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SEN00177-15

ENGINE

125E

-5

SERIES

SEN00179-15

ENGINE
1SHOP MANUAL

125E-5 Series

00 Index and foreword

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 3

125E-5 Series

SEN00179-15

00 Index and foreword

Composition of shop manual

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title

Form Number

Shop Manual, contents binder, binder label and tabs ............................................................ SEN00177-15
00 Index and foreword ......................................................................................................... SEN00178-15
Index ............................................................................................................................... SEN00179-15 q
Foreword and general information .................................................................................. SEN00180-06
01 Specification.................................................................................................................... SEN00181-06
Specification and technical data...................................................................................... SEN00182-06 q
10 Structure, function and maintenance standard ............................................................... SEN00183-07
Structure, function and maintenance standard, Part 1.................................................... SEN00184-06 q
Structure, function and maintenance standard, Part 2.................................................... SEN00185-06 q
20 Standard value table ....................................................................................................... SEN00186-09
Standard service value table........................................................................................... SEN00546-09 q
30 Testing and adjusting ...................................................................................................... SEN00187-05
Testing and adjusting ...................................................................................................... SEN00547-05
40 Troubleshooting .............................................................................................................. SEN00188-04
General information on troubleshooting.......................................................................... SEN00548-03
Troubleshooting of electrical system (E-mode), Part 1 ................................................... SEN00550-01
Troubleshooting of electrical system (E-mode), Part 2 ................................................... SEN00551-01
Troubleshooting of mechanical system (S-mode)........................................................... SEN00549-02
50 Disassembly and assembly ............................................................................................ SEN00189-04
General information on disassembly and assembly ....................................................... SEN00697-03
Disassembly and assembly, Part 1 (With EGR).............................................................. SEN00698-02
Disassembly and assembly, Part 2 (EGR-less) .............................................................. SEN00699-03
Disassembly and assembly, Part 3 ................................................................................. SEN00700-00
90 Repair and replacement of parts..................................................................................... SEN05201-01
Information related to repair and replacement ................................................................ SEN05202-00
Parts related to cylinder head ......................................................................................... SEN05203-01
Parts related to cylinder block......................................................................................... SEN05204-00

125E-5 Series

00 Index and foreword

SEN00179-15

Table of contents

00 Index and foreword


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

SEN00179-15

00 Index and foreword

Oil pump ..................................................................................................................................


Main relief valve.......................................................................................................................
EGR oil pump ..........................................................................................................................
Oil filter.....................................................................................................................................
Safety valve .............................................................................................................................
Oil cooler..................................................................................................................................
Fuel system .................................................................................................................................
CRI system diagram ................................................................................................................
Outline of CRI system..............................................................................................................
Fuel piping ...............................................................................................................................
Fuel filter ..................................................................................................................................
Electric priming pump ..............................................................................................................
Engine controller cooler ...........................................................................................................
Cooling system............................................................................................................................
Cooling system diagram ..........................................................................................................
Water pump .............................................................................................................................
Thermostat...............................................................................................................................
Electrical equipment ....................................................................................................................
Alternator .................................................................................................................................
Starting motor ..........................................................................................................................
Electrical intake air heater .......................................................................................................
Engine controller......................................................................................................................

8
9
10
11
13
14
16
16
18
40
42
44
45
46
46
48
50
52
52
60
64
65

20 Standard value table


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

125E-5 Series

00 Index and foreword

SEN00179-15

Testing exhaust temperature ...................................................................................................


Adjusting valve clearance........................................................................................................
Testing compression pressure.................................................................................................
Testing blow-by pressure.........................................................................................................
Testing engine oil pressure......................................................................................................
Handling fuel system parts ......................................................................................................
Releasing residual pressure in fuel system .............................................................................
Testing fuel pressure ...............................................................................................................
Reduced cylinder mode operation...........................................................................................
No-injection cranking ...............................................................................................................
Testing leakage from pressure limiter and return rate from injector ........................................
Bleeding air from fuel circuit ....................................................................................................
Testing fuel system for leakage ...............................................................................................
Adjusting speed sensor ...........................................................................................................
Testing and adjusting alternator belt tension ...........................................................................
Handling controller voltage circuit............................................................................................

30
31
32
34
35
36
36
37
38
38
39
41
43
44
45
46

40 Troubleshooting
General information on troubleshooting.......................................................................... SEN00548-03
General information on troubleshooting ......................................................................................
2
Points on troubleshooting ........................................................................................................
2
Error code and failure code table ............................................................................................
4
Information in troubleshooting table ........................................................................................
8
Troubleshooting of electrical system (E-mode), Part 1 ................................................... SEN00550-01
Troubleshooting of electrical system (E-mode), Part 1 ...............................................................
4
E-1 Code [111/CA111] ECM Critical Internal Failure................................................................
4
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error ..............................................
6
E-3 Code [122/CA122] Charge Air Press Sensor High Error ..................................................
8
E-4 Code [123/CA123] Charge Air Press Sensor Low Error ................................................... 10
E-5 Code [131/CA131] Throttle Sensor High Error ................................................................. 12
E-6 Code [132/CA132] Throttle Sensor Low Error .................................................................. 16
E-7 Code [135/CA135] Oil press. Sensor High Error .............................................................. 18
E-8 Code [141/CA141] Oil press. Sensor Low Error ............................................................... 20
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ...................................................... 22
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error ..................................................... 24
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error ................................................ 26
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error ................................................ 28
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error .......................................................... 29
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error.............................................. 30
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error............................................... 32
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error ......................................................... 34
E-17 Code [234/CA234] Eng. Overspeed ............................................................................... 36
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error.................................................... 38
E-19 Code [263/CA263] Fuel Temp. Sensor High Error .......................................................... 40
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error........................................................... 42
E-21 Code [271/CA271] PCV1 Short Error ............................................................................. 44
E-22 Code [272/CA272] PCV1 Open Error ............................................................................. 46
E-23 Code [273/CA273] PCV2 Short Error ............................................................................. 48
E-24 Code [274/CA274] PCV2 Open Error ............................................................................. 50
E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error ................................. 52
E-26 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error ................................. 54
E-27 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error ................................. 56
E-28 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error ................................. 58
E-29 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error ................................. 60
E-30 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error ................................. 62
E-31 Code [342/CA342] Calibration Code Incompatibility ....................................................... 64
E-32 Code [351/CA351] INJ. Drive Circuit Error ..................................................................... 66

125E-5 Series

SEN00179-15

00 Index and foreword

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 ................................................... SEN00551-01
Troubleshooting of electrical system (E-mode), Part 2................................................................
3
E-39 Code [449/CA449] Rail Press. Very High Error...............................................................
3
E-40 Code [451/CA451] Rail Press. Sensor High Error ..........................................................
4
E-41 Code [452/CA452] Rail Press. Sensor Low Error ...........................................................
6
E-42 Code [553/CA553] Rail Press. High Error.......................................................................
6
E-43 Code [554/CA554] Rail Press Sensor In Range Error ....................................................
7
E-44 Code [559/CA559] Rail Press. Low Error........................................................................
8
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error ............................................................ 12
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error ............................................. 14
E-47 Code [757/CA757] All Persistent Data Lost Error ........................................................... 15
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error ........................................................ 16
E-49 Code [1228/CA1228] EGR Valve Servo Error 1.............................................................. 18
E-50 Code [1625/CA1625] EGR Valve Servo Error 2.............................................................. 19
E-51 Code [1626/CA1626] Bypass Valve Solenoid Current High Error................................... 20
E-52 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error.................................... 22
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1.......................................................... 23
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2.......................................................... 24
E-55 Code [1631/CA1631] BP valve Lift Position Sensor High Error ...................................... 26
E-56 Code [1632/CA1632] BP valve Lift Position Sensor Low Error ....................................... 28
E-57 Code [1633/CA1633] KOMNET Datalink Timeout Error ................................................. 28
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error............................................... 29
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error .............................................. 30
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ............................................. 32
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error .............................................. 36
E-62 Code [2249/CA2249] Rail Press. Very Low Error ........................................................... 37
E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error................................... 38
E-64 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error.................................... 40
E-65 Code [2351/CA2351] EGR Valve Solenoid Current High Error....................................... 42
E-66 Code [2352/CA2352] EGR Valve Solenoid Current Low Error ....................................... 44
E-67 Code [2555/CA2555] Grid Heater Relay Volt. Low Error ................................................ 45
E-68 Code [2556/CA2556] Grid Heater Relay Volt. High Error ............................................... 46
E-69 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate ................................................... 48
E-70 Code [(146)/B@BCNS] Eng. Overheat ........................................................................... 48
E-71 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate ............................................ 49
Troubleshooting of mechanical system (S-mode)........................................................... SEN00549-02
Troubleshooting of mechanical system (S-mode) .......................................................................
4
Method of using troubleshooting charts...................................................................................
4
S-1 Starting performance is poor .............................................................................................
8
S-2 Engine does not start ........................................................................................................ 10
S-3 Engine does not pick up smoothly .................................................................................... 14
S-4 Engine stops during operations......................................................................................... 15
S-5 Engine does not rotate smoothly....................................................................................... 16
S-6 Engine lacks output (or lacks power) ................................................................................ 17
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 18
S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 20
S-9 Oil becomes contaminated quickly.................................................................................... 21
S-10 Fuel consumption is excessive ....................................................................................... 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .............................. 23
S-12 Oil pressure drops........................................................................................................... 24
S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 25

125E-5 Series

00 Index and foreword

SEN00179-15

S-14 Coolant temperature becomes too high (overheating).................................................... 27


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

125E-5 Series

SEN00179-15

KOMATSU 125E-5 Series engine


Form No. SEN00179-15

2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11

SEN00180-06

ENGINE
1SHOP MANUAL

125E-5 Series

00 Index and foreword

Foreword and general information


Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36

125E-5 Series

SEN00180-06

00 Index and foreword

Safety notice

(Rev. 2008/08)
1

Important safety notice


Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.

General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read all the safety labels stuck to
the machine. For the locations of the
safety labels and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, forklift, service car, etc.

7)

8)

9)

If welding repairs are needed, always


have a trained and experienced welder
carry out the work. When carrying out
w elding work, alw ays wear welding
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.
Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition. Take rests in
specified safe places.

Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5

Prohibition of operation and handling by


unlicensed workers

6 Safety check before starting work


7

Wearing protective goggles


(for cleaning or grinding work)

Wearing shielding goggles and protectors


(for welding work)

9 Good physical condition and preparation


10

Precautions against work which you are


not used to or you are used to too much

125E-5 Series

00 Index and foreword

2.

3.

SEN00180-06

Preparations for work


1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
3) When disassembling or assembling, support the machine with blocks, jacks, or
stands before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders or steps when getting on or off the
m a c h i n e . N e v e r j u m p o n o r o ff t h e
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.

6)

Precautions during work


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

11)

125E-5 Series

7)

8)

9)

10)

12)

13)

14)

15)

16)

When removing a cover which is under


internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
When removing components, be careful
not to break or damage the electrical wiring. Damaged wiring may cause electrical
fires.
When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be damaged by contact with other parts when the
machine is operated.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
installed.
When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.

SEN00180-06

4.

Precautions for sling work and making


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

00 Index and foreword

8)

When installing wire ropes to an angular


load, apply pads to protect the wire ropes.
If the load is slippery, apply proper material to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
q
Slinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle portion.

11) Do not use twisted or kinked wire ropes.


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

125E-5 Series

00 Index and foreword

If the load is unstable or the wire rope


or chains are twisted, lower the load
and lift it up again.
q
Do not lift up the load slantingly.
13) When lifting down a load, observe the following.
q
When lifting down a load, stop it temporarily at 30 cm above the floor, and
then lower it slowly.
q
Check that the load is stable, and
then remove the sling.
q
Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.

SEN00180-06

13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.

5.

6.

Precautions for using mobile crane


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

125E-5 Series

7.

Selecting wire ropes


1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.

Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4

The allowable load is one-sixth of the


breaking strength of the rope used
(Safety coefficient: 6).

SEN00180-06

8.

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

00 Index and foreword


a

Example of O-ring (Fitted to every joint of


hoses and tubes)

For tightening torque, see the precautions for


installation in each section of "Disassembly
and assembly".

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

125E-5 Series

00 Index and foreword

How to read the shop manual


q
q
q

1.

SEN00180-06

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

Composition of shop manual


This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

2.

Revision and distribution


Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

125E-5 Series

SEN00180-06

3.

4.

00 Index and foreword

Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q

Revised edition mark


When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 )

Revisions
Revised brochures are shown in the shop manual composition table.

Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol

Item

Safety

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing work.

Weight

Weight of parts of component or parts. Caution necessary when


selecting hoisting wire, or when working posture is important, etc.

Tightening
torque

Coat

Oil, coolant

Drain

Remarks
Special safety precautions are necessary when performing work.

Places that require special attention for tightening torque during


assembly.
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.

5.

Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

125E-5 Series

00 Index and foreword

SEN00180-06

Explanation of terms for maintenance standard

The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1.

Standard size and tolerance


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

Tolerance
0.022
0.126

The tolerance may be indicated in the text


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

Usually, the size of a hole and the size of


the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them

Example:
Standard size
60

125E-5 Series

Tolerance
Shaft
Hole
0.030
+0.046
0.076
+0

SEN00180-06

2.

Standard clearance and standard value


q
The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.

3.

Standard interference
q
When the diameter of a hole of a part
shown in the given standard size and tolerance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q
The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q
After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.

4.

Repair limit and allowable value or allowable dimension


q
The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q
If a part is worn to the repair limit, it must
be replaced or repaired.
q
The performance and function of a product lowers while it is used. A value which
the product can be used without causing a
problem is called the allowable value or
allowable dimension.
q
If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.

10

00 Index and foreword

5.

Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q

6.

Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q

125E-5 Series

00 Index and foreword

Handling of electric equipment and hydraulic component

SEN00180-06

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).

Points to remember when handling electric


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

Main failures occurring in wiring harness


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

Defective crimping or soldering of connectors


The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.

125E-5 Series

11

SEN00180-06

12

3)

Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the soldering may be damaged, or the wiring
may be broken.

4)

High-pressure water entering connector


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

5)

Oil or dirt stuck to connector


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

00 Index and foreword

125E-5 Series

00 Index and foreword

3.

SEN00180-06

Removing, installing, and drying connectors and wiring harnesses


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

When removing from clips


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

When removing a connector from a


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

3]

Action to take after removing connectors


After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.

125E-5 Series

13

SEN00180-06

2)

14

00 Index and foreword

Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or breakage, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected easily, remove the clamp
and adjust the position.
q
If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.

125E-5 Series

00 Index and foreword

3)

Heavy duty wire connector (DT 8-pole, 12pole)


Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizontally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks

125E-5 Series

SEN00180-06

Disconnection

Connection (Example of
incomplete setting of (a))

15

SEN00180-06

4)

16

00 Index and foreword

Drying wiring harness


If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as follows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the compressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.

125E-5 Series

00 Index and foreword

4.

Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the controller.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness connectors connected to the controller. Fit an
arc welding ground close to the welding
point.

5.

Points to remember when troubleshooting


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

125E-5 Series

SEN00180-06

17

SEN00180-06

00 Index and foreword

Points to remember when handling hydraulic equipment


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

1.

Be careful of the operating environment.


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

2.

Disassembly and maintenance work in the


field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the performance should be checked with special test
equipment.

3.

Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.

4.

Do not let any dirt or dust get in during


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

18

125E-5 Series

00 Index and foreword

5.

Change hydraulic oil when the temperature


is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.

6.

Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.

7.

Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.

125E-5 Series

SEN00180-06

19

SEN00180-06

00 Index and foreword

Handling of connectors newly used for engines


a

1.

Mainly, following engines are object for following connectors.


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

2.

Pull lock type (PACKARD-2)


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

Disconnect connector (1) according to the following procedure.


1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connector (1) toward you.
a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screwdriver while press lock (L2), and then
pull out connector (1) toward you.

20

125E-5 Series

00 Index and foreword

3.

SEN00180-06

Push lock type


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

114 engine

107, 114 engines


Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)

3)

While pressing lock (D), pull out connector


(4) in the direction of the arrow.

107 engine

2)

If the lock is on the underside, use


flat-head screwdriver [1] since you
cannot insert your fingers.
While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.

125E-5 Series

21

SEN00180-06

4)

95, 125 170, 12V140 engines


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

00 Index and foreword

4.

Turn-housing type (Round green connector)


140 engine
Example)
Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.

1)

Disconnect connector (6) according to the


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

2)

Connect the connector according to the


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)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)

Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.

22

125E-5 Series

00 Index and foreword

SEN00180-06

How to read electric wire code


a

The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX

0.85

L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)

1.

Type, symbol, and material


AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.

(Table 1)
Type
Low-voltage
wire for
automobile
Thin-cover
low-voltage
wire for
automobile

Symbol
AV

AVS

Heat-resistant low-voltAEX
age wire for
automobile

125E-5 Series

Material
Conductor
Insulator
Conductor

Annealed copper for electric appliance


Soft polyvinyl chloride
Annealed copper for electric appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric appliance


Heat-resistant crosslinked
polyethylene

Insulator

Using
temperature
range (C)

Example of use
General wiring
(Nominal No. 5 and above)

30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place

23

SEN00180-06

2.

00 Index and foreword

Dimensions

(Table 2)
Nominal No.
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
area (mm2)
d (approx.)
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6

CovAV
Standard

4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1

3.8
4.6

Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard

15

20

30

40

50

60

85

100

50/0.45

84/0.45

41/0.80

70/0.80

85/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

3.7

5.5
5.3

4.8

7.0
7.0

6.0

8.2
8.2

8.0

10.8
10.8

8.6

11.4
11.4

9.8

13.0
13.0

10.4

13.6
13.6

12.0

16.0
16.0

13.6

17.6
17.6

108/0.80 127/0.80 169/0.80 217/0.80

f of nominal No. denotes flexible.

24

125E-5 Series

00 Index and foreword

3.

SEN00180-06

Color codes table

(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR

Color of wire

Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW

Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red

Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.

4.

Types of circuits and color codes

(Table 4)
Type of wire
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit

Others

125E-5 Series

AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch

AEX

R
B
R
D
Y
G
L

WG

RB
YR
GW
LW
BrW
LgR

RY
YB
GR
LR
BrR
LgY

RG
YG
GY
LY
BrY
LgB

RL
YL
GB
LB
BrB
LgW

YW
GL

Gr
Br

25

SEN00180-06

00 Index and foreword

Precautions when carrying out operation

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1.
q
q
q
q
q
q
q
q
q
q

Precautions when carrying out removal work


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

26

Sleeve nut (elbow end)

07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234

02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234

Split flange type hoses and tubes


Nominal
number
04
05

3)

Plug (nut end)

Flange (hose end)

Sleeve head (tube end)

Split flange

07379-00400
07379-00500

07378-10400
07378-10500

07371-30400
07371-30500

If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number

Part Number

06
08
10
12
14
16
18
20
22
24

07049-00608
07049-00811
07049-01012
07049-01215
07049-01418
07049-01620
07049-01822
07049-02025
07049-02228
07049-02430

Dimensions
D
d
L
6
5
8
8
6.5
11
10
8.5
12
12
10
15
14
11.5
18
16
13.5
20
18
15
22
20
17
25
22
18.5
28
24
20
30

27

07049-02734

27

22.5

34

125E-5 Series

00 Index and foreword

2.
q
q
q
q
q
q
q
q
q
q
q
q
q

a
3.

SEN00180-06

Precautions when carrying out installation work


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

125E-5 Series

27

SEN00180-06

4)

5)

28

00 Index and foreword

Checking muffler and exhaust pipe for damage and looseness


1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to Troubleshooting and Disassembly
and assembly.

125E-5 Series

00 Index and foreword

SEN00180-06

Method of disassembling and connecting push-pull type coupler


k
k

Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.

Type 1
1.

Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.

2.

Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.

125E-5 Series

29

SEN00180-06

00 Index and foreword

Type 2
1.

Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to disconnect it. (Fig. 8)

2.

Connection
q
Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)

30

125E-5 Series

00 Index and foreword

SEN00180-06

Type 3
1.

Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect it. (Fig. 12)

2.

Connection
q
Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)

125E-5 Series

31

SEN00180-06

00 Index and foreword

Standard tightening torque table


1.

Table of tightening torques for bolts and nuts


a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a

The following table applies to the bolts in Fig. A.

Thread diameter of bolt


mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
a

Tightening torque
Nm
11.8 14.7
27 34
59 74
98 123
157 196
245 309
343 427
490 608
662 829
824 1,030
1,180 1,470
1,520 1,910
1,960 2,450
2,450 3,040
2,890 3,630

kgm
1.2 1.5
2.8 3.5
6.0 7.5
10.0 12.5
16 20
25 31.5
35 43.5
50 62
67.5 84.5
84 105
120 150
155 195
200 250
250 310
295 370

The following table applies to the bolts in Fig. B.

Thread diameter of bolt


mm
6
8
10
12
a Fig. A

Width across flats


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

Width across flats


mm
10
12
14
17

Tightening torque
Nm
kgm
5.9 9.8
0.6 1.0
13.7 23.5
1.4 2.4
34.3 46.1
3.5 4.7
74.5 90.2
7.6 9.2
a Fig. B

Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)

32

125E-5 Series

00 Index and foreword

2.

Table of tightening torques for split flange bolts


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

Thread diameter of bolt


mm
10
12
16

3.

Width across flats


mm
14
17
22

Tightening torque
Nm
59 74
98 123
235 285

kgm
6.0 7.5
10.0 12.5
23.5 29.5

Table of tightening torques for O-ring boss piping joints


a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter
mm
14
20
24
33
42

Nominal No.
02
03,04
05,06
10,12
14

4.

SEN00180-06

Width across flats


mm

Tightening torque Nm {kgm}


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

Table of tightening torques for O-ring boss plugs


a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal
No.
08
10
12
14
16
18
20
24
30
33
36
42
52

Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52

125E-5 Series

Width across flats


mm
14
17
19
22
24
27
30
32
32

36

Tightening torque Nm {kgm}


Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}

33

SEN00180-06

5.

00 Index and foreword

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}

Nominal
No. of
hose

Width
across
flats

02

19

03
04
05
06
(10)
(12)
(14)

6.

22
24
27
32
36
41
46
55

Range
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}

Target

44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}

Taper seal
Thread size
(mm)

14

18
22
24
30
33
36
42

Face seal
Nominal No.
Thread
Number of
diameter (mm)
threads, type of
(Reference)
thread
9/16-18UN
14.3

11/16-16UN
17.5

13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2

Table of tightening torques for face seal joints


a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).

Outer
diameter
of pipe
(mm)

Width
across
flats
(mm)

8
10
12
15 (16)
22 (20)

19
22
24 (27)
30 (32)
36

Tightening torque Nm {kgm}


Range

Target

14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}

15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}

Face seal
Thread diameter
Nominal No.
(mm)
Number of threads,
(Reference)
type of thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UN
25.4
1-3/16-12UN
30.2

Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.

7.

Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Bolts and nuts

Thread size
mm
6
8
10
12
14

34

Nm
10 2
24 4
43 6
77 12

kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22

125E-5 Series

00 Index and foreword

8.

Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size
mm
6
8
10
12
14

9.

SEN00180-06

Tightening torque
Nm
82
10 2
12 2
24 4
36 5

kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51

Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.

Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4

125E-5 Series

Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51

35

SEN00180-06

00 Index and foreword

Conversion table

Method of using the conversion table


The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1.

Convert 55 mm into inches.


1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.

2.

Convert 550 mm into inches.


1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

(A)

36

(B)

0
10
20
30
40

0
0
0.394
0.787
1.181
1.575

1
0.039
0.433
0.827
1.220
1.614

2
0.079
0.472
0.866
1.260
1.654

3
0.118
0.512
0.906
1.299
1.693

4
0.157
0.551
0.945
1.339
1.732

50
60
70
80
90

1.969
2.362
2.756
3.150
3.543

2.008
2.402
2.795
3.189
3.583

2.047
2.441
2.835
3.228
3.622

2.087
2.480
2.874
3.268
3.661

2.126
2.520
2.913
3.307
3.701

5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740

6
0.236
0.630
1.024
1.417
1.811

7
0.276
0.669
1.063
1.457
1.850

2.205
2.598
2.992
3.386
3.780

2.244
2.638
3.032
3.425
3.819

1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858

2.323
2.717
3.110
3.504
3.898

125E-5 Series

00 Index and foreword

SEN00180-06

Millimeters to inches

0
10
20
30
40

0
0
0.394
0.787
1.181
1.575

1
0.039
0.433
0.827
1.220
1.614

2
0.079
0.472
0.866
1.260
1.654

3
0.118
0.512
0.906
1.299
1.693

4
0.157
0.551
0.945
1.339
1.732

5
0.197
0.591
0.984
1.378
1.772

6
0.236
0.630
1.024
1.417
1.811

1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929

50
60
70
80
90

1.969
2.362
2.756
3.150
3.543

2.008
2.402
2.795
3.189
3.583

2.047
2.441
2.835
3.228
3.622

2.087
2.480
2.874
3.268
3.661

2.126
2.520
2.913
3.307
3.701

2.165
2.559
2.953
3.346
3.740

2.205
2.598
2.992
3.386
3.780

2.244
2.638
3.032
3.425
3.819

1 kg = 2.2046 lb
6
7
8
9
13.23
15.43 17.64
19.84
35.27
37.48 39.68
41.89
57.32
59.53 61.73
63.93
79.37
81.57 83.78
85.98
101.41 103.62 105.82 108.03

2.283
2.677
3.071
3.465
3.858

2.323
2.717
3.110
3.504
3.898

Kilogram to pound

0
10
20
30
40

0
0
22.05
44.09
66.14
88.18

1
2.20
24.25
46.30
68.34
90.39

2
4.41
26.46
48.50
70.55
92.59

3
6.61
28.66
50.71
72.75
94.80

4
8.82
30.86
51.91
74.96
97.00

5
11.02
33.07
55.12
77.16
99.21

50
60
70
80
90

110.23
132.28
154.32
176.37
198.42

112.44
134.48
156.53
178.57
200.62

114.64
136.69
158.73
180.78
202.83

116.85
138.89
160.94
182.98
205.03

119.05
141.10
163.14
185.19
207.24

121.25
143.30
165.35
187.39
209.44

123.46
145.51
167.55
189.60
211.64

125.66
147.71
169.76
191.80
213.85

127.87
149.91
171.96
194.01
216.05

130.07
152.12
174.17
196.21
218.26

Liters to U.S. Gallons

0
10
20
30
40

0
1
2
0
0.264 0.528
2.642
2.906 3.170
5.283
5.548 5.812
7.925
8.189 8.454
10.567 10.831 11.095

3
0.793
3.434
6.076
8.718
11.359

4
1.057
3.698
6.340
8.982
11.624

1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321
1.585
1.849
2.113
2.378
3.963
4.227
4.491 4.755
5.019
6.604
6.869
7.133 7.397
7.661
9.246
9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944

50
60
70
80
90

13.209
15.850
18.492
21.134
23.775

14.001
16.643
19.285
21.926
24.568

14.265
16.907
19.549
22.190
24.832

14.529
17.171
19.813
22.455
25.096

125E-5 Series

13.473
16.115
18.756
21.398
24.040

13.737
16.379
19.020
21.662
24.304

14.795
17.435
20.077
22.719
25.361

15.058
17.700
20.341
22.983
25.625

15.322
17.964
20.605
23.247
25.889

15.586
18.228
20.870
23.511
26.153

37

SEN00180-06

00 Index and foreword

Liters to U.K. Gallons

0
10
20
30
40

0
0
2.200
4.399
6.599
8.799

1
0.220
2.420
4.619
6.819
9.019

2
0.440
2.640
4.839
7.039
9.239

3
0.660
2.860
5.059
7.259
9.459

4
0.880
3.080
5.279
7.479
9.679

5
1.100
3.300
5.499
7.699
9.899

50
60
70
80
90

10.998
13.198
15.398
17.598
19.797

11.281
13.418
15.618
17.818
20.017

11.438
13.638
15.838
18.037
20.237

11.658
13.858
16.058
18.257
20.457

11.878
14.078
16.278
18.477
20.677

12.098
14.298
16.498
18.697
20.897

1 l = 0.21997 U.K.Gal
6
7
8
9
1.320
1.540 1.760
1.980
3.520
3.740 3.950
4.179
5.719
5.939 6.159
6.379
7.919
8.139 8.359
8.579
10.119 10.339 10.559 10.778
12.318
14.518
16.718
18.917
21.117

12.528
14.738
16.938
19.137
21.337

12.758
14.958
17.158
19.357
21.557

12.978
15.178
17.378
19.577
21.777

kgm to ft.lb

0
10
20
30
40

0
0
72.3
144.7
217.0
289.3

1
7.2
79.6
151.9
224.2
296.6

2
14.5
86.8
159.1
231.5
303.8

3
21.7
94.0
166.4
238.7
311.0

4
28.9
101.3
173.6
245.9
318.3

5
36.2
108.5
180.8
253.2
325.5

6
43.4
115.7
188.1
260.4
332.7

1 kgm = 7.233 ft.lb


7
8
9
50.6
57.9
65.1
123.0 130.2
137.4
195.3 202.5
209.8
267.6 274.9
282.1
340.0 347.2
354.4

50
60
70
80
90

361.7
434.0
506.3
578.6
651.0

368.9
441.2
513.5
585.9
658.2

376.1
448.5
520.8
593.1
665.4

383.4
455.7
528.0
600.3
672.7

390.6
462.9
535.2
607.6
679.9

397.8
470.2
542.5
614.8
687.1

405.1
477.4
549.7
622.0
694.4

412.3
484.6
556.9
629.3
701.6

419.5
491.8
564.2
636.5
708.8

426.8
499.1
571.4
643.7
716.1

100
110
120
130
140

723.3
730.5 737.8
745.0
752.2 759.5
766.7
773.9 781.2
788.4
795.6
802.9 810.1
817.3
824.6 831.8
839.0
846.3 853.5
860.7
868.0
875.2 882.4
889.7
896.9 904.1
911.4
918.6 925.8
933.1
940.3
947.5 954.8
962.0
969.2 976.5
983.7
990.9 998.2 1005.4
1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150
160
170
180
190

1084.9
1157.3
1129.6
1301.9
1374.3

38

1092.2
1164.5
1236.8
1309.2
1381.5

1099.4
1171.7
1244.1
1316.4
1388.7

1106.6
1179.0
1251.3
1323.6
1396.0

1113.9
1186.2
1258.5
1330.9
1403.2

1121.1
1193.4
1265.8
1338.1
1410.4

1128.3
1200.7
1273.0
1345.3
1417.7

1135.6
1207.9
1280.1
1352.6
1424.9

1142.8
1215.1
1287.5
1359.8
1432.1

1150.0
1222.4
1294.7
1367.0
1439.4

125E-5 Series

00 Index and foreword

SEN00180-06

kg/cm2 to lb/in2

0
10
20
30
40

0
0
142.2
284.5
426.7
568.9

1
14.2
156.5
298.7
440.9
583.2

2
28.4
170.7
312.9
455.1
597.4

3
42.7
184.9
327.1
469.4
611.6

4
56.9
199.1
341.4
483.6
625.8

5
71.1
213.4
355.6
497.8
640.1

6
85.3
227.6
369.8
512.0
654.3

1 kg/cm2 = 14.2233 lb/in2


7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9

50
60
70
80
90

711.2
853.4
995.6
1,138
1,280

725.4
867.6
1,010
1,152
1,294

739.6
881.8
1,024
1,166
1,309

753.8
896.1
1,038
1,181
1,323

768.1
910.3
1,053
1,195
1,337

782.3
924.5
1,067
1,209
1,351

796.5
938.7
1,081
1,223
1,365

810.7
953.0
1,095
1,237
1,380

825.0
967.2
1,109
1,252
1,394

839.2
981.4
1,124
1,266
1,408

100
110
120
130
140

1,422
1,565
1,707
1,849
1,991

1,437
1,579
1,721
1,863
2,005

1,451
1,593
1,735
1,877
2,020

1,465
1,607
1,749
1,892
2,034

1,479
1,621
1,764
1,906
2,048

1,493
1,636
1,778
1,920
2,062

1,508
1,650
1,792
1,934
2,077

1,522
1,664
1,806
1,949
2,091

1,536
1,678
1,821
1,963
2,105

1,550
1,693
1,835
1,977
2,119

150
160
170
180
190

2,134
2,276
2,418
2,560
2,702

2,148
2,290
2,432
2,574
2,717

2,162
2,304
2,446
2,589
2,731

2,176
2,318
2,460
2,603
2,745

2,190
2,333
2,475
2,617
2,759

2,205
2,347
2,489
2,631
2,773

2,219
2,361
2,503
2,646
2,788

2,233
2,375
2,518
2,660
2,802

2,247
2,389
2,532
2,674
2,816

2,262
2,404
2,546
2,688
2,830

200
210
220
230
240

2,845
2,987
3,129
3,271
3,414

2,859
3,001
3,143
3,286
3,428

2,873
3,015
3,158
3,300
3,442

2,887
3,030
3,172
3,314
3,456

2,901
3,044
3,186
3,328
3,470

2,916
3,058
3,200
3,343
3,485

2,930
3,072
3,214
3,357
3,499

2,944
3,086
3,229
3,371
3,513

2,958
3,101
3,243
3,385
3,527

2,973
3,115
3,257
3,399
3,542

125E-5 Series

39

SEN00180-06

00 Index and foreword

Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

1C = 33.8F
F

40.4
37.2
34.4
31.7
28.9

40
35
30
25
20

40.0
31.0
22.0
13.0
4.0

11.7
11.1
10.6
10.0
9.4

11
12
13
14
15

51.8
53.6
55.4
57.2
59.0

7.8
8.3
8.9
9.4
10.0

46
47
48
49
50

114.8
116.6
118.4
120.2
122.0

27.2
27.8
28.3
28.9
29.4

81
82
83
84
85

177.8
179.6
181.4
183.2
185.0

28.3
27.8
27.2
26.7
26.1

19
18
17
16
15

2.2
0.4
1.4
3.2
5.0

8.9
8.3
7.8
7.2
6.7

16
17
18
19
20

60.8
62.6
64.4
66.2
68.0

10.6
11.1
11.7
12.2
12.8

51
52
53
54
55

123.8
125.6
127.4
129.2
131.0

30.0
30.6
31.1
31.7
32.2

86
87
88
89
90

186.8
188.6
190.4
192.2
194.0

25.6
25.0
24.4
23.9
23.3

14
13
12
11
10

6.8
8.6
10.4
12.2
14.0

6.1
5.6
5.0
4.4
3.9

21
22
23
24
25

69.8
71.6
73.4
75.2
77.0

13.3
13.9
14.4
15.0
15.6

56
57
58
59
60

132.8
134.6
136.4
138.2
140.0

32.8
33.3
33.9
34.4
35.0

91
92
93
94
95

195.8
197.6
199.4
201.2
203.0

22.8
22.2
21.7
21.1
20.6

9
8
7
6
5

15.8
17.6
19.4
21.2
23.0

3.3
2.8
2.2
1.7
1.1

26
27
28
29
30

78.8
80.6
82.4
84.2
86.0

16.1
16.7
17.2
17.8
18.3

61
62
63
64
65

141.8
143.6
145.4
147.2
149.0

35.6
36.1
36.7
37.2
37.8

96
97
98
99
100

204.8
206.6
208.4
210.2
212.0

20.0
19.4
18.9
18.3
17.8

4
3
2
1
0

24.8
26.6
28.4
30.2
32.0

0.6
0
0.6
1.1
1.7

31
32
33
34
35

87.8
89.6
91.4
93.2
95.0

18.9
19.4
20.0
20.6
21.1

66
67
68
69
70

150.8
152.6
154.4
156.2
158.0

40.6
43.3
46.1
48.9
51.7

105
110
115
120
125

221.0
230.0
239.0
248.0
257.0

17.2
16.7
16.1
15.6
15.0

1
2
3
4
5

33.8
35.6
37.4
39.2
41.0

2.2
2.8
3.3
3.9
4.4

36
37
38
39
40

96.8
98.6
100.4
102.2
104.0

21.7
22.2
22.8
23.3
23.9

71
72
73
74
75

159.8
161.6
163.4
165.2
167.0

54.4
57.2
60.0
62.7
65.6

130
135
140
145
150

266.0
275.0
284.0
293.0
302.0

14.4
13.9
13.3
12.8
12.2

6
7
8
9
10

42.8
44.6
46.4
48.2
50.0

5.0
5.6
6.1
6.7
7.2

41
42
43
44
45

105.8
107.6
109.4
111.2
113.0

24.4
25.0
25.6
26.1
26.7

76
77
78
79
80

168.8
170.6
172.4
174.2
176.0

68.3
71.1
73.9
76.7
79.4

155
160
165
170
175

311.0
320.0
329.0
338.0
347.0

40

125E-5 Series

00 Index and foreword

125E-5 Series

SEN00180-06

41

SEN00180-06

KOMATSU 125E-5 Series engine


Form No. SEN00180-06

2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)

42

SEN00182-06

ENGINE
1SHOP MANUAL

125E-5 Series

01 Specification

Specification and technical data


Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 6
General view ...................................................................................................................................... 20
Weight table ....................................................................................................................................... 48
Engine performance curves ............................................................................................................... 51

125E-5 Series

SEN00182-06

01 Specification

Outline

1. Applicable machine
Engine

Engine serial No.

Applicable machine
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
Hydraulic excavator
PC400-8, PC400LC-8, PC400-8R, PC400LC-8R
PC450-8, PC450LC-8, PC450-8R, PC450LC-8R

SAA6D125E-5

D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R

Bulldozer

WA450-6, WA470-6, WA470-6R

Wheel loader

WA480-6, WA480-6R

Wheel loader

HM250-2, HM300-2, HM300-2R

Articulated dump truck

BR580JG-1

Mobile crusher

GD755-5R

Motor grader

DCA-300SSK4 (DENYO/MQ GENERATOR)

Generator

125E-5 Series

01 Specification

SEN00182-06

2. Outline of engine (with EGR)


q

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


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

The 125E-5 engine is the successor to the


125E-3 engine. While it is an in-line 6-cylinder,
water-cooled, common rail direct injection, 4stroke diesel engine, it is equipped with the
cooled EGR system which is a new technology.

1)

The main components of the cooled EGR system are the EGR cooler of corrugated tube
type made of newly developed special stainless steel and the EGR valve driven hydraulically and controlled electronically which
KOMATSU developed by itself. The cooled
EGR system secures the optimum EGR rate
from the low-speed range to the high-speed
range to attain both clean exhaust gas and low
fuel consumption with the bypass assist circuit
consisting of the venturi system and bypass
valve which has the same function and structure as those of the EGR valve.

2)

The special EGR oil pump is employed to generate high oil pressure (1.47 MPa {15 kg/cm2})
as the drive power source of the EGR valve
driven hydraulically and controlled electronically.

3)

The 125E-5 engine is equipped with the combination filter system of high performance and
efficiency, which has been employed for the
125E-3 engine, to meet the requirements of
the EGR system and high-dispersion oil and
capture large and small particles. In addition,
the recommended sub-materials for operation
(oil and fuel) are changed to improve the reliability and durability of the engine.

4)

Since the high-pressure fuel injection system


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

125E-5 Series

5)

The common rail high-pressure fuel injection


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

6)

As the injection pressure of the common rail


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

7)

The main fuel filter of high efficiency and the


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

8)

The high-quality piston made of cast iron which


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

9)

By using the above-mentioned high-pressure


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

10) Since the engine controller is mounted on the


engine and equipped with the automatic highaltitude compensation function, the engine can
be operated at high altitude without replacing
the controller. As a result, the serviceability is
improved.

SEN00182-06

01 Specification

11) The KTR90 turbocharger newly developed and


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

125E-5 Series

01 Specification

SEN00182-06

3. Outline of engine (EGR-less)


q

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


attained low fuel consumption, low noise, better exhaust gas color, and high acceleration
performance. Accordingly, this newly developed engine is suitable as a power source of
construction machinery and industrial machinery used for various purposes.

The 125E-5 EGR-less engine is the successor


to the 125E-3 engine, which is an in-line 6-cylinder, water-cooled, common rail direct injection, and 4-stroke diesel engine.

1)

The 125E-5 EGR-less engine is equipped with


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

5)

The main fuel filter of high efficiency and the


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

6)

The high-quality piston made of cast iron which


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

7)

By using the above-mentioned high-pressure


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

2)

Since the high-pressure fuel injection system


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

8)

Since the engine controller is mounted on the


engine and equipped with the automatic highaltitude compensation function, the engine can
be operated at high altitude without replacing
the controller. As a result, the serviceability is
improved.

3)

The common rail high-pressure fuel injection


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

9)

The KTR90 turbocharger newly developed and


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

4)

The pressure resistance of the common rail,


injector, and supply pump of the common rail
injection system employed for the 125E-3
engine and after models is improved for higher
reliability.

125E-5 Series

10) The copper sleeve at the injector mounting


hole of the cylinder head is eliminated.
Instead, the dry sleeve structure is employed
and the top and bottom faces of the cylinder
head are connected by casting to meet the
requirements of the high output and attain
higher reliability.

