Manual de Taller Motor 125e5

SEN00177-08
ENGINE
125E-5 SERIES
SEN00179-08
ENGINE 1SHOP MANUAL
125E-5 Series
00 Index and foreword 1

Index
Composition of shop manual................................................................................................................ 2

Table of contents .................................................................................................................................. 3
125E-5 Series 1
SEN00179-08 00 Index and foreword
Composition of shop manual 1

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 accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00177-08
00 Index and foreword SEN00178-08

Index SEN00179-08 q
Foreword and general information SEN00180-05 q
01 Specification SEN00181-04
Specification and technical data SEN00182-04 q
10 Structure, function and maintenance standard SEN00183-04

Structure, function and maintenance standard, Part 1 SEN00184-04 q
Structure, function and maintenance standard, Part 2 SEN00185-04 q
20 Standard value table SEN00186-05

Standard service value table SEN00546-05 q
30 Testing and adjusting SEN00187-02

Testing and adjusting SEN00547-02
40 Troubleshooting SEN00188-03
General information on troubleshooting SEN00548-03
Troubleshooting of electrical system (E-mode), Part 1 SEN00550-01
Troubleshooting of mechanical system (S-mode) SEN00549-01
50 Disassembly and assembly SEN00189-01

General information on disassembly and assembly SEN00697-01
Disassembly and assembly, Part 1 (With EGR) SEN00698-01
Disassembly and assembly, Part 2 (EGR-less) SEN00699-01
Disassembly and assembly, Part 3 SEN00700-00
2 125E-5 Series
Table of contents 1
00 Index and foreword
Index SEN00179-08
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00180-05

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 SEN00182-04
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 6
General view............................................................................................................................ 20
Weight table............................................................................................................................. 43
Engine performance curves..................................................................................................... 46
10 Structure, function and maintenance standard

Structure, function and maintenance standard, Part 1 SEN00184-04
General structure ........................................................................................................................ 4
Intake and exhaust system ......................................................................................................... 6
Intake and exhaust unit ........................................................................................................... 6
Air cleaner ............................................................................................................................... 10
Turbocharger ........................................................................................................................... 12
Aftercooler ............................................................................................................................... 19
EGR system ............................................................................................................................ 20
Engine unit .................................................................................................................................. 27
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 SEN00185-04

Lubrication system ...................................................................................................................... 4
125E-5 Series 3
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
Fuel piping ............................................................................................................................... 40
Fuel cooler ............................................................................................................................... 42
Fuel filter .................................................................................................................................. 43
Electric priming pump .............................................................................................................. 44
Engine controller cooler ........................................................................................................... 45
Cooling system............................................................................................................................ 46
Cooling system diagram .......................................................................................................... 46
Water pump ............................................................................................................................. 48
Thermostat............................................................................................................................... 50
Corrosion resistor .................................................................................................................... 52
Electrical equipment .................................................................................................................... 53
Alternator ................................................................................................................................. 53
Starting motor .......................................................................................................................... 60
Electrical intake air heater ....................................................................................................... 64
Engine controller...................................................................................................................... 65
20 Standard value table

Standard service value table SEN00546-05
Standard service value table ....................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ................................. 2
Running-in standard and performance test standard .............................................................. 15
30 Testing and adjusting

Testing and adjusting SEN00547-02
Testing and adjusting (With EGR) ............................................................................................... 4
Testing and adjusting tools list ................................................................................................. 4
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
4 125E-5 Series
Testing air boost pressure ....................................................................................................... 28

Testing exhaust temperature ................................................................................................... 29
Adjusting valve clearance........................................................................................................ 30
Testing compression pressure................................................................................................. 31
Testing blow-by pressure......................................................................................................... 33
Testing engine oil pressure...................................................................................................... 34
Handling fuel system parts ...................................................................................................... 35
Releasing residual pressure in fuel system ............................................................................. 35
Testing fuel pressure ............................................................................................................... 36
Reduced cylinder mode operation........................................................................................... 37
No-injection cranking ............................................................................................................... 37
Testing leakage from pressure limiter and return rate from injector ........................................ 38
Bleeding air from fuel circuit .................................................................................................... 40
Testing fuel system for leakage ............................................................................................... 42
Adjusting speed sensor ........................................................................................................... 43
Testing and adjusting alternator belt tension ........................................................................... 44
Handling controller voltage circuit............................................................................................ 45
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
125E-5 Series 5
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

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) SEN00549-01

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
6 125E-5 Series
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
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 SEN00697-01
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) SEN00698-01

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) SEN00699-01

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
125E-5 Series 7
SEN00179-08
KOMATSU 125E-5 Series engine
Form No. SEN00179-08
2008 KOMATSU
All Rights Reserved
Printed in Japan 07-08 (01)
8
SEN00180-05
ENGINE 1SHOP MANUAL
125E-5 Series
00 Index and foreword 1

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 1
Safety notice (Rev. 2008/06)

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 situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety plates stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety plates and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
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, fork-
lift, service car, etc.
2 125E-5 Series
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
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 parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, 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
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. larly careful to check that they are
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative () terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
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.
125E-5 Series 3
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.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing 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 form-
ing 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 allow-
able 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 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 125E-5 Series
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard Z twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
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 immedi-
ately in an emergency.
125E-5 Series 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner 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 dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
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 recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit 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 dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (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.
6 125E-5 Series
How to read the shop manual 1
q 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.
q Materials and specifications are subject to change without notice.
q 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.
1. 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 dis-
assembly 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 7
3. 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 )
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain 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, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 125E-5 Series
Explanation of terms for maintenance standard 1

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 tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the standard size and the range of differ-
ence 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 Tolerance
0.022
120
0.126
a 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)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
0.030 +0.046
60
0.076 +0
125E-5 Series 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the standard clear- between them is increased to a certain
ance, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the clearance limit.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
standard value, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value interference limit.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance 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 allow-

able 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 prod-
uct 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 vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 125E-5 Series
Handling of electric equipment and hydraulic component 1

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, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted 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 (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
125E-5 Series 11
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 sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), 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-cir-
cuited 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 sur-
face 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 com-
pressed 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 com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 125E-5 Series
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
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 connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

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

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
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 connec-

tors
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 disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
125E-5 Series 13
2) 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 dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
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 break-
age, 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 stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected 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.
14 125E-5 Series
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
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) horizon-
tally 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 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, 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 fol-
lows.
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 com-
pressed 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 con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 125E-5 Series
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol 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 control-
ler.
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 con-
nectors 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 discon-
necting 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 con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
125E-5 Series 17
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 perfor-
mance 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 clean-
ing 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 equip-
ment, 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 cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
125E-5 Series 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 170, 12V140 engine
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure 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)
Disconnect connector (1) according to the fol-

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

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

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.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
125E-5 Series 21
q 95, 125 170, 12V140 engine 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) 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 har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
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)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 125E-5 Series
How to read electric wire code 1

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 sym-
bols. 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 nomi-
nal 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 indi-
cated.)
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)
Using
Sym-
Type Material temperature Example of use
bol
range (C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- 30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX 50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
125E-5 Series 23
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
Cov-
AV Standard 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
f of nominal No. denotes flexible.
24 125E-5 Series
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW 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 AVS or AV AEX
Charge R WG R
Ground B B
Start R R
Light RW RB RY RG RL D
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB L
Type of
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW
O
Others Gr
P
Sb
Dg
Ch
125E-5 Series 25
Precautions when carrying out operation 1

[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. Precautions when carrying out removal work

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

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 125E-5 Series
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 3 drops of adhesive.
q 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.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a 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.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. 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 speci-
fied 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
4) 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.
5) 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.
28 125E-5 Series
Method of disassembling and connecting push-pull type coupler 1

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.
k 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
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 hexag-
onal 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 discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
30 125E-5 Series
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect 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 hexag-
125E-5 Series 31
Standard tightening torque table 1

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 corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 14.7 1.2 1.5
8 13 27 34 2.8 3.5
10 17 59 74 6.0 7.5
12 19 98 123 10.0 12.5
14 22 157 196 16 20
16 24 245 309 25 31.5
18 27 343 427 35 43.5
20 30 490 608 50 62
22 32 662 829 67.5 84.5
24 36 824 1,030 84 105
27 41 1,180 1,470 120 150
30 46 1,520 1,910 155 195
33 50 1,960 2,450 200 250
36 55 2,450 3,040 250 310
39 60 2,890 3,630 295 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 9.8 0.6 1.0
8 12 13.7 23.5 1.4 2.4
10 14 34.3 46.1 3.5 4.7
12 17 74.5 90.2 7.6 9.2
a Fig. A a Fig. B
a Apply the width across flats in the table for Fig.

B to the bolt marked with * in Fig. A. (Apply the
tightening torque in the table for Fig. A.)
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 mm Nm kgm
10 14 59 74 6.0 7.5
12 17 98 123 10.0 12.5
16 22 235 285 23.5 29.5
3. 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 Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 63 { 3.5 6.5} 44 { 4.5}
03,04 20 Varies depending 84 132 { 8.5 13.5} 103 {10.5}
05,06 24 on type of connec- 128 186 {13.0 19.0} 157 {16.0}
10,12 33 tor. 363 480 {37.0 49.0} 422 {43.0}
14 42 746 1,010 {76.0 103} 883 {90.0}
4. 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 Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}
10 10 17 9.81 12.74 {1.0 1.3} 11.27 {1.15}
12 12 19 14.7 19.6 {1.5 2.0} 17.64 {1.8}
14 14 22 19.6 24.5 {2.0 2.5} 22.54 {2.3}
16 16 24 24.5 34.3 {2.5 3.5} 29.4 {3.0}
18 18 27 34.3 44.1 {3.5 4.5} 39.2 {4.0}
20 20 30 44.1 53.9 {4.5 5.5} 49.0 {5.0}
24 24 32 58.8 78.4 {6.0 8.0} 68.6 {7.0}
30 30 32 93.1 122.5 { 9.5 12.5} 107.8 {11.0}
33 33 107.8 147.0 {11.0 15.0} 127.4 {13.0}
36 36 36 127.4 176.4 {13.0 18.0} 151.9 {15.5}
42 42 181.3 240.1 {18.5 24.5} 210.7 {21.5}
52 52 274.4 367.5 {28.0 37.5} 323.4 {33.0}
125E-5 Series 33
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.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No.
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 54 { 3.5 5.5} 9/16-18UN 14.3
02 19 44 { 4.5}
34 63 { 3.5 6.5} 14
22 54 93 { 5.5 9.5} 74 { 7.5} 11/16-16UN 17.5
03
24 59 98 { 6.0 10.0} 78 { 8.0} 18
04 27 84 132 { 8.5 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 186 {13.0 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 245 {18.0 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 245 {18.0 25.0} 216 {22.0} 33
(12) 46 197 294 {20.0 30.0} 245 {25.0} 36
(14) 55 246 343 {25.0 35.0} 294 {30.0} 42
6. 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 Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 16 {1.4 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 27 {2.4 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 47 {4.4 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 68 {6.1 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 95 {9.2 9.7} 92.5 {9.4} 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
Thread size
Bolts and nuts
mm Nm kgm
6 10 2 1.02 0.20
8 24 4 2.45 0.41
10 43 6 4.38 0.61
12 77 12 7.85 1.22
14
34 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 Tightening torque

mm Nm kgm
6 82 0.81 0.20
8 10 2 1.02 0.20
10 12 2 1.22 0.20
12 24 4 2.45 0.41
14 36 5 3.67 0.51
9. 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.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 2 1.53 0.20 51 0.51 0.10
1/8 20 2 2.04 0.20 15 2 1.53 0.20
1/4 25 3 2.55 0.31 20 2 2.04 0.20
3/8 35 4 3.57 0.41 25 3 2.55 0.31
1/2 55 6 5.61 0.61 35 4 3.57 0.41
3/4 75 8 7.65 0.82 45 5 4.59 0.51
125E-5 Series 35
Conversion table 1
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 hori-
zontal 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 (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
36 125E-5 Series
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
125E-5 Series 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 125E-5 Series
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
125E-5 Series 39
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade 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 Fahren-
heit 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 Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
40.4 40 40.0 11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
37.2 35 31.0 11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
34.4 30 22.0 10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
31.7 25 13.0 10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
28.9 20 4.0 9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
28.3 19 2.2 8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

27.8 18 0.4 8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
27.2 17 1.4 7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
26.7 16 3.2 7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
26.1 15 5.0 6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
25.6 14 6.8 6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

25.0 13 8.6 5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
24.4 12 10.4 5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
23.9 11 12.2 4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
23.3 10 14.0 3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
22.8 9 15.8 3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

22.2 8 17.6 2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
21.7 7 19.4 2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
21.1 6 21.2 1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
20.6 5 23.0 1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
20.0 4 24.8 0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

19.4 3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
18.9 2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
18.3 1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 125E-5 Series
125E-5 Series 41
SEN00180-05
2008 KOMATSU
All Rights Reserved
42
SEN00182-04
ENGINE 1SHOP MANUAL
125E-5 Series
01 Specification 1
Specification and technical data
Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 6
General view ...................................................................................................................................... 20
Weight table ....................................................................................................................................... 43
Engine performance curves ............................................................................................................... 46
125E-5 Series 1
SEN00182-04 01 Specification
Outline 1
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
D85EX-15E0, D85EX-15R
Bulldozer
D85PX-15E0, D85PX-15R
SAA6D125E-5
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
DCA-300SSK4 (DENYO/MQ GENERATOR) Generator
2 125E-5 Series
2. Outline of engine (with EGR)
q The 125E-5 engine is a high-performance and 5) The common rail high-pressure fuel injection
high-efficiency engine, which passed strict system controlled electronically is employed
emission regulations (USA: EPA Regulations for the 125E-3 and after models. This system
for 2006, EU: Regulations for 2006, Japan: can inject the fuel at high pressure of 120 MPa
Construction machinery regulations for 2006) {1,200 kg/cm2} from the low-speed range to the
and attained low fuel consumption, low noise, high-speed range. In addition, this system can
better exhaust gas color, and high acceleration control the form of injection most properly by
performance. Accordingly, this newly devel- electronic control according to the speed and
oped engine is suitable as a power source of load. The injection system of 125E-5 is further
construction machinery and industrial machin- improved to employ multiple injection and
ery used for various purposes. increase the injection pressure up to 140 MPa
{1,400 kg/cm2}. As a result, exhaust gas of the
q The 125E-5 engine is the successor to the cleanest level in the world, good exhaust gas
125E-3 engine. While it is an in-line 6-cylinder, color, low fuel consumption, and low noise are
water-cooled, common rail direct injection, 4- realized simultaneously.
stroke diesel engine, it is equipped with the
cooled EGR system which is a new technol- 6) As the injection pressure of the common rail
ogy. injection system employed for the 125E-3
engine and after models is increased (from
1) The main components of the cooled EGR sys- 120 to 140 MPa {from 1,200 to 1,400 kg/cm2}),
tem are the EGR cooler of corrugated tube the pressure resistance of the common rail,
type made of newly developed special stain- injector, and supply pump is improved for
less steel and the EGR valve driven hydrauli- higher reliability.
cally and controlled electronically which
KOMATSU developed by itself. The cooled 7) The main fuel filter of high efficiency and the
EGR system secures the optimum EGR rate pre-fuel filter are installed as standard so that
from the low-speed range to the high-speed the low grade fuel in the market (equivalent to
range to attain both clean exhaust gas and low Class NAS13) can be used. In addition, the
fuel consumption with the bypass assist circuit delivery of the priming pump used to replace
consisting of the venturi system and bypass the filters is increased for higher serviceability.
valve which has the same function and struc-
ture as those of the EGR valve. 8) The high-quality piston made of cast iron which
has been employed for the 125E-2 engine and
2) The special EGR oil pump is employed to gen- after models is employed. This piston has a
erate high oil pressure (1.47 MPa {15 kg/cm2}) less coefficient of thermal expansion, a reen-
as the drive power source of the EGR valve trant combustion chamber, and a shaker cool-
driven hydraulically and controlled electroni- ing gallery. As a result, clean exhaust gas,
cally. good exhaust gas color, and low fuel consump-
tion are attained simultaneously, and high
3) The 125E-5 engine is equipped with the com- durability and reliability are also obtained.
bination filter system of high performance and
efficiency, which has been employed for the 9) By using the above-mentioned high-pressure
125E-3 engine, to meet the requirements of fuel injection system controlled electronically,
the EGR system and high-dispersion oil and the multiple injection and injection characteris-
capture large and small particles. In addition, tics are set most properly to improve the start-
the recommended sub-materials for operation ability and reduce the white exhaust smoke
(oil and fuel) are changed to improve the reli- when the temperature is low.
ability and durability of the engine.
10) Since the engine controller is mounted on the
4) Since the high-pressure fuel injection system engine and equipped with the automatic high-
controlled electronically is employed, less soot altitude compensation function, the engine can
is produced and the draining interval of the oil be operated at high altitude without replacing
is lengthened. (While the capacity of the oil the controller. As a result, the serviceability is
pan is not changed, the oil replacement inter- improved.
val of 500 hours is secured.)
125E-5 Series 3
11) The KTR90 turbocharger newly developed and

manufactured by KOMATSU for higher reliabil-
ity 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 main-
tained.
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.
4 125E-5 Series
3. Outline of engine (EGR-less)
q The 125E-5 EGR-less engine is a high-perfor- 5) The main fuel filter of high efficiency and the
mance and high-efficiency engine, which pre-fuel filter are installed as standard so that
attained low fuel consumption, low noise, bet- the low grade fuel in the market (equivalent to
ter exhaust gas color, and high acceleration Class NAS13) can be used. In addition, the
performance. Accordingly, this newly devel- priming pump used for replacement of the fil-
oped engine is suitable as a power source of ters is electrified for high serviceability.
construction machinery and industrial machin-
ery used for various purposes. 6) The high-quality piston made of cast iron which
has been employed for the 125E-2 engine and
q The 125E-5 EGR-less engine is the successor after models is employed. This piston has a
to the 125E-3 engine, which is an in-line 6-cyl- less coefficient of thermal expansion, a reen-
inder, water-cooled, common rail direct injec- trant combustion chamber, and a shaker cool-
tion, and 4-stroke diesel engine. ing gallery. As a result, clean exhaust gas,
good exhaust gas color, and low fuel consump-
1) The 125E-5 EGR-less engine is equipped with tion are attained simultaneously, and high
the combination filter system of high perfor- durability and reliability are also obtained.
m 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 7) By using the above-mentioned high-pressure
requirements of high-dispersion oil and cap- fuel injection system controlled electronically,
ture large and small particles. In addition, the the multiple injection and injection characteris-
recommended sub-materials for operation (oil tics are set most properly to improve the start-
and fuel) are changed to improve the reliability ability and reduce the white exhaust smoke
and durability of the engine. when the temperature is low.
2) Since the high-pressure fuel injection system 8) Since the engine controller is mounted on the
controlled electronically is employed, less soot engine and equipped with the automatic high-
is produced and the draining interval of the oil altitude compensation function, the engine can
is lengthened. (While the capacity of the oil be operated at high altitude without replacing
pan is not changed, the oil replacement inter- the controller. As a result, the serviceability is
val of 500 hours is secured.) improved.
3) The common rail high-pressure fuel injection 9) The KTR90 turbocharger newly developed and
system controlled electronically is employed manufactured by KOMATSU for higher reliabil-
for the 125E-3 and after models. This system ity and higher performance is mounted. The
can inject the fuel at high pressure of 120 MPa efficiency of the blower impeller is improved
{1,200 kg/cm2} from the low-speed range to the and special manufacturing methods for higher
high-speed range. In addition, this system can strength of the material are employed to obtain
control the form of injection most properly by higher efficiency and higher pressure ratio. As
electronic control according to the speed and a result, high performance is maintained from
load. The injection system of 125E-5 is further the low-speed range to the high-speed range.
improved to employ multiple injection. As a
result, the characteristics of good exhaust gas 10) The copper sleeve at the injector mounting
color, low fuel consumption and low noise are hole of the cylinder head is eliminated.
realized simultaneously. Instead, the dry sleeve structure is employed
and the top and bottom faces of the cylinder
4) The pressure resistance of the common rail, head are connected by casting to meet the
injector, and supply pump of the common rail requirements of the high output and attain
injection system employed for the 125E-3 higher reliability.
engine and after models is improved for higher
reliability.
125E-5 Series 5
Specifications 1
Engine name SAA6D125E-5

PC400-7E0, PC400LC-7E0,
PC400-8, PC400LC-8
Applicable machine
PC450-7E0, PC450LC-7E0,
PC450-8, PC450LC-8
Number of cylinders Bore Stroke mm 6 125 150
Total displacement l {cc} 11.0 {11,040}
Firing order 153624
Overall length mm 1,713
Dimensions
Overall width mm 1,001

Overall height (excluding exhaust pipe) mm
Overall height (including exhaust pipe) mm 1,741
262.5 / 1,900
kW/rpm
Rated output {352 / 1,900}
{HP/rpm}
(Gross)
1,422 / 1,400
Nm/rpm
Performance
Max. torque {145 / 1,400}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 1,930 (+35/-15)
(High idle speed)
No-load min. speed
rpm 1,000 25
(Low idle speed)
g/kWh 211
Fuel consumption ratio at rated output
{g/HPh} {157}
Dry weight kg 1,310
Fuel injection pump DENSO ECD-U2
Governor Electronic control type
Quantity of lubricating oil 46
l
(Refill capacity) (37)
Quantity of coolant
l
(for only engine) (21)
Alternator 24V, 35A, 60A
Starting motor 24V, 7.5kW
Battery 12V, 150Ah2
Turbocharger KOMATSU KTR90
Air compressor
Others With air-cooled aftercooler
6 125E-5 Series

PC400-8R, PC400LC-8R
Applicable machine
Firing order 153624
Dimensions
Overall width mm 975

262.5 / 1,900
kW/rpm
{HP/rpm}
(Gross)
1,422 / 1,400
Nm/rpm
Performance
Max. torque {145 / 1,400}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 1,930 (+35/-15)
(High idle speed)
No-load min. speed
rpm 1,000 25
(Low idle speed)
g/kWh 211
{g/HPh} {157}
Dry weight kg 1,270
l
Quantity of coolant
l
Alternator 24V, 50A, 60A
Battery 12V, 150Ah2
Air compressor
125E-5 Series 7

Applicable machine D85EX-15E0, D85PX-15E0
Firing order 153624
Dimensions

Overall height (excluding exhaust pipe) mm 1,711
Overall height (including exhaust pipe) mm
199 / 1,900
kW/rpm
{HP/rpm}
(Gross)
1,272 / 1,400
Nm/rpm
Performance
Max. torque {130 / 1,400}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 2,100 50
(High idle speed)
No-load min. speed
rpm 750 (+50/0)
(Low idle speed)
g/kWh 215
{g/HPh} {160}
Dry weight kg 1,330
l
Quantity of coolant
l
Alternator 24V, 50A
Battery 12V, 150Ah2
Air compressor
8 125E-5 Series

Applicable machine D85EX-15R, D85PX-15R
Firing order 153624
Dimensions

199 / 1,900
kW/rpm
{HP/rpm}
(Gross)
1,272 / 1,400
Nm/rpm
Performance
Max. torque {130 / 1,400}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 2,100 50
(High idle speed)
No-load min. speed
rpm 750 (+50/0)
(Low idle speed)
g/kWh 215
{g/HPh} {160}
Dry weight kg 1,270
l
Quantity of coolant
l
Alternator 24V, 50A
Battery 12V, 150Ah2
Air compressor
125E-5 Series 9

Applicable machine HM250-2
Number of cylinders Bore Stroke mm 6125 150
Firing order 153624
Dimensions

232 / 2,000
kW/rpm
{HP/rpm}
(Gross)
1,706 / 1,400
Nm/rpm
Performance
Max. torque {174 / 1,400}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 2,100 50
(High idle speed)
No-load min. speed
rpm 725 (+50/0)
(Low idle speed)
g/kWh 218
{g/HPh} {162}
Dry weight kg 1,285
l
Quantity of coolant
l
Alternator 24V, 50A
Battery 12V, 300Ah2
Air compressor
10 125E-5 Series

Applicable machine HM300-2
Firing order 153624
Dimensions

254 / 2,000
kW/rpm
{HP/rpm}
(Gross)
1,706 / 1,400
Nm/rpm
Performance
Max. torque {174 / 1,400}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 2,220 50
(High idle speed)
No-load min. speed
rpm 725 (+50/0)
(Low idle speed)
g/kWh 215
{g/HPh} {161}
Dry weight kg 1,285
l
Quantity of coolant
l
Alternator 24V, 50A
Battery 12V, 300Ah2
Air compressor
125E-5 Series 11

Applicable machine HM300-2R
Firing order 153624
Dimensions

254 / 2,000
kW/rpm
{HP/rpm}
(Gross)
1,706 / 1,400
Nm/rpm
Performance
Max. torque {174 / 1,400}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 2,220 50
(High idle speed)
No-load min. speed
rpm 725 (+50/0)
(Low idle speed)
g/kWh 211
{g/HPh} {157}
Dry weight kg 1,260
l
Quantity of coolant
l
Alternator 24V, 50A
Battery 12V, 300Ah2
Air compressor
12 125E-5 Series

WA450-6
Applicable machine
WA470-6
Firing order 153624
Dimensions

204 / 2,000
kW/rpm
{HP/rpm}
(Gross)
1,307 / 1,450
Nm/rpm
Performance
Max. torque {133 / 1,450}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 2,170 50
(High idle speed)
No-load min. speed
rpm 800 (+50/0)
(Low idle speed)
g/kWh 216
{g/HPh} {161}
Dry weight kg 1,310
l
Quantity of coolant
l
Alternator 24V, 50A
Battery 24V, 136Ah2
Air compressor
125E-5 Series 13
Applicable machine WA470-6R

Firing order 153624
Dimensions

204 / 2,000
kW/rpm
{HP/rpm}
(Gross)
1,307 / 1,450
Nm/rpm
Performance
Max. torque {133 / 1,450}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 2,170 50
(High idle speed)
No-load min. speed
rpm 800 (+50/0)
(Low idle speed)
g/kWh 216
{g/HPh} {161}
Dry weight kg 1,250
l
Quantity of coolant
l
Alternator 24V, 50A
Battery 24V, 136Ah2
Air compressor
14 125E-5 Series
Applicable machine WA480-6

Firing order 153624
Dimensions

224 / 2,000
kW/rpm
{HP/rpm}
(Gross)
1,360 / 1,400
Nm/rpm
Performance
Max. torque {139 / 1,400}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 2,190 50
(High idle speed)
No-load min. speed
rpm 800 (+50/0)
(Low idle speed)
g/kWh 216
{g/HPh} {161}
Dry weight kg 1,310
l
Quantity of coolant
l
Alternator 24V, 50A
Battery 24V, 136Ah2
Air compressor
125E-5 Series 15
Applicable machine WA480-6R

Firing order 153624
Dimensions

224 / 2,000
kW/rpm
{HP/rpm}
(Gross)
1,360 / 1,400
Nm/rpm
Performance
Max. torque {139 / 1,400}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 2,190 50
(High idle speed)
No-load min. speed
rpm 800 (+50/0)
(Low idle speed)
g/kWh 216
{g/HPh} {161}
Dry weight kg 1,250
l
Quantity of coolant
l
Alternator 24V, 50A
Battery 24V, 136Ah2
Air compressor
16 125E-5 Series
Applicable machine BR580JG-1

Firing order 153624
Dimensions

262.5 / 1,900
kW/rpm
{HP/rpm}
(Gross)
1,422 / 1,400
Nm/rpm
Performance
Max. torque {145 / 1,400}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 1,930 (+35/-15)
(High idle speed)
No-load min. speed
rpm 1,000 25
(Low idle speed)
g/kWh 211
{g/HPh} {157}
Dry weight kg 1,310
l
Quantity of coolant
l
Alternator 24V, 35A
Battery 12V, 150Ah2
Air compressor
125E-5 Series 17

DCA-300SSK4
Applicable machine
(DENYO/MQ GENERATOR)
Firing order 153624
Dimensions

272 / 1,800
kW/rpm
{HP/rpm}
(Gross)
Nm/rpm
Performance
Max. torque
{kgm/rpm}
No-load max. speed
rpm Max. 1,890
(High idle speed)
No-load min. speed
rpm 750 25
(Low idle speed)
g/kWh 218
{g/HPh} {162}
Dry weight kg 1,450
l
Quantity of coolant 53
l
Alternator 24V, 35A
Battery 12V, 150Ah2
Air compressor
18 125E-5 Series
125E-5 Series 19
General view 1
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 The shape is subject to machine models.

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

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

2. Center of cylinder liner
125E-5 Series 21

Applicable machines: PC400-8R, PC400LC-8R, PC450-8R, PC450LC-8R

22 125E-5 Series

Applicable machines: PC400-8R, PC400LC-8R, PC450-8R, PC450LC-8R

125E-5 Series 23

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

24 125E-5 Series

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

125E-5 Series 25

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

26 125E-5 Series

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

125E-5 Series 27

Applicable machine: HM250-2, HM300-2

28 125E-5 Series


125E-5 Series 29
SAA6D125E-5 (Top of engine)


30 125E-5 Series

Applicable machine: HM300-2R

125E-5 Series 31


32 125E-5 Series
SAA6D125E-5 (Top of engine)


125E-5 Series 33

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

34 125E-5 Series

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

125E-5 Series 35

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

36 125E-5 Series

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

125E-5 Series 37

Applicable machines: BR580JG-1

38 125E-5 Series

Applicable machines: BR580JG-1

125E-5 Series 39

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

40 125E-5 Series

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

125E-5 Series 41
Dimensions table
Unit: mm
Dimension of each part
Engine Machine
A B C D E F G H J
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
1,713 1,741 438 1,001
PC400-8, PC400LC-8
PC450-8, PC450LC-8
1,713 1,741 438 975
D85EX-15E0, D85EX-15R
1,307 1,711 387 15 15 777 949 1,004
D85PX-15E0, D85PX-15R
SAA6D125E-5 WA450-6, WA470-6
WA480-6, WA470-6R 1,334 1,638 388 25 800 935
WA480-6R
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
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.
42 125E-5 Series
Weight table 1
(with EGR)
Unit: kg
No. Item Main parts SAA6D125E-5
1 Turbocharger KOMATSU KTR90 17
Cylinder head, valve,
2 Cylinder head assembly 15
valve spring
Cylinder block, bearing,
3 Cylinder block assembly 305
cap, cylinder liner
4 Front cover 29
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8,PC400LC-8 18
PC450-8,PC450LC-8
BR580JG-1
5 Oil pan D85EX-15E0, D85PX-15E0 21
WA450-6, WA470-6
WA480-6 22
HM250-2, HM300-2
DCA-300SSK4
35
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8 49
PC450-8, PC450LC-8
BR580JG-1
6 Flywheel assembly Flywheel ring gear D85EX-15E0, D85PX-15E0 55
WA450-6, WA470-6
27
WA480-6
HM250-2, HM300-2 23
DCA-300SSK4
118
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8
54
PC450-8, PC450LC-8
BR580JG-1
7 Flywheel housing assembly D85EX-15E0, D85PX-15E0
WA450-6, WA470-6,
WA480-6 47
HM250-2, HM300-2
DCA-300SSK4
64
125E-5 Series 43
Unit: kg
8 Crankshaft assembly Crankshaft, crank gear 106
Camshaft, cam gear,
9 Camshaft assembly 16
thrust plate
Piston and connecting rod Piston, piston ring,
10 8
assembly piston pin, connecting rod
11 Oil pump 5
12 Fuel supply pump 10
13 Water pump 10
24V, 35A 8
24V, 50A 10
14 Alternator
24V, 60A 11
24V, 75A 13
24V, 7.5kW 16
15 Starting motor
24V, 11kW 18
16 EGR oil pump 6
17 EGR valve 16
18 Bypass valve 16
19 EGR cooler 9
44 125E-5 Series
(EGR-less)
Unit: kg
1 Turbocharger KOMATSU KTR90 17
Cylinder head, valve,
2 Cylinder head assembly 15
valve spring
Cylinder block, bearing,
3 Cylinder block assembly 305
cap, cylinder liner
4 Front cover 29
18
5 Oil pan D85EX-15R, D85PX-15R 21
HM300-2R
22
WA470-6R, WA480-6R
49
6 Flywheel assembly Flywheel ring gear D85EX-15R, D85PX-15R 55
WA470-6R, WA480-6R 27
HM300-2R 23
PC450-8R, PC450LC-8R 54
7 Flywheel housing assembly D85EX-15R, D85PX-15R
HM300-2R
47
WA470-6R, WA480-6R
8 Crankshaft assembly Crankshaft, crank gear 106
Camshaft, cam gear,
9 Camshaft assembly 16
thrust plate
Piston and connecting rod Piston, piston ring,
10 8
assembly piston pin, connecting rod
11 Oil pump 5
12 Fuel supply pump 10
13 Water pump 10
24V, 50A 10
14 Alternator 24V, 60A 11
24V, 75A 13
24V, 7.5kW 16
15 Starting motor
24V, 11kW 18
125E-5 Series 45
Engine performance curves 1
Engine Engine serial No. Applicable machine Page

PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
47
PC400-8, PC400LC-8, PC400-8R, PC400LC-8R
PC450-8, PC450LC-8, PC450-8R, PC450LC-8R
D85EX-15E0, D85EX-15R, D85PX-15E0, D85PX-15R 48
SAA6D125E-5 WA450-6, WA470-6, WA470-6R 49
WA480-6, WA480-6R 50
HM250-2 51
HM300-2, HM300-2R 52
BR580JG-1 53
46 125E-5 Series
SAA6D125E-5
(Applicable machine: 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)
125E-5 Series 47
SAA6D125E-5
(Applicable machine: D85EX-15E0, D85EX-15R, D85PX-15E0, D85PX-15R)
Rated output: 199 kW {266 HP}/1,900 rpm (Gross)

48 125E-5 Series
SAA6D125E-5 (Applicable machine: WA450-6, WA470-6, WA470-6R)

125E-5 Series 49
SAA6D125E-5 (Applicable machine: WA480-6, WA480-6R)

50 125E-5 Series
SAA6D125E-5 (Applicable machine: HM250-2)

125E-5 Series 51
SAA6D125E-5 (Applicable machine: HM300-2, HM300-2R)

52 125E-5 Series
SAA6D125E-5 (Applicable machine: BR580JG-1)

Rated output: 262.5 kW {352 HP}/1,900 rpm (Gross)
125E-5 Series 53
SEN00182-04
2008 KOMATSU
All Rights Reserved
54
SEN00184-04
ENGINE 1SHOP MANUAL
125E-5 Series
10 Structure, function and

maintenance standard 1
Structure, function and maintenance
standard, Part 1
General structure ............................................................................................................................................ 4
Intake and exhaust system ............................................................................................................................. 6
Intake and exhaust unit ........................................................................................................................ 6
Air cleaner .......................................................................................................................................... 10
Turbocharger...................................................................................................................................... 12
Aftercooler .......................................................................................................................................... 19
EGR system ....................................................................................................................................... 20
Engine unit .................................................................................................................................................... 27
Cylinder head ..................................................................................................................................... 27
Cylinder block..................................................................................................................................... 30
Cylinder liner ...................................................................................................................................... 34
125E-5 Series 1
SEN00184-04 10 Structure, function and maintenance standard
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
2 125E-5 Series
125E-5 Series 3
General structure 1
Common rail system specification 1
1. Cylinder block 14. Flywheel

2. Cylinder liner 15. Rear seal
3. Piston 16. Flywheel housing
4. Connecting rod 17. Oil pan
5. Piston pin 18. Crankshaft
6. Cross head 19. Main bearing cap
7. Intake valve 20. Oil strainer
8. Exhaust valve 21. Crank gear
9. Rocker arm shaft 22. Front cover
10. Injector 23. Front seal
11. Cylinder head cover 24. Crankshaft pulley
12. Camshaft 25. Vibration damper
13. Ring gear
4 125E-5 Series
26. Exhaust manifold 31. Air intake manifold

27. Turbocharger 32. Common rail
28. Cylinder head 33. Fuel supply pump
29. Rocker arm 34. Cam follower
30. Push rod 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 5
Intake and exhaust system 1

Intake and exhaust unit 1
A: Intake unit (Between air-cooled aftercooler and intake manifold)
1. Electrical intake air heater

2. Diffuser
3. Intake manifold
6 125E-5 Series
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 7
SAA6D125E-5 (Right side of engine) (EGR-less)
A : To turbocharger
1. Exhaust manifold (Rear)

2. Exhaust manifold (Center)
3. Exhaust manifold (Front)
8 125E-5 Series
125E-5 Series 9
Air cleaner 1
FRG type (Radial seal type)
1. Inlet 6. Evacuator valve

2. Outlet 7. Dust pan
3. Guide vane 8. Guide plate (Sleeve)
4. Primary element 9. Body
5. Safety element 10. Element
Evacuator
Engine Applicable machines Type Number of elements
valve
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8, PC400-8R, PC400LC-8R
PC450-8, PC450LC-8, PC450-8R, PC450LC-8R
D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R FRG Automatic 1 inner element
SAA6D125E-5
WA450-6, WA470-6, WA470-6R (Radial seal type) discharge 1 outer element
WA480-6, WA480-6R
HM250-2, HM300-2, HM300-2R
BR580JG-1
DCA-300SSK4
10 125E-5 Series
Structure Operation
q The size of the body is reduced from the con- q Air containing dust is sucked in vertically
ventional type without changing the diameter through inlet (1) and the dust is separated by
of the element. the centrifugal effect of guide vane (3).
q Since the inlet is set in the tangential direction, q More than 99.9% of the dust is removed by pri-
air is given sufficient centrifugal force by the mary element (4) and clean air is sucked in the
simple spiral guide vane, not by the guide engine through safety element (5) and outlet
plate. (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 dis-
charged out automatically.
125E-5 Series 11
Turbocharger 1
(with EGR)
Model name: KTR90
12 125E-5 Series
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
Unit: mm
No. Check item Criteria Remedy
Standard Repair limit Replace thrust
1 End play (Play in axial direction)
0.08 0.13 0.18 parts
Replace bearing
2 Radial play (Play in radial direction) 0.38 0.59
parts
Clearance between blower housing Replace bearing
3 Clearance limit (Min.): 0.01
and impeller parts
14 125E-5 Series
125E-5 Series 15
(EGR-less)
Model name: KTR90
16 125E-5 Series
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
Unit: mm
Standard Repair limit Replace thrust
1 End play (Play in axial direction)
0.08 0.13 0.18 parts
Replace bearing
2 Radial play (Play in radial direction) 0.38 0.59
parts
Clearance between blower housing Replace bearing
3 Clearance limit (Min.): 0.01
and impeller parts
18 125E-5 Series
Aftercooler 1
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
EGR system 1
No. Component part Function

