 Troubleshooting
SEN00549-02
S-11 Oil is in coolant (or coolant spurts back or coolant level goes
down)
General causes why oil is in coolant
q
Internal leakage in lubrication system
q
Internal leakage in cooling system
1
Broken hydraulic oil cooler or power train oil cooler
Broken oil cooler core, O-ring
Insufficient protrusion of cylinder liner
Damaged cylinder liner O-ring, hole caused by pitting
Cracks inside cylinder block
Broken cylinder head, head gasket
Causes
Degree of use of
machine
Oil level

Q
Suddenly increased
Oil level has risen and oil is milky

Check
items
Q Q
Gradually increased
Q Q
Hard water is being used as coolant

w
There are excessive air bubbles in radiator, coolant spurts back
Hydraulic oil or power train oil on applicable machine side is milky
When hydraulic oil or power train oil is drained, water is found
w
q
Pressure-tightness test of cylinder head shows there is leakage

Troubleshooting
q q
Inspect cylinder block, liner directly
Inspect cylinder liner directly
125E-5 Series
Replace
Replace
Replace
Remedy
Replace
Replace
Questions
Carry out
troubleshooting
on applicable
machine side
23
SEN00549-02
40 Troubleshooting
S-12 Oil pressure drops
General causes why oil pressure drops

q
Leakage, clogging, wear or lubrication system
q
Defective oil pressure control
q
Selection of oil by the temperature etc. specified in the
Operation and Maintenance Manual is not observed
q
Deterioration of oil due to overheating
Defective oil level sensor, wiring harness
Defective oil pressure sensor, wiring harness
Leaking EGR hydraulic piping ["with EGR" only]
Defective EGR oil pump ["with EGR" only]
Leaking, crushed, clogged hydraulic piping
Clogged oil filter
Defective oil pump relief valve
Defective oil pump
Clogged, broken pipe in oil pan
Clogged strainer in oil pan
Coolant, fuel in oil
Lack of oil in oil pan
Worn journal of bearing
Causes
Degree of use of
machine
E
Q w
Oil pressure monitor indicates low oil pressure (if monitor is installed)
Q
Non-specified oil is being used
Replacement of filters has not been carried out according to Operation and Maintenance Manual
w
w
Indicates pressure drop at low idle
Q
Q
Oil pressure monitor Indicates pressure drop at low, high idle

(if installed)
Indicates pressure drop on slopes
Check items
w w w Q
Q Q
w
w
Sometimes indicates pressure drop

Oil level monitor indicates oil level drop (if monitor is installed)
Oil level in oil pan is low
Q Q
w
w
External hydraulic piping is leaking, crushed
Oil is milky or smells of diesel oil

Metal particles are found when oil pan is drained
Metal particles are found in oil filter
q q
Inspect oil pan strainer, pipe directly
Oil pump rotation is heavy, there is play in oil pump

Valve and spring of oil pump relief valve are fatigued, damaged
See SI13.
Troubleshooting
Inspect oil filter directly

Relief valve of EGR oil pump is damaged, oil leaks from it ["with EGR" only]
q
q
q
Inspect EGR hydraulic piping directly ["with EGR" only]

Carry out troubleshooting according to Abnormality in oil pressure sensor (*1) in Emode
q
q
Replace
Replace
Replace
Correct
Replace
Replace
Replace
Clean
Clean
Add
Remedy
Replace
If oil level sensor is replaced, oil pressure monitor indicates normally
Replace
Questions
24
125E-5 Series
40 Troubleshooting
SEN00549-02
S-13 Oil level rises (Entry of coolant or fuel)
Questions
General causes why oil level rises

q
Coolant in oil (milky)
q
Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for S-11 Oil is in
coolant
Defective seal of auxiliary equipment (pump, compressor)
Defects in supply pump
Clogged water pump drain hole (breather hole), defective seal
Broken oil cooler core, O-ring
Worn, damaged rear oil seal
Damaged cylinder liner O-ring, holes caused by pitting
Cracks inside cylinder block

E E
Fuel must be added more frequently
E
w
Q Q
Coolant must be added more frequently
There is oil in coolant
Q Q
Oil smells of diesel fuel
Check items
Fuel leakage inside head cover
Cracked EGR cooler (Entry of coolant) [with EGR only]
Causes
Oil is milky
Q Q
When engine is started, drops of water come from muffler
Q Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appear, or coolant spurts back
w
Q
Q
Q
Exhaust smoke is white
Water pump drain hole (breather hole) is clogged
When water pump drain hole (breather hole) is cleaned, coolant comes out
w
Oil level in clutch or damper chamber of machine is low
Oil level in hydraulic tank of machine is low
Remove and inspect head cover directly
q q
Inspect cylinder block, liner directly
Inspect rear oil seal directly
Remove and inspect water pump directly
Remove and inspect supply pump directly
125E-5 Series
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Replace
Remedy
Replace
Inspect seal of auxiliary equipment directly
Replace
Troubleshooting
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1) q
[with EGR only]
25
SEN00549-02
40 Troubleshooting

26
125E-5 Series
40 Troubleshooting
SEN00549-02
S-14 Coolant temperature becomes too high (overheating)

General causes why coolant temperature becomes too
high
q
Lack of cooling air (deformation, damage of fan)
q
Drop in heat dissipation efficiency
q
Problem in coolant circulation system
q
Rise in oil temperature in power train
o Carry out troubleshooting on applicable machine
side
Rise in power train oil temperature on applicable

machine side
Defective coolant temperature gauge
Slipping fan belt, worn fan pulley
Defective radiator cap (pressure valve)
Clogged radiator core
Clogged, crushed radiator fins
Defective operation of thermostat
Broken water pump
Lack of coolant
Clogged, broken oil cooler
Damaged cylinder liner O-ring, hole caused by pitting
External leakage of coolant from EGR cooler ["with EGR" only]
Causes
Questions

Condition of overheating
E E E
Suddenly overheated
E E
Q w
Q
Q w w
Always tends to overheat

Q
Coolant temperature gauge Rises quickly

(if installed)
Does not go down from red range
w
w
Radiator coolant level monitor indicates drop of coolant level (if monitor is
installed)
w
w Q
Engine oil level has risen, oil is milky
Fan belt tension is low

w
When fan pulley is turned, it has play

w
Milky oil is floating on coolant

w
Check items
There are excessive air bubbles in radiator, coolant spurts back

When light bulb is held behind radiator core, no light passes through
Radiator shroud, inside of underguard on applicable machine side are clogged

with dirt or mud
Coolant is leaking because of cracks in hose or loose clamps
Coolant flows out from radiator overflow hose
Fan belt whines under sudden acceleration

Power train oil temperature enters red range faster than engine coolant temperature (if oil temperature gauge and coolant temperature gauge are installed)
w
q
Inspect EGR cooler for coolant leakage ["with EGR" only]
Inspect cylinder liner directly
Inspect oil cooler directly
Temperature difference between upper and lower tanks of radiator is large

When operation of thermostat is carried out, it does not open at cracking temperature
q
q
Temperature difference between upper and lower tanks of radiator is slight
Inspect radiator core directly
When operation of radiator cap is carried out, its cracking pressure is low
Inspect fan belt, pulley directly
125E-5 Series
Replace
Replace
Correct
Correct
Replace
Replace
Add
Replace
Replace
Replace
Remedy
Replace
When coolant temperature is measured, it is found to be normal
Replace
Troubleshooting

27
SEN00549-02
40 Troubleshooting
S-15 Abnormal noise is made
General causes why abnormal noise is made

q
Abnormality due to defective parts
q
Abnormal combustion
q
Air sucked in from intake system
a Judge if the noise is an internal noise or an external
noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
engine sound becomes a little larger. This does not
indicate abnormality, however.
a When the engine is accelerated, it is operated in the
acceleration mode and its sound becomes a little
larger for up to about 5 seconds. This does not indicate abnormality, however.
Improper fuel injection timing

(abnormality in coolant temperature sensor)
Dirt caught in injector
Clogged, seized injector
Deformed cooling fan, loose fan belt, interference of fan belt
Removed, seized gear train bushing
Improper gear train backlash
Excessive wear of piston ring, cylinder liner
Defective inside of muffler (dividing board out of position)
Broken dynamic valve system (valve, rocker lever)
Cracked, leaking EGR gas piping ["with EGR" only]
Interference of turbocharger, seized turbocharger
Leakage of air between turbocharger and cylinder head
Causes

Abnormal noise
Gradually occurred
Q
Q

Air leaks between turbocharger and cylinder head

When engine is cranked, abnormal sound is generated around EGR gas piping
["with EGR" only]
w
w

Check items
Q Q Q
Suddenly occurred
w
w
When engine is cranked, beat noise is generated around muffler

w Q
w

Q w
Black
Q
w

Q
Abnormal noise is loud when engine is accelerated

When turbocharger is rotated by hand, it is fount to be heavy
Q Q
w
q
Inspect EGR gas piping directly ["with EGR" only]

Troubleshooting
When muffler is removed, abnormal noise disappears
q q
Inspect fan and fan belt directly

does not change
q q
q
Abnormal noise is heard only when engine is started
28
Replace
Replace
Correct
Replace
Replace
Replace
Adjust
Replace
Replace
Replace
Replace
Remedy
Replace
Confirm with INSITE or with monitoring function on applicable machine side
Correct
Questions
125E-5 Series
40 Troubleshooting
SEN00549-02
S-16 Vibration is excessive
General causes why vibration is excessive

q
Defective parts (abnormal wear, breakage)
q
Misalignment between engine and chassis
q
Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out troubleshooting for S-15 Abnormal noise is made, too.
Broken output shaft, parts in damper on applicable machine side
Worn front support spigot joint portion
Misalignment between engine and devices on applicable machine side
Loose engine mounting bolts, broken cushions
Worn camshaft bushing
Improper gear train backlash
Worn main bearing, connecting rod bearing
Stuck dynamic valve system (valve, rocker lever)
Causes

Condition of vibration
E E
Suddenly increased
Q
Q
Q Q
Metal particles are found when oil pan is drained
Oil pressure is low at low idle
Gradually increased
Vibration occurs at mid-range speed

Q
Vibration follows engine speed

Exhaust smoke is black
Q Q Q Q
Inspect main bearing and connecting rod bearing directly
Inspect camshaft bushing directly
Inspect engine mounting bolts and cushions directly
When alignment is checked, radial runout or facial runout is detected
Inspect front support spigot joint portion directly
125E-5 Series
Replace
Adjust
Replace
Replace
Replace
Replace
Remedy
Replace
Inspect output shaft or inside of damper directly
Replace
Troubleshooting
Check items
Questions
29
SEN00549-02

2008 KOMATSU
All Rights Reserved
30
SEN00697-03
ENGINE
1SHOP MANUAL
125E-5 Series

General information on disassembly and
assembly
General information on disassembly and assembly ....................................................................................... 2
How to read this manual ...................................................................................................................... 2
Coating materials list............................................................................................................................ 4
Special tools list.................................................................................................................................... 7
125E-5 Series
SEN00697-03
General information on disassembly and assembly

How to read this manual
1.
1
(Rev. 2009.01)
1
Removal and installation of assemblies

Special tools
q
Special tools which are necessary for
r e mo v a l or i n s ta l l at i o n o f pa r ts a r e
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used
q : Special tools that will be useful if available and are substitutable with tools
available on the market
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
79 T:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
* *** ****
Removal
q
In Removal section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not
described.
q
Various symbols used in Removal section are
explained and listed below.
k : Precautions related to work safety
a : Guidance or precautions for the work
[*1] : This mark shows that instructions or precautions for parts installation work are given in
Installation section.
6 : Amount of oil or coolant to be drained
4:
Weight of part or component
Installation
q
Unless otherwise instructed, installation of
parts is to be done in the reverse order to
removal.
q
Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which
corresponds to the mark in Removal section.
q
Common tools that are necessary for installation are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
Marks shown in the Installation section stand
for the following.
k
: Precautions related to work safety

: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
: Amount of oil or coolant to be replenished

q
Various special tools are illustrated for the local
manufacture.
125E-5 Series
2.
SEN00697-03
Disassembly and assembly of assemblies

Special tools
q
Special tools which are necessary for disassembly and assembly of parts are
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used.
q : Special tools that will be useful if available and are substitutable with tools
available on the market.
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
79 T:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
* *** ****
Disassembly
q
In Disassembly section, the work procedures,
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for disassembly are described as [1], [2] etc. and
their part numbers, part names and quantities
are not described.
q
The meanings of the symbols used in Disassembly section are as follows.
k

6 : Amount of oil or coolant drained
Assembly
q
In Assembly section, the work procedures,
the amount of oil and coolant to be replenished
are described.
q
Common tools that are necessary for assembly are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
The meanings of the symbols used in Assembly section are as follows.
k

2 : Type of coating material
3 : Tightening torque
: Amount of oil or coolant to be replenished

Various special tools are illustrated for the local
manufacture.
125E-5 Series
SEN00697-03
Coating materials list

a
a
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 manual.
Category
Komatsu
code
Part number
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Used for plastic (except polyethylene,

polypropylene, tetrafluoroethylene and vinyl
Polyethylene
chloride), rubber, metal, and non-metal parts
container
which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene Features: Resistance to heat and chemicals.

container Used to fix and seal bolts and plugs.
Adhesive
LT-3
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
790-129-9140
Can
Used to stick and seal metal, glass, and plastics.
Polyethylene
Used to seal plugs.
container
Tube
Heat-resistant seal used to repair engines.
50 g
Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container Used mainly to stick metals, rubbers, plastics,
and woods.
Quick-setting adhesive.
Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
Used mainly to stick rubbers, plastics, and
metals.
Aron-alpha
201
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
Features: Resistance to heat and chemicals.

Polyethylene
Used for fitted portions used at high temperacontainer
tures.
1 kg
Used to seal various threaded portions, pipe

Polyethylene
joints, and flanges.
container Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-5
Gasket sealant
790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)
LT-4
ThreeBond
1735
790-129-9080
LG-6
790-129-9160
200 g
Tube
Features: Silicon-based heat and cold-resistant sealant.

Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.
LG-7
790-129-9170
1 kg
Tube
Features: Silicon-based quick-setting sealant.

Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.

Used to seal transfer case, etc.
LG-8
ThreeBond
1207B
(Rev. 2009.02)
1
419-15-18131
100 g
125E-5 Series
Gasket sealant
CateKomatsu code
gory
Molybdenum
disulfide
lubricant
Container
790-129-9310
200 g
Tube
Used for rough surfaces such as the circle gear

top seal which does not need to be clamped,
water resistance of the clearance at the welded
area, etc.
Can be coated with paint.
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
Used as lubricant/sealant when the radiator

hoses are inserted.
Can be coated with paint.
LG-11
ThreeBond
1121
790-129-9330
200 g
Tube
Feature: Can be used together with gaskets.

Used for covers of the transmission case and
steering case etc.
ThreeBond
1211
790-129-9090
100 g
Tube
Gasket sealant used to repair engine.
Tube
Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.
Can
Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuffing each other.
Applicable for the drive shaft splines, needle
bearings, pins and bolts of various links, etc.
Can
Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc.
Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
Feature: Lithium grease with extreme pressure

lubrication performance.
General purpose type.
LC-G
NEVER-SEEZ
09940-00040
09995-00250
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Grease
Q'ty
LG-9
ThreeBond
1206D
LM-P
Seizure
prevention
compound
Part number
SEN00697-03
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)
Hyper White
Grease G2-T,
G0-T (*)
SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)
125E-5 Series
200 g
190 g
Used for parts under heavy load.

Caution:
400 g x 10 Bellows-type Do not apply grease to rolling bearings like
swing circle bearings, etc. and spline.
400 g x 20 container
The grease should be applied to work equipment
16 kg
Can
pins at their assembly only, not applied for
greasing afterwards.
400 g
16 kg
400 g
16 kg
Bellows-type
container
Can
Seizure resistance, heat resistance and water

resistance higher than molybdenum disulfide
grease.
Not conspicuous on machine since color is
white.
Bellows-type Since this grease is decomposed by natural baccontainer

teria in short period, it has less effects on microCan
organisms, animals, and plants.
SEN00697-03
G2-U-S
ENS grease
427-12-11871
SUNSTAR
PAINT PRIMER
580 SUPER
Caulking material
Adhesive
Primer
SUNSTAR
GLASS
PRIMER 580
SUPER
SUNSTAR
PAINT PRIMER
435-95
Q'ty
Container
Tube
Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent
deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.
2 kg
Can
Feature: Urea (organic system) grease with heat

resistance and long life. Enclosed type.
Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
20 ml
Glass
container
Used as primer for cab side.

(Using limit: 4 months after date of manufacture)
20 ml
Glass
container
Used as primer for glass side.

20 ml
Glass
container
200 g
417-926-3910
22M-54-27230
Adhesive for cab glass
G2-S
ThreeBond
1855
Part number
Used as primer for painted surface on cab

side.
Used as primer for black ceramic-coated
surface on glass side and for hard polycarbonate-coated surface.
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
Used as primer for sash (Almite).

SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W
417-926-3910
320 ml
Polyethylene
container
S is used for high-temperature season

and W for low-temperature season as
adhesive for glass.
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
Used as adhesive for glass.

SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
Used to seal front window.

Cartridge
Used to seal joint of glasses.

Translucent white seal.
GE TOSHIBA
SILICONES
TOSSEAL 381
22M-54-27220
333 ml
Adhesive for cab glass
Grease
CateKomatsu code
gory
Used as adhesive for glass.

Used to seal joints of glass parts.
125E-5 Series
SEN00697-03
Special tools list

a
a
Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
Necessity:
t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
New/Redesign: N ............ Tools newly developed for this model. They have a new part number respectively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any modification.
Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
Sketches of special tools).
Work item
Disassembly and assembly of

engine assembly
Symbol
Part No.
Part name
Necessity
Q'ty
New / Remodel
Sketch
790-501-2001
Engine repair stand
t 1
790-901-1240
Adapter
t 1
Removal and installation of

cylinder head valve spring
795-102-2102
Spring pusher
t 1
Removal and installation of piston

ring
795-100-1191
Piston ring tool
t 1
Removal of cylinder liner
795-220-1000
Liner puller
t 1
Press fitting of cylinder liner
795-225-1520
Liner driver
t 1
Insertion of piston assembly
795-921-1110
Piston holder
t 1
Measuring projection of piston top

surface
795-502-1121
Gauge holder
t 1
795-125-1360
Clearance gauge
q 1
Angle tightening of bolt
790-331-1110
Wrench
q 1
Removal of rear oil seal
795-931-1100
Seal puller assembly
795-931-1210
Sleeve jig
t 1
795-931-1220
Sleeve jig
t 1
01050-31645
Bolt
t 3
01050-31625
Bolt
t 3
795-630-5500
Standard puller
t 1
P 2
01010-81090
Bolt
t 2
01643-31032
Washer
t 2
Press fitting of rear oil seal
Removal of fuel supply pump
125E-5 Series
Remarks
SEN00697-03

2009 KOMATSU
All Rights Reserved
SEN00698-02
ENGINE
1SHOP MANUAL
125E-5 Series
50 Disassembly and assembly1

Disassembly and assembly, Part 1
(With EGR)
Disassembly and assembly, Part 1 (With EGR).............................................................................................. 2
General disassembly of engine............................................................................................................ 2
General assembly of engine .............................................................................................................. 17
125E-5 Series
SEN00698-02
Disassembly and assembly, Part 1 (With EGR)
General disassembly of engine 1

a
The shapes, quantity, locations, etc. of the

parts depend on each applicable machine.
Take care.
1.
Preparation work
Before disassembling the engine, check its parts
for cracking, damage, etc. and clean it generally
and carefully for accurate inspection of its parts
and quick disassembly and assembly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.
2.
Setting engine assembly

1) Set the engine assembly (1) on rigid and
stable stands [1].
a The weight depends on the applicable machines.
4 Engine assembly: 1,300 kg
2)
Alternator
1) Remove cover (1).
2) Loosen alternator mounting bolt (2) and
lock bolt (3).
3) Loosen locknut (4) and then loosen the
belt tension using the tension adjustment
nut and remove V-belt.
4) Remove mounting bolt (2) and lock bolt
(3) and then remove alternator (5).
7.
Water pump suction tube

Remove tube (1).
Drain the engine coolant and engine oil.

a The quantity of the engine oil
depends on each applicable machine.
6
Engine oil: Approx. 40 l
3.
Harness assembly
Disconnect the connector and clamp and
remove the harness assembly.
4.
Heat shielding plate

Remove the heat shielding plate from EGR
and EGR piping.
5.
Starting motor
Remove mounting bolt (1) and remove starting
motor (2).
6.
125E-5 Series
8.
SEN00698-02
EGR cooler
1) Remove turbocharger drain tube (1).
2) Remove exhaust gas discharge tube (2).
3) Remove coolant tube (3).
4) Remove 2 air vent tubes (4).
5) Loosen rubber hose (5) clamp and then
remove the bolt on the water pump side
and remove tube (6).
10. Turbocharger and exhaust manifold assembly

1) Remove bolt (1) used to mount the
assembly to bypass tube.
a The bypass tube is not used on some
machine models.
2) Disconnect turbocharger lubrication tube
(2).
6)
7)
Remove the bolt mounting it to EGR tube

(7).
Remove 4 mounting bolts and remove
EGR cooler (9).
a Remove bracket (8) at the same time.
3)
9.
EGR tube
1) Remove clamps (1) and (2).
2) Remove EGR gas pressure sensor tube (3).
3) Remove the bolt (4) mounting it to the
EGR valve and remove EGR tube (5).
125E-5 Series
Lift up the turbocharger side temporarily,

remove the exhaust manifold mounting
bolt and then remove the turbocharger
and exhaust manifold assembly.
4 Turbocharger and exhaust manifold
assembly: 40 kg
SEN00698-02
11. Oil filter and oil tube assembly

1) Remove the oil tube (1) block side mounting bolt.
2) Remove 4 mounting bolts on the oil filter
head side and remove oil filter and oil tube
assembly (2).
12. Fuel filter

1) Loosen clamp (3) to disconnect fuel tubes
(1) and (2).
2) Remove 4 mounting bolts on the head side
of the fuel filter and remove fuel filter (4).
13. Fuel tube

Remove clamp (3) and remove fuel tubes (1)
and (2).
14. Lubrication tube and bracket

1) Remove brackets (1) and (2).
2) Remove turbocharger lubrication tube (3)
by removing 4 clamps on it.
15. High-pressure pipe

1) Remove bracket (1).
2) Remove splash prevention cover (2).
125E-5 Series
3)
Remove 6 clamps (3) and 6 splash prevention covers (4) on the injector side.
4)
Remove clamps (5), (6), (7) and (8) and

then remove 6 high-pressure pipings (9).
SEN00698-02
17. Bypass valve

1) Remove clamp (1) and loosen clamp (2).
2) Remove oil drain tubes (4) and (5).
3) Remove the mounting bolt on oil inlet tube
(6).
4) Remove 2 mounting bolts (7) and then
remove bypass valve (8).
18. EGR valve

1) Remove oil inlet tube (1).
2) Remove 2 mounting bolts (2) and then
remove EGR valve (3).
16. Bypass tube

Remove bolt (2) on the bypass valve side and
then remove bypass tube (1).
19. Front hanger

Remove front hanger (1).
125E-5 Series
SEN00698-02
20. Diffuser and air housing assembly

1) Remove brackets (1) and (2) and then
remove oil filler (3).
2) Remove mounting bolt (4) at flanged portion of the air housing. Remove the bolt
through the bottom.