SEN00182-06

01 Specification

Specifications

Engine name

SAA6D125E-5

Applicable machine

PC400-7E0, PC400LC-7E0,
PC400-8, PC400LC-8
PC450-7E0, PC450LC-7E0,
PC450-8, PC450LC-8
mm
l {cc}

6 125 150
11.0 {11,040}
153624

Overall length

mm

1,713

Overall width

mm

1,001

Overall height (excluding exhaust pipe)

mm

Overall height (including exhaust pipe)

mm

1,741

Rated output

kW/rpm
{HP/rpm}

262.5 / 1,900
{352 / 1,900}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

1,422 / 1,400
{145 / 1,400}
(Gross)

No-load max. speed


(High idle speed)

rpm

1,930 (+35/-15)

No-load min. speed


(Low idle speed)

rpm

1,000 25

g/kWh
{g/HPh}

211
{157}

Dry weight

kg

1,310

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

46
(37)

Quantity of coolant
(for only engine)

Alternator
Starting motor
Battery

24V, 35A, 60A


24V, 7.5kW
12V, 150Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

(21)

125E-5 Series

01 Specification

SEN00182-06

Engine name

SAA6D125E-5

Applicable machine

PC400-8R, PC400LC-8R
PC450-8R, PC450LC-8R
mm
l {cc}

6 125 150
11.0 {11,040}
153624

Overall length

mm

1,713

Overall width

mm

975

Overall height (excluding exhaust pipe)

mm

Overall height (including exhaust pipe)

mm

1,741

Rated output

kW/rpm
{HP/rpm}

262.5 / 1,900
{352 / 1,900}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

1,422 / 1,400
{145 / 1,400}
(Gross)

No-load max. speed


(High idle speed)

rpm

1,930 (+35/-15)

No-load min. speed


(Low idle speed)

rpm

1,000 25

g/kWh
{g/HPh}

211
{157}

Dry weight

kg

1,270

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

46
(37)

Quantity of coolant
(for only engine)

Alternator
Starting motor
Battery

24V, 50A, 60A


24V, 7.5kW
12V, 150Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

125E-5 Series

(21)

SEN00182-06

01 Specification

Engine name

SAA6D125E-5

Applicable machine

D85EX-15E0, D85PX-15E0
mm
l {cc}

6 125 150
11.0 {11,040}
153624

Overall length

mm

1,307

Overall width

mm

1,004

Overall height (excluding exhaust pipe)

mm

1,711

Overall height (including exhaust pipe)

mm

Rated output

kW/rpm
{HP/rpm}

199 / 1,900
{266 / 1,900}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

1,272 / 1,400
{130 / 1,400}
(Gross)

No-load max. speed


(High idle speed)

rpm

2,100 50

No-load min. speed


(Low idle speed)

rpm

750 (+50/0)

g/kWh
{g/HPh}

215
{160}

Dry weight

kg

1,330

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

44
(38)

Quantity of coolant
(for only engine)

Alternator
Starting motor
Battery

24V, 50A
24V, 7.5kW
12V, 150Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

(21)

125E-5 Series

01 Specification

SEN00182-06

Engine name

SAA6D125E-5

Applicable machine

D85EX-15R, D85PX-15R
mm
l {cc}

6 125 150
11.0 {11,040}
153624

Overall length

mm

1,307

Overall width

mm

1,004

Overall height (excluding exhaust pipe)

mm

1,711

Overall height (including exhaust pipe)

mm

Rated output

kW/rpm
{HP/rpm}

199 / 1,900
{266 / 1,900}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

1,272 / 1,400
{130 / 1,400}
(Gross)

No-load max. speed


(High idle speed)

rpm

2,100 50

No-load min. speed


(Low idle speed)

rpm

750 (+50/0)

g/kWh
{g/HPh}

215
{160}

Dry weight

kg

1,270

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

44
(38)

Quantity of coolant
(for only engine)

Alternator
Starting motor
Battery

24V, 50A
24V, 7.5kW
12V, 150Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

125E-5 Series

(21)

SEN00182-06

01 Specification

Engine name

SAA6D125E-5

Applicable machine

HM250-2
mm
l {cc}

6125 150
11.0 {11,040}
153624

Overall length

mm

1,681

Overall width

mm

1,010

Overall height (excluding exhaust pipe)

mm

1,268

Overall height (including exhaust pipe)

mm

Rated output

kW/rpm
{HP/rpm}

232 / 2,000
{311 / 2,000}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

1,706 / 1,400
{174 / 1,400}
(Gross)

No-load max. speed


(High idle speed)

rpm

2,100 50

No-load min. speed


(Low idle speed)

rpm

725 (+50/0)

g/kWh
{g/HPh}

218
{162}

Dry weight

kg

1,285

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

44
(35)

Quantity of coolant
(for only engine)

Alternator
Starting motor
Battery

24V, 50A
24V, 7.5kW
12V, 300Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

10

(21)

125E-5 Series

01 Specification

SEN00182-06

Engine name

SAA6D125E-5

Applicable machine

HM300-2
mm
l {cc}

6125 150
11.0 {11,040}
153624

Overall length

mm

1,681

Overall width

mm

1,010

Overall height (excluding exhaust pipe)

mm

1,268

Overall height (including exhaust pipe)

mm

Rated output

kW/rpm
{HP/rpm}

254 / 2,000
{340 / 2,000}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

1,706 / 1,400
{174 / 1,400}
(Gross)

No-load max. speed


(High idle speed)

rpm

2,220 50

No-load min. speed


(Low idle speed)

rpm

725 (+50/0)

g/kWh
{g/HPh}

215
{161}

Dry weight

kg

1,285

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

44
(35)

Quantity of coolant
(for only engine)

Alternator
Starting motor
Battery

24V, 50A
24V, 7.5kW
12V, 300Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

125E-5 Series

(21)

11

SEN00182-06

01 Specification

Engine name

SAA6D125E-5

Applicable machine

HM300-2R
mm
l {cc}

6125 150
11.0 {11,040}
153624

Overall length

mm

1,681

Overall width

mm

1,010

Overall height (excluding exhaust pipe)

mm

1,263

Overall height (including exhaust pipe)

mm

Rated output

kW/rpm
{HP/rpm}

254 / 2,000
{340 / 2,000}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

1,706 / 1,400
{174 / 1,400}
(Gross)

No-load max. speed


(High idle speed)

rpm

2,220 50

No-load min. speed


(Low idle speed)

rpm

725 (+50/0)

g/kWh
{g/HPh}

211
{157}

Dry weight

kg

1,260

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

44
(35)

Quantity of coolant
(for only engine)

Alternator
Starting motor
Battery

24V, 50A
24V, 7.5kW
12V, 300Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

12

(21)

125E-5 Series

01 Specification

SEN00182-06

Engine name

SAA6D125E-5

Applicable machine

WA450-6
WA470-6
mm
l {cc}

6 125 150
11.0 {11,040}
153624

Overall length

mm

1,713

Overall width

mm

1,001

Overall height (excluding exhaust pipe)

mm

Overall height (including exhaust pipe)

mm

1,298

Rated output

kW/rpm
{HP/rpm}

204 / 2,000
{273 / 2,000}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

1,307 / 1,450
{133 / 1,450}
(Gross)

No-load max. speed


(High idle speed)

rpm

2,170 50

No-load min. speed


(Low idle speed)

rpm

800 (+50/0)

g/kWh
{g/HPh}

216
{161}

Dry weight

kg

1,310

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

46
(37)

Quantity of coolant
(for only engine)

Alternator
Starting motor
Battery

24V, 50A
24V, 7.5kW
24V, 136Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

125E-5 Series

(21)

13

SEN00182-06

01 Specification

Engine name

SAA6D125E-5

Applicable machine

WA470-6R
mm
l {cc}

6 125 150
11.0 {11,040}
153624

Overall length

mm

1,713

Overall width

mm

1,001

Overall height (excluding exhaust pipe)

mm

Overall height (including exhaust pipe)

mm

1,298

Rated output

kW/rpm
{HP/rpm}

204 / 2,000
{273 / 2,000}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

1,307 / 1,450
{133 / 1,450}
(Gross)

No-load max. speed


(High idle speed)

rpm

2,170 50

No-load min. speed


(Low idle speed)

rpm

800 (+50/0)

g/kWh
{g/HPh}

216
{161}

Dry weight

kg

1,250

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

46
(37)

Quantity of coolant
(for only engine)

Alternator
Starting motor
Battery

24V, 50A
24V, 7.5kW
24V, 136Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

14

(21)

125E-5 Series

01 Specification

SEN00182-06

Engine name

SAA6D125E-5

Applicable machine

WA480-6
mm
l {cc}

6 125 150
11.0 {11,040}
153624

Overall length

mm

1,713

Overall width

mm

1,001

Overall height (excluding exhaust pipe)

mm

Overall height (including exhaust pipe)

mm

1,298

Rated output

kW/rpm
{HP/rpm}

224 / 2,000
{301 / 2,000}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

1,360 / 1,400
{139 / 1,400}
(Gross)

No-load max. speed


(High idle speed)

rpm

2,190 50

No-load min. speed


(Low idle speed)

rpm

800 (+50/0)

g/kWh
{g/HPh}

216
{161}

Dry weight

kg

1,310

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

46
(37)

Quantity of coolant
(for only engine)

Alternator
Starting motor
Battery

24V, 50A
24V, 7.5kW
24V, 136Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

125E-5 Series

(21)

15

SEN00182-06

01 Specification

Engine name

SAA6D125E-5

Applicable machine

WA480-6R
mm
l {cc}

6 125 150
11.0 {11,040}
153624

Overall length

mm

1,713

Overall width

mm

1,001

Overall height (excluding exhaust pipe)

mm

Overall height (including exhaust pipe)

mm

1,298

Rated output

kW/rpm
{HP/rpm}

224 / 2,000
{301 / 2,000}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

1,360 / 1,400
{139 / 1,400}
(Gross)

No-load max. speed


(High idle speed)

rpm

2,190 50

No-load min. speed


(Low idle speed)

rpm

800 (+50/0)

g/kWh
{g/HPh}

216
{161}

Dry weight

kg

1,250

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

46
(37)

Quantity of coolant
(for only engine)

Alternator
Starting motor
Battery

24V, 50A
24V, 7.5kW
24V, 136Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

16

(21)

125E-5 Series

01 Specification

SEN00182-06

Engine name

SAA6D125E-5

Applicable machine

BR580JG-1
mm
l {cc}

6 125 150
11.0 {11,040}
153624

Overall length

mm

1,713

Overall width

mm

1,001

Overall height (excluding exhaust pipe)

mm

Overall height (including exhaust pipe)

mm

1,311

Rated output

kW/rpm
{HP/rpm}

262.5 / 1,900
{352 / 1,900}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

1,422 / 1,400
{145 / 1,400}
(Gross)

No-load max. speed


(High idle speed)

rpm

1,930 (+35/-15)

No-load min. speed


(Low idle speed)

rpm

1,000 25

g/kWh
{g/HPh}

211
{157}

Dry weight

kg

1,310

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

46
(37)

Quantity of coolant
(for only engine)

Alternator
Starting motor
Battery

24V, 35A
24V, 7.5kW
12V, 150Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

125E-5 Series

(21)

17

SEN00182-06

01 Specification

Engine name

SAA6D125E-5

Applicable machine

GD755-5R
mm
l {cc}

6 125 150
11.0 {11,040}
153624

Overall length

mm

1,340

Overall width

mm

984

Overall height (excluding exhaust pipe)

mm

Overall height (including exhaust pipe)

mm

1,640

Rated output

kW/rpm
{HP/rpm}

216 / 2,000
{289.7 / 2,000}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

1,317 / 1,400
{134.3 / 1,400}
(Gross)

No-load max. speed


(High idle speed)

rpm

2,200 50

No-load min. speed


(Low idle speed)

rpm

800 (+50/0)

g/kWh
{g/HPh}

216
{161}

Dry weight

kg

1,340

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

46
(37)

Quantity of coolant
(for only engine)

Alternator
Starting motor
Battery

24V, 75A
24V, 7.5kW
24V, 150Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

18

(21)

125E-5 Series

01 Specification

SEN00182-06

Engine name

SAA6D125E-5

Applicable machine

DCA-300SSK4
(DENYO/MQ GENERATOR)
mm
l {cc}

6125 150
11.0 {11,040}
153624

Overall length

mm

1,753

Overall width

mm

1,143

Overall height (excluding exhaust pipe)

mm

1,420

Overall height (including exhaust pipe)

mm

Rated output

kW/rpm
{HP/rpm}

272 / 1,800
{365 / 1,800}
(Gross)

Max. torque

Nm/rpm
{kgm/rpm}

No-load max. speed


(High idle speed)

rpm

Max. 1,890

No-load min. speed


(Low idle speed)

rpm

750 25

g/kWh
{g/HPh}

218
{162}

Dry weight

kg

1,450

Fuel injection pump


Governor

DENSO ECD-U2
Electronic control type

Quantity of lubricating oil


(Refill capacity)

63
(63)

Quantity of coolant
(for only engine)

53
(21)

Alternator
Starting motor
Battery

24V, 35A
24V, 7.5kW
12V, 150Ah2

Turbocharger
Air compressor
Others

KOMATSU KTR90

With air-cooled aftercooler

Performance

Dimensions

Number of cylinders Bore Stroke


Total displacement
Firing order

Fuel consumption ratio at rated output

125E-5 Series

19

SEN00182-06

01 Specification

General view

SAA6D125E-5 (Left side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Rear face of flywheel housing

20

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Front side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Center of cylinder liner

125E-5 Series

21

SEN00182-06

01 Specification

SAA6D125E-5 (Left side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Rear face of flywheel housing

22

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Front side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Center of cylinder liner

125E-5 Series

23

SEN00182-06

01 Specification

SAA6D125E-5 (Left side of engine)


Applicable machines: PC400-8R, PC400LC-8R, PC450-8R, PC450LC-8R
Reference: The manual priming pump is installed to the engine.

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Rear face of flywheel housing

24

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Rear side of engine)


Applicable machines: PC400-8R, PC400LC-8R, PC450-8R, PC450LC-8R
Reference: The manual priming pump is installed to the engine.

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Center of cylinder liner

125E-5 Series

25

SEN00182-06

01 Specification

SAA6D125E-5 (Left side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Rear face of flywheel housing

26

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Front side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Center of cylinder liner

125E-5 Series

27

SEN00182-06

01 Specification

SAA6D125E-5 (Left side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Rear face of flywheel housing

28

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Front side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Center of cylinder liner

125E-5 Series

29

SEN00182-06

01 Specification

SAA6D125E-5 (Left side of engine)


Applicable machine: HM250-2, HM300-2

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Rear face of flywheel housing

30

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Front side of engine)


Applicable machine: HM250-2, HM300-2

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Center of cylinder liner

125E-5 Series

31

SEN00182-06

01 Specification

SAA6D125E-5 (Top of engine)


Applicable machine: HM250-2, HM300-2

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.

Center of crankshaft

32

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Left side of engine)


Applicable machine: HM300-2R

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Rear face of flywheel housing

125E-5 Series

33

SEN00182-06

01 Specification

SAA6D125E-5 (Front side of engine)


Applicable machine: HM300-2R

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Center of cylinder liner

34

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Top of engine)


Applicable machine: HM300-2R

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.

Center of crankshaft

125E-5 Series

35

SEN00182-06

01 Specification

SAA6D125E-5 (Left side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Rear face of flywheel housing

36

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Front side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Center of cylinder liner

125E-5 Series

37

SEN00182-06

01 Specification

SAA6D125E-5 (Left side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Rear face of flywheel housing

38

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Front side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Center of cylinder liner

125E-5 Series

39

SEN00182-06

01 Specification

SAA6D125E-5 (Left side of engine)


Applicable machines: BR580JG-1

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Rear face of flywheel housing

40

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Front side of engine)


Applicable machines: BR580JG-1

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Center of cylinder liner

125E-5 Series

41

SEN00182-06

01 Specification

SAA6D125E-5 (Left side of engine)


Applicable machine: GD755-5R

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Rear face of flywheel housing

42

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Front side of engine)


Applicable machine: GD755-5R

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Center of cylinder liner

125E-5 Series

43

SEN00182-06

01 Specification

SAA6D125E-5 (Top of engine)


Applicable machine: GD755-5R

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Rear face of flywheel housing

44

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Left side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Rear face of flywheel housing

125E-5 Series

45

SEN00182-06

01 Specification

SAA6D125E-5 (Front side of engine)


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

a
a

The shape is subject to machine models.


For the dimensions of each part, see the last page of the general view.

1.
2.

Center of crankshaft
Center of cylinder liner

46

125E-5 Series

01 Specification

SEN00182-06

Dimensions table
Unit: mm
Engine

Dimension of each part

Machine

1,713 1,741

438

1,001

PC400-8R
PC400LC-8R

(*1) 1,713 1,741

438

PC450-8R
PC450LC-8R

(*2) 1,484 1,744

PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8
PC450-8, PC450LC-8

SAA6D125E-5

975

442

1,002

D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R

1,307 1,711

387

15

15

777

949

1,004

WA450-6, WA470-6
WA480-6, WA470-6R
WA480-6R

1,334 1,638

388

25

800

935

HM250-2, HM300-2

1,681 1,268

401

178

40

530

660

1,010

718

HM300-2R

1,681 1,263

401

178

40

530

660

1,010

718

BR580JG-1

1,713 1,311

453

1,001

GD755-5R

1,340 1,640

390

35

800

984

DCA-300SSK4
(DENYO/MQ GENERATOR)

1,753 1,420

371

160

750

810

1,143

a These dimensions are given for reference when the engine is set on a test bench.
*1: The electric priming pump switch is installed to the chassis.
*2: The manual priming pump is installed to the engine.

125E-5 Series

47

SEN00182-06

01 Specification

Weight table

(with EGR)
Unit: kg
No.

Item

Main parts

SAA6D125E-5

Turbocharger

KOMATSU KTR90

17

Cylinder head assembly

Cylinder head, valve,


valve spring

15

Cylinder block assembly

Cylinder block, bearing,


cap, cylinder liner

305

Front cover

48

29

Oil pan

Flywheel assembly

Flywheel housing assembly

Flywheel ring gear

PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8,PC400LC-8
PC450-8,PC450LC-8
BR580JG-1

18

D85EX-15E0, D85PX-15E0

21

WA450-6, WA470-6
WA480-6
HM250-2, HM300-2

22

DCA-300SSK4
(DENYO/MQ GENERATOR)

35

PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8
PC450-8, PC450LC-8
BR580JG-1

49

D85EX-15E0, D85PX-15E0

55

WA450-6, WA470-6
WA480-6

27

HM250-2, HM300-2

23

DCA-300SSK4
(DENYO/MQ GENERATOR)

118

PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8
PC450-8, PC450LC-8
BR580JG-1
D85EX-15E0, D85PX-15E0

54

WA450-6, WA470-6,
WA480-6
HM250-2, HM300-2

47

DCA-300SSK4
(DENYO/MQ GENERATOR)

64

125E-5 Series

01 Specification

SEN00182-06

Unit: kg
No.

Item

Main parts

SAA6D125E-5

Crankshaft assembly

Crankshaft, crank gear

106

Camshaft assembly

Camshaft, cam gear,


thrust plate

16

10

Piston and connecting rod


assembly

Piston, piston ring,


piston pin, connecting rod

11

Oil pump

12 Fuel supply pump

10

13 Water pump

10

14 Alternator

15 Starting motor

24V, 35A

24V, 50A

10

24V, 60A

11

24V, 75A

13

24V, 7.5kW

16

24V, 11kW

18

16 EGR oil pump

17 EGR valve

16

18 Bypass valve

16

19 EGR cooler

125E-5 Series

49

SEN00182-06

01 Specification

(EGR-less)
Unit: kg
No.

Item

Main parts

SAA6D125E-5

Turbocharger

KOMATSU KTR90

17

Cylinder head assembly

Cylinder head, valve,


valve spring

15

Cylinder block assembly

Cylinder block, bearing,


cap, cylinder liner

305

Front cover

29

Oil pan

Flywheel assembly

Flywheel ring gear

Flywheel housing assembly

PC400-8R, PC400LC-8R
PC450-8R, PC450LC-8R

18

D85EX-15R, D85PX-15R
GD755-5R

21

HM300-2R
WA470-6R, WA480-6R

22

PC400-8R, PC400LC-8R
PC450-8R, PC450LC-8R

49

D85EX-15R, D85PX-15R

55

WA470-6R, WA480-6R

27

HM300-2R

23

GD755-5R

56

PC400-8R, PC400LC-8R
PC450-8R, PC450LC-8R
D85EX-15R, D85PX-15R
GD755-5R

54

HM300-2R
WA470-6R, WA480-6R

47

Crankshaft assembly

Crankshaft, crank gear

106

Camshaft assembly

Camshaft, cam gear,


thrust plate

16

10

Piston and connecting rod


assembly

Piston, piston ring,


piston pin, connecting rod

11

Oil pump

12 Fuel supply pump

10

13 Water pump

10

14 Alternator

15 Starting motor

50

24V, 50A

10

24V, 60A

11

24V, 75A

13

24V, 7.5kW

16

24V, 11kW

18

125E-5 Series

01 Specification

SEN00182-06

Engine performance curves


Engine

SAA6D125E-5

125E-5 Series

Engine serial No.

1
Applicable machine

Page

PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8, PC400-8R, PC400LC-8R
PC450-8, PC450LC-8, PC450-8R, PC450LC-8R

52

D85EX-15E0, D85EX-15R, D85PX-15E0, D85PX-15R

53

WA450-6, WA470-6, WA470-6R

54

WA480-6, WA480-6R

55

HM250-2

56

HM300-2, HM300-2R

57

BR580JG-1

58

GD755-5R

59

51

SEN00182-06

SAA6D125E-5
(Applicable machine:

01 Specification

PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0


PC400-8, PC400LC-8, PC400-8R, PC400LC-8R,
PC450-8, PC450LC-8, PC450-8R, PC450LC-8R)

Rated output: 262.5 kW {352 HP}/1,900 rpm (Gross)


Max. torque: 1,423 Nm {145 kgm}/1,400 rpm (Gross)

52

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5
(Applicable machine: D85EX-15E0, D85EX-15R, D85PX-15E0, D85PX-15R)
Rated output: 199 kW {266 HP}/1,900 rpm (Gross)
Max. torque: 1,272 Nm {130 kgm}/1,400 rpm (Gross)

125E-5 Series

53

SEN00182-06

01 Specification

SAA6D125E-5 (Applicable machine: WA450-6, WA470-6, WA470-6R)


Rated output: 204 kW {273 HP}/2,000 rpm (Gross)
Max. torque: 1,307 Nm {133 kgm}/1,450 rpm (Gross)

54

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Applicable machine: WA480-6, WA480-6R)


Rated output: 224 kW {301 HP}/2,000 rpm (Gross)
Max. torque: 1,360 Nm {139 kgm}/1,400 rpm (Gross)

125E-5 Series

55

SEN00182-06

01 Specification

SAA6D125E-5 (Applicable machine: HM250-2)


Rated output: 232 kW {311 HP}/2,000 rpm (Gross)
Max. torque: 1,706 Nm {174 kgm}/1,400 rpm (Gross)

56

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Applicable machine: HM300-2, HM300-2R)


Rated output: 254 kW {340 HP}/2,000 rpm (Gross)
Max. torque: 1,706 Nm {174 kgm}/1,400 rpm (Gross)

125E-5 Series

57

SEN00182-06

01 Specification

SAA6D125E-5 (Applicable machine: BR580JG-1)


Rated output: 262.5 kW {352 HP}/1,900 rpm (Gross)
Max. torque: 1,423 Nm {145 kgm}/1,400 rpm (Gross)

58

125E-5 Series

01 Specification

SEN00182-06

SAA6D125E-5 (Applicable machine: GD755-5R)


Rated output: 216 kW {289.7 HP}/2,000 rpm (Gross)
Max. torque: 1,317 Nm {134.3 kgm}/1,400 rpm (Gross)

125E-5 Series

59

SEN00182-06

KOMATSU 125E-5 Series engine


Form No. SEN00182-06

2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11

60

SEN00184-06
125E-5 Series
SEN00184-05

ENGINE
Shop Manual

125E-5 Series

Machine model Serial number


125E-5 SERIES ENGINE .........

10 Structure,function and
maintenance standard
Structure, function and maintenance
standard, Part 1
General structure ........................................................................................................................................

Air intake and exhaust unit..........................................................................................................................

Air cleaner................................................................................................................................................... 10
Turbocharger .............................................................................................................................................. 12
Aftercooler................................................................................................................................................... 19
EGR system................................................................................................................................................ 20
Cylinder head.............................................................................................................................................. 27
Cylinder block ............................................................................................................................................. 30

125E-5 Series

SEN00184-06

10 Structure,function and maintenance standard

Cylinder liner ............................................................................................................................................... 34


Main moving parts....................................................................................................................................... 35
Crankshaft................................................................................................................................................... 37
Camshaft..................................................................................................................................................... 38
Cam follower and push rod ......................................................................................................................... 39
Piston, piston ring and piston pin ................................................................................................................ 40
Connecting rod............................................................................................................................................ 42
Flywheel and flywheel housing ................................................................................................................... 43
Vibration damper......................................................................................................................................... 48
Timing gear ................................................................................................................................................. 50
Valve system............................................................................................................................................... 58
Valve and valve guide ................................................................................................................................. 62
Rocker arm and shaft.................................................................................................................................. 64
Crosshead and guide .................................................................................................................................. 65

125E-5 Series

10 Structure,function and maintenance standard

125E-5 Series

SEN00184-06

SEN00184-06

10 Structure,function and maintenance standard

General structure

1. Cylinder block
2. Cylinder liner
3. Piston
4. Connecting rod
5. Piston pin
6. Cross head
7. Intake valve
8. Exhaust valve
9. Rocker arm shaft
10. Injector
11. Cylinder head cover
12. Camshaft
13. Ring gear

14. Flywheel
15. Rear seal
16. Flywheel housing
17. Oil pan
18. Crankshaft
19. Main bearing cap
20. Oil strainer
21. Crank gear
22. Front cover
23. Front seal
24. Crankshaft pulley
25. Vibration damper

125E-5 Series

10 Structure,function and maintenance standard

26. Exhaust manifold


27. Turbocharger
28. Cylinder head
29. Rocker arm
30. Push rod

SEN00184-06

31. Air intake manifold


32. Common rail
33. Fuel supply pump
34. Cam follower
35. Connecting rod cap

Engine
Name: SAA6D125E-5 (with turbocharger and air-cooled aftercooler)
Type : In-line 6-cylinder, water-cooled, direct injection, 4-stroke diesel engine

125E-5 Series

SEN00184-06

10 Structure,function and maintenance standard

Air intake and exhaust unit


SAA6D125E-5 (Left side of engine)

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


1. Electrical intake air heater
2. Diffuser
3. Intake manifold

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

SAA6D125E-5 (Right side of engine) (with EGR)

A: To EGR cooler
B: To turbocharger
C: From bypass valve
1. Exhaust manifold (Rear)
2. Exhaust manifold (Center)
3. Exhaust manifold (Front)

125E-5 Series

SEN00184-06

10 Structure,function and maintenance standard

SAA6D125E-5 (Right side of engine) (EGR-less)

A: To turbocharger
1. Exhaust manifold (Rear)
2. Exhaust manifold (Center)
3. Exhaust manifold (Front)

125E-5 Series

10 Structure,function and maintenance standard

125E-5 Series

SEN00184-06

10 Structure,function and maintenance standard

SEN00184-06

Air cleaner
FRG type (Radial seal type)

a The shape is subject to machine models.


1. Inlet
2. Outlet
3. Guide vane
4. Primary element
5. Safety element
Engine

6. Evacuator valve
7. Dust pan
8. Guide plate (Sleeve)
9. Body
10. Element
Applicable machines

PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8, PC400-8R, PC400LC-8R
PC400-8, PC400LC-8, PC400-8R, PC400LC-8R
D85EX-15E0, D85PX-15R
D85PX-15E0, D85PX-15R
SAA6D125E-5
WA450-6, WA470-6, WA470-6R
WA480-6, WA480-6R
HM250-2, HM300-2, HM300-2R
BR580JG-1, GD755-5R
DCA-300SSK4
(DENYO/MQ GENERATOR)

10

Type

Evacuator
valve

Number of elements

FRG
(Radial seal type)

Automatic
discharge

1 inner element
1 outer element

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

Structure
q The size of the body is reduced from the conventional type without changing the diameter of the
element.
q Since the inlet is set in the tangential direction,
air is given sufficient centrifugal force by the simple spiral guide vane, not by the guide plate.

Operation
q Air containing dust is sucked in vertically through
inlet (1) and the dust is separated by the centrifugal effect of guide vane (3).
q More than 99.9% of the dust is removed by primary element (4) and clean air is sucked in the
engine through safety element (5) and outlet (2).
q The dust and water separated by guide vane (3)
swirl along the inside wall of body (9) and enter
evacuator valve (6) and then are discharged out
automatically.

125E-5 Series

11

SEN00184-06

10 Structure,function and maintenance standard

Turbocharger
(with EGR)
Model name: KTR90

12

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

A: Intake air inlet


B: Intake air outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
E: Oil inlet
F: Oil outlet
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model name: KOMATSU KTR90
Overall length: 268 mm
Overall width: 247 mm
Overall height: 227 mm
Weight: 17 kg

125E-5 Series

13

10 Structure,function and maintenance standard

SEN00184-06

Unit: mm

No.

Check item

1 End play (Play in axial direction)


2 Radial play (Play in radial direction)
3

14

Clearance between blower housing and impeller

Criteria

Remedy

Standard

Repair limit

0.08 0.13

0.18

0.38 0.59

Clearance limit (Min.): 0.01

Replace thrust parts


Replace bearing
parts
Replace bearing
parts

125E-5 Series

10 Structure,function and maintenance standard

125E-5 Series

SEN00184-06

15

SEN00184-06

10 Structure,function and maintenance standard

(EGR-less)
Model name: KTR90

16

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

A: Intake air inlet


B: Intake air outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
E: Oil inlet
F: Oil outlet
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model name: KOMATSU KTR90
Overall length: 268 mm
Overall width: 247 mm
Overall height: 227 mm
Weight: 17 kg

125E-5 Series

17

10 Structure,function and maintenance standard

SEN00184-06

Unit: mm

No.

Check item

1 End play (Play in axial direction)


2 Radial play (Play in radial direction)
3

18

Clearance between blower housing and impeller

Criteria

Remedy

Standard

Repair limit

0.08 0.13

0.18

0.38 0.59

Clearance limit (Min.): 0.01

Replace thrust parts


Replace bearing
parts
Replace bearing
parts

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

Aftercooler
Air-cooled type

a The shape is subject to machine models.


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

10 Structure,function and maintenance standard

SEN00184-06

EGR system

No.
1

Component part
EGR valve (driven hydraulically)

Function
q
q
q

2 Bypass valve

Controls the gas flow from the exhaust system to the air intake system.
Since the exhaust pressure (PEX) is higher than the boost pressure (PIN), the exhaust gas flows to the air intake valve.
Opens the bypass valve when the boost pressure (PIN) is higher than the exhaust
pressure (PEX).
Makes the intake air flow to the exhaust side to increase the exhaust pressure so
that the exhaust gas will be returned to the air intake side easily.

3 EGR cooler

Lowers the exhaust temperature and returns the exhaust gas to the air intake side.

4 Venturi system

Generates negative pressure with the venturi effect and takes in the exhaust gas.

Controls the EGR according to the operating condition.


Troubleshoots the system.

5 Each sensor

Features
q The exhaust gas is kept clean by sensing each
part of the EGR circuit and controlling the EGR
rate according to the operating condition.
q Since the EGR circuit is monitored and troubleshooted, a serious trouble is prevented.

20

125E-5 Series

10 Structure,function and maintenance standard

125E-5 Series

SEN00184-06

21

SEN00184-06

10 Structure,function and maintenance standard

a The above illustration shows the engine for HM300-2.

22

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

1. EGR valve
2. Bypass valve
3. EGR cooler
4. Venturi system
5. EGR valve position sensor
6. Bypass valve position sensor
7. Bypass piping
8. EGR piping
9. EGR oil pump
Operation
q The engine controller outputs signals for opening EGR valve (1) most properly according to the
load on the engine to attain both clean exhaust
gas and low fuel consumption.
q If EGR valve (1) opens, a part of the exhaust gas
(EGR gas) flows from the exhaust manifold
through EGR piping (8) to EGR cooler (3).
q The exhaust gas cooled by EGR cooler (3) flows
through EGR valve (1) and mixes with the intake
air in venturi system (4), and then flows in the air
intake manifold.
q In the operating range where the boost pressure
is higher than the exhaust pressure on the high
load side, the EGR gas does not flow to the air
intake side easily. At this time, the engine controller opens bypass valve (2).
q If bypass valve (2) opens, the intake air flows
through bypass piping (7). As a result, the exhaust pressure rises and more EGR gas mixes
with the intake air.

125E-5 Series

23

SEN00184-06

10 Structure,function and maintenance standard

EGR valve and bypass valve

A: Oil inlet
B: Oil outlet
C: EGR gas passage (EGR valve)
D: Boost air passage (Bypass valve)

1. Stick prevention device


2. Oil pressure control valve
3. Solenoid
4. Position sensor
5. Hydraulic piston
6. Spring
7. Valve

Function
q The EGR valve controls the EGR gas.
q This valve is driven hydraulically and its opening
ratio is controlled electronically.

Operation
The oil pressure (engine oil) of 1.47 MPa {15
kg/cm2} supplied to oil inlet (A) is reduced by oil
pressure control valve (2).
q Hydraulic piston (5) generates pressing force
from the reduced oil pressure.
q The control oil pressure can be changed with the
drive current of solenoid (3).

24

q
q

Valve (7) is closed by spring (6) but pushed open


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

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

EGR cooler

A: EGR gas inlet


B: EGR gas outlet
C: Coolant inlet

D: Coolant outlet
E: Air bleeder

1. Heat exchange tube (Corrugated tube)


Function
q The EGR cooler cools the high-temperature
EGR gas taken out of the exhaust gas to increase the gas density, or the EGR efficiency.
Structure
The EGR cooler is a multi-tube heat exchanger.
When the high-temperature EGR gas flows
through heat exchange tube (1), it is cooled by
the coolant flowing outside of the tube.
q Heat exchange tube (1) is made of corrosion-resistant stainless steel and corrugated to increase the cooling efficiency.
q

125E-5 Series

25

SEN00184-06

10 Structure,function and maintenance standard

Venturi system

A: Air inlet
B: EGR gas inlet

1. Venturi nozzle
2. Throat
3. Diffuser

Structure
q The EGR gas and intake air mix together in the
venturi system.
q The venturi system consists of throat (2), venturi
nozzle (1), and diffuser (3).
Operation
The boost pressure increased by the turbocharger is set negative temporarily with the venturi effect of the throat to take the EGR gas into
the intake air through venturi nozzle (1).
q When the mixture of the EGR gas and intake air
flows through diffuser (3), its pressure is increased again to the normal level and then it
flows in the intake manifold.
q

26

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

Cylinder head

1. Coolant air tube


2. Cylinder head bolt
3. Injector
4. Fuel spill tube
5. Valve guide
6. Cylinder head
7. Cylinder head cover
8. Valve seat insert
9. Rocker arm housing

125E-5 Series

27

SEN00184-06

10 Structure,function and maintenance standard

a The shape is subject to machine models.


Cylinder head
q Direct injection type
q 4-valve type
q Overhead injector (Common rail system specification)
q Split-type 1-cylinder, 1-head
Valve seat
Valve seat inserts are press fitted to both intake and exhaust valves

Head cover
Float-type seal

28

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

a Order of tightening cylinder head mounting bolts


a Tighten the cylinder head mounting bolts in the order of (1) ? (7).
Unit: mm

No.
1

Check item

Criteria
Tolerance

Repair limit

00.06

0.09

Engine

Standard

SAA6D125E - 5

3.203.90

Strain of cylinder head mounting


surface

2 Projection of nozzle

Bolt

Tightening torque of cylinder head


mounting bolt
(apply molybdenum disulfide or
engine oil to underside of bolt
head.)

Procedure
1st stage

(1)(6)

2nd stage
3rd stage

(7)

Tightening torque of injector mounting bolt

Tightening torque of rocker arm


housing mounting bolt

125E-5 Series

Remedy

Correct by grinding
or replace
Replace nozzle
sleeve

Target (Nm {kgm}) Range (Nm {kgm})


88.2107.8
98 {10}
{911}
166.6176.4
Tighten in order
176.4 {18}
{1718}
shown above
Retighten 120
90120
68.6 {7}

58.873.5 {67.5}

Target (Nm {kgm})

Range (Nm {kgm})

66 {6.75}

58.873.5 {6.07.5}

66 {6.75}

58.873.5 {6.07.5}

Tighten

29

SEN00184-06

10 Structure,function and maintenance standard

Cylinder block

1. Cylinder block
2. Cylinder liner
3. Clevis seal
4. Liner ring (Ethylene-propylene rubber)
5. Liner ring (Silicone rubber)
6. Front seal
7. Front cover
8. Main cap bolt
9. Main bearing cap
10. Main bearing
11. Thrust bearing
12. Piston cooling nozzle

30

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

Cylinder block
q Crankshaft section: 7 bearings
q Camshaft section: 7 bearings
Front seal
Single lip with dust seal

Piston cooling
With piston cooling nozzle

Cylinder liner
Wet type
q Machining on inside: Plateau honing
Soft nitriding process
q

Liner ring
Upper: Clevis seal
q Middle: O-ring (Ethylene-propylene rubber)
q Lower: O-ring (Silicone rubber)
q

125E-5 Series

31

10 Structure,function and maintenance standard

SEN00184-06

Unit: mm

No.
1

Check item
Strain of cylinder head mounting
surface
Diameter of main bearing mounting hole

Criteria
Tolerance

Repair limit

0 0.080

0.12

Standard size

Tolerance
+0.015
-0.010

116

Roundness of mounting hole


3
Standard size

Diameter of cam bushing mounting


hole

110

32

Tolerance
+0.040
+0.010

Standard size
63
Standard size

5 Inside diameter of cam bushing

Correct by grinding
or replace
Replace main bearing cap

Repair limit: 0.005

Thickness of main bearing

3 Inside diameter of main bearing

Remedy

60

Tolerance
+0.070
0

-0.005
-0.020
Repair limit
110.15
Tolerance
+0.030
0
Repair limit
60.30

Replace bearing
Replace main bearing
Correct or replace
cylinder block
Replace cam bushing

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

Unit: mm

No.

Check item

Tightening torque of main cap


(apply engine oil to threads)

Tightening torque for oil pan mounting bolt

Tightening torque for crankshaft


pulley mounting bolt

Criteria

Remedy

Procedure
1st stage
2nd stage
3rd stage

Target (Nm {kgm})


98 {10}
196 {20}
Retighten 90

Range (Nm {kgm})


88 108 {9 11}
191 201 {19.5 20.5}
Retighten 90(+30/0)

54 {5.5}

34 73 {3.5 7.5}

M16 (5 pieces)

274 {28}

245 309 {25 31.5}

M14 (1 piece)

176 {18}

157 196 {16 20}

Tighten

Level difference between underside

9 surfaces of cylinder block and flywheel housing


Level difference between underside
10 surfaces of cylinder block and front
cover

125E-5 Series

Repair limit: 0.35


Correct by reassembling
Repair limit: 0.28

33

10 Structure,function and maintenance standard

SEN00184-06

Cylinder liner

Unit: mm

No.

Check item

1 Projection of cylinder liner


Inside diameter of cylinder liner
(unit)

Criteria

Remedy

Permissible range: 0.07 0.15

Replace cylinder liner or


cylinder block

Rank

Standard size

125

125

Roundness of inside of cylinder


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

Outside diameter of cylinder liner


(at counterbore portion) (unit)

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

Outside diameter of cylinder liner


(at O-ring)
Clearance between cylinder liner
and block (at O-ring)

34

Repair limit
125.20
125.20
Replace cylinder liner
(Spare liner is supplied
only for rank B)

Repair limit: 0.08


Repair limit: 0.08
Standard size

Tolerance

153

0.025

Interference of cylinder liner and


block (at counterbore portion)
Outside diameter of cylinder liner
(at bottom of counterbore)

Tolerance
+0.020
0
+0.040
+0.021

Standard clearance: 0 0.113


Standard size

Standard interference

Tolerance
+0.090
+0.040
Interference limit

0.010.12

0.01

Standard size

Tolerance
+0.386
+0.361

145

141

Standard clearance: 0.014 0.079

Replace cylinder liner or


block
Replace cylinder liner
Replace cylinder liner or
block
Replace cylinder liner
Replace cylinder liner or
block

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

Main moving parts

a The shape is subject to machine models.


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

125E-5 Series

7. Connecting rod bearing


8. Connecting rod
9. Connecting rod cap bolt
10. Top ring
11. Second ring
12. Oil ring

35

SEN00184-06

10 Structure,function and maintenance standard

Specifications
Crankshaft: Closed die forging
: Journal, fillet Induction hardening

Piston rings

Piston: Special thin ductile cast iron (FCD piston)


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

36

Top ring (1): Double-side keystone, inner cut, barrel


face, hard chromium-plated
Second ring (2): Keystone, inner cut, taper face,
hard chromium-plated
Oil ring (3): With coil expander and nitrided surface

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

Crankshaft

Unit: mm

No.

Check item

1 End play

Criteria
Standard value

Repair limit

0.140 0.315

0.50

Standard size

Outside diameter of main journal

Roundness

Clearance of crankshaft pin journal

4 Bend of crankshaft

125E-5 Series

Repair limit

110

109.88

0.25 U.S.

109.75

109.63

0.50 U.S.

109.50

0.75 U.S.

109.25

109.13

1.00 U.S.

109.00

108.88

-0.050
-0.070

109.38

Standard

Repair limit

0 0.010

0.020

Standard clearance

Clearance limit

0.062 0.106

0.27

Standard size

Outside diameter of crank pin journal

Tolerance

Replace thrust bearing or use oversize


bearing

S.T.D.

Roundness

Clearance of main journal

Remedy

Tolerance

Use undersize journal or replace

Replace main bearing

Repair limit

S.T.D.

80

79.88

0.25 U.S.

79.75

79.63

0.50 U.S.

79.50

0.75 U.S.

79.25

79.13

1.00 U.S.

79.00

78.88

-0.050
-0.070

79.38

Standard

Repair limit

0 0.010

0.020

Standard clearance

Clearance limit

0.046 0.090

0.24

Standard

Repair limit

0 0.09

0.20

Use undersize journal or replace

Replace connecting
rod bearing
Use undersize
crank-shaft or
replace

37

10 Structure,function and maintenance standard

SEN00184-06

Camshaft

Unit: mm

No.

Check item

1 End play
Outside diameter of camshaft journal

2
Clearance of camshaft journal

3 Bend of camshaft

Criteria
Standard

Repair limit

0.15 0.35

0.50

Standard size

Standard clearance

Tolerance
-0.080
-0.110
Clearance limit

0.080 0.180

0.28

60

38

Replace thrust plate

Replace
Replace cam bushing

Repair limit: 0.03 (Overall swing of indicator)


Standard size

4 Height of cam

Remedy

52

Tolerance
+0.395
+0.195

Repair limit

Replace

51.73

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

Cam follower and push rod

Unit: mm

No.

Check item

Criteria
Standard size

Diameter of cam follower shaft

1
Diameter of cam follower shaft hole

2 Outside diameter of cam roller

Tolerance
-0.040
-0.050
+0.020
0
-0.250
-0.280
-0.262
-0.287
-0.364
-0.376

19.8
19.8
32

Inside diameter of cam roller

13

Diameter of cam roller pin

13

Remedy
Repair limit
19.73

31.70
12.78

Replace

12.62

Standard size

4 Radius of push rod ball end


5 Radius of push rod socket end
6 Bend of push rod

Tightening torque of cam follower


shaft mounting bolt

125E-5 Series

Tolerance
0
12.7
-0.20
0
12.7
-0.20
Repair limit: 0.50 (Overall swing of indicator)
51 7.4 Nm {5.25 0.75 kgm}

Tighten

39

SEN00184-06

10 Structure,function and maintenance standard

Piston, piston ring and piston pin

40

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

Unit: mm

No.

Check item

Outside diameter of piston

Thickness of piston ring

Width of piston ring groove

24
Clearance between piston ring and
piston ring groove

Closed gap of piston ring

Criteria
Rank

Standard size

A or S

125

B or L

125

No.

Measuring point

Tolerance
-0.090
-0.105
-0.075
-0.090
Standard size

No. 1 ring

2.42

No. 2 ring

2.4

Oil ring

No. 1 ring

No. 2 ring

Oil ring

+0.040
+0.020

No.

Measuring point

Standard clearance

Clearance limit

No. 1 ring

Diameter of piston pin hole


Clearance between piston pin and
piston

Weight of piston

Repair limit
124.80
124.80
Tolerance
-0.005
-0.025
-0.010
-0.030
-0.010
-0.030

No. 2 ring

Oil ring

0.030 0.070

0.15

No. 1 ring

0.37 0.47

2.0

No. 2 ring

1.10 1.20

2.0

Oil ring

0.23 0.35

1.0

Standard clearance

Tolerance
0
-0.006
+0.045
+0.035
Clearance limit

0.035 0.051

0.063

48
48

Replace piston
(Spare piston is
supplied for only
rank A or S)

Replace piston ring

*1 Check with groove wear gauge


(When new ring is installed, clearance is 0.15)
Replace piston

Check with groove wear gauge

Standard size
Outside diameter of piston pin

Remedy

3,000g, Permissible range: 60 g

Replace piston or
piston ring

Replace piston ring


or cylinder liner

Replace piston pin


Replace piston
Replace piston or
piston pin
Replace piston

a *1: Part No. (Groove wear gauge) 795-901-1130

125E-5 Series

41

10 Structure,function and maintenance standard

SEN00184-06

Connecting rod

Unit: mm

No.

Check item
Inside diameter of connecting rod
small end bushing

1
Clearance between connecting rod
small end bushing and piston pin

Diameter of connecting rod small


end bushing mounting hole
Inside diameter of connecting rod

3 large end bearing


(crank pin journal)

Diameter of connecting rod large


end bearing mounting hole
Thickness of connecting rod bearing

Parallelism and twist of connecting


rod

Tightening torque of connecting rod


cap mounting bolt
(Apply engine oil to bolt threads
and nut seat)

Weight of connecting rod

Criteria
Standard size

Tolerance
+0.041
+0.025

48

Remedy
Repair limit
48.08

Standard clearance

Clearance limit

0.025 0.047

0.10

Standard size

Tolerance
+0.030
0
Repair limit

53
Standard size

Tolerance
+0.020
80
80.12
-0.010
+0.022

85
-0.004
Before measuring, tighten connecting rod cap mounting bolt to specified torque.
+0.005
2.5

-0.004
Item
Standard
Repair limit
Parallelism a

0 0.20

0.25

Twist b

0 0.30

0.35

Dimension c

240

Procedure

Target (Nm {kgm})

Range (Nm {kgm})

1st stage

98 {10}

93 103 {9.5 10.5}

2nd stage

Retighten 90

Retighten 90 (+30/0)

Permissible range: Dispersion of weight of connecting rods in 1


engine must not exceed 140 g.