Controls the gas flow from the exhaust system to the air intake system.
EGR valve (driven hydrau-
1 Since the exhaust pressure (PEX) is higher than the boost pressure (PIN), the
lically)
exhaust gas flows to the air intake valve.
Opens the bypass valve when the boost pressure (PIN) is higher than the exhaust
pressure (PEX).
2 Bypass valve
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.
5 Each sensor
Troubleshoots the system.
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 trouble-
shooted, a serious trouble is prevented.
20 125E-5 Series
125E-5 Series 21
a The above illustration shows the engine for HM300-2.
22 125E-5 Series
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 open-
ing 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 mani-
fold 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 pres-
sure 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
EGR valve and bypass valve
A: Oil inlet 1. Stick prevention device

B: Oil outlet 2. Oil pressure control valve
C: EGR gas passage (EGR valve) 3. Solenoid
D: Boost air passage (Bypass valve) 4. Position sensor
5. Hydraulic piston
6. Spring
7. Valve
Function q Valve (7) is closed by spring (6) but pushed

q The EGR valve controls the EGR gas. open by hydraulic piston (5) to an opening ratio
q This valve is driven hydraulically and its open- in proportion to the control oil pressure.
ing ratio is controlled electronically. q The valve opening ratio is sensed with position
sensor (4) installed to hydraulic piston (5) and
Operation set to the specified opening ratio by controlling
q The oil pressure (engine oil) of 1.47 MPa {15 the solenoid current.
kg/cm2} supplied to oil inlet (A) is reduced by q The bypass valve assists the EGR gas by
oil pressure control valve (2). increasing the exhaust pressure.
q Hydraulic piston (5) generates pressing force q The structure and operation of the EGR
from the reduced oil pressure. bypass valve are the same as those of the
q The control oil pressure can be changed with EGR valve.
the drive current of solenoid (3).
24 125E-5 Series
EGR cooler
A : EGR gas inlet D : Coolant outlet

B : EGR gas outlet E : Air bleeder
C : Coolant inlet
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 effi-
ciency.
Structure
q 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.
125E-5 Series 25
Venturi system
A : Air inlet 1. Venturi nozzle

B : EGR gas inlet 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), ven-
turi nozzle (1), and diffuser (3).
Operation
q The boost pressure increased by the turbo-
charger 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.
26 125E-5 Series
Engine unit 1
Cylinder head 1
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
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
q Valve seat inserts are press fitted to both intake and exhaust valves
Head cover
q Float-type seal
28 125E-5 Series
a Order of tightening cylinder head mounting bolts

a Tighten the cylinder head mounting bolts in the order of (1) (7).
Unit: mm
Strain of cylinder head Tolerance Repair limit Correct by grind-
1
mounting surface 0 0.06 0.09 ing or replace
Engine Standard Replace nozzle
2 Projection of nozzle
SAA6D125E-5 3.20 3.90 sleeve
Bolt Procedure Target (Nm {kgm}) Range (Nm {kgm})
Tightening torque of cyl- 88.2 107.8

1st stage 98 {10}
inder head mounting bolt {9 11}
Tighten in order
3 (apply molybdenum dis- (1) (6) 166.6 176.4
2nd stage 176.4 {18} shown above
ulfide or engine oil to {17 18}
underside of bolt head.) 3rd stage Retighten 120 90 120
(7) 68.6 {7} 58.8 73.5 {6 7.5}
Tightening torque of Target (Nm {kgm}) Range (Nm {kgm})
4
injector mounting bolt 66 {6.75} 58.8 73.5 {6.0 7.5}
Tightening torque of Tighten
5 rocker arm housing 66 {6.75} 58.8 73.5 {6.0 7.5}
mounting bolt
125E-5 Series 29
Cylinder block 1
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
Cylinder block
q Crankshaft section: 7 bearings
q Camshaft section: 7 bearings
Front seal
q Single lip with dust seal
Piston cooling
q With piston cooling nozzle
Cylinder liner
q Wet type
q Machining on inside: Plateau honing
Soft nitriding process
Liner ring
q Upper : Clevis seal
q Middle : O-ring (Ethylene-propylene rubber)
q Lower : O-ring (Silicone rubber)
125E-5 Series 31
Unit: mm
Strain of cylinder head Tolerance Repair limit Correct by grind-
1
mounting surface 0 0.080 0.12 ing or replace
Diameter of main bearing Replace main
mounting hole +0.015 bearing cap
116
0.010
2 Roundness of mounting
Repair limit: 0.005
hole
Replace bearing
0.005
Thickness of main bearing 3
0.020
Standard size Tolerance Repair limit
Inside diameter of main Replace main
3 +0.040
bearing 110 110.15 bearing
+0.010
Standard size Tolerance Correct or
Diameter of cam bushing
4 +0.030 replace cylinder
mounting hole 63
+0.000 block
Inside diameter of cam Replace cam
5 +0.070
bushing 60 60.30 bushing
0
32 125E-5 Series
Unit: mm
Procedure Target(Nm{kgm}) Range(Nm{kgm})
Tightening torque of main cap 1st stage 98 {10} 88 108 {9 11}
6
(apply engine oil to threads) 2nd stage 196 {20} 191 201 {19.5 20.5}
3rd stage Retighten 90 Retighten 90(+30/0)
Tighten
Tightening torque of oil pan
7 54 {5.5} 34 73 {3.5 7.5}
mounting bolt
Tightening torque of crankshaft M16 (5 pieces) 274 {28} 245 309 {25 31.5}
8
pulley mounting bolt M14 (1 piece) 176 {18} 157 196 {16 20}
Level difference between
9 underside surfaces of cylinder Repair limit: 0.35
block and flywheel housing Correct by
Level difference between reassembling
10 underside surfaces of cylinder Repair limit: 0.28
block and front cover
125E-5 Series 33
Cylinder liner 1
Unit: mm
Replace cylinder liner or
1 Projection of cylinder liner Permissible range: 0.07 0.15
cylinder block
Rank Standard size Tolerance Repair limit
+0.020
Inside diameter of cylinder A 125 125.20
+0.000
liner (unit)
+0.040
B 125 125.20
2 +0.021
Replace cylinder liner
Roundness of inside of cylin- (Spare liner is supplied
Repair limit: 0.08
der liner (unit) only for rank B)
Cylindricality of inside of cyl-
Repair limit: 0.08
inder liner (unit)
Outside diameter of cylinder Standard size Tolerance
liner (at counterbore portion)
(unit) 153 0.025
3
Interference of cylinder liner
and block (at counterbore Standard clearance: 0 0.113
block
portion)
Outside diameter of cylinder Standard size Tolerance
liner (at bottom of counter- +0.090 Replace cylinder liner
bore) 145
+0.040
4
Interference of cylinder liner Standard interference Interference limit
and block (at bottom of coun-
0.01 0.12 0.01 block
terbore)
Outside diameter of cylinder
+0.386 Replace cylinder liner
liner (at O-ring) 141
5 +0.361
Clearance between cylinder Replace cylinder liner or
Standard clearance: 0.014 0.079
liner and block (at O-ring) block
34 125E-5 Series
Main moving parts 1
a. Re-entrant combustion chamber
1. Piston (FCD piston) 7. Connecting rod bearing

2. Connecting rod bushing 8. Connecting rod
3. Piston pin 9. Connecting rod cap bolt
4. Crankshaft 10. Top ring
5. Crank gear (Number of teeth: 33) 11. Second ring
6. Connecting rod cap 12. Oil ring
125E-5 Series 35
Specifications Piston rings

Crankshaft: Closed die forging
: Journal, fillet
Induction hardening
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 Top ring (1) : Double-side keystone, inner cut,
it can be reduced. barrel face, hard chromium-plated
q Since the FCD piston has high strength, the Second ring (2) : Keystone, inner cut, taper face,
top ring can be installed to a higher place, and hard chromium-plated
the loss area of the combustion chamber can Oil ring (3) : With coil expander and nitrided
be reduced. surface
q The exhaust sound is low and the exhaust gas
color is better.
q The output can be heightened.
36 125E-5 Series
Crankshaft 1
Unit: mm
Standard value Repair limit Replace thrust bearing
1 End play
0.140 0.315 0.50 or use oversize bearing
S.T.D. 110 109.88
Outside diameter of main 0.25 U.S. 109.75 109.63
journal 0.050
0.50 U.S. 109.50 109.38 Use undersize journal
0.070
0.75 U.S. 109.25 109.13 or replace
2
1.00 U.S. 109.00 108.88
Standard Repair limit
Roundness
0 0.010 0.020
Standard clearance Clearance limit
Clearance of main journal Replace main bearing
0.062 0.106 0.27
S.T.D. 80 79.88
Outside diameter of crank 0.25 U.S. 79.75 79.63
pin journal 0.050
0.50 U.S. 79.50 79.38 Use undersize journal
0.070
0.75 U.S. 79.25 79.13 or replace
3
1.00 U.S. 79.00 78.88
Roundness
0 0.010 0.020
Clearance of crank pin jour- Standard clearance Clearance limit Replace connecting rod
nal 0.046 0.090 0.24 bearing
Standard Repair limit Use undersize crank-
4 Bend of crankshaft
0 0.09 0.20 shaft or replace
125E-5 Series 37
Camshaft 1
Unit: mm
1 End play Replace thrust plate
0.15 0.35 0.50
Outside diameter of cam-
0.080 Replace
shaft journal 60
2 0.110
Clearance of camshaft jour- Standard clearance Clearance limit
Replace cam bushing
nal 0.080 0.180 0.28
3 Bend of camshaft Repair limit: 0.03 (Overall swing of indicator)
Replace
4 Height of cam +0.395
52 51.73
+0.195
38 125E-5 Series
Cam follower and push rod 1
Unit: mm
Diameter of cam follower
shaft 0.040
19.8 19.73
1 0.050
Diameter of cam follower +0.020
19.8
shaft hole +0.000
Outside diameter of cam 0.250
2 32 31.70
roller 0.280
Inside diameter of cam 0.262
13 12.78
roller 0.287 Replace
3
0.364
Diameter of cam roller pin 13 12.62
0.376
4 Radius of push rod ball end 0.00
12.7
0.20
Radius of push rod socket 0.00
5 12.7
end 0.20
6 Bend of push rod Repair limit: 0.50 (Overall swing of indicator)
Tightening torque of cam
51 7.4 Nm {5.25 0.75 kgm} Tighten
follower shaft mounting bolt
125E-5 Series 39
Piston, piston ring and piston pin 1
40 125E-5 Series
Unit: mm
Rank Standard size Tolerance Repair limit
Replace piston
0.090
A or S 125 124.80 (Spare piston is
1 Outside diameter of piston 0.105
supplied for only
0.075 rank A or S)
B or L 125 124.80
0.090
No. Measuring point Standard size Tolerance
0.005
2 No. 1 ring 2.42
0.025
Replace piston
Thickness of piston ring 0.010
3 No. 2 ring 2.4 ring
0.030
0.010
4 Oil ring 4
0.030
2 No. 1 ring Check with groove wear gauge
(When new ring is installed,
3 No. 2 ring clearance is 0.15)
Width of piston ring groove Replace piston
24 +0.040
4 Oil ring 4
+0.020
Standard clear- Clearance
No. Measuring point
ance limit
Clearance between piston 2 No. 1 ring Replace piston or
ring and piston ring groove Check with groove wear gauge piston ring
3 No. 2 ring
4 Oil ring 0.030 0.070 0.15
2 No. 1 ring 0.37 0.47 2.0 Replace piston
Closed gap of piston ring 3 No. 2 ring 1.10 1.20 2.0 ring or cylinder
4 Oil ring 0.23 0.35 1.0 liner

Outside diameter of pis- Replace piston
ton pin 0 pin
48
0.006
5 +0.045
Diameter of piston pin hole 48 Replace piston
+0.035
Clearance between piston Standard clearance Clearance limit Replace piston or
pin and piston 0.035 0.051 0.063 piston pin
Weight of piston 3,000 g, Permissible range: 60 g Replace piston
125E-5 Series 41
Connecting rod 1
Unit: mm
Inside diameter of Standard size Tolerance Repair limit Replace bushing
connecting rod small end +0.041 (Spare is half
bushing 48 48.08 worked)
+0.025
1
Clearance between Standard clearance Clearance limit
Replace bushing
connecting rod small end
0.025 0.047 0.10 or piston pin
bushing and piston pin
Diameter of connecting rod Standard size Tolerance
Replace connect-
2 small end bushing +0.030
53 ing rod
mounting hole +0.000
Inside diameter of Standard size Tolerance Repair limit
3 connecting rod large end +0.020 Replace bearing
bearing (crank pin journal) 80 80.12
0.010
+0.022
Diameter of connecting rod 85
0.004 Replace connect-
large end bearing mounting
Before measuring, tighten connecting rod cap mounting bolt to ing rod
4 hole
specified torque.
Thickness of connecting +0.005
2.5 Replace bearing
rod bearing 0.004
Item Standard Repair limit
Parallelism and twist of Parallelism a 0 0.20 0.25 Replace connect-
5
connecting rod Twist b 0 0.30 0.35 ing rod
Dimension c 240
Tightening torque of Procedure Target (Nm {kgm}) Range (Nm {kgm})
connecting rod cap 1st stage 98 {10} 93 103 {9.5 10.5}
6 mounting bolt Retighten
(Apply engine oil to bolt 2nd stage Retighten 90 Retighten 90 (+30/0)
threads and nut seat)
Permissible range: Dispersion of weight of connecting rods in 1
Weight of connecting rod Replace
engine must not exceed 140 g.
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
Flywheel and flywheel housing 1

Without PTO
1. Flywheel housing
Number of Number of
2. Ring gear Applicable machine teeth of internal teeth
3. Flywheel ring gear of flywheel
4. Rear seal
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8,
PC450-8, PC450LC-8, 148
D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
BR580JG-1
WA450-6, WA470-6,
WA470-6R
WA480-6, WA480-6R 137
HM250-2
HM300-2, HM300-2R
125E-5 Series 43
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
Unit: mm
Facial runout of flywheel
1 Repair limit: 0.35
housing Correct by reas-
Radial runout of flywheel sembling
housing
Bolt Procedure Target (Nm{kgm}) Range (Nm{kgm})
Tightening torque of fly- 1st stage 191 {19.5} 147 235 {15 24}
3 wheel housing mounting M16 Tighten
bolt 2nd stage 279 {28.5} 245 309 {25 31.5}
M10 69 {7} 59 74 {6 7.5}
4 Facial runout of flywheel Repair limit: 0.20 Correct by reas-
5 Radial runout of flywheel Repair limit: 0.15 sembling
Tightening torque for fly- Procedure Target (Nm{kgm}) Range (Nm{kgm})
wheel mounting bolt 1st stage 147 {15} 127 167 {13 17} Tighten
6
(Apply engine oil to
threads) 2nd stage 289 {29.5} 270 309 {27.5 31.5}
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
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
A: Tightening order of flywheel mounting bolts

B: Tightening order of flywheel housing mounting
bolts
1. Flywheel housing
2. Seal
3. Flywheel
Number of Number of
Applicable machine teeth of internal teeth
ring gear of flywheel
DCA-300SSK4
178
Unit: mm
Facial runout of flywheel
housing Correct by reas-
Radial runout of flywheel sembling
housing
Bolt Procedure Target (Nm{kgm}) Range (Nm{kgm})
Tightening torque of fly- 1st stage 191 {19.5} 147 235 {15 24}
6 wheel housing mounting M16 Tighten
bolt 2nd stage 279 {28.5} 245 309 {25 31.5}
M10 69 {7} 59 74 {6 7.5}
7 Facial runout of flywheel Repair limit: 0.28 Correct by reas-
8 Radial runout of flywheel Repair limit: 0.13 sembling
Tightening torque for fly- Procedure Target (Nm{kgm}) Range (Nm{kgm})
wheel mounting bolt 1st stage 147 {15} 127 167 {13 17} Tighten
9
(Apply engine oil to
threads) 2nd stage 289 {29.5} 270 309 {27.5 31.5}
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
Vibration damper 1
1. Vibration damper
2. Pin
3. Crankshaft pulley
4. Crankshaft pulley mounting bolt
5. Vibration damper mounting bolt
48 125E-5 Series
Unit: mm
1 Outside check Rubber parts must be free from cracking and flaking.
2 Radial runout of damper Repair limit: 0.80 Replace
3 Facial runout of damper Repair limit: 0.80
Tightening torque of vibra- Bolt Target (Nm {kgm}) Range (Nm {kgm})
4 Tighten
tion damper mounting bolt M12 111 {11.3} 98 213 {10 12.5}
125E-5 Series 49
Timing gear 1
(with EGR)
1. Cylinder block 7. Oil pump idler gear (Number of teeth: 25)

2. Water pump drive gear (Number of teeth: 22) 8. Injection drive gear (Number of teeth: 44)
3. Main idler gear (Number of teeth: 57) 9. Timing gear cover
4. EGR oil pump drive gear (Number of teeth: 20) 10. Camshaft gear (Number of teeth: 44)
5. Main idler gear, small (Number of teeth: 38) 11. Crankshaft gear (Number of teeth: 33)
6. Oil pump drive gear (Number of teeth: 21) 12. Crankshaft
A, B, C: Timing gear mating marks
50 125E-5 Series
125E-5 Series 51
Unit: mm
Position Check parts Standard Repair limit
Crank gear and main idler gear
A 0.116 0.359
(large)
Main idler gear (small) and cam
B 0.105 0.325
gear
Cam gear and fuel supply pump
C 0.105 0.325
Backlash of each gear gear Replace
0.6
Main idler gear (large) and water
a 0.076 0.366
pump gear
Main idler gear (large) and oil
b 0.105 0.337
pump idler gear
Oil pump idler gear and oil pump
c 0.082 0.389
drive gear
Tolerance Standard Clearance
Standard size
Clearance between main Shaft Hole clearance limit
1
idler gear bushing and shaft +0.165 +0.115 0.025
47.5 0.20 Replace
+0.140 +0.100 0.060 bushing
Clearance between oil
0.025 +0.065 0.025
2 pump idler gear bushing 35 0.20
0.040 +0.000 0.105
and shaft
3 End play of main idler gear Replace
0.05 0.17 0.4
thrust bear-
End play of oil pump idler ing
4 0.05 0.21 0.4
gear
52 125E-5 Series
125E-5 Series 53
(EGR-less)
1. Cylinder block 7. Injection drive gear (Number of teeth: 44)

2. Water pump drive gear (Number of teeth: 22) 8. Timing gear cover
3. Main idler gear (Number of teeth: 57) 9. Camshaft gear (Number of teeth: 44)
4. Main idler gear, small (Number of teeth: 38) 10. Crankshaft gear (Number of teeth: 33)
5. Oil pump drive gear (Number of teeth: 21) 11. Crankshaft
6. Oil pump idler gear (Number of teeth: 25) A, B, C: Timing gear mating marks
54 125E-5 Series
125E-5 Series 55
Unit: mm
Position Check parts Standard Repair limit
Crank gear and main idler gear
A 0.116 0.359
(large)
Main idler gear (small) and cam
B 0.105 0.325
gear
Cam gear and fuel supply pump
C 0.105 0.325
Backlash of each gear gear Replace
0.6
Main idler gear (large) and water
a 0.076 0.366
pump gear
Main idler gear (large) and oil
b 0.105 0.337
pump idler gear
Oil pump idler gear and oil pump
c 0.082 0.389
drive gear
Tolerance Standard Clearance
Standard size
Clearance between main Shaft Hole clearance limit
1
idler gear bushing and shaft +0.165 +0.115 0.025
47.5 0.20 Replace
+0.140 +0.100 0.060 bushing
Clearance between oil
0.025 +0.065 0.025
2 pump idler gear bushing 35 0.20
0.040 +0.000 0.105
and shaft
3 End play of main idler gear Replace
0.05 0.17 0.4
thrust bear-
End play of oil pump idler ing
4 0.05 0.21 0.4
gear
56 125E-5 Series
125E-5 Series 57
Valve system 1
1. Rocker arm shaft 11. Valve spring

2. Cam roller 12. Valve spring seat (lower) (both IN and EX)
3. Cam roller pin 13. Adjustment screw
4. Camshaft 14. Locknut
5. Cam gear (Number of teeth: 44) 15. Rocker arm
6. Adjustment screw 16. Push rod
7. Locknut 17. Cam follower
8. Cross head 18. Valve cotter
9. Valve seat (upper) 19. Exhaust valve
10. Intake valve 20. Valve stem seal (both IN and EX)
58 125E-5 Series
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
Parts related to valves

Part IN EX
Cross head 6150-42-5610 6150-42-5610
Valve 6150-42-4110 6150-42-4210
Valve spring 6251-41-4450 6251-41-4450
(Color code) (Light blue) (Light blue)
Valve spring seat
6150-41-4430 6150-41-4430
(lower)
Valve rotator
Valve guide 6150-11-1370 6150-11-1370
Valve stem seal 6150-41-4570 6150-41-4570
Valve timing
60 125E-5 Series
125E-5 Series 61
Valve and valve guide 1
Unit: mm
Valve Standard size Tolerance Repair limit
Replace valve or
1 Sinking distance of valve Intake 1.88 0.10 2.51
valve seat
Exhaust 1.20 0.10 1.90
Valve Standard size Repair limit
2 Thickness of valve lip Intake 2.10 1.7 Replace valve
Exhaust 1.50 1.2
Intake Exhaust Correct or replace
3 Valve seat angle
Standard 30 15' 45 15' valve or valve seat
Valve Standard size Tolerance
0.045
Intake 9
Diameter of valve stem 0.065 Replace valve
0.050
Exhaust 9
0.070
Before head is Intake/Exhaust +0.015
9
4 Inside diameter of valve press fitted valve 0.003 Replace valve
guide After head is Intake/Exhaust +0.009 guide
9
press fitted valve 0.011
Valve Standard clearance Clearance limit
Clearance between valve Replace valve or
Intake 0.034 0.074 0.22
guide and stem valve guide
Exhaust 0.039 0.079 0.24
Bend of valve stem Repair limit: 0.01 (Overall swing of indicator in 100 mm) Replace
62 125E-5 Series
Unit: mm
Driving height of valve Standard Tolerance
5 Correct
guide 20 0.2
Valve Color code Standard size Repair limit
Free length of valve spring Intake Light blue 76.2
Exhaust Light blue 76.2
Standard Allowable
Installed
Valve Color code load load
length
(N {kg}) (N {kg}) Replace valve
6 Installed load of valve
519.8 26 spring
spring Intake Light blue 56.0 468 {47.7}
{53.0 2.7}
519.8 26
Exhaust Light blue 56.0 468 {47.7}
{53.0 2.7}
Perpendicularity of valve
Repair limit: 2 (both sides)
spring
125E-5 Series 63
Rocker arm and shaft 1
Unit: mm
Diameter of rocker arm Replace rocker
shaft 0.053 arm and shaft
28.6
0.066
Diameter of rocker arm +0.033 Replace rocker
28.6
shaft hole 0.027 arm
1
Standard clearance Clearance limit Replace rocker
Clearance between rocker
arm or rocker arm
arm shaft and rocker arm 0.026 0.099 0.13 shaft
Replace rocker
Bend of rocker arm shaft Repair limit: 0.20 (Overall swing of indicator)
arm shaft
Tightening torque of locknut Target (Nm {kg}) Range (Nm {kg})
2 of rocker arm adjustment Tighten
screw 59 {6.0} 53 65 {5.4 6.6}
Valve Standard Tolerance

Valve clearance
3 Intake side 0.33 Adjust
(Both when hot and cold) 0.02
Exhaust side 0.71
64 125E-5 Series
Crosshead and guide 1
Unit: mm
Inside diameter of cross-
head +0.075
11 11.18
1 +0.025 Replace
Outside diameter of cross- +0.011
11 10.95
head guide +0.000
Projection of crosshead
2 45.5 0.25 Correct
guide
125E-5 Series 65
SEN00184-04
2008 KOMATSU
All Rights Reserved
66
SEN00185-04
ENGINE 1SHOP MANUAL
125E-5 Series
10 Structure, function and

maintenance standard 1
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 1
Fuel piping.......................................................................................................................................... 40
Fuel cooler.......................................................................................................................................... 42
Fuel filter............................................................................................................................................. 43
Electric priming pump......................................................................................................................... 44
Engine controller cooler...................................................................................................................... 45
Cooling system.............................................................................................................................................. 46
Cooling system diagram..................................................................................................................... 46
Water pump ........................................................................................................................................ 48
Thermostat ......................................................................................................................................... 50
Corrosion resistor ............................................................................................................................... 52
Electrical equipment...................................................................................................................................... 53
Alternator............................................................................................................................................ 53
Starting motor ..................................................................................................................................... 60
Electrical intake air heater .................................................................................................................. 64
Engine controller ................................................................................................................................ 65
2 125E-5 Series
125E-5 Series 3
Lubrication system 1
Lubrication system diagram 1
(with EGR)
a The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
4 125E-5 Series
W: Coolant
1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil pump relief valve
5. Oil cooler
6. Thermo-valve
7. Oil filter
8. Safety valve
9. Crankshaft
11. Piston
12. Camshaft
13. Cam follower
14. Rocker arm
15. Air intake valve and exhaust valve
16. Timing gear
17. Turbocharger
18. Fuel supply pump
19. EGR oil pump
20. EGR oil pump relief valve
21. EGR valve
22. Bypass valve
23. Main gallery
24. Oil filter clogging switch (for DCA-300SSK4)
125E-5 Series 5
(EGR-less)
a The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
6 125E-5 Series
W: Coolant
1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil pump relief valve
5. Oil cooler
6. Thermo-valve
7. Oil filter
8. Safety valve
9. Crankshaft
11. Piston
12. Camshaft
13. Cam follower
14. Rocker arm
15. Air intake valve and exhaust valve
16. Timing gear
17. Turbocharger
18. Fuel supply pump
19. Main gallery
125E-5 Series 7
Oil pump 1
1. Oil pump drive gear (Number of teeth: 21) Oil pump gear
2. Bushing Type: Gear pump
3. Pump cover Speed: Engine speed 1.571
4. Drive gear
5. Pump body Main relief valve
6. Drive shaft Cracking pressure:
7. Main relief valve 0.65 0.8 MPa {6.63 8.16 kg/cm2}
8. Valve spring
9. Retainer
10. Drive shaft
11. Bushing
12. Driven gear
8 125E-5 Series
Main relief valve 1
Unit: mm
Cracking pressure of Correct or
1
relief valve Standard: 0.65 0.8 MPa {6.63 8.16 kg/cm2} replace spring
125E-5 Series 9
EGR oil pump 1
A: From main gallery Specifications

B: To EGR valve and bypass valve Oil pump
C: Rotation direction Type: Gear pump
Speed: Engine speed 1.1
1. Pump cover
2. Driven gear Main relief valve
3. Pump body Cracking pressure:
4. Drive gear 1.43 0.1 MPa {14.6 1.0 kg/cm2}
5. Pump drive gear (Number of teeth: 20)
6. Main relief valve
7. Main valve spring
10 125E-5 Series
Oil filter 1
Remote mount type
A: Oil inlet Specifications

B: Oil outlet Oil filter
Filtration area: 0.44 m2 (Full-flow)
1. Safety valve
2. Filter head Safety valve
3. Cartridge Cracking pressure: 343 19 kPa {3.5 0.2 kg/cm2}
125E-5 Series 11
Remote mount type (for DCA-300SSK4)
A: Oil inlet Specifications

B: Oil outlet Oil filter
Filtration area: 0.44 m2 (Full-flow)
1. Safety valve
2. Filter head Safety valve
3. Cartridge Cracking pressure: 343 19 kPa {3.5 0.2 kg/cm2}
4. Clogging switch
Clogging switch
+39 +0.4
Operating pressure: 147 0 kPa {1.5 0 kg/cm2}
12 125E-5 Series
Safety valve 1
1. Safety valve
2. Filter head
3. Spring
4. Cap
Unit: mm
Cracking pressure of safety
1 Standard: 343 19 kPa {3.5 0.2 kg/cm2} Replace
valve
125E-5 Series 13
Oil cooler 1

Oil cooler thermostat (Thermo-valve)
a. Water drain Opening temperature: 71C 1.5C
b. Oil inlet Full opening temperature: 85C
c. To each part of engine (Oil) Full opening lift: Min. 8 mm
d. Water inlet
1. Thermostat cover Oil cooler

2. Thermostat (Thermo-valve) Heat dissipation surface: 0.575 m2
3. Cooler cover
4. Cooler element
5. Strainer
Unit: mm
Min. 8 mm
Full opening lift of thermostat SAA6D125E-5
(Check after soaking in oil tank at 85C for 4 5 minutes)
6 Replace
Opening and closing of ther- When valve full open (at 85C) is soaked in oil tank at full closing tempera-
mostat ture (71C), it must close fully in 4 5 minutes.
14 125E-5 Series
125E-5 Series 15
Fuel system 1
CRI system diagram 1
(with EGR)
a CRI is an abbreviation for Common Rail Injection. Hereinafter, the common rail injection is referred to
as the CRI.
1. Fuel tank 3. Fuel filter 11. NE speed sensor

2. Fuel supply pump assembly 4. Overflow valve 12. Large-capacity priming pump
2A. PCV 5. Common rail 13. Check valve
2B. High pressure pump 6. Pressure limiter 14. Pre-fuel filter
2C. Priming pump 7. Flow damper
2D. Feed pump 8. Injector assembly
2E. Bypass valve 9. Fuel cooler
2F. G speed sensor 10. Engine controller
16 125E-5 Series
(EGR-less)
a CRI is an abbreviation for Common Rail Injection. Hereinafter, the common rail injection is referred to
as the CRI.
1. Fuel tank 3. Fuel filter 11. NE speed sensor

2. Fuel supply pump assembly 4. Overflow valve 12. Electric priming pump
2A. PCV 5. Common rail 13. Water separator
2B. High pressure pump 6. Pressure limiter 14. Pre-fuel filter
2C. Priming pump 7. Flow damper
2D. Feed pump 8. Injector assembly
2E. Bypass valve 9. Fuel cooler
2F. G speed sensor 10. Engine controller
125E-5 Series 17
Outline of CRI system 1

Outline 1. Fuel system
q The CRI system checks the condition of the
engine (engine speed, accelerator angle, cool-
ant 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 func-
tion which stops the engine when a certain
parts fail and a backup function which contin-
ues the operation by changing the control
method in such a case.
Configuration
q The CRI system is divided by the function into
the fuel system and control system.
q The fuel system distributes the high-pressure

fuel supplied by the fuel supply pump to the
cylinders through the common rail.
q The solenoid valve in the injector opens and
closes the nozzle needle valve to start and fin-
ish injection.
18 125E-5 Series
2. Control system
a Parts marked with * (2 places) are installed to only the engines with EGR.
q 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 quan-
tity of fuel in proper timing.
q The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.
125E-5 Series 19
Structure and operation of CRI system
q The CRI system consists of the fuel supply q If the TWV is turned on (energized), the fuel
pump, common rail, injector, engine controller circuit is so changed that the high-pressure
to control them, and sensors. fuel in the control chamber will flow through the
q The fuel supply pump generates fuel pressure orifice. As a result, the needle valve is raised
in the common rail. The fuel pressure is con- to start fuel injection by the nozzle cracking
trolled by the fuel discharge rate of the supply pressure of the high-pressure fuel on the noz-
pump. zle side.
q The discharge rate is controlled by turning on q If the TWV is turned off (de-energized), the fuel
and off the PCV (pressure control valve) of the circuit is so changed that the high-pressure
fuel supply pump according to the electric sig- fuel will be applied to the control chamber
nals from the engine controller. through the orifice. As a result, the needle
q The common rail receives the pressurized fuel valve lowers and finishes fuel injection.
from the fuel supply pump and distributes it to q Accordingly, the fuel injection timing and fuel
the cylinders. injection rate are controlled respectively by the
q The fuel pressure is sensed by the common timing to turn on the TWV and the length of the
rail fuel pressure sensor installed to the com- turn-on time of the TWV.
mon rail.
q A feedback control is applied so that the actual
fuel pressure will match to the command pres-
sure set according to the engine speed and the
load on the engine.
q 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.
q The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve).
20 125E-5 Series
Structure and operation of component parts 1

1. Fuel supply pump
1. 3-head cam 6. No. 2 high-pressure pump

2. Overflow valve 7. Priming pump
3. Drive gear 8. Feed pump
4. No. 1 high-pressure pump 9. Gear for Bkup speed sensor (G sensor)
5. PCV (Pressure control valve)
Outline q Since the number of the times of feeding fuel

q The fuel supply pump consists of priming to the common rail is the same as the number
pump (7), feed pump (8), and high-pressure of the times of fuel injection, the common rail
pumps (4) and (6). fuel pressure is smooth and stable.
q The function of the fuel supply pump is to gen- q The fuel fed by high-pressure pumps (4) and
erate common rail fuel pressure by controlling (6) to the common rail is divided as follows.
the fuel delivery. q No. 1 high-pressure pump (on the drive gear
side) (4) compensates for drop in the common
Structure rail fuel pressure caused by fuel injection into
q High-pressure pumps (4) and (6) have the the No. 1, 3, and 5 cylinders.
pressure feed systems similar to those of the q No. 2 high-pressure pump (on the feed pump
conventional in-line fuel injection pump and the side) (6) compensates for drop in the common
PCVs (pressure control valves) for each cylin- rail fuel pressure caused by fuel injection into
der to control the fuel delivery. the No. 2, 4, and 6 cylinders.
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.
125E-5 Series 21
Operation
q (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.
q (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.
q (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.
q (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 de-
energized, it opens and the low-pressure
fuel is sucked in the plunger chamber, or
the state of (A) starts again.
22 125E-5 Series
1) PCV (Pressure control valve) 2) Feed pump

q The PCV adjusts the fuel delivery from the fuel q The feed pump built in the fuel supply pump
supply pump to adjust the common rail fuel assembly draws the fuel from the fuel tank and
pressure. The delivery from the fuel supply sends it through the fuel filter to the high-pres-
pump to the common rail is decided by the tim- sure pump chamber.
ing of energizing the PCV. q The outer and inner rotors of the feed pump
are rotated by the camshaft.
q 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.
125E-5 Series 23
2. Common rail
Structure Operation
q Common rail (4) distributes the high-pressure When fuel is not injected
fuel from the high-pressure pump to the injec-
q Piston (2) is in contact with stopper (1) (initial
tors of the cylinders.
position).
q Common rail (4) is equipped with common rail
q The fuel for static leakage is supplied through
fuel pressure sensor (2), flow dampers (1), and
orifice (a) of piston (2) and clearance in the
pressure limiter (3).
sliding parts.
q The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
When fuel is injected
the injectors.
q The fuel pressure is applied to piston (2),
q The piping of the pressure limiter (3) is
which compresses spring (3) and moves to the
returned to the fuel tank.
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.
1) 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) Pressure limiter 3) Common rail fuel pressure sensor

q If abnormally high pressure is generated, the q The common rail fuel pressure sensor is
pressure limiter opens to release that pres- installed to the common rail to sense the fuel
sure. pressure.
q If the common rail fuel pressure reaches about q This sensor is a semiconductor pressure sen-
200 MPa {2,040 kg/cm2}, the pressure limiter sor, which utilizes the phenomenon that the
operates (opens). electric resistance of silicon changes according
q If the common rail fuel pressure lowers to 30 to pressure applied to it.
MPa {310 kg/cm2}, the pressure limiter resets
itself (closes) to maintain the pressure.
q Under the normal condition, the pressure lim-
iter does not reset itself (close) until the engine
is stopped.
1. Ball
2. Housing
3. Spring
4. Body
5. Guide
125E-5 Series 25
3. Injector
Outline
q The function of the injector is to inject the high-
pressure fuel from the common rail into each
combustion chamber of the engine in the opti-
mum 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 noz-
zle and controls the fuel injection rate.
q The hydraulic piston transmits the force gener-
ated by the pressure in the control chamber to
the needle valve of the nozzle.
q The nozzle sprays the fuel.
26 125E-5 Series
Structure
1. Inlet connector 7. Orifice (in)

2. Terminal 8. Pressure control chamber
3. Upper body 9. Control piston
4. Solenoid 10. Spring
5. Valve body 11. Pressure pin
6. Orifice (out) 12. Nozzle assembly
q The injector consists of the nozzle section, ori-

fice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve sec-
tion.
125E-5 Series 27
A: No fuel injection C: Finish of fuel injection

B: Start of fuel injection D: From common rail
1. Nozzle 5. Valve body

2. Control piston 6. Solenoid
3. Orifice (in) 7. Spring
4. Orifice (out) 8. Pressure control chamber
Operation
1) No fuel injection (A) 3) Finish of fuel injection (C)

q While solenoid (6) is not energized, valve body q If solenoid (6) is de-energized, valve body (5)
(5) is pressed down by spring (7). is lowered by spring (7) and the fuel passage is
q Since the high-pressure fuel is applied from closed.
the common rail to pressure control chamber q At this time, the high-pressure fuel in the com-
(8), nozzle (1) is closed and the fuel is not mon rail is applied to pressure control chamber
injected. (8) suddenly and nozzle (1) is closed quickly,
fuel injection is finished sharply.
2) Start of fuel injection (B)
q If solenoid (6) is energized, valve body (5) is
pulled up by the electromagnetic force and the
fuel passage is opened.
q Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and fuel injection pump starts.
q The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
q If solenoid (6) is kept energized, the fuel injec-
tion rate is increased to the maximum.
28 125E-5 Series
Electric circuit diagram
k 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
Various controls
a Parts marked with * (3 places) are installed to only the engines with EGR.
q The CRI system controls the fuel injection rate 2. Fuel injection timing control function
and fuel injection timing more properly than the q The fuel injection timing control function is
mechanical governor or timer of the conven- employed instead of the function of the con-
tional fuel injection pump. ventional timer. It controls the fuel injection
q For the control of the system, calculations nec- timing most properly from the engine speed
essary to the engine controller are performed and fuel injection rate.
from the signals sent from the sensors
installed to the engine and machine.
q The energizing timing and energizing period of 3. Fuel injection pressure control function
the injector are so controlled that the optimum (Common rail fuel pressure control function)
quantity of fuel will be injected in the optimum q The fuel injection pressure control function
timing. (common rail fuel pressure control function) is
a function of measuring the fuel pressure with
the common rail fuel pressure sensor and
1. Fuel injection rate control function feeding it back to the engine controller to con-
q The fuel injection rate control function is trol the delivery of the fuel supply pump.
employed instead of the function of the con- q This function performs pressure feedback con-
ventional governor. It controls the fuel injection trol so that the fuel injection pressure will be
according to the signals of engine speed and the same as the optimum value (command
accelerator angle so that the fuel injection rate value) set according to the engine speed and
will be most proper. fuel injection rate.
30 125E-5 Series
125E-5 Series 31
4. Various sensors
a Nos. 1 13 in the above illustration correspond to title Nos. 1) 13).