2)
3)
4)
Lift air intake manifold (2) temporarily,

remove its 24 mounting bolts and then
remove manifold.
4 Air intake manifold: 25 kg
Remove bracket (5) and then lift the diffuser temporarily.

Remove the mounting bolt and then remove
diffuser and air housing assembly (6).
4 Diffuser and air housing assembly:
35 kg
22. Engine controller cooler

Disconnect fuel hose (1) and remove engine
controller cooler (2).
a Fuel hose (1) is not used on some
machine models.
125E-5 Series
SEN00698-02
23. Fuel supply pump piping

1) Remove clamps (3), (4) and (5) and then
remove splash prevention cover (6).
2) Remove 2 high-pressure pipings (7).
3) Remove lubrication tube (8).
4) Remove fuel tube (1).
4)
5)
24. Fuel supply pump assembly
2) Rotate the crankshaft forward and set
intermediate point (a) between stamped
2/5 TOP and 3/4 TOP on damper (2) to
pointer (3) (stamped 1/6 TOP comes
almost directly under).
a Make sure at this point that the forcing tap of the drive gear is aligned to
the bolt hole at the top of cover (1).
(If not, rotate the crankshaft 1 more
turn.)
a At this point, the key of the shaft is
turned clockwise by 15 from the top.
3)
6)
Remove pump mounting bolts (6) and

bracket (7).
a Leave bolts (6) tightened by 2 3
threads to prevent the pump from falling down.
Install tool P1 with P2 and P3 and then
screw in the center bolt of P1 to remove
the gear from the shaft.
Remove remaining bolts and then remove
fuel supply pump assembly (8).
a Leave tools P1, P2 and P3 in the
installed condition.
Remove mounting nut (4) and then remove

washer (5).
a Use a magnet or the like in this operation so that washer (5) may not be
inadvertently dropped into the case.
125E-5 Series
SEN00698-02
25. Common rail and overflow tube

1) Remove common rail (1).
2) Remove spill tube (2), overflow tube (3)
and block (4).
26. Spill tube

Remove spill tube (1).
2)
Remove the mounting bolt and then

remove oil cooler assembly (4) using
guide bolt [1].
29. Engine repair stand adapter

Install tool A2.
27. Air vent tube

Remove air vent tube (2).
30. Head cover

Remove head cover (1).
28. Oil cooler assembly

1) Remove brackets (1) and (2) and drain
hose (3).
125E-5 Series
31. Injector harness

1) Fully loosen 2 harness terminal mounting
nuts (2) on the head of injector (1).
a Loosen nuts alternately.
2) Loosen bolt (3) of harness fixing holder.
32. Rocker arm and shaft assembly

1) Loosen locknut (3) and then loosen
adjustment screw (2).
2) Remove mounting bolt (4) and then
remove rocker arm and shaft assembly
(1).
33. Push rod

Remove 12 push rods (1).
125E-5 Series
SEN00698-02
34. Injector
Remove holder mounting bolt (3) of injector (1)
and then remove injector (1) along with holder
(2).
a Do not try to grip the solenoid valve at the
top of the injector using a pliers and the
like.
35. Crosshead
Remove 12 crossheads (1).
36. Injector wiring harness

1) Remove mounting bolt (2) of harness connector (1).
2) Remove holder (3) from the harness.
SEN00698-02
3)
4)
Remove harness connector (1) by pushing outward from inside of rocker housing
(4).
Remove O-ring (5) from the rocker housing.

Remove rocker arm housing (1).
38. Thermostat and water pump

1) Remove thermostat case (1) and tube (2).
2) Remove water pump (3).
10
39. Cam follower cover

1) Remove oil level gauge tube (1).
2) Remove oil tube (2) and bracket (3).
3) Remove 3 cam follower covers (4).
40. Cam follower

Remove 12 mounting bolts (1) and then
remove cam followers (2).
a Remove dowel pin (3).
41. Removal of cylinder head assembly

1) Remove each set of 7 mounting bolts (2)
of cylinder head assembly (1).
2) Using eyebolt [1], lift and remove cylinder
head assembly (1).
4 Cylinder head assembly: 20 kg
3) Remove each head gasket.
125E-5 Series
42. Disassembly of cylinder head assembly

1) Using tool C, compress valve spring (3)
and remove valve cotter (4).
2) Remove upper seat (5) and valve spring (3).
3)
4)
Remove seal (7) and then remove lower

seat (8).
Raise the cylinder head and remove valve
(6).
a Apply an marking and the like to the
valve so that it may be identifiable to
which head it should be combined.
SEN00698-02
43. Setting to engine repair stand

Lift the engine and then align currently installed
tools A2 and A1 to set the engine.
44. Oil pan

Remove oil pan (1) by reversing the engine.
45. Speed sensor

Remove speed sensors (1) and (2) by turning
over the engine.
a Speed sensor (2) is not used on some
machine models.
125E-5 Series
11
SEN00698-02
46. Flywheel
1) Using slings [1], lift up flywheel (1) temporarily.
2) Remove 6 mounting bolts to remove the
flywheel from the dowel pin and then lift off
the flywheel.
4 Flywheel: 25 kg
49. EGR oil pump

Remove EGR oil pump (1).

1) Apply slings [1] to both sides of housing
(1) to lift it up temporarily.
2) Remove 10 mounting bolts to remove the
housing from the dowel pin and then lift it off.
4 Flywheel housing: 80 kg
48. Damper and pulley assembly

Lift the damper and pulley assembly (1) temporarily and then remove its 6 mounting bolts.
4
12
50. Front support and front cover

1) Lift up front support (1) temporarily and
then remove it by removing the mounting
bolts.
a Its shape depends on the applicable
machines.
4 Front support: 30 kg
2) Remove adjustment rod (2).
3) Lift up front cover (3) temporarily and then
remove it by removing the mounting bolts.
4 Front cover: 30 kg
4) Remove tool P and then remove the supply pump drive gear.
Damper and pulley assembly: 25 kg
125E-5 Series
51. Camshaft
1) Remove 2 mounting bolts (1).
2) Remove camshaft (2).
a When pulling out the camshaft, turn it
gently so that damages may not be
left on the cam bushing.
SEN00698-02
53. Idler gear

1) Remove mounting bolt (1) and then remove
plate (2) and oil pump idler gear (3).
2)
3)
52. Oil pump
Remove 4 mounting bolts (1) and then remove
oil pump (2).
Remove shaft (4).

Remove mounting bolt (5) and then
remove shaft (6), main idler gear (7) and
plate (8).
54. Oil suction pipe

Remove brackets (1) and then remove oil suction pipe (2).
125E-5 Series
13
SEN00698-02

Remove mounting bolt (1) and each piston
cooling nozzle (2).
6)
56. Piston and connecting rod assembly
a Before removing the piston and connecting rod assembly, measure its end play
with dial gauge [3], if necessary.
7)
1)
2)
3)
4)
5)
14
Check the stamped No. of the connecting

rod cap.
q
The cap No. and cylinder No. must be
the same.
q
The cap No. must be stamped on the
cam side.
a If the No. is not stamped, stamp it
before removing the connecting rod.
Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
Scrub the carbon off the top wall of the cylinder liner with fine sandpaper.
Remove connecting rod cap mounting
bolts (1).
Hit connecting rod cap (2) with a plastic
hammer so lightly that the threads of the
connecting rod bolts will not be damaged
and remove connecting rod cap (2) and
connecting rod bearing as a unit.
8)
Push in and remove the piston and connecting rod assembly with a wood bar, etc.
from the oil pan side, while supporting piston (3) on the cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the connecting rod.
Remove the other piston and connecting
rod assemblies according to the above
procedure.
a Take care not to damage the sliding
portions of the pistons and bearings.
a Assemble each connecting rod and
cap temporarily so that they will not
be assembled with other ones and
keep them and the bearing together.
Disassemble the piston and connecting

rod assembly according to the following
procedure.
1] Remove 2 snap rings (4).
2] While supporting connecting rod (5),
remove piston pin (6) to disconnect
piston (7) and connecting rod.
125E-5 Series
SEN00698-02
2)
3]
Using tool D, remove piston ring (8).

a Keep the piston, connecting rod,
connecting rod bearing, piston
rings, and piston pin by each cylinder.
Insert the bolts in the bolt holes of the

main cap and remove the cap, while shaking it.
Thrust bearing (3) is assembled to

No. 7 main cap. After removing the
cap, apply a marking to the re-assembly position.
57. Crankshaft
a Before removing the crankshaft, measure its
end play with dial gauge [3], if necessary.
3)
1)
Lift off crankshaft (4).

a When removing the crankshaft, take
care so that its sliding surfaces may
not be damaged.
4 Crankshaft: 110 kg
Remove mounting bolts (2) of main cap (1).
125E-5 Series
15
SEN00698-02
16
4)
Remove upper thrust bearing (5).
5)
Remove upper bearing (6).

a Apply a marking to the assembly
positions of the main cap, main bearing, and thrust bearing. And store
them by the journal No.
58. Cylinder liner

Using tool E, pull out cylinder (1).
a Before removing the cylinder liner, measure its projection with dial gauge [3], if
necessary.
125E-5 Series
General assembly of engine

a
a
SEN00698-02
2]

Take care.
Clean each part carefully, and check it for
bruise, flaw, cavity, etc. Make sure each oil or
coolant path is through.
3]
Tightening bolts by plastic-region turning angle

method
a Bolts tightened by plastic-region turning angle
method
q
Cylinder head mounting bolt
q
Main cap mounting bolt
q
Connecting rod cap mounting bolt
a If the plastic-region turning angle method is
applied, the tightened bolts have permanent
strain. Accordingly, the allowable number of
using times of each bolt is limited. Observe the
following precautions.
q
Before tightening each bolt, measure its
stem length and make sure that the length
is less than the using limit. If the stem is
longer than the using limit, it should not be
used but replaced.
q
Check each mounting bolt head for punch
marks. If there are punch marks more than
the specified numbers, replace the bolt.
1.
Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 320 kg
2)
Before inserting the cylinder liners, prepare the cylinder block according to the
1] Remove the rust and scales from faces
(A) and (B) with sandpaper, etc. until
the machined surfaces are exposed.
125E-5 Series
4]
5]
2.
Polish part (R) with sandpaper of

about No. 240 until it becomes a
smooth rounded surface.
If part (R) is sharp or has burrs, finish
it with a scraper or sandpaper.
Finish this surface particularly smoothly
so that it will not damage the O-ring.
If face (B) is so pitted that it cannot be
repaired, replace the cylinder block.
If faces (A) and (R) are pitted, finish
them smoothly.
Check the counterbored part and
remove burrs. If chips or dust is
present on face (C), the liner may not
fit well, resulting in coolant leakage or
insufficient liner protrusion. Thus,
they must be eliminated.
a If the counterbored part is drooping, corroded, or pitted, repair it.
Cylinder liner
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not roughened
because of rusting or pitting. If those parts
are roughened, replace the cylinder liner.
2) Install clevis seal (1), O-rings (2) and (3) to
the cylinder liner.
a Check that there is not a burr, dust,
etc. in the groove of the liner.
a Replace the O-ring and clevis seal
with new ones.
a Fit the clevis seal with the chamfered
side down. When fitting it, press it
against the seal groove all round so
that it will not be twisted.
a When installing O-rings (2) and (3),
refer to the following.
q
O-ring (2): The whole ring is black.
q
O-ring (3): The whole ring is red.
2 Clevis seal and O-ring:
Rubber lubricant (LH-50 from NOF
Corporation)
17
SEN00698-02
a
a
If LH-50 is not available, apply clean

engine oil SAE No. 30.
Since the clevis seal and O-ring are
swollen and deteriorated by oil, apply
a small amount of oil to them thinly
with a brush just before fitting them.
4)
Apply gasket sealant to the parts of the

cylinder block and cylinder liner which will
fit to the counterboared parts.
a Wipe off dirt and oil with cloth from
the contact faces of the counterboared parts of the cylinder block and
liner flange.
2 Cylinder block: Gasket sealant (LG-6)
q
Gasket sealant:
0.8 1.6 mm in diameter
q
Overlap (a) of gasket sealant: 6 6 mm
a If the applied gasket sealant is left for a
long time, its surface becomes hard.
Accordingly, install the cylinder block to
the cylinder head within 50 minutes.
5)
Insert cylinder liner (1) to the cylinder block.

a Insert cylinder liner (1) in the cylinder
block slowly, taking care not to damage the O-ring.
Push in cylinder liner (1) further by both
hands.
a If the liner does not enter the cylinder
smoothly, the O-ring may be damaged. In this case, check the cylinder
block for burrs.
Using tool F, press fit cylinder liner (1) to
the cylinder block.
6)
3)
After fitting the O-ring, check it for twist. If

it is twisted, correct it with a flexible rod
(about 10 mm in diameter).
7)
18
125E-5 Series
8)
To prevent the gasket sealant from projecting through the clearance between the
block and liner after the cylinder head is
tightened, tighten the cylinder head temporarily with the used head gasket
inserted.
a At this time, observe the following tightening torque and tightening order.
3 Temporary tightening torque:
127.5 147.1 Nm {13 15 kgm}
9)
Remove the cylinder head and wipe off

the gasket sealant projected from the
counterbored part.
a Be sure to perform steps 8) and 9)
above since the projected gasket
sealant can deform the grommet of
the head gasket.
SEN00698-02
3.
Crankshaft
a Cylinder block and main bearing are
selective mating parts and the prepared
spare parts ensure the required clearance.
1) Install the upper main bearing (6) to the
notch of the cylinder block while aligning
the bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.
2 Bearing inner surface:
Engine oil (EO30)
2)
Drive in the roll pin so that its projection

from the block end face may become 1.5
1.9 mm and then install upper side thrust
bearing (5).
a Install each thrust bearing with the
grooved surface on the crankshaft side.
3)
Before assembling the crankshaft, check

the following.
q
Troubles on the front side and rear
side threaded portions
(Bottom can be easily screwed in by
hand)
q
Scratches or dents on pin and main
journal
q
Presence or absence of dust inside
oil hole
10) Using dial gauge [3], measure the projection of the cylinder liner.
a When measuring projection of the
liner, fix the liner using a plate so that
it may not be lifted by the O-ring.
a Projection of cylinder liner:
0.07 0.15 mm
a If the end play is out of the standard,
correct it. For details, see Structure,
function and maintenance standard.
125E-5 Series
19
SEN00698-02
4)
5)
Lift and set crankshaft (4) to the mounting

position.
a When installing the crankshaft, take
care not to damage its sliding surfaces by, for instance, bumping
against the cylinder block.
a When replacing the crank gear, heat it
with a bearing heater set at 150C
and then fit it immediately after the
heating.
2 Cylinder block journal:
Engine oil (EO30)
6)
Install main cap (1).

a When installing, make sure that the
stamped No. at center of the main
cap is aligned to the stamped journal
No. of the cylinder block.
a Install the main cap with the cast letter (F) toward the front of the engine.
2 Crankshaft journal surface:
Engine oil (EO30)
7)
Before tightening the main cap mounting

bolts, check the following items. If any of
the following conditions applies, do not
reuse that bolt but replace it.
q
Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q
Length (a) of bolt stem:
Min. 159.8 mm
Install lower main bearing (7) to the main

cap.
a Install lower main bearing (7) to the
notch of the main cap while aligning
a Drive the roll pin of cap No. 7 so that it
will be projected by 1.5 1.9 mm from
the cap end and then install thrust
bearings (3) to both sides.
8)
Screw in main cap mounting bolts (2)

alternately until the main cap (1) is
securely fitted in its place.
9) Tighten main cap mounting bolts (2)
a Tighten the bolts from the center one
to the outer ones in order.
2 Threaded portion of mounting bolt and washer:
Engine oil (EO30)
20
125E-5 Series

3
SEN00698-02
Mounting bolt
1st time : 98.1 9.8 Nm {10 1 kgm}
2nd time : 196.1 4.9 Nm {20 0.5 kgm}
3rd time : Using tool J, tighten the bolt by
90 (+30/0).
4.
When not using tool J, apply mark (b)

to the main cap and bolt with paint,
then tighten the bolt by 90 (+30/0).
10) Make punch mark (c) on the mounting bolt
head.
a When a new bolt is used, do not
make a punch mark on its head.
11) Check that the crankshaft turns smoothly.

12) Measure the end play of the crankshaft
with dial gauge [3].
a End play: 0.14 0.315 mm
125E-5 Series
Piston and connecting rod assembly

a Piston and cylinder liner are selective mating parts and the prepared spare parts
ensure the required clearance.
1) Using tool D, assemble piston ring (8) in
the order of oil ring, second ring and top
ring starting from the bottom.
a Fit the top ring and second ring to the
piston with the stamped mark side up.
q
Stamp on top ring: 1R
q
Stamp on second ring: 2R
a Take the expander out of the oil ring
and fit it to the piston first and then fit
the oil ring. At this time, make sure
that the expander is fitted to the ring
groove perfectly.
2)
Set the abutment joint of each piston ring

as shown in the following figure.
a Adjust oil ring so that the joint of the
expander will be at 180 to the abutment joint of the oil ring.
21
SEN00698-02
3)
4)
Install snap ring (4) to one side of piston (7).

Heat piston (7) at 100C for 5 minutes
minimum in the heating furnace.
a When the furnace is not available,
heat it at 100C for 5 minutes minimum in hot water.
Set connecting rod (5) on piston (7).

a Set the connecting rod so that the ID
marking "6251" at the bottom of the
connecting rod comes to the left side
as the grade marking on the piston
top surface is faced toward the front
side of the engine. Then insert the
connecting rod to piston pin (6).
2 Piston boss: Engine oil (EO30)
6) Install snap ring (4) on the opposite side.
a Turn the snap ring on both sides to
make sure they are securely fitted to
the ring groove.
7)
Install upper main bearing (8) to the notch

of the connecting rod while aligning the
bearing projection to it.
a Make sure that the bearing hole and
connecting rod oil hole are aligned.
8)
Install the connecting rod lower bearing

(9) to the notch of the connecting rod cap
while aligning the bearing projection to it.
5)
22
125E-5 Series
9)
Set the cylinder crankshaft, to which the piston and connecting rod assembly is to be
assembled, to the bottom dead center.
10) Insert piston and connecting rod assembly
(3) in the cylinder block so that ID marking
"6251" of the connecting rod may be faced
toward the left side face of the engine.
a Make sure the abutment joint of the
piston ring is located in the position
indicated in the following figure.
2 Inner surface of connecting rod and
cylinder: Engine oil (EO30)
11) Using tool G, reduce the piston ring and

then push in the piston head with a wood
bar, etc.
125E-5 Series
SEN00698-02
12) Install connecting rod cap (2).

a Align match mark of connecting rod
(5 ) and connecting ro d cap (2).
(Above aligns the match mark to ID
marking "6251" on the opposite side.)
2 Inner surface of connecting rod cap
bearing: Engine oil (EO30)
13) Before tightening the connecting rod cap

mounting bolts, check the following items.
If any of the following conditions applies,
do not reuse that bolt but replace it.
q
is 5.)
q
Length (a) of bolt stem: Min. 84.1 mm
23
SEN00698-02
14) Tighten connecting rod cap mounting bolts

alternately until the connecting rod cap is
closely contacted.
(1) according to the following procedure.
3 Mounting bolt
1st time : 98.1 4.9 Nm {10 0.5 kgm}
2nd time : Using tool J, tighten the
bolt by 90 (+30/0).
19) Set the dial gauge on tool H and then

measure the projection of the piston top
surface from the top face of the cylinder
block.
a Piston projection: 0.984 1.335 mm
a Prior to the measurement, push the
piston top surface to eliminate the oil
clearance.
a
When not using tool J, apply marking

(b) to the connecting rod, cap and
bolt with paint, then tighten the bolt by
90 (+30/0).
16) After tightening the bolt, make a punch
mark (C) on its head.
5.
17) Turn the crankshaft to check that it rotates

normally.
18) Measure the side clearance of the connecting rod with dial gauge [3].
a Side clearance: 0.2 0.375 mm
24

1) Rotate the crankshaft and set the No. 1
No. 3 pistons to the following positions for
installation of the piston cooling nozzles of
each piston.
q
Set the No. 1 piston to top: Piston
cooling nozzles of the No. 1 and No. 6
pistons can be installed.
q
q
piston can be installed.
2) Set piston cooling nozzle (2) adjusting the
dowel pin position and then tighten mounting bolt (1).
3 Mounting bolt:
27 34 Nm {2.8 3.5 kgm}
125E-5 Series

a
6.
SEN00698-02
After the installation, make sure the

nozzle end is situated at center of the
cut of respective pistons.
Oil suction pipe

Install oil suction pipe (2) after attaching the Oring to it and then fix them using bracket (1).
8.
7.
Oil pump
1) Install oil pump (2) after attaching the Oring to it and then tighten 4 mounting bolts
(1).
2) Drive in the pin and then install shaft (4).
Idler gear
1) Install plate (8) to the engine block and then
install main idler gear (7) and shaft (6).
a When installing plate (8), set its
chamfered side to the front side of the
engine.
2) Matching A mark of the crankshaft gear
and A mark of main idler gear (7),
tighten mounting bolt (5).
3 Mounting bolt:
245 294 Nm {25 30 kgm}
125E-5 Series
25
SEN00698-02
9.
Idler gear
Assemble oil pump idler gear (3), attach plate
(2) to it and then tighten them using mounting
bolt (1).
3 Mounting bolt:
147 176.4 Nm {15 18 kgm}
11. Cam follower

1) Drive in dowel pin (3) to the cylinder block.
2) Tighten 6 cam followers (2) using mounting bolt (1).
3 Mounting bolt:
44 59 Nm {4.5 6 kgm}
10. Camshaft
1) Assemble camshaft (2) to the cylinder
block.
a Rotate the camshaft when assembling so that the cam bushing may not
be damaged.
a When replacing the cam gear, heat it
at 200 240C for 30 minutes minimum in an electronic oven and then
shrink fit it.
2 Camshaft journal surface:
Engine oil (EO30)
2) Matching B mark of the crankshaft gear
and B mark of the main idler gear,

1) Install the O-ring and cam follower cover (4).
3 Mounting bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
2) Install brackets (3), oil tube (2) and oil
level gauge (1).
13. Water pump assembly

Fit the O-ring to water pump assembly (3) and
install them.
26
125E-5 Series
SEN00698-02
14. Thermostat and water tube

Fit the gasket and then install thermostat (1)
and tube (2).
16. Make sure that match marks (A to C) of drive

gears and idler gears are matched.
1) Set fuel supply pump assembly (3) and
then tighten it temporarily using 4 mounting bolts (5).
a Tighten it permanently according to
Step 43 described below.
2 Mounting bolt: Adhesive (LT-2)
2) Set the assembly by aligning C mark to
C mark of camshaft gear (2) while aligning the key groove of supply pump drive
gear (1) to the woodruff key of the shaft.
3) Fit the washer and then tighten them
using gear mounting nut (4).
3 Gear mounting nut:
127 147 Nm {13 15 kgm}
4) Install bracket (6).
3 Mounting bolt (supply pump side):
19.6 29.4 Nm {2.0 3.0 kgm}
a Leave the cylinder block side mounting bolt in temporarily tightened state
(it is to be tightened permanently in
the following Step 43).
17. Measuring backlash and end play

a Measure the backlash and end play of
each gear with dial gauge [3].
Standard backlash of each gear
Position
Range (mm)
0.105 0.325
0.105 0.325
0.116 0.359
0.105 0.337
0.082 0.389
0.076 0.366
Standard end play of each gear
125E-5 Series
Position
Range (mm)
0.05 0.17
0.05 0.21
If the end play is out of the standard, correct it. For details, see Structure, function
and maintenance standard.
27
SEN00698-02
3)
4)
5)
6)
18. Front cover

1) Using the push tool (outside diameter 120
mm), press fit oil seal (5) to the cover.
a Oil seal press fit allowance (a):
16 (+1/0) mm
2 Oil seal lip (50 80% of void lip
space): Grease (G2-LI)

1) Apply a string of gasket sealant 1 mm in
diameter as shown below.
2)
3)
2)
28
Install cover (2).