Replace bushing
(Spare is half
worked)
Replace bushing or
piston pin
Replace connecting rod
Replace bearing

Replace connecting rod


Replace bearing

Replace connecting rod

Retighten

Replace

a Do not use a connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on its head.

42

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

Flywheel and flywheel housing


Without PTO

a The shape is subject to machine models.


1. Flywheel housing
2. Ring gear
3. Flywheel
4. Rear seal

125E-5 Series

Applicable machine
PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8,
PC400-8R, PC400LC-8R
PC450-8, PC450LC-8,
PC450-8R, PC450LC-8R
D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
BR580JG-1, GD755-5R
WA450-6, WA470-6,
WA470-6R
WA480-6, WA480-6R
HM250-2
HM300-2, HM300-2R

Number of
teeth of ring
gear

Number of
internal
teeth of flywheel

148

137

43

SEN00184-06

10 Structure,function and maintenance standard

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

10 Structure,function and maintenance standard

SEN00184-06

Unit: mm

No.

Check item

Criteria

1 Face runout of flywheel housing

Repair limit: 0.35

2 Radial runout of flywheel housing

Repair limit: 0.30


Bolt

Tightening torque of flywheel housing mounting bolt

Procedure

Target (Nm {kgm})

Range (Nm {kgm})

1st stage

191 {19.5}

147 235 {15 24}

2nd stage

279 {28.5}

245 309 {25 31.5}

69 {7}

59 74 {6 7.5}

4 Facial runout of flywheel

Repair limit: 0.20

5 Radial runout of flywheel

Repair limit: 0.15

Correct by reassembling

M16

M10

Tightening torque for flywheel


mounting bolt (Apply engine oil to
threads)

Remedy

Tighten

Correct by reassembling

Procedure

Target (Nm {kgm})

Range (Nm {kgm})

1st stage

147 {15}

127 167 {13 17}

2nd stage

289 {29.5}

270 309 {27.5 31.5}

Tighten

a Do not use a flywheel mounting bolt more than 5


times.
Each time the bolt is used, make a punch mark
on its head.

125E-5 Series

45

SEN00184-06

10 Structure,function and maintenance standard

DCA-300SSK4 (DENYO/MQ GENERATOR)

a The shape is subject to machine models.


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

10 Structure,function and maintenance standard

SEN00184-06

A: Tightening order of flywheel mounting bolts


B: Tightening order of flywheel housing mounting
bolts
1. Flywheel housing
2. Seal
3. Flywheel

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

Number of
teeth of
ring gear

Number of
internal teeth
of flywheel

178

Unit: mm

No.

Check item

Criteria

Facial runout of flywheel housing

Repair limit: 0.25

Radial runout of flywheel housing

Repair limit: 0.25


Bolt

Tightening torque of flywheel housing mounting bolt

Remedy
Correct by reassembling

Procedure

Target (Nm {kgm})

Range (Nm {kgm})

1st stage

191 {19.5}

147 235 {15 24}

2nd stage

279 {28.5}

245 309 {25 31.5}

69 {7}

59 74 {6 7.5}

M16

M10

Tighten

Facial runout of flywheel

Repair limit: 0.28

Radial runout of flywheel

Repair limit: 0.13

Tightening torque for flywheel


mounting bolt (Apply engine oil to
threads)

Correct by reassembling

Procedure

Target (Nm {kgm})

Range (Nm {kgm})

1st stage

147 {15}

127 167 {13 17}

2nd stage

289 {29.5}

270 309 {27.5 31.5}

Tighten

a Do not use a flywheel mounting bolt more than 5


times.
Each time the bolt is used, make a punch mark
on its head.

125E-5 Series

47

SEN00184-06

10 Structure,function and maintenance standard

Vibration damper

a The shape is subject to machine models.


1. Vibration damper
2. Pin
3. Crankshaft pulley
4. Crankshaft pulley mounting bolt
5. Vibration damper mounting bolt

48

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

Unit: mm

No.

Check item

1 Outside check

Criteria
Rubber parts must be free from cracking and flaking.

2 Radial runout of damper

Repair limit: 0.80

3 Facial runout of damper

Repair limit: 0.80

Tightening torque of vibration


damper mounting bolt

125E-5 Series

Remedy

Replace

Bolt

Target (Nm {kgm})

Range (Nm {kgm})

M12

111 {11.3}

98 213 {10 12.5}

Tighten

49

SEN00184-06

10 Structure,function and maintenance standard

Timing gear
(with EGR)

a The shape is subject to machine models.


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

50

7. Oil pump idler gear (Number of teeth: 25)


8. Injection drive gear (Number of teeth: 44)
9. Timing gear cover
10. Camshaft gear (Number of teeth: 44)
11. Crankshaft gear (Number of teeth: 33)
12. Crankshaft
A.B.C: Timing gear mating marks

125E-5 Series

10 Structure,function and maintenance standard

125E-5 Series

SEN00184-06

51

10 Structure,function and maintenance standard

SEN00184-06

Unit: mm

No.

Check item

Criteria
Position

Backlash of each gear

1
2

Clearance between main idler gear


bushing and shaft
Clearance between oil pump idler
gear bushing and shaft

3 End play of main idler gear


4 End play of oil pump idler gear

52

Check parts

Remedy
Standard

Crank gear and main idler gear (large) 0.116 0.359

Main idler gear (small) and cam gear

0.105 0.325

Cam gear and fuel supply pump gear

0.105 0.325

Main idler gear (large) and water


a
pump gear
Main idler gear (large) and oil pump
b
idler gear
Oil pump idler gear and oil pump drive
c
gear
Tolerance
Standard size
Shaft
Hole
+0.165
+0.115
47.5
+0.140
+0.100
-0.025
+0.065
35
-0.040
0
Standard

Repair limit

Replace

0.6
0.076 0.366
0.105 0.337
0.082 0.389
Standard
clearance

Clearance
limit

0.025 0.060

0.20

0.025 0.105

0.20

Replace
bushing

Repair limit

0.05 0.17

0.4

0.05 0.21

0.4

Replace
thrust bearing

125E-5 Series

10 Structure,function and maintenance standard

125E-5 Series

SEN00184-06

53

SEN00184-06

10 Structure,function and maintenance standard

(EGR-less)

a The shape is subject to machine models.


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

54

7. Injection drive gear (Number of teeth: 44)


8. Timing gear cover
9. Camshaft gear (Number of teeth: 44)
10. Crankshaft gear (Number of teeth: 33)
11. Crankshaft
A.B.C: Timing gear mating marks

125E-5 Series

10 Structure,function and maintenance standard

125E-5 Series

SEN00184-06

55

10 Structure,function and maintenance standard

SEN00184-06

Unit: mm

No.

Check item

Criteria
Position

Backlash of each gear

1
2

Clearance between main idler gear


bushing and shaft
Clearance between oil pump idler
gear bushing and shaft

3 End play of main idler gear


4 End play of oil pump idler gear

56

Check parts

Remedy
Standard

Crank gear and main idler gear (large) 0.116 - 0.359

Main idler gear (small) and cam gear

0.105 - 0.325

Cam gear and fuel supply pump gear

0.105 - 0.325

Main idler gear (large) and water


a
pump gear
Main idler gear (large) and oil pump
b
idler gear
Oil pump idler gear and oil pump drive
c
gear
Tolerance
Standard size
Shaft
Hole
+0.165
+0.115
47.5
+0.140
+0.100
-0.025
+0.065
35
-0.040
0
Standard

Repair limit

Replace

0.6
0.076 - 0.366
0.105 - 0.337
0.082 - 0.389
Standard
clearance

Clearance
limit

0.025 - 0.060

0.20

0.025 - 0.105

0.20

Replace
bushing

Repair limit

0.05 - 0.17

0.4

0.05 - 0.21

0.4

Replace
thrust bearing

125E-5 Series

10 Structure,function and maintenance standard

125E-5 Series

SEN00184-06

57

SEN00184-06

10 Structure,function and maintenance standard

Valve system

1. Rocker arm shaft


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

58

11. Valve spring


12. Valve spring seat (lower) (both IN and EX)
13. Adjustment screw
14. Locknut
15. Rocker arm
16. Push rod
17. Cam follower
18. Valve cotter
19. Exhaust valve
20. Valve stem seal (both IN and EX)

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

A: No.1 cylinder intake side


B: No.1 cylinder exhaust side
Camshaft: Closed die forging
Journal and cam sections: Induction hardening

125E-5 Series

59

10 Structure,function and maintenance standard

SEN00184-06

Parts related to valves


Part
Cross head
Valve
Valve spring
(Color code)
Valve spring seat
(lower)
Valve rotator
Valve guide
Valve stem seal

IN
6150-42-5610
6150-42-4110
6251-41-4450
( Light blue )

EX
6150-42-5610
6150-42-4210
6251-41-4450
( Light blue )

6150-41-4430 6150-41-4430

6150-11-1370 6150-11-1370
6150-41-4570 6150-41-4570

Valve timing

60

125E-5 Series

10 Structure,function and maintenance standard

125E-5 Series

SEN00184-06

61

10 Structure,function and maintenance standard

SEN00184-06

Valve and valve guide

Unit: mm

No.

Check item

1 Sinking distance of valve

2 Thickness of valve lip

3 Valve seat angle

Diameter of valve stem

Inside diameter of valve guide

4
Clearance between valve guide
and stem

Bend of valve stem

62

Criteria

Remedy

Valve

Standard size

Tolerance

Repair limit

Intake

1.88

0.10

2.51

Exhaust

1.20

0.10

1.90

Valve

Standard size

Repair limit

Intake

2.10

1.7

Exhaust

1.50

1.2

Intake

Exhaust

Standard

30 15L

45 15L

Valve

Standard size

Intake

Exhaust

Tolerance
-0.045
-0.065
-0.050
-0.070
+0.015
-0.003
+0.009
-0.011
Clearance limit

Before head is
press fitted
After head is
press fitted
Valve

Intake/Exhaust
9
valve
Intake/Exhaust
9
valve
Standard clearance

Intake

0.034 ? 0.074

0.22

Exhaust

0.039 ? 0.079

0.24

Repair limit: 0.01 (Overall swing of indicator in 100 mm)

Replace valve or
valve seat

Replace valve

Correct or replace
valve or valve seat

Replace valve

Replace valve
guide

Replace valve or
valve guide

Replace

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

Unit: mm

No.

Check item

Criteria

5 Driving height of valve guide

Free length of valve spring

6
Installed load of valve spring

Perpendicularity of valve spring

125E-5 Series

Remedy

Standard

Tolerance

22

0.2

Correct

Valve

Color code

Standard size

Repair limit

Intake

Light blue

76.2

Exhaust

Light blue

76.2

Valve

Color code

Installed
length

Intake

Light blue

56.0

Exhaust

Light blue

56.0

Standard load Allowable load


Replace valve
(N {kg})
(N {kg})
spring
519.8 26
468 {47.7}
{53.0 2.7}
519.8 26
468 {47.7}
{53.0 2.7}

Repair limit: 2 (both sides)

63

10 Structure,function and maintenance standard

SEN00184-06

Rocker arm and shaft

Unit: mm

No.

Check item

Criteria
Standard size

Standard clearance

Tolerance
-0.053
-0.066
+0.033
-0.027
Clearance limit

0.026 0.099

0.13

Diameter of rocker arm shaft

28.6

Diameter of rocker arm shaft hole

1
Clearance between rocker arm
shaft and rocker arm
Bend of rocker arm shaft

Tightening torque of locknut of


rocker arm adjustment screw

Valve clearance
(Both when hot and cold)

28.6

Repair limit: 0.20 (Overall swing of indicator)


Target (Nm {kg})

Range (Nm {kg})

59 {6.0}

53 65 {5.4 6.6}

Valve

Standard

Intake side

0.33

Replace rocker arm


and shaft
Replace rocker arm
Replace rocker arm
or rocker arm shaft
Replace rocker arm
shaft
Tighten

Tolerance
0.02

Exhaust side

64

Remedy

Adjust

0.71

125E-5 Series

10 Structure,function and maintenance standard

SEN00184-06

Crosshead and guide

Unit: mm

No.

Check item

Criteria
Standard size

Inside diameter of crosshead

1
Outside diameter of crosshead
guide

2 Projection of crosshead guide

125E-5 Series

11
11
45.5

Remedy

Tolerance
+0.075
+0.025
+0.011
0

Repair limit

0.25

11.18

Replace

10.95
Correct

65

SEN00184-06

10 Structure,function and maintenance standard

KOMATSU 125E-5 Series engine


Form Number : SEN00184-06

2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11

66

SEN00185-06

ENGINE
1SHOP MANUAL

125E-5 Series

10 Structure, function and


maintenance standard

Structure, function and maintenance


standard, Part 2
Lubrication system .......................................................................................................................................... 4
Lubrication system diagram ................................................................................................................. 4
Oil pump............................................................................................................................................... 8
Main relief valve ................................................................................................................................... 9
EGR oil pump..................................................................................................................................... 10
Oil filter ................................................................................................................................................11
Safety valve........................................................................................................................................ 13
Oil cooler ............................................................................................................................................ 14
Fuel system................................................................................................................................................... 16
CRI system diagram........................................................................................................................... 16
Outline of CRI system ........................................................................................................................ 18

125E-5 Series

SEN00185-06

10 Structure, function and maintenance standard

Fuel piping.......................................................................................................................................... 40
Fuel filter............................................................................................................................................. 42
Electric priming pump......................................................................................................................... 44
Engine controller cooler...................................................................................................................... 45
Cooling system.............................................................................................................................................. 46
Cooling system diagram..................................................................................................................... 46
Water pump ........................................................................................................................................ 48
Thermostat ......................................................................................................................................... 50
Electrical equipment...................................................................................................................................... 52
Alternator............................................................................................................................................ 52
Starting motor ..................................................................................................................................... 60
Electrical intake air heater .................................................................................................................. 64
Engine controller ................................................................................................................................ 65

125E-5 Series

10 Structure, function and maintenance standard

125E-5 Series

SEN00185-06

SEN00185-06

10 Structure, function and maintenance standard

Lubrication system

Lubrication system diagram

(with EGR)

The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

W: Coolant
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.

Oil pan
Oil strainer
Oil pump
Oil pump relief valve
Oil cooler
Thermo-valve
Oil filter
Safety valve
Crankshaft
Piston cooling nozzle
Piston
Camshaft
Cam follower
Rocker arm
Air intake valve and exhaust valve
Timing gear
Turbocharger
Fuel supply pump
EGR oil pump
EGR oil pump relief valve
EGR valve
Bypass valve
Main gallery
Oil filter clogging switch (for DCA-300SSK4)

125E-5 Series

SEN00185-06

10 Structure, function and maintenance standard

(EGR-less)

The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.

125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

W: Coolant
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.

Oil pan
Oil strainer
Oil pump
Oil pump relief valve
Oil cooler
Thermo-valve
Oil filter
Safety valve
Crankshaft
Piston cooling nozzle
Piston
Camshaft
Cam follower
Rocker arm
Air intake valve and exhaust valve
Timing gear
Turbocharger
Fuel supply pump
Main gallery

125E-5 Series

SEN00185-06

Oil pump

The shape is subject to machine models.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Oil pump drive gear (Number of teeth: 21)


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

10 Structure, function and maintenance standard

Oil pump gear


Type: Gear pump
Speed: Engine speed 1.571
Main relief valve
Cracking pressure:
0.65 0.8 MPa {6.63 8.16 kg/cm2}

125E-5 Series

10 Structure, function and maintenance standard

Main relief valve

SEN00185-06

Unit: mm
No.
1

Check item
Cracking pressure of
relief valve

125E-5 Series

Criteria
Standard: 0.65 0.8 MPa {6.63 8.16 kg/cm2}

Remedy
Correct or
replace spring

SEN00185-06

EGR oil pump

A:
B:
C:

From main gallery


To EGR valve and bypass valve
Rotation direction

1.
2.
3.
4.
5.
6.
7.

Pump cover
Driven gear
Pump body
Drive gear
Pump drive gear (Number of teeth: 20)
Main relief valve
Main valve spring

10

10 Structure, function and maintenance standard

Specifications
Oil pump
Type: Gear pump
Speed: Engine speed 1.1
Main relief valve
Cracking pressure:
1.43 0.1 MPa {14.6 1.0 kg/cm2}

125E-5 Series

10 Structure, function and maintenance standard

Oil filter

SEN00185-06

Remote mount type

The shape is subject to machine models.

A:
B:

Oil inlet
Oil outlet

1.
2.
3.

Safety valve
Filter head
Cartridge

125E-5 Series

Specifications
Oil filter
Filtration area: 0.44 m2 (Full-flow)
Safety valve
Cracking pressure: 343 19 kPa {3.5 0.2 kg/cm2}

11

SEN00185-06

10 Structure, function and maintenance standard

Remote mount type (for DCA-300SSK4)

The shape is subject to machine models.

A:
B:

Oil inlet
Oil outlet

1.
2.
3.
4.

Safety valve
Filter head
Cartridge
Clogging switch

Specifications
Oil filter
Filtration area: 0.44 m2 (Full-flow)
Safety valve
Cracking pressure: 343 19 kPa {3.5 0.2 kg/cm2}
Clogging switch
Operating pressure: 147

12

+39
0

kPa {1.5

+0.4
0

kg/cm2}

125E-5 Series

10 Structure, function and maintenance standard

Safety valve

1.
2.
3.
4.

SEN00185-06

Safety valve
Filter head
Spring
Cap
Unit: mm

No.
1

Check item
Cracking pressure of safety
valve

125E-5 Series

Criteria
Standard: 343 19 kPa {3.5 0.2 kg/cm2}

Remedy
Replace

13

SEN00185-06

10 Structure, function and maintenance standard

Oil cooler

The shape is subject to machine models.

a.
b.
c.
d.

Water drain
Oil inlet
To each part of engine (Oil)
Water inlet

1.
2.
3.
4.
5.

Thermostat cover
Thermostat (Thermo-valve)
Cooler cover
Cooler element
Strainer

Oil cooler thermostat (Thermo-valve)


Opening temperature:
71C 1.5C
Full opening temperature: 85C
Full opening lift:
Min. 8 mm

Oil cooler
Heat dissipation surface: 0.575 m2

Unit: mm
No.

Check item
Full opening lift of thermostat SAA6D125E-5

14

Criteria
Min. 8 mm
(Check after soaking in oil tank at 85C for 4 5 minutes)

Opening and closing of ther- When valve full open (at 85C) is soaked in oil tank at full closing temperamostat
ture (71C), it must close fully in 4 5 minutes.

Remedy

Replace

125E-5 Series

10 Structure, function and maintenance standard

125E-5 Series

SEN00185-06

15

SEN00185-06

10 Structure, function and maintenance standard

Fuel system

CRI system diagram

(with EGR)

CRI is an abbreviation for Common Rail Injection. Hereinafter, the common rail injection is referred to
as the CRI.

1.
2.

Fuel tank
Fuel supply pump assembly
2A. PCV
2B. High pressure pump
2C. Priming pump
2D. Feed pump
2E. Bypass valve
2F. G speed sensor

16

3.
4.
5.
6.
7.
8.
9.
10.

Fuel filter
Overflow valve
Common rail
Pressure limiter
Flow damper
Injector assembly
Engine controller
NE speed sensor

11. Large-capacity priming pump


12. Check valve
13. Pre-fuel filter

125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

(EGR-less)

CRI is an abbreviation for Common Rail Injection. Hereinafter, the common rail injection is referred to
as the CRI.

1.
2.

Fuel tank
Fuel supply pump assembly
2A. PCV
2B. High pressure pump
2C. Priming pump
2D. Feed pump
2E. Bypass valve
2F. G speed sensor

125E-5 Series

3.
4.
5.
6.
7.
8.
9.
10.

Fuel filter
Overflow valve
Common rail
Pressure limiter
Flow damper
Injector assembly
Engine controller
NE speed sensor

11. Electric priming pump


12. Water separator
13. Pre-fuel filter

17

SEN00185-06

10 Structure, function and maintenance standard

Outline of CRI system


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

1
1. Fuel system

Configuration
The CRI system is divided by the function into
the fuel system and control system.

18

The fuel system distributes the high-pressure


fuel supplied by the fuel supply pump to the
cylinders through the common rail.
The solenoid valve in the injector opens and
closes the nozzle needle valve to start and finish injection.

125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

2. Control system

Parts marked with * (2 places) are installed to only the engines with EGR.

The engine controller calculates and controls


the energizing timing and energizing period of
the injector with the signals from the sensors
installed to the machine to inject proper quantity of fuel in proper timing.
The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.

125E-5 Series

19

SEN00185-06

10 Structure, function and maintenance standard

Structure and operation of CRI system

20

The CRI system consists of the fuel supply


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

If the TWV is turned on (energized), the fuel


circuit is so changed that the high-pressure
fuel in the control chamber will flow through the
orifice. As a result, the needle valve is raised
to start fuel injection by the nozzle cracking
pressure of the high-pressure fuel on the nozzle side.
If the TWV is turned off (de-energized), the fuel
circuit is so changed that the high-pressure
fuel will be applied to the control chamber
through the orifice. As a result, the needle
valve lowers and finishes fuel injection.
Accordingly, the fuel injection timing and fuel
injection rate are controlled respectively by the
timing to turn on the TWV and the length of the
turn-on time of the TWV.

125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

Structure and operation of component parts

1. Fuel supply pump

1.
2.
3.
4.
5.

3-head cam
Overflow valve
Drive gear
No. 1 high-pressure pump
PCV (Pressure control valve)

Outline
q
The fuel supply pump consists of priming
pump (7), feed pump (8), and high-pressure
pumps (4) and (6).
q
The function of the fuel supply pump is to generate common rail fuel pressure by controlling
the fuel delivery.
Structure
High-pressure pumps (4) and (6) have the
pressure feed systems similar to those of the
conventional in-line fuel injection pump and the
PCVs (pressure control valves) for each cylinder to control the fuel delivery.
q
By employing the 3-head cam, the necessary
number of the cylinders of high-pressure
pumps (4) and (6) is reduced to 1/3 of the
engine cylinders.
q

125E-5 Series

6.
7.
8.
9.

No. 2 high-pressure pump


Priming pump
Feed pump
Gear for Bkup speed sensor (G sensor)

Since the number of the times of feeding fuel


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

q
q

21

SEN00185-06

10 Structure, function and maintenance standard

Operation

22

(A): During the lowering stroke of the plunger,


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

125E-5 Series

10 Structure, function and maintenance standard

1)
q

PCV (Pressure control valve)


The PCV adjusts the fuel delivery from the fuel
supply pump to adjust the common rail fuel
pressure. The delivery from the fuel supply
pump to the common rail is decided by the timing of energizing the PCV.

SEN00185-06

2)
q

q
q

125E-5 Series

Feed pump
The feed pump built in the fuel supply pump
assembly draws the fuel from the fuel tank and
sends it through the fuel filter to the high-pressure pump chamber.
The outer and inner rotors of the feed pump
are rotated by the camshaft.
The fuel is sucked in on the suction side and
discharged on the delivery side according to
the increase and decrease of the spaces
between the outer and inner rotors.

23

SEN00185-06

10 Structure, function and maintenance standard

2. Common rail
Structure
q
Common rail (4) distributes the high-pressure
fuel from the high-pressure pump to the injectors of the cylinders.
q
Common rail (4) is equipped with common rail
fuel pressure sensor (2), flow dampers (1), and
pressure limiter (3).
q
The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
the injectors.
q
The piping of the pressure limiter (3) is
returned to the fuel tank.

1)

Operation
When fuel is not injected
q
Piston (2) is in contact with stopper (1) (initial
position).
q
The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
When fuel is injected
q
The fuel pressure is applied to piston (2),
which compresses spring (3) and moves to the
right.
q
The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
When fuel is stopped
q
If the fuel flows out abnormally because of a
burst of the piping, etc., piston (2) moves to the
right stroke end.
q
The tip of piston (2) contacts seat (b) to stop
the fuel.
q
Once the fuel is stopped, piston (2) does not
return to the initial position until the engine is
stopped.

Flow damper

Function
q
The flow dampers damp the pressure pulses in
the high pressure piping and supply the fuel to
the injectors with stable pressure.
q
If excessive fuel flows out, the flow dampers
block the fuel passage to prevent abnormal
outflow of the fuel.
q
If the fuel flows out abnormally, high pressure
is applied to the piston, which moves to the
right until it reaches the seat to stop the fuel.

24

125E-5 Series

10 Structure, function and maintenance standard

2)
q

1.
2.
3.
4.
5.

Pressure limiter
If abnormally high pressure is generated, the
pressure limiter opens to release that pressure.
If the common rail fuel pressure reaches about
200 MPa {2,040 kg/cm2}, the pressure limiter
operates (opens).
If the common rail fuel pressure lowers to 30
MPa {310 kg/cm2}, the pressure limiter resets
itself (closes) to maintain the pressure.
Under the normal condition, the pressure limiter does not reset itself (close) until the engine
is stopped.

SEN00185-06

3)
q

Common rail fuel pressure sensor


The common rail fuel pressure sensor is
installed to the common rail to sense the fuel
pressure.
This sensor is a semiconductor pressure sensor, which utilizes the phenomenon that the
electric resistance of silicon changes according
to pressure applied to it.

Ball
Housing
Spring
Body
Guide

125E-5 Series

25

SEN00185-06

10 Structure, function and maintenance standard

3. Injector

Outline
q
The function of the injector is to inject the highpressure fuel from the common rail into each
combustion chamber of the engine in the optimum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q
The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q
The orifice limits the opening speed of the nozzle and controls the fuel injection rate.
q
The hydraulic piston transmits the force generated by the pressure in the control chamber to
the needle valve of the nozzle.
q
The nozzle sprays the fuel.

26

125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

Structure

1.
2.
3.
4.
5.
6.

Inlet connector
Terminal
Upper body
Solenoid
Valve body
Orifice (out)

The injector consists of the nozzle section, orifice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve section.

125E-5 Series

7.
8.
9.
10.
11.
12.

Orifice (in)
Pressure control chamber
Control piston
Spring
Pressure pin
Nozzle assembly

27

SEN00185-06

10 Structure, function and maintenance standard

A:
B:

No fuel injection
Start of fuel injection

C:
D:

Finish of fuel injection


From common rail

1.
2.
3.
4.

Nozzle
Control piston
Orifice (in)
Orifice (out)

5.
6.
7.
8.

Valve body
Solenoid
Spring
Pressure control chamber

3)

Finish of fuel injection (C)


If solenoid (6) is de-energized, valve body (5)
is lowered by spring (7) and the fuel passage is
closed.
At this time, the high-pressure fuel in the common rail is applied to pressure control chamber
(8) suddenly and nozzle (1) is closed quickly,
fuel injection is finished sharply.

Operation
1)
q
q

2)
q

q
q

28

No fuel injection (A)


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

Start of fuel injection (B)


If solenoid (6) is energized, valve body (5) is
pulled up by the electromagnetic force and the
fuel passage is opened.
Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and fuel injection pump starts.
The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
If solenoid (6) is kept energized, the fuel injection rate is increased to the maximum.

125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

Electric circuit diagram

Since high voltage (118 V) is applied to the


wiring harnesses connected to the engine
controller, COMMON 1 and COMMON 2 of
the supply pump, and TWV #1 #6 of the
injector, take care not get an electric shock.

125E-5 Series

29

SEN00185-06

10 Structure, function and maintenance standard

Various controls

Parts marked with * (3 places) are installed to only the engines with EGR.

The CRI system controls the fuel injection rate


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

2. Fuel injection timing control function


q

3. Fuel injection pressure control function


(Common rail fuel pressure control function)
q

1. Fuel injection rate control function


q

30

The fuel injection rate control function is


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

The fuel injection timing control function is


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

The fuel injection pressure control function


(common rail fuel pressure control function) is
a function of measuring the fuel pressure with
the common rail fuel pressure sensor and
feeding it back to the engine controller to control the delivery of the fuel supply pump.
This function performs pressure feedback control so that the fuel injection pressure will be
the same as the optimum value (command
value) set according to the engine speed and
fuel injection rate.
125E-5 Series

10 Structure, function and maintenance standard

125E-5 Series

SEN00185-06

31

SEN00185-06

10 Structure, function and maintenance standard

4. Various sensors

a
a
a

32

Nos. 1 13 in the above illustration correspond to title Nos. 1) 13).


The above illustration shows the engine for HM300-2.
Parts *1, *3 and *4 are installed to only the engines with EGR.

125E-5 Series

10 Structure, function and maintenance standard

125E-5 Series

SEN00185-06

33

SEN00185-06

1)
q

34

EGR inlet pressure sensor (with EGR)


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

10 Structure, function and maintenance standard

2)
q

Atmospheric pressure sensor


This sensor is used to correct altitude.

The following graph shows the output characteristics of the EGR inlet pressure sensor.

A:
B:

Pressure inlet
Mounting screw: M5
Tightening torque: 4.5 0.5 Nm {0.46 0.05 kgm}

The following graph shows the output characteristics of the atmospheric pressure sensor.

125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

3)

EGR valve position sensor (with EGR)

4)
q

Bypass valve position sensor (Applicable machine: HM300-2) (with EGR)


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

1.

EGR and bypass valve position sensors

The following graph shows the output characteristics of the position sensor.

125E-5 Series

35

SEN00185-06

5)

Common rail pressure sensor

6)

NE speed sensor (Crank angle sensor)


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

10 Structure, function and maintenance standard

7)
q

q
q

36

Fuel temperature sensor


The fuel temperature sensor senses the fuel
temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance of which changes according to the
temperature.
The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the computer and the resistance of the thermistor.

8)

Engine controller

9)

Oil pressure sensor

125E-5 Series

10 Structure, function and maintenance standard

10) Bkup speed sensor (G sensor)


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

125E-5 Series

SEN00185-06

11) Charge pressure sensor


q
This sensor is used to sense the charge pressure (boost pressure).

A:

Mounting screw: M6
Tightening torque: 5.5 0.5 Nm {0.56 0.05 kgm}

1.
2.

Sensor
O-ring

The following graph shows the output characteristics of the charge pressure sensor.

37

SEN00185-06

12) Charge temperature sensor


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

38

10 Structure, function and maintenance standard

13) Coolant temperature sensor


q
The coolant temperature sensor senses the
coolant temperature and sends it to the engine
controller.
q
The sensor unit is a thermistor the resistance
of which changes according to the temperature. The engine controller applies voltage to
the thermistor and senses the temperature by
the voltage divided by the resistance in the
computer and the resistance of the thermistor.

125E-5 Series

10 Structure, function and maintenance standard

125E-5 Series

SEN00185-06

39

SEN00185-06

Fuel piping

10 Structure, function and maintenance standard

The shape is subject to machine models.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Fuel injection pipe (No. 1 cylinder)


Fuel injection pipe (No. 2 cylinder)
Fuel injection pipe (No. 3 cylinder)
Fuel injection pipe (No. 4 cylinder)
Fuel injection pipe (No. 5 cylinder)
Fuel injection pipe (No. 6 cylinder)
Fuel return pipe
Common rail
Priming pump
Feed pump
Oil inlet pipe (for pump lubricating oil)
High pressure pump
Fuel supply pump drive gear
(Number of teeth: 44)
14. Overflow valve
15. PCV

40

125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

The shape is subject to machine models.

A:
B:
C:
D:
E:

Fuel inlet
To fuel filter
From fuel filter
To injector
Fuel return (between overflow valve and fuel
tank)
F: Fuel return (between injector and fuel tank)
G: Engine oil (to fuel supply pump)
Specifications
Fuel supply pump
Manufacturer:
DENSO CORPORATION
Model:
DENSO ECD-U2
Lubrication method: Forced lubrication with engine oil

125E-5 Series

41

SEN00185-06

Fuel filter

10 Structure, function and maintenance standard

Main fuel filter

The shape is subject to machine models.

A:
B:

Fuel inlet
Fuel outlet

1.
2.
3.

Air bleeding plug


Filter head
Cartridge

Specifications
Filtration area: 1.0 m2

42

125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

Pre-fuel filter

The shape is subject to machine models.

A: Fuel inlet
B: Fuel outlet
1. Air bleeding plug
2. Filter head
3. Cartridge
Specifications
Filtration area: 1.06 m2

125E-5 Series

43

SEN00185-06

Electric priming pump

A:
B:

Fuel IN
Fuel OUT

1.
2.

Connector
Vibration prevention rubber

44

10 Structure, function and maintenance standard

125E-5 Series

10 Structure, function and maintenance standard

Engine controller cooler

SEN00185-06

A:
B:

Fuel IN (From feed pump of fuel supply pump)


Fuel OUT (Main fuel filter)

1.
2.

Engine controller
Engine controller cooler

Outline
q
The fuel is circulated as refrigerant through
engine controller cooler (2) to prevent engine
controller (1) from overheating.
q
The fuel is not circuited in some applicable
machines.

125E-5 Series

45

SEN00185-06

10 Structure, function and maintenance standard

Cooling system
Cooling system diagram

1
1

(with EGR)

The shape is subject to machine models.

A:
B:
C:
D:

Oil inlet
Oil outlet
Exhaust gas inlet
Exhaust gas outlet

1.
2.
3.
4.
5.
6.

Radiator
Thermostat
Water pump
Coolant temperature gauge
Water manifold (made one with cylinder block)
Corrosion resistor

46

7.
8.
9.
10.
11.
12.
13.

Cylinder head
Cylinder liner
Piston
Cylinder block
Oil cooler
Air compressor
EGR cooler

125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

(EGR-less)

The shape is subject to machine models.

A:
B:
C:
D:

Oil inlet
Oil outlet
Exhaust gas inlet
Exhaust gas outlet

125E-5 Series

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Radiator
Thermostat
Water pump
Coolant temperature gauge
Water manifold (made one with cylinder block)
Corrosion resistor
Cylinder head
Cylinder liner
Piston
Cylinder block
Oil cooler
Air compressor

47

SEN00185-06

Water pump

10 Structure, function and maintenance standard

Mounting

The shape is subject to machine models.

A:
B:
C:
D:
E:
F:

To radiator (Coolant)
From each part of engine (Coolant)
To each part of engine through oil cooler
(Coolant)
From radiator (Coolant)
From oil pump (Oil)
To each part of engine (Oil)

a.
b.
c.

Cab heater take-out opening


Coolant temperature gauge pickup port
Water drain valve

48

1.
2.
3.
4.
5.

Thermostat
Housing cover
Thermostat housing
Water pump
Oil cooler

125E-5 Series

10 Structure, function and maintenance standard

a.
b.
c.

From thermostat
From radiator
To each part of engine

1.
2.
3.
4.
5.
6.
7.

Water pump drive gear (Number of teeth: 22)


Pump shaft
Ball bearing
Pump body
Water seal
Impeller
Pump cover

SEN00185-06

Water pump
Type: Centrifugal, gear-driven
Speed: Engine speed 1.5
Unit: mm
No.

Check item
Interference of impeller
and shaft

Interference of drive gear


and shaft

10

Clearance between impeller and body

11

Wear of water seal ring

125E-5 Series

Criteria
Standard size

Remedy

Tolerance
Shaft

Hole

15.9

+0.018
+0.005

0.020
0.050

20.0

+0.015
+0.002

0.023
0.053

Standard inter- Replace


ference
Usually, impeller needs to be
replaced (Outside diameter of
0.025 0.068 shaft changes little)
0.025 0.068

Standard clearance: 0.30 1.10 (including end play)

Replace (Usually, gear needs to


be replaced)
Replace

Limits of size: 1.5

49

SEN00185-06

Thermostat

10 Structure, function and maintenance standard

Mounting

The shape is subject to machine models.

a.
b.

To radiator
To water pump

1.
2.

Thermostat
Thermostat housing

50

125E-5 Series

10 Structure, function and maintenance standard

A:
B:

When cold (Fully closed)


When hot (Fully open)

a.
b.
c.

To water pump (bypass)


To radiator
From engine

1.
2.
3.
4.
5.
6.
7.

SEN00185-06

Thermostat
Seal
Valve
Body
Piston
Heat sensing portion
Inflating portion

8.
9.

Sleeve
Flange

Function of thermostat (before


installed)
Opening temperature:
76.5C
Full opening temperature: 90C
Valve lift:
Min. 10 mm

Unit: mm
No.
1

Check item

Criteria

Remedy

Full opening lift of thermostat

Min. 10 mm (Check after soaking in oil tank at 90C for 4 5 minutes.)

Opening and closing of


thermostat

When valve full open (at 90C) is soaked in oil tank at full closing temper- Replace
ature (71C) , it must close fully in 4 5 minutes.

125E-5 Series

51

SEN00185-06

10 Structure, function and maintenance standard

Electrical equipment
Alternator

1
1

1. Alternator with built-in regulator (Open type, 35 A)

The shape is subject to machine models.

1.
2.
3.
4.
5.

Alternator
Alternator pulley
Terminal B
Terminal R
Terminal E

6.

Internal electric circuit diagram


6A. Initial excitation resistor
6B. Regulator
6C. Field coil

Pulley
Engine

Applicable machine

Type

PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0 Open type (brushless),
SAA6D125E-5 BR580JG-1
manufactured by NIKKO
DCA-300SSK4
DENKI
(DENYO/MQ GENERATOR)

52

Specification Number Outside


diameter
of stages
(mm)

24V, 35A

93

Weight
(kg)

8.0

125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

2. Alternator with built-in regulator (Open type, 50 A)

The shape is subject to machine models.

1.
2.
3.
4.
5.

Alternator
Alternator pulley
Terminal B
Terminal R
Terminal E

6.

Internal electric circuit diagram


6A. Initial excitation resistor
6B. Regulator
6C. Field coil

Pulley
Engine

Applicable machine

PC400-7E0, PC400LC-7E0
PC450-7E0, PC450LC-7E0
PC400-8, PC400LC-8,
PC400-8R, PC400LC-8R
PC450-8, PC450LC-8,
PC450-8R, PC450LC-8R
SAA6D125E-5 D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
WA450-6, WA470-6,
WA470-6R
WA480-6, WA480-6R
HM250-2, HM300-2,
HM300-2R

125E-5 Series

Type

Open type (brushless),


manufactured by NIKKO
DENKI

Specification Number Outside


diameter
of stages
(mm)

24V, 50A

75

Weight
(kg)

10

53

SEN00185-06

10 Structure, function and maintenance standard

3. Alternator with built-in regulator (Open type, 60 A)

The shape is subject to machine models.

a.

Load

1.
2.
3.
4.

Alternator
Alternator pulley
Terminal B
Terminal R

5.
6.

Terminal E
Internal electric circuit diagram
6A. Field coil
6B. Primary energized resistance
6C. Regulator
Pulley

Engine

Applicable machine

Type

PC400-8, PC400LC-8
Open type, manufactured by
PC450-8, PC450LC-8
SAA6D125E-5
PC400-8R, PC400LC-8R NIKKO DENKI
PC450-8R, PC450LC-8R

54

Specification Number Outside


diameter
of stages
(mm)
24V, 60A

85

Weight
(kg)

11

125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

4. Alternator with built-in regulator (Open type, 75 A)

The shape is subject to machine models.

a.

Load

1.
2.
3.
4.
5.
6.

Alternator
Alternator pulley
Terminal R
Terminal E
Terminal B
Internal electric circuit diagram
6A. Alternator
6B. Regulator

Engine

Applicable machine

D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
HM250-2, HM300-2,
HM300-2R
SAA6D125E-5
WA450-6, WA470-6,
WA480-6
WA470-6R, WA480-6R
GD755-5R

125E-5 Series

Type

Open type, manufactured


by SAWAFUJI DENKI

Pulley
Specification Number Outside
diameter
of stages
(mm)

24V, 75A

95

Weight
(kg)

13

55

SEN00185-06

10 Structure, function and maintenance standard

Alternator mounting
SAA6D125E-5 (D85EX-15E0, D85EX-15R, D85PX-15E0, D85PX-15R, WA450-6, WA470-6, WA480-6,
WA470-6R, WA480-6R, GD755-5R)

The shape is subject to machine models.

1.
2.
3.
4.

Alternator pulley
Alternator drive belt
Crankshaft pulley
Adjustment bolt

56

125E-5 Series

10 Structure, function and maintenance standard

SEN00185-06

SAA6D125E-5 (PC400-7E0, PC400LC-7E0, PC450-7E0, PC450LC-7E0, PC400-8, PC400LC-8, PC450-8,


PC450LC-8, PC400-8R, PC400LC-8R, PC450-8R, PC450LC-8R, BR580JG-1)

The shape is subject to machine models.

1.
2.
3.
4.

Alternator pulley
Alternator drive belt
Crankshaft pulley
Adjustment bolt

125E-5 Series

57

SEN00185-06

10 Structure, function and maintenance standard

SAA6D125E-5 [DCA-300SSK4 (DENYO/MQ GENERATOR)]

The shape is subject to machine models.

1.
2.
3.
4.

Alternator pulley
Alternator drive belt
Crankshaft pulley
Adjustment bolt

58

125E-5 Series

10 Structure, function and maintenance standard

125E-5 Series

SEN00185-06

59

SEN00185-06

Starting motor

10 Structure, function and maintenance standard

Starting motor with built-in safety relay (7.5 kW)

60

The shape is subject to machine models.

125E-5 Series

10 Structure, function and maintenance standard

1.
2.
3.
4.

5.
6.

SEN00185-06

Pinion gear
Starting motor (body)
Magnetic switch
External electric circuit diagram [2P connector (male)]
4A. Safety relay
4B. Starting motor
External electric circuit diagram [3P connector (male)]
5A. Safety relay
5B. Starting motor
Specifications of connector
Type A: 2P connector (male)
Type B: 2P dust-proof connector (male)
Type C: 3P dust-proof connector (male)
Type D: 2P connector (male)

B, C, R, S, E: Terminals

Engine

Applicable
machine

Type

Specification

Number of
pinion teeth

Weight (kg)

Type of
connector

SAA6D125E-5

All machines

Waterproof, oilproof, manufactured


by NIKKO DENKI

24V, 7.5kW

12

20

125E-5 Series

61

SEN00185-06

10 Structure, function and maintenance standard

Starting motor with built-in safety relay (11 kW)

62

The shape is subject to machine models.

125E-5 Series

10 Structure, function and maintenance standard

1.
2.
3.
4.

5.

SEN00185-06

Pinion gear
Starting motor (body)
Magnetic switch
External electric circuit diagram
4A. Safety relay
4B. Starting motor
Specifications of connector
Type A: 2P connector (male)
Type B: Dust-proof connector (male)

B, C, R, S, E: Terminals

Engine

Applicable
machine

Type

Specification

Number of
pinion teeth

Weight (kg)

Type of
connector

SAA6D125E-5

All machines
(if equipped)

Waterproof, oilproof, manufactured


by NIKKO DENKI

24V, 11kW

12

18

125E-5 Series

63

SEN00185-06

Electrical intake air heater

10 Structure, function and maintenance standard

SAA6D125E-5

1.
2.
3.
4.

Terminal
Body
Heater coil
Electric circuit diagram

Electrical intake air heater


Rated voltage: 22 V (DC)
Rated current: 111 A

64

125E-5 Series

10 Structure, function and maintenance standard

Engine controller

SEN00185-06

Features
Mounting of engine controller on engine
q
Since the engine controller is mounted on the
engine, the operator can service it easily in the
field.
q
The engine controller cooler (if equipped) is
prepared to cool the engine controller with the
fuel to secure the reliability of the mounted
engine controller.
q
Vibrations are damped by the vibration-proof
rubber.
Unified specifications of engine controller
q
Engine controller CM850 developed by the
cooperation between KOMATSU and CUMMINS is employed.