a The above illustration shows the engine for HM300-2.
a Parts *1, *3 and *4 are installed to only the engines with EGR.
32 125E-5 Series
125E-5 Series 33
1) EGR inlet pressure sensor (with EGR) 2) Atmospheric pressure sensor

(Applicable machine: HM300-2) q This sensor is used to correct altitude.
q This sensor is used to sense the EGR pres-
sure.
q The following graph shows the output charac-

teristics of the EGR inlet pressure sensor.
A: Pressure inlet
B: Mounting screw: M5
Tightening torque: 4.5 0.5 Nm {0.46 0.05 kgm}

teristics of the atmospheric pressure sensor.
34 125E-5 Series
3) EGR valve position sensor (with EGR)
4) Bypass valve position sensor (Applicable machine: HM300-2) (with EGR)

q These sensors sense the opening and closing positions of the EGR valve and bypass valve.
1. EGR and bypass valve position sensors

teristics of the position sensor.
125E-5 Series 35
5) Common rail pressure sensor 7) Fuel temperature sensor

q The fuel temperature sensor senses the fuel
6) NE speed sensor (Crank angle sensor) temperature and sends it to the engine control-
q If the signal hole made on the flywheel passes ler. The sensor unit is a thermistor the resis-
the sensor, the magnetic line of force changes. tance of which changes according to the
q If the magnetic line of force changes, the out- temperature.
put of the Hall element sensor changes linearly q The engine controller applies voltage to the
and it is converted into pulse of 0 5 V by the thermistor and senses the temperature by the
wave form shaping circuit in the sensor, and voltage divided by the resistance in the com-
then output. puter and the resistance of the thermistor.
8) Engine controller
9) Oil pressure sensor
36 125E-5 Series
10) Bkup speed sensor (G sensor) 11) Charge pressure sensor

(Cylinder No. sensor) q This sensor is used to sense the charge pres-
q Similarly to the NE speed sensor, this sensor sure (boost pressure).
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 gener-
ated every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-
ognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
A: Mounting screw: M6
Tightening torque: 5.5 0.5 Nm {0.56 0.05 kgm}
1. Sensor
2. O-ring

teristics of the charge pressure sensor.
125E-5 Series 37
12) Charge temperature sensor 13) Coolant temperature sensor

q The charge temperature sensor senses the q The coolant temperature sensor senses the
intake air temperature (boost temperature) and coolant temperature and sends it to the engine
sends it to the engine controller. controller.
q The sensor unit is a thermistor the resistance q The sensor unit is a thermistor the resistance
of which changes according to the tempera- of which changes according to the tempera-
ture. The engine controller applies voltage to ture. The engine controller applies voltage to
the thermistor and senses the temperature by the thermistor and senses the temperature by
the voltage divided by the resistance in the the voltage divided by the resistance in the
computer and the resistance of the thermistor. computer and the resistance of the thermistor.
38 125E-5 Series
125E-5 Series 39
Fuel piping 1
1. Fuel injection pipe (No. 1 cylinder)

7. Fuel return pipe
8. Common rail
9. Priming pump
10. Feed pump
11. Oil inlet pipe (for pump lubricating oil)
12. High pressure pump
13. Fuel supply pump drive gear
(Number of teeth: 44)
14. Overflow valve
15. PCV
40 125E-5 Series
A: Fuel inlet
B: To fuel filter
C: From fuel filter
D: To injector
E: 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
Fuel cooler 1
A: From fuel tank

B: To fuel supply pump
1. Mount bracket
2. Core
Specifications
Cooling method: Cooling with air
Type of core: AL-CFT-1
Heat dissipation surface: 3.31 m2
42 125E-5 Series
Fuel filter 1
Main fuel filter
A: Fuel inlet
B: Fuel outlet
1. Air bleeding plug

2. Filter head
3. Cartridge
Specifications
Filtration area: 1.0 m2
125E-5 Series 43
Electric priming pump 1
A: Fuel IN
B: Fuel OUT
1. Connector
2. Vibration prevention rubber
44 125E-5 Series
Engine controller cooler 1
A: Fuel IN (From feed pump of fuel supply pump)

B: Fuel OUT (Main fuel filter)
1. Engine controller
2. 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
Cooling system 1
Cooling system diagram 1
(with EGR)
A: Oil inlet 7. Cylinder head

B: Oil outlet 8. Cylinder liner
C: Exhaust gas inlet 9. Piston
D: Exhaust gas outlet 10. Cylinder block
11. Oil cooler
1. Radiator 12. Air compressor
2. Thermostat 13. EGR cooler
3. Water pump
4. Coolant temperature gauge
5. Water manifold (made one with cylinder block)
6. Corrosion resistor
46 125E-5 Series
(EGR-less)
A: Oil inlet 1. Radiator

B: Oil outlet 2. Thermostat
C: Exhaust gas inlet 3. Water pump
D: Exhaust gas outlet 4. Coolant temperature gauge
5. Water manifold (made one with cylinder block)
6. Corrosion resistor
7. Cylinder head
8. Cylinder liner
9. Piston
10. Cylinder block
11. Oil cooler
12. Air compressor
125E-5 Series 47
Water pump 1
Mounting
A: To radiator (Coolant) 1. Thermostat

B: From each part of engine (Coolant) 2. Housing cover
C: To each part of engine through oil cooler 3. Thermostat housing
(Coolant) 4. Water pump
D: From radiator (Coolant) 5. Oil cooler
E: From oil pump (Oil)
F: To each part of engine (Oil)
a. Cab heater take-out opening

b. Coolant temperature gauge pickup port
c. Water drain valve
48 125E-5 Series
a. From thermostat
b. From radiator
c. To each part of engine
1. Water pump drive gear (Number of teeth: 22)

2. Pump shaft
3. Ball bearing
4. Pump body
5. Water seal
6. Impeller
7. Pump cover
Water pump
Type: Centrifugal, gear-driven
Speed: Engine speed 1.5
Unit: mm
Tolerance Standard inter- Replace
Standard size
Interference of impeller Shaft Hole ference Usually, impeller needs to be
8
and shaft replaced (Outside diameter of
+0.018 0.020
15.9 0.025 0.068 shaft changes little)
+0.005 0.050
Interference of drive gear +0.015 0.023 Replace (Usually, gear needs to
9 20.0 0.025 0.068
and shaft +0.002 0.053 be replaced)
Clearance between impel-
10 Standard clearance: 0.30 1.10 (including end play)
ler and body Replace
11 Wear of water seal ring Limits of size: 1.5
125E-5 Series 49
Thermostat 1
Mounting
a. To radiator
b. To water pump
1. Thermostat
2. Thermostat housing
50 125E-5 Series
A: When cold (Fully closed) 1. Thermostat 8. Sleeve

B: When hot (Fully open) 2. Seal 9. Flange
3. Valve
a. To water pump (bypass) 4. Body Function of thermostat (before
b. To radiator 5. Piston installed)
c. From engine 6. Heat sensing portion Opening temperature: 76.5C
7. Inflating portion Full opening temperature: 90C
Valve lift: Min. 10 mm
Unit: mm
Full opening lift of thermostat Min. 10 mm (Check after soaking in oil tank at 90C for 4 5 minutes.)
1 Opening and closing of When valve full open (at 90C) is soaked in oil tank at full closing temper- Replace
thermostat ature (71C) , it must close fully in 4 5 minutes.
125E-5 Series 51
Corrosion resistor 1
A: Coolant inlet Corrosion resistor

B: Coolant outlet Chemical weight: 400 g
1. Head
2. Cartridge
3. Element (Paper)
4. Element (Chemical)
5. Spring
52 125E-5 Series
Electrical equipment 1
Alternator 1
1. Alternator with built-in regulator (Open type, 35 A)
1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Initial excitation resistor
3. Terminal B 6B. Regulator
4. Terminal R 6C. Field coil
5. Terminal E
Pulley
Weight
Engine Applicable machine Type Specification Number Outside
diameter (kg)
of stages
(mm)
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0 Open type (brushless),
SAA6D125E-5 BR580JG-1 manufactured by NIKKO 24V, 35A 2 93 8.0
DCA-300SSK4 DENKI
125E-5 Series 53
1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Initial excitation resistor
3. Terminal B 6B. Regulator
4. Terminal R 6C. Field coil
5. Terminal E
Pulley
Weight
diameter (kg)
of stages
(mm)
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8,
PC450-8, PC450LC-8,
PC450-8R, PC450LC-8R Open type (brushless),
SAA6D125E-5 D85EX-15E0, D85EX-15R manufactured by NIKKO 24V, 50A 2 75 10
D85PX-15E0, D85PX-15R DENKI
WA450-6, WA470-6,
WA470-6R
WA480-6, WA480-6R
HM250-2, HM300-2,
HM300-2R
54 125E-5 Series
a. Load
1. Alternator 5. Terminal E
2. Alternator pulley 6. Internal electric circuit diagram
3. Terminal B 6A. Field coil
4. Terminal R 6B. Primary energized resistance
6C. Regulator
Pulley
Weight
diameter (kg)
of stages
(mm)
PC400-8, PC400LC-8
PC450-8, PC450LC-8 Open type, manufactured by
SAA6D125E-5 24V, 60A 2 85 11
PC400-8R, PC400LC-8R NIKKO DENKI
125E-5 Series 55
a. Load
1. Alternator
2. Alternator pulley
3. Terminal R
4. Terminal E
5. Terminal B
6. Internal electric circuit diagram
6A. Alternator
6B. Regulator
Pulley
Weight
diameter (kg)
of stages
(mm)
D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
HM250-2, HM300-2,
Open type, manufactured
SAA6D125E-5 HM300-2R 24V, 75A 2 95 13
by SAWAFUJI DENKI
WA450-6, WA470-6,
WA480-6
WA470-6R, WA480-6R
56 125E-5 Series
Alternator mounting
SAA6D125E-5 (D85EX-15E0, D85EX-15R, D85PX-15E0, D85PX-15R, WA450-6, WA470-6, WA480-6,

WA470-6R, WA480-6R)
2. Alternator drive belt
4. Adjustment bolt
125E-5 Series 57
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)
4. Adjustment bolt
58 125E-5 Series
SAA6D125E-5 [DCA-300SSK4 (DENYO/MQ GENERATOR)]
4. Adjustment bolt
125E-5 Series 59
Starting motor 1
Starting motor with built-in safety relay (7.5 kW)
60 125E-5 Series
1. Pinion gear
2. Starting motor (body)
3. Magnetic switch
4. External electric circuit diagram [2P connector (male)]
4A. Safety relay
4B. Starting motor
5. External electric circuit diagram [3P connector (male)]
5A. Safety relay
5B. Starting motor
6. 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
Applicable Number of Type of

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

Engine Type Specification Weight (kg)
machine pinion teeth connector
All machines Waterproof, oilproof, manufactured
SAA6D125E-5 24V, 11kW 12 18 A
(if equipped) by NIKKO DENKI
125E-5 Series 63
Electrical intake air heater 1

SAA6D125E-5
1. Terminal
2. Body
3. Heater coil
4. Electric circuit diagram
Electrical intake air heater

Rated voltage: 22 V (DC)
Rated current: 111 A
64 125E-5 Series
Engine controller 1
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 CUM-
MINS is employed.
125E-5 Series 65
SEN00185-04
2008 KOMATSU
All Rights Reserved
66
SEN00546-05
ENGINE 1SHOP MANUAL
125E-5 Series
20 Standard value table 1
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 ......................................................................... 15
125E-5 Series 1
SEN00546-05 20 Standard value table
Standard service value table 1
Standard service value table for testing, adjusting, and troubleshooting

Engine SAA6D125E-5
D85EX-15E0
Machine model
D85PX-15E0
Performance Category
Standard value Judgement

Item Measurement conditions Unit
for new machine criteria
High idle rpm 2,100 50 2,100 50

Speed
Low idle rpm 750 (+50/0) 750 (+50/0)
Necessary speed for At 0C (Without starting aid) rpm Min. 100
starting At 20C (With starting aid) rpm Min. 85
kPa Max. 3.73 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 93 73
Air boost pressure At rated output
{mmHg} {Min. 700} {550}
kPa Min. 113 93
Exhaust pressure At rated output
{mmHg} {Min. 850} {700}
Air intake and exhaust system
Exhaust temperature Whole speed range (20C) C 650 700

%
Max. 25
At sudden acceleration (Low o High) (Bosch
{Max. 2.5}
index)
Exhaust gas color Bosch
At rated output Max. 1.5
index
Bosch
At high idle Max. 1.0
index
Intake valve mm 0.33
Valve clearance
Exhaust valve mm 0.71
MPa Min. 1.18
EGR valve and At low idle
{kg/cm2} {Min. 12}
bypass valve drive
pressure MPa Min. 1.43
At high idle
{kg/cm2} {Min. 14.6}
Compression pres- Engine oil temperature: 40 60C MPa Min. 2.9 2.0
sure Engine speed: 200 250 rpm {kg/cm2} {Min. 30} {20}
Body
At rated output kPa Max. 1.47 2.94

Blow-by pressure
Engine coolant temperature: Min. 70C {mmH2O} {Max. 150} {300}
At rated output
SAE0W30E0S MPa 0.29 0.69 0.18
Engine oil temperature:
SAE5W40E0S {kg/cm2} {3.0 7.0} {1.8}
Min. 80C
Lubrication system
Engine oil pressure SAE10W30DH

At low idle SAE15W40DH MPa Min. 0.08 0.05
Engine oil temperature: SAE30DH {kg/cm2} {Min. 0.8} {0.5}
Min. 80C
Engine oil tempera-
Whole speed range (In oil pan) C 90 110 120
ture
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.3 1.0
rated output
Function of radiator kPa
Cracking pressure (Differential pressure)
pressure valve {kg/cm2}
Cooling system
Fan speed At rated speed rpm

Deflection under finger pressure of 98 N
Fan belt tension mm
{10 kg}
Alternator belt ten- Deflection under finger pressure of 98 N
mm 13 16 13 16
sion {10 kg}
2 125E-5 Series
Engine SAA6D125E-5
D85EX-15R
Machine model
D85PX-15R

High idle rpm 2,100 50 2,100 50

Speed
Low idle rpm 750 (+50/0) 750 (+50/0)
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 80 67
{mmHg} {Min. 600} {500}
kPa Min. 87 73
{mmHg} {Min. 650} {550}
Exhaust temperature Whole speed range (20C) C 650 700
%
Max. 40
{Max. 4.0}
index)
index
Bosch
index
Valve clearance
Body

Blow-by pressure
At rated output
SAE0W30E0S MPa 0.29 0.69 0.18
SAE5W40E0S {kg/cm2} {3.0 7.0} {1.8}
Min. 80C
Lubrication system

Min. 80C
Engine oil tempera-
ture
rated output
Cooling system

Fan belt tension mm
{10 kg}
mm 13 16 13 16
sion {10 kg}
125E-5 Series 3
Engine SAA6D125E-5
PC400, 400LC-7E0,
PC400, 400LC-8
Machine model
PC450, 450LC-7E0,
PC450, 450LC-8

High idle rpm 1,930 50 1,930 50

Speed
Low idle rpm 1,000 25 1,000 25
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 140 113
{mmHg} {Min. 1,050} {850}
kPa Min. 167 140
{mmHg} {Min. 1,250} {1,050}
Exhaust temperature Whole speed range (20C) C Max. 700 700

%
Max. 25
{Max. 2.5}
index)
index
Bosch
index
Valve clearance
MPa Min. 1.18
{kg/cm2} {Min. 12}
bypass valve drive
At high idle
{kg/cm2} {Min. 14.6}
Body

Blow-by pressure
At rated output
SAE0W30E0S MPa 0.29 0.69 0.18
SAE5W40E0S {kg/cm2} {3.0 7.0} {1.8}
Min. 80C
Lubrication system

Min. 80C
Engine oil tempera-
ture
rated output
Cooling system

Fan belt tension mm
{10 kg}
mm 13 16 13 16
sion {10 kg}
4 125E-5 Series
Engine SAA6D125E-5
PC400, 400LC-8R
Machine model
PC450, 450LC-8R

High idle rpm 1,930 (+35/-15) 1,930 (+35/-15)

Speed
Low idle rpm 1,000 25 1,000 25
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 127 107
{mmHg} {Min. 950} {800}
kPa Min. 153 127

{mmHg} {Min. 1,150} {950}
%
Max. 40
{Max. 4.0}
index)
index
Bosch
index
Valve clearance
Body

Blow-by pressure
At rated output
SAE0W30E0S MPa 0.29 0.69 0.18
SAE5W40E0S {kg/cm2} {3.0 7.0} {1.8}
Min. 80C
Lubrication system

Min. 80C
Engine oil tempera-
ture
rated output
Cooling system

Fan belt tension mm
{10 kg}
mm 13 16 13 16
sion {10 kg}
125E-5 Series 5
Engine SAA6D125E-5
Machine model HM250-2

High idle rpm 2,100 50 2,100 50

Speed
Low idle rpm 725 (+50/0) 725 (+50/0)
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 127 100
{mmHg} {Min. 950} {750}
kPa Min. 140 113
{mmHg} {Min. 1,050} {850}

%
Max. 25
{Max. 2.5}
index)
index
Bosch
index
Valve clearance
MPa Min. 1.18
{kg/cm2} {Min. 12}
bypass valve drive
At high idle
{kg/cm2} {Min. 14.6}
Body

Blow-by pressure
At rated output
SAE0W30E0S MPa 0.29 0.69 0.18
SAE5W40E0S {kg/cm2} {3.0 7.0} {1.8}
Min. 80C
Lubrication system

Min. 80C
Engine oil tempera-
ture
rated output
Cooling system

Fan belt tension mm
{10 kg}
mm 13 16 13 16
sion {10 kg}
6 125E-5 Series
Engine SAA6D125E-5

High idle rpm 2,220 50 2,220 50

Speed
Low idle rpm 725 (+50/0) 725 (+50/0)
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 133 107
{mmHg} {Min. 1,000} {800}
kPa Min. 147 120
{mmHg} {Min. 1,100} {900}

%
Max. 25
{Max. 2.5}
index)
index
Bosch
index
Valve clearance
MPa Min. 1.18
{kg/cm2} {Min. 12}
bypass valve drive
At high idle
{kg/cm2} {Min. 14.6}
Body

Blow-by pressure
At rated output
SAE0W30E0S MPa 0.29 0.69 0.18
SAE5W40E0S {kg/cm2} {3.0 7.0} {1.8}
Min. 80C
Lubrication system

Min. 80C
Engine oil tempera-
ture
rated output
Cooling system

Fan belt tension mm
{10 kg}
mm 13 16 13 16
sion {10 kg}
125E-5 Series 7
Engine SAA6D125E-5
Machine model HM300-2R

High idle rpm 2,220 50 2,220 50

Speed
Low idle rpm 725 (+50/0) 725 (+50/0)
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 113 93
{mmHg} {Min. 850} {700}
kPa Min. 120 100

{mmHg} {Min. 900} {750}
%
Max. 40
{Max. 4.0}
index)
index
Bosch
index
Valve clearance
Body

Blow-by pressure
At rated output
SAE0W30E0S MPa 0.29 0.69 0.18
SAE5W40E0S {kg/cm2} {3.0 7.0} {1.8}
Min. 80C
Lubrication system

Min. 80C
Engine oil tempera-
ture
rated output
Cooling system

Fan belt tension mm
{10 kg}
mm 13 16 13 16
sion {10 kg}
8 125E-5 Series
Engine SAA6D125E-5
Machine model WA450-6, WA470-6

High idle rpm 2,170 50 2,170 50

Speed
Low idle rpm 800 (+50/0) 800 (+50/0)
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 100 80
{mmHg} {Min. 750} {600}
kPa Min. 113 93
{mmHg} {Min. 850} {700}

%
Max. 25
{Max. 2.5}
index)
index
Bosch
index
Valve clearance
MPa Min. 1.18
{kg/cm2} {Min. 12}
bypass valve drive
At high idle
{kg/cm2} {Min. 14.6}
Body

Blow-by pressure
At rated output
SAE0W30E0S MPa 0.29 0.69 0.18
SAE5W40E0S {kg/cm2} {3.0 7.0} {1.8}
Min. 80C
Lubrication system

Min. 80C
Engine oil tempera-
ture
rated output
Cooling system

Fan belt tension mm
{10 kg}
mm 13 16 13 16
sion {10 kg}
125E-5 Series 9
Engine SAA6D125E-5
Machine model WA470-6R

High idle rpm 2,170 50 2,170 50

Speed
Low idle rpm 800 (+50/0) 800 (+50/0)
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 107 87
{mmHg} {Min. 800} {650}
kPa Min. 127 107

{mmHg} {Min. 950} {800}
%
Max. 25
{Max. 2.5}
index)
index
Bosch
index
Valve clearance
Body

Blow-by pressure
At rated output
SAE0W30E0S MPa 0.29 0.69 0.18
SAE5W40E0S {kg/cm2} {3.0 7.0} {1.8}
Min. 80C
Lubrication system

Min. 80C
Engine oil tempera-
ture
rated output
Cooling system

Fan belt tension mm
{10 kg}
mm 13 16 13 16
sion {10 kg}
10 125E-5 Series
Engine SAA6D125E-5
Machine model WA480-6

High idle rpm 2,190 50 2,190 50

Speed
Low idle rpm 800 (+50/0) 800 (+50/0)
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 113 93
{mmHg} {Min. 850} {700}
kPa Min. 133 113
{mmHg} {Min. 1,000} {850}

%
Max. 25
{Max. 2.5}
index)
index
Bosch
index
Valve clearance
MPa Min. 1.18
{kg/cm2} {Min. 12}
bypass valve drive
At high idle
{kg/cm2} {Min. 14.6}
Body

Blow-by pressure
At rated output
SAE0W30E0S MPa 0.29 0.69 0.18
SAE5W40E0S {kg/cm2} {3.0 7.0} {1.8}
Min. 80C
Lubrication system

Min. 80C
Engine oil tempera-
ture
rated output
Cooling system

Fan belt tension mm
{10 kg}
mm 13 16 13 16
sion {10 kg}
125E-5 Series 11
Engine SAA6D125E-5
Machine model WA480-6R

High idle rpm 2,190 50 2,190 50

Speed
Low idle rpm 800 (+50/0) 800 (+50/0)
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 113 93
{mmHg} {Min. 850} {700}
kPa Min. 133 113

{mmHg} {Min. 1,000} {850}
%
Max. 25
{Max. 2.5}
index)
index
Bosch
index
Valve clearance
Body

Blow-by pressure
At rated output
SAE0W30E0S MPa 0.29 0.69 0.18
SAE5W40E0S {kg/cm2} {3.0 7.0} {1.8}
Min. 80C
Lubrication system

Min. 80C
Engine oil tempera-
ture
rated output
Cooling system

Fan belt tension mm
{10 kg}
mm 13 16 13 16
sion {10 kg}
12 125E-5 Series
Engine SAA6D125E-5
Machine model BR580JG-1

High idle rpm 1,930 50 1,930 50

Speed
Low idle rpm 1,000 25 1,000 25
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 140 113
{mmHg} {Min. 1,050} {850}
kPa Min. 167 140
{mmHg} {Min. 1,250} {1,050}

%
Max. 25
{Max. 2.5}
index)
index
Bosch
index
Valve clearance
MPa Min. 1.18
{kg/cm2} {Min. 12}
bypass valve drive
At high idle
{kg/cm2} {Min. 14.6}
Body

Blow-by pressure
At rated output
SAE0W30E0S MPa 0.29 0.69 0.18
SAE5W40E0S {kg/cm2} {3.0 7.0} {1.8}
Min. 80C
Lubrication system

Min. 80C
Engine oil tempera-
ture
rated output
Cooling system

Fan belt tension mm
{10 kg}
mm 13 16 13 16
sion {10 kg}
125E-5 Series 13
Engine SAA6D125E-5
DCA-300SSK4
Machine model

High idle rpm 1,890 50 1,890 50

Speed
Low idle rpm 750 25 750 25
kPa Max. 3.73 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 173 140
{mmHg} {Min. 1,300} {1,050}
kPa Min. 173 140

{mmHg} {Min. 1,300} {1,050}
At sudden acceleration (Low o High) %
Exhaust gas color At rated output % Max. 10
At high idle % Max. 10
Valve clearance
MPa Min. 1.18
{kg/cm2} {Min. 12}
bypass valve drive
At high idle
{kg/cm2} {Min. 14.6}
Body

Blow-by pressure
At rated output
MPa 0.29 0.69 0.18
SAE10W30DH {kg/cm2} {3.0 7.0} {1.8}
Min. 80C
Lubrication system

At low idle SAE30DH MPa Min. 0.08 0.05
{kg/cm2} {Min. 0.8} {0.5}
Min. 80C
Engine oil tempera-
ture
rated output
Function of radiator kPa 0.069
pressure valve {kg/cm2} {0.7}
Cooling system
Fan speed At rated speed rpm 1,543

Fan/alternator belt Deflection under finger pressure of 98 N
mm 10 13
tension {10 kg}
Alternator belt ten- Deflection under finger pressure of 58.9 N
mm 10 15
sion {6 kg}
14 125E-5 Series
Running-in standard and performance test standard 1
Running-in standard
Engine SAA6D125E-5
D85EX-15E0, D85EX-15R
Machine model
D85PX-15E0, D85PX-15R
Procedure
Item
1 2 3 4 5
Running time min. 2 8 2 3 5
Speed rpm 750 950 1,140 1,425 1,900
Dynamometer
N {kg} 0 {0} 275 {28} 697 {71} 1,115 {114} 1,394 {142}
load
Output kW {HP} 0 {0} 20 {26.6} 60 {80} 119 {160} 199 {266}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard
Engine SAA6D125E-5
D85EX-15E0, D85EX-15R
Machine model
D85PX-15E0, D85PX-15R
Max. speed at no Min. speed at no
Test item Rated output Max. torque
load load
Specification
value
(Gross value)
Speed rpm 1,900 1,400 2,100 50 750 (+50/0)
Dynamometer N 1,354 1,432 1,727 1,834

load {kg} {138 146} {176 187}
Output kW 199

(Gross value) {HP} {266}
Torque Nm 1,272

(Gross value) {kgm} {130}
Fuel consumption sec/300cc
Coolant
C 80 90 80 90 80 90 80 90
temperature
Lubricating oil
C 90 110 90 110 90 110 90 110
temperature
Lubricating oil kPa 290 690 190 540 290 690 Min. 80
pressure {kg/cm2} {3.0 7.0} {2.0 5.5} {3.0 7.0} {Min. 0.8}
Exhaust
C Max. 650 Max. 650
temperature
a This table shows the standard values obtained by using the JIS correction coefficients.
a 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.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
125E-5 Series 15
Running-in standard
Engine SAA6D125E-5
PC400, 400LC-7E0, PC400, 400LC-8, PC400, 400LC-8R
Machine model
PC450, 450LC-7E0, PC450, 450LC-8, PC450, 450LC-8R
Procedure
Item
1 2 3 4 5
Speed rpm 1,000 1,000 1,200 1,500 1,900
Dynamometer
N {kg} 0 {0} 353 {36} 875 {89} 1,400 {143} 1,893 {193}
load
Output kW {HP} 0 {0} 26 {35.5} 79 {106} 157 {211} 262.5 {352}
Engine SAA6D125E-5
PC400, 400LC-7E0, PC400, 400LC-8, PC400, 400LC-8R
Machine model
PC450, 450LC-7E0, PC450, 450LC-8, PC450, 450LC-8R
load load
Specification
value
(Gross value)
Speed rpm 1,900 1,400 1,930 50 1,000 25
Dynamometer N 1,785 1,900 1,920 2,050

load {kg} {182 194} {196 209}
Output kW 262.5

Torque Nm 1,422

Coolant
C 80 90 80 90 80 90 80 90
temperature
Lubricating oil
C 90 110 90 110 90 110 90 110
temperature
Exhaust
C Max. 700 Max. 700
temperature
16 125E-5 Series
Running-in standard
Engine SAA6D125E-5
Procedure
Item
1 2 3 4 5
Speed rpm 725 1,000 1,200 1,500 2,000
Dynamometer
N {kg} 0 {0} 307 {31} 774 {79} 1,238 {126} 1,547 {158}
load
Output kW {HP} 0 {0} 23 {31} 70 {94} 139 {186} 232 {311}
Engine SAA6D125E-5
load load
Specification
value
(Gross value)
Speed rpm 2,000 1,400 2,100 50 725 (+50/0)
Dynamometer N 1,500 1,593 2,320 2,450

load {kg} {153 162} {236 250}
Output kW 232

Torque Nm 1,706

Coolant
C 80 90 80 90 80 90 80 90
temperature
Lubricating oil
C 90 110 90 110 90 110 90 110
temperature
Exhaust
C Max. 700 Max. 750
temperature
125E-5 Series 17
Running-in standard
Engine SAA6D125E-5
Machine model HM300-2, HM300-2R
Procedure
Item
1 2 3 4 5
Speed rpm 725 1,000 1,200 1,500 2,000
Dynamometer
N {kg} 0 {0} 343 {35} 850 {87} 1,354 {138} 1,692 {173}
load
Output kW {HP} 0 {0} 26 {34.5} 76 {103} 152 {204} 254 {340}
Engine SAA6D125E-5
Machine model HM300-2, HM300-2R
load load
Specification
value
(Gross value)
Speed rpm 2,000 1,400 2,220 50 725 (+50/0)
Dynamometer N 1,650 1,750 2,320 2,450

load {kg} {168 178} {236 250}
Output kW 254

Torque Nm 1,706

Coolant
C 80 90 80 90 80 90 80 90
temperature
Lubricating oil
C 90 110 90 110 90 110 90 110
temperature
Exhaust
C Max. 700 Max. 750
temperature
18 125E-5 Series
Running-in standard
Engine SAA6D125E-5
WA450-6
Machine model
WA470-6, WA470-6R
Procedure
Item
1 2 3 4 5
Speed rpm 800 1,000 1,200 1,500 2,000
Dynamometer
N {kg} 0 {0} 275 {28} 677 {69} 1,079 {110} 1,353 {138}
load
Output kW {HP} 0 {0} 21 {27.6} 61 {82} 121 {163} 203 {272}
Engine SAA6D125E-5
WA450-6
Machine model
WA470-6, WA470-6R
load load
Specification
value
(Gross value)
Speed rpm 2,000 1,450 2,170 50 800 (+50/0)
Dynamometer N 1,319 1,400 1,267 1,345

load {kg} {135 143} {129 137}
Output kW 204

Torque Nm 1,307

Coolant
C 80 90 80 90 80 90 80 90
temperature
Lubricating oil
C 90 110 90 110 90 110 90 110
temperature
Exhaust
C Max. 650 Max. 650
temperature
125E-5 Series 19
Running-in standard
Engine SAA6D125E-5
Machine model WA480-6, WA480-6R
Procedure
Item
1 2 3 4 5
Speed rpm 800 1,000 1,200 1,500 2,000
Dynamometer
N {kg} 0 {0} 294 {30} 735 {75} 1,196 {122} 1,491 {152}
load
Output kW {HP} 0 {0} 22 {29.6} 66 {89} 135 {180} 224 {300}
Engine SAA6D125E-5
Machine model WA480-6, WA480-6R
load load
Specification
value
(Gross value)
Speed rpm 2,000 1,400 2,190 50 800 (+50/0)
Dynamometer N 1,450 1,541 1,843 1,956

load {kg} {148 157} {188 200}
Output kW 224

Torque Nm 1,360

Coolant
C 80 90 80 90 80 90 80 90
temperature
Lubricating oil
C 90 110 90 110 90 110 90 110
temperature
Exhaust
C Max. 700 Max. 700
temperature
20 125E-5 Series
Running-in standard
Engine SAA6D125E-5
Procedure
Item
1 2 3 4 5
Speed rpm 1,000 1,000 1,200 1,500 1,900
Dynamometer
N {kg} 0 {0} 353 {36} 875 {89} 1,400 {143} 1,893 {193}
load
Output kW {HP} 0 {0} 26 {35.5} 79 {106} 157 {211} 262.5 {352}
Engine SAA6D125E-5
load load
Specification
value
(Gross value)
Speed rpm 1,900 1,400 1,930 50 1,000 25
Dynamometer N 1,785 1,900 1,920 2,050

load {kg} {182 194} {196 209}
Output kW 262.5

Torque Nm 1,422

Coolant
C 80 90 80 90 80 90 80 90
temperature
Lubricating oil
C 90 110 90 110 90 110 90 110
temperature
Exhaust
C Max. 700 Max. 700
temperature
125E-5 Series 21
Running-in standard
Engine SAA6D125E-5
DCA-300SSK4
Machine model
Procedure
Item
1 2 3 4 5
Speed rpm 750 1,500 1,500 1,500 1,800
Dynamometer
N {kg} 0 {0} 366 {37} 970 {99} 1,568 {160} 2,019 {206}
load
Output kW {HP} 0 {0} 41 {56} 109 {148} 177 {240} 277 {370}
Engine SAA6D125E-5
DCA-300SSK4
Machine model
Test item Rated output Max. output
load load
Specification
kW 272 7.36 313 9.56
value
{HP} {365 10} {420 13}
(Gross value)
Speed rpm 1,800 1,800 Max. 1,890 750 25
Dynamometer N 1,960 2,068 2,244 2,391

load {kg} {200 211} {229 244}
Output kW 272

Torque Nm

(Gross value) {kgm}
Coolant
C 80 90 80 90 80 90 80 90
temperature
Lubricating oil
C 90 110 90 110 90 110 90 110
temperature
Exhaust
C Max. 700 Max. 750
temperature
22 125E-5 Series
125E-5 Series 23
SEN00546-05
2008 KOMATSU
All Rights Reserved
24
SEN00547-02
ENGINE 1SHOP MANUAL
125E-5 Series
30 Testing and adjusting 1

Testing and adjusting
Testing and adjusting (With EGR)................................................................................................................... 4
Testing and adjusting tools list ............................................................................................................. 4
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
125E-5 Series 1
SEN00547-02 30 Testing and adjusting
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
Testing air boost pressure .................................................................................................................. 28
Testing exhaust temperature .............................................................................................................. 29
Adjusting valve clearance................................................................................................................... 30
Testing compression pressure............................................................................................................ 31
Testing blow-by pressure.................................................................................................................... 33
Testing engine oil pressure................................................................................................................. 34
Handling fuel system parts ................................................................................................................. 35
Releasing residual pressure in fuel system........................................................................................ 35
Testing fuel pressure .......................................................................................................................... 36
Reduced cylinder mode operation...................................................................................................... 37
No-injection cranking.......................................................................................................................... 37
Testing leakage from pressure limiter and return rate from injector ................................................... 38
Bleeding air from fuel circuit ............................................................................................................... 40
Testing fuel system for leakage .......................................................................................................... 42
Adjusting speed sensor ...................................................................................................................... 43
Testing and adjusting alternator belt tension ...................................................................................... 44
Handling controller voltage circuit ...................................................................................................... 45
2 125E-5 Series
125E-5 Series 3
Testing and adjusting (With EGR) 1

Testing and adjusting tools list 1
Sym-
Testing and adjusting item Part No. Part name Q'ty Remarks
bol
799-201-2202 Boost gauge kit 1 101 200 kPa {760 1,500 mmHg}
Testing air boost pressure A
799-401-2220 Hose 1 I-coupler type (if necessary)
Testing exhaust
B 799-101-1502 Digital thermometer 1 99.9 1,299C
temperature
Commercially Intake: 0.33 mm
Adjusting valve clearance C Clearance gauge 1
available Exhaust: 0.71 mm
1 795-502-1590 Compression gauge 1 0 7 MPa {0 70 kg/cm2}
Testing compression
D 795-471-1420 Adapter 1
pressure 2 For 125E-5
6217-71-6112 Gasket 1
Testing blow-by pressure E 799-201-1504 Blow-by checker 1 0 5 kPa {0 500 mmH2O}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing oil pressure F
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 {25, 60, 400, 600 kg/cm2}
Testing fuel pressure G
795-471-1450 Adapter 1
3 8 x 1.25 mm o R1/8
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 5 mm x 2 3 m
available
Testing leakage from
pressure limiter and return H 4 Commercially
Hose 1 15 mm x 2 3 m
rate from injector available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
4 125E-5 Series
Sym-
bol
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
For coolant temperature sensor
795-799-5530 T-adapter
For fuel temperature sensor
Troubleshooting for
For EGR valve solenoid
controllers, J 799-601-9020 T-adapter
For bypass valve solenoid
sensors, and actuators
For EGR valve solenoid
799-601-9030 T-adapter
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)
799-601-9320 T-box
For 24-pole type
799-601-9310 Plate
799-601-4350 T-box For 60-pole type
125E-5 Series 5
Testing air boost pressure 1

a Testing tools for air boost pressure
Symbol Part No. Part name

799-201-2202 Boost gauge kit
A
799-401-2220 Hose
k Be careful not to touch any hot part when

removing or installing the testing tools.
a The test point is subject to machine models.
1. Remove one air boost pressure pickup plug

(1).
a You may check at either front or rear plug.
4. After finishing testing, remove the testing tools
and return the removed parts.
2. Install nipple [1] of boost gauge kit A and con-

nect 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.
6 125E-5 Series
Testing exhaust temperature 1

a Testing tools for exhaust temperature

B 799-101-1502 Digital thermometer
k Remove and install the testing tools after

the exhaust manifold temperature has low-
ered.
1. Remove exhaust temperature pickup plug (1)

from the side face of the center of the exhaust
manifold.
3 Exhaust temperature pickup plug:
3.9 6.9 Nm {0.4 0.7 kgm}
2. Install sensor [1] of digital thermometer B and

connect it to thermometer [2].
3. Run the engine and test the exhaust tempera-

ture in the whole speed range.
machine.
125E-5 Series 7
Adjusting valve clearance 1 3. While fixing adjustment screw (3), loosen lock-
nut (4).
a Adjusting tools for valve clearance a After setting the No. 1 cylinder to the com-
pression top dead center, adjust the valve
Symbol Part No. Part name clearance of the No. 1 cylinder.
Commercially
C Clearance gauge 4. Insert clearance gauge C in the clearance
available
between rocker arm (5) and crosshead (6) and
adjust the valve clearance with adjustment
1. Remove 6 cylinder head covers (1). screw (3).
a With the clearance gauge inserted, turn
the adjustment screw to a degree that you
can move the clearance gauge lightly.
a Valve clearance
Intake valve: 0.33 mm
Exhaust valve: 0.71 mm
5. While fixing adjustment screw (3), tighten lock-

nut (4).
3 Locknut:
58.8 73.5 Nm {6.0 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.
2. 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 compres-
sion 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. 6. After adjusting the No. 1 cylinder, rotate the
crankshaft forward by 120 and adjust the
clearance of each cylinder according to the fir-
ing 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}
8 125E-5 Series
Testing compression pressure 1 a Pass a wire, etc. under the fuel path pro-
jected sideways and pull up the injector
a Testing tools for compression pressure (Do not pry the injector top up).