Using dial gauge, measure the level difference between underside faces of the cylinder block and front cover.
a Difference: 0 0.275 mm
a If the difference is out of the standard,
Install adjustment rod (3).
Install front support (4).
machines.
Sling flywheel housing (1) and then install

it to the cylinder block.
Tighten flywheel housing mounting bolts (2).
Lift front cover (1) and then install it using

the guide bolt.
a When installing, take care not to damage the oil seal.
2 Front cover mounting surface:
Gasket sealant (LG-7)
125E-5 Series
SEN00698-02
a
a
Tighten the flywheel housing mounting bolts in the following order in 2

steps.
a The following indicates that mounting
bolts 1, 4 and 2, 9 are to be tightened
twice in 1st time.
2 Mounting bolt: Engine oil (EO30)
3 Mounting bolt:
1st time:
147 235 Nm {15 24 kgm}
2nd time:
245 309 Nm {25 31.5 kgm}
4)
After installing the flywheel housing, measure its facial runout and radial runout with
dial gauge [3].
imum on the flywheel housing including the periphery.

Move the crankshaft either in the front
or rear side in order to prevent errors
due to the end play.
Make sure after rotating the crankshaft by a turn that the gauge pointer
is returned to the position where it
had been situated when the crankshaft was started to turn.
The gauge pointer deflects in both
sides right and left. Thus, reasonable care must be exercised to avoid
misreading of the pointer when the
gauge is provided in the top, bottom,
left and right side of the measured
end face.
Facial runout: Max. 0.20 mm
Measurement of radial runout of flywheel

housing
Like in measurement of the facial runout, set
dial gauge [3] so that its probe may contact
against the flywheel housing centering location
at a right angle.
a In measurement of radial runout, errors
due to end play of the crankshaft do not
occur. As for other points, however, the
precautions noted for the facial runout
remain applicable to the radial runout
as they are.
a Radial runout: Max. 0.20 mm
Measurement of facial runout of flywheel

housing
1] Apply the magnet stand to the crankshaft end face.
2] Set dial gauge [3] so that its probe
may contact against the flywheel
housing end face at a right angle.
3] Rotate the crankshaft by a turn to
read the difference between the maximum and minimum values indicated
by the gauge pointer.
a Measurement shall be conducted at
eight equally distanced positions min125E-5 Series
29
SEN00698-02
5)
Using dial gauge [3], measure the level

difference between underside faces of the
cylinder block and flywheel housing.

a
1)
Never remove inside plastic cylinder

(3) of the standard spare seal before
installing the seal.
Set the large inside diameter side (b)
of plastic inside cylinder (3) to the end
of crankshaft (4).
a Take care not to mistake the direction of the plastic inside cylinder.
20. Rear oil seal

a Check the Teflon seal (Laydown lip seal)
by checking the wear of the crankshaft
and replace it with the Standard seal or
Sleeved seal.
a If the crankshaft is worn to the degree of
luster (If wear which you feel with your finger is less than 10 mm) and does not have
any flaw, install the standard seal. In other
cases, install the sleeved seal.
a The left one in the following figure is the
standard seal and the right one is the
sleeved seal.
2)
3)
Hold the metal ring of seal (1) by both

hands and push it in firmly.
After pushing in the seal, remove
plastic inside cylinder (3).
a When removing the inside cylinder, take care not to damage the
seal lip.
Procedure for installing standard seal

a Before installing the seal, check that
the end corners and lip sliding surfaces of crankshaft (4) are free from
flaw, burr, and rust of the housing.
a When installing the seal, do not apply
oil or grease to the shaft and seal lip
(a). Wipe off the oil from the shaft.
30
125E-5 Series
4)
SEN00698-02
Tighten bolts (N3 and N4) evenly to press

fit seal (1) until the end of tool N1 reaches
the end of crankshaft (4).
a First tighten tool N1 until it is contacted
against bolt N3 (bolt stem 45 mm) and
then further tighten the tool with bolt N4
(bolt stem 25 mm).
a When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool set, etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
Procedure for installing sleeved seal

a Before installing the seal, make sure
that the end corners and lip sliding surfaces of crankshaft (4) are free from
flaws, burrs, and rusts of the housing.
oil or grease to the shaft, sleeve (1),
and seal lip (a). Wipe off the oil from
the shaft.
a Handle the seal and sleeve as an
assembly and don't separate them
from each other.
1)
2)
Set the sleeve of the seal to the end

of the crankshaft, and then tighten
bolt N3 evenly to press fit sleeve and
seal assembly (2) until the end face of
tool N2 reaches the end of crankshaft
(4).
3)
Remove tool N2 and then replace it

with tool N1.
Tighten bolt N4 evenly to press fit
sleeve and seal assembly (2) until the
end face of tool N1 reaches the end
of crankshaft (4).
a After press fitting the seal, remove
the red sealant layer from its
periphery.
4)
Set sleeve and seal assembly (2) to

tool N2.
2 Inside sleeve:
125E-5 Series
31
SEN00698-02
21. Flywheel
1) Using sling [1], lift up flywheel (1) and then
install it aligning to the dowel pin.
2) Tighten mounting bolts (2) in the following
order in 2 steps.
2 Mounting bolt: Engine oil (EO30)
3 Mounting bolt
1st time:
147 19.6 Nm {15 2.0 kgm}
2nd time:
289.1 19.6 Nm {29.5 2.0 kgm}
3)
32
Using dial gauge [3], measure the facial

and radial runout.
a Facial runout : Max. 0.20 mm
22. Speed sensor

a Before installing the sensor, make sure its
tip is free from steel chips or flaws.
1) Install speed sensor (1).
3 Mounting bolt:
4.9 7.9 Nm {0.5 0.8 kgm}
1] Screw in speed sensor (2) until its tip
lightly touches the tooth tip of ring
gear (3).
2 Threads:Gasket sealant
(Hydraulic sealant
from Loctite)
2] Rotate speed sensor (2) in the opposite direction by 1/2 2/3 turns.
a Clearance (a) will become 0.75
1 mm.
3] Tighten nut (4) while fixing sensor (2).
3 Nut: 69 74 Nm {7 7.5 kgm}
125E-5 Series
SEN00698-02
25. Oil pan

1) Reverse the engine.
2) Apply gasket sealant of 5 mm in diameter
along the entire inside periphery of oil pan
(1) mounting bolt hole and then tighten the
mounting bolt.
2 Mating face: Gasket sealant (LG-7)
23. EGR oil pump

Install the O-ring and EGR oil pump (1).
26. Removal from engine repair stand

2) Lift the engine temporarily.
3) Disconnect tool A1 from tool A2.
4) Remove tool A2 from the engine.

Lift and install damper and pulley assembly (1).
3 Mounting bolt (Width across flat 22 mm,
a single bolt):
157 196 Nm {16 20 kgm}
Mounting bolt (Width across flat 24 mm,
5 bolts):
245 309 Nm {25 31.5 kgm}
125E-5 Series
33
SEN00698-02
27. Setting the engine

Set engine (1) on a rigid and stable stands [1].
29. Installation of cylinder head assembly

1) Check that the cylinder head mounting
face and inside of the cylinder are free
from foreign matter and then set cylinder
head gasket (1).
a When fitting the gasket, check that
the grommets are fitted correctly.
28. Assembly of cylinder head assembly

1) Assemble valve (6).
2 Valve stem: Engine oil (EO30)
2) Raise the cylinder head and then install
lower seat (8) and seal (7).
2)
3)
4)
34
Before tightening the cylinder head

q
is 5.)
q
Min. 171.4 mm
Assemble valve spring (3) and upper

sheet (5).
Using tool C, compress the valve spring
and install valve cotter (4).
a Hit the valve stem lightly with a plastic
hammer to make sure that the valve
cotter is fitted to the groove of the
valve stem.
125E-5 Series
3)
SEN00698-02
Using sling [1], lift and set cylinder head

assembly (2) to the cylinder block.
4)
Tighten the cylinder head assembly

mounting bolts and auxiliary bolts.
1] Tighten the mounting bolts in the
order of 1 to 6 shown in the figure.
2 Mounting bolt:
Molybdenum disulfide lubricant (LM-P) or engine oil
(EO30)
3 Mounting bolt
1st time : 98.1 9.8 Nm {10
1 kgm}
2nd time: 166.6 176.4 Nm
{17 18 kgm}
(Target: 176.4 Nm
{18 kgm})
3rd time : Using tool J, tighten
the bolt by 90 120
(Target: 120).
2]
3]
125E-5 Series
When not using tool J, apply

marking (b) to the cylinder head
and bolt with paint, then tighten
the bolt by 90 120 (Target:
120).
Mark a punch mark (C) on its head to
show the number of tightening times.
Tighten the auxiliary cylinder head

bolt (following figure 7).
3 Auxiliary bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
35
SEN00698-02

1) Install gasket (1) and then install rocker
arm housing (2).
2) Tighten mounting bolts (3).
3 Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
32. Crosshead
1) Set crosshead (1) and then loosen locknut
(2) to return adjustment screw (3) to its
original position.
2) Using your finger, lightly hold down the
crosshead (1) face contacting the rocker
arm to maintain contact between the push
rod side valve stem and crosshead (1).
3) Screw in adjustment screw (3) until crosshead (1) comes in contact with another
valve stem.
4) As they are contacted, further screw in the
adjustment screw by 20 and then tighten
locknut (2) from that state.
2 Crosshead guide and crosshead
top face: Engine oil (EO30)
3 Locknut:
58.7 5.9 Nm {6.0 0.6 kgm}
31. Injector harness connector

1) Install O-ring (4) to harness connector (1).
2 O-ring: Engine oil (EO30)
2) Insert harness connector (1) to rocker
housing (3) and then tighten them with
mounting bolt (2).
3) Fit in harness to holder (3).
36
125E-5 Series
33. Injector
a Check that the inside of the injector sleeve
is free from dirt.
1) Install common rail (9) temporarily.
SEN00698-02
4)
5)
6)
7)
2)
3)
Install gasket (6) and O-rings (7) and (8) to

injector (1).
2 O-ring: Engine oil (EO30)
Insert holder (2) to injector (1). Continue

from that state, insert inlet connector (5) to
the high-pressure pipe insertion hole
through the rocker housing.
125E-5 Series
8)
Fit the ball washer to bolt (3) and tighten

holder (2) temporarily.
Engine oil (EO30)
Locate high-pressure sleeve (4) to inlet
connector (5) and then tighten them temporarily.
a Tighten the common rail side sleeve
nut temporarily, too.
Tighten holder (2) with bolt (3) permanently.
a Tighten bolt (3) while pulling the tube
of the high-pressure pipe in the opposite direction of the injector.
58.8 73.5 Nm {6.0 7.5 kgm}
After tightening the holder, remove the
high-pressure sleeve (4) from the inlet
connector (5) and then install the other
injectors in order according to the above
procedure.
Remove the temporarily installed common
rail.
34. Push rod

Install push rod (1).
a Check that the push rod end is placed in
the cam follower socket.
37
SEN00698-02

1) Set rocker arm and shaft assembly (1).
a When installing the rocker arm shaft,
be sure to set its side with a larger
mounting hole diameter to the bottom
and to direct ball plug (6) side toward
the front side of the engine.
2) Before tightening mounting bolts (4),
check that the ball of adjustment screw (2)
is fitted to socket (5) of the push rod.
a Install the mounting bolt after cleaning
its oil hole.
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}

1) Tighten mounting bolts (3) of the harness
fixing holder.
3 Mounting bolt:
27.0 34.0 Nm {2.8 3.5 kgm}
2) Tighten 2 harness terminal mounting nuts
(2) to injector (1).
a Tighten the nuts alternately.
3 Mounting nut:
2.0 2.4 Nm {0.2 0.24 kgm}
38
37. Adjusting valve clearance

a Adjust the clearance between the crosshead and rocker arm to the following
value.
a Valve clearance (in cold state)
Unit: mm
1)
2)
Intake valve
Exhaust valve
0.33
0.71
Rotate the engine and adjust the valve

clearance of each cylinder in the firing
order of 1 5 3 6 2 4.
Rotate the crankshaft forward and match
stamped line of 1.6 TOP on vibration
damper (1) to pointer (2), watching the
movement of the valve.
Insert clearance gauge l between rocker

arm (3) and crosshead (4) and screw in
adjustment screw (5) until the gauge
becomes movable. Then tighten the locknut.
3 Locknut:
58.8 73.5 Nm {6 7.5 kgm}
125E-5 Series
38. Head cover

Fit the O-ring and install head cover (1).
a Take care so that O-ring may not be twisted.
3 Mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}
SEN00698-02

1) Fit the gasket to oil cooler assembly (4)
and then install them using guide bolt [1].
2)
Install drain hose (3) and brackets (2) and

(1).
39. Air vent tube

Fit a gasket on both sides and then install air
vent tube (2).
3 Joint bolt: 9.8 12.7 Nm {1.0 1.3 kgm}
40. Spill tube
Fit a gasket on both sides and then install spill
tube (1).
3 Joint bolt: 9.8 12.7 Nm {1.0 1.3 kgm}
42. Common rail and overflow tube

1) Install block (4) and then install overflow
tube (3) and spill tube (2).
2) Install common rail (1).
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
125E-5 Series
39
SEN00698-02
43. Installation of high-pressure pipe between

fuel supply pump and common rail
1) Tighten high-pressure pipes (3) and (4) by
hand first, and then tighten them permanently.
3 Sleeve nut
(Pump side):
39.2 49 Nm {4 5 kgm}
(Common rail side):
39.2 58.8 Nm {4 6 kgm}
2) Tighten supply pump mounting bolts (2)
permanently.
3) Tighten the cylinder block side mounting
bolt of bracket (1) permanently.
4) Install the splash prevention cover on both
ends of the high-pressure pipe.
a Face the common rail side slit downward and the supply side slit toward
the cylinder block.
5) Tighten lubrication tube (12) by hand.
6) Tighten and install clamp (10) by hand
first, and then tighten it permanently.
7) Tighten and install brackets (6) and (5) by
8) Tighten and install bracket (8) and clamp
(9) by hand first, and then tighten them
permanently.
3 Clamp (9) mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
11.8 14.7 Nm {1.2 1.5 kgm}
10) Tighten lubrication tube (12) permanently.
3 Joint bolt:
7.9 12.7 Nm {0.8 1.3 kgm}
11) Tighten and install clamp (7) by hand first,
and then tighten it permanently.
11.8 14.7 Nm {1.2 1.5 kgm}
40
125E-5 Series
44. Engine controller cooler

1) Install engine controller cooler (1).
3 Joint bolt:
14.8 19.6 Nm {1.5 2.0 kgm}
2) Install fuel hose (2).
3 Fuel hose:
84 132 Nm {8.5 13.5 kgm}

1) Fit the gasket and then install air intake
manifold (2) temporarily.
4 Air intake manifold: 25 kg
2)
Tighten the mounting bolts in the order of

given below.
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
125E-5 Series
SEN00698-02
3)
Install bracket (1).

1) Fit the gasket and then install diffuser (2)
and air housing assembly (4) temporarily.
2) Fit the gasket and then install front hanger
(3) temporarily.
3) After fixing the front hanger, move air
housing assembly (4) in order to eliminate
clearance in (b) (between front hanger
and air housing) and part (a) (between air
housing and diffuser). Then tighten every
bolt.
4)
5)
Install brackets (5), (6), (7) and (8).

Install oil filler port (9).
41
SEN00698-02
47. EGR valve

1) Install tube (5) with clamp (4) temporarily.
2) Fit the gasket and then install EGR valve
(3) with bolts (2) temporarily.
Step 56. described below.
3) Install oil inlet tube (1).
a Make sure when installing the tube
that it is free from twist or interference.
3 Sleeve nut:
24 27 Nm {2.4 2.7 kgm}
4) Tighten clamp (4).
4)
Install clamps (2) and (1).
49. Bypass tube

1) Fit the gasket and then install bypass tube
(1) temporarily.
2) Adjust the angle between the bypass
valve and bypass tube and then tighten
their mounting bolt permanently.
3 Bypass valve mounting bolt:
59 74 Nm {6 7.5 kgm}
48. Bypass valve

1) Fit the gasket and then install bypass
valve (8) with bolt (7) temporarily.
2) Install oil inlet tube (6).
a Make sure when installing the tube
that it is free from twist or interference.
3 Sleeve nut:
24 27 Nm {2.4 2.7 kgm}
3) Install drain tubes (5) and (4).
a Make sure when installing the tubes
that they are free from twist or interference.
3 Joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
42

a Before installing the high-pressure pipe,
check it for the following defects. If there is
any of these defects, it can cause fuel
leakage. Accordingly, replace the highpressure pipe.
q
Check the taper seal of the connecting
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q
Check part (d) (end of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
125E-5 Series
1)
2)
3)
4)
Install high-pressure pipes (3), (4), (5), (6),

(7) and (8).
a Mounting angle of the high-pressure
injection pipe is adjusted before the
installation of the injector.
3 Sleeve nut (on both sides):
39.2 49 Nm {4 5 kgm}
Tighten bracket (9) and clamp (10) by
3 Mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
Install clamps (11), (12), (13) and (14) by
tightening them by hand.
Install 6 each of the splash prevention
covers (15) and (16).
Direct the slit on the injector side downward and that on the common rail side
toward the cylinder block.
SEN00698-02
5)
6)
Install bracket (17).

3 Clamp tightening torque:
11.8 14.7 Nm {1.2 1.5 kgm}
Tighten clamps (11), (12), (13), and (14)
permanently.
3 Mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
51. Lubrication tube and bracket

1) Install lubrication tube (3).
3 Sleeve nut:
24 27 Nm {2.4 2.7 kgm}
2) Install brackets (1) and (2).
125E-5 Series
43
SEN00698-02
52. Fuel tube

Install fuel tubes (1) and (2) and clamp (3) temporarily.
a Tighten them permanently after installing
the fuel filter.
53. Fuel filter

1) Install fuel filter (4) with the 4 bolts.
2) Tighten permanently above fuel tubes (1)
and (2) and clamp (3) that are currently
temporarily installed.
3 Joint bolt (for both tubes (1) and (2)):
24.5 34.3 Nm {2.5 3.5 kgm}
44
54. Oil filter and oil tube

1) Install oil filter (2) temporarily with the 4
bolts.
2) Install the O-ring and then install oil tube
(1) temporarily.
3) Tighten the bottom flange of oil tube (1)
permanently and then tighten the top
flange permanently.
4) Tighten 4 oil filter (2) mounting bolts permanently.
55. Turbocharger and exhaust manifold assembly

1) Lift turbocharger and exhaust manifold
assembly (1), fit the gasket to the assembly and then install them temporarily.
4 Turbocharger and manifold assembly: 40 kg
2) After tightening bolts (2), (3) and (4), and
then tighten remaining bolts.
3 Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
125E-5 Series
3)
4)
SEN00698-02
Fit the gasket and then connect lubrication

tube (2).
Fit the gasket and then connect EGR
bypass tube (1).
4)
5)
6)
56. EGR tube
1) Fit the gasket, adjust its angle to the EGR
valve and then install EGR tube (5) temporarily.
2) Tighten EGR tube mounting bolt (4) and
EGR valve mounting bolt.
3 EGR valve mounting bolt:
59 74 Nm {6 7.5 kgm}
3) Fit the gasket and then install EGR gas
pressure sensor tube (3).
4) Install clamps (2) and (1).
7)
Install air vent tube (4).