125E-5 Series

65

SEN00185-06

KOMATSU 125E-5 Series engine


Form No. SEN00185-06

2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11

66

SEN00546-09

ENGINE
1SHOP MANUAL

125E-5 Series

20 Standard value table

Standard service value table


Standard service value table ........................................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ............................................. 2
Running-in standard and performance test standard ......................................................................... 16

125E-5 Series

SEN00546-09

20 Standard value table

Standard service value table

Cooling system

Lubrication system

Body

Air intake and exhaust system

Performance Category

Standard service value table for testing, adjusting, and troubleshooting

Engine

SAA6D125E-5

Machine model

D85EX-15E0
D85PX-15E0
Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

2,100 50

2,100 50

Low idle

rpm

750 (+50/0)

750 (+50/0)

rpm

Min. 100

rpm

Min. 85

Item

Speed

Measurement conditions

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 93
{Min. 700}

73
{550}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 113
{Min. 850}

93
{700}

650

700

At sudden acceleration (Low o High)

%
(Bosch
index)

Max. 25
{Max. 2.5}

At rated output

Bosch
index

Max. 1.5

At high idle

Bosch
index

Max. 1.0

Intake valve

mm

0.33

Exhaust valve

mm

0.71

Exhaust temperature Whole speed range (20C)

Exhaust gas color

Valve clearance
EGR valve and
bypass valve drive
pressure

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.47
{Max. 150}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

At low idle
Engine oil temperature:
Min. 80C

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

13 16

13 16

125E-5 Series

Air intake and exhaust system

Performance Category

20 Standard value table

Body
Lubrication system

Engine

SAA6D125E-5

Machine model

D85EX-15R
D85PX-15R
Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

2,100 50

2,100 50

Low idle

rpm

750 (+50/0)

750 (+50/0)

rpm

Min. 100

rpm

Min. 85

Item

Speed

Measurement conditions

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 80
{Min. 600}

67
{500}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 87
{Min. 650}

73
{550}

650

700

At sudden acceleration (Low o High)

%
(Bosch
index)

Max. 40
{Max. 4.0}

At rated output

Bosch
index

Max. 1.5

At high idle

Bosch
index

Max. 1.0

Intake valve

mm

0.33

Exhaust temperature Whole speed range (20C)

Exhaust gas color

Valve clearance

Cooling system

SEN00546-09

mm

0.71

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.47
{Max. 150}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

Exhaust valve

At low idle
Engine oil temperature:
Min. 80C

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

13 16

13 16

125E-5 Series

Cooling system

Lubrication system

Body

Air intake and exhaust system

Performance Category

SEN00546-09

20 Standard value table

Engine

SAA6D125E-5

Machine model

PC400, 400LC-7E0,
PC400, 400LC-8
PC450, 450LC-7E0,
PC450, 450LC-8
Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

1,930 50

1,930 50

Low idle

rpm

1,000 25

1,000 25

rpm

Min. 100

rpm

Min. 85

Item

Speed

Measurement conditions

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 140
{Min. 1,050}

113
{850}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 167
{Min. 1,250}

140
{1,050}

Max. 700

700

At sudden acceleration (Low o High)

%
(Bosch
index)

Max. 25
{Max. 2.5}

At rated output

Bosch
index

Max. 1.5

At high idle

Bosch
index

Max. 1.0

Intake valve

mm

0.33

Exhaust temperature Whole speed range (20C)

Exhaust gas color

Valve clearance

Exhaust valve

mm

0.71

Min. 1.18
{Min. 12}

EGR valve and


bypass valve drive
pressure

At low idle

MPa
{kg/cm2}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.47
{Max. 150}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

At low idle
Engine oil temperature:
Min. 80C

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

13 16

13 16

125E-5 Series

Air intake and exhaust system

Performance Category

20 Standard value table

Body
Lubrication system

Engine

SAA6D125E-5

Machine model

PC400, 400LC-8R
PC450, 450LC-8R
Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

1,930 (+35/-15)

1,930 (+35/-15)

Low idle

rpm

1,000 25

1,000 25

rpm

Min. 100

rpm

Min. 85

Item

Speed

Measurement conditions

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 127
{Min. 950}

107
{800}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 153
{Min. 1,150}

127
{950}

Max. 700

700

At sudden acceleration (Low o High)

%
(Bosch
index)

Max. 40
{Max. 4.0}

At rated output

Bosch
index

Max. 1.5

At high idle

Bosch
index

Max. 1.0

Intake valve

mm

0.33

Exhaust temperature Whole speed range (20C)

Exhaust gas color

Valve clearance

Cooling system

SEN00546-09

mm

0.71

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.47
{Max. 150}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

Exhaust valve

At low idle
Engine oil temperature:
Min. 80C

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

13 16

13 16

125E-5 Series

Cooling system

Lubrication system

Body

Air intake and exhaust system

Performance Category

SEN00546-09

20 Standard value table

Engine

SAA6D125E-5

Machine model

HM250-2

Item

Speed

Measurement conditions

Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

2,100 50

2,100 50

Low idle

rpm

725 (+50/0)

725 (+50/0)

rpm

Min. 100

rpm

Min. 85

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 127
{Min. 950}

100
{750}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 140
{Min. 1,050}

113
{850}

Max. 700

700

At sudden acceleration (Low o High)

%
(Bosch
index)

Max. 25
{Max. 2.5}

At rated output

Bosch
index

Max. 1.5

At high idle

Bosch
index

Max. 1.0

Intake valve

mm

0.33

Exhaust valve

mm

0.71

Exhaust temperature Whole speed range (20C)

Exhaust gas color

Valve clearance
EGR valve and
bypass valve drive
pressure

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.47
{Max. 150}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

At low idle
Engine oil temperature:
Min. 80C

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

13 16

13 16

125E-5 Series

Cooling system

Lubrication system

Body

Air intake and exhaust system

Performance Category

20 Standard value table

SEN00546-09

Engine

SAA6D125E-5

Machine model

HM300-2

Item

Speed

Measurement conditions

Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

2,220 50

2,220 50

Low idle

rpm

725 (+50/0)

725 (+50/0)

rpm

Min. 100

rpm

Min. 85

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 133
{Min. 1,000}

107
{800}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 147
{Min. 1,100}

120
{900}

Max. 700

700

At sudden acceleration (Low o High)

%
(Bosch
index)

Max. 25
{Max. 2.5}

At rated output

Bosch
index

Max. 1.5

At high idle

Bosch
index

Max. 1.0

Intake valve

mm

0.33

Exhaust valve

mm

0.71

Exhaust temperature Whole speed range (20C)

Exhaust gas color

Valve clearance
EGR valve and
bypass valve drive
pressure

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.47
{Max. 150}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

At low idle
Engine oil temperature:
Min. 80C

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

13 16

13 16

125E-5 Series

Air intake and exhaust system

Performance Category

SEN00546-09

Body
Lubrication system
Cooling system

Engine

SAA6D125E-5

Machine model

HM300-2R

Item

Speed

Measurement conditions

Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

2,220 50

2,220 50

Low idle

rpm

725 (+50/0)

725 (+50/0)

rpm

Min. 100

rpm

Min. 85

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 113
{Min. 850}

93
{700}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 120
{Min. 900}

100
{750}

Max. 700

700

At sudden acceleration (Low o High)

%
(Bosch
index)

Max. 40
{Max. 4.0}

At rated output

Bosch
index

Max. 1.5

At high idle

Bosch
index

Max. 1.0

Intake valve

mm

0.33

Exhaust valve

mm

0.71

Exhaust temperature Whole speed range (20C)

Exhaust gas color

Valve clearance

20 Standard value table

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.47
{Max. 150}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

At low idle
Engine oil temperature:
Min. 80C

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

13 16

13 16

125E-5 Series

Cooling system

Lubrication system

Body

Air intake and exhaust system

Performance Category

20 Standard value table

SEN00546-09

Engine

SAA6D125E-5

Machine model

WA450-6, WA480-6

Item

Speed

Measurement conditions

Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

2,170 50

2,170 50

Low idle

rpm

800 (+50/0)

800 (+50/0)

rpm

Min. 100

rpm

Min. 85

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 100
{Min. 750}

80
{600}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 113
{Min. 850}

93
{700}

Max. 650

650

At sudden acceleration (Low o High)

%
(Bosch
index)

Max. 25
{Max. 2.5}

At rated output

Bosch
index

Max. 1.5

At high idle

Bosch
index

Max. 1.0

Intake valve

mm

0.33

Exhaust valve

mm

0.71

Exhaust temperature Whole speed range (20C)

Exhaust gas color

Valve clearance
EGR valve and
bypass valve drive
pressure

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.47
{Max. 150}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

At low idle
Engine oil temperature:
Min. 80C

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

13 16

13 16

125E-5 Series

Air intake and exhaust system

Performance Category

SEN00546-09

Body
Lubrication system
Cooling system

Engine

SAA6D125E-5

Machine model

WA470-6R

Item

Speed

Measurement conditions

Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

2,170 50

2,170 50

Low idle

rpm

800 (+50/0)

800 (+50/0)

rpm

Min. 100

rpm

Min. 85

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 107
{Min. 800}

87
{650}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 127
{Min. 950}

107
{800}

Max. 650

650

At sudden acceleration (Low o High)

%
(Bosch
index)

Max. 25
{Max. 2.5}

At rated output

Bosch
index

Max. 1.5

At high idle

Bosch
index

Max. 1.0

Intake valve

mm

0.33

Exhaust valve

mm

0.71

Exhaust temperature Whole speed range (20C)

Exhaust gas color

Valve clearance

10

20 Standard value table

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.47
{Max. 150}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

At low idle
Engine oil temperature:
Min. 80C

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

13 16

13 16

125E-5 Series

Cooling system

Lubrication system

Body

Air intake and exhaust system

Performance Category

20 Standard value table

SEN00546-09

Engine

SAA6D125E-5

Machine model

WA480-6

Item

Speed

Measurement conditions

Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

2,190 50

2,190 50

Low idle

rpm

800 (+50/0)

800 (+50/0)

rpm

Min. 100

rpm

Min. 85

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 113
{Min. 850}

93
{700}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 133
{Min. 1,000}

113
{850}

Max. 700

700

At sudden acceleration (Low o High)

%
(Bosch
index)

Max. 25
{Max. 2.5}

At rated output

Bosch
index

Max. 1.5

At high idle

Bosch
index

Max. 1.0

Intake valve

mm

0.33

Exhaust valve

mm

0.71

Exhaust temperature Whole speed range (20C)

Exhaust gas color

Valve clearance
EGR valve and
bypass valve drive
pressure

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.47
{Max. 150}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

At low idle
Engine oil temperature:
Min. 80C

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

13 16

13 16

125E-5 Series

11

Air intake and exhaust system

Performance Category

SEN00546-09

Body
Lubrication system
Cooling system

Engine

SAA6D125E-5

Machine model

WA480-6R

Item

Speed

Measurement conditions

Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

2,190 50

2,190 50

Low idle

rpm

800 (+50/0)

800 (+50/0)

rpm

Min. 100

rpm

Min. 85

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 113
{Min. 850}

93
{700}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 133
{Min. 1,000}

113
{850}

Max. 700

700

At sudden acceleration (Low o High)

%
(Bosch
index)

Max. 25
{Max. 2.5}

At rated output

Bosch
index

Max. 1.5

At high idle

Bosch
index

Max. 1.0

Intake valve

mm

0.33

Exhaust valve

mm

0.71

Exhaust temperature Whole speed range (20C)

Exhaust gas color

Valve clearance

12

20 Standard value table

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.47
{Max. 150}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

At low idle
Engine oil temperature:
Min. 80C

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

13 16

13 16

125E-5 Series

Cooling system

Lubrication system

Body

Air intake and exhaust system

Performance Category

20 Standard value table

SEN00546-09

Engine

SAA6D125E-5

Machine model

BR580JG-1

Item

Speed

Measurement conditions

Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

1,930 50

1,930 50

Low idle

rpm

1,000 25

1,000 25

rpm

Min. 100

rpm

Min. 85

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 140
{Min. 1,050}

113
{850}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 167
{Min. 1,250}

140
{1,050}

Max. 700

700

At sudden acceleration (Low o High)

%
(Bosch
index)

Max. 25
{Max. 2.5}

At rated output

Bosch
index

Max. 1.5

At high idle

Bosch
index

Max. 1.0

Intake valve

mm

0.33

Exhaust valve

mm

0.71

Exhaust temperature Whole speed range (20C)

Exhaust gas color

Valve clearance
EGR valve and
bypass valve drive
pressure

At low idle

MPa
{kg/cm2}

Min. 1.18
{Min. 12}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.47
{Max. 150}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

At low idle
Engine oil temperature:
Min. 80C

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

13 16

13 16

125E-5 Series

13

Air intake and exhaust system

Performance Category

SEN00546-09

Body
Lubrication system
Cooling system

Engine

SAA6D125E-5

Machine model

GD755-5R

Item

Speed

Measurement conditions

Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

2,200 50

2,200 50

Low idle

rpm

800 (+50/0)

800 (+50/0)

rpm

Min. 100

rpm

Min. 85

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 113
{Min. 850}

93
{700}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 133
{Min. 1,000}

113
{850}

Max. 700

700

At sudden acceleration (Low o High)

%
(Bosch
index)

Max. 25
{Max. 2.5}

At rated output

Bosch
index

Max. 1.5

At high idle

Bosch
index

Max. 1.0

Intake valve

mm

0.33

Exhaust valve

mm

0.71

Exhaust temperature Whole speed range (20C)

Exhaust gas color

Valve clearance

14

20 Standard value table

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.47
{Max. 150}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

At low idle
Engine oil temperature:
Min. 80C

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

Fan speed

At rated speed

rpm

Fan belt tension

Deflection under finger pressure of 98 N


{10 kg}

mm

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

13 16

13 16

125E-5 Series

Cooling system

Lubrication system

Body

Air intake and exhaust system

Performance Category

20 Standard value table

SEN00546-09

Engine

SAA6D125E-5

Machine model

DCA-300SSK4
(DENYO/MQ GENERATOR)
Unit

Standard value
for new machine

Judgement
criteria

High idle

rpm

1,890 50

1,890 50

Low idle

rpm

750 25

750 25

rpm

Min. 100

rpm

Min. 85

Item

Speed

Measurement conditions

Necessary speed for At 0C (Without starting aid)


starting
At 20C (With starting aid)
Air intake resistance

Whole speed range

kPa
{mmH2O}

Max. 3.73
{Max. 380}

7.47
{762}

Air boost pressure

At rated output

kPa
{mmHg}

Min. 173
{Min. 1,300}

140
{1,050}

Exhaust pressure

At rated output

kPa
{mmHg}

Min. 173
{Min. 1,300}

140
{1,050}

Max. 700

700

Exhaust temperature Whole speed range (20C)


Exhaust gas color

Valve clearance

At sudden acceleration (Low o High)

At rated output

Max. 10

At high idle

Max. 10

Intake valve

mm

0.33

Exhaust valve

mm

0.71

Min. 1.18
{Min. 12}

EGR valve and


bypass valve drive
pressure

At low idle

MPa
{kg/cm2}

At high idle

MPa
{kg/cm2}

Min. 1.43
{Min. 14.6}

Compression pressure

Engine oil temperature: 40 60C


Engine speed: 200 250 rpm

MPa
{kg/cm2}

Min. 2.9
{Min. 30}

2.0
{20}

Blow-by pressure

At rated output
Engine coolant temperature: Min. 70C

kPa
{mmH2O}

Max. 1.67
{Max. 170}

2.94
{300}

At rated output
Engine oil temperature:
Min. 80C

MPa
{kg/cm2}

0.29 0.69
{3.0 7.0}

0.18
{1.8}

MPa
{kg/cm2}

Min. 0.08
{Min. 0.8}

0.05
{0.5}

Engine oil pressure

At low idle
Engine oil temperature:
Min. 80C

SAE10W30DH
SAE15W40DH
SAE30DH

Engine oil temperature

Whole speed range (In oil pan)

90 110

120

Oil consumption

Ratio to fuel consumption at continuous


rated output

Max. 0.15

0.3

Function of radiator
pressure valve

Cracking pressure (Differential pressure)

kPa
{kg/cm2}

0.069
{0.7}

Fan speed

At rated speed

rpm

1,543

Fan/alternator belt
tension

Deflection under finger pressure of 98 N


{10 kg}

mm

10 13

Alternator belt tension

Deflection under finger pressure of 58.8 N


{6 kg}

mm

10 15

125E-5 Series

15

SEN00546-09

20 Standard value table

Running-in standard and performance test standard

Running-in standard
Engine

SAA6D125E-5

Machine model

D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R
Procedure

Item

Running time

min.

Speed

rpm

750

950

1,140

1,425

1,900

Dynamometer
load

N {kg}

0 {0}

275 {28}

697 {71}

1,115 {114}

1,394 {142}

Output

kW {HP}

0 {0}

20 {26.6}

60 {80}

119 {160}

199 {266}

a
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D125E-5

Machine model

D85EX-15E0, D85EX-15R
D85PX-15E0, D85PX-15R

Test item

Rated output

Max. torque

Max. speed at no
load

Min. speed at no
load

Specification
value
(Gross value)

Speed

rpm

1,900

1,400

2,100 50

750 (+50/0)

Dynamometer
load

N
{kg}

1,354 1,432
{138 146}

1,727 1,834
{176 187}

Output
(Gross value)

kW
{HP}

199
{266}

Torque
(Gross value)

Nm
{kgm}

1,272
{130}

Fuel consumption sec/300cc


Coolant
temperature

80 90

80 90

80 90

80 90

Lubricating oil
temperature

90 110

90 110

90 110

90 110

Lubricating oil
pressure

kPa
{kg/cm2}

290 690
{3.0 7.0}

190 540
{2.0 5.5}

290 690
{3.0 7.0}

Min. 80
{Min. 0.8}

Exhaust
temperature

Max. 650

Max. 650

a
a
a
a
a
a

16

This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No. 1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

125E-5 Series

20 Standard value table

SEN00546-09

Running-in standard
Engine

SAA6D125E-5

Machine model

PC400, 400LC-7E0, PC400, 400LC-8, PC400, 400LC-8R


PC450, 450LC-7E0, PC450, 450LC-8, PC450, 450LC-8R
Procedure

Item

a
a

Running time

min.

Speed

rpm

1,000

1,000

1,200

1,500

1,900

Dynamometer
load

N {kg}

0 {0}

353 {36}

875 {89}

1,400 {143}

1,893 {193}

Output

kW {HP}

0 {0}

26 {35.5}

79 {106}

157 {211}

262.5 {352}

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D125E-5

Machine model

PC400, 400LC-7E0, PC400, 400LC-8, PC400, 400LC-8R


PC450, 450LC-7E0, PC450, 450LC-8, PC450, 450LC-8R

Test item

a
a
a
a

Max. torque

Max. speed at no
load

Min. speed at no
load

Specification
value
(Gross value)

Speed

rpm

1,900

1,400

1,930 50

1,000 25

Dynamometer
load

N
{kg}

1,785 1,900
{182 194}

1,920 2,050
{196 209}

Output
(Gross value)

kW
{HP}

262.5
{352}

Torque
(Gross value)

Nm
{kgm}

1,422
{145}

Fuel consumption sec/300cc

a
a

Rated output

Coolant
temperature

80 90

80 90

80 90

80 90

Lubricating oil
temperature

90 110

90 110

90 110

90 110

Lubricating oil
pressure

kPa
{kg/cm2}

290 690
{3.0 7.0}

190 540
{2.0 5.5}

290 690
{3.0 7.0}

Min. 80
{Min. 0.8}

Exhaust
temperature

Max. 700

Max. 700

This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No. 1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

125E-5 Series

17

SEN00546-09

20 Standard value table

Running-in standard
Engine

SAA6D125E-5

Machine model

HM250-2
Procedure

Item

Running time

min.

Speed

rpm

725

1,000

1,200

1,500

2,000

Dynamometer
load

N {kg}

0 {0}

307 {31}

774 {79}

1,238 {126}

1,547 {158}

Output

kW {HP}

0 {0}

23 {31}

70 {94}

139 {186}

232 {311}

a
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D125E-5

Machine model

HM250-2

Test item

Rated output

Max. torque

Max. speed at no
load

Min. speed at no
load

Specification
value
(Gross value)

Speed

rpm

2,000

1,400

2,100 50

725 (+50/0)

Dynamometer
load

N
{kg}

1,500 1,593
{153 162}

2,320 2,450
{236 250}

Output
(Gross value)

kW
{HP}

232
{311}

Torque
(Gross value)

Nm
{kgm}

1,706
{174}

Fuel consumption sec/300cc


Coolant
temperature

80 90

80 90

80 90

80 90

Lubricating oil
temperature

90 110

90 110

90 110

90 110

Lubricating oil
pressure

kPa
{kg/cm2}

290 690
{3.0 7.0}

190 540
{2.0 5.5}

290 690
{3.0 7.0}

Min. 80
{Min. 0.8}

Exhaust
temperature

Max. 700

Max. 750

a
a
a
a
a
a

18

This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No. 1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

125E-5 Series

20 Standard value table

SEN00546-09

Running-in standard
Engine

SAA6D125E-5

Machine model

HM300-2, HM300-2R
Procedure

Item

a
a

Running time

min.

Speed

rpm

725

1,000

1,200

1,500

2,000

Dynamometer
load

N {kg}

0 {0}

343 {35}

850 {87}

1,354 {138}

1,692 {173}

Output

kW {HP}

0 {0}

26 {34.5}

76 {103}

152 {204}

254 {340}

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D125E-5

Machine model

HM300-2, HM300-2R

Test item

a
a
a
a

Max. torque

Max. speed at no
load

Min. speed at no
load

Specification
value
(Gross value)

Speed

rpm

2,000

1,400

2,220 50

725 (+50/0)

Dynamometer
load

N
{kg}

1,650 1,750
{168 178}

2,320 2,450
{236 250}

Output
(Gross value)

kW
{HP}

254
{340}

Torque
(Gross value)

Nm
{kgm}

1,706
{174}

Fuel consumption sec/300cc

a
a

Rated output

Coolant
temperature

80 90

80 90

80 90

80 90

Lubricating oil
temperature

90 110

90 110

90 110

90 110

Lubricating oil
pressure

kPa
{kg/cm2}

290 690
{3.0 7.0}

190 540
{2.0 5.5}

290 690
{3.0 7.0}

Min. 80
{Min. 0.8}

Exhaust
temperature

Max. 700

Max. 750

This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No. 1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

125E-5 Series

19

SEN00546-09

20 Standard value table

Running-in standard
Engine

SAA6D125E-5

Machine model

WA450-6
WA470-6, WA470-6R
Procedure

Item

Running time

min.

Speed

rpm

800

1,000

1,200

1,500

2,000

Dynamometer
load

N {kg}

0 {0}

275 {28}

677 {69}

1,079 {110}

1,353 {138}

Output

kW {HP}

0 {0}

21 {27.6}

61 {82}

121 {163}

203 {272}

a
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D125E-5

Machine model

WA450-6
WA470-6, WA470-6R

Test item

Rated output

Max. torque

Max. speed at no
load

Min. speed at no
load

Specification
value
(Gross value)

Speed

rpm

2,000

1,450

2,170 50

800 (+50/0)

Dynamometer
load

N
{kg}

1,319 1,400
{135 143}

1,267 1,345
{129 137}

Output
(Gross value)

kW
{HP}

204
{273}

Torque
(Gross value)

Nm
{kgm}

1,307
{133}

Fuel consumption sec/300cc


Coolant
temperature

80 90

80 90

80 90

80 90

Lubricating oil
temperature

90 110

90 110

90 110

90 110

Lubricating oil
pressure

kPa
{kg/cm2}

290 690
{3.0 7.0}

190 540
{2.0 5.5}

290 690
{3.0 7.0}

Min. 80
{Min. 0.8}

Exhaust
temperature

Max. 650

Max. 650

a
a
a
a
a
a

20

This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No. 1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

125E-5 Series

20 Standard value table

SEN00546-09

Running-in standard
Engine

SAA6D125E-5

Machine model

WA480-6, WA480-6R
Procedure

Item

a
a

Running time

min.

Speed

rpm

800

1,000

1,200

1,500

2,000

Dynamometer
load

N {kg}

0 {0}

294 {30}

735 {75}

1,196 {122}

1,491 {152}

Output

kW {HP}

0 {0}

22 {29.6}

66 {89}

135 {180}

224 {300}

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D125E-5

Machine model

WA480-6, WA480-6R

Test item

a
a
a
a

Max. torque

Max. speed at no
load

Min. speed at no
load

Specification
value
(Gross value)

Speed

rpm

2,000

1,400

2,190 50

800 (+50/0)

Dynamometer
load

N
{kg}

1,450 1,541
{148 157}

1,843 1,956
{188 200}

Output
(Gross value)

kW
{HP}

224
{301}

Torque
(Gross value)

Nm
{kgm}

1,360
{139}

Fuel consumption sec/300cc

a
a

Rated output

Coolant
temperature

80 90

80 90

80 90

80 90

Lubricating oil
temperature

90 110

90 110

90 110

90 110

Lubricating oil
pressure

kPa
{kg/cm2}

290 690
{3.0 7.0}

190 540
{2.0 5.5}

290 690
{3.0 7.0}

Min. 80
{Min. 0.8}

Exhaust
temperature

Max. 700

Max. 700

This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No. 1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

125E-5 Series

21

SEN00546-09

20 Standard value table

Running-in standard
Engine

SAA6D125E-5

Machine model

BR580JG-1
Procedure

Item

Running time

min.

Speed

rpm

1,000

1,000

1,200

1,500

1,900

Dynamometer
load

N {kg}

0 {0}

353 {36}

875 {89}

1,400 {143}

1,893 {193}

Output

kW {HP}

0 {0}

26 {35.5}

79 {106}

157 {211}

262.5 {352}

a
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D125E-5

Machine model

BR580JG-1

Test item

Rated output

Max. torque

Max. speed at no
load

Min. speed at no
load

Specification
value
(Gross value)

Speed

rpm

1,900

1,400

1,930 50

1,000 25

Dynamometer
load

N
{kg}

1,785 1,900
{182 194}

1,920 2,050
{196 209}

Output
(Gross value)

kW
{HP}

262.5
{352}

Torque
(Gross value)

Nm
{kgm}

1,422
{145}

Fuel consumption sec/300cc


Coolant
temperature

80 90

80 90

80 90

80 90

Lubricating oil
temperature

90 110

90 110

90 110

90 110

Lubricating oil
pressure

kPa
{kg/cm2}

290 690
{3.0 7.0}

190 540
{2.0 5.5}

290 690
{3.0 7.0}

Min. 80
{Min. 0.8}

Exhaust
temperature

Max. 700

Max. 700

a
a
a
a
a
a

22

This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No. 1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

125E-5 Series

20 Standard value table

SEN00546-09

Running-in standard
Engine

SAA6D125E-5

Machine model

GD755-5R
Procedure

Item

a
a

Running time

min.

Speed

rpm

800

1,000

1,200

1,500

2,000

Dynamometer
load

N {kg}

0 {0}

288 {29}

720 {73}

1,152 {117}

1,440 {147}

Output

kW {HP}

0 {0}

21.6 {29.0}

64.8 {86.9}

129.6 {173.8}

216 {289.7}

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D125E-5

Machine model

GD755-5R

Test item

a
a
a
a

Max. torque

Max. speed at no
load

Min. speed at no
load

Specification
value
(Gross value)

Speed

rpm

2,000

1,400

2,200 50

800 (+50/0)

Dynamometer
load

N
{kg}

1,397 1,483
{142.5 151.3}

1,784 1,894
{181.9 193.1}

Output
(Gross value)

kW
{HP}

216
{289.7}

Torque
(Gross value)

Nm
{kgm}

1,317
{134.3}

Fuel consumption sec/300cc

a
a

Rated output

Coolant
temperature

80 90

80 90

80 90

80 90

Lubricating oil
temperature

90 110

90 110

90 110

90 110

Lubricating oil
pressure

kPa
{kg/cm2}

290 690
{3.0 7.0}

190 540
{2.0 5.5}

290 690
{3.0 7.0}

Min. 80
{Min. 0.8}

Exhaust
temperature

Max. 700

Max. 700

This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No. 1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

125E-5 Series

23

SEN00546-09

20 Standard value table

Running-in standard
Engine

SAA6D125E-5

Machine model

DCA-300SSK4
(DENYO/MQ GENERATOR)
Procedure

Item

Running time

min.

Speed

rpm

750

1,500

1,500

1,500

1,800

Dynamometer
load

N {kg}

0 {0}

366 {37}

970 {99}

1,568 {160}

2,019 {206}

Output

kW {HP}

0 {0}

41 {56}

109 {148}

177 {240}

277 {370}

a
a

This table shows the values when the fan is not installed.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.

Performance test standard


Engine

SAA6D125E-5

Machine model

DCA-300SSK4
(DENYO/MQ GENERATOR)

Test item

Rated output

Max. output

Max. speed at no
load

Min. speed at no
load

Specification
value
(Gross value)

kW
{HP}

272 7.36
{365 10}

313 9.56
{420 13}

Speed

rpm

1,800

1,800

Max. 1,890

750 25

Dynamometer
load

N
{kg}

1,960 2,068
{200 211}

2,244 2,391
{229 244}

Output
(Gross value)

kW
{HP}

272
{370}

Torque
(Gross value)

Nm
{kgm}

Fuel consumption sec/300cc


Coolant
temperature

80 90

80 90

80 90

80 90

Lubricating oil
temperature

90 110

90 110

90 110

90 110

Lubricating oil
pressure

kPa
{kg/cm2}

290 690
{3.0 7.0}

190 540
{2.0 5.5}

290 690
{3.0 7.0}

Min. 80
{Min. 0.8}

Exhaust
temperature

Max. 700

Max. 750

a
a
a
a
a
a

24

This table shows the standard values obtained by using the JIS correction coefficients.
Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Use ASTM No. 1 or No. 2 diesel fuel as fuel.
Use SAE15W-40 as lubricating oil.

125E-5 Series

20 Standard value table

125E-5 Series

SEN00546-09

25

SEN00546-09

KOMATSU 125E-5 Series engine


Form No. SEN00546-09

2011 KOMATSU
All Rights Reserved
Printed in Japan 11-11

26

SEN00547-05

ENGINE
1SHOP MANUAL

125E-5 Series

30 Testing and adjusting

Testing and adjusting


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

125E-5 Series

SEN00547-05

30 Testing and adjusting

Bleeding air from fuel circuit ............................................................................................................... 20


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

125E-5 Series

30 Testing and adjusting

SEN00547-05

Testing and adjusting (With EGR)

Testing and adjusting tools list 1


Testing and adjusting item

Symbol

Testing air boost pressure

Testing exhaust
temperature
Adjusting valve clearance

Q'ty

Remarks

799-201-2202 Boost gauge kit

101 200 kPa {760 1,500 mmHg}

799-401-2220 Hose

I-coupler type (if necessary)

799-101-1502 Digital thermometer

99.9 1,299C

Commercially
Feeler gauge
available

Intake: 0.33 mm
Exhaust: 0.71 mm

795-502-1590 Compression gauge

0 7 MPa {0 70 kg/cm2}

795-471-1420 Adapter

6217-71-6112 Gasket

799-201-1504 Blow-by checker

0 5 kPa {0 500 mmH2O}

799-101-5002 Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa


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

790-261-1204 Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

799-401-2320 Hydraulic tester

Pressure gauge: 1 MPa {10 kg/cm2}

799-101-5002 Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa


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

790-261-1204 Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

799-401-2320 Gauge

Pressure gauge: 1 MPa {10 kg/cm2}

795-471-1450 Adapter

07005-00812 Gasket

6151-51-8490 Spacer

Inside diameter: 14 mm

6206-71-1770 Joint

Inside diameter of joint: 10 mm

Commercially
Hose
available

5 mm x 2 3 m

Commercially
Hose
available

15 mm x 2 3 m

Commercially
Measuring cylinder
available

Commercially
Stopwatch
available

1
Testing compression
pressure

Testing blow-by pressure

Testing oil pressure

2
E

1
2
1

Testing fuel pressure

2
3

Testing leakage from


pressure limiter and return H 4
rate from injector

125E-5 Series

Part No.

Part name

For 125E-5

8 x 1.25 mm o R1/8

SEN00547-05

Testing and adjusting item

Troubleshooting for
controllers,
sensors, and actuators

Removal and installation


of engine coolant
temperature sensor

30 Testing and adjusting

Symbol

Part No.

Part name

Remarks

799-601-4130 T-adapter

For Ne sensor

799-601-4330 Socket

For Bkup sensor

799-601-4240 Socket

For atmospheric pressure sensor

799-601-4250 Socket

For boost pressure sensor

799-601-4180 T-adapter

For EGR gas sensor

799-601-9420 T-adapter

For common rail pressure

799-601-4150 T-adapter

For oil pressure sensor

795-799-5540 T-adapter

For boost temperature sensor

795-799-5530 T-adapter

For coolant temperature sensor


For fuel temperature sensor

799-601-9020 T-adapter

For EGR valve solenoid


For bypass valve solenoid

799-601-9030 T-adapter

For EGR valve solenoid


For bypass valve stroke sensor

799-601-9430 T-adapter

For supply pump PCV

799-601-9020 T-adapter

For injector

799-601-4260 T-adapter

For controller (4-pole)

799-601-4210 T-adapter

For controller (50-pole)

799-601-4220 T-adapter

For controller (60-pole)

799-601-9320 T-box

799-601-9310 Plate

799-601-4350 T-box

For 60-pole type

Commercially
Socket
available

For 24-pole type

21 mm deep socket
(MITOLOY 4ML-21 or equivalent)
Applicable engine serial No.:
560001 - 564999

19 mm deep socket
(MITOLOY 4ML-19 or equivalent)
Applicable engine serial No.:
565000 and up

795T-981-1010 Socket

Q'ty

125E-5 Series

30 Testing and adjusting

Sketches of special tools

SEN00547-05

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

Socket

125E-5 Series

SEN00547-05

30 Testing and adjusting

Testing air boost pressure


a

Testing tools for air boost pressure

Symbol
A
k

a
1.

Part No.

Part name

799-201-2202

Boost gauge kit

799-401-2220

Hose

Be careful not to touch any hot part when


removing or installing the testing tools.
The test point is subject to machine models.
Remove one air boost pressure pickup plug
(1).
a You may check at either front or rear plug.

2.

Install nipple [1] of boost gauge kit A and connect it to gauge [2].

3.

Run the engine at the rated output and test the


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

4.

After finishing testing, remove the testing tools


and return the removed parts.

125E-5 Series

30 Testing and adjusting

SEN00547-05

Testing exhaust temperature


a

Testing tools for exhaust temperature

Symbol

Part No.

799-101-1502

a
1.

Part name
Digital thermometer

Remove and install the testing tools after


the exhaust manifold temperature has lowered.
The test point is subject to machine models.
Remove exhaust temperature pickup plug (1)
from the side face of the center of the exhaust
manifold.
4.

2.

Install sensor [1] of digital thermometer B and


connect it to thermometer [2].

3.

Run the engine and test the exhaust temperature in the whole speed range.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

125E-5 Series

After finishing testing, remove the testing tools


and return the removed parts.
3 Exhaust temperature pickup plug:
3.9 6.9 Nm {0.4 0.7 kgm}

SEN00547-05

30 Testing and adjusting

Adjusting valve clearance


a

Part No.

Commercially
available

2.

3.

While fixing adjustment screw (3), loosen locknut (4).


a After setting the No. 1 cylinder to the compression top dead center, adjust the valve
clearance of the No. 1 cylinder.

4.

Insert feeler gauge C in the clearance between


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

5.

While fixing adjustment screw (3), tighten locknut (4).


3 Locknut:
58.8 73.5 Nm {6.0 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.

6.

After adjusting the No. 1 cylinder, rotate the


crankshaft forward by 120 and adjust the
clearance of each cylinder according to the firing order.
a Firing order: 1-5-3-6-2-4

7.

After finishing adjustment, return the removed


parts.
3 Cylinder head cover mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}

Adjusting tools for valve clearance

Symbol

1.

Part name
Feeler gauge

Remove 6 cylinder head covers (1).

Rotate the crankshaft forward to bring the


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

125E-5 Series

30 Testing and adjusting

SEN00547-05

Testing compression pressure


a

Testing tools for compression pressure

Symbol
1
D
k

1.

Part No.

Pass a wire, etc. under the fuel path projected sideways and pull up the injector
(Do not pry the injector top up).

Part name

795-502-1590

Compression gauge

795-471-1420

Adapter

6217-71-6112

Gasket

When measuring the compression pressure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
Measure the compression pressure after the
engine is warmed up
(Engine oil temperature: 40 60C).
Remove cylinder head cover (1) of the cylinder
to be tested for compression pressure.

2.

Bring the cylinder to be tested to the compression top dead center and remove rocker arm
assembly (2).
a See "Adjusting valve clearance".

3.

Disconnect fuel high-pressure tube (3) and


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

125E-5 Series

4.

Install adapter D2 to the mounting hole on the


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

5.

Install rocker arm assembly (2) and adjust the


valve clearance.
3 Rocker arm assembly mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
a See "Adjusting valve clearance".

SEN00547-05

6.

Connect the INSITE (bench test tool) to the


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

7.

Rotate the engine with the starting motor and


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

8.

After finishing testing, remove the testing tools


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

10

30 Testing and adjusting


3

Rocker arm assembly mounting


bolt:
58.8 73.5 Nm {6.0 7.5 kgm}

Adjust the valve clearance.


For
details, see "Adjusting valve clearance".

Cylinder head cover mounting bolt:


9.8 1 Nm {1.0 0.1 kgm}

125E-5 Series

30 Testing and adjusting

SEN00547-05

Testing blow-by pressure


a

Testing tool for blow-by pressure

Symbol

Part No.

799-201-1504

Part name
Blow-by checker

The test point is subject to machine models.

1.

Install nozzle [1] of blow-by checker E to the


end of breather hose (1).

2.

Connect hose [2], and then connect it to gauge


[3].

3.

Run the engine at the rated output and test the


blow-by pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

4.

After finishing testing, remove the testing tools


and return the removed parts.

125E-5 Series

11

SEN00547-05

30 Testing and adjusting

Testing engine oil pressure


a

Testing tools for engine oil pressure

Symbol
F

1
2

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Hydraulic tester

The test point is subject to machine models.

1.

Remove oil pressure pickup plug (1) from the


cylinder block.
4.

2.

Connect nipple [1] of hydraulic tester F1 and


connect it to hydraulic tester F2.

3.

Run the engine at the rated output and low idle


and test the oil pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

12

After finishing testing, remove the testing tools


and return the removed parts.

125E-5 Series

30 Testing and adjusting

SEN00547-05

Measuring EGR valve and bypass


valve drive pressure
1
a

Part No.

4.

Start the engine and measure the oil pressure


at low idle and high idle.
a When measuring without removing the
engine from the machine, measure under
the condition described in the shield
machine for the machine.

5.

After finishing measurement, remove the measuring instruments and return the removed
parts.
q
Replace the removed plug with new one.
When reusing it, remove the sticking gasket sealant from it with a wire brush and
apply new adhesive or gasket sealant to it
before installing.
2 Plug:
Adhesive (LT-2) or Gasket sealant (LG-4)
3 Plug: 16.7 37.2 Nm {1.7 3.8 kgm}

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

The measuring points may be different from


the following explanation, depending on each
applicable machine.

1.

Remove either of oil pressure pickup plugs (2)


of timing gear cover (1).
Reference: When measuring without removing the engine from the machine, if it is difficult
to remove the pickup plug, remove or move the
following parts.
q
Remove the belt cover.
q
Remove the air conditioner compressor
belt.
q
Move the air conditioner compressor so
that it will not be an obstacle to the work.

2.

Connect hydraulic tester [1] to the nipple.

Measuring instruments for EGR valve and


bypass valve drive pressure

Symbol
F

3.

Install nipple (Component of tool F1: 790-3011190) to the oil pressure pickup hole.

125E-5 Series

13

SEN00547-05

Handling fuel system parts


a

14

30 Testing and adjusting

Precautions for testing and maintaining fuel


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

Releasing residual pressure in


fuel system
a

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

125E-5 Series

30 Testing and adjusting

SEN00547-05

Testing fuel pressure


a

1
2
3

a
k

1.

3.

Testing tools for fuel pressure

Symbol

Part No.
799-101-5002

Part name
Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Gauge

795-471-1450

Adapter

07005-00812

Gasket

Engine speed

Fuel pressure

High idle

0.15 0.3 MPa


{1.5 3 kg/cm2}

Test only the fuel pressure in the low-pressure


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

4.

2.

Run the engine at high idle and measure the


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

After finishing testing, remove the testing tools


and return the removed parts.

Install adapter G3 and nipple [1] of hydraulic


tester G1 and connect it to gauge G2.

125E-5 Series

15

SEN00547-05

30 Testing and adjusting

Reduced cylinder mode operation1

No-injection cranking

1.

2.

3.

16

Reduced cylinder mode operation means to


run the engine with the fuel injectors of 1 or
more cylinders disabled electrically to reduce
the number of effective cylinders. The purposes and effects of this operation are as follows.
This operation is used to find out a cylinder
which does not output power normally (or,
combustion in it is abnormal).
When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects.
The possible defects are as follows.
q
Leakage from the cylinder head gasket
q
Defective injection
q
Defective piston, piston ring, or cylinder
liner
q
Defective valve mechanism (Moving valve
system)
q
Defect in electrical system
Since the common rail fuel injection system
controls the injector of each cylinder electronically, the operator can perform the reduced
cylinder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode operation with the engine mounted on the
machine or connected to INSITE (bench
test tool).
a Before performing, see "Testing method"
in the shop manual for the machine or
INSITE (bench test tool).

a
a

No-injection cranking means to crank the


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

125E-5 Series

30 Testing and adjusting

SEN00547-05

Testing leakage from pressure limiter and return rate from injector

The locations of the fuel circuit parts are subject to machine models (The figure shows the
engine for PC400/400LC-7E0 and PC450/
450LC-7E0).
Testing tools for leakage from pressure limiter
and return rate from injector

Symbol

Part No.

Preparation work
1) Remove tube (3) between common rail (1)
and return block (2).

Part name

6151-51-8490

Spacer

6206-71-1770

Joint

Commercially available

Hose

Commercially available

Hose

Commercially available

Measuring cylinder

Commercially available

Stopwatch

Prepare a pan of about 20 l to receive the fuel


flowing out during the test.

125E-5 Series

1.

2)

Insert spacer H1 on return block (2) side


and tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the spacer.

17

SEN00547-05

3)

4)

30 Testing and adjusting

Insert joint H2 on common rail (1) side and


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

2.

18

Testing leakage from pressure limiter


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

Leakage
(cc/min)

At rated output

Max. 10

After finishing testing, stop the engine.

Testing return rate from injector


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

2)

3)

Connect test hose H4 to the return block


(2) side.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
Lay test hose H4 so that it will not slacken
and put its end in the pan.

125E-5 Series

30 Testing and adjusting

SEN00547-05

4.

Work after finishing testing


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

4)

5)
6)

Connect INSITE (bench test tool) to the


engine 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.
Run the engine at the rated output.
After the engine speed is stabilized, test
the return rate in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injector is in the following range, it is normal.
Rated output speed
(rpm)

7)

Return (Spill) limit


(cc/min)

1,600

960

1,700

1,020

1,800

1,080

1,900

1,140

2,000

1,200

After finishing testing, stop the engine.

125E-5 Series

19

SEN00547-05

Bleeding air from fuel circuit

a
a

1.

20

30 Testing and adjusting

If fuel is used up or if a fuel circuit part is


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

125E-5 Series

30 Testing and adjusting

2.

Install pre-fuel filter (1) to the filter head.


a Apply engine oil thinly over the packing on
the pre-fuel filter side.
a After the packing of the pre-fuel filter
touches the sealing face of the filter head,
tighten the fuel filter 3/4 turns.

3.

Remove air bleeding plug (4) of the fuel main


filter and operate priming pump (4).
a Operate the priming pump until the fuel
flows out of the plug hole and install the
plug.
3 Air bleeding plug:
7.8 9.8 Nm {0.8 1.0 kgm}

4.

Loosen air bleeding plug (5) of the fuel main filter (2) and operate priming pump (4).
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

SEN00547-05

5.

Loosen air bleeder (6) of the fuel supply pump


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

6.

Start the engine with the starting motor.


a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 3.

21

SEN00547-05

Testing fuel system for leakage 1


k

Very high pressure is generated in the


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

1.