1 795-502-1590 Compression gauge
D 795-471-1420 Adapter
2
6217-71-6112 Gasket
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the
engine is warmed up
(Engine oil temperature: 40 60C).
1. Remove cylinder head cover (1) of the cylinder 4. Install adapter D2 to the mounting hole on the
to be tested for compression pressure. 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}
a See "Adjusting valve clearance".
2. Bring the cylinder to be tested to the compres-
sion 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-pres-
sure tube, loosen all center clamps.
a Disconnect the terminal of the injector wir-
ing 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 9
6. Connect the INSITE (bench test tool) to the 3 Rocker arm assembly mounting
engine and set the engine in the no-injection bolt:
cranking mode. 58.8 73.5 Nm {6.0 7.5 kgm}
k If the engine is not set in the no-injec-
tion cranking mode, it will start and will a Adjust the valve clearance. For
be dangerous. Accordingly, be sure to details, see "Adjusting valve clear-
set the engine in this mode. ance".
7. Rotate the engine with the starting motor and 3 Cylinder head cover mounting bolt:
measure the compression pressure. 9.8 1 Nm {1.0 0.1 kgm}
a Read the pressure gauge pointer when it
is stabilized.

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 tempo-
rarily assemble them as a unit to the cylin-
der 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 pip-
ing.
3 Clamping bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
10 125E-5 Series
Testing blow-by pressure 1

a Testing tool for blow-by pressure

E 799-201-1504 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].

blow-by pressure.
machine.

125E-5 Series 11
Testing engine oil pressure 1

a Testing tools for engine oil pressure

799-101-5002 Hydraulic tester
1
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
1. Remove oil pressure pickup plug (1) from the

cylinder block.

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
Measuring EGR valve and bypass 3. Connect hydraulic tester [1] to the nipple.
valve drive pressure 1
4. Start the engine and measure the oil pressure
a Measuring instruments for EGR valve and at low idle and high idle.
bypass valve drive pressure a When measuring without removing the
engine from the machine, measure under
Symbol Part No. Part name the condition described in the shield
799-101-5002 Hydraulic tester machine for the machine.
F 1
790-261-1204 Digital hydraulic tester
a 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 remov-
ing 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
5. After finishing measurement, remove the mea-
belt.
suring instruments and return the removed
q Move the air conditioner compressor so
parts.
that it will not be an obstacle to the work.
q Replace the removed plug with new one.
When reusing it, remove the sticking gas-
2. Install nipple (Component of tool F1: 790-301-
ket sealant from it with a wire brush and
1190) to the oil pressure pickup hole.
apply new adhesive or gasket sealant to it
before installing.
2 Plug: LT-2 or LG-4
3 Plug: 16.7 37.2 Nm {1.7 3.8 kgm}
125E-5 Series 13
Handling fuel system parts 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump Fuel filter Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump Common rail Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is tested and its parts are
cartridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at least 30 seconds after stop-
vent foreign matter from entering it. ping the engine until the residual pressure
If a filter other than the genuine one is used, in the fuel circuit is released. (Do not start
the fuel system may have a trouble. Accord- the work just after stopping the engine
ingly, never use such a filter. since there is residual pressure.)
14 125E-5 Series
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 0.3 MPa
High idle
G 2 799-401-2320 Hydraulic tester {1.5 3 kg/cm2}
795-471-1450 Adapter
3
07005-00812 Gasket
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the fuel fil-
ter to the supply pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Remove fuel pressure pickup plug (1) from the

fuel filter head.

2. Install adapter G3 and nipple [1] of hydraulic

tester G1 and connect it to hydraulic tester G2.
125E-5 Series 15
Reduced cylinder mode No-injection cranking 1

operation 1 a No-injection cranking means to crank the
a Reduced cylinder mode operation means to engine with the starting motor while all the
run the engine with the fuel injectors of 1 or injections are stopped electrically. The pur-
more cylinders disabled electrically to reduce pose and effect of this operation are as follows.
the number of effective cylinders. The pur- q Before the engine is started after it or the
poses and effects of this operation are as fol- engine unit has been stored for a long period,
lows. the no-injection cranking is performed to lubri-
1. This operation is used to find out a cylinder cate the engine parts and protect them from
which does not output power normally (or, seizure.
combustion in it is abnormal). a Perform the no-injection operation with the
2. When a cylinder is selected for the reduced engine mounted on the machine or connected
cylinder mode operation, if the engine speed to INSITE (bench test tool).
and output do not change from the normal a Before performing, see "Testing method" in the
operation (all-cylinder operation), that cylinder shop manual for the machine or INSITE
has 1 or more defects. (bench test tool).
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
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode opera-
tion 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).
16 125E-5 Series
Testing leakage from pressure limiter and return rate from injector 1
a The locations of the fuel circuit parts are sub- 1. Preparation work
ject to machine models (The figure shows the 1) Remove tube (3) between common rail (1)
engine for PC400/400LC-7E0 and PC450/ and return block (2).
450LC-7E0).
a Testing tools for leakage from pressure limiter
and return rate from injector

1 6151-51-8490 Spacer
2 6206-71-1770 Joint
3 Commercially available Hose
H
5 Commercially available Measuring cylinder
6 Commercially available Stopwatch
a Prepare a pan of about 20 l to receive the fuel

flowing out during the test. 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.
125E-5 Series 17
3) Insert joint H2 on common rail (1) side and

tighten the removed joint bolt again.
of the joint.
4) 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) After finishing testing, stop the engine.
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 injec-
tor.
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. 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 out-
put.
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
2) Connect test hose H4 to the return block
judge by multiplying the result by 3.
(2) side.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
from coming off.
Leakage 3) Lay test hose H4 so that it will not slacken
Engine speed
(cc/min) and put its end in the pan.
At rated output Max. 10
18 125E-5 Series
4. Work after finishing testing
After finishing all testing, remove the testing

tools and return the removed parts.

engine speed.
5) Run the engine at the rated output.
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 injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (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
Bleeding air from fuel circuit 1
a 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.
a The locations of the fuel circuit parts are sub-
ject to machine models (The figure shows the
engine for PC400/400LC-7E0 and PC450/
450LC-7E0).
1. 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) exter-
nally.
20 125E-5 Series
2. Install pre-fuel filter (1) to the filter head. 5. Loosen air bleeder (6) of the fuel supply pump
a Apply engine oil thinly over the packing on and operate priming pump (4) 90 100 times.
the pre-fuel filter side. a Operate the priming pump until the fuel
a After the packing of the pre-fuel filter flows out of the air bleeder and tighten the
touches the sealing face of the filter head, air bleeder. Then, operate the priming
tighten the fuel filter 3/4 turns. 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.
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 fil-

ter (2) 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}
125E-5 Series 21
Testing fuel system for leakage 1 9. Inspect the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the high- a Inspect mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
its parts, test it for fuel leakage according a If no fuel leakage is detected, inspection is
to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily 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.

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

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 125E-5 Series
Adjusting speed sensor 1

a The Ne speed sensor and Bkup speed sensor
for the common rail fuel injection system can-
not be adjusted.
a Adjust speed sensor (1), which detects the sig-
nal of the flywheel ring gear to use it for the
electronic system on the machine side, accord-
ing 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
Testing and adjusting alternator Simultaneous fan drive type

belt tension 1
Testing
Separately installed fan type
Press the intermediate point of the belt between
alternator pulley and fan pulley with a finger and
Testing measure deflection (a) of the belt.
Press the intermediate point of the belt between a Pressing force: Approx. 98 N {Approx. 10 kg}
alternator pulley and crankshaft pulley with a finger a Deflection (a): 13 16 mm
and measure deflection (a) of the belt.
a Pressing force: Approx. 58.8 N {Approx. 6 kg}
a Deflection (a): 13 16 mm
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
Adjusting
a If the deflection is out of the standard range, 1. Loosen locknut (1) and bolts (2) and (3).
a The figure shows an example. The number of 2. Move alternator (5) with adjustment nut (4) to
the belt may be different and locknut (1) may adjust the tension of belt (6).
not be used depending on each model.
3. Tighten bolts (3) and (2) and tighten locknut
1. Loosen locknut (1) and loosen rocknut (2) and (1).
bolts (3) and (4). 3 Bolt (3): 107.8 147 Nm {11 15 kgm}
3 Bolt (2): 28.4 38.2 Nm {2.9 3.9 kgm}
2. Move alternator (6) with adjustment nut (5) to a After adjusting, test the belt tension again.
adjust the tension of belt (7).

(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 125E-5 Series
Handling controller voltage

circuit 1
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
Testing and adjusting (EGR-less) 1

Testing and adjusting tools list 1
Sym-
bol
799-201-2202 Boost gauge kit 1 101 200 kPa {760 1,500 mmHg}
Testing air boost pressure A
799-401-2220 Hose 1 I-coupler type (if necessary)
Testing exhaust
B 799-101-1502 Digital thermometer 1 99.9 1,299C
temperature
Commercially Intake: 0.33 mm
Adjusting valve clearance C Clearance gauge 1
available Exhaust: 0.71 mm
1 795-502-1590 Compression gauge 1 0 7 MPa {0 70 kg/cm2}
Testing compression
D 795-471-1420 Adapter 1
pressure 2 For 125E-5
6217-71-6112 Gasket 1
Testing blow-by pressure E 799-201-1504 Blow-by checker 1 0 5 kPa {0 500 mmH2O}
1 {25, 60, 400, 600 kg/cm2}
Testing oil pressure F
1 {25, 60, 400, 600 kg/cm2}
Testing fuel pressure G
795-471-1450 Adapter 1
3 8 x 1.25 mm o R1/8
07005-00812 Gasket 1
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 5 mm x 2 3 m
available
Testing leakage from
pressure limiter and return H 4 Commercially
Hose 1 15 mm x 2 3 m
rate from injector available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
26 125E-5 Series
Sym-
bol
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
Troubleshooting for For coolant temperature sensor
795-799-5530 T-adapter
controllers, J For fuel temperature sensor
sensors, and actuators 799-601-9430 T-adapter For supply pump PCV
799-601-9020 T-adapter For injector
799-601-9320 T-box
For 24-pole type
799-601-9310 Plate
799-601-4350 T-box For 60-pole type
125E-5 Series 27
Testing air boost pressure 1

a Testing tools for air boost pressure

799-201-2202 Boost gauge kit
A
799-401-2220 Hose
k Be careful not to touch any hot part when

removing or installing the testing tools.
1. 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 con-

nect it to gauge [2].

air boost pressure.
machine.
28 125E-5 Series
Testing exhaust temperature 1

a Testing tools for exhaust temperature

B 799-101-1502 Digital thermometer
k Remove and install the testing tools after

the exhaust manifold temperature has low-
ered.
1. Remove exhaust temperature pickup plug (1)

from the side face of the center of the exhaust
manifold.
3 Exhaust temperature pickup plug:
3.9 6.9 Nm {0.4 0.7 kgm}
2. Install sensor [1] of digital thermometer B and

connect it to thermometer [2].
3. Run the engine and test the exhaust tempera-

ture in the whole speed range.
machine.
125E-5 Series 29
Adjusting valve clearance 1 3. While fixing adjustment screw (3), loosen lock-
nut (4).
a Adjusting tools for valve clearance a After setting the No. 1 cylinder to the com-
pression top dead center, adjust the valve
Symbol Part No. Part name clearance of the No. 1 cylinder.
Commercially
C Clearance gauge 4. Insert clearance gauge C in the clearance
available
between rocker arm (5) and crosshead (6) and
adjust the valve clearance with adjustment
1. Remove 6 cylinder head covers (1). screw (3).
a With the clearance gauge inserted, turn
the adjustment screw to a degree that you
can move the clearance gauge lightly.
a Valve clearance
Intake valve: 0.33 mm
Exhaust valve: 0.71 mm
5. While fixing adjustment screw (3), tighten lock-

nut (4).
3 Locknut:
58.8 73.5 Nm {6.0 7.5 kgm}
2. 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 compres-
sion 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. 6. After adjusting the No. 1 cylinder, rotate the
crankshaft forward by 120 and adjust the
clearance of each cylinder according to the fir-
ing 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}
30 125E-5 Series
Testing compression pressure 1 a Pass a wire, etc. under the fuel path pro-
jected sideways and pull up the injector
a Testing tools for compression pressure (Do not pry the injector top up).

1 795-502-1590 Compression gauge
D 795-471-1420 Adapter
2
6217-71-6112 Gasket
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the
engine is warmed up
(Engine oil temperature: 40 60C).
1. Remove cylinder head cover (1) of the cylinder 4. Install adapter D2 to the mounting hole on the
to be tested for compression pressure. 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}
2. Bring the cylinder to be tested to the compres-
sion 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-pres-
sure tube, loosen all center clamps.
a Disconnect the terminal of the injector wir-
ing 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 31
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 no-
injection cranking mode by operating the
monitor panel.
k If the engine is not set in the no-injec-
tion 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
3 Rocker arm assembly mounting
is stabilized.
bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a Adjust the valve clearance. For
a Install the injector, injector wiring harness,
details, see "Adjusting valve clear-
and fuel high-pressure tube according to
ance".
the following procedure.
3
1) Install the O-ring and gasket to injector
Cylinder head cover mounting bolt:
(11).
9.8 1 Nm {1.0 0.1 kgm}
2) Fit holder (12) to injector (11) to tempo-
rarily assemble them as a unit to the cylin-
der 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 pip-
ing.
3 Clamping bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
32 125E-5 Series
Testing blow-by pressure 1

a Testing tool for blow-by pressure

E 799-201-1504 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].

blow-by pressure.
machine.

125E-5 Series 33
Testing engine oil pressure 1

a Testing tools for engine oil pressure

799-101-5002 Hydraulic tester
1
F 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
1. Remove oil pressure pickup plug (1) from the

cylinder block.

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.
34 125E-5 Series
Handling fuel system parts 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump Fuel filter Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump Common rail Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is tested and its parts are
cartridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at least 30 seconds after stop-
vent foreign matter from entering it. ping the engine until the residual pressure
If a filter other than the genuine one is used, in the fuel circuit is released. (Do not start
the fuel system may have a trouble. Accord- the work just after stopping the engine
ingly, never use such a filter. since there is residual pressure.)
125E-5 Series 35
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 0.3 MPa
High idle
G 2 799-401-2320 Hydraulic tester {1.5 3 kg/cm2}
795-471-1450 Adapter
3
07005-00812 Gasket
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the fuel fil-
ter to the supply pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Remove fuel pressure pickup plug (1) from the

fuel filter head.

2. Install adapter G3 and nipple [1] of hydraulic

tester G1 and connect it to hydraulic tester G2.
36 125E-5 Series
Reduced cylinder mode operation1 No-injection cranking 1

a Reduced cylinder mode operation means to a No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The purpose and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after it or the
lows. engine unit has been stored for a long period,
1. This operation is used to find out a cylinder the no-injection cranking is performed to lubri-
which does not output power normally (or, cate the engine parts and protect them from
combustion in it is abnormal). seizure.
2. When a cylinder is selected for the reduced a Perform the no-injection operation with the
cylinder mode operation, if the engine speed engine mounted on the machine or connected
and output do not change from the normal to INSITE (bench test tool).
operation (all-cylinder operation), that cylinder a Before performing, see "Testing method" in the
has 1 or more defects. shop manual for the machine or INSITE
The possible defects are as follows. (bench test tool).
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
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode opera-
tion 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).
125E-5 Series 37
Testing leakage from pressure

limiter and return rate from
injector 1
a The locations of the fuel circuit parts are sub-

ject to machine models.
a Testing tools for leakage from pressure limiter
and return rate from injector
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
H
4 Commercially available Hose 2. Testing leakage from pressure limiter
5 Commercially available Measuring cylinder 1) Lay test hose H3 so that it will not slacken
6 Commercially available Stopwatch
a Prepare a pan of about 20 l to receive the fuel
engine speed.
flowing out during the test.
1. Preparation work
3) Start the engine and run it at the rated out-
1) Remove tube (3) between common rail (1)
put.
and return block (2).
the leakage in 1 minute with measuring
cylinder H5.
a If the leakage from the pressure lim-
iter is in the following range, it is nor-
mal.
Leakage
Engine speed
(cc/min)
At rated output Max. 10
2) Insert spacer H1 on return block (2) side

and tighten the removed joint bolt again.
of the spacer.
3) Insert joint H2 on common rail (1) side and
tighten the removed joint bolt again.
of the joint.
4) Connect test hose H3 to the end of joint
H2.
hose with a wire, etc. to prevent it 5) After finishing testing, stop the engine.
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
38 125E-5 Series
3. Testing return rate from injector 6) After the engine speed is stabilized, test
a Keep the hose on the pressure limiter side the return rate in 1 minute with measuring
connected and keep its end in the pan while cylinder H5.
testing the return rate from the injector. a You may test for 20 seconds and
1) Disconnect fuel return hose (4) from return judge by multiplying the result by 3.
block (2). a If the supply pump is not supplying
a Stop the fuel return hose with a plug, fuel, the engine speed may not rise.
etc. and fix it to the fuel tank. In this case, record the engine speed,
Plug: 07376-70315 too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
2) Connect test hose H4 to the return block

(2) side.
from coming off.
3) Lay test hose H4 so that it will not slacken
4. Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.

engine speed.
5) Run the engine at the rated output.
125E-5 Series 39
Bleeding air from fuel circuit 1 4. Turn ON switch (3) of electric priming pump
(2) installed to the chassis.
Reference: The electric priming pump switch is a The electric priming pump operates and
installed to the chassis. lamp (4) blinks.
a 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
a 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.
a The electric priming pump has a timer in it
3. Turn lever (1) of the air bleeding piping to the to start and stop itself automatically (See
parallel position with the piping to open the cir- the following figure).
cuit valve. a The electric priming pump stops while the
lamp is blinking. This phenomenon is not
abnormal, however.
a If the switch is turned to the OFF position
while the lamp is blinking, the lamp goes
off and the electric priming pump stops.
k 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.
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.
40 125E-5 Series
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 cir-
cuit valve.
9. Start the engine with the starting motor.

a Do not operate the starting motor continu-
ously 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 bleed-
ing 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 operat-
ing, crank the engine.
q If the engine does not start, repeat the
above operation.
a Do not operate the starting motor continu-
ously 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.
125E-5 Series 41
Testing fuel system for leakage 1 9. Inspect the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the high- a Inspect mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
its parts, test it for fuel leakage according a If no fuel leakage is detected, inspection is
to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily 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.

leakage.
for fuel leakage.
4. Run the engine at low idle.

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

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

a When testing the engine mounted on the
relieve the oil from the hydraulic pump.
42 125E-5 Series
Adjusting speed sensor 1

a The Ne speed sensor and Bkup speed sensor
for the common rail fuel injection system can-
not be adjusted.
a Adjust speed sensor (1), which detects the sig-
nal of the flywheel ring gear to use it for the
electronic system on the machine side, accord-
ing 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 43
Testing and adjusting alternator Simultaneous fan drive type

belt tension 1
Testing
Separately installed fan type
Press the intermediate point of the belt between
alternator pulley and fan pulley with a finger and
Testing measure deflection (a) of the belt.
Press the intermediate point of the belt between a Pressing force: Approx. 98 N {Approx. 10 kg}
alternator pulley and crankshaft pulley with a finger a Deflection (a): 13 16 mm
and measure deflection (a) of the belt.
a Pressing force: Approx. 58.8 N {Approx. 6 kg}
a Deflection (a): 13 16 mm
Adjusting
a If the deflection is out of the standard range,
Adjusting
a If the deflection is out of the standard range, 1. Loosen locknut (1) and bolts (2) and (3).
a The figure shows an example. The number of 2. Move alternator (5) with adjustment nut (4) to
the belt may be different and locknut (1) may adjust the tension of belt (6).
not be used depending on each model.
1. Loosen locknut (1) and loosen rocknut (2) and (1).
bolts (3) and (4). 3 Bolt (3): 107.8 147 Nm {11 15 kgm}
3 Bolt (2): 28.4 38.2 Nm {2.9 3.9 kgm}
2. Move alternator (6) with adjustment nut (5) to a After adjusting, test the belt tension again.
adjust the tension of belt (7).

(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.
44 125E-5 Series
Handling controller voltage

circuit 1
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 45
SEN00547-02
2007 KOMATSU
All Rights Reserved
46
SEN00548-03
ENGINE 1SHOP MANUAL
125E-5 Series
40 Troubleshooting 1
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 1
SEN00548-03 40 Troubleshooting
General information on troubleshooting 1

Points on troubleshooting 1
k When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.
k 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.
k 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.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative () terminal of the battery first.
k 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 con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand 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 symp-
toms.
1. When carrying out troubleshooting, do not 3. Check before troubleshooting

hurry to disassemble the components. 1) Check for symptoms of any abnormality in
If components are disassembled immediately the machine and engine.
after any failure occurs: 2) Be sure to check the CHECKS BEFORE
q Parts that have no connection with the fail- STARTING items.
ure or other unnecessary parts will be dis- 3) Check other inspection items, if neces-
assembled. sary.
q It will become impossible to find the cause 4) Some other maintenance items can be
of the failure. checked externally, so check any item that
It will also cause a waste of manhours, parts, is considered to be necessary.
or oil or grease, and at the same time, will also 5) Check the controller for display of an error.
lose the confidence of the user or operator.
For this reason, when carrying out trouble- 4. Confirming failure
shooting, it is necessary to carry out thorough Confirm the extent of the failure yourself, and
prior investigation and to carry out trouble- judge whether to handle it as a real failure or
shooting in accordance with the fixed proce- as a problem with the method of operation, etc.
dure. a When operating the machine or engine to
reenact the troubleshooting symptoms, do
2. Points to ask user or operator not carry out any investigation or mea-
1) Have any other problems occurred apart surement that may make the problem
from the problem that has been reported? worse.
2) Was there anything strange about the
machine before the failure occurred? 5. Troubleshooting
3) Did the failure occur suddenly, or were Use the results of the investigation and inspec-
there problems with the machine condition tion in Items 2 4 to narrow down the causes
before this? of failure, then use the troubleshooting matrix
4) Under what conditions did the failure to locate the position of the failure exactly.
occur? a The basic procedure for troubleshooting is
5) Had any repairs been carried out before as follows.
the failure? When were these repairs car- 1) Start from the simple points.
ried out? 2) Start from the most likely points.
6) Has the same kind of failure occurred 3) Investigate other related parts or informa-
before? tion.
2 125E-5 Series
6. 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 inves-
tigate why the problem occurred. Then,
remove the root cause.
125E-5 Series 3
Error code and failure code table 1

(for construction equipment)
INSITE Machine failure Reference
Failure phenomenon
error code code document No.
111 CA111 ECM Critical Internal Failure
115 CA115 Eng. Ne and Bkup Speed Sensor Error
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 Troubleshooting of electrical
system (E-mode), Part 1
265 CA265 Fuel Temp. Sensor Low Error SEN00550-01
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
342 CA342 Calibration Code Incompatibility
351 CA351 INJ. Drive Circuit Error
352 CA352 Sensor Sup. 1 Volt. Low Error
386 CA386 Sensor Sup. 1 Volt. High Error
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
4 125E-5 Series
INSITE Machine failure Reference

Failure phenomenon
error code code document No.
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]
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] Troubleshooting of electrical
1631 CA1631 BP valve Lift Position Sensor High Error ["with EGR" only] system (E-mode), Part 2
1632 CA1632 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
a 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.
a 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 5
(for Generator)
Machine failure Reference
Failure phenomenon
code document No.
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 Troubleshooting of electrical
CA238 Ne Speed Sensor Sup. Volt. Error CA238 system (E-mode), Part 1
CA263 Fuel Temp. Sensor High CA263 SEN00550-01
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
CA342 Calibration Code Incompatibility CA342
CA351 INJ. Drive Circuit Error CA351
CA352 Sensor Sup. 1 Volt. Low CA352
6 125E-5 Series
Machine failure Reference

Failure phenomenon
code document No.
CA386 Sensor Sup. 1 Volt. High CA386 Troubleshooting of electrical
CA441 Battery Voltage Low CA441 system (E-mode), Part 1
CA442 Battery Voltage High CA442 SEN00550-01
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 Troubleshooting of electrical
system (E-mode), Part 2
CA1632 BP Valve Lift Position Low CA1632 SEN00551-01
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 7
Information in troubleshooting table 1

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 Display on applica- Trouble Problem that appears on engine
INSITE ble machine
Contents of
Contents of trouble detected by engine controller
trouble
Action of Action taken by engine controller to protect system or devices when engine controller detects
controller trouble
Problem that
appears on Problem that appears on engine as result of action taken by engine controller (shown above)
machine
Related
Information related to detected trouble or troubleshooting
information
Causes Standard value in normal state/Remarks on troubleshooting

<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
1
<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
2 (24 V) circuit is in contact with power source (24 V) circuit.
Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are reference
state numbers, which do not indicate <Precautions for troubleshooting>
priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trou-
bleshooting, 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
4 specified.
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.
8 125E-5 Series
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/merg-
ing 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 9
SEN00548-03
2007 KOMATSU
All Rights Reserved
10
SEN00550-01
ENGINE 1SHOP MANUAL
125E-5 Series
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 1
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
2 125E-5 Series
125E-5 Series 3
Troubleshooting of electrical system (E-mode), Part 1 1

E-1 Code [111/CA111] ECM Critical Internal Failure 1

Trouble ECM Critical Internal Failure
111 CA111
Contents of
Abnormality occurred in controller.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine runs normally but it may stop during operation or may not be able to start.
machine
Related
Different machine models may have different connector Nos.
information
Cause Standard value in normal state/Remarks on troubleshooting

Check fuse or circuit breaker on machine side directly for defect.
1 Defective fuse (If fuse is broken or circuit breaker is turned OFF, circuit probably
has ground fault.)
a Prepare with starting switch OFF, then carry out troubleshoot-
Disconnection in wiring har- ing without turning starting switch ON.
ness (Disconnection in wiring Wiring harness between E03 (female) (3), Resis-
2 Max. 1 z
or defective contact in connec- (4) battery (+) tance
tor) Wiring harness between E03 (female) (1), Resis-
Possible causes Max. 1 z
and standard (2) chassis ground tance
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
Ground fault in wiring harness Wiring harness between E03 (female) (3), Resis- Min.
3
(Short circuit with GND circuit) (4) battery (+) and chassis ground tance 1 Mz
Wiring harness between E03 (female) (1), Resis- Min.
(2) chassis ground tance 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
4 125E-5 Series
Circuit diagram related to controller power supply
125E-5 Series 5
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error 1

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

Defective Ne speed sensor
1 Carry out troubleshooting for code [689/CA689].
system
Defective Bkup speed sensor
2 Carry out troubleshooting for code [778/CA778].
system
Possible causes Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
3
and standard sensor installation of sensor, internal of flywheel, etc.)
value in normal Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defective
state 4
speed sensor installation of sensor, internal of supply pump, etc.)
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for
5
connection) defective connection (wrong connection).
If causes 1 5 are not detected, engine controller may be defec-
6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be car-
ried out.)
6 125E-5 Series
125E-5 Series 7
E-3 Code [122/CA122] Charge Air Press Sensor High Error 1

Trouble Charge Air Press Sensor High Error
122 CA122
Contents of
Signal voltage in charge pressure sensor circuit is abnormally high.
trouble
Action of
Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
controller
Problem that
appears on Acceleration performance of engine drops.
machine
Related
information

Defective sensor power supply If code [187/CA187] or [227/CA227] is indicated, carry out trou-
1
system bleshooting for it first.
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
Defective charge pressure PIM Voltage
2 sensor Between (1) (3) Power supply 4.75 5.25V
(Internal trouble)
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.
Possible causes ing without turning starting switch ON.
and standard Disconnection in wiring har- Wiring harness between ENG (female) Resis-
value in normal Max. 1 z
ness (37) PIM (female) (1) and chassis ground tance
state 3
(Disconnection in wiring or Wiring harness between ENG (female) Resis-
defective contact in connector) Max. 1 z
(44) PIM (female) (2) and chassis ground tance
Wiring harness between ENG (female) Resis-
Max. 1 z
(47) PIM (female) (3) and chassis ground tance
ing without turning starting switch ON.
Wiring harness between ENG (female) Resis- Min.
Ground fault in wiring harness (37) PIM (female) (1) tance 1 Mz
4
(Short circuit with GND circuit) Wiring harness between ENG (female) Resis- Min.
(44) PIM (female) (2) tance 1 Mz
(47) PIM (female) (3) tance 1 Mz
8 125E-5 Series

Wiring harness between ENG (female)
(37) PIM (female) (1) and wiring harness Resis- Min.
between ENG (female) (44) PIM (female) tance 1 Mz
(2)
Short circuit in wiring harness Wiring harness between ENG (female)
Possible causes 5
(With another wiring harness) (37) PIM (female) (1) and wiring harness Resis- Min.
and standard between ENG (female) (47) PIM (female) tance 1 Mz
value in normal (3)
state
(44) PIM (female) (2) and wiring harness Resis- Min.
between ENG (female) (47) PIM (female) tance 1 Mz
(3)
or start engine and carry out troubleshooting.
ENG Voltage
Between (37) (47) 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 9
E-4 Code [123/CA123] Charge Air Press Sensor Low Error 1

Trouble Charge Air Press Sensor Low Error
123 CA123
Contents of
Signal voltage in charge pressure sensor circuit is abnormally low.
trouble
Action of
Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.
controller
Problem that
appears on Acceleration performance of engine drops.
machine
Related
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for E-3 Code [122/CA122].
state
10 125E-5 Series
125E-5 Series 11
E-5 Code [131/CA131] Throttle Sensor High Error 1

Throttle sensor of accelerator pedal type (Case of HM300-2)

Trouble Throttle Sensor High Error
131 CA131
Contents of
Signal voltage in throttle sensor circuit is abnormally high.
trouble
Action of Sets throttle angle with signal other than throttle sensor signal and continues operation
controller (depending on each model)
Problem that
appears on Different problems occur on different machine models.
machine
Related
information

Defective sensor power supply If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
1
system troubleshooting for it first.
AS1 Accelerator pedal Voltage
All range
Between (1) (3) 4.75 5.25V
(Power supply)
Defective accelerator pedal (13 2% of source
2 Released
(Internal trouble) voltage)
Between (2) (3)
(77 2% of source
Pressed
voltage)
Possible causes controller, too, for another cause of trouble, and then judge.
and standard
Disconnection in wiring har- Wiring harness between E02 (female) (22) Resis-
Max. 1 z
ness AS1 (female) (1) tance
3
(Disconnection in wiring or Wiring harness between E02 (female) (9) Resis-
AS1 (female) (2) tance
Wiring harness between E02 (female) (23) Resis-
Max. 1 z
Wiring harness between E02 (female) (22) Resis- Min.
Ground fault in wiring harness AS1 (female) (1) and chassis ground tance 1 Mz
4
(Short circuit with GND circuit) Wiring harness between E02 (female) (9) Resis- Min.
AS1 (female) (2) and chassis ground tance 1 Mz
12 125E-5 Series

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

Trouble Throttle Sensor High Error
131 CA131
Contents of
Signal voltage in throttle sensor circuit is abnormally high.
trouble
Problem that
machine
Related
information

Defective sensor power supply If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
1
system troubleshooting for it first.
Defective fuel control dial P20 (male) Resistance

2
(Internal trouble) Between (1) (3) 4.0 6.0 kz
Between (2) (1) 0.25 5.0 kz
Between (2) (3) 0.25 5.0 kz
Max. 1 z
ness P20 (female) (1) tance
3
Possible causes (Disconnection in wiring or Wiring harness between E02 (female) (9) Resis-
and standard P20 (female) (2) tance
value in normal Wiring harness between E02 (female) (23) Resis-
state Max. 1 z
P20 (female) (3) tance
Ground fault in wiring harness P20 (female) (1) and chassis ground tance 1 Mz
4
P20 (female) (2) and chassis ground tance 1 Mz
5 Defective engine controller E02 Voltage
Between (9) (23) Signal 0.5 4.5V
14 125E-5 Series
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC400/400LC/450/450LC-7)
125E-5 Series 15
E-6 Code [132/CA132] Throttle Sensor Low Error 1

Trouble Throttle Sensor Low Error
132 CA132
Contents of
Signal voltage in throttle sensor circuit is abnormally low.
trouble
Action of Sets throttle angle with signal other than throttle signal and continues operation (depending on each
controller model).
Problem that
machine
Related
information

and standard
state
16 125E-5 Series
125E-5 Series 17
E-7 Code [135/CA135] Oil press. Sensor High Error 1

Trouble Oil press. Sensor High Error
135 CA135
Contents of
Signal voltage in oil pressure sensor circuit is abnormally high.
trouble
Action of
Sets oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
controller
Problem that
appears on
machine
Related
information

1
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
POIL Voltage
Defective oil pressure sensor
2 Between (1) (2) Power supply 4.75 5.25V
(Internal trouble)
Possible causes Wiring harness between ENG (female)

Resis-
and standard (37) POIL (female) (1) and chassis Max. 1 z
Disconnection in wiring har- tance
value in normal ground
ness
state 3 Wiring harness between ENG (female)
(Disconnection in wiring or Resis-
defective contact in connector) (47) POIL (female) (2) and chassis Max. 1 z
tance
ground
Resis-
(13) POIL (female) (3) and chassis Max. 1 z
tance
ground
Ground fault in wiring harness (37) POIL (female) (1) tance 1 Mz
4
(47) POIL (female) (2) tance 1 Mz
(13) POIL (female) (3) tance 1 Mz
18 125E-5 Series

(37) POIL (female) (1) and wiring har- Resis- Min.
ness between ENG (female) (47) POIL tance 1 Mz
(female) (2)
Possible causes 5
(With another wiring harness) (37) POIL (female) (1) and wiring har- Resis- Min.
and standard ness between ENG (female) (13) POIL tance 1 Mz
value in normal (female) (3)
state
(47) POIL (female) (2) and wiring har- Resis- Min.
ness between ENG (female) (13) POIL tance 1 Mz
(female) (3)
ENG Voltage
Circuit diagram related to oil pressure sensor

<Applied connector>
q BP
q EGR
q PEVA
q SEGR
q SBP
125E-5 Series 19
E-8 Code [141/CA141] Oil press. Sensor Low Error 1

Trouble Oil press. Sensor Low Error
141 CA141
Contents of
Signal voltage in oil pressure sensor circuit is abnormally low.
trouble
Action of
Sets oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.
controller
Problem that
appears on
machine
Related
information

and standard
state
20 125E-5 Series
125E-5 Series 21
E-9 Code [144/CA144] Coolant Temp. Sensor High Error 1

Trouble Coolant Temp. Sensor High Error
144 CA144
Contents of
Signal voltage in coolant temperature sensor circuit is abnormally high.
trouble
Action of
Fixes coolant temperature (90C) and continues operation.
controller
Problem that
appears on Engine starting performance decreases during low temperature.
machine
Related
information

Defective coolant temperature ing without turning starting switch ON.
1
sensor (Internal trouble) TWTR (male) Coolant temperature Resistance
Between (A) (B) 10 100C 0.6 20 kz
ness (Disconnection in wiring Wiring harness between ENG (female) Resis-
2 Max. 1 z
Possible causes or defective contact in connec- (15) TWTR (female) (A) tance
and standard tor) Wiring harness between ENG (female) Resis-
(38) TWTR (female) (B) tance
state
Ground fault in wiring harness
3
(15) TWTR (female) (A) and chassis
tance 1 Mz
ground
ENG (female) Coolant temperature Resistance
Between (15) (38) 10 100C 0.6 20 kz
22 125E-5 Series
Circuit diagram related to coolant temperature sensor

<Applied connector>
q BP
q EGR
q PEVA
q SEGR
q SBP
125E-5 Series 23
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error 1

Trouble Coolant Temp. Sensor Low Error
145 CA145
Contents of
Signal voltage in coolant temperature sensor circuit is abnormally low.
trouble
Action of
Fixes coolant temperature (90C) and continues operation.
controller
Problem that
machine
Related
information

and standard
value in normal Carry out troubleshooting E-9 Code [144/CA144].
state
24 125E-5 Series
125E-5 Series 25
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error 1

Trouble Charge Air Temp. Sensor High Error
153 CA153
Contents of
Signal voltage in charge temperature sensor circuit is abnormally high.
trouble
Action of
Fixes charge temperature (intake air temperature) (70C) and continues operation.
controller
Problem that
machine
Related
information