Fit the gasket and O-ring, and then install
coolant tube (3).
Fit the gasket and install exhaust gas discharge tube (2).
3 Mounting bolt:
59 74 Nm {6.0 7.5 kgm}
Fit the gasket and install drain tube (1).
58. Water pump suction tube

Fit the gasket and install tube (1).
57. EGR cooler

1) Install EGR cooler (9) with the 4 bolts.
2) Fit the gasket and then connect EGR tube
(7).
a Clamp (8) is to be tightened together.
3) Fit the O-ring, install coolant tube (6) and
then tighten the clamp of rubber hose (5).
125E-5 Series
45
SEN00698-02
59. Alternator
1) Hang V-belt on the pulley of alternator (5)
and tighten mounting bolt (2) and lock bolt
(3) temporarily.
2) Adjust the belt tension with V-belt tension
adjustment nut and tighten mounting bolt
(2) and lock bolt (3).
3) Check the belt tension and then tighten
locknut (4).
4) Install cover (1).
60. Starting motor

Set starting motor (2) and then tighten 3
mounting bolts (1).
61. Heat shielding plate

Install the heat shielding plate to EGR and
EGR pipe.
62. Harness assembly
Locate the harness in the specified position,
connect the harness connectors to the specified counterparts and then fix them using the
clamp.
46
63. Tightening torque for sensor

Use the following tightening torque when
removal and installation or replacement of the
sensor.
Sensor name
Fuel
temperature
Tightening torque
23 3 Nm {2.35 0.3 kgm}
Boost pressure 5.5 0.5 Nm {0.56 0.05 kgm}

Intake air
temperature
23 3 Nm {2.35 0.3 kgm}
Coolant
temperature
23 3 Nm {2.35 0.3 kgm}
EGR gas
pressure
23 3 Nm {2.35 0.3 kgm}
Engine oil
pressure
23 3 Nm {2.35 0.3 kgm}
Atmospheric
pressure
4.5 0.5 Nm {0.46 0.05 kgm}

(Hexagonal head bolt and hexagonal socket head bolt)
Fuel pressure
Never disassemble.
64. Checking for fuel leakage

a If fuel supply pump (2), common rail (1), or
high-pressure pipe is removed and
installed, after assembling the engine,
check for fuel leakage according to the following procedure.
1)
2)
Clean and degrease the engine and the

parts around it in advance so that you can
test it easily for fuel leakage.
Spray color checker (developer) over the
fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
125E-5 Series
3)
4)
5)
6)
7)
8)
9)
SEN00698-02
Check the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
leakage.
leakage.
a When checking while the components
to be checked are mounted on the
relieve the hydraulic pump.
leakage.
a If no fuel leakage is detected, check
is completed.
125E-5 Series
47
SEN00698-02

2008 KOMATSU
All Rights Reserved
48
SEN00699-03
ENGINE
1SHOP MANUAL
125E-5 Series

(EGR-less)
Disassembly and assembly, Part 2 (EGR-less) .............................................................................................. 2
General disassembly of engine............................................................................................................ 2
General assembly of engine .............................................................................................................. 16
125E-5 Series
SEN00699-03
Disassembly and assembly, Part 2 (EGR-less)

General disassembly of engine 1
a

Take care.
1.
Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean it
generally and carefully for accurate inspection
of its parts and quick disassembly and assembly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.
2.
Setting engine assembly

1) Place engine assembly (1) on stable block
[1] so that it will not tip over.
a The weight depends on each applicable machine.
4
2)
4.
Wiring harness assembly

Disconnect the connectors and clamps and
remove wiring harness assembly (1).
5.
Starting motor assembly

Remove 3 mounting bolts (1) and starting
motor assembly (2).
Engine assembly: 1,250 kg
Drain the engine coolant and engine oil.

a The quantity of the engine oil
depends on each applicable machine.
6
3.
Engine oil: Approx. 40 l
Muffler, air cleaner and related parts

a These parts depend on each applicable
machine.
Remove the muffler, air cleaner and related
parts.
125E-5 Series
6.
SEN00699-03
Alternator assembly
2) Loosen alternator mounting bolt (2) and
fixing bolt (3).
3) Remove nut (4), loosen the locknut, lower
the belt tension with the tension adjustment nut, and remove V-belt (5).
4) Remove mounting bolt (2), fixing bolt (3)
and alternator assembly (6).
5) Remove plate (7) and bracket (8).
a These parts depend on each applicable
machine.
9.
Exhaust manifold assembly

Sling exhaust manifold assembly (1), remove
18 mounting bolts (2), and remove the exhaust
manifold assembly.
4
7.
Exhaust manifold assembly: 35 kg
Water pump suction tube

Remove tube (1).
10. Thermostat housing assembly

1) Remove connector (1).
2) Remove thermostat housing assembly (2).
8.
Turbocharger assembly
2) Remove the 5 clamps and turbocharger
lubricating oil inlet tube (2).
3) Remove the tube bracket and turbocharger outlet tube (3).
4) Remove 4 mounting bolts (4) and turbocharger assembly (5).
125E-5 Series
SEN00699-03

1) Remove connector (1).
2) Remove 3 mounting bolts (2) and water
pump assembly (3).
14. Fuel filters

2) Remove the joint bolt and tubes (2) and
(3).
3) Remove the joint bolt and hose (4).
4) Remove the 2 clamps, joint bolt and tube
(5).
5) Remove clamp (6), joint bolt and tubes (7)
and (8).
6) Remove fuel filters (9) and (10).

Remove the mounting bolts and then remove
oil cooler assembly (1), using guide bolts.
15. Brackets
Remove brackets (1), (2), (3), (4), (5), (6) and
(7).
13. Oil filter

1) Disconnect clamp (1).
2) Remove oil tubes (2) and (3).
3) Remove oil filter (4).
125E-5 Series
16. Engine controller cooler assembly and

block
1) Remove the 5 mounting bolts and engine
controller cooler assembly (1).
2) Remove the joint bolt and tubes (2) and
(3).
3) Remove block (4).
17. Electric priming pump and block

a Electric priming pump is not set for some
models.
1) Disconnect wiring harness connector (1).
2) Remove the joint bolt and hoses (2) and
(3).
3) Remove the joint bolt and tube (4).
4) Remove the joint bolt, loosen the sleeve
nut, and remove tube (5).
5) Remove Electric priming pump (6).
6) Remove block (7).
SEN00699-03
18. Bracket
1) Remove wiring harness (1).
2) Remove brackets (2) and (3).
19. Air connector, electrical intake air heater

and front hanger
1) Remove the 6 mounting bolts, air connector (1) and electrical intake air heater (2).
2) Remove plates (3) and (4).
3) Remove front hanger (5).
20. Diffuser air housing assembly

Remove the 8 mounting bolts and lift off diffuser and air housing assembly (1).
4
125E-5 Series
Diffuser and air housing assembly: 40 kg
SEN00699-03
21. Bracket
1) Remove the 2 mounting bolts and bracket
(1).
(2).
22. Spill pipe

Remove 6 joint bolts (1) and spill pipe (2).

1) Remove high-pressure pipe clamp mounting bolt (1).
(2).
3)
4)
5)
6)
7)
Remove high-pressure pipe clamp (3).

Remove 10 high-pressure pipe clamps
(4).
Remove 6 brackets (5).
Remove the pin, 6 splash prevention covers (6) on the injector side and 6 splash
prevention covers (7) on the common rail
side.
Remove 6 high-pressure pipes (8).
125E-5 Series

Sling air intake manifold (1), remove the 24
mounting bolts, and remove the air intake manifold.
4
Air intake manifold: 40 kg
25. Common rail

1) Remove the pin, 2 splash prevention covers (1) on the common rail side and 2
splash prevention covers (2) on the fuel
supply pump side.
2) Remove high-pressure pipe clamps (3),
(4), (5) and (6) and high-pressure pipes
(7) and (8).
3) Remove the joint bolt and tube (9).
4) Remove common rail (10).
(11).
125E-5 Series
SEN00699-03

2) Rotate the crankshaft forward and set
intermediate point (a) between stamped
2/5 TOP and 3/4 TOP on damper (2) to
pointer (3) (stamped 1/6 TOP comes
almost directly under).
a Make sure at this point that the forcing tap of the drive gear is aligned to
the bolt hole at the top of cover (1).
(If not, rotate the crankshaft 1 more
turn.)
a At this point, the key of the shaft is
turned clockwise by 15 from the top.
3)

washer (5).
a Use a magnet or the like in this operation so that washer (5) may not be
inadvertently dropped into the case.
SEN00699-03
4)
5)
6)
Remove pump mounting bolts (6) and

bracket (7).
threads to prevent the pump from falling down.
Install tool P1 with P2 and P3 and then
screw in the center bolt of P1 to remove
the gear from the shaft.
Remove remaining bolts and then remove
fuel supply pump assembly (8).
a Leave tools P1, P2 and P3 in the
installed condition.

1) Fully loosen 2 wiring harness terminal
mounting nuts (2) on the head of injector
(1).
a Loosen nuts alternately.
2) Loosen bolt (3) of harness fixing holder.

1) Loosen locknut (3) and adjustment screw
(2).
2) Remove mounting bolts (4) and rocker
arm and shaft assembly (1).
27. Tube and head cover

1) Remove 6 joint bolts (1) and tube (2).
2) Remove the mounting bolts and head covers (3).
30. Push rods

Remove 12 push rods (1).
125E-5 Series
31. Injector
Remove holder mounting bolts (3) of injector
(1) and then remove injector (1) and holder (2)
together.
a Never hold the solenoid valve at the top of
the injector with pliers, etc.
32. Crosshead
Remove 12 crossheads (1).

1) Remove mounting bolt (2) of wiring harness connector (1).
2) Remove holder (3) from the wiring harness.
125E-5 Series
SEN00699-03
3)
4)
Press out wiring harness connector (1)

from inside of rocker housing (4) to
remove it.
Remove O-ring (5) from the rocker housing.

Remove rocker arm housing (1).

1) Remove 3 cam follower covers (1).
2) Remove oil level gauge tube (2).
SEN00699-03
36. Cam follower

Remove 12 mounting bolts (1) and 6 cam followers (2).
a Remove dowel pin (3).
37. Removal of cylinder head assembly

1) Remove 7 mounting bolts (2) each from
cylinder head assembly (1).
2) Using eyebolts [1], lift off cylinder head
assembly (1).
3)
38. Disassembly of cylinder head assembly

1) Using tool C, compress valve spring (3)
and remove valve cotter (4).
2) Remove upper seat (5) and valve spring
(3).
3)
4)
Remove seal (7) and lower seat (8).

Raise the cylinder head and remove valve
(6).
a Make marks for combinations of the
valves and heads.
Remove each head gasket.
39. Setting to engine repair stand

Sling the engine, install tool A2, and set the
engine while matching tool A2 to tool A1.
10
125E-5 Series
40. Oil pan

Reverse the engine and remove oil pan (1).
SEN00699-03

1) Install slings [1] to the right and left of
housing (1) and sling the housing.
2) Remove the 10 mounting bolts, remove
the housing from the dowel pins, and lift it
off.
4
Flywheel housing: 80 kg
41. Speed sensors

Reverse the engine and remove speed sensors (1) and (2).
a Speed sensor (2) may not be installed,
depending on each applicable machine.
Sling damper and pulley assembly (1), remove
the 6 mounting bolts, and lift off the assembly.
4 Damper and pulley assembly: 25 kg
42. Flywheel
1) Install sling [1] to flywheel (1) and lift it up.
2) Remove the 6 mounting bolts, remove the
flywheel from the dowel pins, and lift it off.
4
125E-5 Series
Flywheel: 25 kg
11
SEN00699-03
45. Front support and front cover

1) Sling front support (1), remove the mounting bolts, and lift off the front support.
a The shape depends on the applicable
machine.
2) Sling front cover (2), remove the mounting
bolts, and lift off the front cover.
3) Remove tool P and supply pump drive
gear.
47. Oil pump

Remove 4 mounting bolts (1) and then remove
oil pump (2).
48. Idler gear

1) Remove mounting bolt (1) and then remove
plate (2) and oil pump idler gear (3).
2) Remove shaft (4).
3) Remove mounting bolt (5) and then
remove shaft (6), main idler gear (7) and
plate (8).
46. Camshaft
1) Remove 2 mounting bolts (1).
2) Remove camshaft (2).
a When pulling out the camshaft, turn it
gently so that damages may not be
left on the cam bushing.
12
125E-5 Series
49. Oil suction pipe

Remove brackets (1) and then remove oil suction pipe (2).

Remove mounting bolt (1) and each piston
cooling nozzle (2).
SEN00699-03
51. Piston and connecting rod assembly

a Before removing the piston and connecting rod assembly, measure its end play
with dial gauge [3], if necessary.
1)
2)
3)
4)
5)
125E-5 Series
Check the stamped No. of the connecting

rod cap.
q
The cap No. and cylinder No. must be
the same.
q
The cap No. must be stamped on the
cam side.
a If the No. is not stamped, stamp it
before removing the connecting rod.
Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
Scrub the carbon off the top wall of the cylinder liner with fine sandpaper.
Remove connecting rod cap mounting
bolts (1).
Hit connecting rod cap (2) with a plastic
hammer so lightly that the threads of the
connecting rod bolts will not be damaged
and remove connecting rod cap (2) and
connecting rod bearing as a unit.
13
SEN00699-03
6)
7)
Push in and remove the piston and connecting rod assembly with a wood bar, etc.
from the oil pan side, while supporting piston (3) on the cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the connecting rod.
Remove the other piston and connecting
rod assemblies according to the above
procedure.
a Take care not to damage the sliding
portions of the pistons and bearings.
a Assemble each connecting rod and
cap temporarily so that they will not
be assembled with other ones and
keep them and the bearing together.
3]
Using tool D, remove piston ring (8).

a Keep the piston, connecting rod,
connecting rod bearing, piston
rings, and piston pin by each cylinder.
52. Crankshaft
a Before removing the crankshaft, measure its
end play with dial gauge [3], if necessary.
8)
14
Disassemble the piston and connecting

rod assembly according to the following
procedure.
1] Remove 2 snap rings (4).
2] While supporting connecting rod (5),
remove piston pin (6) to disconnect
piston (7) and connecting rod.
1)
2)
Remove mounting bolts (2) of main cap (1).

Insert the bolts in the bolt holes of the
main cap and remove the cap, while shaking it.
125E-5 Series

a
3)
4)
Thrust bearing (3) is assembled to

No. 7 main cap. After removing the
cap, apply a marking to the re-assembly position.
Lift off crankshaft (4).

a When removing the crankshaft, take
care so that its sliding surfaces may
not be damaged.
SEN00699-03
5)
Remove upper bearing (6).

a Apply a marking to the assembly
positions of the main cap, main bearing, and thrust bearing. And store
them by the journal No.
53. Cylinder liner

Using tool E, pull out cylinder (1).
a Before removing the cylinder liner, measure its projection with dial gauge [3], if
necessary.
Remove upper thrust bearing (5).
125E-5 Series
15
SEN00699-03
General assembly of engine

a
a
2]

Take care.
Clean each part carefully, and check it for
bruise, flaw, cavity, etc. Make sure each oil or
coolant path is through.
3]
Tightening bolts by plastic-region turning angle

method
a Bolts tightened by plastic-region turning angle
method
q
Cylinder head mounting bolt
q
Main cap mounting bolt
q
Connecting rod cap mounting bolt
a If the plastic-region turning angle method is
applied, the tightened bolts have permanent
strain. Accordingly, the allowable number of
using times of each bolt is limited. Observe the
following precautions.
q
Before tightening each bolt, measure its
stem length and make sure that the length
is less than the using limit. If the stem is
longer than the using limit, it should not be
used but replaced.
q
Check each mounting bolt head for punch
marks. If there are punch marks more than
the specified numbers, replace the bolt.
1.
Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 320 kg
2)
16
Before inserting the cylinder liners, prepare the cylinder block according to the
1] Remove the rust and scales from faces
(A) and (B) with sandpaper, etc. until
the machined surfaces are exposed.
4]
5]
2.
Polish part (R) with sandpaper of

about No. 240 until it becomes a
smooth rounded surface.
If part (R) is sharp or has burrs, finish
it with a scraper or sandpaper.
Finish this surface particularly smoothly
so that it will not damage the O-ring.
If face (B) is so pitted that it cannot be
repaired, replace the cylinder block.
If faces (A) and (R) are pitted, finish
them smoothly.
Check the counterbored part and
remove burrs. If chips or dust is
present on face (C), the liner may not
fit well, resulting in coolant leakage or
insufficient liner protrusion. Thus,
they must be eliminated.
a If the counterbored part is drooping, corroded, or pitted, repair it.
Cylinder liner
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not roughened
because of rusting or pitting. If those parts
are roughened, replace the cylinder liner.
2) Install clevis seal (1), O-rings (2) and (3) to
the cylinder liner.
a Check that there is not a burr, dust,
etc. in the groove of the liner.
a Replace the O-ring and clevis seal
with new ones.
a Fit the clevis seal with the chamfered
side down. When fitting it, press it
against the seal groove all round so
that it will not be twisted.
a When installing O-rings (2) and (3),
refer to the following.
q
O-ring (2): The whole ring is black.
q
O-ring (3): The whole ring is red.
2 Clevis seal and O-ring:
Rubber lubricant (LH-50 from NOF
Corporation)
125E-5 Series

a
a
If LH-50 is not available, apply clean

engine oil SAE No. 30.
Since the clevis seal and O-ring are
swollen and deteriorated by oil, apply
a small amount of oil to them thinly
with a brush just before fitting them.
SEN00699-03
4)
Apply gasket sealant to the parts of the

cylinder block and cylinder liner which will
fit to the counterboared parts.
a Wipe off dirt and oil with cloth from
the contact faces of the counterboared parts of the cylinder block and
liner flange.
2 Cylinder block: Gasket sealant (LG-6)
q
Gasket sealant:
0.8 1.6 mm in diameter
q
Overlap (a) of gasket sealant: 6 6 mm
a If the applied gasket sealant is left for a
long time, its surface becomes hard.
Accordingly, install the cylinder block to
the cylinder head within 50 minutes.
5)
Insert cylinder liner (1) to the cylinder block.

a Insert cylinder liner (1) in the cylinder
block slowly, taking care not to damage the O-ring.
Push in cylinder liner (1) further by both
hands.
a If the liner does not enter the cylinder
smoothly, the O-ring may be damaged. In this case, check the cylinder
block for burrs.
Using tool F, press fit cylinder liner (1) to
the cylinder block.
6)
3)
After fitting the O-ring, check it for twist. If

it is twisted, correct it with a flexible rod
(about 10 mm in diameter).
7)
125E-5 Series
17
SEN00699-03
8)
To prevent the gasket sealant from projecting through the clearance between the
block and liner after the cylinder head is
tightened, tighten the cylinder head temporarily with the used head gasket
inserted.
a At this time, observe the following tightening torque and tightening order.
3 Temporary tightening torque:
127.5 147.1 Nm {13 15 kgm}
9)
Remove the cylinder head and wipe off

the gasket sealant projected from the
counterbored part.
a Be sure to perform steps 8) and 9)
above since the projected gasket
sealant can deform the grommet of
the head gasket.
3.
Crankshaft
a Cylinder block and main bearing are
selective mating parts and the prepared
spare parts ensure the required clearance.
1) Install the upper main bearing (6) to the
notch of the cylinder block while aligning
2 Bearing inner surface:
Engine oil (EO30-DH)
2)
Drive in the roll pin so that its projection

from the block end face may become 1.5
1.9 mm and then install upper side thrust
bearing (5).
3)
Before assembling the crankshaft, check

the following.
q
Troubles on the front side and rear
side threaded portions
(Bottom can be easily screwed in by
hand)
q
Scratches or dents on pin and main
journal
q
Presence or absence of dust inside
oil hole
10) Using dial gauge [3], measure the projection of the cylinder liner.
a When measuring projection of the
liner, fix the liner using a plate so that
it may not be lifted by the O-ring.
a Projection of cylinder liner:
0.07 0.15 mm
18
125E-5 Series
4)
5)
Lift and set crankshaft (4) to the mounting

position.
a When installing the crankshaft, take
care not to damage its sliding surfaces by, for in stance, bumping
against the cylinder block.
a When replacing the crank gear, heat it
with a bearing heater set at 150C
and then fit it immediately after the
heating.
2 Cylinder block journal:
SEN00699-03
6)
Install main cap (1).

a When installing, make sure that the
stamped No. at center of the main
cap is aligned to the stamped journal
No. of the cylinder block.
a Install the main cap with the cast letter (F) toward the front of the engine.
2 Crankshaft journal surface:
7)
Before tightening the main cap mounting

bolts, check the following items. If any of
the following conditions applies, do not
reuse that bolt but replace it.
q
is 5.)
q
Min. 159.8 mm
Install lower main bearing (7) to the main

cap.
a Install lower main bearing (7) to the
notch of the main cap while aligning
a Drive the roll pin of cap No. 7 so that it
will be projected by 1.5 1.9 mm from
the cap end and then install thrust
bearings (3) to both sides.
8)
Screw in main cap mounting bolts (2)

alternately until the main cap (1) is
securely fitted in its place.
9) Tighten main cap mounting bolts (2)
a Tighten the bolts from the center one
to the outer ones in order.
2 Threaded portion of mounting bolt and washer:
125E-5 Series
19
SEN00699-03
3
Mounting bolt
1st time : 98.1 9.8 Nm {10 1 kgm}
2nd time : 196.1 4.9 Nm {20 0.5 kgm}
3rd time : Using tool J, tighten the bolt by
90 (+30/0).
4.
When not using tool J, apply mark (b)

to the main cap and bolt with paint,
then tighten the bolt by 90 (+30/0).
10) Make punch mark (c) on the mounting bolt
head.
11) Check that the crankshaft turns smoothly.

12) Measure the end play of the crankshaft
with dial gauge [3].
a End play: 0.14 0.315 mm
20
Piston and connecting rod assembly

a Piston and cylinder liner are selective mating parts and the prepared spare parts
ensure the required clearance.
1) Using tool D, assemble piston ring (8) in
the order of oil ring, second ring and top
ring starting from the bottom.
a Fit the top ring and second ring to the
piston with the stamped mark side up.
q
Stamp on top ring: 1R
q
Stamp on second ring: 2R
a Take the expander out of the oil ring
and fit it to the piston first and then fit
the oil ring. At this time, make sure
that the expander is fitted to the ring
groove perfectly.
2)
Set the abutment joint of each piston ring

as shown in the following figure.
a Adjust oil ring so that the joint of the
expander will be at 180 to the abutment joint of the oil ring.
125E-5 Series
3)
4)
Install snap ring (4) to one side of piston (7).