Spray color checker (developer) over the fuel


supply pump, common rail, fuel injector, and
joints of the high-pressure piping.

2.

Run the engine at speed below 1,000 rpm and


stop it after its speed is stabilized.

3.

Inspect the fuel piping and devices for fuel


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

4.

Run the engine at low idle.

5.

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.

6.

Run the engine at high idle.

7.

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.

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

30 Testing and adjusting

9.

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.
a If no fuel leakage is detected, inspection is
completed.

125E-5 Series

30 Testing and adjusting

Adjusting speed sensor


a
a

SEN00547-05

The Ne speed sensor and Bkup speed sensor


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

1.

Remove speed sensor (1) and check that its tip


is free from steel chips and flaws, and then
install it again temporarily.
2 Threads: Gasket sealant (LG-6)

2.

Screw in sensor (1) until its tip touches the


tooth tip of flywheel ring gear (2).

3.

Return sensor (1) by 1/2 2/3 turns.


a Adjust clearance (a) between the sensor
tip and gear tooth tip to 0.75 1.00 mm.

4.

While fixing sensor (1), tighten nut (3).


3 Nut: 69 74 Nm {7.0 7.5 kgm}

125E-5 Series

23

SEN00547-05

Testing and adjusting alternator


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

30 Testing and adjusting

Simultaneous fan drive type


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

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,
adjust it according to the following procedure.
a The figure shows an example. The number of
the belt may be different and locknut (1) may
not be used depending on each model.
1.

Loosen locknut (1) and loosen rocknut (2) and


bolts (3) and (4).

2.

Move alternator (6) with adjustment nut (5) to


adjust the tension of belt (7).

3.

Tighten bolts (4) and (3) and tighten locknut


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

24

1.

Loosen locknut (1) and bolts (2) and (3).

2.

Move alternator (5) with adjustment nut (4) to


adjust the tension of belt (6).

3.

Tighten bolts (3) and (2) and tighten locknut


(1).
3 Bolt (3): 107.8 147 Nm {11 15 kgm}
3 Bolt (2): 28.4 38.2 Nm {2.9 3.9 kgm}
a After adjusting, test the belt tension again.

125E-5 Series

30 Testing and adjusting

SEN00547-05

Handling controller voltage circuit1


1.

When disconnecting or connecting a connector


between the engine controller and engine, be
sure to turn the starting switch OFF.

2.

If a T-adapter is inserted in or connected to a


connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.

125E-5 Series

25

SEN00547-05

30 Testing and adjusting

Testing and adjusting (EGR-less)

Testing and adjusting tools list 1


Testing and adjusting item

Symbol

Testing air boost pressure

Testing exhaust
temperature
Adjusting valve clearance

Q'ty

Remarks

799-201-2202 Boost gauge kit

101 200 kPa {760 1,500 mmHg}

799-401-2220 Hose

I-coupler type (if necessary)

799-101-1502 Digital thermometer

99.9 1,299C

Commercially
Feeler gauge
available

Intake: 0.33 mm
Exhaust: 0.71 mm

795-502-1590 Compression gauge

0 7 MPa {0 70 kg/cm2}

795-471-1420 Adapter

6217-71-6112 Gasket

799-201-1504 Blow-by checker

0 5 kPa {0 500 mmH2O}

799-101-5002 Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa


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

790-261-1204 Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

799-401-2320 Hydraulic tester

Pressure gauge: 1 MPa {10 kg/cm2}

799-101-5002 Hydraulic tester

Pressure gauge: 2.5, 6, 40, 60 MPa


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

790-261-1204 Digital hydraulic tester

Pressure gauge: 60 MPa {600 kg/cm2}

799-401-2320 Gauge

Pressure gauge: 1 MPa {10 kg/cm2}

795-471-1450 Adapter

07005-00812 Gasket

6151-51-8490 Spacer

Inside diameter: 14 mm

6206-71-1770 Joint

Inside diameter of joint: 10 mm

Commercially
Hose
available

5 mm x 2 3 m

Commercially
Hose
available

15 mm x 2 3 m

Commercially
Measuring cylinder
available

Commercially
Stopwatch
available

1
Testing compression
pressure

Testing blow-by pressure

Testing oil pressure

2
E

1
2
1

Testing fuel pressure

2
3

Testing leakage from


pressure limiter and return H 4
rate from injector

26

Part No.

Part name

For 125E-5

8 x 1.25 mm o R1/8

125E-5 Series

30 Testing and adjusting

Testing and adjusting item

Troubleshooting for
controllers,
sensors, and actuators

Removal and installation


of engine coolant
temperature sensor

SEN00547-05

Symbol

Part No.

Part name

Remarks

799-601-4130 T-adapter

For Ne sensor

799-601-4330 Socket

For Bkup sensor

799-601-4240 Socket

For atmospheric pressure sensor

799-601-4250 Socket

For boost pressure sensor

799-601-9420 T-adapter

For common rail pressure

799-601-4150 T-adapter

For oil pressure sensor

795-799-5540 T-adapter

For boost temperature sensor

795-799-5530 T-adapter

799-601-9430 T-adapter

For supply pump PCV

799-601-9020 T-adapter

For injector

799-601-4260 T-adapter

For controller (4-pole)

799-601-4210 T-adapter

For controller (50-pole)

799-601-4220 T-adapter

For controller (60-pole)

799-601-9320 T-box

799-601-9310 Plate

799-601-4350 T-box

For 60-pole type

Commercially
Socket
available

For coolant temperature sensor


For fuel temperature sensor

For 24-pole type

21 mm deep socket
(MITOLOY 4ML-21 or equivalent)
Applicable engine serial No.:
560001 - 564999

19 mm deep socket
(MITOLOY 4ML-19 or equivalent)
Applicable engine serial No.:
565000 and up

795T-981-1010 Socket

125E-5 Series

Q'ty

27

SEN00547-05

Sketches of special tools

30 Testing and adjusting

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

Socket

28

125E-5 Series

30 Testing and adjusting

SEN00547-05

Testing air boost pressure


a

Testing tools for air boost pressure

Symbol
A
k

a
1.

Part No.

Part name

799-201-2202

Boost gauge kit

799-401-2220

Hose

Be careful not to touch any hot part when


removing or installing the testing tools.
The test point is subject to machine models.
Remove one air boost pressure pickup plug
(1).
a You may check at either front or rear plug.

2.

Install nipple [1] of boost gauge kit A and connect it to gauge [2].

3.

Run the engine at the rated output and test the


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

125E-5 Series

4.

After finishing testing, remove the testing tools


and return the removed parts.

29

SEN00547-05

30 Testing and adjusting

Testing exhaust temperature


a

Testing tools for exhaust temperature

Symbol

Part No.

799-101-1502

a
1.

Part name
Digital thermometer

Remove and install the testing tools after


the exhaust manifold temperature has lowered.
The test point is subject to machine models.
Remove exhaust temperature pickup plug (1)
from the side face of the center of the exhaust
manifold.
4.

2.

Install sensor [1] of digital thermometer B and


connect it to thermometer [2].

3.

Run the engine and test the exhaust temperature in the whole speed range.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

30

After finishing testing, remove the testing tools


and return the removed parts.
3 Exhaust temperature pickup plug:
3.9 6.9 Nm {0.4 0.7 kgm}

125E-5 Series

30 Testing and adjusting

SEN00547-05

Adjusting valve clearance


a

Part No.

Commercially
available

2.

3.

While fixing adjustment screw (3), loosen locknut (4).


a After setting the No. 1 cylinder to the compression top dead center, adjust the valve
clearance of the No. 1 cylinder.

4.

Insert feeler gauge C in the clearance between


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

5.

While fixing adjustment screw (3), tighten locknut (4).


3 Locknut:
58.8 73.5 Nm {6.0 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.

6.

After adjusting the No. 1 cylinder, rotate the


crankshaft forward by 120 and adjust the
clearance of each cylinder according to the firing order.
a Firing order: 1-5-3-6-2-4

7.

After finishing adjustment, return the removed


parts.
3 Cylinder head cover mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}

Adjusting tools for valve clearance

Symbol

1.

Part name
Feeler gauge

Remove 6 cylinder head covers (1).

Rotate the crankshaft forward to bring the


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

125E-5 Series

31

SEN00547-05

30 Testing and adjusting

Testing compression pressure


a

Testing tools for compression pressure

Symbol
1
D
k

1.

Part No.

Pass a wire, etc. under the fuel path projected sideways and pull up the injector
(Do not pry the injector top up).

Part name

795-502-1590

Compression gauge

795-471-1420

Adapter

6217-71-6112

Gasket

When measuring the compression pressure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
Measure the compression pressure after the
engine is warmed up
(Engine oil temperature: 40 60C).
Remove cylinder head cover (1) of the cylinder
to be tested for compression pressure.

2.

Bring the cylinder to be tested to the compression top dead center and remove rocker arm
assembly (2).
a See "Adjusting valve clearance".

3.

Disconnect fuel high-pressure tube (3) and


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

32

4.

Install adapter D2 to the mounting hole on the


injector and the compression gauge D1.
a Fit the gasket to the adapter end without
fail
a Fix the adapter with the injector holder.
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".

125E-5 Series

30 Testing and adjusting

6.

Connect the INSITE (bench test tool) to the


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

7.

Rotate the engine with the starting motor and


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

8.

After finishing testing, remove the testing tools


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

125E-5 Series

SEN00547-05

Rocker arm assembly mounting


bolt:
58.8 73.5 Nm {6.0 7.5 kgm}

Adjust the valve clearance.


For
details, see "Adjusting valve clearance".

Cylinder head cover mounting bolt:


9.8 1 Nm {1.0 0.1 kgm}

33

SEN00547-05

30 Testing and adjusting

Testing blow-by pressure


a

Testing tool for blow-by pressure

Symbol

Part No.

799-201-1504

Part name
Blow-by checker

The test point is subject to machine models.

1.

Install nozzle [1] of blow-by checker E to the


end of breather hose (1).

2.

Connect hose [2], and then connect it to gauge


[3].

3.

Run the engine at the rated output and test the


blow-by pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

4.

After finishing testing, remove the testing tools


and return the removed parts.

34

125E-5 Series

30 Testing and adjusting

SEN00547-05

Testing engine oil pressure


a

Testing tools for engine oil pressure

Symbol
F

1
2

Part No.

Part name

799-101-5002

Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Hydraulic tester

The test point is subject to machine models.

1.

Remove oil pressure pickup plug (1) from the


cylinder block.
4.

2.

Connect nipple [1] of hydraulic tester F1 and


connect it to hydraulic tester F2.

3.

Run the engine at the rated output and low idle


and test the oil pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.

125E-5 Series

After finishing testing, remove the testing tools


and return the removed parts.

35

SEN00547-05

Handling fuel system parts


a

36

30 Testing and adjusting

Precautions for testing and maintaining fuel


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

Releasing residual pressure in


fuel system
a

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

125E-5 Series

30 Testing and adjusting

SEN00547-05

Testing fuel pressure


a

1
2
3

a
k

1.

3.

Testing tools for fuel pressure

Symbol

Part No.
799-101-5002

Part name
Hydraulic tester

790-261-1204

Digital hydraulic tester

799-401-2320

Gauge

795-471-1450

Adapter

07005-00812

Gasket

Engine speed

Fuel pressure

High idle

0.15 0.3 MPa


{1.5 3 kg/cm2}

Test only the fuel pressure in the low-pressure


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

4.

2.

Run the engine at high idle and measure the


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

After finishing testing, remove the testing tools


and return the removed parts.

Install adapter G3 and nipple [1] of hydraulic


tester G1 and connect it to gauge G2.

125E-5 Series

37

SEN00547-05

30 Testing and adjusting

Reduced cylinder mode operation1

No-injection cranking

1.

2.

3.

38

Reduced cylinder mode operation means to


run the engine with the fuel injectors of 1 or
more cylinders disabled electrically to reduce
the number of effective cylinders. The purposes and effects of this operation are as follows.
This operation is used to find out a cylinder
which does not output power normally (or,
combustion in it is abnormal).
When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed
and output do not change from the normal
operation (all-cylinder operation), that cylinder
has 1 or more defects.
The possible defects are as follows.
q
Leakage from the cylinder head gasket
q
Defective injection
q
Defective piston, piston ring, or cylinder
liner
q
Defective valve mechanism (Moving valve
system)
q
Defect in electrical system
Since the common rail fuel injection system
controls the injector of each cylinder electronically, the operator can perform the reduced
cylinder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode operation with the engine mounted on the
machine or connected to INSITE (bench
test tool).
a Before performing, see "Testing method"
in the shop manual for the machine or
INSITE (bench test tool).

a
a

No-injection cranking means to crank the


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

125E-5 Series

30 Testing and adjusting

SEN00547-05

Testing leakage from pressure


limiter and return rate from
injector
a
a

The locations of the fuel circuit parts are subject to machine models.
Testing tools for leakage from pressure limiter
and return rate from injector

Symbol

Part No.

Part name

6151-51-8490

Spacer

6206-71-1770

Joint

Commercially available

Hose

Commercially available

Hose

Commercially available

Measuring cylinder

Commercially available

Stopwatch

Prepare a pan of about 20 l to receive the fuel


flowing out during the test.

1.

Preparation work
1) Remove tube (3) between common rail (1)
and return block (2).

2)

3)

4)

Insert spacer H1 on return block (2) side


and tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the spacer.
Insert joint H2 on common rail (1) side and
tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the joint.
Connect test hose H3 to the end of joint
H2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.

125E-5 Series

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 output.
4) After the engine speed is stabilized, test
the leakage in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the leakage from the pressure limiter is in the following range, it is normal.

5)

Engine speed

Leakage
(cc/min)

At rated output

Max. 10

After finishing testing, stop the engine.

39

SEN00547-05

3.

30 Testing and adjusting

Testing return rate from injector


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

2)

3)

6)

4.

5)

40

Rated output speed


(rpm)

Return (Spill) limit


(cc/min)

1,600

960

1,700

1,020

1,800

1,080

1,900

1,140

2,000

1,200

Connect test hose H4 to the return block


(2) side.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
Lay test hose H4 so that it will not slacken
and put its end in the pan.

7)

4)

After the engine speed is stabilized, test


the return rate in 1 minute with measuring
cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injector is in the following range, it is normal.

After finishing testing, stop the engine.

Work after finishing testing


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

Connect INSITE (bench test tool) to the


engine 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.
Run the engine at the rated output.

125E-5 Series

30 Testing and adjusting

Bleeding air from fuel circuit

SEN00547-05

4.

Reference: The electric priming pump switch is


installed to the chassis.
a
a

Turn ON switch (3) of electric priming pump


(2) installed to the chassis.
a The electric priming pump operates and
lamp (4) blinks.

Manual priming pump is set for some models.


(See the"with EGR")
Bleed air from the fuel circuit in the following
cases according to this procedure.
q
When the fuel filter is replaced
q
When fuel is used up
q
When the engine is started for the first
time after the fuel piping or supply pump is
replaced
If the fuel filter was replaced, do not fill the
main filter and prefilter with the fuel.

1.

Turn the starting switch to the OFF position.

2.

Check that the fuel valve on the fuel tank side


is open.

3.

Turn lever (1) of the air bleeding piping to the


parallel position with the piping to open the circuit valve.

a
a
k

The electric priming pump has a timer in it


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

Reference: The operating procedure sticker is


stuck near the air bleeding piping lever.

125E-5 Series

5.

After the specified time (approx. 7 minutes),


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

6.

If the fuel was used up or the fuel piping or


supply pump was replaced and there is not fuel
in the fuel circuit, turn switch (3) ON after the
electric priming pump stops automatically.

41

SEN00547-05

7.

When lamp (4) goes off, the air bleeding work


is completed.

8.

Turn lever (1) of the air bleeding piping to the


cross position with the piping to close the circuit valve.

30 Testing and adjusting

9.

Start the engine with the starting motor.


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

42

125E-5 Series

30 Testing and adjusting

Testing fuel system for leakage 1


k

Very high pressure is generated in the


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

1.

Spray color checker (developer) over the fuel


supply pump, common rail, fuel injector, and
joints of the high-pressure piping.

2.

Run the engine at speed below 1,000 rpm and


stop it after its speed is stabilized.

3.

Inspect the fuel piping and devices for fuel


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

4.

Run the engine at low idle.

5.

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.

6.

Run the engine at high idle.

7.

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.

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.

125E-5 Series

SEN00547-05

9.

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.
a If no fuel leakage is detected, inspection is
completed.

43

SEN00547-05

Adjusting speed sensor


a
a

30 Testing and adjusting

The Ne speed sensor and Bkup speed sensor


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

1.

Remove speed sensor (1) and check that its tip


is free from steel chips and flaws, and then
install it again temporarily.
2 Threads: Gasket sealant (LG-6)

2.

Screw in sensor (1) until its tip touches the


tooth tip of flywheel ring gear (2).

3.

Return sensor (1) by 1/2 2/3 turns.


a Adjust clearance (a) between the sensor
tip and gear tooth tip to 0.75 1.00 mm.

4.

While fixing sensor (1), tighten nut (3).


3 Nut: 69 74 Nm {7.0 7.5 kgm}

44

125E-5 Series

30 Testing and adjusting

Testing and adjusting alternator


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

SEN00547-05

Simultaneous fan drive type


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

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,
adjust it according to the following procedure.
a The figure shows an example. The number of
the belt may be different and locknut (1) may
not be used depending on each model.
1.

Loosen locknut (1) and loosen rocknut (2) and


bolts (3) and (4).

2.

Move alternator (6) with adjustment nut (5) to


adjust the tension of belt (7).

3.

Tighten bolts (4) and (3) and tighten locknut


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

125E-5 Series

1.

Loosen locknut (1) and bolts (2) and (3).

2.

Move alternator (5) with adjustment nut (4) to


adjust the tension of belt (6).

3.

Tighten bolts (3) and (2) and tighten locknut


(1).
3 Bolt (3): 107.8 147 Nm {11 15 kgm}
3 Bolt (2): 28.4 38.2 Nm {2.9 3.9 kgm}
a After adjusting, test the belt tension again.

45

SEN00547-05

30 Testing and adjusting

Handling controller voltage circuit1


1.

When disconnecting or connecting a connector


between the engine controller and engine, be
sure to turn the starting switch OFF.

2.

If a T-adapter is inserted in or connected to a


connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.

46

125E-5 Series

30 Testing and adjusting

125E-5 Series

SEN00547-05

47

SEN00547-05

KOMATSU 125E-5 Series engine


Form No. SEN00547-05

2010 KOMATSU
All Rights Reserved
Printed in Japan 04-10

48

SEN00548-03

ENGINE
1SHOP MANUAL

125E-5 Series

40 Troubleshooting

General information on troubleshooting


General information on troubleshooting.......................................................................................................... 2
Points on troubleshooting..................................................................................................................... 2
Error code and failure code table ......................................................................................................... 4
Information in troubleshooting table ..................................................................................................... 8

125E-5 Series

SEN00548-03

40 Troubleshooting

General information on troubleshooting


Points on troubleshooting
k
k
k
k
k
k

When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so be sure to wait for the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.

The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1.

2.

When carrying out troubleshooting, do not


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

3.

Check before troubleshooting


1) Check for symptoms of any abnormality in
the machine and engine.
2) Be sure to check the CHECKS BEFORE
STARTING items.
3) Check other inspection items, if necessary.
4) Some other maintenance items can be
checked externally, so check any item that
is considered to be necessary.
5) Check the controller for display of an error.

4.

Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
as a problem with the method of operation, etc.
a When operating the machine or engine to
reenact the troubleshooting symptoms, do
not carry out any investigation or measurement that may make the problem
worse.

5.

Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the causes
of failure, then use the troubleshooting matrix
to locate the position of the failure exactly.
a The basic procedure for troubleshooting is
as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.

125E-5 Series

40 Troubleshooting

6.

SEN00548-03

Measures to remove root cause of failure


Even if the failure is repaired, if the root cause
of the failure is not repaired, the same failure
will occur again. To prevent this, always investigate why the problem occurred. Then,
remove the root cause.

125E-5 Series

SEN00548-03

40 Troubleshooting

Error code and failure code table

(for construction equipment)

INSITE
error code

Machine failure
code

111

CA111

ECM Critical Internal Failure

115

CA115

Eng. Ne and Bkup Speed Sensor Error

Failure phenomenon

122

CA122

Charge Air Press Sensor High Error

123

CA123

Charge Air Press Sensor Low Error

131

CA131

Throttle Sensor High Error

132

CA132

Throttle Sensor Low Error

135

CA135

Oil Press. Sensor High Error

141

CA141

Oil Press. Sensor Low Error

144

CA144

Coolant Temp. Sensor High Error

145

CA145

Coolant Temp. Sensor Low Error

153

CA153

Charge Air Temp. Sensor High Error

154

CA154

Charge Air Temp. Sensor Low Error

187

CA187

Sensor Sup. 2 Volt. Low Error

221

CA221

Ambient Air Press. Sensor High Error

222

CA222

Ambient Air Press. Sensor Low Error

227

CA227

Sensor Sup. 2 Volt. High Error

234

CA234

Eng. Overspeed

238

CA238

Ne Speed Sensor Sup. Volt. Error

263

CA263

Fuel Temp. Sensor High Error

265

CA265

Fuel Temp. Sensor Low Error

271

CA271

PCV1 Short Error

272

CA272

PCV1 Open Error

273

CA273

PCV2 Short Error

274

CA274

PCV2 Open Error

322

CA322

Injector #1 (L/B #1) System Open/Short Error

323

CA323

Injector #5 (L/B #5) System Open/Short Error

324

CA324

Injector #3 (L/B #3) System Open/Short Error

325

CA325

Injector #6 (L/B #6) System Open/Short Error

331

CA331

Injector #2 (L/B #2) System Open/Short Error

332

CA332

Injector #4 (L/B #4) 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

Reference
document No.

Troubleshooting of electrical
system (E-mode), Part 1
SEN00550-01

125E-5 Series

40 Troubleshooting

SEN00548-03

INSITE
error code

Machine failure
code

449

CA449

Rail Press. Very High Error

451

CA451

Rail Press. Sensor High Error

452

CA452

Rail Press. Sensor Low Error

553

CA553

Rail Press. High Error

554

CA554

Rail Press Sensor In Range Error

559

CA559

Rail Press. Low Error

689

CA689

Eng. Ne Speed Sensor Error

731

CA731

Eng. Bkup Speed Sensor Phase Error

757

CA757

All Persistent Data Lost Error

778

CA778

Eng. Bkup Speed Sensor Error

1228

CA1228

EGR Valve Servo Error 1 ["with EGR" only]

a
a

Failure phenomenon

Reference
document No.

1625

CA1625

EGR Valve Servo Error 2 ["with EGR" only]

1626

CA1626

Bypass Valve Solenoid Current High Error ["with EGR" only]

1627

CA1627

Bypass Valve Solenoid Current Low Error ["with EGR" only]

1628

CA1628

Bypass Valve Servo Error 1 ["with EGR" only]

1629

CA1629

Bypass Valve Servo Error 2 ["with EGR" only]

1631

CA1631

1632

CA1632

Troubleshooting of electrical
BP valve Lift Position Sensor High Error ["with EGR" only] system (E-mode), Part 2
BP valve Lift Position Sensor Low Error ["with EGR" only] SEN00551-01

1633

CA1633

KOMNET Datalink Timeout Error

1642

CA1642

EGR Inlet Press Sensor Low Error ["with EGR" only]

1653

CA1653

EGR Inlet Press Sensor High Error ["with EGR" only]

2185

CA2185

Throttle Sens. Sup. Volt. High Error

2186

CA2186

Throttle Sens. Sup. Volt. Low Error

2249

CA2249

Rail Press. Very Low Error

2271

CA2271

EGR Valve Lift Position Sensor High Error ["with EGR" only]

2272

CA2272

EGR Valve Lift Position Sensor Low Error ["with EGR" only]

2351

CA2351

EGR Valve Solenoid Current High Error ["with EGR" only]

2352

CA2352

EGR Valve Solenoid Current Low Error ["with EGR" only]

2555

CA2555

Grid Heater Relay Volt. Low Error

2556

CA2556

Grid Heater Relay Volt. High Error

(143)

B@BAZG

Eng. Oil press. Torque Derate

(146)

B@BCNS

Eng. Overheat

(415)

B@BAZG

Eng. Oil press. Low Speed Derate

INSITE error code:


An error code of 3 or 4 digits displayed on the INSITE (bench test tool) when the occurrence condition of
the failure is confirmed with the INSITE.
Machine failure code:
An error code of 5 or 6 digits displayed on the machine monitor when the occurrence condition of the
failure is confirmed with the machine monitor, etc. on the machine side.

125E-5 Series

SEN00548-03

40 Troubleshooting

(for Generator)
Machine failure
code

Failure phenomenon

A8

Speed Adj. Vol. High (Isochronous) A8

A9

Speed Adj. Vol. Low (Isochronous) A9

AA

Speed Adj. Vol. High (Droop) AA

AB

Speed Adj. Vol. Low (Droop) AB

AF

KOMNET Error (CR710) AF

b6

Droop Rate Adj. Vol. High b6

b7

Droop Rate Adj. Vol. Low b7

b8

Low Idle Speed Adj. Vol. High b8

b9

Low Idle Speed Adj. Vol. Low b9

bc

Speed Adj. Vol. High (Default) bc

bd

Speed Adj. Vol. Low (Default) bd

bE

Ramptime Adj. Vol. High bE

bF

Ramptime Adj. Vol. Low bF

CA111

ECM Critical Internal Failure CA111

CA115

Ne, Bkup Speed Sensor Error CA115

CA122

Charge Air Press Sensor High CA122

CA123

Charge Air Press Sensor Low CA123

CA135

Oil Press. Sensor High CA135

CA141

Oil Press. Sensor Low CA141

CA144

Coolant Temp. Sensor High CA144

CA145

Coolant Temp. Sensor Low CA145

CA153

Charge Air Temp. Sensor High CA153

CA154

Charge Air Temp. Sensor Low CA154

CA187

Sensor Sup. 2 Volt. Low CA187

CA221

Ambient Air Press. Sensor High CA221

CA222

Ambient Air Press. Sensor Low CA222

CA227

Sensor Sup. 2 Volt. High CA227

CA234

Eng. Overspeed CA234

CA238

Ne Speed Sensor Sup. Volt. Error CA238

CA263

Fuel Temp. Sensor High CA263

CA265

Fuel Temp. Sensor Low CA265

CA271

IMV/PCV1 Short CA271

CA272

IMV/PCV1 Open CA272

CA273

PCV2 Short CA273

CA274

PCV2 Open CA274

CA322

Injector #1 Open/Short CA322

CA323

Injector #5 Open/Short CA323

CA324

Injector #3 Open/Short CA324

CA325

Injector #6 Open/Short CA325

CA331

Injector #2 Open/Short CA331

CA332

Injector #4 Open/Short CA332

CA342

Calibration Code Incompatibility CA342

CA351

INJ. Drive Circuit Error CA351

CA352

Sensor Sup. 1 Volt. Low CA352

Reference
document No.

Troubleshooting of electrical
system (E-mode), Part 1
SEN00550-01

125E-5 Series

40 Troubleshooting

Machine failure
code

SEN00548-03

Failure phenomenon

CA386

Sensor Sup. 1 Volt. High CA386

CA441

Battery Voltage Low CA441

CA442

Battery Voltage High CA442

CA449

Rail Press. Very High CA449

CA451

Rail Press. Sensor High CA451

CA452

Rail Press. Sensor Low CA452

CA553

Rail Press. High CA553

CA559

Rail Press. Low CA559

CA689

Ne Speed Sensor Error CA689

CA731

Bkup Speed Sensor Phase CA731

CA757

All Data Lost CA757

CA778

Bkup Speed Sensor Error CA778

CA1228

EGR Valve Servo Error 1 CA1228

CA1625

EGR Valve Servo Error 2 CA1625

CA1626

Bypass Valve Solenoid Current High CA1626

CA1627

Bypass Valve Solenoid Current Low CA1627

CA1628

Bypass Valve Servo Error 1 CA1628

CA1629

Bypass Valve Servo Error 2 CA1629

CA1631

BP Valve Lift Position High CA1631

CA1632

BP Valve Lift Position Low CA1632

CA1633

KOMNET Error CA1633

CA1642

EGR Inlet Press Sensor Low CA1642

CA1653

EGR Inlet Press Sensor High CA1653

CA2185

Throttle Sensor Sup. Volt. High CA2185

CA2186

Throttle Sensor Sup. Volt. Low CA2186

CA2249

Rail Press. Very Low CA2249

CA2271

EGR Valve Lift Position High CA2271

CA2272

EGR Valve Lift Position Low CA2272

CA2341

Eng. Overspeed CA2341

CA2351

EGR Valve Solenoid Current High CA2351

CA2352

EGR Valve Solenoid Current Low CA2352

CA2555

Heater Relay Volt. Low CA2555

CA2556

Heater Relay Volt. High CA2556

CA143

Oil Press. Low CA143

CA146

Eng. Overheat CA146

125E-5 Series

Reference
document No.
Troubleshooting of electrical
system (E-mode), Part 1
SEN00550-01

Troubleshooting of electrical
system (E-mode), Part 2
SEN00551-01

SEN00548-03

40 Troubleshooting

Information in troubleshooting table


a

The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Error code

Failure code

Display on
INSITE

Display on applicable machine

Contents of
trouble

Trouble

Problem that appears on engine

Contents of trouble detected by engine controller

Action of
controller

Action taken by engine controller to protect system or devices when engine controller detects
trouble

Problem that
appears on
machine

Problem that appears on engine as result of action taken by engine controller (shown above)

Related
information

Information related to detected trouble or troubleshooting

Causes

Standard value in normal state/Remarks on troubleshooting


<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment

2
Possible causes
and standard
value in normal
state

<Troubles in wiring harness>


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

Possible causes of trouble


(Given numbers are reference
numbers, which do not indicate <Precautions for troubleshooting>
(1) Method of indicating connector No. and handling of Tpriority)
adapter
Insert or connect T-adapter as explained below for troubleshooting, unless otherwise specified.
3
If connector No. has no marks of male and female,
disconnect connector and insert T-adapters in both
male side and female side.
If connector No. has marks of male and female,
disconnect connector and connect T-adapter to only
male side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester
as explained below for troubleshooting, unless otherwise
specified.
4
Connect positive (+) lead to pin No. or wiring harness
entered on front side.
Connect negative () lead to pin No. or wiring harness
entered on rear side.

125E-5 Series

40 Troubleshooting

SEN00548-03

Related circuit diagram

This drawing is a part of the electric circuit diagram related


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

125E-5 Series

SEN00548-03

KOMATSU 125E-5 Series engine


Form No. SEN00548-03

2007 KOMATSU
All Rights Reserved
Printed in Japan 03-07 (01)

10

SEN00550-01

ENGINE
1SHOP MANUAL

125E-5 Series

40 Troubleshooting

Troubleshooting of electrical system


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

125E-5 Series

SEN00550-01

40 Troubleshooting

E-14 Code [221/CA221] Ambient Air Press. Sensor High Error......................................................... 30


E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error ......................................................... 32
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error .................................................................... 34
E-17 Code [234/CA234] Eng. Overspeed .......................................................................................... 36
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error............................................................... 38
E-19 Code [263/CA263] Fuel Temp. Sensor High Error..................................................................... 40
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error ..................................................................... 42
E-21 Code [271/CA271] PCV1 Short Error ........................................................................................ 44
E-22 Code [272/CA272] PCV1 Open Error ........................................................................................ 46
E-23 Code [273/CA273] PCV2 Short Error ........................................................................................ 48
E-24 Code [274/CA274] PCV2 Open Error ........................................................................................ 50
E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error ............................................ 52
E-26 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error ............................................ 54
E-27 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error ............................................ 56
E-28 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error ............................................ 58
E-29 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error ............................................ 60
E-30 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error ............................................ 62
E-31 Code [342/CA342] Calibration Code Incompatibility.................................................................. 64
E-32 Code [351/CA351] INJ. Drive Circuit Error ................................................................................ 66
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error..................................................................... 68
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error .................................................................... 70
E-35 Code [431/CA431] Idle Validation SW Low error ....................................................................... 72
E-36 Code [432/CA432] Idle Validation Process error ....................................................................... 74
E-37 Code [441/CA441] Battery voltage low error ............................................................................. 74
E-38 Code [442/CA442] Battery voltage high error............................................................................ 75

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00550-01

SEN00550-01

40 Troubleshooting

Troubleshooting of electrical system (E-mode), Part 1

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

Error code

Failure code

111

CA111

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

ECM Critical Internal Failure

Abnormality occurred in controller.


None in particular.

Engine runs normally but it may stop during operation or may not be able to start.

Different machine models may have different connector Nos.

Cause
1 Defective fuse

Standard value in normal state/Remarks on troubleshooting


Check fuse or circuit breaker on machine side directly for defect.
(If fuse is broken or circuit breaker is turned OFF, circuit probably
has ground fault.)
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness (Disconnection in wiring Wiring harness between E03 (female) (3),
2
or defective contact in connec- (4) battery (+)
tor)
Wiring harness between E03 (female) (1),
(2) chassis ground

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3

Ground fault in wiring harness Wiring harness between E03 (female) (3),
(Short circuit with GND circuit) (4) battery (+) and chassis ground

Resistance

Min.
1 Mz

Wiring harness between E03 (female) (1),


(2) chassis ground

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
4 Defective engine controller

E03

Voltage

Between (3), (4) (1), (2)

20 30 V

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to controller power supply

125E-5 Series

SEN00550-01

40 Troubleshooting

E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error


Error code

Failure code

115

CA115

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Eng. Ne and Bkup Speed Sensor Error

Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
None in particular.
Engine cannot be started (if engine has been stopped).
Engine stops (if engine has been running).

Related
information
Causes

Possible causes
and standard
value in normal
state

Defective Ne speed sensor


system

Carry out troubleshooting for code [689/CA689].

Defective Bkup speed sensor


system

Carry out troubleshooting for code [778/CA778].

Defective mount of Ne speed


sensor

Check mount of Ne speed sensor directly for defect (defective


installation of sensor, internal of flywheel, etc.)

Defective mount of Bkup


speed sensor

Check mount of Bkup speed sensor directly for defect (defective


installation of sensor, internal of supply pump, etc.)

Defective connection (Wrong


connection)

Check Ne speed sensor and Bkup speed sensor directly for


defective connection (wrong connection).

6 Defective engine controller

Standard value in normal state/Remarks on troubleshooting

If causes 1 5 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00550-01

SEN00550-01

40 Troubleshooting

E-3 Code [122/CA122] Charge Air Press Sensor High Error


Error code

Failure code

122

CA122

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Charge Air Press Sensor High Error

Signal voltage in charge pressure sensor circuit is abnormally high.


Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.

Acceleration performance of engine drops.

Different machine models may have different connector Nos.

Causes
1

Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply If code [187/CA187] or [227/CA227] is indicated, carry out trousystem
bleshooting for it first.
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.

Defective charge pressure


2 sensor
(Internal trouble)

Possible causes
and standard
value in normal
state

PIM
Between (1) (3)

Voltage
Power supply

4.75 5.25V

Sensor voltage is measured with wiring harness connected.


Accordingly, if voltage is abnormal, check wiring harness and
controller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness


3
(Disconnection in wiring or
defective contact in connector)

Wiring harness between ENG (female)


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

Resistance

Max. 1 z

Wiring harness between ENG (female)


(44) PIM (female) (2) and chassis ground

Resistance

Max. 1 z

Wiring harness between ENG (female)


(47) PIM (female) (3) and chassis ground

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Wiring harness between ENG (female)


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

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(47) PIM (female) (3)

Resistance

Min.
1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Causes

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Short circuit in wiring harness


(With another wiring harness)

Wiring harness between ENG (female)


(37) PIM (female) (1) and wiring harness
between ENG (female) (44) PIM (female)
(2)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(37) PIM (female) (1) and wiring harness
between ENG (female) (47) PIM (female)
(3)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(44) PIM (female) (2) and wiring harness
between ENG (female) (47) PIM (female)
(3)

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


or start engine and carry out troubleshooting.
6 Defective engine controller

ENG
Between (37) (47)

Voltage
Power supply

4.75 5.25V

Circuit diagram related to charge pressure sensor

Remarks: The figure shows with EGR for an example.


Following connectors apply to only with EGR.
<Applied connector>
q
BP
q
EGR
q
PEVA
q
SEGR
q
SBP

125E-5 Series

SEN00550-01

40 Troubleshooting

E-4 Code [123/CA123] Charge Air Press Sensor Low Error


Error code

Failure code

123

CA123

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Charge Air Press Sensor Low Error

Signal voltage in charge pressure sensor circuit is abnormally low.


Fixes charge pressure (400 kPa {4.08 kg/cm2}) and continues operation.

Acceleration performance of engine drops.

Related
information
Possible causes
and standard
value in normal
state

10

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-3 Code [122/CA122].

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00550-01

11

SEN00550-01

40 Troubleshooting

E-5 Code [131/CA131] Throttle Sensor High Error

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


Error code

Failure code

131

CA131

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Throttle Sensor High Error

Signal voltage in throttle sensor circuit is abnormally high.


Sets throttle angle with signal other than throttle sensor signal and continues operation
(depending on each model)
Different problems occur on different machine models.

Different machine models may have different connector Nos.

Causes
1

Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
system
troubleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

AS1

Accelerator pedal

Voltage

Between (1) (3)

All range
(Power supply)

4.75 5.25V

Released

(13 2% of source
voltage)

Pressed

(77 2% of source
voltage)

Defective accelerator pedal


(Internal trouble)
Between (2) (3)

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
and standard
value in normal
state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness
3
(Disconnection in wiring or
defective contact in connector)

Wiring harness between E02 (female) (22)


AS1 (female) (1)

Resistance

Max. 1 z

Wiring harness between E02 (female) (9)


AS1 (female) (2)

Resistance

Max. 1 z

Wiring harness between E02 (female) (23)


AS1 (female) (3)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

12

Wiring harness between E02 (female) (22)


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

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

Wiring harness between E02 (female) (23)


AS1 (female) (3) and chassis ground

Resistance

Min.
1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Causes

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Possible causes
and standard
value in normal
state

5 Defective engine controller

E02

Accelerator pedal

Voltage

Between (22) (23)

All range
(Power supply)

4.75 5.25V

Released

(13 2% of source
voltage)

Pressed

(77 2% of source
voltage)

Between (9) (23)

Circuit diagram related to throttle sensor of accelerator pedal type (Case of HM300-2)

125E-5 Series

13

SEN00550-01

40 Troubleshooting

Throttle sensor of fuel control dial type (Case of PC400/400LC/450/450LC-7)


Error code

Failure code

131

CA131

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Throttle Sensor High Error

Signal voltage in throttle sensor circuit is abnormally high.


Sets throttle angle with signal other than throttle sensor signal and continues operation
(depending on each model)
Different problems occur on different machine models.

Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
1
system
troubleshooting for it first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2

Defective fuel control dial


(Internal trouble)

P20 (male)

Resistance

Between (1) (3)

4.0 6.0 kz

Between (2) (1)

0.25 5.0 kz

Between (2) (3)

0.25 5.0 kz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness


3
(Disconnection in wiring or
defective contact in connector)

Wiring harness between E02 (female) (22)


P20 (female) (1)

Resistance

Max. 1 z

Wiring harness between E02 (female) (9)


P20 (female) (2)

Resistance

Max. 1 z

Wiring harness between E02 (female) (23)


P20 (female) (3)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between E02 (female) (22)
Ground fault in wiring harness P20 (female) (1) and chassis ground
4
(Short circuit with GND circuit) Wiring harness between E02 (female) (9)
P20 (female) (2) and chassis ground

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

Wiring harness between E02 (female) (23)


P20 (female) (3) and chassis ground

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
5 Defective engine controller

14

E02

Voltage

Between (22) (23)

Power supply

4.75 5.25V

Between (9) (23)

Signal

0.5 4.5V

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to throttle sensor of fuel control dial type (Case of PC400/400LC/450/450LC-7)

125E-5 Series

15

SEN00550-01

40 Troubleshooting

E-6 Code [132/CA132] Throttle Sensor Low Error


Error code

Failure code

132

CA132

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Throttle Sensor Low Error

Signal voltage in throttle sensor circuit is abnormally low.


Sets throttle angle with signal other than throttle signal and continues operation (depending on each
model).
Different problems occur on different machine models.

Related
information
Possible causes
and standard
value in normal
state

16

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-5 Code [131/CA131].

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00550-01

17

SEN00550-01

40 Troubleshooting

E-7 Code [135/CA135] Oil press. Sensor High Error


Error code

Failure code

135

CA135

Contents of
trouble
Action of
controller

Trouble

Oil press. Sensor High Error

Signal voltage in oil pressure sensor circuit is abnormally high.


Sets oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.

Problem that
appears on
machine
Related
information

Different machine models may have different connector Nos.

Causes
1

Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply If code [187/CA187] or [227/CA227] is indicated, carry out trousystem
bleshooting for it first.
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.

Defective oil pressure sensor


(Internal trouble)

POIL
Between (1) (2)

Voltage
Power supply

4.75 5.25V

Sensor voltage is measured with wiring harness connected.


Accordingly, if voltage is abnormal, check wiring harness and
controller, too, for another cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state

Wiring harness between ENG (female)


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

Disconnection in wiring harness


3
Wiring harness between ENG (female)
(Disconnection in wiring or
defective contact in connector) (47) POIL (female) (2) and chassis
ground
Wiring harness between ENG (female)
(13) POIL (female) (3) and chassis
ground

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

18

Wiring harness between ENG (female)


Ground fault in wiring harness (37) POIL (female) (1)
4
(Short circuit with GND circuit) Wiring harness between ENG (female)
(47) POIL (female) (2)

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(13) POIL (female) (3)

Resistance

Min.
1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Causes

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Short circuit in wiring harness


(With another wiring harness)

Wiring harness between ENG (female)


(37) POIL (female) (1) and wiring harness between ENG (female) (47) POIL
(female) (2)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(37) POIL (female) (1) and wiring harness between ENG (female) (13) POIL
(female) (3)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(47) POIL (female) (2) and wiring harness between ENG (female) (13) POIL
(female) (3)

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


or start engine and carry out troubleshooting.
6 Defective engine controller

ENG
Between (37) (47)

Voltage
Power supply

4.75 5.25V

Circuit diagram related to oil 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

19

SEN00550-01

40 Troubleshooting

E-8 Code [141/CA141] Oil press. Sensor Low Error


Error code

Failure code

141

CA141

Contents of
trouble
Action of
controller

Trouble

Oil press. Sensor Low Error

Signal voltage in oil pressure sensor circuit is abnormally low.


Sets oil pressure to default value (250 kPa {2.55 kg/cm2}) and continues operation.

Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state

20

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-7 Code [135/CA135].

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00550-01

21

SEN00550-01

40 Troubleshooting

E-9 Code [144/CA144] Coolant Temp. Sensor High Error


Error code

Failure code

144

CA144

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Coolant Temp. Sensor High Error

Signal voltage in coolant temperature sensor circuit is abnormally high.


Fixes coolant temperature (90C) and continues operation.

Engine starting performance decreases during low temperature.

Different machine models may have different connector Nos.

Cause

Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective coolant temperature
1
sensor (Internal trouble)
TWTR (male)
Coolant temperature
Resistance
Between (A) (B)

10 100C

0.6 20 kz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female)
2
or defective contact in connec- (15) TWTR (female) (A)
tor)
Wiring harness between ENG (female)
(38) TWTR (female) (B)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Ground fault in wiring harness


(Short circuit with GND circuit) Wiring harness between ENG (female)
(15) TWTR (female) (A) and chassis
ground

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller

22

ENG (female)

Coolant temperature

Resistance

Between (15) (38)

10 100C

0.6 20 kz

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to coolant temperature sensor

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

23

SEN00550-01

40 Troubleshooting

E-10 Code [145/CA145] Coolant Temp. Sensor Low Error


Error code

Failure code

145

CA145

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Coolant Temp. Sensor Low Error

Signal voltage in coolant temperature sensor circuit is abnormally low.