Intake air tempera-
Defective charge temperature TIM (male) Resistance
1 ture
sensor (Internal trouble)
Between (A) (B) 10 100C 0.5 20 kz
Between (A)
All range Min. 1 Mz
chassis ground
Possible causes
and standard 2 Max. 1 z
or defective contact in connec- (23) TIM (female) (A) tance
value in normal
tor) Wiring harness between ENG (female) Resis-
state Max. 1 z
(47) TIM (female) (B) tance
Ground fault in wiring harness ing without turning starting switch ON.
3
(23) TIM (female) (A) and chassis ground tance 1 Mz
4 Defective engine controller Intake air tempera-
ENG (female) Resistance
ture
Between (23) (47) 10 100C 0.5 20 kz
26 125E-5 Series
Circuit diagram related to charge temperature sensor

<Applied connector>
q BP
q EGR
q PEVA
q SEGR
q SBP
125E-5 Series 27
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error 1

Trouble Charge Air Temp. Sensor Low Error
154 CA154
Contents of
Signal voltage in charge temperature sensor circuit is abnormally low.
trouble
Action of
Fixes charge temperature (intake air temperature) (70C) and continues operation.
controller
Problem that
machine
Related
information

and standard
state
28 125E-5 Series
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error 1

Trouble Sensor Sup. 2 Volt. Low Error
187 CA187
Contents of
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
trouble
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 opera-
tion.
Action of
Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
controller
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].
Problem that
appears on Output drops.
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting

and standard
state
125E-5 Series 29
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error 1

Trouble Ambient Air Press. Sensor High Error
221 CA221
Contents of
Signal voltage in atmospheric pressure sensor circuit is abnormally high.
trouble
Action of Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues opera-
controller tion.
Problem that
machine
Related
information

1
PAMB Voltage
Defective atmospheric pres-
2 sure sensor
(Internal trouble) Between (2) (3) Signal 0.3 4.7V
Disconnection in wiring har- Wiring harness between ENG (female) Resis-
Max. 1 z
ness (37) PAMB (female) (1) tance
3
Possible causes (Disconnection in wiring or Wiring harness between ENG (female) (3) Resis-
and standard PAMB (female) (2) tance
value in normal Wiring harness between ENG (female) Resis-
state Max. 1 z
(38) PAMB (female) (3) tance
Resis- Min.
(37) PAMB (female) (1) and chassis
tance 1 Mz
Ground fault in wiring harness ground
4
(Short circuit with GND circuit) Wiring harness between ENG (female) (3) Resis- Min.
PAMB (female) (2) and chassis ground tance 1 Mz
Resis- Min.
(38) PAMB (female) (3) and chassis
tance 1 Mz
ground
5
(With another wiring harness) (37) PAMB (female) (1) and wiring har- Resis- Min.
ness between ENG (female) (3) PAMB tance 1 Mz
(female) (2)
30 125E-5 Series

(37) PAMB (female) (1) and wiring har- Resis- Min.
ness between ENG (female) (38) PAMB tance 1 Mz
Short circuit in wiring harness (female) (3)
5
(With another wiring harness) Wiring harness between ENG (female) (3)
Possible causes
and standard PAMB (female) (2) and wiring harness Resis- Min.
value in normal between ENG (female) (38) PAMB tance 1 Mz
state (female) (3)
6 Defective engine controller 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
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error 1

Trouble Ambient Air Press. Sensor Low Error
222 CA222
Contents of
Signal voltage in atmospheric pressure sensor circuit is abnormally low.
trouble
Action of
Sets oil pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
controller
Problem that
machine
Related
information

and standard
state
32 125E-5 Series
125E-5 Series 33
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error 1

Trouble Sensor Sup. 2 Volt. High Error
227 CA227
Contents of
Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
trouble
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 opera-
tion.
Action of
Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
controller
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].
Problem that
machine
Related
information

If another failure code is indicated, carry out troubleshooting for
1 Defective related system
it.
Bkup speed sensor G connector
Oil pressure sensor POIL connector
Disconnect devices Atmospheric

PAMB connector
pressure sensor
Defective sensor (Internal trou- at right in order. If
2 ble) error code disap- Charge pressure
PIM connector
(*: "With EGR" only) pears when a device sensor
is disconnected, that EGR inlet pressure
device has a defect PEVA connector
sensor (*)
in it.
Possible causes (*: "with EGR" only) EGR valve lift
SEGR connector
and standard sensor (*)
value in normal Bypass valve lift
SBP connector
state sensor (*)
ness Wiring harness between ENG (female) Resis-
3 Max. 1 z
(Disconnection in wiring or (37) each sensor (female) tance
defective contact in connector) Wiring harness between ENG (female) Resis-
Max. 1 z
(47) each sensor (female) tance
Resis- Min.
Ground fault in wiring harness (37) each sensor (female) and chassis
4 tance 1 Mz
(Short circuit with GND circuit) ground
Resis- Min.
(47) each sensor (female) and chassis
tance 1 Mz
ground
34 125E-5 Series

Possible causes 5
(With another wiring harness) (37) each sensor (female) and Resis- Min.
and standard Wiring harness between ENG (female) tance 1 Mz
value in normal (47) each sensor (female)
state
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
E-17 Code [234/CA234] Eng. Overspeed 1

Trouble Eng. Overspeed
234 CA234
Contents of
Engine speed is above operating range.
trouble
Action of
Limits fuel injection rate until engine speed lowers to operating range.
controller
Problem that
appears on Engine speed fluctuates.
machine
Related
information

Possible causes it.
and standard Way of use may be improper. Teach proper way of use to opera-
value in normal 2 Improper way of use
tor.
state
If causes 1 and 2 are not detected, engine controller may be
3 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
36 125E-5 Series
125E-5 Series 37
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error 1

Trouble Ne Speed Sensor Sup. Volt. Error
238 CA238
Contents of
Abnormality occurred in Ne speed sensor power supply (5 V) circuit.
trouble
Action of
Controls Ne speed sensor with signals of Bkup speed sensor.
controller
Problem that
Running engine stops (when Bkup speed sensor is also abnormal).
appears on
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
machine
Related
information

Disconnect devices
Defective Ne speed sensor at right in order. If
1 error code disap-
(Internal trouble)
pears when a device Ne speed sensor NE connector
is disconnected, that
device has a defect
in it.
2 Max. 1 z
or defective contact in connec- (16) NE (female) (1) tance
Possible causes
Max. 1 z
and standard (48) NE (female) (2) tance
Ground fault in wiring harness Wiring harness between ENG (female) Resis- Min.
3
(Short circuit with GND circuit) (16) NE (female) (1) and chassis ground tance 1 Mz
(48) NE (female) (2) and chassis ground tance 1 Mz
Short circuit in wiring harness
4 Wiring harness between ENG (female)
(with another wiring harness) Resis- Min.
(16) NE (female) (1) and between ENG
tance 1 Mz
(female) (48) NE (female) (2)
ENG Voltage
Between (16) (48) 4.75 5.25 V
38 125E-5 Series
Circuit diagram related to Ne speed sensor power supply
125E-5 Series 39
E-19 Code [263/CA263] Fuel Temp. Sensor High Error 1

Trouble Fuel Temp. Sensor High Error
263 CA263
Contents of
Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Uses coolant temperature sensor instead of fuel temperature sensor for correction of injection rate.
Action of
Fixes fuel temperature (95C) and continues operation, if coolant temperature sensor is also defec-
controller
tive.
Problem that
appears on
machine
Related
information

Defective fuel temperature ing without turning starting switch ON.
1 sensor
TFUEL (male) Fuel temperature Resistance
(Internal trouble)
Between (A) (B) 10 100C 0.6 20 kz
2 Max. 1 z
Possible causes (Disconnection in wiring or (30) TFUEL (female) (A) tance
and standard defective contact in connector) Wiring harness between ENG (female) Resis-
(47) TFUEL (female) (B) tance
state
Ground fault in wiring harness Resis- Min.
3 (30) TFUEL (female) (A) and chassis
(Short circuit with GND circuit) tance 1 Mz
ground
ENG (female) Fuel temperature Resistance
Between (30) (47) 10 100C 0.6 20 kz
40 125E-5 Series
Circuit diagram related to fuel temperature sensor

<Applied connector>
q BP
q EGR
q PEVA
q SEGR
q SBP
125E-5 Series 41
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error 1

Trouble Fuel Temp. Sensor Low Error
265 CA265
Contents of
Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
Uses coolant temperature sensor instead of fuel temperature sensor for correction of injection rate.
Action of
Fixes fuel temperature (95C) and continues operation, if coolant temperature sensor is also defec-
controller
tive.
Problem that
appears on
machine
Related
information

and standard
state
42 125E-5 Series
125E-5 Series 43
E-21 Code [271/CA271] PCV1 Short Error 1

Trouble PCV1 Short Error
271 CA271
Contents of
There is short circuit in PCV1 circuit of supply pump.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
While engine is running normally, pulse voltage of about 24 V is applied to PCV (1). This pulse volt-
Related
age cannot be measured with circuit tester.
information

Defective supply pump PCV1 PCV1 (male) Resistance
1
(Internal trouble) Between (1) (2) 2.3 5.3 z
Between (1), (2) chassis
Min. 1 Mz
ground
Ground fault in wiring harness Wiring harness between ENG (female) (4) Resis- Min.
2
(Short circuit with GND circuit) PCV1 (female) (1) tance 1 Mz
Possible causes
Wiring harness between ENG (female) (5) Resis- Min.
and standard
PCV1 (female) (2) tance 1 Mz
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with Wiring harness between ENG (female) (4)
3 Voltage Max. 1V
24V circuit) in wiring harness PCV1 (female) (1) and chassis ground
Wiring harness between ENG (female) (5)
Voltage Max. 1V
PCV1 (female) (2) and chassis ground
Between (4) (5) 2.3 5.3 z
Min. 1 Mz
ground
44 125E-5 Series
Circuit diagram related to supply pump PCV1
125E-5 Series 45
E-22 Code [272/CA272] PCV1 Open Error 1

Trouble PCV1 Open Error
272 CA272
Contents of
There is disconnection in PCV1 circuit of supply pump.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

1
(Internal disconnection) Between (1) (2) 2.3 5.3 z
Min. 1 Mz
ground
ness Wiring harness between ENG (female) (4) Resis-
2 Max. 1 z
(Disconnection in wiring or PCV1 (female) (1) tance
Possible causes defective contact in connector) Wiring harness between ENG (female) (5) Resis-
and standard Max. 1 z
PCV1 (female) (2) tance
value in normal
state a Prepare with starting switch OFF, then carry out troubleshoot-
3
(Short circuit with GND circuit) PCV1 (female) (1) and chassis ground tance 1 Mz
PCV1 (female) (2) and chassis ground tance 1 Mz
Between (4) (5) 2.3 5.3 z
Between (4) (5) chassis
Min. 1 Mz
ground
46 125E-5 Series
125E-5 Series 47
E-23 Code [273/CA273] PCV2 Short Error 1

Trouble PCV2 Short Error
273 CA273
Contents of
There is short circuit in PCV2 circuit of supply pump.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
ground
2
(Short circuit with GND circuit) PCV2 (female) (1) and chassis ground tance 1 Mz
Possible causes Wiring harness between ENG (female) Resis- Min.
and standard (10) PCV2 (female) (2) tance 1 Mz
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting.
Hot short (Short circuit with Voltage Max. 1V
3 PCV2 (female) (1) and chassis ground
24V circuit) in wiring harness
(10) PCV2 (female) (2) and chassis Voltage Max. 1V
ground
Between (9) (10) 2.3 5.3 z
Min. 1 Mz
ground
48 125E-5 Series
125E-5 Series 49
E-24 Code [274/CA274] PCV2 Open Error 1

Trouble PCV2 Open Error
274 CA274
Contents of
There is disconnection in PCV2 circuit of supply pump.
trouble
Action of
None in particular.
controller
Problem that
appears on
machine
Related
information

Defective supply pump PCV2 ing without turning starting switch ON.
1
(Internal disconnection) PCV2 (male) Resistance
Between (1) (2) 2.3 5.3 z
ness Wiring harness between ENG (female) (9) Resis-
2 Max. 1 z
(Disconnection in wiring or PCV2 (female) (1) tance
Max. 1 z
Possible causes (10) PCV2 (female) (2) tance
and standard a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ing without turning starting switch ON.
state
3 PCV2 (female) (1) and chassis ground tance 1 Mz
(Short circuit with GND circuit)
Resis- Min.
(10) PCV2 (female) (2) and chassis
tance 1 Mz
ground
Between (9) (10) 2.3 5.3 z
Min. 1 Mz
ground
50 125E-5 Series
125E-5 Series 51
E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error 1

Trouble Injector #1 (L/B #1) System Open/Short Error
322 CA322
Contents of
There is disconnection or short circuit in injector #1 circuit.
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
Rotation is unstable.
machine
While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of injec-
Related
tor. This pulse voltage cannot be measured with circuit tester.
information

Defective injector #1 CN1 (male) Resistance
1
Min. 1 Mz
ground
2 Max. 1 z
(Disconnection in wiring or (45) CN1 (female) (1) tance
Max. 1 z
(53) CN1 (female) (2) tance
Possible causes
state Wiring harness between ENG (female)
Resis- Min.
Ground fault in wiring harness (45) CN1 (female) (1) and chassis
3 tance 1 Mz
Resis- Min.
(53) CN1 (female) (2) and chassis
tance 1 Mz
ground
Defective injector or wiring If failure code of another cylinder is displayed, carry out trouble-
4
harness of another cylinder shooting for it, too.
Between (45) (53) 0.4 1.1 z
Min. 1 Mz
ground
52 125E-5 Series
Circuit diagram related to injector #1
125E-5 Series 53

323 CA323
Contents of
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
machine
Related
information

Defective injector #5 (Internal CN5 (male) Resistance
1
trouble) Between (1) (2) 0.4 1.1 z
Min. 1 Mz
ground
2 Max. 1 z
or defective contact in connec- (46) CN5 (female) (1) tance
Max. 1 z
Possible causes
Resis- Min.
3 tance 1 Mz
Resis- Min.
tance 1 Mz
ground
4
Between (46) (60) 0.4 1.1 z
Min. 1 Mz
ground
54 125E-5 Series
125E-5 Series 55

324 CA324
Contents of
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
Possible causes
Resis- Min.
3 tance 1 Mz
Resis- Min.
tance 1 Mz
ground
4
Between (55) (52) 0.4 1.1 z
Min. 1 Mz
ground
56 125E-5 Series
125E-5 Series 57

325 CA325
Contents of
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
Possible causes
Resis- Min.
3 tance 1 Mz
Resis- Min.
tance 1 Mz
ground
4
Between (57) (59) 0.4 1.1 z
Min. 1 Mz
ground
58 125E-5 Series
125E-5 Series 59

331 CA331
Contents of
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
Possible causes
Resis- Min.
3 tance 1 Mz
Resis- Min.
tance 1 Mz
ground
4
Between (54) (51) 0.4 1.1 z
Min. 1 Mz
ground
60 125E-5 Series
125E-5 Series 61

332 CA332
Contents of
trouble
Action of
None in particular.
controller
Problem that
Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
Max. 1 z
Possible causes
Resis- Min.
3 tance 1 Mz
Resis- Min.
tance 1 Mz
ground
4
Between (56) (58) 0.4 1.1 z
Min. 1 Mz
ground
62 125E-5 Series
125E-5 Series 63
E-31 Code [342/CA342] Calibration Code Incompatibility 1

Trouble Calibration Code Incompatibility
342 CA342
Contents of
Matching error occurred in engine controller data.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information

and standard
state
64 125E-5 Series
125E-5 Series 65
E-32 Code [351/CA351] INJ. Drive Circuit Error 1

Trouble INJ. Drive Circuit Error
351 CA351
Contents of
Abnormality occurred in injector drive circuit.
trouble
Action of
Limits output and continues operation (Limits common rail pressure).
controller
Problem that
machine
Related
information

If another failure code (code of abnormality in injector system) is
indicated, carry out troubleshooting for it.
Check fuse or circuit breaker on machine side directly for defect.
2 Defective fuse (If fuse is broken or circuit breaker is turned OFF, circuit probably
has ground fault.)
ness (Disconnection in wiring Wiring harness between E03 (female) (3), Resis-
3 Max. 1 z
or defective contact in connec- (4) battery (+) tance
Possible causes
tor) Wiring harness between E03 (female) (1), Resis-
and standard Max. 1 z
value in normal (2) chassis ground tance
Ground fault in wiring harness Wiring harness between E03 (female) (3), Resis- Min.
4
(Short circuit with GND circuit) (4) battery (+) and chassis ground tance 1 Mz
Wiring harness between E03 (female) (1), Resis- Min.
(2) chassis ground tance 1 Mz
E03 Voltage
Between (3), (4) (1), (2) 20 30 V
66 125E-5 Series
Circuit diagram related to controller power supply
125E-5 Series 67
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error 1

Trouble Sensor Sup. 1 Volt. Low Error
352 CA352
Contents of
Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low.
trouble
Action of Limits output of common rail pressure sensor and continues operation (Limits common rail pres-
controller sure).
Problem that
machine
Related
information

and standard
state
68 125E-5 Series
125E-5 Series 69
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error 1

Trouble Sensor Sup. 1 Volt. High Error
386 CA386
Contents of
Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high.
trouble
Action of Limits output of common rail pressure sensor and continues operation (Limits common rail pres-
controller sure).
Problem that
machine
Related
information

it.
Disconnect devices
Defective sensor (Internal trou- at right in order. If
2 error code disap-
ble) Common rail pres-
pears when a device PFUEL connector
sure sensor
device has a defect
in it.
3 Max. 1 z
(Disconnection in wiring or (33) PFUEL (female) (1) tance
and standard (47) PFUEL (female) (3) tance
Resis- Min.
Ground fault in wiring harness (33) PFUEL (female) (1) and chassis
4 tance 1 Mz
Wiring harness between CE01 (female)
Resis- Min.
(47) PFUEL (female) (3) and chassis
tance 1 Mz
ground
5
(With another wiring harness) (33) PFUEL (female) (1) and Resis- Min.
wiring harness between ENG (female) (47) tance 1 Mz
PFUEL (female) (3)
ENG Voltage
Between (33) (47) 4.75 5.25V
70 125E-5 Series
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
E-35 Code [431/CA431] Idle Validation SW Low error 1


Trouble Idle Validation SW Low error
431 CA431
Contents of
Abnormality occurred in idle validation switch circuit
trouble
Action of
Sets throttle angle to certain value and continues operation (depending on each model).
controller
Problem that
appears on
machine
Related
information

AS1 Signal name Voltage
Defective accelerator pedal Between (5) (4) Signal 1
1 See Fig. 1
(Internal trouble) Between (6) (4) Signal 2
Max. 1 z
ness AS1 (female) (4) tance
2
(Disconnection in wiring or Wiring harness between E02 (female) (11) Resis-
Possible causes
and standard Wiring harness between E02 (female) (1) Resis-
Max. 1 z
value in normal AS1 (female) (6) tance
Ground fault in wiring harness AS1 (female) (4) and chassis ground tance 1 Mz
3
Wiring harness between E02 (female) (32)
Hot short (Short circuit with Voltage Max. 1V
AS1 (female) (4) and chassis ground
4 24V circuit)
in wiring harness Wiring harness between E02 (female) (11)
Voltage Max. 1V
Wiring harness between E02 (female) (1)
Voltage Max. 1V
72 125E-5 Series
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal 5 Defective engine controller E02 Signal name Voltage
state Between (11) (32) Signal 1
See Fig. 1
Between (1) (32) Signal 2
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
E-36 Code [432/CA432] Idle Validation Process error 1

Trouble Idle Validation Process error
432 CA432
Contents of
Abnormality occurred in processing of idle validation switch circuit.
trouble
Action of
Sets throttle angle to certain value and continues operation (depending on each model).
controller
Problem that
appears on
machine
Related
information

and standard
state
E-37 Code [441/CA441] Battery voltage low error 1

Trouble Battery voltage low error
441 CA441
Contents of
Power supply voltage is abnormally low.
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

and standard
state
74 125E-5 Series
E-38 Code [442/CA442] Battery voltage high error 1

Trouble Battery voltage high error
442 CA442
Contents of
Power supply voltage is abnormally high.
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

and standard
state
125E-5 Series 75
SEN00550-01
2007 KOMATSU
All Rights Reserved
76
SEN00551-01
ENGINE 1SHOP MANUAL
125E-5 Series
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 1
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
2 125E-5 Series
Troubleshooting of electrical system (E-mode), Part 2 1

E-39 Code [449/CA449] Rail Press. Very High Error 1

Trouble Rail Press. Very High Error
449 CA449
Contents of
Common rail pressure sensor circuit detected abnormally high pressure (level 2).
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
125E-5 Series 3
E-40 Code [451/CA451] Rail Press. Sensor High Error 1

Trouble Rail Press. Sensor High Error
451 CA451
Contents of
Signal voltage in common rail pressure sensor circuit is abnormally high.
trouble
Action of
controller
Problem that
machine
Related
information

1
PFUEL Voltage
Defective common rail pres-
2 sure sensor
(Internal trouble) Between (2) (3) Signal 0.25 4.6V
Possible causes Wiring harness between ENG (female) Resis-
Disconnection in wiring har- Max. 1 z
and standard (33) PFUEL (female) (1) tance
ness
value in normal 3
state Max. 1 z
defective contact in connector) (25) PFUEL (female) (2) tance
Max. 1 z
(47) PFUEL (female) (3) tance
Resis- Min.
tance 1 Mz
ground
4
tance 1 Mz
ground
Resis- Min.
tance 1 Mz
ground
4 125E-5 Series

(33) PFUEL (female) (1) and Resis- Min.
PFUEL (female) (2)
5
(With another wiring harness) (33) PFUEL (female) (1) and Resis- Min.
Possible causes
and standard wiring harness between ENG (female) (47) tance 1 Mz
value in normal PFUEL (female) (3)
(25) PFUEL (female) (2) and Resis- Min.
PFUEL (female) (3)
6 Defective engine controller 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 5
E-41 Code [452/CA452] Rail Press. Sensor Low Error 1

Trouble Rail Press. Sensor Low Error
452 CA452
Contents of
Signal voltage in common rail pressure sensor circuit is abnormally low.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
E-42 Code [553/CA553] Rail Press. High Error 1

Trouble Rail Press. High Error
553 CA553
Contents of
Common rail pressure sensor circuit detected abnormally high pressure (level 1).
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

it.
Check fuel used directly
2 Use of improper fuel
(for high viscosity).
Possible causes Defective electrical system of Common rail pressure sensor may have electric trouble. Carry
3
and standard common rail pressure sensor out troubleshooting for code [451/CA451] (E-40).
value in normal Defective mechanical system
state Check mechanical system of common rail pressure sensor
4 of common rail pressure sen-
directly.
sor
Check overflow valve directly for broken spring, worn seat, and
5 Defective overflow valve
stuck ball.
6 Clogging of overflow piping Check overflow piping directly for clogging.
7 Defective pressure limiter Check pressure limiter directly for mechanical defect.
6 125E-5 Series
E-43 Code [554/CA554] Rail Press Sensor In Range Error 1

Trouble Rail Press Sensor In Range Error
554 CA554
Contents of
In-range error occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
125E-5 Series 7
E-44 Code [559/CA559] Rail Press. Low Error 1

Trouble Rail Press. Low Error
559 CA559
Contents of
Supply pump does not feed fuel (level 1).
trouble
Action of
Limits common rail pressure.
controller
Problem that
machine
Related
information

it.
2 Use of improper fuel Check fuel used directly (for high viscosity).
a For contents of troubleshooting, see Note 1. For check of pres-
sure in fuel low-pressure circuit, see Testing and adjusting,
Defective low-pressure circuit "Testing fuel pressure".
3
device Pressure in fuel low-pressure circuit
Min. 0.15 MPa
(At high idle or equivalent to rated load
{Min. 1.5 kg/cm2}
(stall))
4 Clogging of filter or strainer a For contents of troubleshooting, see Note 2.
Supply pump PCV may have electric trouble. Carry out trouble-
Defective electrical system of
5 shooting for following codes [271/CA271] (E-21), [272/CA272]
supply pump PCV
(E-22), [273/CA273] (E-23),[274/CA274] (E-24).
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring
Possible causes 6
sure sensor harness for damage.
and standard
value in normal a For testing of leakage from pressure limiter, see Testing and
state adjusting, "Testing leakage from pressure limiter and return
7 Defective pressure limiter rate from injector".
Leakage from pressure limiter
Max. 10 cc/min
(At equivalent to rated operation by models)
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
Return (Spill) limit from injector
(at stall)
8 Defective 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
9 Defective supply pump 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 no-
pressure feed.
8 125E-5 Series
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 9
Check sheet for no-pressure feed

Model Work No.
Machine serial No. # Date of check / /
Engine Service meter h
Engine serial No. # Worker's name
A. Visual check Good NG

1 Fuel leakage to outside
2 Clogging of fuel tank breather
B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function) Good NG
3 Check of error/failure code / / / /
Check of monitoring information
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
Low idle rpm <By models>
*1 Engine speed High idle rpm <By models>
Equivalent to rating <By models> rpm <By models>
Low idle % 0
*2 Throttle opening
High idle % 100
*3 Fuel injection command Equivalent to rating <By models> mm3
4 Common rail pressure
*4 Equivalent to rating <By models> MPa
command
Common rail fuel
*5 Equivalent to rating <By models> MPa
pressure
Low idle CA
Fuel injection timing
*6 High idle CA
command
Equivalent to rating <By models> CA
*7 Boost pressure Equivalent to rating <By models> kPa
Engine coolant
*8 Low idle C
temperature
*9 Fuel temperature Low idle C
Check of reduced cylinder mode operation (Engine speed)
Standard value
Function Reduced cylinder Checking condition Unit Measured value Good NG
(Reference value)
No. 1 cylinder Low idle rpm
5 No. 2 cylinder Low idle rpm
*10
C. Check of fuel circuit pressure Standard value

Checking condition Unit Measured value Good NG
(Reference value)
High idle or equivalent to rated load MPa
6 Fuel low-pressure circuit pressure Min. 0.15 {Min. 1.5}
(stall) {kg/cm2}
D. Check of strainers and filters Good NG

7 Visual check of strainers
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve
E.Check of leakage and return rate Standard value

Checking condition Unit Measured value Good NG
(Reference value)
11 Leakage through pressure limiter Equivalent to rating <By models> cc/min Max. 10
Equivalent to rating <By models>
cc/min 960
1,600 rpm
cc/min 1,020
1,700 rpm
Speed:
12 Return rate from injector cc/min 1,080
1,800 rpm
Return rate:
cc/min 1,140
1,900 rpm
cc/min 1,200
2,000 rpm
10 125E-5 Series
*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
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error 1

Trouble Eng. Ne Speed Sensor Error
689 CA689
Contents of
Abnormality occurred in engine Ne speed sensor circuit.
trouble
Action of
Operates with signals of Bkup speed sensor.
controller
Problem that
Running engine stops (when Bkup speed sensor is also abnormal).
appears on
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
machine
Related
information

Defective sensor power supply If code [238/CA238] is indicated, carry out troubleshooting for it
1
system first.
Max. 1 z
ness (16) NE (female) (1) tance
2
(48) NE (female) (2) tance
Max. 1 z
(27) NE (female) (3) tance
Ground fault in wiring harness (16) NE (female) (1) and chassis ground tance 1 Mz
3
(48) NE (female) (2) and chassis ground tance 1 Mz
and standard (27) NE (female) (3) and chassis ground tance 1 Mz
value in normal
(16) NE (female) (1) and Resis- Min.
NE (female) (2)
4
(With another wiring harness) (16) NE (female) (1) and Resis- Min.
NE (female) (3)
(48) NE (female) (2) and Resis- Min.
NE (female) (3)
Check Ne speed sensor directly for defective mount (defective
Defective mount of sensor or
5 clearance) or check rotation sensing part (flywheel) directly for
defective rotation sensing part
defect.
If causes 1 5 are not detected, engine Ne speed sensor may be
Defective engine Ne speed
6 defective. (Since trouble is in system, troubleshooting cannot be
sensor
carried out.)
12 125E-5 Series

and standard If causes 1 6 are not detected, engine controller may be defec-
value in normal 7 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be car-
state ried out.)
Circuit diagram related to engine Ne speed sensor
125E-5 Series 13
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error 1

Trouble Eng. Bkup Speed Sensor Phase Error
731 CA731
Contents of
Engine Bkup sensor circuit detected abnormality in phase.
trouble
Action of
Controls with signals of engine Ne speed sensor.
controller
Problem that
Running engine stops (when Ne speed sensor is also abnormal).
appears on
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out trouble-
and standard 1
sensor system shooting for [689/CA698] (E-45).
value in normal
state Defective engine Bkup speed Engine Bkup speed sensor may be defective. Carry out trouble-
2
sensor system shooting for [778/CA778] (E-48).
14 125E-5 Series
E-47 Code [757/CA757] All Persistent Data Lost Error 1

Trouble All Persistent Data Lost Error
757 CA757
Contents of
All data in engine controller are lost.
trouble
Action of
None in particular.
controller
Problem that
machine
Related
information

and standard
state
125E-5 Series 15
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error 1

Trouble Eng. Bkup Speed Sensor Error
778 CA778
Contents of
Abnormality occurred in engine Bkup speed sensor circuit.
trouble
Action of
Operates with signals of Ne speed sensor.
controller
Problem that
Running engine stops (when Ne speed sensor is also abnormal).
appears on
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
machine
Related
information

1
Max. 1 z
ness (37) G (female) (1) tance
2
(47) G (female) (2) tance
Max. 1 z
(26) G (female) (3) tance
Ground fault in wiring harness (37) G (female) (1) and chassis ground tance 1 Mz
3
(47) G (female) (2) and chassis ground tance 1 Mz
and standard (26) G (female) (3) and chassis ground tance 1 Mz
Resis- Min.
(37) G (female) (1) and between ENG
tance 1 Mz
(female) (47) G (female) (2)
4 Wiring harness between ENG (female)
(With another wiring harness) Resis- Min.
tance 1 Mz
Resis- Min.
tance 1 Mz
Check Bkup speed sensor directly for defective mount (defective
Defective mount of sensor or
5 clearance) or check rotation sensing part (in supply pump)
defective rotation sensing part
directly for defect.
If causes 1 5 are not detected, engine Bkup speed sensor may
Defective engine Bkup speed
6 be defective. (Since trouble is in system, troubleshooting cannot
sensor
be carried out.)
ried out.)
16 125E-5 Series
Circuit diagram related to engine Bkup speed sensor

<Applied connector>
q BP
q EGR
q PEVA
q SEGR
q SBP
125E-5 Series 17
E-49 Code [1228/CA1228] EGR Valve Servo Error 1 1

a This code applies to only with EGR.
Trouble EGR Valve Servo Error 1
1228 CA1228
Contents of
Abnormality (level 1) occurred in EGR valve servo.
trouble
Action of
Performs open control.
controller
Problem that
appears on
machine
Related
information

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 Engine speed EGR valve drive pressure
2
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
Engine speed Engine oil pressure
and standard Defective engine oil pressure
value in normal 3 Low idle 0.08 MPa {0.8 kg/cm2}
system (main circuit)
state 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).
Defective oil pump for EGR
4 Check oil pump and relief valve for EGR valve circuit directly.
valve
Defective oil feed piping for
5 Check oil feed piping for EGR valve circuit directly.
EGR valve
Defective oil return piping for
6 Check oil return piping for EGR valve circuit directly.
EGR valve
7 Defective EGR valve Check mechanical section of EGR valve directly.
ried out.)
18 125E-5 Series
E-50 Code [1625/CA1625] EGR Valve Servo Error 2 1

Trouble EGR Valve Servo Error 2
1625 CA1625
Contents of
Abnormality (level 2) occurred in EGR valve servo.
trouble
Action of Limits output and continues operation.
controller Closes EGR valve and bypass valve.
Problem that
machine
Related
information

and standard
state
125E-5 Series 19
E-51 Code [1626/CA1626] Bypass Valve Solenoid Current High Error 1

Trouble Bypass Valve Solenoid Current High Error
1626 CA1626
Contents of
There is short circuit in drive circuit of bypass valve solenoid.
trouble
Problem that
machine
Related
information

Defective bypass valve sole- ing without turning starting switch ON.
1
noid (Internal trouble) BP (male) Resistance
Between (1) (2) 10 21 z
2 Max. 1 z
or defective contact in connec- (31) BP (female) (1) tance
tor) Wiring harness between ENG (female) (11) Resis-
Max. 1 z
BP (female) (2) tance
Possible causes ing without turning starting switch ON.
and standard
value in normal Ground fault in wiring harness Wiring harness between ENG (female) Resis- Min.
3
state (Short circuit with GND circuit) (31) BP (female) (1) and chassis ground tance 1 Mz
BP (female) (2) and chassis ground tance 1 Mz
Hot short (Short circuit with Wiring harness between ENG (female)
4 Voltage Max. 1 V
24V circuit) in wiring harness (31) BP (female) (1) and chassis ground
Voltage Max. 1 V
BP (female) (2) and chassis ground
Between (31) (11) 10 21 z
20 125E-5 Series
Circuit diagram related to bypass valve solenoid & lift sensor
125E-5 Series 21
E-52 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error 1

a [with EGR only]
Trouble Bypass Valve Solenoid Current Low Error
1627 CA1627
Contents of
There is disconnection in drive circuit of bypass valve solenoid.
trouble
Problem that
machine
Related
information

and standard
state
22 125E-5 Series
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1 1

Trouble Bypass Valve Servo Error 1
1628 CA1628
Contents of
Abnormality (level 1) occurred in bypass valve servo.
trouble
Action of
Performs open control.
controller
Problem that
appears on
machine
Related
information

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 Engine speed Bypass valve drive pressure
2
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
Engine speed Engine oil pressure
and standard Defective engine oil pressure
value in normal 3 Low idle 0.08 MPa {0.8 kg/cm2}
system (main circuit)
state 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).
Defective oil pump for bypass
4 Check oil pump and relief valve for bypass valve circuit directly.
valve
Defective oil feed piping for
5 Check oil feed piping for bypass valve circuit directly.
bypass valve
Defective oil return piping for
6 Check oil return piping for bypass valve circuit directly.
bypass valve
7 Defective bypass valve Check mechanical section of bypass valve directly.
ried out.)
125E-5 Series 23
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2 1

Trouble Bypass Valve Servo Error 2
1629 CA1629
Contents of
Abnormality (level 2) occurred in bypass valve servo.
trouble
Problem that
machine
Related
information

and standard
state
24 125E-5 Series
125E-5 Series 25
E-55 Code [1631/CA1631] BP valve Lift Position Sensor High Error 1

Trouble BP valve Lift Position Sensor High Error
1631 CA1631
Contents of
Signal voltage in bypass valve lift sensor circuit is abnormally high.
trouble
Problem that
machine
Related
information

If code [187/CA187] or [227/CA227] is indicated, carry out trou-
1 Defective sensor power supply
bleshooting for it first.
SBP Voltage
Defective bypass valve lift sen- Accordingly, if voltage is abnormal, check wiring harness and
2 controller, too, for another cause of trouble, and then judge.
sor (Internal trouble)
(keep engine stopped, however) and carry out troubleshooting.
SBP Voltage
Possible causes
and standard
value in normal
state Disconnection in wiring har- Wiring harness between ENG (female) Resis-
ness Max. 1 z
(37) SBP (female) (1) tance
3 (Disconnection in wiring or
Max. 1 z
(38) SBP (female) (2) tance
Max. 1 z
(29) SBP (female) (3), (4) tance
Resis- Min.
(37) SBP (female) (1) and chassis
tance 1 Mz
ground
4
(38) SBP (female) (2) and chassis
tance 1 Mz
ground
Resis- Min.
(29) SBP (female) (3), (4) and chassis
tance 1 Mz
ground
26 125E-5 Series

(37) SBP (female) (1) and Resis- Min.
SBP (female) (2)
Possible causes 5
(With another wiring harness) (37) SBP (female) (1) and Resis- Min.
and standard wiring harness between ENG (female) (29) tance 1 Mz
value in normal SBP (female) (3), (4)
state
(38) SBP (female) (2) and Resis- Min.
SBP (female) (3), (4)
ENG Voltage
Between (37) (38) 4.75 5.25V
Circuit diagram related to bypass valve solenoid & lift sensor
125E-5 Series 27
E-56 Code [1632/CA1632] BP valve Lift Position Sensor Low Error 1

Trouble BP valve Lift Position Sensor Low Error
1632 CA1632
Contents of
Signal voltage in bypass valve lift sensor circuit is abnormally low.
trouble
Problem that
machine
Related
information

and standard
state
E-57 Code [1633/CA1633] KOMNET Datalink Timeout Error 1

Trouble KOMNET Datalink Timeout Error
1633 CA1633
Contents of
Abnormality occurred in circuit of KOMNET communication with machine.
trouble
Action of
Operates in default mode or maintains condition when abnormality occurs.
controller
Problem that
appears on
machine
Related
information

Possible causes
and standard This fault is detected and indicated when KOMNET communica-
value in normal Carry out troubleshooting on tion with machine monitor or controller on the machine side is
1
state machine side abnormal. Accordingly, contents of troubleshooting depends on
machine model. See Shop manual for machine.
28 125E-5 Series
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error 1

Trouble EGR Inlet Press Sensor Low Error
1642 CA1642
Contents of
Signal voltage in EGR inlet pressure sensor circuit is abnormally low.
trouble
Action of Sets EGR inlet pressure to default value (102 kPa {10.4 kg/cm2}) and continues operation.
controller Limits output and continues operation.
Problem that
machine
Related
information

and standard
state
125E-5 Series 29
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error 1

Trouble EGR Inlet Press Sensor High Error
1653 CA1653
Contents of
Signal voltage in EGR inlet pressure sensor circuit is abnormally high.
trouble
Action of Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
controller Limits output and continues operation.
Problem that
machine
Related
information

PEVA Voltage
Defective EGR inlet pressure
2 Between (1) (2) Power supply 4.75 5.25 V
sensor (Internal trouble)
Possible causes Disconnection in wiring har- Wiring harness between ENG (female) Resis-
Max. 1 z
and standard ness (Disconnection in wiring (37) PEVA (female) (1) tance
3
value in normal or defective contact in connec- Wiring harness between ENG (female) Resis-
tor) Max. 1 z
state (47) PEVA (female) (2) tance
Max. 1 z
(20) PEVA (female) (3) tance
Resis- Min.
(37) PEVA (female) (1) and chassis
tance 1 Mz
ground
4
tance 1 Mz
ground
Resis- Min.
tance 1 Mz
ground
30 125E-5 Series