Heat piston (7) at 100C for 5 minutes
minimum in the heating furnace.
a When the furnace is not available,
heat it at 100C for 5 minutes minimum in hot water.
Set connecting rod (5) on piston (7).

a Set the connecting rod so that the ID
marking "6251" at the bottom of the
connecting rod comes to the left side
as the grade marking on the piston
top surface is faced toward the front
side of the engine. Then insert the
connecting rod to piston pin (6).
2 Piston boss: Engine oil (EO30-DH)
6) Install snap ring (4) on the opposite side.
a Turn the snap ring on both sides to
make sure they are securely fitted to
the ring groove.
SEN00699-03
7)
Install upper main bearing (8) to the notch

of the connecting rod while aligning the
bearing projection to it.
a Make sure that the bearing hole and
connecting rod oil hole are aligned.
8)
Install the connecting rod lower bearing

(9) to the notch of the connecting rod cap
while aligning the bearing projection to it.
5)
125E-5 Series
21
SEN00699-03
9)
Set the cylinder crankshaft, to which the piston and connecting rod assembly is to be
assembled, to the bottom dead center.
10) Insert piston and connecting rod assembly
(3) in the cylinder block so that ID marking
"6251" of the connecting rod may be faced
toward the left side face of the engine.
a Make sure the abutment joint of the
piston ring is located in the position
indicated in the following figure.
2 Inner surface of connecting rod and
cylinder: Engine oil (EO30-DH)
11) Using tool G, reduce the piston ring and

then push in the piston head with a wood
bar, etc.
22
12) Install connecting rod cap (2).

a Align match mark of connecting rod
(5 ) and connecting ro d cap (2).
(Above aligns the match mark to ID
marking "6251" on the opposite side.)
2 Inner surface of connecting rod cap
bearing: Engine oil (EO30-DH)
13) Before tightening the connecting rod cap

q
is 5.)
q
Length (a) of bolt stem: Min. 84.1 mm
125E-5 Series
SEN00699-03

alternately until the connecting rod cap is
closely contacted.
(1) according to the following procedure.
3 Mounting bolt
1st time : 98.1 4.9 Nm {10 0.5 kgm}
2nd time : Using tool J, tighten the
bolt by 90 (+30/0).
19) Set the dial gauge on tool H and then

measure the projection of the piston top
surface from the top face of the cylinder
block.
a Piston projection: 0.984 1.335 mm
a Prior to the measurement, push the
piston top surface to eliminate the oil
clearance.
a
When not using tool J, apply marking

(b) to the connecting rod, cap and
bolt with paint, then tighten the bolt by
90 (+30/0).
16) After tightening the bolt, make a punch
mark (C) on its head.
5.
17) Turn the crankshaft to check that it rotates

normally.
18) Measure the side clearance of the connecting rod with dial gauge [3].
a Side clearance: 0.2 0.375 mm
125E-5 Series

1) Rotate the crankshaft and set the No. 1
No. 3 pistons to the following positions for
installation of the piston cooling nozzles of
each piston.
q
q
q
piston can be installed.
2) Set piston cooling nozzle (2) adjusting the
dowel pin position and then tighten mounting bolt (1).
3 Mounting bolt:
27 34 Nm {2.8 3.5 kgm}
23
SEN00699-03
a
6.
After the installation, make sure the

nozzle end is situated at center of the
cut of respective pistons.
Oil suction pipe

Install oil suction pipe (2) after attaching the Oring to it and then fix them using bracket (1).
8.
7.
24
Oil pump
1) Install oil pump (2) after attaching the Oring to it and then tighten 4 mounting bolts
(1).
2) Drive in the pin and then install shaft (4).
Idler gear
1) Install plate (8) to the engine block and then
install main idler gear (7) and shaft (6).
a When installing plate (8), set its
chamfered side to the front side of the
engine.
2) Matching A mark of the crankshaft gear
and A mark of main idler gear (7),
3 Mounting bolt:
245 294 Nm {25 30 kgm}
125E-5 Series
9.
SEN00699-03
Idler gear
Assemble oil pump idler gear (3), attach plate
(2) to it and then tighten them using mounting
bolt (1).
3 Mounting bolt:
147 176.4 Nm {15 18 kgm}
11. Cam follower

1) Drive in dowel ring (3) to the cylinder block.
2) Tighten 6 cam followers (2) using mounting bolt (1).
3 Mounting bolt:
44 59 Nm {4.5 6 kgm}
10. Camshaft
1) Assemble camshaft (2) to the cylinder
block.
a Rotate the camshaft when assembling so that the cam bushing may not
be damaged.
a When replacing the cam gear, heat it
at 200 240C for 30 minutes minimum in an electronic oven and then
shrink fit it.
2 Camshaft journal surface:
2) Matching B mark of the crankshaft gear
and B mark of the main idler gear,

Install the O-ring and cam follower cover (1).
3 Mounting bolt:
9.8 12.7 Nm {1.0 1.3 kgm}

Fit the O-ring to water pump assembly (3) and
install them temporarily.
125E-5 Series
25
SEN00699-03

1) Set fuel supply pump assembly (3) and
then tighten it temporarily using 4 mounting bolts (5).
2 Mounting bolt: Adhesive (LT-2)
2) Set the assembly by aligning C mark to
C mark of camshaft gear (2) while aligning the key groove of supply pump drive
gear (1) to the woodruff key of the shaft.
3) Fit the washer and then tighten them
using gear mounting nut (4).
3 Gear mounting nut:
127 147 Nm {13 15 kgm}
3 Mounting bolt (supply pump side):
19.6 29.4 Nm {2.0 3.0 kgm}
a Leave the cylinder block side mounting bolt in temporarily tightened state
(it is to be tightened permanently in
the following Step 39.).
15. Make sure that match marks (A to C) of drive

gears and idler gears are matched.
16. Measuring backlash and end play

a Measure the backlash and end play of
each gear with dial gauge [3].
Standard backlash of each gear
Position
Range (mm)
0.105 0.325
0.105 0.325
0.116 0.359
0.105 0.337
0.082 0.389
0.076 0.366
Standard end play of each gear
26
Position
Range (mm)
0.05 0.17
0.05 0.21
If the end play is out of the standard, correct it. For details, see Structure, function
and maintenance standard.
125E-5 Series
SEN00699-03
2)
3)
4)
5)
17. Front cover

1) Using the push tool (outside diameter 120
mm), press fit oil seal (5) to the cover.
a Oil seal press fit allowance (a):
16 (+1/0) mm
2 Oil seal lip (50 80% of void lip
space): Grease (G2-LI)

1) Apply a string of gasket sealant 1 mm in
diameter as shown below.
2)
3)
125E-5 Series
Lift front cover (2) and then install it using

the guide bolt.
a When installing, take care not to damage the oil seal.
2 Front cover mounting surface:
Install cover (3).
Using dial gauge, measure the level difference between underside faces of the cylinder block and front cover.
Install front support (1).
machines.
Sling flywheel housing (1) and then install

it to the cylinder block.
Tighten flywheel housing mounting bolts (2).
27
SEN00699-03
a
a
Tighten the flywheel housing mounting bolts in the following order in 2

steps.
a The following indicates that mounting
bolts 1, 4 and 2, 9 are to be tightened
twice in 1st time.
2 Mounting bolt: Engine oil (EO30DH)
3 Mounting bolt:
1st time:
147 235 Nm {15 24 kgm}
2nd time:
245 309 Nm {25 31.5 kgm}
4)
After installing the flywheel housing, measure its facial runout and radial runout with
dial gauge [3].
imum on the flywheel housing including the periphery.

Move the crankshaft either in the front
or rear side in order to prevent errors
due to the end play.
Make sure after rotating the crankshaft by a turn that the gauge pointer
is returned to the position where it
had been situated when the crankshaft was started to turn.
The gauge pointer deflects in both
sides right and left. Thus, reasonable care must be exercised to avoid
misreading of the pointer when the
gauge is provided in the top, bottom,
left and right side of the measured
end face.
Facial runout: Max. 0.20 mm
Measurement of radial runout of flywheel

housing
Like in measurement of the facial runout, set
dial gauge [3] so that its probe may contact
against the flywheel housing centering location
at a right angle.
a In measurement of radial runout, errors
due to end play of the crankshaft do not
occur. As for other points, however, the
precautions noted for the facial runout
remain applicable to the radial runout
as they are.
Measurement of facial runout of flywheel

housing
1] Apply the magnet stand to the crankshaft end face.
2] Set dial gauge [3] so that its probe
may contact against the flywheel
housing end face at a right angle.
3] Rotate the crankshaft by a turn to
read the difference between the maximum and minimum values indicated
by the gauge pointer.
a Measurement shall be conducted at
eight equally distanced positions min-
28
125E-5 Series
5)
Using dial gauge [3], measure the level

difference between underside faces of the
cylinder block and flywheel housing.
SEN00699-03
a
1)
Never remove inside plastic cylinder

(3) of the standard spare seal before
installing the seal.
Set the large inside diameter side (b)
of plastic inside cylinder (3) to the end
of crankshaft (4).
a Take care not to mistake the direction of the plastic inside cylinder.
19. Rear oil seal

a Check the Teflon seal (Laydown lip seal)
by checking the wear of the crankshaft
and replace it with the Standard seal or
Sleeved seal.
a If the crankshaft is worn to the degree of
luster (If wear which you feel with your finger is less than 10 mm) and does not have
any flaw, install the standard seal. In other
cases, install the sleeved seal.
a The left one in the following figure is the
standard seal and the right one is the
sleeved seal.
2)
3)

After pushing in the seal, remove
plastic inside cylinder (3).
a When removing the inside cylinder, take care not to damage the
seal lip.

a Before installing the seal, check that
the end corners and lip sliding surfaces of crankshaft (4) are free from
flaw, burr, and rust of the housing.
oil or grease to the shaft and seal lip
(a). Wipe off the oil from the shaft.
125E-5 Series
29
SEN00699-03
4)

fit seal (1) until the end of tool N1 reaches
the end of crankshaft (4).
a First tighten tool N1 until it is contacted
against bolt N3 (bolt stem 45 mm) and
then further tighten the tool with bolt N4
(bolt stem 25 mm).

a Before installing the seal, make sure
that the end corners and lip sliding surfaces of crankshaft (4) are free from
flaws, burrs, and rusts of the housing.
oil or grease to the shaft, sleeve (1),
and seal lip (a). Wipe off the oil from
the shaft.
a Handle the seal and sleeve as an
assembly and don't separate them
from each other.
1)
30
2)
Set the sleeve of the seal to the end

of the crankshaft, and then tighten
bolt N3 evenly to press fit sleeve and
seal assembly (2) until the end face of
tool N2 reaches the end of crankshaft
(4).
3)
Remove tool N2 and then replace it

with tool N1.
Tighten bolt N4 evenly to press fit
sleeve and seal assembly (2) until the
end face of tool N1 reaches the end
of crankshaft (4).
a After press fitting the seal, remove
the red sealant layer from its
periphery.
4)
Set sleeve and seal assembly (2) to

tool N2.
2 Inside sleeve:
125E-5 Series
SEN00699-03
20. Flywheel
1) Using sling [1], lift up flywheel (1) and then
install it aligning to the dowel pin.
2) Tighten mounting bolts (2) in the following
order in 2 steps.
2 Mounting bolt: Engine oil (EO30DH)
3 Mounting bolt
1st time:
147 19.6 Nm {15 2.0 kgm}
2nd time:
289.1 19.6 Nm {29.5 2.0 kgm}
3)
Using dial gauge [3], measure the facial

and radial runout.
a Facial runout : Max. 0.20 mm
125E-5 Series
21. Speed sensor

a Before installing the sensor, make sure its
tip is free from steel chips or flaws.
3 Mounting bolt:
4.9 7.9 Nm {0.5 0.8 kgm}
1] Screw in speed sensor (2) until its tip
lightly touches the tooth tip of ring
gear (3).
2 Threads:Gasket sealant
(Hydraulic sealant
from Loctite)
2] Rotate speed sensor (2) in the opposite direction by 1/2 2/3 turns.
a Clearance (a) will become 0.75
1 mm.
3] Tighten nut (4) while fixing sensor (2).
3 Nut: 69 74 Nm {7 7.5 kgm}
31
SEN00699-03
23. Oil pan

2) Apply gasket sealant of 5 mm in diameter
along the entire inside periphery of oil pan
(1) mounting bolt hole and then tighten the
mounting bolt.
2 Mating face: Gasket sealant (LG-7)
24. Removal from engine repair stand

2) Disconnect tool A1 from tool A2.
3) Remove tool A2 from the engine.

Lift and install damper and pulley assembly (1).
3 Mounting bolt (Width across flat 22 mm,
a single bolt):
157 196 Nm {16 20 kgm}
Mounting bolt (Width across flat 24 mm,
5 bolts):
245 309 Nm {25 31.5 kgm}
25. Setting the engine

Set engine (1) on a rigid and stable stands [1].
32
125E-5 Series
26. Assembly of cylinder head assembly

1) Assemble valve (6).
2 Valve stem: Engine oil (EO30-DH)
2) Raise the cylinder head and then install
lower seat (8) and seal (7).
3)
4)
Assemble valve spring (3) and upper

sheet (5).
Using tool C, compress the valve spring
and install valve cotter (4).
a Hit the valve stem lightly with a plastic
hammer to make sure that the valve
cotter is fitted to the groove of the
valve stem.
125E-5 Series
SEN00699-03
27. Installation of cylinder head assembly

1) Check that the cylinder head mounting
face and inside of the cylinder are free
from foreign matter and then set cylinder
head gasket (1).
a When fitting the gasket, check that
the grommets are fitted correctly.
2)
Before tightening the cylinder head

q
is 5.)
q
Min. 171.4 mm
33
SEN00699-03
3)
Using sling [1], lift and set cylinder head

assembly (2) to the cylinder block.
4)
Tighten the cylinder head assembly

mounting bolts and auxiliary bolts.
1] Tighten the mounting bolts in the
order of 1 to 6 shown in the figure.
2 Mounting bolt:
Molybdenum disulfide lubricant (LM-P) or engine oil
(EO30-DH)
3 Mounting bolt
1st time : 98.1 9.8 Nm {10
1 kgm}
2nd time: 166.6 176.4 Nm
{17 18 kgm}
(Target: 176.4 Nm
{18 kgm})
3rd time : Using tool J, tighten
the bolt by 90 120
(Target: 120).
2]
3]
34
When not using tool J, apply

marking (b) to the cylinder head
and bolt with paint, then tighten
the bolt by 90 120 (Target:
120).
Mark a punch mark (C) on its head to
show the number of tightening times.
Tighten the auxiliary cylinder head

bolt (following figure 7).
3 Auxiliary bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
125E-5 Series

1) Install gasket (1) and then install rocker
arm housing (2).
2) Tighten mounting bolts (3).
3 Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
SEN00699-03
30. Crosshead
1) Set crosshead (1) and then loosen locknut
(2) to return adjustment screw (3) to its
original position.
2) Using your finger, lightly hold down the
crosshead (1) face contacting the rocker
arm to maintain contact between the push
rod side valve stem and crosshead (1).
3) Screw in adjustment screw (3) until crosshead (1) comes in contact with another
valve stem.
4) As they are contacted, further screw in the
adjustment screw by 20 and then tighten
locknut (2) from that state.
2 Crosshead guide and crosshead
top face: Engine oil (EO30-DH)
3 Locknut:
58.7 5.9 Nm {6.0 0.6 kgm}
29. Injector harness connector

1) Install O-ring (4) to harness connector (1).
2 O-ring: Engine oil (EO30-DH)
2) Insert harness connector (1) to rocker
housing (3) and then tighten them with
mounting bolt (2).
3) Fit in harness to holder (3).
125E-5 Series
35
SEN00699-03
31. Injector
a Check that the inside of the injector sleeve
is free from dirt.
1) Fit bracket (5) and install common rail (6)
temporarily.
4)
5)
6)
7)
2)
3)
36
Install gasket (6) and O-rings (7) and (8) to

injector (1).
2 O-ring: Engine oil (EO30-DH)
Insert holder (2) to injector (1). Continue

from that state, insert inlet connector (5) to
the high-pressure pipe insertion hole
through the rocker housing.
8)
Fit the ball washer to bolt (3) and tighten

holder (2) temporarily.
Locate high-pressure sleeve (4) to inlet
connector (5) and then tighten them temporarily.
a Tighten the common rail side sleeve
nut temporarily, too.
Tighten holder (2) with bolt (3) permanently.
a Tighten bolt (3) while pulling the tube
of the high-pressure pipe in the opposite direction of the injector.
58.8 73.5 Nm {6.0 7.5 kgm}
After tightening the holder, remove the
high-pressure sleeve (4) from the inlet
connector (5) and then install the other
injectors in order according to the above
procedure.
Remove the temporarily installed common
rail.
32. Push rod

Install push rod (1).
a Check that the push rod end is placed in
the cam follower socket.
125E-5 Series

1) Set rocker arm and shaft assembly (1).
a When installing the rocker arm shaft,
be sure to set its side with a larger
mounting hole diameter to the bottom
and to direct ball plug (6) side toward
the front side of the engine.
2) Before tightening mounting bolts (4),
check that the ball of adjustment screw (2)
is fitted to socket (5) of the push rod.
a Install the mounting bolt after cleaning
its oil hole.
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
34. Injector harness

1) Tighten mounting bolts (3) of the harness
fixing holder.
3 Mounting bolt:
27.0 34.0 Nm {2.8 3.5 kgm}
2) Tighten 2 harness capture nuts (2) to
injector (1).
a Tighten the nuts alternately.
3 Mounting nut:
2.0 2.4 Nm {0.2 0.24 kgm}
125E-5 Series
SEN00699-03
35. Adjusting valve clearance

a Adjust the clearance between the crosshead and rocker arm to the following
value.
a Valve clearance (in cold state)
Unit: mm
1)
2)
Intake valve
Exhaust valve
0.33
0.71
Rotate the engine and adjust the valve

clearance of each cylinder in the firing
order of 1 5 3 6 2 4.
Rotate the crankshaft forward and match
stamped line of 1.6 TOP on vibration
damper (1) to pointer (2), watching the
movement of the valve.
Insert clearance gauge l between rocker

arm (3) and crosshead (4) and screw in
adjustment screw (5) until the gauge
becomes movable. Then tighten the locknut.
3 Locknut:
58.8 73.5 Nm {6 7.5 kgm}
37
SEN00699-03
36. Head cover and tube

1) Fit the O-ring and install head cover (3).
a Install the O-ring without twisting it.
3 Mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}
2) Fit the gaskets on both sides, install tube
(2), and tighten joint bolt (1).
3 Joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
38. Common rail

Install common rail (5).
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
37. Oil level gauge tube

Install oil level gauge tube (2).
3 Sleeve nut:
44.1 58.8 Nm {4.5 6.0 kgm}
38
125E-5 Series
SEN00699-03
39. Installation of high-pressure pipes between

fuel supply pump and common rail
1) Tighten high-pressure pipes (3) and (4) by
3 Sleeve nut
(Pump side):
39.2 49 Nm {4 5 kgm}
(Common rail side):
39.2 58.8 Nm {4 6 kgm}
2) Tighten supply pump mounting bolts (2)
permanently.
3) Tighten the cylinder block side mounting
bolt of bracket (1) permanently.
4) Install the splash prevention cover on both
ends of the high-pressure pipe.
a Face the common rail side slit downward and the supply side slit toward
the cylinder block.
5) Tighten lubrication tube (12) by hand.
7) Tighten and install brackets (6) and (5) by
8) Tighten and install bracket (8) and clamp
(9) by hand first, and then tighten them
permanently.
11.8 14.7 Nm {1.2 1.5 kgm}
11.8 14.7 Nm {1.2 1.5 kgm}
10) Tighten lubrication tube (12) permanently.
3 Joint bolt:
7.9 12.7 Nm {0.8 1.3 kgm}
11) Tighten and install clamp (7) by hand first,
and then tighten it permanently.
11.8 14.7 Nm {1.2 1.5 kgm}
125E-5 Series
39
SEN00699-03

1) Fit the gasket and install air intake manifold (1) temporarily.
4
2)
Air intake manifold: 40 kg
41. High-pressure pipes

a Before installing each high-pressure pipe,
check it for the following defects. If there is
any of these defects, it can cause fuel leakage.
Accordingly, replace the high-pressure pipe.
q
Check the taper seal of the connecting part
(Part a: Part of 2 mm from the end) for visible
lengthwise slit b and dent c.
q
Check part d (end of the taper seal: Part at 2
mm from the end) for stepped-type wear
(fatigue) which your nail can feel.
Tighten the mounting bolts in the numeric

order shown below.
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
1)
2)
3)
4)
40
Install 6 high-pressure pipes (8).

a The installed angle of the high-pressure pipes was set when the injectors
were installed.
3 Sleeve nut (for both sides):
39.2 49 Nm {4 5 kgm}
Tighten 6 brackets (5) and 10 high-pressure pipe clamps (4) with your fingers and
then tighten them permanently.
3 Clamp mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
Install 6 each of scatter prevention covers
(6) and (7).
a Direct the slit on the injector side
down and that on the common rail
side toward the cylinder block.
Set high-pressure pipe clamp (3) to the
high-pressure pipes.
125E-5 Series
5)
6)
Install bracket (2) and tighten the 2 mounting bolts.