Fixes coolant temperature (90C) and continues operation.

Engine starting performance decreases during low temperature.

Related
information
Possible causes
and standard
value in normal
state

24

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting E-9 Code [144/CA144].

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00550-01

25

SEN00550-01

40 Troubleshooting

E-11 Code [153/CA153] Charge Air Temp. Sensor High Error


Error code

Failure code

153

CA153

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Charge Air Temp. Sensor High Error

Signal voltage in charge temperature sensor circuit is abnormally high.


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

Engine starting performance decreases during low temperature.

Different machine models may have different connector Nos.

Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective charge temperature


1
sensor (Internal trouble)

TIM (male)

Intake air temperature

Resistance

Between (A) (B)

10 100C

0.5 20 kz

Between (A)
chassis ground

All range

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female)
2
or defective contact in connec- (23) TIM (female) (A)
tor)
Wiring harness between ENG (female)
(47) TIM (female) (B)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Ground fault in wiring harness
3
(Short circuit with GND circuit) Wiring harness between ENG (female)
ResisMin.
(23) TIM (female) (A) and chassis ground tance
1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4

26

Defective engine controller

ENG (female)

Intake air temperature

Resistance

Between (23) (47)

10 100C

0.5 20 kz

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to charge temperature sensor

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

27

SEN00550-01

40 Troubleshooting

E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error


Error code

Failure code

154

CA154

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Charge Air Temp. Sensor Low Error

Signal voltage in charge temperature sensor circuit is abnormally low.


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

Engine starting performance decreases during low temperature.

Related
information
Possible causes
and standard
value in normal
state

28

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting E-11 Code [153/CA153].

125E-5 Series

40 Troubleshooting

SEN00550-01

E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error


Error code

Failure code

187

CA187

Contents of
trouble

Action of
controller

Problem that
appears on
machine

Trouble

Sensor Sup. 2 Volt. Low Error

Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.


Operates Bkup speed sensor with signals of Ne speed sensor.
Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Sets EGR inlet pressure sensor to default value (102 kPa {1.04 kg/cm2}) and continues operation.
["with EGR" only]
Limits output of EGR valve lift sensor and closes EGR valve and bypass valve ["with EGR" only].
Limits output of bypass valve lift sensor and closes EGR valve and bypass valve ["with EGR" only].
Output drops.

Related
information
Possible causes
and standard
value in normal
state

125E-5 Series

Causes

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-16 Code [227/CA227].

29

SEN00550-01

40 Troubleshooting

E-14 Code [221/CA221] Ambient Air Press. Sensor High Error


Error code

Failure code

221

CA221

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Ambient Air Press. Sensor High Error

Signal voltage in atmospheric pressure sensor circuit is abnormally high.


Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Output drops.

Different machine models may have different connector Nos.

Causes
1

Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply If code [187/CA187] or [227/CA227] is indicated, carry out trousystem
bleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
PAMB

Defective atmospheric pres2 sure sensor


(Internal trouble)

Voltage

Between (1) (3)

Power supply

4.75 5.25V

Between (2) (3)

Signal

0.3 4.7V

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.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness


3
(Disconnection in wiring or
defective contact in connector)

Wiring harness between ENG (female)


(37) PAMB (female) (1)

Resistance

Max. 1 z

Wiring harness between ENG (female) (3)


PAMB (female) (2)

Resistance

Max. 1 z

Wiring harness between ENG (female)


(38) PAMB (female) (3)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
(37) PAMB (female) (1) and chassis
Ground fault in wiring harness ground
4
(Short circuit with GND circuit) Wiring harness between ENG (female) (3)
PAMB (female) (2) and chassis ground
Wiring harness between ENG (female)
(38) PAMB (female) (3) and chassis
ground

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5

30

Short circuit in wiring harness


(With another wiring harness)

Wiring harness between ENG (female)


(37) PAMB (female) (1) and wiring harness between ENG (female) (3) PAMB
(female) (2)

Resistance

Min.
1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Causes

5
Possible causes
and standard
value in normal
state

Short circuit in wiring harness


(With another wiring harness)

Standard value in normal state/Remarks on troubleshooting


Wiring harness between ENG (female)
(37) PAMB (female) (1) and wiring harness between ENG (female) (38) PAMB
(female) (3)

Resistance

Min.
1 Mz

Wiring harness between ENG (female) (3)


PAMB (female) (2) and wiring harness
between ENG (female) (38) PAMB
(female) (3)

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


or start engine and carry out troubleshooting.
ENG

Voltage

Between (37) (38)

4.75 5.25V

Between (3) (38)

0.3 4.7V

6 Defective engine controller

Circuit diagram related to atmospheric 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

31

SEN00550-01

40 Troubleshooting

E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error


Error code

Failure code

222

CA222

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Ambient Air Press. Sensor Low Error

Signal voltage in atmospheric pressure sensor circuit is abnormally low.


Sets oil pressure to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.

Output drops.

Related
information
Possible causes
and standard
value in normal
state

32

Causes

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-14 Code [221/CA221].

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00550-01

33

SEN00550-01

40 Troubleshooting

E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error


Error code

Failure code

227

CA227

Contents of
trouble

Action of
controller

Problem that
appears on
machine
Related
information

Trouble

Sensor Sup. 2 Volt. High Error

Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.


Operates Bkup speed sensor with signals of Ne speed sensor.
Sets oil pressure sensor to default value (250 kPa {2.55 kg/cm2}) and continues operation.
Sets atmospheric pressure sensor to default value (52.44 kPa {0.53 kg/cm2}) and continues operation.
Fixes charge pressure sensor value (400 kPa {4.08 kg/cm2}) and continues operation.
Sets EGR inlet pressure sensor to default value (102 kPa {1.04 kg/cm2}) and continues operation.
["with EGR" only]
Limits output of EGR valve lift sensor and closes EGR valve and bypass valve ["with EGR" only].
Limits output of bypass valve lift sensor and closes EGR valve and bypass valve ["with EGR" only].
Output drops.

Different machine models may have different connector Nos.

Causes
1 Defective related system

Standard value in normal state/Remarks on troubleshooting


If another failure code is indicated, carry out troubleshooting for
it.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Possible causes
and standard
value in normal
state

Disconnect devices
Defective sensor (Internal trou- at right in order. If
error code disap2 ble)
pears when a device
(*: "With EGR" only)
is disconnected, that
device has a defect
in it.
(*: "with EGR" only)

Bkup speed sensor

G connector

Oil pressure sensor

POIL connector

Atmospheric
pressure sensor

PAMB connector

Charge pressure
sensor

PIM connector

EGR inlet pressure


sensor (*)

PEVA connector

EGR valve lift


sensor (*)

SEGR connector

Bypass valve lift


sensor (*)

SBP connector

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness


Wiring harness between ENG (female)
3
(Disconnection in wiring or
(37) each sensor (female)
defective contact in connector) Wiring harness between ENG (female)
(47) each sensor (female)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

34

Wiring harness between ENG (female)


Ground fault in wiring harness (37) each sensor (female) and chassis
4
(Short circuit with GND circuit) ground

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(47) each sensor (female) and chassis
ground

Resistance

Min.
1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Causes

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Short circuit in wiring harness


(With another wiring harness)

Wiring harness between ENG (female)


(37) each sensor (female) and
Wiring harness between ENG (female)
(47) each sensor (female)

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
6

Defective engine controller

ENG

Voltage

Between (37) (47)

4.75 5.25V

Circuit diagram related to sensor power supply 2 (5 V)

Remarks: The figure shows with EGR for an example. Following connectors apply to only with EGR.
Applied connector: BP, EGR, PEVA, SEGR, SBP

125E-5 Series

35

SEN00550-01

40 Troubleshooting

E-17 Code [234/CA234] Eng. Overspeed


Error code

Failure code

234

CA234

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Eng. Overspeed

Engine speed is above operating range.


Limits fuel injection rate until engine speed lowers to operating range.

Engine speed fluctuates.

Related
information
Cause
Possible causes
and standard
value in normal
state

36

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code is indicated, carry out troubleshooting for


it.

2 Improper way of use

Way of use may be improper. Teach proper way of use to operator.

3 Defective engine controller

If causes 1 and 2 are not detected, engine controller may be


defective. (Since trouble is in system, troubleshooting cannot be
carried out.)

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00550-01

37

SEN00550-01

40 Troubleshooting

E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error


Error code

Failure code

238

CA238

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Ne Speed Sensor Sup. Volt. Error

Abnormality occurred in Ne speed sensor power supply (5 V) circuit.


Controls Ne speed sensor with signals of Bkup speed sensor.
Running engine stops (when Bkup speed sensor is also abnormal).
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Different machine models may have different connector Nos.

Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Possible causes
and standard
value in normal
state

Defective Ne speed sensor


(Internal trouble)

Disconnect devices
at right in order. If
error code disappears when a device
is disconnected, that
device has a defect
in it.

Ne speed sensor

NE connector

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female)
Resis2
Max. 1 z
or defective contact in connec- (16) NE (female) (1)
tance
tor)
Wiring harness between ENG (female)
ResisMax. 1 z
(48) NE (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3

Ground fault in wiring harness Wiring harness between ENG (female)


(Short circuit with GND circuit) (16) NE (female) (1) and chassis ground

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(48) NE (female) (2) and chassis ground

Resistance

Min.
1 Mz

Short circuit in wiring harness


(with another wiring harness)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
(16) NE (female) (1) and between ENG
(female) (48) NE (female) (2)

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
5 Defective engine controller

38

ENG

Voltage

Between (16) (48)

4.75 5.25 V

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to Ne speed sensor power supply

125E-5 Series

39

SEN00550-01

40 Troubleshooting

E-19 Code [263/CA263] Fuel Temp. Sensor High Error


Error code

Failure code

263

CA263

Contents of
trouble
Action of
controller

Trouble

Fuel Temp. Sensor High Error

Signal voltage in fuel temperature sensor circuit is abnormally high.


Uses coolant temperature sensor instead of fuel temperature sensor for correction of injection rate.
Fixes fuel temperature (95C) and continues operation, if coolant temperature sensor is also defective.

Problem that
appears on
machine
Related
information

Different machine models may have different connector Nos.

Causes
Defective fuel temperature
1 sensor
(Internal trouble)

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
TFUEL (male)

Fuel temperature

Resistance

Between (A) (B)

10 100C

0.6 20 kz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness
Wiring harness between ENG (female)
Resis2
Max. 1 z
(Disconnection in wiring or
(30) TFUEL (female) (A)
tance
defective contact in connector) Wiring harness between ENG (female)
ResisMax. 1 z
(47) TFUEL (female) (B)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3

Wiring harness between ENG (female)


Ground fault in wiring harness
(30) TFUEL (female) (A) and chassis
(Short circuit with GND circuit)
ground

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4

40

Defective engine controller

ENG (female)

Fuel temperature

Resistance

Between (30) (47)

10 100C

0.6 20 kz

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to fuel temperature sensor

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

41

SEN00550-01

40 Troubleshooting

E-20 Code [265/CA265] Fuel Temp. Sensor Low Error


Error code

Failure code

265

CA265

Contents of
trouble
Action of
controller

Trouble

Fuel Temp. Sensor Low Error

Signal voltage in fuel temperature sensor circuit is abnormally low.


Uses coolant temperature sensor instead of fuel temperature sensor for correction of injection rate.
Fixes fuel temperature (95C) and continues operation, if coolant temperature sensor is also defective.

Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state

42

Causes

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-19 Code [263/CA263].

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00550-01

43

SEN00550-01

40 Troubleshooting

E-21 Code [271/CA271] PCV1 Short Error


Error code

Failure code

271

CA271

Contents of
trouble
Action of
controller

Trouble

PCV1 Short Error

There is short circuit in PCV1 circuit of supply pump.


None in particular.

Problem that
appears on
machine
Related
information

While engine is running normally, pulse voltage of about 24 V is applied to PCV (1). This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Causes

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective supply pump PCV1


(Internal trouble)

PCV1 (male)

Resistance

Between (1) (2)

2.3 5.3 z

Between (1), (2) chassis


ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2

Ground fault in wiring harness Wiring harness between ENG (female) (4)
(Short circuit with GND circuit) PCV1 (female) (1)

Resistance

Min.
1 Mz

Wiring harness between ENG (female) (5)


PCV1 (female) (2)

Resistance

Min.
1 Mz

Possible causes
and standard
value in normal
state

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
3

Hot short (Short circuit with


24V circuit) in wiring harness

Wiring harness between ENG (female) (4)


PCV1 (female) (1) and chassis ground

Voltage

Max. 1V

Wiring harness between ENG (female) (5)


PCV1 (female) (2) and chassis ground

Voltage

Max. 1V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4

44

Defective engine controller

ENG (female)

Resistance

Between (4) (5)

2.3 5.3 z

Between (4), (5) chassis


ground

Min. 1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to supply pump PCV1

125E-5 Series

45

SEN00550-01

40 Troubleshooting

E-22 Code [272/CA272] PCV1 Open Error


Error code

Failure code

272

CA272

Contents of
trouble
Action of
controller

Trouble

PCV1 Open Error

There is disconnection in PCV1 circuit of supply pump.


None in particular.

Problem that
appears on
machine
Related
information

While engine is running normally, pulse voltage of about 24 V is applied to PCV (1). This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Causes

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective supply pump PCV1


(Internal disconnection)

PCV1 (male)

Resistance

Between (1) (2)

2.3 5.3 z

Between (1), (2) chassis


ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness


Wiring harness between ENG (female) (4)
2
(Disconnection in wiring or
PCV1 (female) (1)
defective contact in connector) Wiring harness between ENG (female) (5)
PCV1 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3

Ground fault in wiring harness Wiring harness between ENG (female) (4)
(Short circuit with GND circuit) PCV1 (female) (1) and chassis ground

Resistance

Min.
1 Mz

Wiring harness between ENG (female) (5)


PCV1 (female) (2) and chassis ground

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4

46

Defective engine controller

ENG (female)

Resistance

Between (4) (5)

2.3 5.3 z

Between (4) (5) chassis


ground

Min. 1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to supply pump PCV1

125E-5 Series

47

SEN00550-01

40 Troubleshooting

E-23 Code [273/CA273] PCV2 Short Error


Error code

Failure code

273

CA273

Contents of
trouble
Action of
controller

Trouble

PCV2 Short Error

There is short circuit in PCV2 circuit of supply pump.


None in particular.

Problem that
appears on
machine
Related
information

While engine is running normally, pulse voltage of about 24 V is applied to PCV (2). This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Causes

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective supply pump PCV2


(Internal trouble)

PCV2 (male)

Resistance

Between (1) (2)

2.3 5.3 z

Between (1), (2) chassis


ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
2

Ground fault in wiring harness Wiring harness between ENG (female) (9)
(Short circuit with GND circuit) PCV2 (female) (1) and chassis ground

Possible causes
and standard
value in normal
state

Wiring harness between ENG (female)


(10) PCV2 (female) (2)

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
3

Hot short (Short circuit with


24V circuit) in wiring harness

Wiring harness between ENG (female) (9)


PCV2 (female) (1) and chassis ground

Voltage

Max. 1V

Wiring harness between ENG (female)


(10) PCV2 (female) (2) and chassis
ground

Voltage

Max. 1V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4 Defective engine controller

48

ENG (female)

Resistance

Between (9) (10)

2.3 5.3 z

Between (9), (10) chassis


ground

Min. 1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to supply pump PCV2

125E-5 Series

49

SEN00550-01

40 Troubleshooting

E-24 Code [274/CA274] PCV2 Open Error


Error code

Failure code

274

CA274

Contents of
trouble
Action of
controller

Trouble

PCV2 Open Error

There is disconnection in PCV2 circuit of supply pump.


None in particular.

Problem that
appears on
machine
Related
information

While engine is running normally, pulse voltage of about 24 V is applied to PCV (2). This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Causes
Defective supply pump PCV2
1
(Internal disconnection)

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
PCV2 (male)

Resistance

Between (1) (2)

2.3 5.3 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness
Wiring harness between ENG (female) (9)
Resis2
Max. 1 z
(Disconnection in wiring or
PCV2 (female) (1)
tance
defective contact in connector) Wiring harness between ENG (female)
ResisMax. 1 z
(10) PCV2 (female) (2)
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3

Wiring harness between ENG (female) (9)


Ground fault in wiring harness
PCV2 (female) (1) and chassis ground
(Short circuit with GND circuit)
Wiring harness between ENG (female)
(10) PCV2 (female) (2) and chassis
ground

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4

50

Defective engine controller

ENG (female)

Resistance

Between (9) (10)

2.3 5.3 z

Between (9), (10) chassis


ground

Min. 1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to supply pump PCV2

125E-5 Series

51

SEN00550-01

40 Troubleshooting

E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error 1


Error code

Failure code

322

CA322

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Injector #1 (L/B #1) System Open/Short Error

There is disconnection or short circuit in injector #1 circuit.


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

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective injector #1
(Internal trouble)

CN1 (male)

Resistance

Between (1) (2)

0.4 1.1 z

Between (1), (2) chassis


ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness


Wiring harness between ENG (female)
2
(Disconnection in wiring or
(45) CN1 (female) (1)
defective contact in connector) Wiring harness between ENG (female)
(53) CN1 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
Ground fault in wiring harness (45) CN1 (female) (1) and chassis
3
(Short circuit with GND circuit) ground

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(53) CN1 (female) (2) and chassis
ground

Resistance

Min.
1 Mz

Defective injector or wiring


harness of another cylinder

If failure code of another cylinder is displayed, carry out troubleshooting for it, too.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5 Defective engine controller

52

ENG (female)

Resistance

Between (45) (53)

0.4 1.1 z

Between (45), (53) chassis


ground

Min. 1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to injector #1

125E-5 Series

53

SEN00550-01

40 Troubleshooting

E-26 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error 1


Error code

Failure code

323

CA323

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Injector #5 (L/B #5) System Open/Short Error

There is disconnection or short circuit in injector #5 circuit.


None in particular.
Output drops.
Rotation is unstable.
While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective injector #5 (Internal


trouble)

CN5 (male)

Resistance

Between (1) (2)

0.4 1.1 z

Between (1), (2) chassis


ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female)
2
or defective contact in connec- (46) CN5 (female) (1)
tor)
Wiring harness between ENG (female)
(60) CN5 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
Ground fault in wiring harness (46) CN5 (female) (1) and chassis
3
(Short circuit with GND circuit) ground

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(60) CN5 (female) (2) and chassis
ground

Resistance

Min.
1 Mz

Defective injector or wiring


harness of another cylinder

If failure code of another cylinder is displayed, carry out troubleshooting for it, too.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5 Defective engine controller

54

ENG (female)

Resistance

Between (46) (60)

0.4 1.1 z

Between (46), (60) chassis


ground

Min. 1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to injector #5

125E-5 Series

55

SEN00550-01

40 Troubleshooting

E-27 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error 1


Error code

Failure code

324

CA324

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Injector #3 (L/B #3) System Open/Short Error

There is disconnection or short circuit in injector #3 circuit.


None in particular.
Output drops.
Rotation is unstable.
While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective injector #3 (Internal


trouble)

CN3 (male)

Resistance

Between (1) (2)

0.4 1.1 z

Between (1), (2) chassis


ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female)
2
or defective contact in connec- (55) CN3 (female) (1)
tor)
Wiring harness between ENG (female)
(52) CN3 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
Ground fault in wiring harness (55) CN3 (female) (1) and chassis
3
(Short circuit with GND circuit) ground

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(52) CN3 (female) (2) and chassis
ground

Resistance

Min.
1 Mz

Defective injector or wiring


harness of another cylinder

If failure code of another cylinder is displayed, carry out troubleshooting for it, too.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5 Defective engine controller

56

ENG (female)

Resistance

Between (55) (52)

0.4 1.1 z

Between (55), (52) chassis


ground

Min. 1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to injector #3

125E-5 Series

57

SEN00550-01

40 Troubleshooting

E-28 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error 1


Error code

Failure code

325

CA325

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Injector #6 (L/B #6) System Open/Short Error

There is disconnection or short circuit in injector #6 circuit.


None in particular.
Output drops.
Rotation is unstable.
While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective injector #6 (Internal


trouble)

CN6 (male)

Resistance

Between (1) (2)

0.4 1.1 z

Between (1), (2) chassis


ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female)
2
or defective contact in connec- (57) CN6 (female) (1)
tor)
Wiring harness between ENG (female)
(59) CN6 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
Ground fault in wiring harness (57) CN6 (female) (1) and chassis
3
(Short circuit with GND circuit) ground

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(59) CN6 (female) (2) and chassis
ground

Resistance

Min.
1 Mz

Defective injector or wiring


harness of another cylinder

If failure code of another cylinder is displayed, carry out troubleshooting for it, too.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5 Defective engine controller

58

ENG (female)

Resistance

Between (57) (59)

0.4 1.1 z

Between (57), (59) chassis


ground

Min. 1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to injector #6

125E-5 Series

59

SEN00550-01

40 Troubleshooting

E-29 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error 1


Error code

Failure code

331

CA331

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Injector #2 (L/B #2) System Open/Short Error

There is disconnection or short circuit in injector #2 circuit.


None in particular.
Output drops.
Rotation is unstable.
While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective injector #2 (Internal


trouble)

CN2 (male)

Resistance

Between (1) (2)

0.4 1.1 z

Between (1), (2) chassis


ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female)
2
or defective contact in connec- (54) CN2 (female) (1)
tor)
Wiring harness between ENG (female)
(51) CN2 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
Ground fault in wiring harness (54) CN2 (female) (1) and chassis
3
(Short circuit with GND circuit) ground

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(51) CN2 (female) (2) and chassis
ground

Resistance

Min.
1 Mz

Defective injector or wiring


harness of another cylinder

If failure code of another cylinder is displayed, carry out troubleshooting for it, too.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5 Defective engine controller

60

ENG (female)

Resistance

Between (54) (51)

0.4 1.1 z

Between (54), (51) chassis


ground

Min. 1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to injector #2

125E-5 Series

61

SEN00550-01

40 Troubleshooting

E-30 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error 1


Error code

Failure code

332

CA332

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Injector #4 (L/B #4) System Open/Short Error

There is disconnection or short circuit in injector #4 circuit.


None in particular.
Output drops.
Rotation is unstable.
While engine is running normally, pulse voltage of about 70 V is applied to positive (+) side of injector. This pulse voltage cannot be measured with circuit tester.
Different machine models may have different connector Nos.
Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Defective injector #4 (Internal


trouble)

CN4 (male)

Resistance

Between (1) (2)

0.4 1.1 z

Between (1), (2) chassis


ground

Min. 1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female)
2
or defective contact in connec- (56) CN4 (female) (1)
tor)
Wiring harness between ENG (female)
(58) CN4 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
Ground fault in wiring harness (56) CN4 (female) (1) and chassis
3
(Short circuit with GND circuit) ground

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(58) CN4 (female) (2) and chassis
ground

Resistance

Min.
1 Mz

Defective injector or wiring


harness of another cylinder

If failure code of another cylinder is displayed, carry out troubleshooting for it, too.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5 Defective engine controller

62

ENG (female)

Resistance

Between (56) (58)

0.4 1.1 z

Between (56), (58) chassis


ground

Min. 1 Mz

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to injector #4

125E-5 Series

63

SEN00550-01

40 Troubleshooting

E-31 Code [342/CA342] Calibration Code Incompatibility


Error code

Failure code

342

CA342

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Calibration Code Incompatibility

Matching error occurred in engine controller data.


None in particular.

Engine continues operation normally, but it may stop during operation or may not be able to start.

Related
information
Possible causes
and standard
value in normal
state

64

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-1 Code [111/CA111].

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00550-01

65

SEN00550-01

40 Troubleshooting

E-32 Code [351/CA351] INJ. Drive Circuit Error


Error code

Failure code

351

CA351

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

INJ. Drive Circuit Error

Abnormality occurred in injector drive circuit.


Limits output and continues operation (Limits common rail pressure).

Output drops.

Different machine models may have different connector Nos.

Cause

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code (code of abnormality in injector system) is


indicated, carry out troubleshooting for it.

2 Defective fuse

Check fuse or circuit breaker on machine side directly for defect.


(If fuse is broken or circuit breaker is turned OFF, circuit probably
has ground fault.)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between E03 (female) (3),
Resis3
Max. 1 z
or defective contact in connec- (4) battery (+)
tance
tor)
Wiring harness between E03 (female) (1),
ResisMax. 1 z
(2) chassis ground
tance
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4

Ground fault in wiring harness Wiring harness between E03 (female) (3),
(Short circuit with GND circuit) (4) battery (+) and chassis ground

Resistance

Min.
1 Mz

Wiring harness between E03 (female) (1),


(2) chassis ground

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
5 Defective engine controller

66

E03

Voltage

Between (3), (4) (1), (2)

20 30 V

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to controller power supply

125E-5 Series

67

SEN00550-01

40 Troubleshooting

E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error


Error code

Failure code

352

CA352

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Sensor Sup. 1 Volt. Low Error

Signal voltage in sensor power supply 1 (5 V) circuit is abnormally low.


Limits output of common rail pressure sensor and continues operation (Limits common rail pressure).
Output drops.

Related
information
Possible causes
and standard
value in normal
state

68

Causes

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-34 Code [386/CA386].

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00550-01

69

SEN00550-01

40 Troubleshooting

E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error


Error code

Failure code

386

CA386

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Sensor Sup. 1 Volt. High Error

Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high.


Limits output of common rail pressure sensor and continues operation (Limits common rail pressure).
Output drops.

Different machine models may have different connector Nos.

Causes
1 Defective related system

Standard value in normal state/Remarks on troubleshooting


If another failure code is indicated, carry out troubleshooting for
it.
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Disconnect devices
Defective sensor (Internal trou- at right in order. If
2
error code disapble)
pears when a device
is disconnected, that
device has a defect
in it.

Common rail pressure sensor

PFUEL connector

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness


Wiring harness between ENG (female)
3
(Disconnection in wiring or
(33) PFUEL (female) (1)
defective contact in connector) Wiring harness between ENG (female)
(47) PFUEL (female) (3)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
Ground fault in wiring harness (33) PFUEL (female) (1) and chassis
4
(Short circuit with GND circuit) ground
Wiring harness between CE01 (female)
(47) PFUEL (female) (3) and chassis
ground

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5

Short circuit in wiring harness


(With another wiring harness)

Wiring harness between ENG (female)


(33) PFUEL (female) (1) and
wiring harness between ENG (female) (47)
PFUEL (female) (3)

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
6

70

Defective engine controller

ENG

Voltage

Between (33) (47)

4.75 5.25V

125E-5 Series

40 Troubleshooting

SEN00550-01

Circuit diagram related to sensor power supply 1 (5 V)

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

71

SEN00550-01

40 Troubleshooting

E-35 Code [431/CA431] Idle Validation SW Low error

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


Error code

Failure code

431

CA431

Contents of
trouble
Action of
controller

Trouble

Idle Validation SW Low error

Abnormality occurred in idle validation switch circuit


Sets throttle angle to certain value and continues operation (depending on each model).

Problem that
appears on
machine
Related
information

Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Defective accelerator pedal


(Internal trouble)

AS1

Signal name

Between (5) (4)

Signal 1

Between (6) (4)

Signal 2

Voltage
See Fig. 1

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.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harness
2
(Disconnection in wiring or
defective contact in connector)
Possible causes
and standard
value in normal
state

Wiring harness between E02 (female) (32)


AS1 (female) (4)

Resistance

Max. 1 z

Wiring harness between E02 (female) (11)


AS1 (female) (5)

Resistance

Max. 1 z

Wiring harness between E02 (female) (1)


AS1 (female) (6)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between E02 (female) (32)
Ground fault in wiring harness AS1 (female) (4) and chassis ground
3
(Short circuit with GND circuit) Wiring harness between E02 (female) (11)
AS1 (female) (5) and chassis ground

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

Wiring harness between E02 (female) (1)


AS1 (female) (6) and chassis ground

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
Hot short (Short circuit with
4 24V circuit)
in wiring harness

72

Wiring harness between E02 (female) (32)


AS1 (female) (4) and chassis ground

Voltage

Max. 1V

Wiring harness between E02 (female) (11)


AS1 (female) (5) and chassis ground

Voltage

Max. 1V

Wiring harness between E02 (female) (1)


AS1 (female) (6) and chassis ground

Voltage

Max. 1V

125E-5 Series

40 Troubleshooting

SEN00550-01

Causes
Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Defective engine controller

E02

Signal name

Between (11) (32)

Signal 1

Between (1) (32)

Signal 2

Voltage
See Fig. 1

Circuit diagram related to throttle sensor of accelerator pedal type (Case of HM300-2)

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

SEN00550-01

40 Troubleshooting

E-36 Code [432/CA432] Idle Validation Process error


Error code

Failure code

432

CA432

Contents of
trouble
Action of
controller

Trouble

Idle Validation Process error

Abnormality occurred in processing of idle validation switch circuit.


Sets throttle angle to certain value and continues operation (depending on each model).

Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-35 Code [431/CA431].

E-37 Code [441/CA441] Battery voltage low error


Error code

Failure code

441

CA441

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Battery voltage low error

Power supply voltage is abnormally low.


None in particular.

Engine continues operation normally, but it may stop during operation or may not be able to start.

Related
information
Possible causes
and standard
value in normal
state

74

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-1 Code [111/CA111].

125E-5 Series

40 Troubleshooting

SEN00550-01

E-38 Code [442/CA442] Battery voltage high error


Error code

Failure code

442

CA442

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Battery voltage high error

Power supply voltage is abnormally high.


None in particular.

Engine continues operation normally, but it may stop during operation or may not be able to start.

Related
information
Possible causes
and standard
value in normal
state

125E-5 Series

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-1 Code [111/CA111].

75

SEN00550-01

KOMATSU 125E-5 Series engine


Form No. SEN00550-01

2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (01)

76

SEN00551-01

ENGINE
1SHOP MANUAL

125E-5 Series

40 Troubleshooting

Troubleshooting of electrical system


(E-mode), Part 2
Troubleshooting of electrical system (E-mode), Part 2 ................................................................................... 3
E-39 Code [449/CA449] Rail Press. Very High Error ........................................................................... 3
E-40 Code [451/CA451] Rail Press. Sensor High Error ....................................................................... 4
E-41 Code [452/CA452] Rail Press. Sensor Low Error........................................................................ 6
E-42 Code [553/CA553] Rail Press. High Error ................................................................................... 6
E-43 Code [554/CA554] Rail Press Sensor In Range Error................................................................. 7
E-44 Code [559/CA559] Rail Press. Low Error .................................................................................... 8
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error ...................................................................... 12
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error........................................................ 14
E-47 Code [757/CA757] All Persistent Data Lost Error...................................................................... 15
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error................................................................... 16
E-49 Code [1228/CA1228] EGR Valve Servo Error 1 ........................................................................ 18
E-50 Code [1625/CA1625] EGR Valve Servo Error 2 ........................................................................ 19
E-51 Code [1626/CA1626] Bypass Valve Solenoid Current High Error ............................................. 20

125E-5 Series

SEN00551-01

40 Troubleshooting

E-52 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error .............................................. 22
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1 .................................................................... 23
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2 .................................................................... 24
E-55 Code [1631/CA1631] BP valve Lift Position Sensor High Error................................................. 26
E-56 Code [1632/CA1632] BP valve Lift Position Sensor Low Error ................................................. 28
E-57 Code [1633/CA1633] KOMNET Datalink Timeout Error ............................................................ 28
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error ......................................................... 29
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error......................................................... 30
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ........................................................ 32
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error......................................................... 36
E-62 Code [2249/CA2249] Rail Press. Very Low Error ...................................................................... 37
E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error ............................................. 38
E-64 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error .............................................. 40
E-65 Code [2351/CA2351] EGR Valve Solenoid Current High Error ................................................. 42
E-66 Code [2352/CA2352] EGR Valve Solenoid Current Low Error .................................................. 44
E-67 Code [2555/CA2555] Grid Heater Relay Volt. Low Error........................................................... 45
E-68 Code [2556/CA2556] Grid Heater Relay Volt. High Error .......................................................... 46
E-69 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate.............................................................. 48
E-70 Code [(146)/B@BCNS] Eng. Overheat...................................................................................... 48
E-71 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate....................................................... 49

125E-5 Series

40 Troubleshooting

SEN00551-01

Troubleshooting of electrical system (E-mode), Part 2

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

Error code

Failure code

449

CA449

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Rail Press. Very High Error

Common rail pressure sensor circuit detected abnormally high pressure (level 2).
Limits output and continues operation (Limits common rail pressure).

Output drops.

Related
information
Possible causes
and standard
value in normal
state

125E-5 Series

Causes

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-42 Code [553/CA553].

SEN00551-01

40 Troubleshooting

E-40 Code [451/CA451] Rail Press. Sensor High Error


Error code

Failure code

451

CA451

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Rail Press. Sensor High Error

Signal voltage in common rail pressure sensor circuit is abnormally high.


Limits output and continues operation (Limits common rail pressure).

Output drops.

Different machine models may have different connector Nos.

Causes
1

Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply If code [352/CA352] or [386/CA386] is indicated, carry out trousystem
bleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
PFUEL

Defective common rail pres2 sure sensor


(Internal trouble)

Voltage

Between (1) (3)

Power supply

4.75 5.25V

Between (2) (3)

Signal

0.25 4.6V

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.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state

Disconnection in wiring harness


3
(Disconnection in wiring or
defective contact in connector)

Wiring harness between ENG (female)


(33) PFUEL (female) (1)

Resistance

Max. 1 z

Wiring harness between ENG (female)


(25) PFUEL (female) (2)

Resistance

Max. 1 z

Wiring harness between ENG (female)


(47) PFUEL (female) (3)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
(33) PFUEL (female) (1) and chassis
ground

Resistance

Min.
1 Mz

Ground fault in wiring harness


(Short circuit with GND circuit) Wiring harness between ENG (female)
(25) PFUEL (female) (2) and chassis
ground

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(47) PFUEL (female) (3) and chassis
ground

Resistance

Min.
1 Mz

125E-5 Series

40 Troubleshooting

SEN00551-01

Causes

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

5
Possible causes
and standard
value in normal
state

Short circuit in wiring harness


(With another wiring harness)

Wiring harness between ENG (female)


(33) PFUEL (female) (1) and
wiring harness between ENG (female) (25)
PFUEL (female) (2)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(33) PFUEL (female) (1) and
wiring harness between ENG (female) (47)
PFUEL (female) (3)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(25) PFUEL (female) (2) and
wiring harness between ENG (female) (47)
PFUEL (female) (3)

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


or start engine and carry out troubleshooting.
ENG

Voltage

Between (33) (47)

4.75 5.25V

Between (25) (47)

0.25 4.6V

6 Defective engine controller

Circuit diagram related to common rail 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

SEN00551-01

40 Troubleshooting

E-41 Code [452/CA452] Rail Press. Sensor Low Error


Error code

Failure code

452

CA452

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Rail Press. Sensor Low Error

Signal voltage in common rail pressure sensor circuit is abnormally low.


Limits output and continues operation (Limits common rail pressure).

Output drops.

Related
information
Possible causes
and standard
value in normal
state

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-40 Code [451/CA451].

E-42 Code [553/CA553] Rail Press. High Error


Error code

Failure code

553

CA553

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Rail Press. High Error

Common rail pressure sensor circuit detected abnormally high pressure (level 1).
None in particular.

Output drops.

Related
information
Causes

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting

1 Defective related system

If another failure code is indicated, carry out troubleshooting for


it.

2 Use of improper fuel

Check fuel used directly


(for high viscosity).

Defective electrical system of


common rail pressure sensor

Common rail pressure sensor may have electric trouble. Carry


out troubleshooting for code [451/CA451] (E-40).

Defective mechanical system


4 of common rail pressure sensor

Check mechanical system of common rail pressure sensor


directly.

5 Defective overflow valve

Check overflow valve directly for broken spring, worn seat, and
stuck ball.

6 Clogging of overflow piping

Check overflow piping directly for clogging.

7 Defective pressure limiter

Check pressure limiter directly for mechanical defect.

125E-5 Series

40 Troubleshooting

SEN00551-01

E-43 Code [554/CA554] Rail Press Sensor In Range Error


Error code

Failure code

554

CA554

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Rail Press Sensor In Range Error

In-range error occurred in common rail pressure sensor circuit.


Limits output and continues operation (Limits common rail pressure).

Output drops.

Related
information
Possible causes
and standard
value in normal
state

125E-5 Series

Causes

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-40 Code [451/CA451].

SEN00551-01

40 Troubleshooting

E-44 Code [559/CA559] Rail Press. Low Error


Error code

Failure code

559

CA559

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Rail Press. Low Error

Supply pump does not feed fuel (level 1).


Limits common rail pressure.

Output drops.

Related
information
Causes
1 Defective related system

If another failure code is indicated, carry out troubleshooting for


it.

2 Use of improper fuel

Check fuel used directly (for high viscosity).

Defective low-pressure circuit


device

4 Clogging of filter or strainer

Possible causes
and standard
value in normal
state

Standard value in normal state/Remarks on troubleshooting

a For contents of troubleshooting, see Note 1. For check of pressure in fuel low-pressure circuit, see Testing and adjusting,
"Testing fuel pressure".
Pressure in fuel low-pressure circuit
(At high idle or equivalent to rated load
(stall))

Min. 0.15 MPa


{Min. 1.5 kg/cm2}

a For contents of troubleshooting, see Note 2.

Defective electrical system of


supply pump PCV

Supply pump PCV may have electric trouble. Carry out troubleshooting for following codes [271/CA271] (E-21), [272/CA272]
(E-22), [273/CA273] (E-23),[274/CA274] (E-24).

Defective common rail pressure sensor

Common rail pressure sensor may be defective. Check wiring


harness for damage.

7 Defective pressure limiter

a For testing of leakage from pressure limiter, see Testing and


adjusting, "Testing leakage from pressure limiter and return
rate from injector".
Leakage from pressure limiter
(At equivalent to rated operation by models)

Max. 10 cc/min

a For testing of return rate (spill) from injector, see Testing and
adjusting, "Testing leakage from pressure limiter and return
rate from injector".
Speed at rated operation
(at stall)
8 Defective injector

9 Defective supply pump

Return (Spill) limit from injector

1,600 rpm

960 cc/min

1,700 rpm

1,020 cc/min

1,800 rpm

1,080 cc/min

1,900 rpm

1,140 cc/min

2,000 rpm

1,200 cc/min

If causes 1 8 are not detected, supply pump may be defective.

<How to use check sheet>


Carry out the above troubleshooting and take a record of the contents of the attached Check sheet for nopressure feed.

125E-5 Series

40 Troubleshooting

SEN00551-01

Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q
Overflow valve (1): Spring is seen through both holes.
q
Bypass valve (2): Spring is seen through hole on nut side.
q
Fuel inlet joint (3): Gauze filter is seen through both holes.

Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.

125E-5 Series

SEN00551-01

40 Troubleshooting

Check sheet for no-pressure feed


Model
Machine serial No.

Work No.
#

Date of check

Engine
Engine serial No.

Worker's name

A. Visual check

Good NG

Fuel leakage to outside

Clogging of fuel tank breather

B. Check with machine monitor (Fault history function, monitoring function, and reduced cylinder mode function)
3

Service meter

Check of error/failure code

Good NG

Check of monitoring information


Code

*1

*2

Unit

Standard value
(Reference value)

Low idle

rpm

<By models>

High idle

rpm

<By models>

Equivalent to rating <By models>

rpm

<By models>

Displayed item

Engine speed

Throttle opening

Checking condition

Measured value

Good NG

Low idle

High idle

100

*3

Fuel injection command

Equivalent to rating <By models>

mm3

*4

Common rail pressure


command

Equivalent to rating <By models>

MPa

*5

Common rail fuel


pressure

Equivalent to rating <By models>

MPa

*6

Fuel injection timing


command

Low idle

CA

High idle

CA

Equivalent to rating <By models>

CA

*7

Boost pressure

Equivalent to rating <By models>

kPa

*8

Engine coolant
temperature

Low idle

*9

Fuel temperature

Low idle

Unit

Standard value
(Reference value)

Check of reduced cylinder mode operation (Engine speed)


Function

5
*10

Reduced cylinder

Measured value

No. 1 cylinder

Low idle

rpm

Low idle

rpm

No. 3 cylinder

Low idle

rpm

No. 4 cylinder

Low idle

rpm

No. 5 cylinder

Low idle

rpm

No. 6 cylinder

Low idle

rpm

Checking condition

Unit

Standard value
(Reference value)

High idle or equivalent to rated load


(stall)

MPa
{kg/cm2}

Min. 0.15 {Min. 1.5}

Fuel low-pressure circuit pressure

Measured value

D. Check of strainers and filters


7

Good NG

No. 2 cylinder

C. Check of fuel circuit pressure


6

Checking condition

Good NG

Good NG

Visual check of strainers

Visual check of gauze filter

Visual check of fuel filter

10 Visual check of bypass valve


E.Check of leakage and return rate
11 Leakage through pressure limiter

12 Return rate from injector

10

Checking condition

Unit

Standard value
(Reference value)

Equivalent to rating <By models>

cc/min

Max. 10

Equivalent to rating <By models>


1,600 rpm

cc/min

960

Equivalent to rating <By models>


1,700 rpm

cc/min

1,020

Equivalent to rating <By models>


1,800 rpm

cc/min

1,080

Equivalent to rating <By models>


1,900 rpm

cc/min

1,140

Equivalent to rating <By models>


2,000 rpm

cc/min

1,200

Measured value

Good NG

Speed:
Return rate:

125E-5 Series

40 Troubleshooting

SEN00551-01

*1 *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.

125E-5 Series

11

SEN00551-01

40 Troubleshooting

E-45 Code [689/CA689] Eng. Ne Speed Sensor Error


Error code

Failure code

689

CA689

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Eng. Ne Speed Sensor Error

Abnormality occurred in engine Ne speed sensor circuit.


Operates with signals of Bkup speed sensor.
Running engine stops (when Bkup speed sensor is also abnormal).
Stopped engine cannot be started (when Bkup speed sensor is also abnormal).
Different machine models may have different connector Nos.

Causes
1

Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply If code [238/CA238] is indicated, carry out troubleshooting for it
system
first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness


2
(Disconnection in wiring or
defective contact in connector)

Wiring harness between ENG (female)


(16) NE (female) (1)

Resistance

Max. 1 z

Wiring harness between ENG (female)


(48) NE (female) (2)

Resistance

Max. 1 z

Wiring harness between ENG (female)


(27) NE (female) (3)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
Ground fault in wiring harness (16) NE (female) (1) and chassis ground
3
(Short circuit with GND circuit) Wiring harness between ENG (female)
(48) NE (female) (2) and chassis ground

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(27) NE (female) (3) and chassis ground

Resistance

Min.
1 Mz

Possible causes
and standard
value in normal
state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

12

Short circuit in wiring harness


(With another wiring harness)

Wiring harness between ENG (female)


(16) NE (female) (1) and
wiring harness between ENG (female) (48)
NE (female) (2)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(16) NE (female) (1) and
wiring harness between ENG (female) (27)
NE (female) (3)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(48) NE (female) (2) and
wiring harness between ENG (female) (27)
NE (female) (3)

Resistance

Min.
1 Mz

Check Ne speed sensor directly for defective mount (defective


Defective mount of sensor or
clearance) or check rotation sensing part (flywheel) directly for
defective rotation sensing part
defect.

Defective engine Ne speed


sensor

If causes 1 5 are not detected, engine Ne speed sensor may be


defective. (Since trouble is in system, troubleshooting cannot be
carried out.)

125E-5 Series

40 Troubleshooting

Possible causes
and standard
value in normal
state

SEN00551-01

Causes
7 Defective engine controller

Standard value in normal state/Remarks on troubleshooting


If causes 1 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

Circuit diagram related to engine Ne speed sensor

125E-5 Series

13

SEN00551-01

40 Troubleshooting

E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error


Error code

Failure code

731

CA731

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Eng. Bkup Speed Sensor Phase Error

Engine Bkup sensor circuit detected abnormality in phase.