Resis- Min.
(37) PEVA (female) (1) and between
tance 1 Mz
ENG (female) (47) PEVA (female) (2)
Possible causes 5 Wiring harness between ENG (female)
and standard (37) PEVA (female) (1) and between
tance 1 Mz
value in normal ENG (female) (20) PEVA (female) (3)
Resis- Min.
(47) PEVA (female) (2) and between
tance 1 Mz
ENG (female) (20) PEVA (female) (3)
ENG Voltage
Between (37) (47) 4.75 5.25 V
Circuit diagram related to EGR inlet pressure sensor
125E-5 Series 31
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error 1


Trouble Throttle Sens. Sup. Volt. High Error
2185 CA2185
Contents of
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
trouble
Problem that
machine
Related
information

Disconnect devices
Defective accelerator pedal at right in order. If
1 error code disap-
(Internal trouble)
pears when a device Accelerator pedal AS1 connector
device has a defect
in it.
ness Wiring harness between E02 (female) (22) Resis-
2 Max. 1 z
(Disconnection in wiring or AS1 (female) (1) tance
defective contact in connector) Wiring harness between E02 (female) (23) Resis-
and standard
Ground fault in wiring harness Wiring harness between E02 (female) (22) Resis- Min.
3
(Short circuit with GND circuit) AS1 (female) (1) and chassis ground tance 1 Mz
Short circuit in wiring harness Wiring harness between E02 (female) (22)
4
(With another wiring harness) AS1 (female) (1) and Resis- Min.
wiring harness between E02 (female) (23) tance 1 Mz
AS1 (female) (3)
E02 Voltage
Between (22) (23) 4.75 5.25V
32 125E-5 Series
125E-5 Series 33
Throttle sensor of fuel control dial type (Case of PC400/400LC/450/450LC-7E0)

Trouble Throttle Sens. Sup. Volt. High Error
2185 CA2185
Contents of
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.
trouble
Action of Sets throttle angle with signal other than throttle sensor signal and continues operation (depending
controller on each model).
Problem that
appears on Depends on machine model.
machine
Related
information

Disconnect devices
Defective fuel control dial at right in order. If
1 error code disap-
(Internal trouble)
pears when a device Fuel control dial P20 connector
device has a defect
in it.
ness (Disconnection in wiring Wiring harness between E02 (female) (22) Resis-
2 Max. 1 z
or defective contact in connec- P20 (female) (1) tance
tor) Wiring harness between E02 (female) (23) Resis-
Possible causes
Max. 1 z
and standard P20 (female) (3) tance
3
(Short circuit with GND circuit) P20 (female) (1) and chassis ground tance 1 Mz
4 Wiring harness between E02 (female) (22)
P20 (female) (1) and between E02
tance 1 Mz
(female) (23) P20 (female) (3)
E02 Voltage
Between (22) (23) 4.75 5.25 V
34 125E-5 Series
Circuit diagram related to throttle sensor of fuel control dial type

(Case of PC400/400LC/450/450LC-7E0)
125E-5 Series 35
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error 1

Trouble Throttle Sens. Sup. Volt. Low Error
2186 CA2186
Contents of
Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low.
trouble
Action of Sets throttle angle with signal other than throttle sensor signal and continues operation (depending
controller on each model).
Problem that
appears on Depends on machine model.
machine
Related
information

and standard
state
36 125E-5 Series
E-62 Code [2249/CA2249] Rail Press. Very Low Error 1

Trouble Rail Press. Very Low Error
2249 CA2249
Contents of
Supply pump does not feed fuel (level 2).
trouble
Action of
Limits common rail pressure.
controller
Problem that
machine
Related
information

and standard
state
125E-5 Series 37
E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error 1
Trouble EGR Valve Lift Position Sensor High Error
2271 CA2271
Contents of
Signal voltage in EGR valve lift sensor circuit is abnormally high.
trouble
Problem that
machine
Related
information

SEGR Voltage
Between (1) (2) Power supply 4.75 5.25 V
Defective EGR valve lift sensor Accordingly, if voltage is abnormal, check wiring harness and
2 controller, too, for another cause of trouble, and then judge.
(Internal trouble)
(keep engine stopped, however) and carry out troubleshooting.
SEGR Voltage
Between (3) (2) Signal 0.8 1.2 V
Between (4) (2) Signal 0.8 1.2 V
Possible causes
and standard
value in normal
Resis-
(37) SEGR (female) (1) and chassis Max. 1 z
Disconnection in wiring har- tance
ground
ness (Disconnection in wiring
3
or defective contact in connec- Wiring harness between ENG (female) Resis-
tor) (47) SEGR (female) (2) and chassis Max. 1 z
tance
ground
Resis-
(19) SEGR (female) (3), (4) and chassis Max. 1 z
tance
ground
Ground fault in wiring harness (37) SEGR (female) (1) tance 1 Mz
4
(47) SEGR (female) (2) tance 1 Mz
(19) SEGR (female) (3), (4) tance 1 Mz
38 125E-5 Series

Resis- Min.
(37) SEGR (female) (1) and between
tance 1 Mz
ENG (female) (47) SEGR (female) (2)

Possible causes 5 (37) SEGR (female) (1) and between Resis- Min.
(with another wiring harness)
and standard ENG (female) (19) SEGR (female) (3), tance 1 Mz
value in normal (4)
(47) SEGR (female) (2) and between Resis- Min.
ENG (female) (19) SEGR (female) (3), tance 1 Mz
(4)
ENG Voltage
Between (37) (47) 4.75 5.25 V
Circuit diagram related to EGR valve solenoid & lift sensor
a Apply wiring harness joint JM04 to only a bypass valve-fitted engine.
125E-5 Series 39
E-64 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error 1
Trouble EGR Valve Lift Position Sensor Low Error
2272 CA2272
Contents of
Signal voltage in EGR valve lift sensor circuit is abnormally low.
trouble
Problem that
machine
Related
information

and standard
state
40 125E-5 Series
125E-5 Series 41
E-65 Code [2351/CA2351] EGR Valve Solenoid Current High Error 1

Trouble EGR Valve Solenoid Current High Error
2351 CA2351
Contents of
There is short circuit in drive circuit of EGR valve solenoid.
trouble
Problem that
machine
Related
information

Defective EGR valve solenoid ing without turning starting switch ON.
1
(Internal trouble) EGR (male) Resistance
Between (1) (2) 10 21 z
2 Max. 1 z
or defective contact in connec- (22) EGR (female) (1) tance
tor) Wiring harness between ENG (female) (11) Resis-
Max. 1 z
EGR (female) (2) tance
Possible causes
and standard Wiring harness between ENG (female)
Ground fault in wiring harness Resis- Min.
value in normal 3 (22) EGR (female) (1) and chassis
(Short circuit with GND circuit) tance 1 Mz
state ground
EGR (female) (2) and chassis ground tance 1 Mz
Hot short (Short circuit with
4 (22) EGR (female) (1) and chassis Voltage Max. 1 V
24V circuit) in wiring harness
ground
Voltage Max. 1 V
EGR (female) (2) and chassis ground
Between (22) (11) 10 21 z
42 125E-5 Series
Circuit diagram related to EGR valve solenoid & lift sensor
a Apply wiring harness joint JM04 to only a bypass valve-fitted engine.
125E-5 Series 43
E-66 Code [2352/CA2352] EGR Valve Solenoid Current Low Error 1

Trouble EGR Valve Solenoid Current Low Error
2352 CA2352
Contents of
There is disconnection in drive current of EGR valve solenoid.
trouble
Problem that
machine
Related
information

and standard
state
44 125E-5 Series
E-67 Code [2555/CA2555] Grid Heater Relay Volt. Low Error 1

Trouble Grid Heater Relay Volt. Low Error
2555 CA2555
Contents of
There is disconnection in intake air heater relay.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine does not start easily at low temperature.
machine
Related
information

and standard
state
125E-5 Series 45
E-68 Code [2556/CA2556] Grid Heater Relay Volt. High Error 1

Trouble Grid Heater Relay Volt. High Error
2556 CA2556
Contents of
There is short circuit in intake air heater relay.
trouble
Action of
None in particular.
controller
Problem that
appears on Engine does not start easily at low temperature.
machine
Related Condition for driving heater relay depends on machine.
information Different machine models may have different connector Nos.

Defective intake air heater ing without turning starting switch ON.
1
relay (Internal trouble) R18 (male) Resistance
Between (1) (2) 200 400 z
ness (Disconnection in wiring Wiring harness between E02 (female) (40) Resis-
2 Max. 1 z
or defective contact in connec- R18 (female) (1) tance
tor) Wiring harness between E02 (female) (42) Resis-
Max. 1 z
Possible causes R18 (female) (2) tance
state
3
(Short circuit with GND circuit) R18 (female) (1) and chassis ground tance 1 Mz
R18 (female) (2) and chassis ground tance 1 Mz
E02 Heater relay Voltage
4 Defective engine controller Under operating
Max. 1 V
condition
Between (40) (42)
Under stopping con-
20 30 V
dition
46 125E-5 Series
Circuit diagram related to intake air heater (Case of PC400/400LC/450/450LC-7E0)
125E-5 Series 47
E-69 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate 1

Trouble Eng. Oil press. Torque Derate
(143) B@BAZG
Contents of
Engine oil pressure is below operating range.
trouble
Action of
Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Problem that
machine
Related
information

and standard This fault is indicated on only machine side when detected.
value in normal Carry out troubleshooting on
1 Accordingly, contents of troubleshooting depends on machine
state machine side
model. See Shop manual for machine.
E-70 Code [(146)/B@BCNS] Eng. Overheat 1

Trouble Eng. Overheat
(146) B@BCNS
Contents of
Engine coolant temperature is above operating range.
trouble
Action of
Limits output and continues operation.
controller
Problem that
machine
Related
information

state machine side
48 125E-5 Series
E-71 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate 1

Trouble Eng. Oil press. Low Speed Derate
(415) B@BAZG
Contents of
Engine oil pressure is below operating range.
trouble
Action of
Limits output and continues operation (Limits fuel injection rate and engine speed).
controller
Problem that
machine
Related
information

state machine side
125E-5 Series 49
SEN00551-01
2007 KOMATSU
All Rights Reserved
50
SEN00549-01
ENGINE 1SHOP MANUAL
125E-5 Series
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 1
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
2 125E-5 Series
125E-5 Series 3
Troubleshooting of mechanical system (S-mode) 1

Method of using troubleshooting charts 1
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.)
4 125E-5 Series
125E-5 Series 5
<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 gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
6 125E-5 Series
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 7
S-1 Starting performance is poor 1

General causes why starting performance is poor Causes
q Defective electrical system
(Coolant in exhaust pipe) ["with EGR" only]
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
q Insufficient supply of fuel
Defective alternator (generator section)

Defective alternator (regulator section)
q Insufficient intake of air
Stuck, seized supply pump plunger
Defective intake air heater system

q Improper selection of fuel
Defective or deteriorated battery

Clogged feed pump gauze filter
q Coolant in exhaust pipe ("with EGR" only)
Clogged air cleaner element

a The common rail fuel injection system (CRI) controls
Clogged fuel filter, element

Worn piston ring, cylinder
the fuel injection timing electrically. Accordingly, even
Cracked EGR cooler

if the starting operation is carried out, the engine may
Defective injector
not start until the crankshaft revolves 2 turns at maxi-
mum. This phenomenon does not indicate a trouble,
however.
Confirm recent repair history

Degree of use
Operated for long period E E E E E
of machine
Starting perfor- Became worse gradually Q Q w w Q Q
mance Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q Q

Replacement of filters has not been carried out according to Operation and Main-
w w w Q Q
tenance Manual
Oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does
w
not indicate normally (if monitor is installed)
During operation, charge level monitor indicates abnormal charge (if monitor is installed) w w
Dust indicator is red (if indicator is installed) w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Starting motor cranks engine slowly Q w
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow out w w
cranked with
starting motor, If spill hose from injector is disconnected, little fuel spills w
Check items
When exhaust manifold is touched immediately after starting engine, temperature

of some cylinders is low w
Engine does not pick up smoothly and combustion is irregular Q Q w

There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When EGR cooler outlet gas piping is removed, coolant containing antifreeze
q
flows out (*1) ["with EGR" only]
When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Troubleshooting
Inspect fuel filter, element directly q

Inspect feed pump gauze filter directly q
Carry out troubleshooting according to No-pressure feed by supply pump (*2) in
q
E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 30 V between alternator terminal B and terminal E with Yes q
engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
8 125E-5 Series
*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, how-
ever, it is not a problem.
*2: Code [559/CA559] and code [2249/CA2249] in E-mode
125E-5 Series 9
S-2 Engine does not start 1

a) Engine does not turn Causes
General causes why engine does not turn
Defective starting motor (safety relay section)

(Coolant in exhaust pipe) ["with EGR" only]
q Internal parts of engine seized
Defective connection of battery terminal
Defective starting motor (motor section)

o See S-4 Engine stops during operations
q Water hammer caused by coolant which entered cylinder
Defective or deteriorated battery

q Defective electrical system
Defective steering circuit wiring

q Problem in drive devices on applicable machine side
Broken flywheel ring gear

o Requires troubleshooting on applicable machine side.
Defective starting switch

Defective battery relay
Cracked EGR cooler
Questions
Degree of use of machine Operated for long period E E E

Condition of horn when Horn does not sound Q Q w
starting switch is turned ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low Q w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages again w
Makes rattling noise and does not turn w Q Q w
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1) q
["with EGR" only].
on applicable machine side

Carry out troubleshooting
Inspect flywheel ring gear directly q
Troubleshooting
There is not voltage (20 30 V) between battery relay terminal q
B and terminal E
When terminal B and terminal C of starting switch are con- q
Turn starting switch OFF, nected, engine starts
connect cord, and carry out
troubleshooting at ON When terminal B and terminal C at safety relay outlet are con-
q
nected, engine starts
Even if terminal B and terminal C at safety relay outlet are con-
q
nected, engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
10 125E-5 Series

125E-5 Series 11
b) Engine turns but no exhaust smoke comes out Causes

General causes why engine turns but no exhaust smoke
Defective operation of overflow valve (Does not close)

comes out
q Fuel is not being supplied
q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Wrong connection of supply pump PCV

Seized, abnormally worn feed pump
Defective operation of flow damper

Broken supply pump shaft, key
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Questions
Degree of use of
Operated for long period E E E
machine
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w E E
Replacement of filters has not been carried out according to Operation and
Maintenance Manual w w E Q
When fuel tank is inspected, it is found to be empty w

Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is not fuel in it w w
Check items
Fuel is leaking from fuel piping w

While engine is If air bleeding plug of fuel filter is removed, fuel does not Q Q w Q
cranked with starting flow out
motor, If spill hose from injector is disconnected, little fuel spills Q w w w w Q

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to No-pressure feed by supply pump (*1)
q q q q
in E-mode
Carry out troubleshooting according to Abnormality in PCV1 (*2) or Abnormality q
in PCV2 (*3) in E-mode
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Add
Remedy

12 125E-5 Series
c) Exhaust smoke comes out but engine does not start Causes
(fuel is being injected)
Worn dynamic valve system (Valve, rocker lever, etc.)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine
does not start
Leaking or clogged fuel system, entry of air

q Lack of rotating force due to defective electrical system

Defective intake air heater system

Clogged injector, defective spray

Worn piston ring, cylinder liner
Defective, deteriorated battery

Clogged fuel filter, strainer

Use of improper fuel
Degree of use of
Operated for long period E E E E
machine
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

Replacement of filters has not been carried out according to Operation and Mainte- w w w
nance Manual
When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed) w

Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w w
When fuel filter is removed, there is not fuel in it w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow Q w w
cranked with starting out
motor, If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of
w
some cylinders is low

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting
Inspect fuel filter, strainer directly q

Carry out troubleshooting according to No-pressure feed by supply pump (*1) in E-
q
mode
When injector unit is tested, spray condition is bad q
Coolant temperature gauge does not indicate normally (if coolant temperature
q
gauge is installed)
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Remedy
125E-5 Series 13
S-3 Engine does not pick up smoothly 1

General causes why engine does not pick up smoothly Causes
Insufficient intake of air
Seized turbocharger, interference of turbocharger

q
q Defective condition of fuel spray

Defective EGR valve or bypass valve

q Controller is controlling in derate mode

Defective operation of flow damper
(limiting injection rate (output) because of an error in
Clogged injector, defective spray

electrical system)
(Large leakage from injector)


q EGR valve is stuck open ["with EGR" only]
Improper valve clearance

(There is much EGR gas and intake of air is insuffi-
cient)
["with EGR" only]

Degree of use of machine Operated for long period E E E E E E
Questions
Engine pick-up suddenly became worse Q w Q Q Q

Non-specified fuel is being used w w w w
Maintenance Manual w w w

When exhaust manifold is touched immediately after starting engine, tempera- Q w
ture of some cylinders is low
Blue under light load w
Color of exhaust gas
w Q w w
Check items
Black
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
Q w w
applied
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w w

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] q

Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
q
in E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed q q
does not change
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in
E-mode
14 125E-5 Series
S-4 Engine stops during operations 1

General causes why engine stops during operations Causes
Seized parts inside engine
Broken dynamic valve system (valve, rocker arm, etc.)
Problem in drive devices on applicable machine side

q
Broken auxiliary equipment (pump, compressor, etc.)

Defective engine controller power supply wiring

q There is overheating
q Problem in drive devices on applicable machine

side
Broken, seized piston, connecting rod

o Requires troubleshooting on applicable

Broken, seized crankshaft bearing
machine side.
Broken supply pump shaft, key
Defective starting switch wiring

Leaking, clogged fuel piping
Broken, seized feed pump

Broken, seized gear train
Degree of use of machine Operated for long period E E
Abnormal noise was heard and engine
stopped suddenly w w w w Q w Q w w
Questions
Condition when engine Engine overheated and stopped w Q Q

stopped
Engine stopped slowly w Q Q Q Q
There was hunting and engine stopped w Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation w w
and Maintenance Manual
Fuel level monitor indicates low level (if monitor is installed) w
w w w
Check items
Metal particles are found when oil is drained

Does not turn at all w w
When engine is cranked Turns in opposite direction w
by hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Inspect piston, connecting rod directly q
Inspect crankshaft bearing directly q
Inspect gear train directly q

Troubleshooting

Inspect feed pump directly q
Carry out troubleshooting according to No-pressure feed by supply
q q
pump (*1) in E-mode
Engine rotates when pump auxiliary equipment (pump, compressor, etc.)
q
is removed
Inspect controller power supply wiring q
Inspect starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Add
Remedy
125E-5 Series 15
S-5 Engine does not rotate smoothly 1

General causes why engine does not rotate smoothly Causes
Air in fuel system
Defective operation of flow damper (Large leakage from injector)

q
q Defective speed sensor
(Error at degree that it is not indicated)
q Defective EGR valve ["with EGR" only]
Defective operation of bypass valve ["with EGR" only]

Defective bypass valve ["with EGR" only]
Defective operation of EGR valve ["with EGR" only]

q
Clogged injector, defective spray (dirt in injector)
Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness

Low setting of low idle speed

Degree of use of machine Operated for long period E E E E
Occurs at a certain speed range Q Q Q Q Q
Questions
Occurs at low idle w Q Q Q Q Q Q Q

Condition of hunting
Occurs even when speed is raised Q Q Q Q Q
Occurs on slopes w Q Q
Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual w w

Check items
Rust and water are found when fuel tank is drained Q Q

Carry out troubleshooting according to Abnormality in EGR valve servo (*1) in E-mode
q
["with EGR" only]
Carry out troubleshooting according to Abnormality in bypass valve servo (*2) in E-
q
mode ["with EGR" only]
Troubleshooting

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q q
change
Carry out troubleshooting according to Abnormality in engine Ne speed sensor (*3) in
E-mode q
Carry out troubleshooting according to Abnormality in engine Bkup speed sensor (*4)
in E-mode q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Clean
Add
Remedy

*3: Code [689/CA689] in E-mode
*4: Code [778/CA778] in E-mode
16 125E-5 Series
S-6 Engine lacks output (or lacks power) 1

General causes why engine lacks output Causes
Insufficient intake of air
Defective fuel temperature sensor, wiring harness

q
Defective charge pressure sensor, wiring harness

Clogged injector, defective spray (dirt in injector)
Defective installation of charge pressure sensor

Defective drive of injector (signal, solenoid)

q Defective spray condition of fuel


Air leakage from air intake piping

o See S-14 Coolant temperature becomes

Leaking, clogged fuel piping

too high (Overheating)

q Controller is controlling in derate mode
(limiting injection rate (output) because of an
error in electrical system)
(air leakage)
Degree of use of machine Operated for long period E E E E E
Suddenly Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q Q
Maintenance Manual w
Oil must be added more frequently Q Q Q

Output becomes insufficient after short stop of operation w
Black w w w
Color of exhaust gas color
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Check items

High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops when load is
applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w

There is hunting from engine (rotation is irregular) Q Q Q Q

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Troubleshooting

q
in E-mode
does not change q q
Inspect charge pressure sensor mount directly q

Carry out troubleshooting according to Abnormality in charge pressure sensor
q
(*2) in E-mode
Carry out troubleshooting according to Abnormality in fuel temperature sensor
q
(*3) in E-mode
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy

125E-5 Series 17
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head

Defective EGR valve or bypass valve ["with EGR" only]
q Excessive injection of fuel

q Defective condition of fuel injection
Clogged fuel spill piping (on cylinder head side)

EGR gas piping is clogged ["with EGR" only]


o See S-14 Coolant temperature becomes too high

(Overheating)
Improper fuel injection pressure

Controller is controlling in derate mode (limiting

q

injection rate (output) because of an error in electri-
Crushed, clogged muffler
Abnormally worn injector
Improper injection timing

Clogged, seized injector
cal 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)
Degree of use of
machine
Suddenly became black w Q Q Q Q
Questions
Color of exhaust gas Gradually became black w w Q Q Q

color
Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low Q w

Check items

Torque converter stall speed or pump relief speed is high (Fuel is injected exces- Q Q
sively)
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w

When turbocharger is rotated by hand, it is fount to be heavy 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] q
Inspect EGR gas piping directly (*2) ["with EGR" only] q

Troubleshooting

When muffler is removed, exhaust color improves q
Carry out troubleshooting according to No-pressure feed by supply pump (*3) in E- q q
mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change q
Inspect fuel spill piping (on cylinder head side) directly q

Carry out troubleshooting according to Abnormality in coolant temperature sensor q
(*4) in E-mode
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
18 125E-5 Series
*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in E-
mode
*2: EGR gas piping
Remove EGR gas piping (2) and confirm for internal clogging

125E-5 Series 19
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1

General causes why oil consumption is excessive Causes
Abnormal consumption of oil
Turbocharger
q
Oil leakage from EGR valve stem ["with EGR" only]

q Long-time operation of engine at low idle or high
idle (Do not run engine at idle for more than 20
Oil leakage from oil pan, cylinder head, etc.

minutes continuously)
Worn, damaged valve (stem, guide, seal)

q External leakage of oil
Wear of parts in lubrication system
Dust sucked in from intake system

q
Clogged breather, breather hose
Oil leakage from oil drain plug

Worn, damaged rear oil seal
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at turbine side
Worn seal at blower side
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of use of
Questions

machine
Oil consumption suddenly increased w Q
Oil must be added more frequently Q w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in clutch chamber or damper chamber is high w
Exhaust smoke is blue under light load Q w w
Excessive Q Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be dirty abnormally q
Excessive play of turbocharger shaft q q
Troubleshooting
When EGR valve is removed, exhaust port is found to be dirty with oil ["with
EGR" only] q
Inspect breather and breather hose directly q

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20 125E-5 Series
S-9 Oil becomes contaminated quickly 1

General causes why oil becomes contaminated quickly Causes
Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

q
Defective seal at turbocharger turbine side

Worn EGR valve guide ["with EGR" only]
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
Clogged breather, breather hose

Operation under excessive load

q
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions
Non-specified fuel is being used Q

Oil must be added more frequently Q w
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
Engine oil temperature rises quickly w
Check items

Black w
Excessive Q Q w
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

When EGR valve is removed, exhaust port is found to be dirty with oil ["with EGR" only] q
Troubleshooting
See S-7.
Inspect breather and breather hose directly q
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy
125E-5 Series 21
S-10 Fuel consumption is excessive 1

General causes why fuel consumption is excessive Causes
q Leakage of fuel

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector
Improper injection timing

Degree of use of
Questions
Operated for long period E E E

machine
More than for other machines of same model Q Q Q Q
Condition of fuel
consumption Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some cylin- w w
ders is low
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Color of exhaust Black Q Q Q Q
gas White Q
Remove and inspect head cover directly q

Troubleshooting
Inspect feed pump oil seal directly q

Carry out troubleshooting according to No-pressure feed by supply pump (*1) in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q q
If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) in E-mode q
Confirm with INSITE or with monitoring function on applicable machine side q q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy

22 125E-5 Series
S-11 Oil is in coolant (or coolant spurts back or coolant level goes
down) 1
General causes why oil is in coolant Causes
Internal leakage in lubrication system
Damaged cylinder liner O-ring, hole caused by pitting

q
Broken hydraulic oil cooler or power train oil cooler

q Internal leakage in cooling system
Insufficient protrusion of cylinder liner

Broken cylinder head, head gasket
Broken oil cooler core, O-ring

Cracks inside cylinder block

Degree of use of
Questions
machine Operated for long period E E
Suddenly increased Q Q Q
Oil level
Gradually increased Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w w
Check
items
Hydraulic oil or power train oil on applicable machine side is milky w

When hydraulic oil or power train oil is drained, water is found w
Pressure-tightness test of cylinder head shows there is leakage q

Carry out
shooting
Trouble-
Inspect cylinder block, liner directly q q troubleshooting

Inspect cylinder liner directly q on applicable
machine side
Pressure-tightness test of oil cooler shows there is leakage q
Replace
Replace
Replace
Replace
Replace
Remedy
125E-5 Series 23
S-12 Oil pressure drops 1

General causes why oil pressure drops Causes
q Leakage, clogging, wear or lubrication system
Leaking EGR hydraulic piping ["with EGR" only]

Defective oil pressure sensor, wiring harness
q Defective oil pressure control
Leaking, crushed, clogged hydraulic piping

Defective EGR oil pump ["with EGR" only]
q Improper selection of fuel (improper viscosity)
Defective oil level sensor, wiring harness

q Deterioration of oil due to overheating
Clogged, broken pipe in oil pan
Defective oil pump relief valve

Clogged strainer in oil pan
Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Degree of use of
Operated for long period E E E E
Questions
machine
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Mainte-
nance Manual w
Indicates pressure drop at low idle w Q Q

Oil pressure monitor Indicates pressure drop at low, high idle Q w w w Q Q Q
(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q Q
Metal particles are found in oil filter q

Inspect oil pan strainer, pipe directly q q
Oil pump rotation is heavy, there is play in oil pump q
Troubleshooting
Valve and spring of oil pump relief valve are fatigued, damaged q
See SI13.
Inspect oil filter directly q

Relief valve of EGR oil pump is damaged, oil leaks from it ["with EGR" only] q
Inspect EGR hydraulic piping directly ["with EGR" only] q
Carry out troubleshooting according to Abnormality in oil pressure sensor (*1) in E-
mode q
If oil level sensor is replaced, oil pressure monitor indicates normally q

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Add
Remedy
24 125E-5 Series
S-13 Oil level rises (Entry of coolant or fuel) 1

General causes why oil level rises Causes
q Coolant in oil (milky)
Clogged water pump drain hole (breather hole), defective seal

q Fuel in oil (smells diluted diesel fuel)
Defective seal of auxiliary equipment (pump, compressor)

a If oil is in coolant, carry out troubleshooting for S-11 Oil is in
Cracked EGR cooler (Entry of coolant) [with EGR only]
Damaged cylinder liner O-ring, holes caused by pitting

coolant

Fuel leakage inside head cover
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Cracks inside cylinder block
Defects in supply pump

Questions

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q 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 bub-
w Q
bles appear, or coolant spurts back
Check items
Exhaust smoke is white Q

Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, coolant comes out w
Oil level in clutch or damper chamber of machine is low w
Oil level in hydraulic tank of machine is low w
When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1) q
[with EGR only]
Troubleshooting
Remove and inspect head cover directly q

Inspect cylinder block, liner directly q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect water pump directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
125E-5 Series 25

26 125E-5 Series
S-14 Coolant temperature becomes too high (overheating) 1

General causes why coolant temperature becomes too Causes
high
External leakage of coolant from EGR cooler ["with EGR" only]

q Lack of cooling air (deformation, damage of fan)
q Drop in heat dissipation efficiency
Damaged cylinder liner O-ring, hole caused by pitting

q Problem in coolant circulation system
q Rise in oil temperature in power train
Rise in power train oil temperature on applicable

o Carry out troubleshooting on applicable machine
side
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

Defective operation of thermostat
Slipping fan belt, worn fan pulley

Clogged, crushed radiator fins
Clogged, broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
machine side
Degree of use of machine Operated for long period E E E E E
Questions
Suddenly overheated Q Q w Q
Condition of overheating
Always tends to overheat Q w w Q
Coolant temperature gauge Rises quickly Q w
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is Q w
installed)
Engine oil level has risen, oil is milky w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
When light bulb is held behind radiator core, no light passes through w
Check items
Radiator shroud, inside of underguard on applicable machine side are clogged

with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w

Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant temper- w
ature (if oil temperature gauge and coolant temperature gauge are installed)
Inspect EGR cooler for coolant leakage ["with EGR" only] q

Inspect cylinder liner directly q

Inspect oil cooler directly q

Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

When operation of thermostat is carried out, it does not open at cracking temper-
q
ature
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Add
Remedy
125E-5 Series 27
S-15 Abnormal noise is made 1

General causes why abnormal noise is made Causes
Abnormality due to defective parts
Deformed cooling fan, loose fan belt, interference of fan belt

q
Abnormal combustion
Defective inside of muffler (dividing board out of position)

q
Leakage of air between turbocharger and cylinder head

q Air sucked in from intake system
Cracked, leaking EGR gas piping ["with EGR" only]

a Judge if the noise is an internal noise or an external
Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger
noise before starting troubleshooting.
(abnormality in coolant temperature sensor)

a The engine is operated in the low-temperature mode
Excessive wear of piston ring, cylinder liner

while it is not warmed up sufficiently. Accordingly, the
engine sound becomes a little larger. This does not
Removed, seized gear train bushing

indicate abnormality, however.
a When the engine is accelerated, it is operated in the
Improper fuel injection timing

Improper gear train backlash
acceleration mode and its sound becomes a little
Clogged, seized injector

larger for up to about 5 seconds. This does not indi-
Dirt caught in injector

cate abnormality, however.

Degree of use of machine Operated for long period E
Questions
Gradually occurred Q Q
Abnormal noise
Suddenly occurred Q Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around EGR gas piping w
["with EGR" only]
When engine is cranked, abnormal sound is generated around cylinder head w w
w
Check items
When engine is cranked, beat noise is generated around muffler

When exhaust manifold is touched immediately after starting engine, tempera-
ture of some cylinders is low w Q

Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is fount to be heavy q

Inspect EGR gas piping directly ["with EGR" only] q
When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
does not change q q
Abnormal noise is heard only when engine is started q

Confirm with INSITE or with monitoring function on applicable machine side q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
28 125E-5 Series
S-16 Vibration is excessive 1

General causes why vibration is excessive Causes
q Defective parts (abnormal wear, breakage)
Misalignment between engine and devices on applicable machine side

q Misalignment between engine and chassis
Broken output shaft, parts in damper on applicable machine side

q Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out trou-
bleshooting for S-15 Abnormal noise is made, too.
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
Worn front support spigot joint portion

Improper gear train backlash
Worn camshaft bushing
Questions

Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q Q
Exhaust smoke is black w

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect front support spigot joint portion directly q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
125E-5 Series 29
SEN00549-01
2007 KOMATSU
All Rights Reserved
30
SEN00697-01
ENGINE 1SHOP MANUAL
125E-5 Series
50 Disassembly and assembly1

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 1
SEN00697-01 50 Disassembly and assembly
General information on disassembly and assembly 1

How to read this manual 1 Installation
q Except where otherwise instructed, installation
1. Removal and installation of assemblies of parts is done in the r evers e order of
Special tools removal.
q As to the special tools needed for removal q Instructions and precautions for installing parts
and installation, symbols such A1X1 are are shown with [*1] mark in the Removal sec-
attached in the table along with respective tion, identifying which step the instructions are
part numbers, part names and quantity. intended for.
q In addition to the above, the list of special q As to the multi purpose tools used in installa-
tools contains the following information. tion, the numbers such [1], [2] are given.
1) Necessity Their part numbers, part names and quantity
t: Special tools that cannot be substi- are not described.
tuted and should always be used q Marks shown in the Installation section stand
(installed). for the following.
k : Precautions related to safety in execution
q: Special tools that will be useful if
available and are substitutable with of work.
commercially available tools. a : This mark gives guidance or precautions
2) Distinction of new and existing special when doing the procedure.
2 : Type of coating material
tools
3 : Tightening torque
N: Tools newly developed for this model.
They respectively have a new part
5 : Quantity of oil or coolant to be added
number.
R: Tools with upgraded part numbers.
They are remodeled from already Sketches of special tools
available tools for other models. q Various special tools are illustrated for the con-
Blank: Tools already available for other venience of local manufacture.
models. They can be used without
any modification.
3) Circle mark (Q) in sketch column:
q A circle mark means that a 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 locally
made parts and as such not inter-
changeable with those made by
Komatsu in Japan, e.g. 79*T-***-****.
Removal
q The Removal section contains procedures,
precautions and the amount of oil or coolant to
be drained.
q As to the multi purpose tools used in removal,
the numbers such [1], [2] are given. Their
part numbers, part names and quantity are not
described.
q Various symbols used in the Removal section
are explained and listed below.
of work.
a : This mark gives guidance or precautions
when doing the procedure.
[*1] : This mark shows that there are instructions
or precautions for installing parts.
6 This mark shows oil or coolant to be drained.
4 : Weight of part or component
2 125E-5 Series
2. Disassembly and assembly of assem- Assembly

blies q In Assembly section, the work procedures,
special tools precautions and know-how for carrying out
q As to the special tools needed for disas- those procedures, and quantity of the oil and
sembly and assembly, symbols such coolant added are described.
A1X1 are attached along with respective q As to the multi purpose tools used in assembly,
part numbers, part names and quantity. the numbers such [1], [2] are given. Their
q In addition to the above, the list of special part numbers, part names and quantity are not
tools contains the following information. described.
1) Necessity q Various symbols used in Assembly section
t: Special tools that cannot be substi- are explained and listed below.
tuted and should always be used k : Precautions related to safety in execution
(installed). of work
q: Special tools that will be useful if a : This mark gives guidance or precautions
available and are substitutable with when doing the procedure.
commercially available tools. 2 : Type of coating material
2) Distinction of new and existing special 3 : Tightening torque
tools 5 : Quantity of oil or coolant to be added
N: Tools newly developed for this model.
They respectively have a new part
Sketches of special tools
number.
R: Tools with upgraded part numbers. q Various special tools are illustrated for the con-
They are remodeled from already venience of local manufacture.
available tools for other models.
Blank: Tools already available for other
models. They can be used without
any modification.
3) Circle mark (Q) in sketch column:
q A circle mark means that a 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 locally
made parts and as such not inter-
changeable with those made by
Komatsu in Japan, e.g. 79*T-***-****.
Disassembly
q In Disassembly section, the work procedures,
precautions and know-how for carrying out
those procedures, and quantity of the oil and
coolant drained are described.
q As to the multi purpose tools used in disas-
sembly, the numbers such [1], [2] are given.
Their part numbers, part names and quantity
are not described.
q Various symbols used in the Disassembly
section are explained and listed below.
of work.
a : This mark gives guidance or precautions
when doing the procedure.
6 This mark shows oil or coolant to be drained.
125E-5 Series 3
Coating materials list 1

a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part No. Q'ty Container Main features and applications
gory code
Used to prevent falling off of rubber gaskets, rub-
LT-1A 790-129-9030 150 g Tube
ber cushions, and cork plugs.
Used for plastic (except polyethylene, polypropy-
20 g Polyethylene lene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050
(2 pcs.) container ber, metal, and non-metal parts which require
immediate and strong adhesion.
Polyethylene Features: Resistant to heat and chemicals.
LT-2 09940-00030 50 g
container Used to fix and seal bolts and plugs.
Adhesive:
790-129-9060
1 kg
LT-3 Set of adhesive Can Used to stick and seal metal, glass, and plastics.
Hardener:
and hardener
500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g Used to seal plugs for drilled holes.
container
Holtz MH 705 790-129-9120 75 g Tube Heat-resistant sealant used to repair engines.
Quick-setting adhesive.
Three Bond Polyethylene Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container Used mainly to stick metals, rubbers, plastics, and
woods.
Quick-setting adhesive.
Aron-alpha Polyethylene Quick-hardening type. (max. strength is obtained
790-129-9130 2g
201 container after 30 minutes of application)
Used mainly to stick rubbers, plastics, and metals.
Loctite Polyethylene Features: Resistant to heat and chemicals.
79A-129-9110 50 cc
648-50 container Used for fitted portions of high temperatures.
Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
Used to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container Used to seal tapered plugs, elbows, and nipples of
hydraulic pipes.
Features: Silicon-based heat and cold-resistant
Gasket sealant
sealant.
LG-6 790-129-9020 200 g Tube Used to seal flanged surfaces and threaded por-
tions.
Used to seal oil pan, final drive case, etc.
Features: Silicon-based quick-hardening sealant.
LG-7 790-129-9070 1 kg Tube Used to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
Three Bond
790-129-9090 100 g Tube Gasket sealant used to repair engine.
1211
Features: Silicon-based, heat-resistant, vibration-
Three Bond
419-15-18131 100 g Tube resistant and impact-resistant sealant.
1207B
Used to seal transfer case, etc.
4 125E-5 Series
Cate- Komatsu
gory code
Used to lubricate sliding portions (for preventing
disulfide lubricant
LM-G 09940-00051 60 g Can

Molybdenum
squeaking)
Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Used to lubricate linkages, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI
SYG2-400LI-A
G0-LI(*)
SYG2-160LI Various Various General purpose type.
*: For cold
SYGA-160CNLI
districts
SYG0-400LI-A(*)
SYG0-16CNLI(*)
SYG2-400CA
SYG2-350CA
Used for bearings used at normal temperature
G2-CA SYG2-400CA-A Various Various
under light load in contact with water or steam.
SYG2-160CA
SYGA-160CNCA
Used for parts under heavy load.
Molybdenum Caution:
SYG2-400M 400 g 10
disulfide lubri- Bellows-type Do not use this grease for ball bearings such
Grease
SYG2-400M-A 400 g 20
cant LM-G as swing circle bearing.
SYGA-16CNM 16 kg Can
(G2-M) Apply this grease to work equipment pins only
when installing but do not use it after then.
SYG2-400T-A
Hyper white
SYG2-16CNT Seizure resistance and heat resistance higher
grease
SYG0-400T-A 400 g Bellows-type than molybdenum disulfide grease.
G2-T, G0-T(*)
(*) 16 kg Can Not conspicuous on machine since its color is
*: For cold
SYG0-16CNT white.
districts
(*)
Bio grease
SYG2-400B
G2-B, G2-
SYGA-16CNB
BT(*) Since this grease is decomposed by natural bacte-
SYG2-400BT 400 g Bellows-type
*For use at ria in short period, its impacts on microorganisms,
(*) 16 kg Can
high tempera- animals, and plants are minimized.
SYGA-16CNBT
ture under
(*)
high load
SUNSTAR
Used as primer for cab side.
PAINT Glass
20 ml (Using limit: 4 months after date of manufac-
PRIMER 580 container
ture)
SUPER
417-926-3910
SUNSTAR
Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manufac-
PRIMER 580 container
Adhesive for cab glass
ture)
SUPER
SUNSTAR Used as primer for painted surface on cab
Primer
PAINT Glass side.