Tighten 7 high-pressure pipe clamp
mounting bolts (1).
11.8 14.7 Nm {1.2 1.5 kgm}
42. Spill pipe

Fit the gasket to both ends of spill pipe (2),
install them, and tighten joint bolt (1).
3 Joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
SEN00699-03

Fit the gasket and install diffuser and air housing assembly temporarily.
4
Diffuser and air housing assembly: 40 kg
Fix the front hanger first and then tighten

the mounting bolts permanently.
45. Front hanger, electrical intake air heater

and air connector
1) Fit the gasket and install front hanger (5).
2) Install plates (4) and (3) and tighten 6 diffuser and air housing assembly mounting
bolts and 4 plate mounting bolts.
3) Fit the gasket, install electrical intake air
heater (2) and air connector (1), and
tighten the 6 mounting bolts.
43. Bracket
125E-5 Series
41
SEN00699-03
46. Brackets
2) Install wiring harness (1).
47. Electric priming pump and block

a Electric priming pump is not set for some
models.
1) Install block (7).
2) Install electric priming pump (6) and
bracket together.
3) Install the tube and hose according to the
1] Install hose (3) and tube (4) temporarily.
2] Install tube (5) temporarily.
3] Tighten the joint bolts of tube (4) and
hose (3).
3 Joint bolt
(Block side):
24.5 34.3 Nm {2.5 3.5 kgm}
(Supply pump side):
14.8 19.6 Nm {1.5 2.0 kgm}
4] Tighten the joint bolt and sleeve nut of
tube (5).
3 Joint bolt:
14.8 19.6 Nm {1.5 2.0 kgm}
3 Sleeve nut:
43 47 Nm {4.4 4.8 kgm}
5] Install hose (2) and tighten the joint
bolts.
3 Joint bolt
(Block side):
19.6 29.4 Nm {2.0 3.0 kgm}
(Electric priming pump):
17.6 22.6 Nm {1.8 2.3 kgm}
a When tightening the joint bolt on
the electric priming pump side,
fix the hexagonal part of the
priming pump.
6] Connect connector (1).
42
48. Overflow tube, spill tube and engine controller cooler assembly
1) Install block (4).
2) Install tube (3).
3 Joint bolts:
(Block side):
24.5 34.3 Nm {2.5 3.5 kgm}
(Cylinder head side):
9.8 12.7 Nm {1.0 1.3 kgm}
3) Install tube (2) temporarily.
4) Install engine controller cooler assembly
(1).
49. Brackets
Install brackets (1), (2), (3), (4), (5), (6) and (7).
125E-5 Series
50. Fuel filters

1) Install fuel filters (9) and (10).
2) Install tubes (7) and (8) and clamp (6).
3 Joint bolts (for both tubes (7) (8)):
24.5 34.3 Nm {2.5 3.5 kgm}
27 34 Nm {2.8 3.5 kgm}
3) Install tube (5) and connect the 2 clamps.
3 Joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
4) Install hose (4).
3 Joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
5) Install tubes (3) and (2).
3 Joint bolt (for both tubes (9) and
(10)): 7.8 9.8 Nm {0.8 1.0 kgm}
SEN00699-03

Fit the gasket to oil cooler assembly (1) and
install them by using the guide bolts.

1) Fit the O-ring, install water pump assembly (3), and tighten mounting bolts (2).
2) Fit the gasket and install connector (1).
51. Oil filter

1) Install oil filter (4) with the 4 bolts temporarily.
2) Fit the O-ring and install oil tubes (2) and
(3).
3) Tighten the lower flanges of oil tubes (2)
and (3) permanently and then tighten the
upper flanges permanently.
4) Tighten the 4 mounting bolts of oil filter (4)
permanently.
5) Install clamp (1).
125E-5 Series
54. Thermostat housing assembly

1) Fit the gasket and install thermostat housing assembly (2).
2) Fit the gasket and install connector (1).
43
SEN00699-03
55. Exhaust manifold assembly

1) Sling exhaust manifold assembly (1), fit
the gasket, and tighten mounting bolts (2)
temporarily
4
2)
Exhaust manifold assembly: 35 kg
56. Turbocharger assembly

1) Fit the gasket, install turbocharger assembly (6), and tighten mounting bolts (5).
3 Mounting bolt:
44.1 49 Nm {4.5 5.0 kgm}
2) Fit the gasket and install turbocharger outlet tube (4) and tube bracket.
3) Fit the gasket and install turbocharger
lubricating oil inlet tube (3) and 5 clamps.
3 Sleeve nut (Cylinder block side):
40 44 Nm {4.1 4.5 kgm}
Tighten bolts (3), (4) and (5) first and then

tighten the other bolts.
3 Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}
57. Water pump suction tube

Fit the gasket and install suction tube (1).
44
125E-5 Series
58. Alternator assembly

1) Install bracket (8) and plate (7).
2) Install V-belt (5) to the pulley of alternator
assembly (6) and secure the alternator
assembly with mounting bolt (2) and fixing
bolt (3).
3) Adjust the belt tension with the V-belt tension adjustment nut and tighten mounting
bolt (2) and fixing bolt (3).
a Adjust the V-belt tension so that the
belt will be deflected by 13 16 mm
when it is pressed with a force of
about 6 kg by the center between the
crankshaft pulley and alternator pulley.
3 Mounting bolt (2):
107.8 147 Nm {11 15 kgm}
3 Mounting bolt (3):
28.4 38.2 Nm {2.9 3.9 kgm}
4) Check the belt tension and tighten the
locknut.
5) Tighten nut (4).
SEN00699-03
60. Wiring harness assembly

Install wiring harness assembly (1), connect
each connector, and install each clamp.
61. Air cleaner, muffler and heat insulation

plate
1) Install the air cleaner.
2) Install the muffler and the drain tube.
3) Install the heat insulation plate.
59. Starting motor assembly

Fit the gasket, install starting motor assembly
(2), and tighten mounting bolts (1).
125E-5 Series
45
SEN00699-03
62. Tightening torque for sensor

Use the following tightening torque when
removal and installation or replacement of the
sensor.
Sensor name
Fuel
temperature
5)
Tightening torque
23 3 Nm {2.35 0.3 kgm}
Boost pressure 5.5 0.5 Nm {0.56 0.05 kgm}

Intake air
temperature
23 3 Nm {2.35 0.3 kgm}
Coolant
temperature
23 3 Nm {2.35 0.3 kgm}
Engine oil
pressure
23 3 Nm {2.35 0.3 kgm}
Atmospheric
pressure
4.5 0.5 Nm {0.46 0.05 kgm}

(Hexagonal head bolt and hexagonal socket head bolt)
Fuel pressure
Never disassemble.
6)
7)
8)
9)
63. Checking for fuel leakage
a If fuel supply pump (2), common rail (1), or
high-pressure pipe is removed and
installed, after assembling the engine,
check for fuel leakage according to the following procedure.
1)
2)
3)
4)
46

leakage.
leakage.
a When checking while the components
to be checked are mounted on the
relieve the hydraulic pump.
leakage.
a If no fuel leakage is detected, check
is completed.
Clean and degrease the engine and the

parts around it in advance so that you can
test it easily for fuel leakage.
Spray color checker (developer) over the
fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
leakage.
125E-5 Series
125E-5 Series
SEN00699-03
47
SEN00699-03

2010 KOMATSU
All Rights Reserved
48
SEN00700-00
ENGINE
1SHOP MANUAL
125E-5 Series

Disassembly and assembly, Part 3 ................................................................................................................. 2
Removal and installation of fuel supply pump unit ............................................................................... 2
Replacement of oil seal of engine mounted on machine ..................................................................... 4
125E-5 Series
SEN00700-00

Removal and installation of fuel
supply pump unit
1
7.
Remove cover (16).
8.
Rotate the crankshaft forward and set intermediate point (a) between stamped 2/5 TOP and
3/4 TOP on damper (17) to pointer (18).
(Stamped 1/6 TOP comes almost directly bottom)
a At this time, check that the forcing tap of
the drive gear is aligned to the mounting
bolt hole of cover (16).
(If not, rotate the crankshaft one more
turn.)
a At this point, the key of the shaft is turned
clockwise by 15 from the top.
9.

washer (20).
[*5]
a Use a magnet or the like in this operation
so that washer (20) may not be inadvertently dropped into the case.
Removal
1. Disconnect sensor connectors (1), (2) and (3).
2.
Remove clamps (4) and (5) and then remove

fuel tube (6).
[*1]
3.
Remove clamps (7), (8) and (9) and then

remove splash prevention covers (10) and
(11).
[*2]
4.
Remove high-pressure pipes (12) and (13).
[*3]
5.
Remove lubrication tube (14).
6.
Remove fuel tube (15).
[*4]
125E-5 Series
SEN00700-00
10. Loosen mounting bolts (21) and then remove

the mounting bolt on the cylinder block side of
bracket (22).
[*6]
threads to prevent the pump from falling
down.
Installation
a Carry out installation in the reverse order to
removal.
[*1]
3 Joint bolt of tube (6):
24.5 34.3 Nm {2.5 3.5 kgm}
11. Install tool P1 with P2 and P3 and then screw

in the center bolt of P1 to remove the gear from
the shaft.
[*2]
1) Tighten clamps (7), (8), and (9) by hand first,
and then tighten them permanently.
11.8 4.7 Nm {1.2 1.5 kgm}
2) Face the pump side slit of the splash prevention cover to the cylinder block side and the
common rail side slit downward.
12. Remove bolts (21) and then remove fuel supply pump assembly (23).
a If tool P is removed, the gear falls down.
Accordingly, keep it installed until the
pump is installed.
[*3]
a Tighten high-pressure pipes (12) and (13) by
3 Sleeve nut of high-pressure tubes (12) and
(13)
Common rail side:
39.2 58.8 Nm {4 6 kgm}
Pump side:
39.2 49 Nm {4 5 kgm}
[*4]
Joint bolt of pump side:

24.5 34.3 Nm {2.5 3.5 kgm}
[*5]
Gear mounting nut:

127 147 Nm {13 15 kgm}
[*6]
125E-5 Series
Mounting bolt: Gasket sealant (LT-2)
SEN00700-00
Replacement of oil seal of engine

mounted on machine
1
Rear oil seal
a For the work up to removal of the flywheel, see
the Shop manual for the applicable machine.
Removal of standard seal
Hitch the end of tool L to the metal ring of seal (1)
and pull out the seal with impacts of slide hammer
[1].
a Before pulling out the seal, drive in it a little to
separate it from housing (2) for the ease of
removal.
a Do not use a drill, etc. since chips may enter
the engine.
Removal of sleeved seal

1) Hitch the end of tool L to the metal ring of
seal (1) and pull out the seal with impacts
of slide hammer [1].
a Before pulling out the seal, drive in it
a little to separate it from housing (2)
for the ease of removal.
2) Cut and remove sleeve (3) with a chisel
and a hammer.
a Take care not to damage crankshaft
(4).
a Remove all the chips.
Installation
a Check the Teflon seal (Laydown lip seal) by
checking the wear of the shaft and replace it
with the Standard seal or Sleeved seal.
a If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less
than 10 mm) and does not have any flaw, install
the standard seal. In other cases, install the
sleeved seal.
a The left one in the following figure is the standard seal and the right one is the sleeved seal.

a Before installing the seal, check that the end
corners and lip sliding surfaces of crankshaft
(4) are free from flaw, burr, and rust of the
housing.
a When installing the seal, do not apply oil or
grease to the shaft and seal lip (a). Wipe off oil
from the shaft.
a Never remove inside plastic cylinder (3) of the
standard spare seal before installing the seal.
1) Set the large diameter side (b) of plastic
inside cylinder (3) to the end of crankshaft
(4).
a Take care not to mistake the direction
of the plastic inside cylinder.
125E-5 Series
2)
3)
4)

After pushing in the seal, remove plastic
inside cylinder (3).
a When removing the inside cylinder,
take care not to damage the seal lip.

fit seal (1) until the end face of tool N1
reaches the end face crankshaft (4).
a First tighten tool N1 until it is contacted against bolt N3 (stem length 45
mm) and then further tighten the tool
with bolt N4 (stem length 25 mm).
125E-5 Series
SEN00700-00

a Before installing the seal, make sure that the
end corners and lip sliding surfaces of crankshaft (4) are free from flaws, burrs, and rusts of
the housing.
a When installing the seal, do not apply oil or
grease to the shaft, sleeve (1), and seal lip (a).
Wipe off oil from the shaft.
a Handle the seal and sleeve as an assembly
and don't separate them from each other.
1)
Set sleeve and seal assembly (2) to tool

N2.
2 Inside sleeve: Gasket sealant (LG-7)
SEN00700-00
2)
3)
4)
Set the sleeve of the seal to the end of the

crankshaft, and then tighten bolt N3
evenly to press fit sleeve and seal assembly (2) until the end face of tool N2
reaches the end of crankshaft (4).
Remove tool N2 and then replace it with

tool N1.
Tighten bolt N4 evenly to press fit sleeve
and seal assembly (2) until the end face of
tool N1 reaches the end of crankshaft (4).
Front oil seal

Removal
Remove front oil seal (1).
a For the work up to removal of the clamp pulley
(damper), see the Shop manual for the applicable machine.
Installation
Using the push tool (outside diameter 120 mm),
press fit front oil seal (1) to the cover.
a Oil seal press fit allowance (a): 16 (+1/0) mm
2 Oil seal lip (50 80% of void lip space):
Grease (G2-LI)
125E-5 Series
125E-5 Series
SEN00700-00
SEN00700-00

2006 KOMATSU
All Rights Reserved
SEN05202-00
ENGINE
1SHOP MANUAL
125E-5 Series

Information related to repair and replacement
Flowchart ........................................................................................................................................................ 2
Special tool table............................................................................................................................................. 4
Special tool sketch .......................................................................................................................................... 6
125E-5 Series
SEN05202-00
Flowchart
Repair of cylinder block top and counterbore by grinding
a
a
For removal, installation, disassembly and assembly of the engine, see the Shop Manual, "Disassembly
and assembly".
If the judgment of No. 9 is NO, examine A.
125E-5 Series
125E-5 Series
SEN05202-00
SEN05202-00
Special tool table

Replacement/Rebuilding
item
Symbol
Part No.
795-411-1400
Pressure test of cylinder

head
Replacement of valve
guide
B
C
Pump assembly
Push tool
795-100-1661
Push tool
795-100-1670
Push tool
For exhaust
795-100-4801
Seat puller
For valve seat insert
795-901-1260
Push tool
For intake valve
795-901-1250
Push tool
For exhaust valve
795-100-3005
Seat cutter
KIT
795-100-3100
Body assembly
795-100-3200
Micrometer
795-100-3300
Gauge
795-100-3401
Tool head
795-100-3601
Head support
Repair of valve by grinding
795-100-3710
Cutter
For oversize machining
795-100-3720
Cutter
For 30
795-100-3730
Cutter
For 45
f9.000 mm
Pilot
f9.010 mm
795-100-4131
Pilot
f9.020 mm
f9.030 mm
795-100-4141
Pilot
Guide puller
790-471-1120
Guide driver
Commercially
available
Valve refacer
795-240-6401
Push tool
795-240-6411
Push tool
795-240-6420
Push tool
795-240-6431
Block
795-240-6440
Nut
Replacement of cam
bushing
Pilot
795-130-3300
795-100-4111
795-100-4121
L
Replacement of connecting
rod small end bushing
For intake
KIT
795-100-1531
Replacement of valve seat

insert
Replacement of crosshead
guide
Remarks
79A-471-1050
Coolant tester
Q'ty
D
E
Part name
795-213-1200
Push tool
795-213-1250
Bar
795-213-1210
Push tool
795-213-1240
Collar
795-213-1230
Guide
795-103-0400
Grip
KIT
KIT
125E-5 Series
Replacement/Rebuilding
item
Symbol
Part No.
795-931-1100
1
795T-421-1340 Sleeve jig
1
3
01643-31645
Washer

01010-61650
Bolt
01643-31645
Washer
3
1
01010-61645
Bolt
01643-31645
Washer
1
3
4
5
6
7

01010-61635
Bolt
01643-31645
Washer

01010-61650
Bolt
01643-31645
Washer
For press fitting standard

seal
(For wet type)
Remarks
Bolt
Q'ty
01010-61635
7
Replacement of engine
rear seal
Part name
2
4
P
125E-5 Series
SEN05202-00
1
3
3
For press fitting sleeved seal

(For wet type)
For press fitting standard

seal
(For dry type)
1
3
3
1
01010-61645
Bolt
01643-31645
Washer
For press fitting sleeved seal

(For dry type)
SEN05202-00
Special tool sketch

Note) We will not be liable for any result of use of special tools manufactured according
to the following drawings.
P1. Sleeve jig
P7. Sleeve jig
125E-5 Series
SEN05202-00
Note) We will not be liable for any result of use of special tools manufactured according
to the following drawings.
Q1. Sleeve jig
Q7. Sleeve jig
125E-5 Series
SEN05202-00

2009 KOMATSU
All Rights Reserved
SEN05203-01
ENGINE
1SHOP MANUAL
125E-5 Series

Parts related to cylinder head
Part names related to cylinder head ............................................................................................................... 2
Testing and inspection of cylinder head .......................................................................................................... 3
Pressure test of cylinder head ........................................................................................................................ 5
Replacement of valve guide............................................................................................................................ 5
Replacement of valve seat insert.................................................................................................................... 6
Replacement of crosshead guide ................................................................................................................. 13
Repair of valve by grinding ........................................................................................................................... 14
125E-5 Series
SEN05203-01
Part names related to cylinder head
1.
2.
3.
4.
5.
6.
7.
Cylinder head
Crosshead guide
Valve guide
Valve seat insert (exhaust side)
Valve (exhaust valve)
Valve (intake valve)
Valve seat insert (intake side)
125E-5 Series
SEN05203-01
Testing and inspection of cylinder head

Unit: mm
Inspection item
Criteria
Remedy
Presence of crack (External dye check)

Water leakage from and crack Presence of water leakage during air pressure test
of cylinder head
(0.29 0.34 MPa {3.0 3.5 kg/cm2}, 30 sec)
Water pressure test (0.34 0.39 MPa {3.5 4.0 kg/cm2}, 10 min)
Tolerance
Distortion of cylinder head top
and bottom
0 0.06
Damage of valve contact
surface of valve seat insert or
looseness of valve seat insert
Valve sinking quantity
Presence of dent on valve seat insert contact surface

Check of valve seat insert contact surface
Airtightness test
Hit cylinder head lightly to check for looseness
a See Fig. A
Sink (a) (When master valve is used)
Valve
Standard value
Repair limit
Intake
1.88 0.1
Exhaust
1.20 0.1
Standard value
Repair limit
Intake
2.10
Exhaust
1.50
a See Fig. B
Valve head thickness (c)
Valve
Repair by welding
or replace cylinder
head
Repair by grinding
or replace cylinder
head
Repair valve seat
insert contact
surface or replace
valve seat insert
Replace valve seat

insert
Valve head thickness
Abnormality in valve
Replace valve
Valve seat contact surface angle (b)

Intake valve: 30 15'
Exhaust valve: 45 15'
Deformation of head into dish shape
Presence of crack or dent on seat contact surface of valve
Airtightness test
Play when new cotter pin is inserted in cotter groove
Uneven wear or bend of valve stem
Presence of dent at valve stem end
Outside diameter of valve

stem
Repair stem
Valve
Standard size
Standard value
Repair limit
Intake
8.935 8.955
Exhaust
8.930 8.950
Intake
8.989 9.009
Exhaust
8.989 9.009
Inside diameter of valve guide
Projection of valve guide

Outside diameter of crosshead
guide
Projection of crosshead guide
125E-5 Series
a See Fig. C
Allowable range of projection (d): 20 0.2
Standard size
Standard value
11
11.000 11.011
a See Fig. D
Allowable range of projection (e): 45.5 0.25
Repair limit
Replace valve
Replace valve
guide
Replace crosshead
guide
Repair crosshead
guide
SEN05203-01
Illustrations related to testing and inspection table

Fig. A
Fig. D
a: Sink
e: Projection
1. Crosshead guide
2. Cylinder head
Fig. B
b: Valve seat contact surface angle

c: Valve head thickness
Fig. C
d: Projection
125E-5 Series
SEN05203-01
Pressure test of cylinder head
Replacement of valve guide
Pressure test tools
Symbol
Part No.
Part name
790-553-1501
Coolant tester
79A-471-1050
Pump assembly
If the cylinder head parts were repaired, perform the test according to the following procedure.
Valve guide replacement tools
Symbol
C
Part No.
Part name
795-100-1531
Push tool
795-100-1661
Push tool (For intake)
795-100-1670
Push tool (For exhaust)
Pulling out of valve guide

q
Using tool C1, pull out the valve guide.
Water pressure test

1.
Combine tools A and B and connect the hose

to the cylinder head.
2.
Apply water pressure (0.35 0.4 MPa {3.5

4.0 kg/cm2}) for about 10 minutes and check
around the cylinder head for leakage.
Warm the whole cylinder head and then perform the test with hot water at 80 95C.
Pay fully attention to handling the cylinder
head and water whose temperature are
high, and take care not to get burnt.
Press fitting of valve guide

1.
2.
3.
Machine the valve guide hole of the cylinder

head to the dimension below.
q
Inside diameter: 16(+0.018/0)mm
Press fit the valve guide until the tool C2 or C3
end touches the cylinder head.
Check that the projection of the valve guide is
within the standard value.
a Projection tolerance of valve guide:
20 0.2 mm
Air pressure test

1.
Connect the air compressor hose to the cylinder head.
2.
Put the cylinder head in a water tub, apply air

pressure (0.3 0.35 MPa {3.0 3.5 kg/cm2} for
about 30 seconds, and check for air leakage.
If any crack is detected in the cylinder head by

the above tests, replace the cylinder head.
125E-5 Series
SEN05203-01
Replacement of valve seat insert

a
Valve seat insert replacement tools
Symbol
Part No.
D
E
Part name
795-100-4801
Seat puller
795-901-1260
Push tool
795-901-1250
Push tool
795-100-3005
Seat cutter
795-100-3710
Cutter
795-100-3720
Cutter
795-100-3730
Cutter
795-100-4111
Pilot
Pulling out of valve seat insert

k
k
k
Keep the air pressure at 0.5 0.6 MPa {5 6

kg/cm2} during the work.
When replacing the grinding stone, stop
the air.
Before starting the grinding work, perform
a trial operation of the grinder for 1 minute
and ensure that the grinder is normal.
a After replacing the grinding stone, perform
a trial operation for 3 minutes.
Ensure that the grinding stone is free from
damage and install it to the grinder shaft
with no play.
When using the grinder, put on safety
glasses.
When pulling out with seat puller of tool D