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

Related
information
Cause
Possible causes
and standard
value in normal
state

14

Standard value in normal state/Remarks on troubleshooting

Defective engine Ne speed


sensor system

Engine Ne speed sensor may be defective. Carry out troubleshooting for [689/CA698] (E-45).

Defective engine Bkup speed


sensor system

Engine Bkup speed sensor may be defective. Carry out troubleshooting for [778/CA778] (E-48).

125E-5 Series

40 Troubleshooting

SEN00551-01

E-47 Code [757/CA757] All Persistent Data Lost Error


Error code

Failure code

757

CA757

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

All Persistent Data Lost Error

All data in engine controller are lost.


None in particular.

Engine continues operation normally, but it may stop during operation or may not be able to start.

Related
information
Possible causes
and standard
value in normal
state

125E-5 Series

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-1 Code [111/CA111].

15

SEN00551-01

40 Troubleshooting

E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error


Error code

Failure code

778

CA778

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Eng. Bkup Speed Sensor Error

Abnormality occurred in engine Bkup speed sensor circuit.


Operates with signals of Ne speed sensor.
Running engine stops (when Ne speed sensor is also abnormal).
Stopped engine cannot be started (when Ne speed sensor is also abnormal).
Different machine models may have different connector Nos.

Causes
1

Standard value in normal state/Remarks on troubleshooting

Defective sensor power supply If code [187/CA187] or [227/CA227] is indicated, carry out trousystem
bleshooting for it first.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness


2
(Disconnection in wiring or
defective contact in connector)

Wiring harness between ENG (female)


(37) G (female) (1)

Resistance

Max. 1 z

Wiring harness between ENG (female)


(47) G (female) (2)

Resistance

Max. 1 z

Wiring harness between ENG (female)


(26) G (female) (3)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
Ground fault in wiring harness (37) G (female) (1) and chassis ground
3
(Short circuit with GND circuit) Wiring harness between ENG (female)
(47) G (female) (2) and chassis ground

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(26) G (female) (3) and chassis ground

Resistance

Min.
1 Mz

Possible causes
and standard
value in normal
state

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Short circuit in wiring harness


(With another wiring harness)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(37) G (female) (1) and between ENG
(female) (26) G (female) (3)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(47) G (female) (2) and between ENG
(female) (26) G (female) (3)

Resistance

Min.
1 Mz

Check Bkup speed sensor directly for defective mount (defective


Defective mount of sensor or
clearance) or check rotation sensing part (in supply pump)
defective rotation sensing part
directly for defect.

Defective engine Bkup speed


sensor

7 Defective engine controller

16

Wiring harness between ENG (female)


(37) G (female) (1) and between ENG
(female) (47) G (female) (2)

If causes 1 5 are not detected, engine Bkup speed sensor may


be defective. (Since trouble is in system, troubleshooting cannot
be carried out.)
If causes 1 6 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

125E-5 Series

40 Troubleshooting

SEN00551-01

Circuit diagram related to engine Bkup speed sensor

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

17

SEN00551-01

40 Troubleshooting

E-49 Code [1228/CA1228] EGR Valve Servo Error 1


a

This code applies to only with EGR.


Error code

Failure code

1228

CA1228

Contents of
trouble
Action of
controller

Trouble

EGR Valve Servo Error 1

Abnormality (level 1) occurred in EGR valve servo.


Performs open control.

Problem that
appears on
machine
Related
information
Causes
1 Defective related system

Standard value in normal state/Remarks on troubleshooting


If another failure code is indicated, carry out troubleshooting for
it.
a For measurement of EGR valve drive pressure, see Testing
and adjusting, Measuring EGR valve and bypass valve drive
pressure.

Improper EGR valve drive


pressure

Engine speed

EGR valve drive pressure

Low idle

1.18 MPa {12 kg/cm2}

High idle

1.43 MPa {14.6 kg/cm2}

If EGR valve drive pressure is abnormal, check causes 3 and 4.


a For check of engine oil pressure, see Testing and adjusting,
Testing engine oil pressure.
Possible causes
and standard
value in normal
state

Defective engine oil pressure


system (main circuit)

Engine speed

Engine oil pressure

Low idle

0.08 MPa {0.8 kg/cm2}

High idle

0.21 MPa {2.1 kg/cm2}

If engine oil pressure is abnormal, carry out troubleshooting for


mechanical system (S-12 Oil pressure lowers).

18

Defective oil pump for EGR


valve

Check oil pump and relief valve for EGR valve circuit directly.

Defective oil feed piping for


EGR valve

Check oil feed piping for EGR valve circuit directly.

Defective oil return piping for


EGR valve

Check oil return piping for EGR valve circuit directly.

7 Defective EGR valve

Check mechanical section of EGR valve directly.

8 Defective engine controller

If causes 1 7 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

125E-5 Series

40 Troubleshooting

SEN00551-01

E-50 Code [1625/CA1625] EGR Valve Servo Error 2


a

This code applies to only with EGR.


Error code

Failure code

1625

CA1625

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

EGR Valve Servo Error 2

Abnormality (level 2) occurred in EGR valve servo.


Limits output and continues operation.
Closes EGR valve and bypass valve.
Output drops.

Related
information
Possible causes
and standard
value in normal
state

125E-5 Series

Causes

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-49 Code [1228/CA1228].

19

SEN00551-01

40 Troubleshooting

E-51 Code [1626/CA1626] Bypass Valve Solenoid Current High Error


a

This code applies to only with EGR.


Error code

Failure code

1626

CA1626

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Bypass Valve Solenoid Current High Error

There is short circuit in drive circuit of bypass valve solenoid.


Limits output and continues operation.
Closes EGR valve and bypass valve.
Output drops.

Different machine models may have different connector Nos.

Cause

Defective bypass valve solenoid (Internal trouble)

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
BP (male)

Resistance

Between (1) (2)

10 21 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female)
2
or defective contact in connec- (31) BP (female) (1)
tor)
Wiring harness between ENG (female) (11)
BP (female) (2)
Possible causes
and standard
value in normal
state

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3

Ground fault in wiring harness Wiring harness between ENG (female)


(Short circuit with GND circuit) (31) BP (female) (1) and chassis ground

Resistance

Min.
1 Mz

Wiring harness between ENG (female) (11)


BP (female) (2) and chassis ground

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
4

Hot short (Short circuit with


24V circuit) in wiring harness

Wiring harness between ENG (female)


(31) BP (female) (1) and chassis ground

Voltage

Max. 1 V

Wiring harness between ENG (female) (11)


BP (female) (2) and chassis ground

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller

20

ENG (female)

Resistance

Between (31) (11)

10 21 z

125E-5 Series

40 Troubleshooting

SEN00551-01

Circuit diagram related to bypass valve solenoid & lift sensor

125E-5 Series

21

SEN00551-01

40 Troubleshooting

E-52 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error


a

[with EGR only]


Error code

Failure code

1627

CA1627

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Bypass Valve Solenoid Current Low Error

There is disconnection in drive circuit of bypass valve solenoid.


Limits output and continues operation.
Closes EGR valve and bypass valve.
Output drops.

Related
information
Possible causes
and standard
value in normal
state

22

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-51 Code [1626/CA1626].

125E-5 Series

40 Troubleshooting

SEN00551-01

E-53 Code [1628/CA1628] Bypass Valve Servo Error 1


a

This code applies to only with EGR.


Error code

Failure code

1628

CA1628

Contents of
trouble
Action of
controller

Trouble

Bypass Valve Servo Error 1

Abnormality (level 1) occurred in bypass valve servo.


Performs open control.

Problem that
appears on
machine
Related
information
Causes
1 Defective related system

Standard value in normal state/Remarks on troubleshooting


If another failure code is indicated, carry out troubleshooting for
it.
a For measurement of bypass valve drive pressure, see Testing
and adjusting, Measuring EGR valve and bypass valve drive
pressure.

Improper bypass valve drive


pressure

Engine speed

Bypass valve drive pressure

Low idle

1.18 MPa {12 kg/cm2}

High idle

1.43 MPa {14.6 kg/cm2}

If EGR valve drive pressure is abnormal, check causes 3 and 4.


a For check of engine oil pressure, see Testing and adjusting,
"Testing engine oil pressure".
Possible causes
and standard
value in normal
state

Defective engine oil pressure


system (main circuit)

Engine speed

Engine oil pressure

Low idle

0.08 MPa {0.8 kg/cm2}

High idle

0.21 MPa {2.1 kg/cm2}

If engine oil pressure is abnormal, carry out troubleshooting for


mechanical system (S-12 Oil pressure lowers).

125E-5 Series

Defective oil pump for bypass


valve

Check oil pump and relief valve for bypass valve circuit directly.

Defective oil feed piping for


bypass valve

Check oil feed piping for bypass valve circuit directly.

Defective oil return piping for


bypass valve

Check oil return piping for bypass valve circuit directly.

7 Defective bypass valve

Check mechanical section of bypass valve directly.

8 Defective engine controller

If causes 1 7 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

23

SEN00551-01

40 Troubleshooting

E-54 Code [1629/CA1629] Bypass Valve Servo Error 2


a

This code applies to only with EGR.


Error code

Failure code

1629

CA1629

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Bypass Valve Servo Error 2

Abnormality (level 2) occurred in bypass valve servo.


Limits output and continues operation.
Closes EGR valve and bypass valve.
Output drops.

Related
information
Possible causes
and standard
value in normal
state

24

Causes

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-53 Code [1628/CA1628].

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00551-01

25

SEN00551-01

40 Troubleshooting

E-55 Code [1631/CA1631] BP valve Lift Position Sensor High Error


a

This code applies to only with EGR.


Error code

Failure code

1631

CA1631

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

BP valve Lift Position Sensor High Error

Signal voltage in bypass valve lift sensor circuit is abnormally high.


Limits output and continues operation.
Closes EGR valve and bypass valve.
Output drops.

Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting

If code [187/CA187] or [227/CA227] is indicated, carry out trou1 Defective sensor power supply
bleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
SBP
Between (1) (2)

Voltage
Power supply

4.75 5.25V

Sensor voltage is measured with wiring harness connected.


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)
a Prepare with starting switch OFF, then turn starting switch ON
(keep engine stopped, however) and carry out troubleshooting.
SBP

Possible causes
and standard
value in normal
state

Voltage

Between (3) (2)

Signal

0.8 1.2V

Between (4) (2)

Signal

0.8 1.2V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Disconnection in wiring harWiring harness between ENG (female)
ness
(37) SBP (female) (1)
3 (Disconnection in wiring or
defective contact in connector) Wiring harness between ENG (female)
(38) SBP (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

Wiring harness between ENG (female)


(29) SBP (female) (3), (4)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
(37) SBP (female) (1) and chassis
ground

Ground fault in wiring harness


(Short circuit with GND circuit) Wiring harness between ENG (female)
(38) SBP (female) (2) and chassis
ground
Wiring harness between ENG (female)
(29) SBP (female) (3), (4) and chassis
ground

26

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

125E-5 Series

40 Troubleshooting

SEN00551-01

Causes

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Short circuit in wiring harness


(With another wiring harness)

Wiring harness between ENG (female)


(37) SBP (female) (1) and
wiring harness between ENG (female) (38)
SBP (female) (2)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(37) SBP (female) (1) and
wiring harness between ENG (female) (29)
SBP (female) (3), (4)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(38) SBP (female) (2) and
wiring harness between ENG (female) (29)
SBP (female) (3), (4)

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


or start engine and carry out troubleshooting.
6 Defective engine controller

ENG

Voltage

Between (37) (38)

4.75 5.25V

Circuit diagram related to bypass valve solenoid & lift sensor

125E-5 Series

27

SEN00551-01

40 Troubleshooting

E-56 Code [1632/CA1632] BP valve Lift Position Sensor Low Error


a

This code applies to only with EGR.


Error code

Failure code

1632

CA1632

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

BP valve Lift Position Sensor Low Error

Signal voltage in bypass valve lift sensor circuit is abnormally low.


Limits output and continues operation.
Closes EGR valve and bypass valve.
Output drops.

Related
information
Possible causes
and standard
value in normal
state

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-55 Code [1631/CA1631].

E-57 Code [1633/CA1633] KOMNET Datalink Timeout Error


Error code

Failure code

1633

CA1633

Trouble

KOMNET Datalink Timeout Error

Contents of
trouble

Abnormality occurred in circuit of KOMNET communication with machine.

Action of
controller

Operates in default mode or maintains condition when abnormality occurs.

Problem that
appears on
machine
Related
information

Possible causes
and standard
value in normal
state

28

Cause

Standard value in normal state/Remarks on troubleshooting

Carry out troubleshooting on


1
machine side

This fault is detected and indicated when KOMNET communication with machine monitor or controller on the machine side is
abnormal. Accordingly, contents of troubleshooting depends on
machine model. See Shop manual for machine.

125E-5 Series

40 Troubleshooting

SEN00551-01

E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error


a

This code applies to only with EGR.


Error code

Failure code

1642

CA1642

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

EGR Inlet Press Sensor Low Error

Signal voltage in EGR inlet pressure sensor circuit is abnormally low.


Sets EGR inlet pressure to default value (102 kPa {10.4 kg/cm2}) and continues operation.
Limits output and continues operation.
Output drops.

Related
information
Possible causes
and standard
value in normal
state

125E-5 Series

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-59 Code [1653/CA1653].

29

SEN00551-01

40 Troubleshooting

E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error


a

This code applies to only with EGR.


Error code

Failure code

1653

CA1653

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

EGR Inlet Press Sensor High Error

Signal voltage in EGR inlet pressure sensor circuit is abnormally high.


Sets EGR inlet pressure to default value (102 kPa {1.04 kg/cm2}) and continues operation.
Limits output and continues operation.
Output drops.

Different machine models may have different connector Nos.

Cause

Standard value in normal state/Remarks on troubleshooting

If code [187/CA187] or [227/CA227] is indicated, carry out trou1 Defective sensor power supply
bleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
Defective EGR inlet pressure
2
sensor (Internal trouble)

PEVA
Between (1) (2)

Voltage
Power supply

4.75 5.25 V

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.
a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Possible causes
and standard
value in normal
state

Disconnection in wiring harness (Disconnection in wiring


3
or defective contact in connector)

Wiring harness between ENG (female)


(37) PEVA (female) (1)

Resistance

Max. 1 z

Wiring harness between ENG (female)


(47) PEVA (female) (2)

Resistance

Max. 1 z

Wiring harness between ENG (female)


(20) PEVA (female) (3)

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
(37) PEVA (female) (1) and chassis
ground

30

Resistance

Min.
1 Mz

Ground fault in wiring harness


(Short circuit with GND circuit) Wiring harness between ENG (female)
(47) PEVA (female) (2) and chassis
ground

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(20) PEVA (female) (3) and chassis
ground

Resistance

Min.
1 Mz

125E-5 Series

40 Troubleshooting

SEN00551-01

Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Short circuit in wiring harness


(with another wiring harness)

Wiring harness between ENG (female)


(37) PEVA (female) (1) and between
ENG (female) (47) PEVA (female) (2)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(37) PEVA (female) (1) and between
ENG (female) (20) PEVA (female) (3)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(47) PEVA (female) (2) and between
ENG (female) (20) PEVA (female) (3)

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


or start engine and carry out troubleshooting.
6 Defective engine controller

ENG

Voltage

Between (37) (47)

4.75 5.25 V

Circuit diagram related to EGR inlet pressure sensor

125E-5 Series

31

SEN00551-01

40 Troubleshooting

E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error

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


Error code

Failure code

2185

CA2185

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Throttle Sens. Sup. Volt. High Error

Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.


Sets throttle angle with signal other than throttle sensor signal and continues operation
(depending on each model)
Different problems occur on different machine models.

Different machine models may have different connector Nos.

Causes

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Defective accelerator pedal


1
(Internal trouble)

Disconnect devices
at right in order. If
error code disappears when a device
is disconnected, that
device has a defect
in it.

Accelerator pedal

AS1 connector

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness


Wiring harness between E02 (female) (22)
2
(Disconnection in wiring or
AS1 (female) (1)
defective contact in connector) Wiring harness between E02 (female) (23)
AS1 (female) (3)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3

Ground fault in wiring harness Wiring harness between E02 (female) (22)
(Short circuit with GND circuit) AS1 (female) (1) and chassis ground

Resistance

Min.
1 Mz

Wiring harness between E02 (female) (23)


AS1 (female) (3) and chassis ground

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
4

Short circuit in wiring harness


(With another wiring harness)

Wiring harness between E02 (female) (22)


AS1 (female) (1) and
wiring harness between E02 (female) (23)
AS1 (female) (3)

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
5 Defective engine controller

32

E02

Voltage

Between (22) (23)

4.75 5.25V

125E-5 Series

40 Troubleshooting

SEN00551-01

Circuit diagram related to throttle sensor of accelerator pedal type (Case of HM300-2)

125E-5 Series

33

SEN00551-01

40 Troubleshooting

Throttle sensor of fuel control dial type (Case of PC400/400LC/450/450LC-7E0)


Error code

Failure code

2185

CA2185

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Throttle Sens. Sup. Volt. High Error

Signal voltage in throttle sensor power supply (5 V) circuit is abnormally high.


Sets throttle angle with signal other than throttle sensor signal and continues operation (depending
on each model).
Depends on machine model.

Different machine models may have different connector Nos.

Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.

Defective fuel control dial


1
(Internal trouble)

Disconnect devices
at right in order. If
error code disappears when a device
is disconnected, that
device has a defect
in it.

Fuel control dial

P20 connector

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness (Disconnection in wiring Wiring harness between E02 (female) (22)
2
or defective contact in connec- P20 (female) (1)
tor)
Wiring harness between E02 (female) (23)
P20 (female) (3)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3

Ground fault in wiring harness Wiring harness between E02 (female) (22)
(Short circuit with GND circuit) P20 (female) (1) and chassis ground

Resistance

Min.
1 Mz

Wiring harness between E02 (female) (23)


P20 (female) (3) and chassis ground

Resistance

Min.
1 Mz

Short circuit in wiring harness


(with another wiring harness)

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between E02 (female) (22)
P20 (female) (1) and between E02
(female) (23) P20 (female) (3)

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
5 Defective engine controller

34

E02

Voltage

Between (22) (23)

4.75 5.25 V

125E-5 Series

40 Troubleshooting

SEN00551-01

Circuit diagram related to throttle sensor of fuel control dial type


(Case of PC400/400LC/450/450LC-7E0)

125E-5 Series

35

SEN00551-01

40 Troubleshooting

E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error


Error code

Failure code

2186

CA2186

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Throttle Sens. Sup. Volt. Low Error

Signal voltage in throttle sensor power supply (5 V) circuit is abnormally low.


Sets throttle angle with signal other than throttle sensor signal and continues operation (depending
on each model).
Depends on machine model.

Related
information
Possible causes
and standard
value in normal
state

36

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-60 Code [2185/CA2185].

125E-5 Series

40 Troubleshooting

SEN00551-01

E-62 Code [2249/CA2249] Rail Press. Very Low Error


Error code

Failure code

2249

CA2249

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Rail Press. Very Low Error

Supply pump does not feed fuel (level 2).


Limits common rail pressure.

Output drops.

Related
information
Possible causes
and standard
value in normal
state

125E-5 Series

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-44 Code [559/CA559].

37

SEN00551-01

40 Troubleshooting

E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error 1
a

This code applies to only with EGR.


Error code

Failure code

2271

CA2271

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

EGR Valve Lift Position Sensor High Error

Signal voltage in EGR valve lift sensor circuit is abnormally high.


Limits output and continues operation.
Closes EGR valve and bypass valve.
Output drops.

Different machine models may have different connector Nos.

Cause

Standard value in normal state/Remarks on troubleshooting

If code [187/CA187] or [227/CA227] is indicated, carry out trou1 Defective sensor power supply
bleshooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON
or start engine and carry out troubleshooting.
SEGR
Between (1) (2)

Voltage
Power supply

4.75 5.25 V

Sensor voltage is measured with wiring harness connected.


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)
a Prepare with starting switch OFF, then turn starting switch ON
(keep engine stopped, however) and carry out troubleshooting.
SEGR

Possible causes
and standard
value in normal
state

Voltage

Between (3) (2)

Signal

0.8 1.2 V

Between (4) (2)

Signal

0.8 1.2 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Wiring harness between ENG (female)
(37) SEGR (female) (1) and chassis
ground

Disconnection in wiring harness (Disconnection in wiring


3
or defective contact in connec- Wiring harness between ENG (female)
(47) SEGR (female) (2) and chassis
tor)
ground
Wiring harness between ENG (female)
(19) SEGR (female) (3), (4) and chassis
ground

Resistance

Max. 1 z

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

38

Wiring harness between ENG (female)


Ground fault in wiring harness (37) SEGR (female) (1)
4
(Short circuit with GND circuit) Wiring harness between ENG (female)
(47) SEGR (female) (2)

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(19) SEGR (female) (3), (4)

Resistance

Min.
1 Mz

125E-5 Series

40 Troubleshooting

SEN00551-01

Cause

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Short circuit in wiring harness


(with another wiring harness)

Wiring harness between ENG (female)


(37) SEGR (female) (1) and between
ENG (female) (47) SEGR (female) (2)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(37) SEGR (female) (1) and between
ENG (female) (19) SEGR (female) (3),
(4)

Resistance

Min.
1 Mz

Wiring harness between ENG (female)


(47) SEGR (female) (2) and between
ENG (female) (19) SEGR (female) (3),
(4)

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


or start engine and carry out troubleshooting.
6 Defective engine controller

ENG

Voltage

Between (37) (47)

4.75 5.25 V

Circuit diagram related to EGR valve solenoid & lift sensor

Apply wiring harness joint JM04 to only a bypass valve-fitted engine.

125E-5 Series

39

SEN00551-01

40 Troubleshooting

E-64 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error
a

This code applies to only with EGR.


Error code

Failure code

2272

CA2272

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

EGR Valve Lift Position Sensor Low Error

Signal voltage in EGR valve lift sensor circuit is abnormally low.


Limits output and continues operation.
Closes EGR valve and bypass valve.
Output drops.

Related
information
Possible causes
and standard
value in normal
state

40

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting for E-63 Code [2271/CA2271].

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00551-01

41

SEN00551-01

40 Troubleshooting

E-65 Code [2351/CA2351] EGR Valve Solenoid Current High Error


a

This code applies to only with EGR.


Error code

Failure code

2351

CA2351

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

EGR Valve Solenoid Current High Error

There is short circuit in drive circuit of EGR valve solenoid.


Limits output and continues operation.
Closes EGR valve and bypass valve.
Output drops.

Different machine models may have different connector Nos.

Cause

Standard value in normal state/Remarks on troubleshooting

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective EGR valve solenoid
1
(Internal trouble)
EGR (male)
Resistance
Between (1) (2)

10 21 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Disconnection in wiring harness (Disconnection in wiring Wiring harness between ENG (female)
2
or defective contact in connec- (22) EGR (female) (1)
tor)
Wiring harness between ENG (female) (11)
EGR (female) (2)

Possible causes
and standard
value in normal
state

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3

Wiring harness between ENG (female)


Ground fault in wiring harness
(22) EGR (female) (1) and chassis
(Short circuit with GND circuit)
ground
Wiring harness between ENG (female) (11)
EGR (female) (2) and chassis ground

Resistance

Min.
1 Mz

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
4

Hot short (Short circuit with


24V circuit) in wiring harness

Wiring harness between ENG (female)


(22) EGR (female) (1) and chassis
ground

Voltage

Max. 1 V

Wiring harness between ENG (female) (11)


EGR (female) (2) and chassis ground

Voltage

Max. 1 V

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
5 Defective engine controller

42

ENG (female)

Resistance

Between (22) (11)

10 21 z

125E-5 Series

40 Troubleshooting

SEN00551-01

Circuit diagram related to EGR valve solenoid & lift sensor

Apply wiring harness joint JM04 to only a bypass valve-fitted engine.

125E-5 Series

43

SEN00551-01

40 Troubleshooting

E-66 Code [2352/CA2352] EGR Valve Solenoid Current Low Error


a

This code applies to only with EGR.


Error code

Failure code

2352

CA2352

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

EGR Valve Solenoid Current Low Error

There is disconnection in drive current of EGR valve solenoid.


Limits output and continues operation.
Closes EGR valve and bypass valve.
Output drops.

Related
information
Possible causes
and standard
value in normal
state

44

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting E-65 Code [2351/CA2351].

125E-5 Series

40 Troubleshooting

SEN00551-01

E-67 Code [2555/CA2555] Grid Heater Relay Volt. Low Error


Error code

Failure code

2555

CA2555

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Grid Heater Relay Volt. Low Error

There is disconnection in intake air heater relay.


None in particular.

Engine does not start easily at low temperature.

Related
information
Possible causes
and standard
value in normal
state

125E-5 Series

Cause

Standard value in normal state/Remarks on troubleshooting


Carry out troubleshooting E-68 Code [2556/CA2556].

45

SEN00551-01

40 Troubleshooting

E-68 Code [2556/CA2556] Grid Heater Relay Volt. High Error


Error code

Failure code

2556

CA2556

Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Trouble

Grid Heater Relay Volt. High Error

There is short circuit in intake air heater relay.


None in particular.

Engine does not start easily at low temperature.


Condition for driving heater relay depends on machine.
Different machine models may have different connector Nos.
Cause

Defective intake air heater


relay (Internal trouble)

Standard value in normal state/Remarks on troubleshooting


a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
R18 (male)

Resistance

Between (1) (2)

200 400 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.

Possible causes
and standard
value in normal
state

Disconnection in wiring harness (Disconnection in wiring Wiring harness between E02 (female) (40)
2
or defective contact in connec- R18 (female) (1)
tor)
Wiring harness between E02 (female) (42)
R18 (female) (2)

Resistance

Max. 1 z

Resistance

Max. 1 z

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
3

Ground fault in wiring harness Wiring harness between E02 (female) (40)
(Short circuit with GND circuit) R18 (female) (1) and chassis ground

Resistance

Min.
1 Mz

Wiring harness between E02 (female) (42)


R18 (female) (2) and chassis ground

Resistance

Min.
1 Mz

a Prepare with starting switch OFF, then turn starting switch ON


and carry out troubleshooting.
E02
4 Defective engine controller
Between (40) (42)

46

Heater relay

Voltage

Under operating
condition

Max. 1 V

Under stopping condition

20 30 V

125E-5 Series

40 Troubleshooting

SEN00551-01

Circuit diagram related to intake air heater (Case of PC400/400LC/450/450LC-7E0)

125E-5 Series

47

SEN00551-01

40 Troubleshooting

E-69 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate


Error code

Failure code

(143)

B@BAZG

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Eng. Oil press. Torque Derate

Engine oil pressure is below operating range.


Limits output and continues operation (Limits fuel injection rate and engine speed).

Output drops.

Related
information

Possible causes
and standard
value in normal
state

Causes
1

Standard value in normal state/Remarks on troubleshooting

Carry out troubleshooting on


machine side

This fault is indicated on only machine side when detected.


Accordingly, contents of troubleshooting depends on machine
model. See Shop manual for machine.

E-70 Code [(146)/B@BCNS] Eng. Overheat


Error code

Failure code

(146)

B@BCNS

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Eng. Overheat

Engine coolant temperature is above operating range.


Limits output and continues operation.

Output drops.

Related
information

Possible causes
and standard
value in normal
state

48

Causes
1

Carry out troubleshooting on


machine side

Standard value in normal state/Remarks on troubleshooting


This fault is indicated on only machine side when detected.
Accordingly, contents of troubleshooting depends on machine
model. See Shop manual for machine.

125E-5 Series

40 Troubleshooting

SEN00551-01

E-71 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate


Error code

Failure code

(415)

B@BAZG

Contents of
trouble
Action of
controller
Problem that
appears on
machine

Trouble

Eng. Oil press. Low Speed Derate

Engine oil pressure is below operating range.


Limits output and continues operation (Limits fuel injection rate and engine speed).

Output drops.

Related
information

Possible causes
and standard
value in normal
state

125E-5 Series

Causes
1

Carry out troubleshooting on


machine side

Standard value in normal state/Remarks on troubleshooting


This fault is indicated on only machine side when detected.
Accordingly, contents of troubleshooting depends on machine
model. See Shop manual for machine.

49

SEN00551-01

KOMATSU 125E-5 Series engine


Form No. SEN00551-01

2007 KOMATSU
All Rights Reserved
Printed in Japan 02-07 (01)

50

SEN00549-02

ENGINE
1SHOP MANUAL

125E-5 Series

40 Troubleshooting

Troubleshooting of mechanical system


(S-mode)
Troubleshooting of mechanical system (S-mode)........................................................................................... 4
Method of using troubleshooting charts ............................................................................................... 4
S-1 Starting performance is poor ......................................................................................................... 8
S-2 Engine does not start................................................................................................................... 10
S-3 Engine does not pick up smoothly............................................................................................... 14
S-4 Engine stops during operations ................................................................................................... 15
S-5 Engine does not rotate smoothly ................................................................................................. 16
S-6 Engine lacks output (or lacks power)........................................................................................... 17
S-7 Exhaust smoke is black (incomplete combustion) ....................................................................... 18
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 20
S-9 Oil becomes contaminated quickly .............................................................................................. 21
S-10 Fuel consumption is excessive.................................................................................................. 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 23
S-12 Oil pressure drops ..................................................................................................................... 24

125E-5 Series

SEN00549-02

40 Troubleshooting

S-13 Oil level rises (Entry of coolant or fuel) ...................................................................................... 25


S-14 Coolant temperature becomes too high (overheating) .............................................................. 27
S-15 Abnormal noise is made ............................................................................................................ 28
S-16 Vibration is excessive ................................................................................................................ 29

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00549-02

SEN00549-02

40 Troubleshooting

Troubleshooting of mechanical system (S-mode)

Method of using troubleshooting charts

The troubleshooting chart consists of the questions, check items, causes, and troubleshooting blocks.
The questions and check items are used to pinpoint high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the
most probable one to make final confirmation according to the troubleshooting procedure.
Questions:
Items to be drawn from the user or operator. They correspond to A and B in the chart on the right.
The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their
level.
Check items:
Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the
right.
Causes:
Items to be narrowed from the questions and check items.
The serviceman narrows down the probable causes from A, B, and C.
Troubleshooting:
Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable
one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the causes, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)

125E-5 Series

40 Troubleshooting

125E-5 Series

SEN00549-02

SEN00549-02

40 Troubleshooting

<Example of troubleshooting> Exhaust smoke is black


Let us assume that when Color of exhaust gas is black occurs, the relevant items of [questions] and [check
items] are the following 3 symptoms: [Color of exhaust gas gradually became black], [Power was lost gradually], and [Air cleaner clogging caution lamp is flashing].

125E-5 Series

40 Troubleshooting

SEN00549-02

6 items of [causes] have causal relationship with these 3 items of [questions] and [check items].
Let us explain the method of using this causal relationship in Step 1 to Step 3 in the figure below to narrow
the [causes] to lead to [troubleshooting].

125E-5 Series

SEN00549-02

40 Troubleshooting

S-1 Starting performance is poor

General causes why starting performance is poor


q
Defective electrical system
q
Insufficient supply of fuel
q
Insufficient intake of air
q
Improper selection of fuel
q
Coolant in exhaust pipe ("with EGR" only)
a The common rail fuel injection system (CRI) controls
the fuel injection timing electrically. Accordingly, even
if the starting operation is carried out, the engine may
not start until the crankshaft revolves 2 turns at maximum. This phenomenon does not indicate a trouble,
however.

Clogged air cleaner element


Cracked EGR cooler
(Coolant in exhaust pipe) ["with EGR" only]
Defective contact of valve and valve seat
Worn piston ring, cylinder
Clogged air breather hole of fuel tank cap
Leaking or clogged fuel piping, entry of air
Clogged fuel filter, element
Clogged feed pump gauze filter
Stuck, seized supply pump plunger
Defective injector
Defective intake air heater system
Defective alternator (regulator section)
Defective alternator (generator section)
Defective or deteriorated battery

Causes

Confirm recent repair history

Questions

Degree of use
of machine

E E

Operated for long period

Starting perfor- Became worse gradually


mance
Engine starts easily when warm

E E
w w

Q Q
w

Non-specified fuel is being used

Q Q Q Q

Replacement of filters has not been carried out according to Operation and Mainw
tenance Manual

w w Q Q
w

Oil must be added more frequently


When engine is preheated or when temperature is low, preheating monitor does
not indicate normally (if monitor is installed)

w
w w

During operation, charge level monitor indicates abnormal charge (if monitor is installed)

Dust indicator is red (if indicator is installed)

Air breather hole of fuel tank cap is clogged


Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q Q

w
Q Q

Engine does not pick up smoothly and combustion is irregular

w
Q w Q Q

There is hunting from engine (rotation is irregular)


w
q

When EGR cooler outlet gas piping is removed, coolant containing antifreeze
flows out (*1) ["with EGR" only]

q
q q

When compression pressure is measured, it is found to be low

When air is bled from fuel system, air comes out

Inspect fuel filter, element directly

Inspect feed pump gauze filter directly


Carry out troubleshooting according to No-pressure feed by supply pump (*2) in
E-mode

When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change

q
q

When starting switch is turned to HEAT, intake air heater mount does not become warm

Is voltage 20 30 V between alternator terminal B and terminal E with Yes


engine at low idle?
No

q
q
Replace

Remedy

Clean

When specific gravity of electrolyte and voltage of battery are measured, they are low

Correct
Replace
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Replace
Replace
Replace

Check items

If spill hose from injector is disconnected, little fuel spills

When exhaust manifold is touched immediately after starting engine, temperature


of some cylinders is low

Inspect air cleaner directly

Troubleshooting

w
w w

If air bleeding plug of fuel filter is removed, fuel does not flow out

Blow-by gas is excessive

Starting motor cranks engine slowly


While engine is
cranked with
starting motor,

125E-5 Series

40 Troubleshooting

SEN00549-02

*1: EGR cooler outlet gas piping


Loosen 4 mounting bolts (1) of the EGR cooler
outlet gas piping and check that the coolant
flows out. A little condensate produced from
cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.

*2: Code [559/CA559] and code [2249/CA2249] in


E-mode

125E-5 Series

SEN00549-02

40 Troubleshooting

S-2 Engine does not start

Degree of use of machine

Operated for long period

Condition of horn when


starting switch is turned ON Horn volume is low

Battery electrolyte is low

w
Q

When starting switch is turned to START, starting pinion does not move out

Q
Q

Speed of rotation is low


When starting switch is
turned to START, starting
pinion moves out, but

Defective steering circuit wiring

When starting switch is turned ON, there is no operating sound from battery relay

w
w

Makes grating noise

w
w

Soon disengages again


w

Makes rattling noise and does not turn


When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1)
["with EGR" only].

Q w

q
q

Inspect flywheel ring gear directly

When specific gravity of electrolyte and voltage of battery are measured, they are low
There is not voltage (20 30 V) between battery relay terminal
B and terminal E

When terminal B and terminal C of starting switch are conTurn starting switch OFF,
nected, engine starts
connect cord, and carry out
When terminal B and terminal C at safety relay outlet are controubleshooting at ON
nected, engine starts

q
q

Even if terminal B and terminal C at safety relay outlet are connected, engine does not start
Replace

Replace

Replace

Correct

Replace

Replace

q
Replace

Remedy

10

Defective starting motor (motor section)

Defective starting motor (safety relay section)

Defective starting switch

E E

Horn does not sound

Carry out troubleshooting


on applicable machine side

Check items

Defective battery relay

Confirm recent repair history

Battery terminal is loose

Troubleshooting

Defective connection of battery terminal

Defective or deteriorated battery

Broken flywheel ring gear

Cracked EGR cooler


(Coolant in exhaust pipe) ["with EGR" only]

Causes

Replace

Questions

a) Engine does not turn


General causes why engine does not turn
q
Internal parts of engine seized
o See S-4 Engine stops during operations
q
Water hammer caused by coolant which entered cylinder
q
Defective electrical system
q
Problem in drive devices on applicable machine side
o Requires troubleshooting on applicable machine side.

125E-5 Series

40 Troubleshooting

SEN00549-02

*1: EGR cooler outlet gas piping


Loosen 4 mounting bolts (1) of the EGR cooler
outlet gas piping and check that the coolant
flows out. A little condensate produced from
cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.

125E-5 Series

11

SEN00549-02

40 Troubleshooting

b) Engine turns but no exhaust smoke comes out


General causes why engine turns but no exhaust smoke
comes out
q
Fuel is not being supplied
q
Supply of fuel is extremely small
q
Improper selection of fuel (particularly in winter)

Defective fuel injector

Defective operation of flow damper

Defective operation of overflow valve (Does not close)

Wrong connection of supply pump PCV

Defective supply pump PCV

Stuck, seized supply pump plunger

Broken supply pump shaft, key

Seized, abnormally worn feed pump

Clogged feed pump gauze filter

Clogged fuel filter element

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap

Insufficient fuel in tank

Use of improper fuel

Causes

E E E

Operated for long period

w Q w w w

Exhaust smoke suddenly stopped coming out (when starting again)


Replacement of filters has not been carried out according to Operation and
Maintenance Manual

Q Q Q

Q Q

Air breather hole of fuel tank cap is clogged


Rust and water are found when fuel tank is drained
w

When fuel filter is removed, there is not fuel in it


Check items

When fuel tank is inspected, it is found to be empty

Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q Q

If air bleeding plug of fuel filter is removed, fuel does not


While engine is
cranked with starting flow out
motor,
If spill hose from injector is disconnected, little fuel spills

w Q

w w w w

q q

When air is bled from fuel system, air comes out

Inspect fuel filter directly


Troubleshooting

w w

E E

Inspect feed pump gauze filter directly

Inspect feed pump directly


Carry out troubleshooting according to No-pressure feed by supply pump (*1)
in E-mode
Carry out troubleshooting according to Abnormality in PCV1 (*2) or Abnormality
in PCV2 (*3) in E-mode

q
q
q

Inspect overflow valve directly

q q
Correct

Replace

Replace

Replace

Replace

Replace

Clean

Replace

Correct

Correct

Add

Remedy

Replace

Engine can be started in reduced cylinder mode

Replace

Degree of use of
machine

Replace

Questions

Confirm recent repair history

*1: Code [559/CA559] and code [2249/CA2249] in E-mode


*2: Code [271/CA271] and code [272/CA272] in E-mode
*3: Code [273/CA273] and code [274/CA274] in E-mode

12

125E-5 Series

40 Troubleshooting

SEN00549-02

c) Exhaust smoke comes out but engine does not start


(fuel is being injected)
General causes why exhaust smoke comes out but engine
does not start
q
Lack of rotating force due to defective electrical system
q
Insufficient supply of fuel
q
Insufficient intake of air
q
Improper selection of fuel

Defective intake air heater system

Defective coolant temperature sensor, wiring harness

Defective, deteriorated battery

Clogged injector, defective spray

Stuck, seized supply pump plunger

Clogged feed pump gauze filter

Clogged fuel filter, strainer

Leaking or clogged fuel system, entry of air

Clogged air breather hole of fuel tank cap

Use of improper fuel

Worn piston ring, cylinder liner

Worn dynamic valve system (Valve, rocker lever, etc.)

Clogged air cleaner element

Causes

Confirm recent repair history


E

Operated for long period

E E

Suddenly failed to start

E
w

Q Q

Non-specified fuel is being used


Replacement of filters has not been carried out according to Operation and Maintew
nance Manual

w w
w

Oil must be added more frequently


When engine is preheated or when temperature is low, preheating monitor does not
indicate normally (if monitor is installed)

w
w

Dust indicator is red (if indicator is installed)

Air breather hole of fuel tank cap is clogged

w w

Rust and water are found when fuel tank is drained


w

When fuel filter is removed, there is not fuel in it


Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q Q
w

Check items

Starting motor cranks engine slowly


w

When engine is cranked, abnormal sound is generated around cylinder head


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

When exhaust manifold is touched immediately after starting engine, temperature of


some cylinders is low

w
q

Inspect air cleaner directly

Inspect dynamic valve system directly

When compression pressure is measured, it is found to be low


Troubleshooting

w w

When air is bled from fuel system, air comes out

Inspect fuel filter, strainer directly

Inspect feed pump gauze filter directly


Carry out troubleshooting according to No-pressure feed by supply pump (*1) in Emode

q
q

When injector unit is tested, spray condition is bad

When specific gravity of electrolyte and voltage of battery are measured, they are low
Coolant temperature gauge does not indicate normally (if coolant temperature
gauge is installed)

q
q
Replace

Replace

Replace

Replace

Clean

Clean

Correct

Clean

Replace

Replace

Clean

Remedy

Replace

When starting switch is turned to HEAT, intake air heater mount does not become warm

Replace

Questions

Degree of use of
machine

*1: Code [559/CA559] and code [2249/CA2249] in E-mode


125E-5 Series

13

SEN00549-02

40 Troubleshooting

S-3 Engine does not pick up smoothly

General causes why engine does not pick up smoothly


Insufficient intake of air
q
Insufficient supply of fuel
q
Defective condition of fuel spray
q
Improper selection of fuel
q
Controller is controlling in derate mode
(limiting injection rate (output) because of an error in
electrical system)
q
EGR valve is stuck open ["with EGR" only]
(There is much EGR gas and intake of air is insufficient)

Clogged injector, defective spray

Defective EGR valve or bypass valve


["with EGR" only]
E

Defective operation of flow damper


(Large leakage from injector)

Clogged air cleaner element


E

Defective contact of valve and valve seat


Improper valve clearance
Seized turbocharger, interference of turbocharger
Worn piston ring, cylinder liner
Clogged air breather hole of fuel tank cap
Leaking or clogged fuel piping, entry of air
Clogged fuel filter, strainer
Clogged feed pump gauze filter
Stuck, seized supply pump plunger

Causes

Operated for long period

Engine pick-up suddenly became worse

E E
Q Q

Q
w w w

Non-specified fuel is being used


Replacement of filters has not been carried out according to Operation and
Maintenance Manual

w w
w

Oil must be added more frequently


w

Dust indicator is red (if indicator is installed)

Air breather hole of fuel tank cap is clogged

w w

Rust and water are found when fuel tank is drained


Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q Q

Check items

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Color of exhaust gas

Blue under light load


w

Black

When engine is cranked, abnormal sound is generated around cylinder head

When engine is cranked, interference sound is generated around turbocharger


High idle speed under no load is normal, but speed suddenly drops when load is
applied
There is hunting from engine (rotation is irregular)

w w

Q w

w w

Blow-by gas is excessive


q

Inspect air cleaner directly


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

q
q

When compression pressure is measured, it is found to be low

q
q

Inspect valve clearance directly

When turbocharger is rotated by hand, it is found to be heavy

When air is bled from fuel system, air comes out

Inspect fuel filter, strainer directly

Inspect feed pump gauze filter directly


Carry out troubleshooting according to No-pressure feed by supply pump (*2)
in E-mode

Replace
Adjust
Replace
Replace
Clean
Correct
Clean
Clean
Replace

Replace

Remedy

Clean

When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change

q
Replace

Degree of use of machine

Replace

Questions

Confirm recent repair history

*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in
E-mode
*2: Code [559/CA559] and code [2249/CA2249] in E-mode

14

125E-5 Series

40 Troubleshooting

SEN00549-02

S-4 Engine stops during operations

General causes why engine stops during operations


q
Seized parts inside engine
q
Insufficient supply of fuel
q
There is overheating
q
Problem in drive devices on applicable machine
side
o Requires troubleshooting on applicable
machine side.

Problem in drive devices on applicable machine side

Broken dynamic valve system (valve, rocker arm, etc.)