22M-54-27230 20 ml
PRIMER 435- container (Using limit: 4 months after date of manufac-
95 ture)
SUNSTAR Used as primer for black ceramic-coated sur-
GLASS face on glass side and for hard polycarbon-
22M-54-27240 150 ml Steal can
PRIMER 435- ate-coated surface. (Using limit: 4 months
41 after date of manufacture)
SUNSTAR
Used as primer for sash (processing of Alu-
SASH Glass
22M-54-27250 20 ml mite surface) (Using limit: 4 months after date
PRIMER GP- container
of manufacture)
402
125E-5 Series 5
Cate- Komatsu
gory code
SUNSTAR S is used for high-temperature season (April
PENGUINE October) and W for low-temperature sea-
Polyethylene
SEAL 580 417-926-3910 320 ml son (October April) as adhesive for glass.
container
SUPER S or (Using limit: 4 months after date of manufac-
W ture)
Adhesive
Sika Ltd., Used as adhesive for glass.

Polyethylene
Japan, Sikaf- 20Y-54-39850 310 ml (Using limit: 6 months after date of manufac-
container
lex 256HV ture)
Adhesive for cab glass

SUNSTAR Ecocart Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manufac-
SUPER 560 container) ture)
SUNSTAR
Used to seal joint of glasses.
PENGUINE Polyethylene
417-926-3920 320 ml (Using limit: 4 months after date of manufac-
SEAL No. container
ture)
Caulking material
2505
SEKISUI SIL- Used to seal front window.
Polyethylene
ICON SEAL- 20Y-54-55130 333 ml (Using limit: 6 months after date of manufac-
container
ANT ture)
GE TOSHIBA Used to seal joint of glasses
SILICON Translucent white seal
22M-54-27220 333 ml Cartridge
TOSSEAL (Using limit: 12 months after date of manufac-
381 ture)
6 125E-5 Series
Special tools list 1

a Tools with part number 79QTQQQQQQQ cannot be supplied (they must be locally manufactured).
a Necessity : t Cannot be substituted and should always be installed (used)
: q Extremely useful if available or can be substituted with commercially available
part
a New/Remodel : N Tools newly developed for this model and given new part Nos.
: R Tools remodeled from tools already available for other models and provided
with upgraded part Nos.
: Blank Tools already available for other models and usable for the given model with-
out any modification
a Tools marked with Q in the sketch column are tools being introduced in the sketches of the special tools
(See Sketches of special tools)
New / Remodel
Necessity
Sketch
Sym-
Q'ty
Work item Part No. Part name Remarks
bol
Disassembly and assembly of 1 790-501-2001 Engine repair stand t 1

A
engine assembly 2 790-901-1240 Adapter t 1
Removal and installation of
C 795-102-2102 Spring pusher t 1
cylinder head valve spring
Removal and installation of piston
D 795-100-1191 Piston ring tool t 1
ring
Removal of cylinder liner E 795-220-1000 Liner puller t 1
Press fitting of cylinder liner F 795-225-1520 Liner driver t 1
Insertion of piston assembly G 795-921-1110 Piston holder t 1
Measuring projection of piston top
H 795-502-1121 Gauge holder t 1
surface
Adjusting valve clearance I 795-125-1360 Clearance gauge q 1
Angle tightening of bolt J 790-331-1110 Wrench q 1
Removal of rear oil seal L 795-931-1100 Seal puller assembly q
1 795-931-1210 Sleeve jig t 1
2 795-931-1220 Sleeve jig t 1
Press fitting of rear oil seal N
3 01050-31645 Bolt t 3
4 01050-31625 Bolt t 3
1 795-630-5500 Standard puller t 1
Removal of fuel supply pump P 2 01010-81090 Bolt t 2
3 01643-31032 Washer t 2
125E-5 Series 7
SEN00697-01
2007 KOMATSU
All Rights Reserved
8
SEN00698-01
ENGINE 1SHOP MANUAL
125E-5 Series

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 1
Disassembly and assembly, Part 1 (With EGR) 1

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.
6. Alternator
2. Setting engine assembly 1) Remove cover (1).
1) Set the engine assembly (1) on rigid and 2) Loosen alternator mounting bolt (2) and
stable stands [1]. lock bolt (3).
a The weight depends on the applica- 3) Loosen locknut (4) and then loosen the
ble machines. belt tension using the tension adjustment
4 Engine assembly: 1,300 kg
nut and remove V-belt.
4) Remove mounting bolt (2) and lock bolt
(3) and then remove alternator (5).
2) 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 7. Water pump suction tube
Remove tube (1).
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).
2 125E-5 Series
8. 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 assem-

bly
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) Remove the bolt mounting it to EGR tube
(7).
7) Remove 4 mounting bolts and remove
EGR cooler (9).
a Remove bracket (8) at the same time.
3) 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
9. EGR tube assembly: 40 kg
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 3
11. Oil filter and oil tube assembly 13. Fuel tube
1) Remove the oil tube (1) block side mount- Remove clamp (3) and remove fuel tubes (1)
ing bolt. and (2).
2) Remove 4 mounting bolts on the oil filter
head side and remove oil filter and oil tube
assembly (2).
14. Lubrication tube and bracket

1) Remove brackets (1) and (2).
2) Remove turbocharger lubrication tube (3)
12. Fuel filter by removing 4 clamps on it.
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).
15. High-pressure pipe

1) Remove bracket (1).
2) Remove splash prevention cover (2).
4 125E-5 Series
3) Remove 6 clamps (3) and 6 splash pre- 17. Bypass valve

vention covers (4) on the injector side. 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).
4) Remove clamps (5), (6), (7) and (8) and

then remove 6 high-pressure pipings (9).
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 5
20. Diffuser and air housing assembly 21. Air intake manifold
1) Remove brackets (1) and (2) and then 1) Remove bracket (1).
remove oil filler (3).
2) Remove mounting bolt (4) at flanged por-
tion of the air housing. Remove the bolt
through the bottom.
2) Lift air intake manifold (2) temporarily,

remove its 24 mounting bolts and then
remove manifold.
4 Air intake manifold: 25 kg
3) Remove bracket (5) and then lift the dif-
fuser temporarily.
4) 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.
6 125E-5 Series
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) Remove pump mounting bolts (6) and

bracket (7).
a Leave bolts (6) tightened by 2 3
threads to prevent the pump from fall-
ing down.
5) Install tool P1 with P2 and P3 and then
24. Fuel supply pump assembly screw in the center bolt of P1 to remove
1) Remove cover (1). the gear from the shaft.
2) Rotate the crankshaft forward and set 6) Remove remaining bolts and then remove
intermediate point (a) between stamped fuel supply pump assembly (8).
2/5 TOP and 3/4 TOP on damper (2) to a Leave tools P1, P2 and P3 in the
pointer (3) (stamped 1/6 TOP comes installed condition.
almost directly under).
a Make sure at this point that the forc-
ing 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) Remove mounting nut (4) and then remove

washer (5).
a Use a magnet or the like in this opera-
tion so that washer (5) may not be
inadvertently dropped into the case.
125E-5 Series 7
25. Common rail and overflow tube 2) Remove the mounting bolt and then
1) Remove common rail (1). remove oil cooler assembly (4) using
2) Remove spill tube (2), overflow tube (3) guide bolt [1].
and block (4).
29. Engine repair stand adapter

26. Spill tube Install tool A2.
Remove spill tube (1).
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).
8 125E-5 Series
31. Injector harness 34. Injector

1) Fully loosen 2 harness terminal mounting Remove holder mounting bolt (3) of injector (1)
nuts (2) on the head of injector (1). and then remove injector (1) along with holder
a Loosen nuts alternately. (2).
2) Loosen bolt (3) of harness fixing holder. a Do not try to grip the solenoid valve at the
top of the injector using a pliers and the
like.
32. Rocker arm and shaft assembly

1) Loosen locknut (3) and then loosen
adjustment screw (2). 35. Crosshead
2) Remove mounting bolt (4) and then Remove 12 crossheads (1).
remove rocker arm and shaft assembly
(1).
36. Injector wiring harness

1) Remove mounting bolt (2) of harness con-
33. Push rod nector (1).
Remove 12 push rods (1). 2) Remove holder (3) from the harness.
125E-5 Series 9
3) Remove harness connector (1) by push- 39. Cam follower cover

ing outward from inside of rocker housing 1) Remove oil level gauge tube (1).
(4). 2) Remove oil tube (2) and bracket (3).
4) Remove O-ring (5) from the rocker housing. 3) Remove 3 cam follower covers (4).
37. Rocker arm housing 40. Cam follower

Remove rocker arm housing (1). Remove 12 mounting bolts (1) and then
remove cam followers (2).
a Remove dowel pin (3).
38. Thermostat and water pump

1) Remove thermostat case (1) and tube (2).
2) Remove water pump (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.
10 125E-5 Series
42. Disassembly of cylinder head assembly 43. Setting to engine repair stand
1) Using tool C, compress valve spring (3) Lift the engine and then align currently installed
and remove valve cotter (4). tools A2 and A1 to set the engine.
2) Remove upper seat (5) and valve spring (3).
44. Oil pan

3) Remove seal (7) and then remove lower
Remove oil pan (1) by reversing the engine.
seat (8).
4) 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.
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
46. Flywheel
1) Using slings [1], lift up flywheel (1) tempo-
rarily.
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).
47. Flywheel housing

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
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
48. Damper and pulley assembly 4) Remove tool P and then remove the sup-
Lift the damper and pulley assembly (1) tem- ply pump drive gear.
porarily and then remove its 6 mounting bolts.
4 Damper and pulley assembly: 25 kg
12 125E-5 Series
51. Camshaft 53. Idler gear

1) Remove 2 mounting bolts (1). 1) Remove mounting bolt (1) and then remove
2) Remove camshaft (2). plate (2) and oil pump idler gear (3).
a When pulling out the camshaft, turn it
gently so that damages may not be
left on the cam bushing.
2) Remove shaft (4).

3) Remove mounting bolt (5) and then
remove shaft (6), main idler gear (7) and
plate (8).
52. Oil pump
Remove 4 mounting bolts (1) and then remove
oil pump (2).
54. Oil suction pipe

Remove brackets (1) and then remove oil suc-
tion pipe (2).
125E-5 Series 13

Remove mounting bolt (1) and each piston
cooling nozzle (2).
6) Push in and remove the piston and con-

necting rod assembly with a wood bar, etc.
from the oil pan side, while supporting pis-
56. Piston and connecting rod assembly
ton (3) on the cylinder head side.
a Before removing the piston and connect-
a Take care not to damage the inside of
ing rod assembly, measure its end play
the cylinder with a corner of the con-
with dial gauge [3], if necessary.
necting rod.
7) 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.
1) 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.
2) Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
3) Scrub the carbon off the top wall of the cyl- 8) Disassemble the piston and connecting
inder liner with fine sandpaper. rod assembly according to the following
4) Remove connecting rod cap mounting procedure.
bolts (1). 1] Remove 2 snap rings (4).
5) Hit connecting rod cap (2) with a plastic 2] While supporting connecting rod (5),
hammer so lightly that the threads of the remove piston pin (6) to disconnect
connecting rod bolts will not be damaged piston (7) and connecting rod.
and remove connecting rod cap (2) and
connecting rod bearing as a unit.
14 125E-5 Series
2) Insert the bolts in the bolt holes of the

main cap and remove the cap, while shak-
ing it.
3] Using tool D, remove piston ring (8).

a Keep the piston, connecting rod,
connecting rod bearing, piston
rings, and piston pin by each cyl-
inder. a Thrust bearing (3) is assembled to
No. 7 main cap. After removing the
cap, apply a marking to the re-assem-
bly position.
57. Crankshaft
a Before removing the crankshaft, measure its
end play with dial gauge [3], if necessary.
3) Lift off crankshaft (4).
a When removing the crankshaft, take
care so that its sliding surfaces may
not be damaged.
4 Crankshaft: 110 kg
1) Remove mounting bolts (2) of main cap (1).
125E-5 Series 15
4) Remove upper thrust bearing (5). 58. Cylinder liner

Using tool E, pull out cylinder (1).
a Before removing the cylinder liner, mea-
sure its projection with dial gauge [3], if
necessary.
5) Remove upper bearing (6).

a Apply a marking to the assembly
positions of the main cap, main bear-
ing, and thrust bearing. And store
them by the journal No.
16 125E-5 Series
General assembly of engine 1 2] Polish part (R) with sandpaper of

about No. 240 until it becomes a
a The shapes, quantity, locations, etc. of the smooth rounded surface.
parts depend on each applicable machine. If part (R) is sharp or has burrs, finish
Take care. it with a scraper or sandpaper.
a Clean each part carefully, and check it for Finish this surface particularly smoothly
bruise, flaw, cavity, etc. Make sure each oil or so that it will not damage the O-ring.
coolant path is through. 3] If face (B) is so pitted that it cannot be
repaired, replace the cylinder block.
Tightening bolts by plastic-region turning angle 4] If faces (A) and (R) are pitted, finish
method them smoothly.
a Bolts tightened by plastic-region turning angle 5] Check the counterbored part and
method remove burrs. If chips or dust is
q Cylinder head mounting bolt present on face (C), the liner may not
q Main cap mounting bolt fit well, resulting in coolant leakage or
q Connecting rod cap mounting bolt insufficient liner protrusion. Thus,
a If the plastic-region turning angle method is they must be eliminated.
applied, the tightened bolts have permanent a If the counterbored part is droop-
strain. Accordingly, the allowable number of ing, corroded, or pitted, repair it.
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. 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),
2) Before inserting the cylinder liners, pre- refer to the following.
pare the cylinder block according to the q O-ring (2): The whole ring is black.
following procedure. q O-ring (3): The whole ring is red.
1] Remove the rust and scales from faces 2 Clevis seal and O-ring:
(A) and (B) with sandpaper, etc. until Rubber lubricant (LH-50 from NOF
the machined surfaces are exposed. Corporation)
125E-5 Series 17
a If LH-50 is not available, apply clean 4) Apply gasket sealant to the parts of the
engine oil SAE No. 30. cylinder block and cylinder liner which will
a Since the clevis seal and O-ring are fit to the counterboared parts.
swollen and deteriorated by oil, apply a Wipe off dirt and oil with cloth from
a small amount of oil to them thinly the contact faces of the counter-
with a brush just before fitting them. boared 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 dam-
age the O-ring.
6) Push in cylinder liner (1) further by both
3) After fitting the O-ring, check it for twist. If hands.
it is twisted, correct it with a flexible rod a If the liner does not enter the cylinder
(about 10 mm in diameter). smoothly, the O-ring may be dam-
aged. In this case, check the cylinder
block for burrs.
7) Using tool F, press fit cylinder liner (1) to
the cylinder block.
18 125E-5 Series
8) To prevent the gasket sealant from pro- 3. Crankshaft

jecting through the clearance between the a Cylinder block and main bearing are
block and liner after the cylinder head is selective mating parts and the prepared
tightened, tighten the cylinder head tem- spare parts ensure the required clearance.
po r ar i l y wi t h t he u s e d h e ad g a s k e t 1) Install the upper main bearing (6) to the
inserted. notch of the cylinder block while aligning
a At this time, observe the following tight- the bearing projection to it.
ening torque and tightening order. a Before fitting the bearing, check that its
3 Temporary tightening torque: back side is free from foreign matter.
127.5 147.1 Nm {13 15 kgm} 2 Bearing inner surface:
Engine oil (EO30)
9) Remove the cylinder head and wipe off

the gasket sealant projected from the
counterbored part. 2) Drive in the roll pin so that its projection
a Be sure to perform steps 8) and 9) from the block end face may become 1.5
above since the projected gasket 1.9 mm and then install upper side thrust
sealant can deform the grommet of bearing (5).
the head gasket. a Install each thrust bearing with the
grooved surface on the crankshaft side.
10) Using dial gauge [3], measure the projec-
tion 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.
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
125E-5 Series 19
4) Lift and set crankshaft (4) to the mounting 6) Install main cap (1).
position. a When installing, make sure that the
a When installing the crankshaft, take stamped No. at center of the main
care not to damage its sliding sur- cap is aligned to the stamped journal
fac es by, for ins ta nce, bumpi ng No. of the cylinder block.
against the cylinder block. a Install the main cap with the cast let-
a When replacing the crank gear, heat it ter (F) toward the front of the engine.
with a bearing heater set at 150C 2 Crankshaft journal surface:
and then fit it immediately after the Engine oil (EO30)
heating.
2 Cylinder block journal:
Engine oil (EO30)
7) Before tightening the main cap mounting

bolts, check the following items. If a bolt is
out of the standard, do not reuse that bolt
but replace it.
5) Install lower main bearing (7) to the main q Number of tightening time of bolt
cap. (Number of punch marks on bolt
a Install lower main bearing (7) to the head): 5 or less
notch of the main cap while aligning q Using limit length (a) of bolt stem:
the bearing projection to it. Less than 159.8 mm
a Before fitting the bearing, check that its
back side is free from foreign matter.
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.
a Install each thrust bearing with the
8)
Screw in main cap mounting bolts (2)
al ter nately until the main c ap ( 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 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).

a Piston and cylinder liner are selective mat-
ing parts and the prepared spare parts
ensure the required clearance.
1) Using tool D, assemble piston ring (8) in
a When not using tool J, apply mark (b) the order of oil ring, second ring and top
to the main cap and bolt with paint, ring starting from the bottom.
then tighten the bolt by 90 (+30/0). a Fit the top ring and second ring to the
10) Make punch mark (c) on the mounting bolt piston with the stamped mark side up.
head. q Stamp on top ring: 1R
a When a new bolt is used, do not q Stamp on second ring: 2R
make a punch mark on its head. 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.
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
a If the end play is out of the standard, 2) Set the abutment joint of each piston ring
correct it. For details, see Structure, as shown in the following figure.
function and maintenance standard. a Adjust oil ring so that the joint of the
expander will be at 180 to the abut-
ment joint of the oil ring.
125E-5 Series 21
3) Install snap ring (4) to one side of piston (7). 7) Install upper main bearing (8) to the notch
4) Heat piston (7) at 100C for 5 minutes of the connecting rod while aligning the
minimum in the heating furnace. bearing projection to it.
a When the furnace is not available, a Before fitting the bearing, check that its
heat it at 100C for 5 minutes mini- back side is free from foreign matter.
mum in hot water. a Make sure that the bearing hole and
connecting rod oil hole are aligned.
5) Set connecting rod (5) on piston (7).

a Set the connecting rod so that the ID 8) Install the connecting rod lower bearing
marking "6251" at the bottom of the (9) to the notch of the connecting rod cap
connecting rod comes to the left side while aligning the bearing projection to it.
as the grade marking on the piston a Before fitting the bearing, check that its
top surface is faced toward the front back side is free from foreign matter.
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.
22 125E-5 Series
9) Set the cylinder crankshaft, to which the pis- 12) Install connecting rod cap (2).
ton and connecting rod assembly is to be a Align match mark of connecting rod
assembled, to the bottom dead center. ( 5) a nd co nnec ti ng ro d c ap ( 2) .
10) Insert piston and connecting rod assembly (Above aligns the match mark to ID
(3) in the cylinder block so that ID marking marking "6251" on the opposite side.)
"6251" of the connecting rod may be faced 2 Inner surface of connecting rod cap
toward the left side face of the engine. bearing: Engine oil (EO30)
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)
13) Before tightening the connecting rod cap

mounting bolts, check the following items.
If a bolt is out of the standard, do not
reuse that bolt but replace it.
q Number of tightening time of bolt
11) Using tool G, reduce the piston ring and (Number of punch marks on bolt
then push in the piston head with a wood head): 6 or less
bar, etc. q Using limit length (a) of bolt stem:
Less than 84.1 mm
125E-5 Series 23
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.
a When a new bolt is used, do not
make a punch mark on its head.

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.
17) Turn the crankshaft to check that it rotates cooling nozzles of the No. 2 and No. 5
normally. pistons can be installed.
18) Measure the side clearance of the con- q Set the No. 3 piston to top: Piston
necting rod with dial gauge [3]. cooling nozzles of the No. 3 and No. 4
a Side clearance: 0.2 0.375 mm piston can be installed.
2) Set piston cooling nozzle (2) adjusting the
dowel pin position and then tighten mount-
ing bolt (1).
3 Mounting bolt:
27 34 Nm {2.8 3.5 kgm}
24 125E-5 Series
a After the installation, make sure the

nozzle end is situated at center of the
cut of respective pistons.
6. Oil suction pipe

Install oil suction pipe (2) after attaching the O-
ring to it and then fix them using bracket (1).
8. Oil pump
1) Install oil pump (2) after attaching the O-
ring to it and then tighten 4 mounting bolts
(1).
2) Drive in the pin and then install shaft (4).
7. 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
9. Idler gear 11. Cam follower

Assemble oil pump idler gear (3), attach plate 1) Drive in dowel pin (3) to the cylinder block.
(2) to it and then tighten them using mounting 2) Tighten 6 cam followers (2) using mount-
bolt (1). ing bolt (1).
3 Mounting bolt: 3 Mounting bolt:
147 176.4 Nm {15 18 kgm} 44 59 Nm {4.5 6 kgm}
10. Camshaft 12. Cam follower cover

1) Assemble camshaft (2) to the cylinder 1) Install the O-ring and cam follower cover (4).
block. 3 Mounting bolt:
a Rotate the camshaft when assem- 9.8 12.7 Nm {1.0 1.3 kgm}
bling so that the cam bushing may not 2) Install brackets (3), oil tube (2) and oil
be damaged. level gauge (1).
a When replacing the cam gear, heat it
at 200 240C for 30 minutes mini-
mum 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,
13. Water pump assembly

Fit the O-ring to water pump assembly (3) and
install them.
26 125E-5 Series
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.
15. Fuel supply pump assembly

1) Set fuel supply pump assembly (3) and
then tighten it temporarily using 4 mount-
ing 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 align-
ing 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} 17. Measuring backlash and end play
4) Install bracket (6). a Measure the backlash and end play of
3 Mounting bolt (supply pump side): each gear with dial gauge [3].
19.6 29.4 Nm {2.0 3.0 kgm}
a Leave the cylinder block side mount- Standard backlash of each gear
ing bolt in temporarily tightened state Position Range (mm)
(it is to be tightened permanently in
a 0.105 0.325
the following Step 43).
b 0.105 0.325
c 0.116 0.359
d 0.105 0.337
e 0.082 0.389
f 0.076 0.366
Standard end play of each gear

Position Range (mm)
1 0.05 0.17
2 0.05 0.21
a If the end play is out of the standard, cor-

rect it. For details, see Structure, function
and maintenance standard.
125E-5 Series 27
3) Install cover (2).

4) Using dial gauge, measure the level differ-
ence between underside faces of the cyl-
inder block and front cover.
a Difference: 0 0.275 mm
a If the difference is out of the standard,
5) Install adjustment rod (3).
6) Install front support (4).
machines.

1) Apply a string of gasket sealant 1 mm in
18. Front cover
diameter as shown below.
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)
2) Sling flywheel housing (1) and then install

it to the cylinder block.
3) Tighten flywheel housing mounting bolts (2).
2) Lift front cover (1) and then install it using

the guide bolt.
a When installing, take care not to dam-
age the oil seal.
2 Front cover mounting surface:
Gasket sealant (LG-7)
28 125E-5 Series
imum on the flywheel housing includ-

ing the periphery.
a Move the crankshaft either in the front
or rear side in order to prevent errors
due to the end play.
a Make sure after rotating the crank-
shaft by a turn that the gauge pointer
is returned to the position where it
had been situated when the crank-
shaft was started to turn.
a The gauge pointer deflects in both
sides right and left. Thus, reason-
able care must be exercised to avoid
misreading of the pointer when the
gauge is provided in the top, bottom,
a Tighten the flywheel housing mount- left and right side of the measured
ing bolts in the following order in 2 end face.
steps. a Facial runout: Max. 0.20 mm
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}
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
4) After installing the flywheel housing, mea- remain applicable to the radial runout
sure its facial runout and radial runout with as they are.
dial gauge [3]. a Radial runout: Max. 0.20 mm
Measurement of facial runout of flywheel

housing
1] Apply the magnet stand to the crank-
shaft 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 maxi-
mum and minimum values indicated
by the gauge pointer.
a Measurement shall be conducted at
eight equally distanced positions min-
125E-5 Series 29
5) Using dial gauge [3], measure the level a Never remove inside plastic cylinder
difference between underside faces of the (3) of the standard spare seal before
cylinder block and flywheel housing. installing the seal.
a Difference: 0 0.35 mm 1) Set the large inside diameter side (b)
a If the difference is out of the standard, of plastic inside cylinder (3) to the end
correct it. For details, see Structure, of crankshaft (4).
function and maintenance standard. a Take care not to mistake the direc-
tion 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 fin-
ger 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) Hold the metal ring of seal (1) by both

hands and push it in firmly.
3) After pushing in the seal, remove
plastic inside cylinder (3).
a When removing the inside cylin-
der, 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 sur-
faces 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) 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.
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).
Procedure for installing sleeved seal

a Before installing the seal, make sure
that the end corners and lip sliding sur-
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
3) Remove tool N2 and then replace it
assembly and don't separate them
with tool N1.
from each other.
4) 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.
1) Set sleeve and seal assembly (2) to

tool N2.
2 Inside sleeve:
125E-5 Series 31
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.
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}
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
3) Using dial gauge [3], measure the facial
(Hydraulic sealant
and radial runout.
from Loctite)
a Facial runout : Max. 0.20 mm
2] Rotate speed sensor (2) in the oppo-
a Radial runout: Max. 0.15 mm
site 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}
32 125E-5 Series
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.
24. Damper and pulley assembly

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
27. Setting the engine 29. Installation of cylinder head assembly

Set engine (1) on a rigid and stable stands [1]. 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) Before tightening the cylinder head
(Number of punch marks on bolt
head): 6 or less
q Using limit length (a) of bolt stem:
Less than 171.4 mm
3) Assemble valve spring (3) and upper

sheet (5).
4) 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.
34 125E-5 Series
3) Using sling [1], lift and set cylinder head

assembly (2) to the cylinder block.
a When not using tool J, apply

marking (b) to the cylinder head
and bolt with paint, then tighten
4) Tighten the cylinder head assembly the bolt by 90 120 (Target:
mounting bolts and auxiliary bolts. 120).
1] Tighten the mounting bolts in the 2] Mark a punch mark (C) on its head to
order of 1 to 6 shown in the figure. show the number of tightening times.
2 Mounting bolt: a When a new bolt is used, do not
Molybdenum disulfide lubri- make a punch mark on its head.
cant (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).
3] 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 35
30. Rocker arm housing 32. Crosshead

1) Install gasket (1) and then install rocker 1) Set crosshead (1) and then loosen locknut
arm housing (2). (2) to return adjustment screw (3) to its
2) Tighten mounting bolts (3). original position.
3 Mounting bolt: 2) Using your finger, lightly hold down the
58.8 73.5 Nm {6 7.5 kgm} 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 cross-
head (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 4) Fit the ball washer to bolt (3) and tighten
a Check that the inside of the injector sleeve holder (2) temporarily.
is free from dirt. 2 Spherical part of washer:
1) Install common rail (9) temporarily. Engine oil (EO30)
5) Locate high-pressure sleeve (4) to inlet
connector (5) and then tighten them tem-
porarily.
a Tighten the common rail side sleeve
nut temporarily, too.
6) Tighten holder (2) with bolt (3) perma-
nently.
a Tighten bolt (3) while pulling the tube
of the high-pressure pipe in the oppo-
site direction of the injector.
58.8 73.5 Nm {6.0 7.5 kgm}
7) After tightening the holder, remove the
high-pressure sleeve (4) from the inlet
connector (5) and then install the other
2) Install gasket (6) and O-rings (7) and (8) to injectors in order according to the above
injector (1). procedure.
8) Remove the temporarily installed common
rail.
3) Insert holder (2) to injector (1). Continue

from that state, insert inlet connector (5) to 34. Push rod
the high-pressure pipe insertion hole Install push rod (1).
through the rocker housing. a Check that the push rod end is placed in
the cam follower socket.
125E-5 Series 37
35. Rocker arm and shaft assembly 37. Adjusting valve clearance
1) Set rocker arm and shaft assembly (1). a Adjust the clearance between the cross-
a When installing the rocker arm shaft, head and rocker arm to the following
be sure to set its side with a larger value.
mounting hole diameter to the bottom a Valve clearance (in cold state)
and to direct ball plug (6) side toward
Unit: mm
the front side of the engine.
2) Before tightening mounting bolts (4), Intake valve Exhaust valve
check that the ball of adjustment screw (2) 0.33 0.71
is fitted to socket (5) of the push rod.
a Install the mounting bolt after cleaning a Rotate the engine and adjust the valve
its oil hole. clearance of each cylinder in the firing
3 Mounting bolt: order of 1 5 3 6 2 4.
58.8 73.5 Nm {6.0 7.5 kgm} 1) 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.
36. Injector wiring harness

1) Tighten mounting bolts (3) of the harness
fixing holder.
3 Mounting bolt: 2) Insert clearance gauge l between rocker
27.0 34.0 Nm {2.8 3.5 kgm} arm (3) and crosshead (4) and screw in
2) Tighten 2 harness terminal mounting nuts adjustment screw (5) until the gauge
(2) to injector (1). becomes movable. Then tighten the lock-
a Tighten the nuts alternately. nut.
3 Mounting nut: 3 Locknut:
2.0 2.4 Nm {0.2 0.24 kgm} 58.8 73.5 Nm {6 7.5 kgm}
38 125E-5 Series
38. Head cover 41. Oil cooler assembly

Fit the O-ring and install head cover (1). 1) Fit the gasket to oil cooler assembly (4)
a Take care so that O-ring may not be twisted. and then install them using guide bolt [1].
3 Mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}
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
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 perma-
nently.
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 down-
ward 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
nently.
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 3) Install bracket (1).

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}
46. Diffuser and air housing assembly

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
45. Air intake manifold housing assembly (4) in order to eliminate
1) Fit the gasket and then install air intake clearance in (b) (between front hanger
manifold (2) temporarily. and air housing) and part (a) (between air
4 Air intake manifold: 25 kg housing and diffuser). Then tighten every
bolt.
2) Tighten the mounting bolts in the order of

4) Install brackets (5), (6), (7) and (8).
given below.
5) Install oil filler port (9).
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
125E-5 Series 41
47. EGR valve 4) Install clamps (2) and (1).

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 interfer-
ence.
3 Sleeve nut:
24 27 Nm {2.4 2.7 kgm}
4) Tighten clamp (4).
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 interfer-
ence.
3 Sleeve nut:
24 27 Nm {2.4 2.7 kgm}
50. High-pressure pipe
3) Install drain tubes (5) and (4).
a Before installing the high-pressure pipe,
a Make sure when installing the tubes
check it for the following defects. If there is
that they are free from twist or inter-
any of these defects, it can cause fuel
ference.
3 Joint bolt:
leakage. Accordingly, replace the high-
pressure pipe.
24.5 34.3 Nm {2.5 3.5 kgm}
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.
42 125E-5 Series
1) Install high-pressure pipes (3), (4), (5), (6), 5) Install bracket (17).
(7) and (8). 3 Clamp tightening torque:
a Mounting angle of the high-pressure 11.8 14.7 Nm {1.2 1.5 kgm}
injection pipe is adjusted before the 6) Tighten clamps (11), (12), (13), and (14)
installation of the injector. permanently.
3 Sleeve nut (on both sides): 3 Mounting bolt:
39.2 49 Nm {4 5 kgm} 11.8 14.7 Nm {1.2 1.5 kgm}
2) Tighten bracket (9) and clamp (10) by
nently.
3 Mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
3) Install clamps (11), (12), (13) and (14) by
tightening them by hand.
4) Install 6 each of the splash prevention
covers (15) and (16).
Direct the slit on the injector side down-
ward and that on the common rail side
toward the cylinder block.
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
52. Fuel tube 54. Oil filter and oil tube

Install fuel tubes (1) and (2) and clamp (3) tem- 1) Install oil filter (2) temporarily with the 4
porarily. bolts.
a Tighten them permanently after installing 2) Install the O-ring and then install oil tube
the fuel filter. (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 per-
manently.
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)): 55. Turbocharger and exhaust manifold assem-
24.5 34.3 Nm {2.5 3.5 kgm} bly
1) Lift turbocharger and exhaust manifold
assembly (1), fit the gasket to the assem-
bly and then install them temporarily.
4 Turbocharger and manifold assem-
bly: 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}
44 125E-5 Series
3) Fit the gasket and then connect lubrication

tube (2).
4) Fit the gasket and then connect EGR
bypass tube (1).
4) Install air vent tube (4).

5) Fit the gasket and O-ring, and then install
coolant tube (3).
6) Fit the gasket and install exhaust gas dis-
56. EGR tube charge tube (2).
1) Fit the gasket, adjust its angle to the EGR 3 Mounting bolt:
valve and then install EGR tube (5) tem- 59 74 Nm {6.0 7.5 kgm}
porarily. 7) Fit the gasket and install drain tube (1).
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).
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
59. Alternator 63. Tightening torque for sensor

1) Hang V-belt on the pulley of alternator (5) Use the following tightening torque when
and tighten mounting bolt (2) and lock bolt removal and installation or replacement of the
(3) temporarily. sensor.
2) Adjust the belt tension with V-belt tension
Sensor name Tightening torque
adjustment nut and tighten mounting bolt
(2) and lock bolt (3). Fuel
23 3 Nm {2.35 0.3 kgm}
3) Check the belt tension and then tighten temperature
locknut (4). Boost pressure 5.5 0.5 Nm {0.56 0.05 kgm}
4) Install cover (1). Intake air
23 3 Nm {2.35 0.3 kgm}
temperature
Coolant
23 3 Nm {2.35 0.3 kgm}
temperature
EGR gas
23 3 Nm {2.35 0.3 kgm}
pressure
Engine oil
23 3 Nm {2.35 0.3 kgm}
pressure
4.5 0.5 Nm {0.46 0.05 kgm}
Atmospheric
(Hexagonal head bolt and hexago-
pressure
nal socket head bolt)
Fuel pressure Never disassemble.
64. Checking for fuel leakage

60. Starting motor a If fuel supply pump (2), common rail (1), or
Set starting motor (2) and then tighten 3 h i gh - p r es s u r e p ip e i s r em o v ed a n d
mounting bolts (1). installed, after assembling the engine,
check for fuel leakage according to the fol-
lowing procedure.
61. Heat shielding plate

Install the heat shielding plate to EGR and
EGR pipe. a Clean and degrease the engine and the
parts around it in advance so that you can
62. Harness assembly test it easily for fuel leakage.
Locate the harness in the specified position, 1) Spray color checker (developer) over the
connect the harness connectors to the speci- fuel supply pump, common rail, fuel injec-
fied counterparts and then fix them using the tor, and joints of the high-pressure piping.
clamp. 2) Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
46 125E-5 Series
3) Check the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pres-
sure 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).
4) Run the engine at low idle.
leakage.
6) Run the engine at high idle.
leakage.
8) Run the engine at high idle and load it.
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
SEN00698-01
2007 KOMATSU
All Rights Reserved
48
SEN00699-01
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 1
Disassembly and assembly, Part 2 (EGR-less) 1

General disassembly of engine 1 4. Wiring harness assembly
Disconnect the connectors and clamps and
a The shapes, quantity, locations, etc. of the remove wiring harness assembly (1).
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 assem-
bly.
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 5. Starting motor assembly
[1] so that it will not tip over. Remove 3 mounting bolts (1) and starting
a The weight depends on each applica- motor assembly (2).
ble machine.
4 Engine assembly: 1,250 kg
2) 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. Muffler, air cleaner and related parts

a These parts depend on each applicable
machine.
Remove the muffler, air cleaner and related

parts.
2 125E-5 Series
6. Alternator assembly
1) Remove cover (1).
2) Loosen alternator mounting bolt (2) and
fixing bolt (3).
3) Remove nut (4), loosen the locknut, lower
the belt tension with the tension adjust-
ment 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 Exhaust manifold assembly: 35 kg

Remove tube (1).
10. Thermostat housing assembly

1) Remove connector (1).
2) Remove thermostat housing assembly (2).
8. Turbocharger assembly
1) Remove bracket (1).
2) Remove the 5 clamps and turbocharger
lubricating oil inlet tube (2).
3) Remove the tube bracket and turbo-
charger outlet tube (3).
4) Remove 4 mounting bolts (4) and turbo-
charger assembly (5).
125E-5 Series 3
11. Water pump assembly 14. Fuel filters

1) Remove connector (1). 1) Remove cover (1).
2) Remove 3 mounting bolts (2) and water 2) Remove the joint bolt and tubes (2) and
pump assembly (3). (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).
12. Oil cooler assembly

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).
4 125E-5 Series
16. Engine controller cooler assembly and 18. Bracket

block 1) Remove wiring harness (1).
1) Remove the 5 mounting bolts and engine 2) Remove brackets (2) and (3).
controller cooler assembly (1).
2) Remove the joint bolt and tubes (2) and
(3).
3) Remove block (4).
19. Air connector, electrical intake air heater

and front hanger
1) Remove the 6 mounting bolts, air connec-
tor (1) and electrical intake air heater (2).
17. Electric priming pump and block 2) Remove plates (3) and (4).
1) Disconnect wiring harness connector (1). 3) Remove front hanger (5).
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).
20. Diffuser air housing assembly

Remove the 8 mounting bolts and lift off dif-
fuser and air housing assembly (1).
4 Diffuser and air housing assembly: 40 kg
125E-5 Series 5
21. Bracket 23. High-pressure pipe

1) Remove the 2 mounting bolts and bracket 1) Remove high-pressure pipe clamp mount-
(1). ing bolt (1).
2) Remove the 4 mounting bolts and bracket 2) Remove the 2 mounting bolts and bracket
(2). (2).
22. Spill pipe 3) Remove high-pressure pipe clamp (3).