1. Install grinding stone (4) to grinder (1).
2.
While matching the groove of sleeve (2), insert

the grinder in holder (3).
(Adjust the grinder position with set screw (5).)
3.
Adjust the position of grinder (1) so that the

center of grinding stone (4) will be at the center
of valve seat insert (a) and then tighten set
screw (5) to fix grinder (1).
4.
Rotate grinding stone (4) and move it slowly

until it touches valve seat insert (a).
5.
While lightly pressing grinding stone (4)

against the inside surface of valve seat insert
(a), make a groove about 1 mm deep all
around the inside surface of valve seat insert
(a).
125E-5 Series
6.
Push in 3 claws (10) of puller head (9) of tool D

with the hand and put them in valve seat insert
(a).
7.
Tighten screw (12) to press 3 claws (10)

against the inside groove of valve seat insert
(a).
a If screw (12) is tightened too strongly, the
insert will be broken and become difficult
to pull out. Accordingly, stop tightening
when 3 claws (10) reach the groove fully.
8.
Put bridge (8) in the outside of puller head (9),

place plates (11) and (7) on the bridge, and
tighten nut (6) to pull out valve seat insert (a).
125E-5 Series
SEN05203-01
When pulling out valve seat insert (a) by welding a bar to it

1. Weld bar (b) (Length: 0.1 0.5 mm shorter
than valve seat inside diameter, Diameter:
Approx. 10 mm) to the inside of valve seat
insert (a).
a Take care that welding spatters will not
stick to the head.
2.
After the temperature of the welded parts has

decreased to around the ambient temperature,
insert an unnecessary valve (c) in the reverse
direction and hit its head with a small hammer
to pull out valve seat insert (a).
a If a large impact is given, the welded parts
may come off. Take care.
SEN05203-01
Press fitting of valve seat insert

When press fitting hole for valve seat insert (a)
is not repaired by cutting
1. Using tool E1 or E2, press fit standard valve
seat insert (a) with press (d).
a Do not press fit with a hammer.
a Press fitting force of valve seat insert (a)
Intake side:
Approx. 9.8 kN {Approx. 1.0 ton}
Exhaust side:
Approx. 9.8 kN {Approx. 1.0 ton}
2.
Measure sinking quantity (f) of valve seat

insert (a) from cylinder head bottom (e).
a Sinking quantity (f) of valve seat insert (a)
Intake side: 3.78 4.08 mm
Exhaust side: 3.10 3.40 mm
125E-5 Series
125E-5 Series
SEN05203-01
SEN05203-01
Oversize machining of valve seat insert

mounting hole
q
Using tool F1 and attached cutter F2, increase

the valve seat insert mounting hole to the next
oversize.
Limit the increase of the mounting hole diameter to 1.0 mm. If the hole diameter needs to be
increased more than 1.0 mm, replace the cylinder head.
Machining dimensions of valve seat insert and mounting hole

Intake valve side
Valve seat insert size
Unit: mm
Valve seat insert
d1
Valve seat insert mounting hole

c1
d2
d3
c2
Standard
47.5 +0.100
+0.090
0
7.5 0.1
47.5 +0.020
+0.010
54.06 0.2
11.38 0.1
0.25 OS
47.75 +0.100
+0.090
0
7.5 0.1
47.75 +0.020
+0.010
54.31 0.2
11.38 0.1
0.50 OS
48.0 +0.100
+0.090
0
7.62 0.1
48.0 +0.020
+0.010
54.56 0.2
11.5 0.1
0.75 OS
48.25 +0.100
+0.090
0
7.75 0.1
48.25 +0.020
+0.010
54.81 0.2
11.63 0.1
1.00 OS
48.5 +0.100
+0.090
0
7.88 0.1
48.5 +0.020
+0.010
55.06 0.2
11.76 0.1
OS: Oversize
Exhaust valve side

Valve seat insert size
10
Unit: mm
Valve seat insert
d1

c1
d2
d3
c2
Standard
46.5 +0.080
+0.070
0
7.5 0.1
46.5 +0.020
+0.010
51.70 0.2
10.7 0.1
0.25 OS
46.75 +0.080
+0.070
0
7.5 0.1
46.75 +0.020
+0.010
51.95 0.2
10.7 0.1
0.50 OS
47.0 +0.080
+0.070
0
7.62 0.1
47.0 +0.020
+0.010
52.20 0.2
10.82 0.1
0.75 OS
47.25 +0.080
+0.070
0
7.75 0.1
47.25 +0.020
+0.010
52.45 0.2
10.95 0.1
1.00 OS
47.5 +0.080
+0.070
0
7.88 0.1
47.5 +0.020
+0.010
52.70 0.2
11.08 0.1
OS: Oversize
125E-5 Series
Valve seat insert
SEN05203-01
Finish machining of valve contact surface

of valve seat insert
1.
a
Using tool F1 and attached cutters F3 and F4,

machine the valve contact surface of the valve
seat insert to the following dimensions.
Select tool F5 which will be inserted in the
valve guide with no clearance.
g: Cylinder head bottom

a
a
a
a
a
Inside finished surface roughness: Max. 12.5S

Mounting hole bottom surface roughness:
Max. 12.5S
Concentricity of valve guide hole and valve
seat insert hole: Max. 0.07 mm (TIR)
Squareness of valve guide hole to valve seat
insert hole bottom: Max. 0.03 mm (TIR)
TIR is an abbreviation for Total Indicator Reading, which is the difference between the maximum and minimum readings in runout
measurement.
125E-5 Series
EV: Exhaust valve

IV: Intake valve
h: Finish machining width
11
SEN05203-01
2.
Fit the contact surface of the valve seat insert

to the valve by using compound.
1) Thinly apply rough compound mixed with
oil to the seat surface of a valve and insert
that valve in the valve guide.
2) Install the fitting rod to the valve head and
lightly hit valve against the valve seat
while rotating it with both hands to fit the
valve to the valve seat.
3) After the valve and valve seat are fitted
and their surfaces become smooth, wipe
off the compound.
4) Apply fine compound and fit the valve and
valve seat again similarly to the above
until they are fitted to each other without
breakage.
Final inspection
q
q
q
q
q
Thinly apply red lead to the valve seat insert

contact surface of a new valve and insert that
valve in the valve guide.
Lightly press the valve against the valve seat
insert and rotate it 10.
Check the valve seat insert contact surface of
the valve and ensure that the contact is even
and is not broken.
Or, make marks (m) (about 20 places) on the
valve seat insert contact surface of a new
valve with a pencil and insert that valve in the
valve guide.
Ensure that all the pencil marks (m) have been
erased evenly.
When master valve is used
EV:
IV:
j:
k:
Exhaust valve
Intake valve
Cylinder head bottom
Contact width against valve
Concentricity of contact surfaces of valve

guide and valve seat insert:
Max. 0.07 mm (TIR)
measurement.
12
125E-5 Series
Replacement of crosshead guide

a
Crosshead guide replacement tools
Symbol
G
Part No.
1.
795-130-3300
Guide puller
790-471-1120
Guide driver
Using tool G1, pull out crosshead guide (a)

from cylinder head (b).
Hold crosshead guide (a) with collet (4) of the
puller.
2.
Tighten collet (4) with bolt (1) to lock sleeve

(2).
3.
Rotate nut (3) and pull out the crosshead

guide.
4.
Remove burrs and fins from and clean the

crosshead guide mounting portion.
125E-5 Series
Press fitting of crosshead guide

q
Part name
Pulling out of crosshead guide

q
SEN05203-01
a
a
Using tool G2, insert crosshead guide (a) in

cylinder head (b) and press fit it with a copper
or plastic hammer until the projection is within
the tolerance.
Projection tolerance of crosshead guide:
45.5 0.25 mm
Diameter of cylinder head crosshead guide
f11 0.027
hole:
0.054 mm
13
SEN05203-01
Repair of valve by grinding

a
Valve grinding tool
Symbol
Part No.
Commercially
available
Part name
Valve refacer
Grinding of seat contact surface of valve

q
Using tool H, grind the seat contact surface of

the valve.
Seat contact surface angle of valve (a)

Intake valve: 30
Exhaust valve: 45
Check after grinding

q
Measure the valve head thickness, sinking

quantity of the valve, and contact of the seat
contact surface of the valve, and ensure that
they are within the standard values.
Allowable limit of valve head thickness (b)
Intake valve:
Min. 1.7 mm (Standard size: 2.10 mm)
Exhaust valve:
Min. 1.2 mm (Standard size: 1.50 mm)
Standard of valve sinking quantity:
1.88 0.1 mm
Allowable limit:
1.20 0.1 mm
e: Block
a
q
q
q
q
q
14
Apply dial gauge (1) to the facial runout measuring point of seat contact surface (c) of the
valve and rotate the valve to measure its facial
runout while pressing it toward left (d).
Intake valve: Max. 0.045 mm (TIR)
Exhaust valve: Max. 0.030 mm (TIR)
measurement.
Check the contact of the seat contact surface

of the valve by either of the following methods.
Thinly apply red lead to the seat contact surface of the ground valve and insert that valve
in the valve guide.
Check the valve seat insert contact surface of
the valve and ensure that the contact is even
and is not broken.
Make marks (f) (about 20 places) on the seat
contact surface of the ground valve with a pencil and insert that valve in the valve guide.
Ensure that all the pencil marks (f) have been
erased evenly.
125E-5 Series
125E-5 Series
SEN05203-01
15
SEN05203-01

2010 KOMATSU
All Rights Reserved
16
SEN05204-00
ENGINE
1SHOP MANUAL
125E-5 Series

Parts related to cylinder block
Part names related to cylinder block............................................................................................................... 2
Testing and inspection of cylinder block.......................................................................................................... 3
Part names related to crankshaft .................................................................................................................... 6
Testing and inspection of crankshaft............................................................................................................... 7
Part names related to connecting rod ............................................................................................................. 8
Testing and inspection of connecting rod........................................................................................................ 9
Replacement of flywheel ring gear.................................................................................................................11
Replacement of camshaft gear ......................................................................................................................11
Replacement of main bearing metal cap ...................................................................................................... 12
Replacement of connecting rod small end bushing ...................................................................................... 14
Replacement of cam bushing ....................................................................................................................... 15
Replacement of engine rear seal .................................................................................................................. 17
Replacement of wear sleeve (when sleeve is installed) ............................................................................... 21
Repair of crankshaft by grinding ................................................................................................................... 22
125E-5 Series
SEN05204-00
Part names related to cylinder block
1.
2.
3.
4.
5.
6.
7.
Cylinder liner
Clevis seal
Cylinder liner O-ring
Cylinder block
Main bearing metal cap bolt
Main bearing metal cap (No. 1, 2, 3, 4, 5 and 6 are same)
Camshaft bushing
125E-5 Series
SEN05204-00
Testing and inspection of cylinder block

Unit: mm
Inspection item
Crack
Repair of contact of packing
Clearance to cylinder liner
Inside diameter of camshaft

bushing
Projection of cylinder liner
Criteria
60
60.000 60.070
Standard value
+0.13
+0.08
Tolerance
Flatness of cylinder block top
0 0.09
a See Fig. E
Standard size
Main bearing mounting hole
diameter
Tighten main bearing metal
cap bolt to specified torque
Concentricity of
adjacent holes
a See Fig. F
Fit of main bearing metal cap
and cylinder block
(Interference)
Replace cylinder
liner or cylinder
block
Replace camshaft
bushing
Repair by cutting or
replace cylinder
block
Repair by cutting or
replace cylinder
block
Standard value
116
General concentricity
Replace cylinder
block
Replace cylinder
liner or repair
cylinder block
a See Fig. C
Allowable range: 0.07 0.15
a See Fig. D
Presence of corrosion
Depth and bottom corrosion of
Standard size
counterbore
10
Distortion and wear of cylinder
head mounting face
Remedy
Presence of crack (External dye check)

Cylinder head bolt hole etc.
a See Fig. A
Water leakage caused by corrosion
a See Fig. B
Standard value
Standard
Standard size
Bore of
Outside diameter
clearance
cylinder block
of cylinder liner
+0.040
0.024
f141.4
0.024 0.089
0
0.049
Inside diameter
Standard size
Standard value
116.015 116.000
Roundness of f116
must be 0.005 from
front to rear of cylinder block
Alignment bar for roundness of 0.010 must go
through smoothly
0.012
0.034
Journal
Standard fit
(Interference)
No. 1 7
0.002 0.060
Replace cylinder
block
a See Fig. G
Inside diameter of counterbore

and outside diameter of
cylinder liner flange
Cylinder liner
Standard size
Standard value
Upper section
153
152.975 153.025
Lower section
145
145.040 145.090
Replace cylinder
liner
Cylinder block
125E-5 Series
Upper section
153
153.025 153.088
Lower section
145
144.97 145.03
Replace cylinder
block
SEN05204-00
Illustrations related to testing and inspection table

Fig. A
Fig. D
a: Packing portion
f: Depth of counterbore
Fig. B
Fig. E
b: Clearance
g: Inside diameter
Fig. C
Fig. F
c: Cylinder liner
d: Cylinder block
e: Projection
h: Fit
125E-5 Series
SEN05204-00
Fig. G
i: Upper section
j: Lower section
125E-5 Series
SEN05204-00
Part names related to crankshaft
1.
2.
3.
4.
Crankshaft
Main bearing metal (upper)
Main bearing metal (lower)
Thrust metal (All of upper x 1 and lower x 2 are the same)
125E-5 Series
SEN05204-00
Testing and inspection of crankshaft

Unit: mm
Inspection item
Criteria
Crack
Check for crack by magnaflux inspection
Damage
Presence of damage in journal

Flaw
Seizure
Discoloration
Clogging of oil hole
Remedy
Replace crankshaft
Damage of tap holes at front and rear ends
If damaged slightly,
repair with oilstone
or by lapping.
If seized, replace
crankshaft
Repair or replace
crankshaft
Presence of clogged oil hole
Repair
Standard value
End play of crankshaft
Thrust metal thickness
Outside diameter of crankpin

journal
Size
Standard
0.25 US
0.50 US
0.75 US
1.00 US
Standard
0.25 US
0.50 US
0.75 US
1.00 US
Roundness of crankpin journal
Outside diameter of crank

main journal
Roundness of crank main

journal
Replace thrust
metal or repair with
oversize parts
0.140 0.315
Standard size
4.000
4.125
4.250
4.375
4.500
80.00
79.75
79.50
79.25
79.00
Standard
Tolerance
0.07
0.12
0.050
0.068
Replace thrust
metal or repair with
oversize crankshaft
Repair with
undersize parts or
replace crankshaft
0 0.009
Size
Standard
0.25 US
0.50 US
0.75 US
1.00 US
Standard size
110.00
109.75
109.50
109.25
109.00
Standard
Tolerance
0.050
0.068
Repair with
undersize parts or
replace crankshaft
0 0.009
Standard
Bend of crankshaft
(Total indicator reading)
125E-5 Series
Concentricity of all main journals
0 0.09
Concentricity of adjacent journals
0 0.05
Replace crankshaft
SEN05204-00
Part names related to connecting rod
1.
2.
3.
4.
5.
6.
7.
Connecting rod bolt

Cap
Dowel pin
Bearing metal (lower)
Bearing metal (upper)
Rod
Small end bushing
125E-5 Series
SEN05204-00
Testing and inspection of connecting rod

Unit: mm
Inspection item
Crack
Parallelism and twist of small
and large end holes of
connecting rod
Clearance between
connecting rod small end
bushing and piston pin
Criteria
Remedy
Check for crack by dye check or magnaflux inspection

a See Fig. H
Presence of bend (after small end bushing is installed)
Parallelism: 0.20
Twist:
0.30
Tolerance
Standard size
Shaft
Hole
0
0.006
f48
+0.041
+0.025
Replace connecting
rod
Standard
clearance
0.025 0.047
Standard size
Large end hole diameter
Connecting rod large end hole Without bearing metal.
Inside surface roughness of large
diameter
85
end hole: Max. 6.3S
Size
Standard size
Standard
2.500
1.00 US
3.000
Bearing metal thickness
0.75 US
2.875
0.50 US
2.750
0.25 US
2.625
Tolerance
+0.017
0.009
Standard size
240
Replace connecting
rod
Tolerance
0.005
Replace bearing
metal
Replace bearing
metal or connecting
rod
Flaw on inside of or seizure of Presence of flaw and seizure

bearing metal
Distance between large and
small end hole centers
Replace small end

bushing
Surface roughness
of inside of small
end bushing
Max. 3.2S
Tolerance
0
0.040
Replace connecting
rod
Streak and bruise on I-portion

of connecting rod
a See Fig. J
Presence of lateral streak
Presence of lateral grinding mark
Replace connecting
rod
If there is bruise,
replace connecting
rod regardless of
size of bruise
Fretting on cap mating face
Presence of fretting on mating face

Mating face roughness: Max. 6.3S
Back fitted area of mating face: Min. 70%
a There must not be non-fitted area on outside of bolt hole center.
If fretting is felt with

nail, replace
connecting rod
Scuffing on cap bolt seat surface
Repair with oilstone
Scuffing on bolt seat surface
Replace bolt
Scuffing on washer surface
Replace washer
Replace connecting
rod
Scuffing on bolt seat surface
Deformation of dowel pin

Damage of bolt
Presence of deformation of dowel pin

Presence of deformation of dowel pin hole
Presence of crack and/or damage on threaded portion of bolt
Presence of bend of bolt
Replace bolt
Do not reuse the connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on it.
125E-5 Series
SEN05204-00
Fig. H
a: Measured value
Fig. J
b: Inspection range
c: Streaks
d: Lengthwise direction
10
125E-5 Series
Replacement of flywheel ring gear

k
Take care not to throw down the flywheel

and get hurt by mistake.
Removal of gear
Make a notch at the tooth bottom of the gear
with a grinder and break the gear to remove
with a chisel.
k Take care in handling the grinder and
chisel.
SEN05204-00
Replacement of camshaft gear

k
When setting the camshaft assembly on the

press stand, take care not to catch your fingers between the press stand and the gear.
Removal of gear
Set the camshaft assembly on the press stand and
press the camshaft to pull out the gear.
Press fitting of gear

1. Check the gear mounting face. If there is a
flaw, repair with an oilstone.
2.
Heat the gear at the specified shrink fit temperature for a certain time.
a Gear shrink fit temperature: Max. 200C
(Below ring gear tempering temperature)
Heating time: Min. 50 min
3.
Press fit the gear with the chamfered side

directed toward the flywheel until its side contacts the flywheel.
125E-5 Series
Press fitting of gear

1. Check the gear mounting face, key way and
flange surface. If there is a flaw, repair with an
oilstone.
2.
Drive a new key into the key way of the camshaft.
3.
Install the thrust plate.
4.
Heat the gear at the specified shrink fit temperature for a certain time.
a Gear shrink fit temperature: 220 240C
Heating time: Max. 30 min
5.
Using the drive tool, press fit the gear with the
timing mark out until its side contacts the camshaft flange.
a Press fit the gear quickly before it cools
down.
11
SEN05204-00
Replacement of main bearing

metal cap
a
5.
When replacing the main bearing metal cap,

work on the semi-finished cap according to the
following procedure and install it.
Repair parts
Part No.
Part name
6150-29-1210 No. 1, 2, 3, 4, 5, 6 main bearing metal cap

6150-29-1250 No. 7 main bearing metal cap
Inside machining of main bearing metal cap

1. Remove the cylinder liner.
2.
3.
4.
12
Install the replacement main bearing metal cap

to the cylinder block and tighten it to the specified torque.
a Match the notches of the cylinder block
and main bearing metal cap to each other.
2 Main bearing metal cap mounting bolt:
Apply engine oil to threaded portion
and seat.
a Tighten with the angle tightening wrench
at the 3rd time.
3 Main bearing metal cap mounting bolt:
While checking the inside diameter of main

bearing metal cap (1), cut little by little.
a Cut to the degree that the boring bar tool
almost touches the inside of cylinder block
(2).
a Inside diameter of main bearing metal cap
q
Machining dimension
Tolerance: 116 +0.015
mm
0
q
After machining, remove the main bearing
metal cap, assemble it again, and check
its inside diameter.
Tolerance: 116 +0.013
0.009 mm
(Range to upper and lower 10 from mating face of main bearing metal cap)
a Finished surface roughness: Max. 10S
a Do not cut the inside surface of the cylinder block.
Unit: Nm {kgm}
Range
Step
Target
1st time
98 {10}
88 108 {9 11}
2nd time
196 {20}
191 201 {19.5 20.5}
3rd time
Tightening by
90
90 +30
0
Set the cylinder block mounting jig on the table

of the horizontal boring machine and install the
cylinder block by fitting its cylinder liner mounting hole to the datum line of the jig.
Side machining of main bearing metal cap

(Machine only No. 7 main bearing metal cap)
1. Insert cast iron bushing (3) and pass arbor (4)
through it.
2.
Install facing tool (5) to the arbor.
3.
Cut main bearing metal cap (1) to the degree

that facing tool almost touches the cylinder
block surface.
Apply dial gauges to the inside of the 2 main

bearing metal caps at the longest pitch among
the caps to be used to center the arbor of the
boring machine.
125E-5 Series
4.
SEN05204-00
Cut the opposite side similarly.

a Thrust metal mounting surface roughness:
Max. 12.5S
a Do not cut the cylinder block.
a Tolerance of main bearing metal cap
0
width:
38 0.025
mm
125E-5 Series
13
SEN05204-00
Replacement of connecting rod

small end bushing
Press fitting of bushing

1. Set the connecting rod to block (3) of tool L.
2.
Install the bushing to push tool (1), set push

tool (2), and fix them with nut (4).
a Match the oil holes of the bushing and
connecting rod to each other.
3.
Drive push tool (1) with the press to press fit

the bushing.
a Since the bushing is semi-finished, its
inside diameter is small and the piston pin
does not go through it.
After press fitting the bushing, machine its
inside with a reamer or a honing machine
according to the maintenance standard.
a After machining, remove all the chips from
the oil hole and oil groove.
Connecting rod small end bushing replacement tool
Symbol
Part No.
795-240-6401
Part name
Push tool (KIT)
Pulling out of bushing

1. Set the connecting rod to block (3) of tool L.
2.
14
Using push tool (1) and block (3), drive out the
busing with the press.
a After removing the bushing, remove sharp
edges and burrs from and clean the bushing mounting hole.
125E-5 Series
SEN05204-00
Replacement of cam bushing

a
Cam bushing replacement tools
Symbol
Part No.
795-213-1200
2)
While hitting bar (1), drive out the bushing

from the cylinder block.
Part name
Push tool (KIT)
Before replacing the cam bushing, remove the

plug at the rear of the cylinder block.
Removal
1.
Pulling out of No. 1 and No. 7 bushings

1) Assemble push tool (2), collar (3) and bar
(1) of tool M.
2) While hitting bar (1), drive out the bushing
4.
After removing the bushing, remove burrs and

foreign matter from and clean the bushing
mounting hole.
Installation
2.
3.
Cam bushing installation drawing
1.
Press fitting of No. 3, No. 4 and No. 5 bushings

1) Install bar (1), push tool (2), collar (3) and
guide (4) to the bushing.
2) Press fit the bushing until the oil holes of
th e c y l i n d e r b l o c k a nd b u s h i n g ar e
matched to each other.
Pulling out of No. 2 and No. 6 bushings

1) Assemble bar (1), push tool (2), collar (3)
and guide (4).
2) While hitting bar (1), drive out the bushing
Pulling out of No. 3, No. 4 and No. 5 bushings

1) Assemble bar (1), push tool (2), collar (3)
and guide (4).
125E-5 Series
15
SEN05204-00
2.
Press fitting of No. 2 and No. 6 bushings

1) Install bar (1), push tool (2), collar (3) and
guide (4) to the bushing.
th e c y l i n d e r b l o c k a n d bu s h i n g a r e
4.
Measurement after bushing is press fitted

1) Using dial inside gauge (a), measure the
inside diameter of the bushing.
2)
3.
16
Press fitting of No. 1 and No. 7 bushings

1) Install bar (1), push tool (2) and collar (3)
to the bushing.
th e c y l i n d e r b l o c k a n d bu s h i n g a r e
Measure the clearance between the bushing and shaft. If it is out of the allowable
range or the shaft does not go through
smoothly, repair the inside of the bushing
with a reamer.
a After repairing the inside of the bushing with a reamer, remove all the
chips from the oil hole and oil groove.
a Inside diameter of cam bushing:
f65 +0.07
mm
0
a Clearance to camshaft journal:
0.080 0.180 mm
125E-5 Series
Replacement of engine rear seal

a
Engine rear seal replacement tools
Symbol
Part No.
795-931-1100
Part name
For disassembly and assembly of flywheel and

flywheel housing, see "Disassembly and
assembly".
SEN05204-00
2.
Pull slide hammer (1) of the seal puller to pull

out the seal with impacts.
a Rear seal (c) can be pulled out easily, if it
is driven in a little to separate it from the
flywheel housing in advance.
a Do not damage the crankshaft.
a Do not use a drill since chips will enter the
engine.
Types of engine rear seal (Teflon seal)

Illustration No.
Application
a1
Single lip for dry type (when delivered)
a2
Single lip for dry type (sleeved)
b1
Double lip for wet type (without sleeve)
b2
Double lip for wet type (when delivered)
The sleeved rear seals are used to repair when

the shaft is worn largely.
Removal of rear seal (sleeved)

1. Install drill type attachment (6) to the seal
puller.
Removal of rear seal (without sleeve)

1. Hitch seal puller end (5) of tool N to the metal
ring of rear seal (c).
125E-5 Series
17
SEN05204-00
2.
Screw drill end (6) into the metal ring of rear

seal (c) and pull slide hammer (1) of the seal
puller to pull out the seal with impacts.
a Rear seal (c) can be pulled out easily, if it
is driven in a little to separate it from the
flywheel housing in advance.
a Do not damage the crankshaft.
a Do not use a drill since chips will enter the
engine.
Check of crankshaft for wear

1. If the crankshaft is worn to a degree of luster
(you cannot feel the wear with the cushion of
your finger and the wear depth is maximum of
about 10 m) and there is no scratch on it, it
can be used.
2.
Before installing the rear seal, remove all

flaws, sharp edges, burrs, rust, etc. from the
end corners and sliding surfaces of the crankshaft and from the flywheel housing.
Do not apply oil or grease to the sliding surfaces of the crankshaft and lip (e) of the rear
seal.
Wipe off the oil from the sliding surfaces of the
crankshaft thoroughly.
1.
Set larger inside diameter side (f) of internal

plastic cylinder (d) to crankshaft end (g).
a Take care not to mistake the direction of
rear seal (c).
2.
Hold the metal ring of seal (c) with both hands

and push it in evenly.
a Push in the rear seal as if you pass over
large inside diameter side (f) of internal
plastic cylinder (d).
3.
Remove internal plastic cylinder (d), taking

care not to damage lip (h).
In other cases than 1 above, install the sleeved

rear seal.
Installation of rear seal (without sleeve)

a Do not remove internal plastic cylinder (d) of
the spare rear seal (which is used as an installation guide) before installing the rear seal
since it is also used to protect the seal lip.
18
125E-5 Series
4.
Install sleeve jig (1) and clamp bolts (2) (Stem

length: 35 mm).
a Do not install washers to the bolts.
5.
Evenly tighten clamp bolts (2) to press fit the

rear seal until they stop.
a Take care not to damage the end of lip (j)
on the transmission side.
SEN05204-00
Installation of rear seal (with sleeve)

a Handle the spare rear seal and sleeve (n) as
an assembly and do not separate them.
a
6.
Remove clamp bolts (2) (Stem length: 35 mm),

install 1 washer (3) each, and tighten bolts (2)
evenly again to press fit the rear seal until end
(k) of sleeve jig (1) touches end (m) of the
crankshaft.
a Take care not to damage the end of lip (j)
on the transmission side.
a After press fitting, remove the gasket sealant projected around the periphery.
125E-5 Series
1.
Before installing the rear seal, remove all

flaws, sharp edges, burrs, rust, etc. from the
end corners and sliding surfaces of the crankshaft and from the flywheel housing.
Do not apply oil or grease to the sliding surfaces of the crankshaft and lip (e) of the rear
seal.
Wipe off the oil from the sliding surfaces of the
crankshaft thoroughly.
Apply gasket sealant to inside wall (p) of rear
seal (c) and set it to sleeve jig (4).
2 Inside wall (p) of rear seal (c):
Gasket seal (LG-7)
19
SEN05204-00
2.
Install sleeve jig (4), clamp bolts (5) (Stem

length: 50 mm), and 1 washer (6).
3.
Evenly tighten clamp bolts (5) to press fit the

rear seal until they stop.
a Be sure to press fit rear seal (c) and
sleeve (n) as an assembly.
4.
Replace sleeve jig (4) and clamp bolts (5) with

sleeve jig (7) and clamp bolts (8) (Stem length:
45 mm (wet), 40 mm (dry)) respectively and
tighten bolts (8) evenly to press fit the rear seal
until they stop.
a Do not install washers to the bolts.
20
5.
Remove clamp bolts (8) (Stem length: 45 mm

(wet), 40 mm (dry)), install 3 washers (9) each,
and tighten bolts (8) evenly again to press fit
the rear seal until end (q) of sleeve jig (7)
touches end (r) of the crankshaft.
a After press fitting, remove the gasket sealant projected around the periphery.
125E-5 Series
SEN05204-00
Replacement of wear sleeve

(when sleeve is installed)
a
If the wear sleeve is worn or damaged, replace

it according to the following procedure.
Pulling out of sleeve

1. Make a groove on wear sleeve (1) with a
grinder.
2.
Put a chisel to the groove on the sleeve and hit

it with a hammer to remove the sleeve.
a If the sleeve is difficult to remove, remove
it by the following method.
q
Make a V-notch on the sleeve with a
grinder.
q
Break the V-notched portion with a
chisel to remove the sleeve.
k Take extreme care not to let the chisel
fly out.
a When pulling out the wear sleeve, take
care not to damage the crankshaft.
Press fitting of sleeve

1. Check that the interference between the
sleeve and crankshaft is within the standard
value.
2.
Using the sleeve driver, install the sleeve by

shrink fit.
a When using oil to heat the sleeve, select
an oil of a high flash point and take
extreme care in handling fire.
125E-5 Series
21
SEN05204-00
Repair of crankshaft by grinding

q
q
q
When the crankshaft is worn, seized or damaged slightly and needs to be repaired, grind it
to one of the following undersizes.
Undersizes: 0.25, 0.50, 0.75, 1.00 mm
If the crankshaft is bent or worn unevenly, it
should not be repaired but should be replaced.
(Repairing the crankshaft requires high technologies)
Do not straighten the crankshaft with a press
since it bends again while the engine is operated.
Do not repair the journal portions by build-up
welding or plating since they have been
treated by induction hardening etc.
If the crankshaft is worn unevenly, discard it
since it may be bent and/or unbalanced even
after it is repaired.
Measure the portions to be ground and then
decide the undersize dimension.
Judging from the measured value, if wear of
the crankshaft exceeds the using limit after
grinding to the undersize, discard the crankshaft.
Limit application of repair by plating to the following portions.
q
Rear seal journal portion
q
Crank gear mounting portion
Finish fillet portion (R), shoulder portion (r) and
area (R) around the hole of the crankshaft with
extreme care.
Finish the main journal and pin journal according to the following procedure.
Main journal oil hole (See figure below)

Dimension of tapered part (a) of oil hole:
12 mm
q
Angle (b) of tapered part of oil hole: 120
q
Surface roughness of oil hole top (c):
1.6S (Finished with sandpaper)
q
Dimension of parts (R) at 2 places: 1 2 mm
q
Pin journal oil hole (See figure below)

Finish part (d) with sandpaper.
q
Check part (e) extremely carefully since
quenching crack tends to occur in that part.
q
Finish dimensions of fillet portion

(R): 5.3 +0.3
0 mm
Surface roughness: 3.2S
22
125E-5 Series
Equipment necessary for grinding

q
Magnaflux inspection machine
q
Shore hardness tester
q
Etching kit
q
Crankshaft grinding machine
q
Crankshaft polishing machine
q
Surface roughness gauge
q
Fillet (R) gauge
Inspection before repair by grinding
Visual check
If there is a visible thermal crack on the crankshaft, discard the crankshaft since its hardened layer is damaged.
q
If the journal surface of the crankshaft or a
shoulder portion near the thrust face which has
not been machined are discolored, discard the
crankshaft since its temperature has increased
high.
q
If wear and/or damage of the journal surface of
the crankshaft cannot be removed by grinding
to the undersize, discard the crankshaft. (High
skill is required)
q
If a round portion etc. of the crankshaft which
affects strength is damaged, discard the crankshaft.
q
If only either side of the crankpin journal of the
crankshaft is worn, discard the crankshaft
since such wear affects balance.
q
SEN05204-00
Check during and after repair by grinding

Check of fillet (R) portion
q
Check that each fillet (R) portion is connected
to the journal shoulder smoothly.
q
Ensure that there is not a scratch or a seized
part in the fillet (R) portion at which stress will
be concentrated.
q
Ensure that the (R) dimension of the fillet is
within the standard dimension.
(R) dimension:
Must be between the minimum radius gauge
and maximum radius gauge.
Hardness check of journal surface

Measure the hardness of the journal surface of
the crankshaft with a Shore hardness tester. If
the hardness is out of the standard, discard the
crankshaft since the hardness indicates that
the journal surface has been damaged by
overheating.
Hardness standard: Normally 60 70 Hs
125E-5 Series
23
SEN05204-00
Using a fillet gauge and a penlight, check the

(R) dimension and rise of the fillet according to
1.
While moving the minimum radius gauge from

the journal surface to the fillet portion, through
light from the rear of the ball to check contact
point (a).
q
If the fillet is normal, only 1 contact point
(b) moves around the periphery of the ball
which the ball is moving.
q
If 2 contact points are seen at any place
while the ball is moving, a part of the fillet
radius is smaller than the minimum value.
In this case, repair again.
Check for seizure mark by etching

q
After repairing by grinding, check that there is
no grinding burn mark by etching inspection.
q
If the journal portion is damaged, seized or
streaked in a bearing accident etc., check for a
seizure mark by etching and use the result for
judgment of hardness reduction and decision
of an undersize dimension.
q
The purpose of etching inspection is to check

for a seizure mark that cannot be detected by
visual inspection or hardness test and a grinding burn mark caused by heating during grinding.
Seizure and grinding burn at the journal or fillet

portion are breakage of the metallic organization. Although they occur in a shallow part,
they can cause stress concentration that can
break the crankshaft.
Etching inspection procedure

1. Thoroughly clean the surface to be inspected.
2.
24
Similarly to step 1, while moving the maximum

radius gauge from the journal surface to the fillet portion, check the contact points.
q
If the fillet is normal, 2 contact points (c)
are seen at the (R) portion.
q
If only 1 contact point is seen, the fillet
radius is larger than the maximum value.
In this case, repair again.
q
The radius of the (R) portion can be
adjusted by repairing the grinding stone.
2.
Clean the surface to be inspected with aqueous solution of 4% nitric acid.

Hold an absorbent cotton ball 2 3 cm in diameter with tweezers, soak it with the solution,
and clean the surface with it for 1 2 minutes.
3.
Rinse out the solution of nitric acid with water

from the inspected surface and dry the surface.
Clean the surface with absorbent cotton
soaked with acetone and then dry again.
4.
Soak absorbent cotton with diluted hydrochloric acid (acetone containing 2% of hydrochloric
acid) and etch the inspected surface with it for
30 seconds 1 minute.
5.
Rinse out the diluted hydrochloric acid with

water from the inspected surface, clean with
acetone, and dry with compressed air.
6.
Check the inspected surface.

q
If the etched surface is free from seizure
or burn, it has an even and bright color.
q
A hairline or a dark spot in the bright gray
surface indicates grinding burn.
q
Spreading of streaks brighter than the
gray surface indicates extreme grinding
burn.
q
If there is a suspicious pattern, polish the
etched surface and test it again.
q
If the surface has been seized or burnt,
the same pattern appears again when
etching is repeated.
125E-5 Series
7.
After finishing inspection, polish out the surface discolored by etching and then clean and
dry.
Neutralize the inspected surface by cleaning it
with weak solution of calcium hydroxide or
equivalent alkaline solution.
8.
After drying, coat the crankshaft with rust preventive oil.

Treat the inspected surface and oil holes with
extreme care.
When installing the crankshaft to the engine
immediately, it may be coated with engine oil.
q
If a seized or burnt part is detected, grind
about 0.02 mm to the next undersize.
Undersizes: 0.25, 0.50, 0.75, 1.00 mm
Magnaflux inspection
Before using the repaired crankshaft, check it
by magnaflux inspection to ensure that it has
no crack.
q
Extremely closely check the journal fillet portion which is in the dangerous area of each
web of the crankshaft.
q
This part must not have even a slight crack
since it receives the largest stress on the
crankshaft.
q
SEN05204-00
1.
Measurement of overall length alignment

q
Support the front and rear of the crankshaft and measure the runout of the center main journal with a dial gauge.
2.
Measurement of adjacent alignment

q
Support the journal adjacent to the journal
to be measured and the rear end journal
and measure the runout of the measured
journal with a dial gauge.
3.
Measurement of crankshaft front end alignment

q
Support the front and rear end journals of
the crankshaft and measure the runout at
a part within 6 mm from the crankshaft
front end.
4.
Measurement of crankshaft rear end alignment

q
Support the front and rear end journals of
the crankshaft and measure the runout at
a part within 6 mm from the crankshaft
rear end.
Measurement of bend (Measurement of alignment)

q
Measure the bend of the ground crankshaft
and ensure that it is within the standard value.
q
Measure the bend (alignment) at 4 places 1
4 shown below.
q
Before measuring the bend of the crankshaft,
ensure that its cylindricality and roundness are
within the respective allowable limits.
125E-5 Series
25
SEN05204-00
Grinding of main journal

a Grind all the main journals to the same undersize.
a Stamp undersize dimension (a) on the ground
shaft as shown in the figure to prevent installation of bearing metals of a different size.
a After grinding, ensure that the dimension of the
journal is within the tolerance.
q
q
M: Main journal
P: Crankpin journal
Grinding of pin journal

q
Grind all the pin journals to the same undersize.
q
Stamp crankpin undersize dimension (a) on
the ground shaft similarly to the main journal
undersize dimension.
q
After grinding, ensure that the dimension of the
journal is within the tolerance.
q
q
M: Main journal
P: Crankpin journal
Grinding of thrust surface

a It is not always required to grind the thrust surfaces of front (b) and rear (c) to the same
undersize dimension.
a Stamp the undersize dimension on the ground
shaft as shown in the figure to prevent installation of a wrong thrust bearing.
a After grinding, ensure that the width of the
thrust surface is within the tolerance.
a If the side of thrust surface (a) was repaired by
grinding, ensure that the end play of the crankshaft is within the allowable range.
q
Grinding condition (Reference)
Grinding speed: 1,800 2,200 rpm
Feed rate: 0.2 0.4 mm/min
26
125E-5 Series
SEN05204-00
Grinding of sides of main journal and pin journal

q
When repairing worn surfaces (c) of main journal (a) and pin journal (b), limit the grinding
quantity to the minimum.
q
(d) is thickness of worn surface.
q
Leave at least 0.25 mm of the friction surface
of the main journal.
q
If the pin journal width is increased too much,
the connecting rod may move in the axial
direction or in the piston pin direction on the
crankshaft during operation, and that can
cause uneven wear. Accordingly, limit the
grinding quantity to the minimum and observe
the tolerance.
q
Grinding condition (Reference)
Grinding speed: 1,800 2,200 rpm
Feed rate: 0.2 0.4 mm/min
Dressing of grinding stone

q
Dress the grinding stone for each journal.
q
Since the (R) dimension and rise of the journal
fillet affect the strength of the crankshaft
largely, adjust them by dressing the grinding
stone as explained below.
q
Grinding stone dresser
Grooving angle (a): 75 1
Tip diameter (b): See manual for each series
Use a conical tip in which an industrial diamond is embedded.
When using a dresser, set the conical tip to the
center of the shank.
125E-5 Series
27
SEN05204-00
Adjust the grinding stone edge to the arc of the

fillet with the grinding stone modifying device.
Set the standard peripheral speed of the grinding stone to 2,000 m/min when the crankshaft
rotation speed is about 50 rpm.
Finishing of surface
Finish the journal surface smoothly since it
affects the fatigue strength of the crankshaft
and wear of the bearing.
q
Surface roughness standard after grinding
Journal surface, thrust surface and fillet portion: Max. 0.8S
Pin and main boss portions: Max. 3.2S
End nose portion and rear flange surface:
Max. 2.0S
q
When using a belt-type polishing machine, pull
the sandcloth in the rotation direction of the
crankshaft.
This must be observed to scatter the fine particles and prevent scratches caused by those
particles rolled in.
q
Finish the areas around oil holes to the same
surface roughness of the journal portion.
q
Polish finishing margin: 0.007 0.008 mm
q
Remove all rust and corrosion which can wear
the bearing and then apply high quality rust
preventive oil.
q
Finishing condition (Reference)
Sandpaper: AA#120
Shaft rotation speed: 100 rpm
Grinding speed: 36 m/min
q
q
q
q
q
First, repair the flat face of the grinding stone

and record the reading of the feed dial gauge.
Next, bring the radius of either edge arc in contact with the flat face of the grinding stone.
Limit the final feed rate for the repaired face to
0.013 mm.
Hold a small rough grinding stone with the
hand, apply it to the front face of the repaired
grinding stone, and grind lightly so that the
edge arc will be smoothly in contact with the
front face of the grinding stone.
At this time, slightly slant the grinding stone in
your hand and lightly press it against the
repaired grinding stone.
While grinding a piece of wood on trial and
checking the (R) dimension and rise of the fillet
with the gauges, repair the grinding stone so
that a complete shape of the fillet can be
obtained.
Similarly, repair the edge on the opposite side
of the grinding stone.
Finally, grind the crankshaft on trial and check
the shape of the fillet.
Prevention of grinding burn

Observe the following precautions to prevent
grinding burn.
q
Apply the flange grinding method where the
grinding stone is applied perpendicularly to the
crankshaft.
The bump grinding method, where the grinding
stone is applied to the crankshaft and moved
crosswise, can cause grinding burn.
q
Use all the width of the grinding stone and
avoid grinding the boss surface.
Finish the boss surface by polishing.
When feeding the grinding stone against the
boss surface, limit the feed rate to 0.025 mm/
sec.
q
Start feeding cooling oil to the side profile
machine and main jet before starting grinding
and supply it to the ground portion sufficiently.
q
28
Work after repair by grinding

Ensure again that each dimension is as specified.
q
Thoroughly clean each part, particularly the oil
holes, and then apply high quality rust preventive oil all over the crankshaft.
q
Handle the crankshaft with extreme care not to
scratch or damage it.
q
When storing the crankshaft for a long period,
support it on 3 points or keep it erected with a
sling so that it will not bend.
q
125E-5 Series
125E-5 Series
SEN05204-00
29
SEN05204-00

2009 KOMATSU
All Rights Reserved
30

125E Series: Engine

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

125E Series: Engine

Uploaded by

Copyright:

Available Formats

SEN00177-15

00 Index and foreword

00 Index and foreword

Composition of shop manual

00 Index and foreword

00 Index and foreword

00 Index and foreword

Oil pump ..................................................................................................................................

20 Standard value table

00 Index and foreword

Testing exhaust temperature ...................................................................................................

00 Index and foreword

E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error .......................................................... 68

00 Index and foreword

S-14 Coolant temperature becomes too high (overheating).................................................... 27

KOMATSU 125E-5 Series engine

00 Index and foreword

Foreword and general information

00 Index and foreword

Important safety notice

If welding repairs are needed, always

Prohibition of operation and handling by

6 Safety check before starting work

Wearing protective goggles

Wearing shielding goggles and protectors

9 Good physical condition and preparation

Precautions against work which you are

00 Index and foreword

Preparations for work

Precautions during work

When removing a cover which is under

Precautions for sling work and making

00 Index and foreword

When installing wire ropes to an angular

11) Do not use twisted or kinked wire ropes.

00 Index and foreword

If the load is unstable or the wire rope

Precautions for using mobile crane

Selecting wire ropes

The allowable load is one-sixth of the

00 Index and foreword

Example of O-ring (Fitted to every joint of

For tightening torque, see the precautions for

00 Index and foreword

How to read the shop manual

Composition of shop manual

Revision and distribution

00 Index and foreword

Revised edition mark

Weight of parts of component or parts. Caution necessary when

Places that require special attention for tightening torque during

00 Index and foreword

Explanation of terms for maintenance standard

Standard size and tolerance

The tolerance may be indicated in the text

Usually, the size of a hole and the size of

Standard clearance and standard value

Repair limit and allowable value or allowable dimension

00 Index and foreword

00 Index and foreword

Handling of electric equipment and hydraulic component

Points to remember when handling electric

Main failures occurring in wiring harness