Remove 6 joint bolts (1) and spill pipe (2). 4) Remove 10 high-pressure pipe clamps
(4).
5) Remove 6 brackets (5).
6) Remove the pin, 6 splash prevention cov-
ers (6) on the injector side and 6 splash
prevention covers (7) on the common rail
side.
7) Remove 6 high-pressure pipes (8).
6 125E-5 Series
24. Air intake manifold 26. Fuel supply pump assembly

Sling air intake manifold (1), remove the 24 1) Remove cover (1).
mounting bolts, and remove the air intake man- 2) Rotate the crankshaft forward and set
ifold. intermediate point (a) between stamped
4
2/5 TOP and 3/4 TOP on damper (2) to
Air intake manifold: 40 kg
pointer (3) (stamped 1/6 TOP comes
almost directly under).
a Make sure at this point that the forc-
ing 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.
25. Common rail

1) Remove the pin, 2 splash prevention cov-
ers (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). 3) Remove mounting nut (4) and then remove
4) Remove common rail (10). washer (5).
5) Remove the 4 mounting bolts and bracket a Use a magnet or the like in this opera-
(11). tion so that washer (5) may not be
inadvertently dropped into the case.
125E-5 Series 7
4) Remove pump mounting bolts (6) and 28. Injector wiring harness
bracket (7). 1) Fully loosen 2 wiring harness terminal
a Leave bolts (6) tightened by 2 3 mounting nuts (2) on the head of injector
threads to prevent the pump from fall- (1).
ing down. a Loosen nuts alternately.
5) Install tool P1 with P2 and P3 and then 2) Loosen bolt (3) of harness fixing holder.
screw in the center bolt of P1 to remove
the gear from the shaft.
6) Remove remaining bolts and then remove
fuel supply pump assembly (8).
a Leave tools P1, P2 and P3 in the
installed condition.
29. Rocker arm and shaft assembly

1) Loosen locknut (3) and adjustment screw
(2).
2) Remove mounting bolts (4) and rocker
arm and shaft assembly (1).
30. Push rods

27. Tube and head cover
Remove 12 push rods (1).
1) Remove 6 joint bolts (1) and tube (2).
2) Remove the mounting bolts and head cov-
ers (3).
8 125E-5 Series
31. Injector 3) Press out wiring harness connector (1)

Remove holder mounting bolts (3) of injector from inside of rocker housing (4) to
(1) and then remove injector (1) and holder (2) remove it.
together. 4) Remove O-ring (5) from the rocker hous-
a Never hold the solenoid valve at the top of ing.
the injector with pliers, etc.
34. Rocker arm housing

32. Crosshead Remove rocker arm housing (1).
Remove 12 crossheads (1).
35. Cam follower cover

33. Injector wiring harness 1) Remove 3 cam follower covers (1).
1) Remove mounting bolt (2) of wiring har- 2) Remove oil level gauge tube (2).
ness connector (1).
2) Remove holder (3) from the wiring har-
ness.
125E-5 Series 9
36. Cam follower 38. Disassembly of cylinder head assembly

Remove 12 mounting bolts (1) and 6 cam fol- 1) Using tool C, compress valve spring (3)
lowers (2). and remove valve cotter (4).
a Remove dowel pin (3). 2) Remove upper seat (5) and valve spring
(3).
37. Removal of cylinder head assembly

1) Remove 7 mounting bolts (2) each from 3) Remove seal (7) and lower seat (8).
cylinder head assembly (1). 4) Raise the cylinder head and remove valve
2) Using eyebolts [1], lift off cylinder head (6).
assembly (1). a Make marks for combinations of the
4 Cylinder head assembly: 20 kg valves and heads.
3) 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 43. Flywheel housing

Reverse the engine and remove oil pan (1). 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.
41. Speed sensors

Reverse the engine and remove speed sen-
sors (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 Flywheel: 25 kg
125E-5 Series 11
45. Front support and front cover 47. Oil pump

1) Sling front support (1), remove the mount- Remove 4 mounting bolts (1) and then remove
ing bolts, and lift off the front support. oil pump (2).
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.
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 51. Piston and connecting rod assembly
Remove brackets (1) and then remove oil suc- a Before removing the piston and connect-
tion pipe (2). ing rod assembly, measure its end play
with dial gauge [3], if necessary.

Remove mounting bolt (1) and each piston 1) Check the stamped No. of the connecting
cooling nozzle (2). 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.
2) Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
3) Scrub the carbon off the top wall of the cyl-
inder liner with fine sandpaper.
4) Remove connecting rod cap mounting
bolts (1).
5) 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.
125E-5 Series 13
6) Push in and remove the piston and con- 3] Using tool D, remove piston ring (8).
necting rod assembly with a wood bar, etc. a Keep the piston, connecting rod,
from the oil pan side, while supporting pis- connecting rod bearing, piston
ton (3) on the cylinder head side. rings, and piston pin by each cyl-
a Take care not to damage the inside of inder.
the cylinder with a corner of the con-
necting rod.
7) 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.
52. Crankshaft
a Before removing the crankshaft, measure its
end play with dial gauge [3], if necessary.
8) 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
1) Remove mounting bolts (2) of main cap (1).
piston (7) and connecting rod.
2) Insert the bolts in the bolt holes of the
main cap and remove the cap, while shak-
ing it.
14 125E-5 Series
a Thrust bearing (3) is assembled to 5) Remove upper bearing (6).

No. 7 main cap. After removing the a Apply a marking to the assembly
cap, apply a marking to the re-assem- positions of the main cap, main bear-
bly position. ing, and thrust bearing. And store
them by the journal No.
3) Lift off crankshaft (4).

a When removing the crankshaft, take
53. Cylinder liner
care so that its sliding surfaces may
Using tool E, pull out cylinder (1).
not be damaged.
a Before removing the cylinder liner, mea-
sure its projection with dial gauge [3], if
necessary.
4) Remove upper thrust bearing (5).
125E-5 Series 15
General assembly of engine 1 2] Polish part (R) with sandpaper of

about No. 240 until it becomes a
a The shapes, quantity, locations, etc. of the smooth rounded surface.
parts depend on each applicable machine. If part (R) is sharp or has burrs, finish
Take care. it with a scraper or sandpaper.
a Clean each part carefully, and check it for Finish this surface particularly smoothly
bruise, flaw, cavity, etc. Make sure each oil or so that it will not damage the O-ring.
coolant path is through. 3] If face (B) is so pitted that it cannot be
repaired, replace the cylinder block.
Tightening bolts by plastic-region turning angle 4] If faces (A) and (R) are pitted, finish
method them smoothly.
a Bolts tightened by plastic-region turning angle 5] Check the counterbored part and
method remove burrs. If chips or dust is
q Cylinder head mounting bolt present on face (C), the liner may not
q Main cap mounting bolt fit well, resulting in coolant leakage or
q Connecting rod cap mounting bolt insufficient liner protrusion. Thus,
a If the plastic-region turning angle method is they must be eliminated.
applied, the tightened bolts have permanent a If the counterbored part is droop-
strain. Accordingly, the allowable number of ing, corroded, or pitted, repair it.
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. 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),
2) Before inserting the cylinder liners, pre- refer to the following.
pare the cylinder block according to the q O-ring (2): The whole ring is black.
following procedure. q O-ring (3): The whole ring is red.
1] Remove the rust and scales from faces 2 Clevis seal and O-ring:
(A) and (B) with sandpaper, etc. until Rubber lubricant (LH-50 from NOF
the machined surfaces are exposed. Corporation)
16 125E-5 Series
a If LH-50 is not available, apply clean 4) Apply gasket sealant to the parts of the
engine oil SAE No. 30. cylinder block and cylinder liner which will
a Since the clevis seal and O-ring are fit to the counterboared parts.
swollen and deteriorated by oil, apply a Wipe off dirt and oil with cloth from
a small amount of oil to them thinly the contact faces of the counter-
with a brush just before fitting them. boared 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 dam-
age the O-ring.
6) Push in cylinder liner (1) further by both
3) After fitting the O-ring, check it for twist. If hands.
it is twisted, correct it with a flexible rod a If the liner does not enter the cylinder
(about 10 mm in diameter). smoothly, the O-ring may be dam-
aged. In this case, check the cylinder
block for burrs.
7) Using tool F, press fit cylinder liner (1) to
the cylinder block.
125E-5 Series 17
8) To prevent the gasket sealant from pro- 3. Crankshaft

jecting through the clearance between the a Cylinder block and main bearing are
block and liner after the cylinder head is selective mating parts and the prepared
tightened, tighten the cylinder head tem- spare parts ensure the required clearance.
p or ar i l y wi t h t he u s e d h e ad g a s k e t 1) Install the upper main bearing (6) to the
inserted. notch of the cylinder block while aligning
a At this time, observe the following tight- the bearing projection to it.
ening torque and tightening order. a Before fitting the bearing, check that its
3 Temporary tightening torque: back side is free from foreign matter.
127.5 147.1 Nm {13 15 kgm} 2 Bearing inner surface:
Engine oil (EO30)
9) Remove the cylinder head and wipe off

the gasket sealant projected from the
counterbored part. 2) Drive in the roll pin so that its projection
a Be sure to perform steps 8) and 9) from the block end face may become 1.5
above since the projected gasket 1.9 mm and then install upper side thrust
sealant can deform the grommet of bearing (5).
the head gasket. a Install each thrust bearing with the
10) Using dial gauge [3], measure the projec-
tion 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,
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
18 125E-5 Series
4) Lift and set crankshaft (4) to the mounting 6) Install main cap (1).
position. a When installing, make sure that the
a When installing the crankshaft, take stamped No. at center of the main
care not to damage its sliding sur- cap is aligned to the stamped journal
fac es by, for ins ta nce, bumpi ng No. of the cylinder block.
against the cylinder block. a Install the main cap with the cast let-
a When replacing the crank gear, heat it ter (F) toward the front of the engine.
with a bearing heater set at 150C 2 Crankshaft journal surface:
and then fit it immediately after the Engine oil (EO30)
heating.
2 Cylinder block journal:
Engine oil (EO30)
7) Before tightening the main cap mounting

bolts, check the following items. If a bolt is
out of the standard, do not reuse that bolt
but replace it.
5) Install lower main bearing (7) to the main q Number of tightening time of bolt
cap. (Number of punch marks on bolt
a Install lower main bearing (7) to the head): 5 or less
notch of the main cap while aligning q Using limit length (a) of bolt stem:
the bearing projection to it. Less than 159.8 mm
a Before fitting the bearing, check that its
back side is free from foreign matter.
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.
a Install each thrust bearing with the
8)
Screw in main cap mounting bolts (2)
al ter nately until the main c ap ( 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)
125E-5 Series 19
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).

a Piston and cylinder liner are selective mat-
ing parts and the prepared spare parts
ensure the required clearance.
1) Using tool D, assemble piston ring (8) in
a When not using tool J, apply mark (b) the order of oil ring, second ring and top
to the main cap and bolt with paint, ring starting from the bottom.
then tighten the bolt by 90 (+30/0). a Fit the top ring and second ring to the
10) Make punch mark (c) on the mounting bolt piston with the stamped mark side up.
head. q Stamp on top ring: 1R
a When a new bolt is used, do not q Stamp on second ring: 2R
make a punch mark on its head. 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.
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
a If the end play is out of the standard, 2) Set the abutment joint of each piston ring
correct it. For details, see Structure, as shown in the following figure.
function and maintenance standard. a Adjust oil ring so that the joint of the
expander will be at 180 to the abut-
ment joint of the oil ring.
20 125E-5 Series
3) Install snap ring (4) to one side of piston (7). 7) Install upper main bearing (8) to the notch
4) Heat piston (7) at 100C for 5 minutes of the connecting rod while aligning the
minimum in the heating furnace. bearing projection to it.
a When the furnace is not available, a Before fitting the bearing, check that its
heat it at 100C for 5 minutes mini- back side is free from foreign matter.
mum in hot water. a Make sure that the bearing hole and
connecting rod oil hole are aligned.
5) Set connecting rod (5) on piston (7).

a Set the connecting rod so that the ID 8) Install the connecting rod lower bearing
marking "6251" at the bottom of the (9) to the notch of the connecting rod cap
connecting rod comes to the left side while aligning the bearing projection to it.
as the grade marking on the piston a Before fitting the bearing, check that its
top surface is faced toward the front back side is free from foreign matter.
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.
125E-5 Series 21
9) Set the cylinder crankshaft, to which the pis- 12) Install connecting rod cap (2).
ton and connecting rod assembly is to be a Align match mark of connecting rod
assembled, to the bottom dead center. ( 5) a nd co nnec t i ng ro d c ap ( 2) .
10) Insert piston and connecting rod assembly (Above aligns the match mark to ID
(3) in the cylinder block so that ID marking marking "6251" on the opposite side.)
"6251" of the connecting rod may be faced 2 Inner surface of connecting rod cap
toward the left side face of the engine. bearing: Engine oil (EO30)
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)
13) Before tightening the connecting rod cap

11) Using tool G, reduce the piston ring and (Number of punch marks on bolt
then push in the piston head with a wood head): 6 or less
bar, etc. q Using limit length (a) of bolt stem:
Less than 84.1 mm
22 125E-5 Series

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.
a When a new bolt is used, do not
make a punch mark on its head.

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.
cooling nozzles of the No. 1 and No. 6
pistons can be installed.
17) Turn the crankshaft to check that it rotates cooling nozzles of the No. 2 and No. 5
normally. pistons can be installed.
18) Measure the side clearance of the con- q Set the No. 3 piston to top: Piston
necting rod with dial gauge [3]. cooling nozzles of the No. 3 and No. 4
a Side clearance: 0.2 0.375 mm piston can be installed.
2) Set piston cooling nozzle (2) adjusting the
dowel pin position and then tighten mount-
ing bolt (1).
3 Mounting bolt:
27 34 Nm {2.8 3.5 kgm}
125E-5 Series 23
a After the installation, make sure the

nozzle end is situated at center of the
cut of respective pistons.
6. Oil suction pipe

Install oil suction pipe (2) after attaching the O-
ring to it and then fix them using bracket (1).
8. Oil pump
1) Install oil pump (2) after attaching the O-
ring to it and then tighten 4 mounting bolts
(1).
2) Drive in the pin and then install shaft (4).
7. 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}
24 125E-5 Series
9. Idler gear 11. Cam follower

Assemble oil pump idler gear (3), attach plate 1) Drive in dowel ring (3) to the cylinder block.
(2) to it and then tighten them using mounting 2) Tighten 6 cam followers (2) using mount-
bolt (1). ing bolt (1).
3 Mounting bolt: 3 Mounting bolt:
147 176.4 Nm {15 18 kgm} 44 59 Nm {4.5 6 kgm}
10. Camshaft 12. Cam follower cover

1) Assemble camshaft (2) to the cylinder Install the O-ring and cam follower cover (1).
block. 3 Mounting bolt:
a Rotate the camshaft when assem- 9.8 12.7 Nm {1.0 1.3 kgm}
bling so that the cam bushing may not
be damaged.
a When replacing the cam gear, heat it
at 200 240C for 30 minutes mini-
mum 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,

Fit the O-ring to water pump assembly (3) and
install them temporarily.
125E-5 Series 25
14. Fuel supply pump assembly 15. Make sure that match marks (A to C) of drive
1) Set fuel supply pump assembly (3) and gears and idler gears are matched.
then tighten it temporarily using 4 mount-
ing bolts (5).
2 Mounting bolt: Adhesive (LT-2)
2) Set the assembly by aligning C mark to
C mark of camshaft gear (2) while align-
ing 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).
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} 16. Measuring backlash and end play
a Leave the cylinder block side mount- a Measure the backlash and end play of
ing bolt in temporarily tightened state each gear with dial gauge [3].
(it is to be tightened permanently in
the following Step 39.). Standard backlash of each gear
Position Range (mm)
a 0.105 0.325
b 0.105 0.325
c 0.116 0.359
d 0.105 0.337
e 0.082 0.389
f 0.076 0.366
Standard end play of each gear

Position Range (mm)
1 0.05 0.17
2 0.05 0.21
a If the end play is out of the standard, cor-

rect it. For details, see Structure, function
and maintenance standard.
26 125E-5 Series
2) Lift front cover (2) and then install it using

the guide bolt.
a When installing, take care not to dam-
age the oil seal.
2 Front cover mounting surface:
4) Using dial gauge, measure the level differ-
ence between underside faces of the cyl-
inder block and front cover.
a Difference: 0 0.275 mm
a If the difference is out of the standard,
5) Install front support (1).
machines.
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) Sling flywheel housing (1) and then install

it to the cylinder block.
3) Tighten flywheel housing mounting bolts (2).
125E-5 Series 27
imum on the flywheel housing includ-

ing the periphery.
a Move the crankshaft either in the front
or rear side in order to prevent errors
due to the end play.
a Make sure after rotating the crank-
shaft by a turn that the gauge pointer
is returned to the position where it
had been situated when the crank-
shaft was started to turn.
a The gauge pointer deflects in both
sides right and left. Thus, reason-
able care must be exercised to avoid
misreading of the pointer when the
a Tighten the flywheel housing mount- gauge is provided in the top, bottom,
ing bolts in the following order in 2 left and right side of the measured
steps. end face.
a The following indicates that mounting a Facial runout: Max. 0.20 mm
bolts 1, 4 and 2, 9 are to be tightened
twice in 1st time.
3 Mounting bolt:
1st time:
147 235 Nm {15 24 kgm}
2nd time:
245 309 Nm {25 31.5 kgm}
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
4) After installing the flywheel housing, mea- occur. As for other points, however, the
sure its facial runout and radial runout with precautions noted for the facial runout
dial gauge [3]. remain applicable to the radial runout
as they are.
Measurement of facial runout of flywheel a Radial runout: Max. 0.20 mm
housing
1] Apply the magnet stand to the crank-
shaft 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 maxi-
mum 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 a Never remove inside plastic cylinder
difference between underside faces of the (3) of the standard spare seal before
cylinder block and flywheel housing. installing the seal.
a Difference: 0 0.35 mm 1) Set the large inside diameter side (b)
a If the difference is out of the standard, of plastic inside cylinder (3) to the end
correct it. For details, see Structure, of crankshaft (4).
function and maintenance standard. a Take care not to mistake the direc-
tion 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 fin-
ger 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.

hands and push it in firmly.
3) After pushing in the seal, remove
plastic inside cylinder (3).
a When removing the inside cylin-
der, take care not to damage the
seal lip.

a Before installing the seal, check that
the end corners and lip sliding sur-
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

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).
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).

a Before installing the seal, make sure
that the end corners and lip sliding sur-
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.
3) Remove tool N2 and then replace it
a Handle the seal and sleeve as an
with tool N1.
assembly and don't separate them
4) Tighten bolt N4 evenly to press fit
from each other.
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.
1) Set sleeve and seal assembly (2) to

tool N2.
2 Inside sleeve:
30 125E-5 Series
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.
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}
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).
3) Using dial gauge [3], measure the facial 2 Threads:Gasket sealant
and radial runout. (Hydraulic sealant
a Facial runout : Max. 0.20 mm from Loctite)
a Radial runout: Max. 0.15 mm 2] Rotate speed sensor (2) in the oppo-
site 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 31
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 27. Installation of cylinder head assembly
1) Assemble valve (6). 1) Check that the cylinder head mounting
2 Valve stem: Engine oil (EO30) face and inside of the cylinder are free
2) Raise the cylinder head and then install from foreign matter and then set cylinder
lower seat (8) and seal (7). head gasket (1).
a When fitting the gasket, check that
the grommets are fitted correctly.
3) Assemble valve spring (3) and upper

sheet (5).
4) Using tool C, compress the valve spring
2) Before tightening the cylinder head
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.
(Number of punch marks on bolt
head): 6 or less
q Using limit length (a) of bolt stem:
Less than 171.4 mm
125E-5 Series 33
3) Using sling [1], lift and set cylinder head

assembly (2) to the cylinder block.
a When not using tool J, apply

marking (b) to the cylinder head
and bolt with paint, then tighten
4) Tighten the cylinder head assembly the bolt by 90 120 (Target:
mounting bolts and auxiliary bolts. 120).
1] Tighten the mounting bolts in the 2] Mark a punch mark (C) on its head to
order of 1 to 6 shown in the figure. show the number of tightening times.
2 Mounting bolt: a When a new bolt is used, do not
Molybdenum disulfide lubri- make a punch mark on its head.
cant (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).
3] Tighten the auxiliary cylinder head

bolt (following figure 7).
3 Auxiliary bolt:
66.2 7.4 Nm {6.75 0.75 kgm}
34 125E-5 Series
28. Rocker arm housing 30. Crosshead

1) Install gasket (1) and then install rocker 1) Set crosshead (1) and then loosen locknut
arm housing (2). (2) to return adjustment screw (3) to its
2) Tighten mounting bolts (3). original position.
3 Mounting bolt: 2) Using your finger, lightly hold down the
58.8 73.5 Nm {6 7.5 kgm} 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 cross-
head (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}
29. Injector harness connector

1) Install O-ring (4) to harness connector (1).
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
31. Injector 4) Fit the ball washer to bolt (3) and tighten
a Check that the inside of the injector sleeve holder (2) temporarily.
is free from dirt. 2 Spherical part of washer:
1) Fit bracket (5) and install common rail (6) Engine oil (EO30)
temporarily. 5) Locate high-pressure sleeve (4) to inlet
connector (5) and then tighten them tem-
porarily.
a Tighten the common rail side sleeve
nut temporarily, too.
6) Tighten holder (2) with bolt (3) perma-
nently.
a Tighten bolt (3) while pulling the tube
of the high-pressure pipe in the oppo-
site direction of the injector.
58.8 73.5 Nm {6.0 7.5 kgm}
7) After tightening the holder, remove the
high-pressure sleeve (4) from the inlet
connector (5) and then install the other
2) Install gasket (6) and O-rings (7) and (8) to injectors in order according to the above
injector (1). procedure.
2 O-ring: Engine oil (EO30) 8) Remove the temporarily installed common
rail.
3) Insert holder (2) to injector (1). Continue

from that state, insert inlet connector (5) to 32. Push rod
the high-pressure pipe insertion hole Install push rod (1).
through the rocker housing. a Check that the push rod end is placed in
the cam follower socket.
36 125E-5 Series
33. Rocker arm and shaft assembly 35. Adjusting valve clearance
1) Set rocker arm and shaft assembly (1). a Adjust the clearance between the cross-
a When installing the rocker arm shaft, head and rocker arm to the following
be sure to set its side with a larger value.
mounting hole diameter to the bottom a Valve clearance (in cold state)
and to direct ball plug (6) side toward
Unit: mm
the front side of the engine.
2) Before tightening mounting bolts (4), Intake valve Exhaust valve
check that the ball of adjustment screw (2) 0.33 0.71
is fitted to socket (5) of the push rod.
a Install the mounting bolt after cleaning a Rotate the engine and adjust the valve
its oil hole. clearance of each cylinder in the firing
3 Mounting bolt: order of 1 5 3 6 2 4.
58.8 73.5 Nm {6.0 7.5 kgm} 1) 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.
34. Injector harness

1) Tighten mounting bolts (3) of the harness
fixing holder.
3 Mounting bolt:
2) Insert clearance gauge l between rocker
27.0 34.0 Nm {2.8 3.5 kgm} arm (3) and crosshead (4) and screw in
adjustment screw (5) until the gauge
2) Tighten 2 harness capture nuts (2) to
becomes movable. Then tighten the lock-
injector (1).
nut.
3 Locknut:
a Tighten the nuts alternately.
3 Mounting nut:
58.8 73.5 Nm {6 7.5 kgm}
2.0 2.4 Nm {0.2 0.24 kgm}
125E-5 Series 37
36. Head cover and tube 38. Common rail

1) Fit the O-ring and install head cover (3). Install common rail (5).
a Install the O-ring without twisting it. 3 Mounting bolt:
3 Mounting bolt: 59 74 Nm {6 7.5 kgm}
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}
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
39. Installation of high-pressure pipes between

fuel supply pump and common rail
1) Tighten high-pressure pipes (3) and (4) by
nently.
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 down-
ward 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
nently.
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
40. Air intake manifold 41. High-pressure pipes

1) Fit the gasket and install air intake mani- a Before installing each high-pressure pipe,
fold (1) temporarily. check it for the following defects. If there is
4 Air intake manifold: 40 kg 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.
2) Tighten the mounting bolts in the numeric

order shown below.
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}
1) Install 6 high-pressure pipes (8).

a The installed angle of the high-pres-
sure pipes was set when the injectors
were installed.
3 Sleeve nut (for both sides):
39.2 49 Nm {4 5 kgm}
2) Tighten 6 brackets (5) and 10 high-pres-
sure 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}
3) 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.
4) Set high-pressure pipe clamp (3) to the
high-pressure pipes.
40 125E-5 Series
5) Install bracket (2) and tighten the 2 mount- 44. Diffuser and air housing assembly
ing bolts. Fit the gasket and install diffuser and air hous-
6) Tighten 7 high-pressure pipe clamp ing assembly temporarily.
mounting bolts (1). 4 Diffuser and air housing assembly: 40 kg
a Fix the front hanger first and then tighten
11.8 14.7 Nm {1.2 1.5 kgm}
the mounting bolts permanently.
42. Spill pipe

45. Front hanger, electrical intake air heater
Fit the gasket to both ends of spill pipe (2),
and air connector
install them, and tighten joint bolt (1).
3 Joint bolt:
1) Fit the gasket and install front hanger (5).
2) Install plates (4) and (3) and tighten 6 dif-
9.8 12.7 Nm {1.0 1.3 kgm}
fuser 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
46. Brackets
2) Install wiring harness (1).
48. Overflow tube, spill tube and engine con-

troller cooler assembly
1) Install block (4).
47. Electric priming pump and block 2) Install tube (3).
1) Install block (7). 3 Joint bolts:
2) Install electric priming pump (6) and (Block side):
bracket together. 24.5 34.3 Nm {2.5 3.5 kgm}
3) Install the tube and hose according to the (Cylinder head side):
following procedure. 9.8 12.7 Nm {1.0 1.3 kgm}
1] Install hose (3) and tube (4) tempo- 3) Install tube (2) temporarily.
rarily. 4) Install engine controller cooler assembly
2] Install tube (5) temporarily. (1).
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 49. Brackets
(Block side): Install brackets (1), (2), (3), (4), (5), (6) and (7).
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 125E-5 Series
50. Fuel filters 52. Oil cooler assembly

1) Install fuel filters (9) and (10). Fit the gasket to oil cooler assembly (1) and
2) Install tubes (7) and (8) and clamp (6). install them by using the guide bolts.
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}
1) Fit the O-ring, install water pump assem-
bly (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 tempo-
rarily.
2) Fit the O-ring and install oil tubes (2) and
(3).
54. Thermostat housing assembly
3) Tighten the lower flanges of oil tubes (2)
1) Fit the gasket and install thermostat hous-
and (3) permanently and then tighten the
ing assembly (2).
upper flanges permanently.
2) Fit the gasket and install connector (1).
4) Tighten the 4 mounting bolts of oil filter (4)
permanently.
5) Install clamp (1).
125E-5 Series 43
55. Exhaust manifold assembly 56. Turbocharger assembly

1) Sling exhaust manifold assembly (1), fit 1) Fit the gasket, install turbocharger assem-
the gasket, and tighten mounting bolts (2) bly (6), and tighten mounting bolts (5).
temporarily 3 Mounting bolt:
4
44.1 49 Nm {4.5 5.0 kgm}
Exhaust manifold assembly: 35 kg
2) Fit the gasket and install turbocharger out-
let 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}
2) 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}

Fit the gasket and install suction tube (1).
44 125E-5 Series
58. Alternator assembly 60. Wiring harness assembly

1) Install bracket (8) and plate (7). Install wiring harness assembly (1), connect
2) Install V-belt (5) to the pulley of alternator each connector, and install each clamp.
assembly (6) and secure the alternator
assembly with mounting bolt (2) and fixing
bolt (3).
3) Adjust the belt tension with the V-belt ten-
sion 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 pul-
ley.
3 Mounting bolt (2):
107.8 147 Nm {11 15 kgm}
3 Mounting bolt (3):
61. Air cleaner, muffler and heat insulation
28.4 38.2 Nm {2.9 3.9 kgm}
plate
4) Check the belt tension and tighten the
1) Install the air cleaner.
locknut.
2) Install the muffler and the drain tube.
5) Tighten nut (4).
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
62. Tightening torque for sensor 5) Check the fuel piping and devices for fuel
Use the following tightening torque when leakage.
removal and installation or replacement of the a Check mainly around the high-pres-
sensor. sure circuit parts coated with the color
Sensor name Tightening torque
Fuel it and check again from step 2).
23 3 Nm {2.35 0.3 kgm}
temperature 6) Run the engine at high idle.
Boost pressure 5.5 0.5 Nm {0.56 0.05 kgm} 7) Check the fuel piping and devices for fuel
Intake air leakage.
23 3 Nm {2.35 0.3 kgm} a Check mainly around the high-pres-
temperature
Coolant sure circuit parts coated with the color
23 3 Nm {2.35 0.3 kgm} checker for fuel leakage.
temperature
Engine oil
23 3 Nm {2.35 0.3 kgm} it and check again from step 2).
pressure
8) Run the engine at high idle and load it.
4.5 0.5 Nm {0.46 0.05 kgm} a When checking while the components
Atmospheric
(Hexagonal head bolt and hexago-
pressure to be checked are mounted on the
nal socket head bolt)
Fuel pressure Never disassemble. relieve the hydraulic pump.
leakage.
63. Checking for fuel leakage a Check mainly around the high-pres-
a If fuel supply pump (2), common rail (1), or sure circuit parts coated with the color
hi g h- p r es s u r e p i pe is r e mo v ed an d checker for fuel leakage.
installed, after assembling the engine, a If any fuel leakage is detected, repair
check for fuel leakage according to the fol- it and check again from step 2).
lowing procedure. a If no fuel leakage is detected, check
is completed.
a 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 injec-
tor, 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.
leakage.
4) Run the engine at low idle.
46 125E-5 Series
125E-5 Series 47
SEN00699-01
2007 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 1
Disassembly and assembly, Part 3 1

Removal and installation of fuel 7. Remove cover (16).
supply pump unit 1
8. Rotate the crankshaft forward and set interme-
diate point (a) between stamped 2/5 TOP and
Removal 3/4 TOP on damper (17) to pointer (18).
1. Disconnect sensor connectors (1), (2) and (3). (Stamped 1/6 TOP comes almost directly bot-
tom)
2. Remove clamps (4) and (5) and then remove a At this time, check that the forcing tap of
fuel tube (6). [*1] the drive gear is aligned to the mounting
bolt hole of cover (16).
3. Remove clamps (7), (8) and (9) and then (If not, rotate the crankshaft one more
remove splash prevention covers (10) and turn.)
(11). [*2] a At this point, the key of the shaft is turned
clockwise by 15 from the top.
4. Remove high-pressure pipes (12) and (13).
[*3]
5. Remove lubrication tube (14).
6. Remove fuel tube (15). [*4]
9. Remove mounting nut (19) and then remove

washer (20). [*5]
a Use a magnet or the like in this operation
so that washer (20) may not be inadvert-
ently dropped into the case.
2 125E-5 Series
10. Loosen mounting bolts (21) and then remove Installation

the mounting bolt on the cylinder block side of a Carry out installation in the reverse order to
bracket (22). [*6] removal.
a Leave bolts (21) tightened by 2 3 [*1]
threads to prevent the pump from falling 3 Joint bolt of tube (6):
down. 24.5 34.3 Nm {2.5 3.5 kgm}
11. Install tool P1 with P2 and P3 and then screw [*2]

in the center bolt of P1 to remove the gear from 1) Tighten clamps (7), (8), and (9) by hand first,
the shaft. and then tighten them permanently.
12. Remove bolts (21) and then remove fuel sup- 11.8 4.7 Nm {1.2 1.5 kgm}
ply pump assembly (23).
2) Face the pump side slit of the splash preven-
a If tool P is removed, the gear falls down.
tion cover to the cylinder block side and the
Accordingly, keep it installed until the
common rail side slit downward.
pump is installed.
[*3]
a Tighten high-pressure pipes (12) and (13) by
hand first, and then tighten them permanently.
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]
3 Joint bolt of pump side:
24.5 34.3 Nm {2.5 3.5 kgm}
[*5]
127 147 Nm {13 15 kgm}
[*6]
2 Mounting bolt: Gasket sealant (LT-2)
125E-5 Series 3
Replacement of oil seal of engine Installation

mounted on machine 1 a Check the Teflon seal (Laydown lip seal) by
checking the wear of the shaft and replace it
Rear oil seal with the Standard seal or Sleeved seal.
a For the work up to removal of the flywheel, see a If the shaft is worn to the degree of luster (If
the Shop manual for the applicable machine. wear which you feel with your finger is less
than 10 mm) and does not have any flaw, install
Removal of standard seal the standard seal. In other cases, install the
Hitch the end of tool L to the metal ring of seal (1) sleeved seal.
and pull out the seal with impacts of slide hammer a The left one in the following figure is the stan-
[1]. dard seal and the right one is the sleeved seal.
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.

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.
Removal of sleeved seal a When installing the seal, do not apply oil or
1) Hitch the end of tool L to the metal ring of grease to the shaft and seal lip (a). Wipe off oil
seal (1) and pull out the seal with impacts from the shaft.
of slide hammer [1]. a Never remove inside plastic cylinder (3) of the
a Before pulling out the seal, drive in it standard spare seal before installing the seal.
a little to separate it from housing (2) 1) Set the large diameter side (b) of plastic
for the ease of removal. inside cylinder (3) to the end of crankshaft
2) Cut and remove sleeve (3) with a chisel (4).
and a hammer. a Take care not to mistake the direction
a Take care not to damage crankshaft of the plastic inside cylinder.
(4).
a Remove all the chips.
4 125E-5 Series

hands and push it in firmly. a Before installing the seal, make sure that the
3) After pushing in the seal, remove plastic end corners and lip sliding surfaces of crank-
inside cylinder (3). shaft (4) are free from flaws, burrs, and rusts of
a When removing the inside cylinder, the housing.
take care not to damage the seal lip. 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.

fit seal (1) until the end face of tool N1
reaches the end face crankshaft (4).
a First tighten tool N1 until it is con- 1) Set sleeve and seal assembly (2) to tool
tacted against bolt N3 (stem length 45 N2.
mm) and then further tighten the tool 2 Inside sleeve: Gasket sealant (LG-7)
with bolt N4 (stem length 25 mm).
125E-5 Series 5
2) Set the sleeve of the seal to the end of the Front oil seal
crankshaft, and then tighten bolt N3
evenly to press fit sleeve and seal assem- Removal
bly (2) until the end face of tool N2 Remove front oil seal (1).
reaches the end of crankshaft (4). a For the work up to removal of the clamp pulley
(damper), see the Shop manual for the appli-
cable machine.
3) Remove tool N2 and then replace it with

tool N1.
4) Tighten bolt N4 evenly to press fit sleeve
and seal assembly (2) until the end face of Installation
tool N1 reaches the end of crankshaft (4). Using the push tool (outside diameter 120 mm),
a After press fitting the seal, remove the press fit front oil seal (1) to the cover.
red sealant layer from its periphery. a Oil seal press fit allowance (a): 16 (+1/0) mm
2 Oil seal lip (50 80% of void lip space):
Grease (G2-LI)
6 125E-5 Series
125E-5 Series 7
SEN00700-00
2006 KOMATSU
All Rights Reserved

Manual de Taller Motor 125e5

Uploaded by

Document Information

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

Manual de Taller Motor 125e5

Uploaded by

Copyright:

Available Formats

SEN00177-08

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Composition of shop manual................................................................................................................ 2

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00177-08

00 Index and foreword SEN00178-08

10 Structure, function and maintenance standard SEN00183-04

20 Standard value table SEN00186-05

30 Testing and adjusting SEN00187-02

50 Disassembly and assembly SEN00189-01

Foreword and general information SEN00180-05

10 Structure, function and maintenance standard

Structure, function and maintenance standard, Part 2 SEN00185-04

Lubrication system diagram..................................................................................................... 4

20 Standard value table

30 Testing and adjusting

Testing air boost pressure ....................................................................................................... 28

Troubleshooting of electrical system (E-mode), Part 1 SEN00550-01

E-31 Code [342/CA342] Calibration Code Incompatibility ....................................................... 64

Troubleshooting of electrical system (E-mode), Part 2 SEN00551-01

Troubleshooting of mechanical system (S-mode) SEN00549-01

S-10 Fuel consumption is excessive ....................................................................................... 22

50 Disassembly and assembly

Disassembly and assembly, Part 1 (With EGR) SEN00698-01

Disassembly and assembly, Part 2 (EGR-less) SEN00699-01

Disassembly and assembly, Part 3 SEN00700-00

KOMATSU 125E-5 Series engine

Form No. SEN00179-08

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Safety notice (Rev. 2008/06)

1. General precautions 7) If welding repairs are needed, always

2. Preparations for work 6) When removing a cover which is under

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a