Broken, seized piston, connecting rod
Broken, seized crankshaft bearing
Broken, seized gear train
Insufficient fuel in tank
Clogged air breather hole of fuel tank cap
Leaking, clogged fuel piping
Clogged fuel filter, strainer
Clogged feed pump gauze filter
Broken, seized feed pump
Broken supply pump shaft, key
Stuck, seized supply pump plunger
Broken auxiliary equipment (pump, compressor, etc.)
Defective engine controller power supply wiring
Defective starting switch wiring

Causes

Confirm recent repair history


E E

Degree of use of machine Operated for long period

Questions

Abnormal noise was heard and engine


stopped suddenly
Condition when engine
stopped

w w w w
w Q

Engine overheated and stopped

Q
w

Q Q

Q Q

There was hunting and engine stopped

w Q

Q Q Q

Q Q

Non-specified fuel is being used

Q Q Q

Replacement of filters has not been carried out according to Operation


and Maintenance Manual

w w

Fuel level monitor indicates low level (if monitor is installed)

When fuel tank is inspected, it is found to be empty

Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q Q
w w

Rust and water are found when fuel tank is drained


w w w

Metal particles are found when oil is drained

w w

Does not turn at all


When engine is cranked
by hand

Engine stopped slowly

Air breather hole of fuel tank cap is clogged

Check items

Q w Q w

Turns in opposite direction

Moves by amount of gear backlash

w
w

Supply pump shaft does not turn

Engine turns, but stops when load is applied to machine


q

Inspect dynamic valve system directly

Inspect piston, connecting rod directly

Inspect gear train directly

Inspect fuel filter, strainer directly

Inspect feed pump gauze filter directly

Inspect feed pump directly


Carry out troubleshooting according to No-pressure feed by supply
pump (*1) in E-mode
Engine rotates when pump auxiliary equipment (pump, compressor, etc.)
is removed

q q
q
q

Inspect controller power supply wiring

Inspect starting switch wiring


Remedy

Replace
Replace
Replace
Replace
Add
Clean
Correct
Clean
Clean
Replace
Replace
Replace
Replace
Correct
Correct

Troubleshooting

Carry out troubleshooting


on applicable machine side

Inspect crankshaft bearing directly

*1: Code [559/CA559] and code [2249/CA2249] in E-mode


125E-5 Series

15

SEN00549-02

40 Troubleshooting

S-5 Engine does not rotate smoothly

General causes why engine does not rotate smoothly


q
Air in fuel system
q
Defective speed sensor
(Error at degree that it is not indicated)
q
Defective EGR valve ["with EGR" only]
q
Defective bypass valve ["with EGR" only]

Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness

Clogged injector, defective spray (dirt in injector)

Defective operation of flow damper (Large leakage from injector)

Clogged fuel filter, strainer

Clogged feed pump gauze filter

Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap

Insufficient fuel in tank

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

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

Low setting of low idle speed

Causes

Confirm recent repair history

Condition of hunting

E E

Operated for long period


Occurs at a certain speed range

Q Q Q

Occurs at low idle

E E
Q Q
Q Q Q Q Q Q Q

Q Q

Occurs even when speed is raised

Q Q

Occurs on slopes

Q Q

Replacement of filters has not been carried out according to Operation and Maintenance Manual

w w
w

Check items

When fuel tank is inspected, it is found to be empty

Air breather hole of fuel tank cap is clogged

Q Q

Rust and water are found when fuel tank is drained


Fuel is leaking from fuel piping

When priming pump is operated, it makes no reaction or it is heavy

w Q Q

Troubleshooting

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

Carry out troubleshooting according to Abnormality in bypass valve servo (*2) in Emode ["with EGR" only]

q
q

When air is bled from fuel system, air comes out

Inspect feed pump gauze filter directly

Inspect fuel filter, strainer directly


When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change

q q

Carry out troubleshooting according to Abnormality in engine Ne speed sensor (*3) in


E-mode

Carry out troubleshooting according to Abnormality in engine Bkup speed sensor (*4)
in E-mode

*1: Code
*2: Code
*3: Code
*4: Code

16

Correct

Replace

Replace

Replace

Replace

Correct

Clean

Add

Replace

Replace

Correct

Remedy

q
Correct

Questions

Degree of use of machine

[1228/CA1228] and code [1625/CA1625] in E-mode


[1628/CA1628] and code [1629/CA1629] in E-mode
[689/CA689] in E-mode
[778/CA778] in E-mode

125E-5 Series

40 Troubleshooting

SEN00549-02

S-6 Engine lacks output (or lacks power)


General causes why engine lacks output
q
Insufficient intake of air
q
Insufficient supply of fuel
q
Defective spray condition of fuel
q
Improper selection of fuel
q
There is overheating
o See S-14 Coolant temperature becomes
too high (Overheating)
q
Controller is controlling in derate mode
(limiting injection rate (output) because of an
error in electrical system)

1
Defective charge pressure sensor, wiring harness

Defective fuel temperature sensor, wiring harness

Defective installation of charge pressure sensor


(air leakage)

Defective drive of injector (signal, solenoid)

Clogged injector, defective spray (dirt in injector)

Stuck, seized supply pump plunger

Clogged feed pump gauze filter

Clogged fuel filter, strainer

Leaking, clogged fuel piping

Clogged air breather hole of fuel tank cap

Worn piston ring, cylinder liner

Improper valve clearance

Defective contact of valve and valve seat

Seized turbocharger, interference of turbocharger

Air leakage from air intake piping

Clogged air cleaner element

Causes

Confirm recent repair history

Power was lost

Operated for long period

E E

Q Q

Suddenly

Gradually

Q Q

Non-specified fuel is being used


Replacement of filters has not been carried out according to Operation and
Maintenance Manual

w
Q Q Q

Oil must be added more frequently


w

Dust indicator is red (if indicator is installed)

Air breather hole of fuel tank cap is clogged

Fuel is leaking from fuel piping

Output becomes insufficient after short stop of operation


Color of exhaust gas color

w w w

Black

Blue under light load

Check items

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

w
w

When engine is cranked, interference sound is generated around turbocharger

When engine is cranked, abnormal sound is generated around cylinder head

High idle speed is too low


High idle speed under no load is normal, but speed suddenly drops when load is
applied

w w Q
w

Engine does not pick up smoothly and combustion is irregular

Q Q
w

Blow-by gas is excessive

Inspect air cleaner directly

Inspect air intake piping directly

q q q

When boost pressure is measured, it is found to be low

When compression pressure is measured, it is found to be low

q
q

Inspect valve clearance directly


Troubleshooting

Q Q Q Q

There is hunting from engine (rotation is irregular)

Inspect fuel filter, strainer directly

Inspect feed pump gauze filter directly


Carry out troubleshooting according to No-pressure feed by supply pump (*1)
in E-mode

When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change

q q
q

Inspect charge pressure sensor mount directly


Carry out troubleshooting according to Abnormality in charge pressure sensor
(*2) in E-mode

Carry out troubleshooting according to Abnormality in fuel temperature sensor


(*3) in E-mode
Replace

Correct

Replace

Replace

Replace

Clean

Correct

Replace

Clean

Replace

Adjust

Replace

Replace

Clean

Correct

Remedy

q
Replace

Questions

Degree of use of machine

*1: Code [559/CA559] and code [2249/CA2249] in E-mode


*2: Code [122/CA122] and code [123/CA123] in E-mode
*3: Code [263/CA263] and code [265/CA265] in E-mode
125E-5 Series

17

SEN00549-02

40 Troubleshooting

S-7 Exhaust smoke is black (incomplete combustion)

Defective coolant temperature sensor, wiring harness

Improper fuel injection pressure

Improper injection timing

Clogged fuel spill piping (on cylinder head side)

Abnormally worn injector

Clogged, seized injector

Stuck, seized supply pump plunger

Worn piston ring, cylinder liner

Crushed, clogged muffler

Leakage of air between turbocharger and cylinder head

Improper valve clearance

Defective contact of valve and valve seat

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

Defective EGR valve or bypass valve ["with EGR" only]

Seized turbocharger, interference of turbocharger

Causes

Clogged air cleaner element

General causes why exhaust smoke is black


q
Insufficient intake of air
q
Excessive injection of fuel
q
Defective condition of fuel injection
q
Improper selection of fuel
q
There is overheating
o See S-14 Coolant temperature becomes too high
(Overheating)
q
Controller is controlling in derate mode (limiting
injection rate (output) because of an error in electrical system)
q
EGR valve is stuck open ["with EGR" only] (There is
much EGR gas and intake of air is insufficient)
q
EGR gas piping is clogged ["with EGR" only] (Entry
of exhaust gas into air intake at acceleration or
deceleration)

Confirm recent repair history


Operated for long period

Suddenly became black


Color of exhaust gas
Gradually became black
color
Blue under light load

w Q Q

Q Q

Q Q
w
Q Q

Non-specified fuel is being used


w

Oil must be added more frequently


Power was lost

Suddenly

Gradually

Q Q
Q

Dust indicator is red (if indicator is installed)

Muffler is crushed
w

Air leaks between turbocharger and cylinder head, clamp is loosened

Q Q Q

Engine is operated in low-temperature mode at normal temperature

Check items

When exhaust manifold is touched immediately after starting engine, temperature of


some cylinders is low

Q w
w

When engine is cranked, interference sound is generated around turbocharger

When engine is cranked, abnormal sound is generated around cylinder head


Torque converter stall speed or pump relief speed is high (Fuel is injected excessively)

Q Q

Exhaust noise is abnormal

Engine does not pick up smoothly and combustion is irregular

Q Q

Blow-by gas is excessive

Q Q Q

Q w
w
w

If spill hose from injector is disconnected, abnormally much fuel spills


q

Inspect air cleaner directly

When turbocharger is rotated by hand, it is fount to be heavy

Troubleshooting

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

q
q

Inspect EGR gas piping directly (*2) ["with EGR" only]

When compression pressure is measured, it is found to be low

q
q

Inspect valve clearance directly

When muffler is removed, exhaust color improves


Carry out troubleshooting according to No-pressure feed by supply pump (*3) in Emode

When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change

q
q
q

Inspect fuel spill piping (on cylinder head side) directly


Carry out troubleshooting according to Abnormality in coolant temperature sensor
(*4) in E-mode

18

Adjust

Adjust

Correct

Replace

Replace

Replace

Replace

Replace

Adjust

Correct

Replace

Replace

Replace

Clean

Replace

Remedy

q
Replace

Questions

Degree of use of
machine

125E-5 Series

40 Troubleshooting

SEN00549-02

*1: Code [1228/CA1228] and code [1625/CA1625] or code [1628/CA1628] and code [1629/CA1629] in Emode
*2: EGR gas piping
Remove EGR gas piping (1) and confirm for internal clogging

*3: Code [559/CA559] and code [2249/CA2249] in E-mode


*4: Code [144/CA144] and code [145/CA145] in E-mode

125E-5 Series

19

SEN00549-02

40 Troubleshooting

S-8 Oil consumption is excessive (or exhaust smoke is blue)


General causes why oil consumption is excessive
q
Abnormal consumption of oil
q
Long-time operation of engine at low idle or high
idle (Do not run engine at idle for more than 20
minutes continuously)
q
External leakage of oil
q
Wear of parts in lubrication system

Oil leakage from oil pan, cylinder head, etc.

Oil leakage from oil drain plug

Oil leakage from oil piping

Oil leakage from oil filter

Oil leakage from oil cooler

Broken oil cooler

Worn, damaged rear oil seal

Worn piston ring, cylinder liner

Broken piston ring

Clogged breather, breather hose

Oil leakage from EGR valve stem ["with EGR" only]

Turbocharger
Worn seal at blower side

Worn seal at turbine side

Worn, damaged valve (stem, guide, seal)

Dust sucked in from intake system

Causes

E E E E

Operated for long period

E
w

Oil consumption suddenly increased


Q

Oil must be added more frequently

Q
w

Q Q w

Oil becomes contaminated quickly

w w w w w

Outside of engine is dirty with oil


w

There are loose piping clamps in intake system

w
Q w

Inside of turbocharger exhaust outlet pipe is dirty with oil

There is oil in coolant


w

Oil level in clutch chamber or damper chamber is high


Q

Exhaust smoke is blue under light load

None
q

When intake manifold is removed, dust is found inside

When intake manifold is removed, inside is found to be dirty abnormally


Troubleshooting

w w

q q

Excessive play of turbocharger shaft


When EGR valve is removed, exhaust port is found to be dirty with oil ["with
EGR" only]

q
q

Inspect breather and breather hose directly

q q

When compression pressure is measured, it is found to be low

Inspect rear oil seal directly

q q

Pressure-tightness test of oil cooler shows there is leakage

q q q q

20

Replace

Replace

Replace

Replace

Replace

Clean

Replace

Replace

Replace

Correct

Remedy

Replace

There is external leakage of oil from engine

Correct

Amount of blow-by gas

w w

Q Q Q

Excessive

Correct

Check items

Inside of turbocharger intake outlet pipe is dirty with oil

Correct

Degree of use of
machine

Correct

Questions

Confirm recent repair history

125E-5 Series

40 Troubleshooting

SEN00549-02

S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly


q
Entry of exhaust gas into oil due to internal wear
q
Clogging of lubrication passage
q
Use of improper fuel
q
Use of improper oil
q
Operation under excessive load

Exhaust smoke is bad

Clogged turbocharger lubrication drain tube

Defective oil filter safety valve

Clogged oil filter

Clogged oil cooler

Clogged breather, breather hose

Worn piston ring, cylinder liner

Worn valve, valve guide

Worn EGR valve guide ["with EGR" only]

Defective seal at turbocharger turbine side

Causes

E E E E

Degree of use of machine Operated for long period

Non-specified fuel is being used


Q

Oil must be added more frequently

Even when engine oil temperature rises, oil filter clogging monitor indicates clogging
(if monitor is installed)

w Q

Metal particles are found when oil filter is drained

Q Q

Inside of exhaust pipe is dirty with oil

w
w

Color of exhaust gas


Amount of blow-by gas

Blue under light load

Black
Q

Excessive

None
q

Excessive play of turbocharger shaft


Troubleshooting

Q w

When EGR valve is removed, exhaust port is found to be dirty with oil ["with EGR" only]

q q

When compression pressure is measured, it is found to be low

See S-7.

Check items

Engine oil temperature rises quickly

Inspect breather and breather hose directly

Inspect oil cooler directly

Inspect oil filter directly

Spring of oil filter safety valve is hitched or broken

125E-5 Series

Replace

Replace

Replace

Clean

Replace

Replace

Replace

Remedy

Replace

Inspect turbocharger lubrication drain tube directly

Clean

Questions

Confirm recent repair history

21

SEN00549-02

40 Troubleshooting

S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive


q
Leakage of fuel
q
Defective condition of fuel injection (fuel pressure, injection timing)
q
Excessive injection of fuel

Defective coolant temperature sensor, wiring harness

Improper injection timing

Defective operation of injector

Defective spray by injector

Defective common rail pressure

Defective supply pump plunger

Defective feed pump oil seal

Fuel leakage from fuel filter, piping, etc.

Fuel leakage inside head cover

Causes

E E

Operated for long period

More than for other machines of same model


Condition of fuel
consumption

Gradually increased
Q Q

Suddenly increased

There is external leakage of fuel from engine

Combustion is irregular
w

When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low

w w
Q

Low idle speed is high

Torque converter stall speed or pump relief speed is high


Color of exhaust
gas

Q Q

Black

Q Q

White

Remove and inspect head cover directly

Inspect feed pump oil seal directly

Carry out troubleshooting according to No-pressure feed by supply pump (*1) in E-mode

q q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change

If spill hose from injector is disconnected, much fuel spills

Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) in E-mode
Correct

Replace

Replace

Correct

Correct

Remedy

q
Replace

Confirm with INSITE or with monitoring function on applicable machine side

Replace

Check items

Engine oil level rises and oil smells of diesel fuel

Troubleshooting

Q Q Q
Q

Correct

Degree of use of
machine

Replace

Questions

Confirm recent repair history

*1: Code [559/CA559] and code [2249/CA2249] in E-mode


*2: Code [144/CA144] and code [145/CA145] in E-mode

22

125E-5 Series

40 Troubleshooting

SEN00549-02

S-11 Oil is in coolant (or coolant spurts back or coolant level goes
down)
General causes why oil is in coolant
q
Internal leakage in lubrication system
q
Internal leakage in cooling system

1
Broken hydraulic oil cooler or power train oil cooler
on applicable machine side

Broken oil cooler core, O-ring

Insufficient protrusion of cylinder liner

Damaged cylinder liner O-ring, hole caused by pitting

Cracks inside cylinder block

Broken cylinder head, head gasket

Causes

Degree of use of
machine
Oil level

Operated for long period


Q

Suddenly increased

Oil level has risen and oil is milky


Check
items

Q Q

Gradually increased

Q Q

Hard water is being used as coolant


w

There are excessive air bubbles in radiator, coolant spurts back

Hydraulic oil or power train oil on applicable machine side is milky

When hydraulic oil or power train oil is drained, water is found

w
q

Pressure-tightness test of cylinder head shows there is leakage


Troubleshooting

q q

Inspect cylinder block, liner directly

Inspect cylinder liner directly

125E-5 Series

Replace

Replace

Replace

Remedy

Replace

Pressure-tightness test of oil cooler shows there is leakage

Replace

Questions

Confirm recent repair history

Carry out
troubleshooting
on applicable
machine side

23

SEN00549-02

40 Troubleshooting

S-12 Oil pressure drops

General causes why oil pressure drops


q
Leakage, clogging, wear or lubrication system
q
Defective oil pressure control
q
Selection of oil by the temperature etc. specified in the
Operation and Maintenance Manual is not observed
q
Deterioration of oil due to overheating

Defective oil level sensor, wiring harness

Defective oil pressure sensor, wiring harness

Leaking EGR hydraulic piping ["with EGR" only]

Defective EGR oil pump ["with EGR" only]

Leaking, crushed, clogged hydraulic piping

Clogged oil filter

Defective oil pump relief valve

Defective oil pump

Clogged, broken pipe in oil pan

Clogged strainer in oil pan

Coolant, fuel in oil

Lack of oil in oil pan

Worn journal of bearing

Causes

Degree of use of
machine

Operated for long period

E
Q w

Oil pressure monitor indicates low oil pressure (if monitor is installed)
Q

Non-specified oil is being used

Replacement of filters has not been carried out according to Operation and Maintenance Manual

w
w

Indicates pressure drop at low idle

Q
Q

Oil pressure monitor Indicates pressure drop at low, high idle


(if installed)
Indicates pressure drop on slopes

Check items

w w w Q

Q Q

w
w

Sometimes indicates pressure drop


Oil level monitor indicates oil level drop (if monitor is installed)

Oil level in oil pan is low

Q Q
w
w

External hydraulic piping is leaking, crushed

Oil is milky or smells of diesel oil


Metal particles are found when oil pan is drained

Metal particles are found when oil filter is drained

Metal particles are found in oil filter

q q

Inspect oil pan strainer, pipe directly

Oil pump rotation is heavy, there is play in oil pump


Valve and spring of oil pump relief valve are fatigued, damaged

See SI13.

Troubleshooting

Inspect oil filter directly


Relief valve of EGR oil pump is damaged, oil leaks from it ["with EGR" only]

q
q
q

Inspect EGR hydraulic piping directly ["with EGR" only]


Carry out troubleshooting according to Abnormality in oil pressure sensor (*1) in Emode

q
q
Replace

Replace

Replace

Correct

Replace

Replace

Replace

Clean

Clean

Add

Remedy

Replace

If oil level sensor is replaced, oil pressure monitor indicates normally

Replace

Questions

Confirm recent repair history

*1: Code [135/CA135] and code [141/CA141] in E-mode

24

125E-5 Series

40 Troubleshooting

SEN00549-02

S-13 Oil level rises (Entry of coolant or fuel)

Questions

General causes why oil level rises


q
Coolant in oil (milky)
q
Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for S-11 Oil is in
coolant

Defective seal of auxiliary equipment (pump, compressor)

Defects in supply pump

Clogged water pump drain hole (breather hole), defective seal

Broken oil cooler core, O-ring

Worn, damaged rear oil seal

Damaged cylinder liner O-ring, holes caused by pitting

Cracks inside cylinder block

Confirm recent repair history


Degree of use of machine

E E

Operated for long period

Fuel must be added more frequently

E
w

Q Q

Coolant must be added more frequently

There is oil in coolant

Q Q

Oil smells of diesel fuel

Check items

Fuel leakage inside head cover

Broken cylinder head, head gasket

Cracked EGR cooler (Entry of coolant) [with EGR only]

Causes

Oil is milky

Q Q

When engine is started, drops of water come from muffler

Q Q

When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appear, or coolant spurts back

w
Q

Q
Q

Exhaust smoke is white

Water pump drain hole (breather hole) is clogged

When water pump drain hole (breather hole) is cleaned, coolant comes out
w

Oil level in clutch or damper chamber of machine is low

Oil level in hydraulic tank of machine is low

When compression pressure is measured, it is found to be low

Remove and inspect head cover directly

q q

Inspect cylinder block, liner directly

Inspect rear oil seal directly

Pressure-tightness test of oil cooler shows there is leakage

Remove and inspect water pump directly

Remove and inspect supply pump directly

125E-5 Series

Replace

Replace

Replace

Replace

Replace

Replace

Correct

Replace

Remedy

Replace

Inspect seal of auxiliary equipment directly

Replace

Troubleshooting

When EGR cooler outlet gas piping is removed, coolant containing antifreeze flows out (*1) q
[with EGR only]

25

SEN00549-02

40 Troubleshooting

*1: EGR cooler outlet gas piping


Loosen 4 mounting bolts (1) of the EGR cooler
outlet gas piping and check that the coolant
flows out. A little condensate produced from
cooled exhaust gas may flow out. If it is colorless and transparent, however, it is not a problem.

26

125E-5 Series

40 Troubleshooting

SEN00549-02

S-14 Coolant temperature becomes too high (overheating)


General causes why coolant temperature becomes too
high
q
Lack of cooling air (deformation, damage of fan)
q
Drop in heat dissipation efficiency
q
Problem in coolant circulation system
q
Rise in oil temperature in power train
o Carry out troubleshooting on applicable machine
side

Rise in power train oil temperature on applicable


machine side

Defective coolant temperature gauge

Slipping fan belt, worn fan pulley

Defective radiator cap (pressure valve)

Clogged radiator core

Clogged, crushed radiator fins

Defective operation of thermostat

Broken water pump

Lack of coolant

Clogged, broken oil cooler

Damaged cylinder liner O-ring, hole caused by pitting

Broken cylinder head, head gasket

External leakage of coolant from EGR cooler ["with EGR" only]

Causes

Questions

Confirm recent repair history


Degree of use of machine
Condition of overheating

Operated for long period

E E E

Suddenly overheated

E E
Q w

Q
Q w w

Always tends to overheat


Q

Coolant temperature gauge Rises quickly


(if installed)
Does not go down from red range

w
w

Radiator coolant level monitor indicates drop of coolant level (if monitor is
installed)

w
w Q

Engine oil level has risen, oil is milky

Fan belt tension is low


w

When fan pulley is turned, it has play


w

Milky oil is floating on coolant


w

Check items

There are excessive air bubbles in radiator, coolant spurts back


When light bulb is held behind radiator core, no light passes through

Radiator shroud, inside of underguard on applicable machine side are clogged


with dirt or mud

Coolant is leaking because of cracks in hose or loose clamps

Coolant flows out from radiator overflow hose

Fan belt whines under sudden acceleration


Power train oil temperature enters red range faster than engine coolant temperature (if oil temperature gauge and coolant temperature gauge are installed)

w
q

Inspect EGR cooler for coolant leakage ["with EGR" only]

Inspect cylinder liner directly

Inspect oil cooler directly

Temperature difference between upper and lower tanks of radiator is large


When operation of thermostat is carried out, it does not open at cracking temperature

q
q

Temperature difference between upper and lower tanks of radiator is slight

Inspect radiator core directly

When operation of radiator cap is carried out, its cracking pressure is low

Inspect fan belt, pulley directly

125E-5 Series

Replace

Replace

Correct

Correct

Replace

Replace

Add

Replace

Replace

Replace

Remedy

Replace

When coolant temperature is measured, it is found to be normal

Replace

Troubleshooting

Carry out troubleshooting


on applicable machine side

When compression pressure is measured, it is found to be low

27

SEN00549-02

40 Troubleshooting

S-15 Abnormal noise is made

General causes why abnormal noise is made


q
Abnormality due to defective parts
q
Abnormal combustion
q
Air sucked in from intake system
a Judge if the noise is an internal noise or an external
noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
engine sound becomes a little larger. This does not
indicate abnormality, however.
a When the engine is accelerated, it is operated in the
acceleration mode and its sound becomes a little
larger for up to about 5 seconds. This does not indicate abnormality, however.

Improper fuel injection timing


(abnormality in coolant temperature sensor)

Dirt caught in injector

Clogged, seized injector

Deformed cooling fan, loose fan belt, interference of fan belt

Removed, seized gear train bushing

Improper gear train backlash

Excessive wear of piston ring, cylinder liner

Improper valve clearance

Defective inside of muffler (dividing board out of position)

Broken dynamic valve system (valve, rocker lever)

Cracked, leaking EGR gas piping ["with EGR" only]

Interference of turbocharger, seized turbocharger

Leakage of air between turbocharger and cylinder head

Causes

Degree of use of machine Operated for long period


Abnormal noise

Gradually occurred

Q
Q

Non-specified fuel is being used


Oil must be added more frequently

Metal particles are found when oil filter is drained

Air leaks between turbocharger and cylinder head

When engine is cranked, interference sound is generated around turbocharger


When engine is cranked, abnormal sound is generated around EGR gas piping
["with EGR" only]

w
w

When engine is cranked, abnormal sound is generated around cylinder head


Check items

Q Q Q

Suddenly occurred

w
w

When engine is cranked, beat noise is generated around muffler


When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Color of exhaust gas

w Q
w

Blue under light load


Q w

Black

Q
w

Engine does not pick up smoothly and combustion is irregular


Q

Abnormal noise is loud when engine is accelerated


Blow-by gas is excessive

When turbocharger is rotated by hand, it is fount to be heavy

Q Q

w
q

Inspect EGR gas piping directly ["with EGR" only]

Inspect dynamic valve system directly


Troubleshooting

When muffler is removed, abnormal noise disappears

Inspect valve clearance directly

When compression pressure is measured, it is found to be low

q q

Inspect gear train directly

Inspect fan and fan belt directly


When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change

q q
q

Abnormal noise is heard only when engine is started

28

Replace

Replace

Correct

Replace

Replace

Replace

Adjust

Replace

Replace

Replace

Replace

Remedy

Replace

Confirm with INSITE or with monitoring function on applicable machine side

Correct

Questions

Confirm recent repair history

125E-5 Series

40 Troubleshooting

SEN00549-02

S-16 Vibration is excessive

General causes why vibration is excessive


q
Defective parts (abnormal wear, breakage)
q
Misalignment between engine and chassis
q
Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out troubleshooting for S-15 Abnormal noise is made, too.

Broken output shaft, parts in damper on applicable machine side

Worn front support spigot joint portion

Misalignment between engine and devices on applicable machine side

Loose engine mounting bolts, broken cushions

Worn camshaft bushing

Improper gear train backlash

Worn main bearing, connecting rod bearing

Stuck dynamic valve system (valve, rocker lever)

Causes

Degree of use of machine


Condition of vibration

Operated for long period

E E

Suddenly increased

Q
Q

Q Q

Non-specified fuel is being used

Metal particles are found when oil filter is drained

Metal particles are found when oil pan is drained

Oil pressure is low at low idle

Gradually increased

Vibration occurs at mid-range speed


Q

Vibration follows engine speed


Exhaust smoke is black

Inspect dynamic valve system directly

Q Q Q Q

Inspect main bearing and connecting rod bearing directly

Inspect gear train directly

Inspect camshaft bushing directly

Inspect engine mounting bolts and cushions directly

When alignment is checked, radial runout or facial runout is detected

Inspect front support spigot joint portion directly

125E-5 Series

Replace

Adjust

Replace

Replace

Replace

Replace

Remedy

Replace

Inspect output shaft or inside of damper directly

Replace

Troubleshooting

Check items

Questions

Confirm recent repair history

29

SEN00549-02

KOMATSU 125E-5 Series engine


Form No. SEN00549-02

2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)

30

SEN00697-03

ENGINE
1SHOP MANUAL

125E-5 Series

50 Disassembly and assembly


General information on disassembly and
assembly
General information on disassembly and assembly ....................................................................................... 2
How to read this manual ...................................................................................................................... 2
Coating materials list............................................................................................................................ 4
Special tools list.................................................................................................................................... 7

125E-5 Series

SEN00697-03

50 Disassembly and assembly

General information on disassembly and assembly


How to read this manual
1.

1
(Rev. 2009.01)
1

Removal and installation of assemblies


Special tools
q
Special tools which are necessary for
r e mo v a l or i n s ta l l at i o n o f pa r ts a r e
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used
q : Special tools that will be useful if available and are substitutable with tools
available on the market
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
79 T:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).

* *** ****

Removal
q
In Removal section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not
described.
q
Various symbols used in Removal section are
explained and listed below.
k : Precautions related to work safety
a : Guidance or precautions for the work
[*1] : This mark shows that instructions or precautions for parts installation work are given in
Installation section.
6 : Amount of oil or coolant to be drained
4:

Weight of part or component

Installation
q
Unless otherwise instructed, installation of
parts is to be done in the reverse order to
removal.
q
Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which
corresponds to the mark in Removal section.
q
Common tools that are necessary for installation are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
Marks shown in the Installation section stand
for the following.
k

: Precautions related to work safety


: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque

: Amount of oil or coolant to be replenished

Sketches of special tools


q
Various special tools are illustrated for the local
manufacture.

125E-5 Series

50 Disassembly and assembly

2.

SEN00697-03

Disassembly and assembly of assemblies


Special tools
q
Special tools which are necessary for disassembly and assembly of parts are
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) Necessity
t : Special tools that cannot be substituted and should always be used.
q : Special tools that will be useful if available and are substitutable with tools
available on the market.
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
R:
Tools made available by redesigning the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
79 T:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).

* *** ****

Disassembly
q
In Disassembly section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for disassembly are described as [1], [2] etc. and
their part numbers, part names and quantities
are not described.
q
The meanings of the symbols used in Disassembly section are as follows.
k

: Precautions related to work safety


: Guidance or precautions for the work
6 : Amount of oil or coolant drained

Assembly
q
In Assembly section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be replenished
are described.
q
Common tools that are necessary for assembly are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
The meanings of the symbols used in Assembly section are as follows.
k

: Precautions related to work safety


: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque

: Amount of oil or coolant to be replenished

Sketches of special tools


Various special tools are illustrated for the local
manufacture.

125E-5 Series

SEN00697-03

50 Disassembly and assembly

Coating materials list


a
a

The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this manual.

Category

Komatsu
code

Part number

Q'ty

Container

Main features and applications

LT-1A

790-129-9030

150 g

Tube

Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.

LT-1B

790-129-9050

20 g
(2 pcs.)

Used for plastic (except polyethylene,


polypropylene, tetrafluoroethylene and vinyl
Polyethylene
chloride), rubber, metal, and non-metal parts
container
which require immediate and strong adhesion.

LT-2

09940-00030

50 g

Polyethylene Features: Resistance to heat and chemicals.


container Used to fix and seal bolts and plugs.

Adhesive

LT-3

790-129-9040

250 g

Holtz MH 705

790-129-9120

75 g

790-129-9140

Can

Used to stick and seal metal, glass, and plastics.

Polyethylene
Used to seal plugs.
container
Tube

Heat-resistant seal used to repair engines.

50 g

Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container Used mainly to stick metals, rubbers, plastics,
and woods.
Quick-setting adhesive.
Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
Used mainly to stick rubbers, plastics, and
metals.

Aron-alpha
201

790-129-9130

2g

Loctite
648-50

79A-129-9110

50 cc

Features: Resistance to heat and chemicals.


Polyethylene
Used for fitted portions used at high temperacontainer
tures.

1 kg

Used to seal various threaded portions, pipe


Polyethylene
joints, and flanges.
container Used to seal tapered plugs, elbows, and nipples of hydraulic piping.

LG-5

Gasket sealant

790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)

LT-4

ThreeBond
1735

790-129-9080

LG-6

790-129-9160

200 g

Tube

Features: Silicon-based heat and cold-resistant sealant.


Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.

LG-7

790-129-9170

1 kg

Tube

Features: Silicon-based quick-setting sealant.


Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.

Tube

Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.


Used to seal transfer case, etc.

LG-8
ThreeBond
1207B

(Rev. 2009.02)
1

419-15-18131

100 g

125E-5 Series

50 Disassembly and assembly

Gasket sealant

CateKomatsu code
gory

Molybdenum
disulfide
lubricant

Container

Main features and applications

790-129-9310

200 g

Tube

Used for rough surfaces such as the circle gear


top seal which does not need to be clamped,
water resistance of the clearance at the welded
area, etc.
Can be coated with paint.

LG-10
ThreeBond
1206E

790-129-9320

200 g

Tube

Used as lubricant/sealant when the radiator


hoses are inserted.
Can be coated with paint.

LG-11
ThreeBond
1121

790-129-9330

200 g

Tube

Feature: Can be used together with gaskets.


Used for covers of the transmission case and
steering case etc.

ThreeBond
1211

790-129-9090

100 g

Tube

Gasket sealant used to repair engine.

Tube

Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.

Can

Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuffing each other.
Applicable for the drive shaft splines, needle
bearings, pins and bolts of various links, etc.

Can

Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc.
Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.

Various

Various

Feature: Lithium grease with extreme pressure


lubrication performance.
General purpose type.

LC-G
NEVER-SEEZ

09940-00040

09995-00250

SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)

Grease

Q'ty

LG-9
ThreeBond
1206D

LM-P

Seizure
prevention
compound

Part number

SEN00697-03

Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM

SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)

Hyper White
Grease G2-T,
G0-T (*)

SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)

125E-5 Series

200 g

190 g

Used for parts under heavy load.


Caution:
400 g x 10 Bellows-type Do not apply grease to rolling bearings like
swing circle bearings, etc. and spline.
400 g x 20 container
The grease should be applied to work equipment
16 kg
Can
pins at their assembly only, not applied for
greasing afterwards.
400 g
16 kg

400 g
16 kg

Bellows-type
container
Can

Seizure resistance, heat resistance and water


resistance higher than molybdenum disulfide
grease.
Not conspicuous on machine since color is
white.

Bellows-type Since this grease is decomposed by natural baccontainer


teria in short period, it has less effects on microCan
organisms, animals, and plants.

SEN00697-03

G2-U-S
ENS grease

427-12-11871

SUNSTAR
PAINT PRIMER
580 SUPER

Caulking material

Adhesive

Primer

SUNSTAR
GLASS
PRIMER 580
SUPER

SUNSTAR
PAINT PRIMER
435-95

Q'ty

Container

Main features and applications

Tube

Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent
deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.

2 kg

Can

Feature: Urea (organic system) grease with heat


resistance and long life. Enclosed type.
Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.

20 ml

Glass
container

Used as primer for cab side.


(Using limit: 4 months after date of manufacture)

20 ml

Glass
container

Used as primer for glass side.


(Using limit: 4 months after date of manufacture)

20 ml

Glass
container

200 g

417-926-3910

22M-54-27230

Adhesive for cab glass

G2-S
ThreeBond
1855

Part number

Used as primer for painted surface on cab


side.
(Using limit: 4 months after date of manufacture)
Used as primer for black ceramic-coated
surface on glass side and for hard polycarbonate-coated surface.
(Using limit: 4 months after date of manufacture)

SUNSTAR
GLASS
PRIMER
435-41

22M-54-27240

150 ml

Can

SUNSTAR
SASH PRIMER
GP-402

22M-54-27250

20 ml

Glass
container

Used as primer for sash (Almite).


(Using limit: 4 months after date of manufacture)

SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W

417-926-3910

320 ml

Polyethylene
container

S is used for high-temperature season


and W for low-temperature season as
adhesive for glass.
(Using limit: 4 months after date of manufacture)

Sika Japan,
Sikaflex 256HV

20Y-54-39850

310 ml

Polyethylene
container

Used as adhesive for glass.


(Using limit: 6 months after date of manufacture)

SUNSTAR
PENGUINE
SUPER 560

22M-54-27210

320 ml

Ecocart
(Special
container)

SUNSTAR
PENGUINE
SEAL No. 2505

417-926-3920

320 ml

Polyethylene
container

SEKISUI
SILICONE
SEALANT

20Y-54-55130

333 ml

Polyethylene
container

Used to seal front window.


(Using limit: 6 months after date of manufacture)

Cartridge

Used to seal joint of glasses.


Translucent white seal.
(Using limit: 12 months after date of manufacture)

GE TOSHIBA
SILICONES
TOSSEAL 381

22M-54-27220

333 ml

Adhesive for cab glass

Grease

CateKomatsu code
gory

50 Disassembly and assembly

Used as adhesive for glass.


(Using limit: 6 months after date of manufacture)
Used to seal joints of glass parts.
(Using limit: 4 months after date of manufacture)

125E-5 Series

50 Disassembly and assembly

SEN00697-03

Special tools list


a
a

Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
Necessity:
t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
New/Redesign: N ............ Tools newly developed for this model. They have a new part number respectively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any modification.
Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
Sketches of special tools).

Work item

Disassembly and assembly of


engine assembly

Symbol

Part No.

Part name

Necessity
Q'ty
New / Remodel
Sketch

790-501-2001

Engine repair stand

t 1

790-901-1240

Adapter

t 1

Removal and installation of


cylinder head valve spring

795-102-2102

Spring pusher

t 1

Removal and installation of piston


ring

795-100-1191

Piston ring tool

t 1

Removal of cylinder liner

795-220-1000

Liner puller

t 1

Press fitting of cylinder liner

795-225-1520

Liner driver

t 1

Insertion of piston assembly

795-921-1110

Piston holder

t 1

Measuring projection of piston top


surface

795-502-1121

Gauge holder

t 1

Adjusting valve clearance

795-125-1360

Clearance gauge

q 1

Angle tightening of bolt

790-331-1110

Wrench

q 1

Removal of rear oil seal

795-931-1100

Seal puller assembly

795-931-1210

Sleeve jig

t 1

795-931-1220

Sleeve jig

t 1

01050-31645

Bolt

t 3

01050-31625

Bolt

t 3

795-630-5500

Standard puller

t 1

P 2

01010-81090

Bolt

t 2

01643-31032

Washer

t 2

Press fitting of rear oil seal

Removal of fuel supply pump

125E-5 Series

Remarks

SEN00697-03

KOMATSU 125E-5 Series engine


Form No. SEN00697-03

2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)

SEN00698-02

ENGINE
1SHOP MANUAL

125E-5 Series

50 Disassembly and assembly1


Disassembly and assembly, Part 1
(With EGR)
Disassembly and assembly, Part 1 (With EGR).............................................................................................. 2
General disassembly of engine............................................................................................................ 2
General assembly of engine .............................................................................................................. 17

125E-5 Series

SEN00698-02

50 Disassembly and assembly

Disassembly and assembly, Part 1 (With EGR)

General disassembly of engine 1


a

The shapes, quantity, locations, etc. of the


parts depend on each applicable machine.
Take care.

1.

Preparation work
Before disassembling the engine, check its parts
for cracking, damage, etc. and clean it generally
and carefully for accurate inspection of its parts
and quick disassembly and assembly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.

2.

Setting engine assembly


1) Set the engine assembly (1) on rigid and
stable stands [1].
a The weight depends on the applicable machines.
4 Engine assembly: 1,300 kg

2)

Alternator
1) Remove cover (1).
2) Loosen alternator mounting bolt (2) and
lock bolt (3).
3) Loosen locknut (4) and then loosen the
belt tension using the tension adjustment
nut and remove V-belt.
4) Remove mounting bolt (2) and lock bolt
(3) and then remove alternator (5).

7.

Water pump suction tube


Remove tube (1).

Drain the engine coolant and engine oil.


a The quantity of the engine oil
depends on each applicable machine.
6

Engine oil: Approx. 40 l

3.

Harness assembly
Disconnect the connector and clamp and
remove the harness assembly.

4.

Heat shielding plate


Remove the heat shielding plate from EGR
and EGR piping.

5.

Starting motor
Remove mounting bolt (1) and remove starting
motor (2).

6.

125E-5 Series

50 Disassembly and assembly

8.

SEN00698-02

EGR cooler
1) Remove turbocharger drain tube (1).
2) Remove exhaust gas discharge tube (2).
3) Remove coolant tube (3).
4) Remove 2 air vent tubes (4).
5) Loosen rubber hose (5) clamp and then
remove the bolt on the water pump side
and remove tube (6).

10. Turbocharger and exhaust manifold assembly


1) Remove bolt (1) used to mount the
assembly to bypass tube.
a The bypass tube is not used on some
machine models.
2) Disconnect turbocharger lubrication tube
(2).
6)
7)

Remove the bolt mounting it to EGR tube


(7).
Remove 4 mounting bolts and remove
EGR cooler (9).
a Remove bracket (8) at the same time.

3)

9.

EGR tube
1) Remove clamps (1) and (2).
2) Remove EGR gas pressure sensor tube (3).
3) Remove the bolt (4) mounting it to the
EGR valve and remove EGR tube (5).

125E-5 Series

Lift up the turbocharger side temporarily,


remove the exhaust manifold mounting
bolt and then remove the turbocharger
and exhaust manifold assembly.
4 Turbocharger and exhaust manifold
assembly: 40 kg

SEN00698-02

11. Oil filter and oil tube assembly


1) Remove the oil tube (1) block side mounting bolt.
2) Remove 4 mounting bolts on the oil filter
head side and remove oil filter and oil tube
assembly (2).

12. Fuel filter


1) Loosen clamp (3) to disconnect fuel tubes
(1) and (2).
2) Remove 4 mounting bolts on the head side
of the fuel filter and remove fuel filter (4).

50 Disassembly and assembly

13. Fuel tube


Remove clamp (3) and remove fuel tubes (1)
and (2).

14. Lubrication tube and bracket


1) Remove brackets (1) and (2).
2) Remove turbocharger lubrication tube (3)
by removing 4 clamps on it.

15. High-pressure pipe


1) Remove bracket (1).
2) Remove splash prevention cover (2).

125E-5 Series

50 Disassembly and assembly

3)

Remove 6 clamps (3) and 6 splash prevention covers (4) on the injector side.

4)

Remove clamps (5), (6), (7) and (8) and


then remove 6 high-pressure pipings (9).

SEN00698-02

17. Bypass valve


1) Remove clamp (1) and loosen clamp (2).
2) Remove oil drain tubes (4) and (5).
3) Remove the mounting bolt on oil inlet tube
(6).
4) Remove 2 mounting bolts (7) and then
remove bypass valve (8).

18. EGR valve


1) Remove oil inlet tube (1).
2) Remove 2 mounting bolts (2) and then
remove EGR valve (3).

16. Bypass tube


Remove bolt (2) on the bypass valve side and
then remove bypass tube (1).

19. Front hanger


Remove front hanger (1).

125E-5 Series

SEN00698-02

20. Diffuser and air housing assembly


1) Remove brackets (1) and (2) and then
remove oil filler (3).
2) Remove mounting bolt (4) at flanged portion of the air housing. Remove the bolt
through the bottom.

50 Disassembly and assembly

21. Air intake manifold


1) Remove bracket (1).

2)

3)
4)

Lift air intake manifold (2) temporarily,


remove its 24 mounting bolts and then
remove manifold.
4 Air intake manifold: 25 kg

Remove bracket (5) and then lift the diffuser temporarily.


Remove the mounting bolt and then remove
diffuser and air housing assembly (6).
4 Diffuser and air housing assembly:
35 kg

22. Engine controller cooler


Disconnect fuel hose (1) and remove engine
controller cooler (2).
a Fuel hose (1) is not used on some
machine models.

125E-5 Series

50 Disassembly and assembly

SEN00698-02

23. Fuel supply pump piping


1) Remove clamps (3), (4) and (5) and then
remove splash prevention cover (6).
2) Remove 2 high-pressure pipings (7).
3) Remove lubrication tube (8).
4) Remove fuel tube (1).

4)

5)
24. Fuel supply pump assembly
1) Remove cover (1).
2) Rotate the crankshaft forward and set
intermediate point (a) between stamped
2/5 TOP and 3/4 TOP on damper (2) to
pointer (3) (stamped 1/6 TOP comes
almost directly under).
a Make sure at this point that the forcing tap of the drive gear is aligned to
the bolt hole at the top of cover (1).
(If not, rotate the crankshaft 1 more
turn.)
a At this point, the key of the shaft is
turned clockwise by 15 from the top.

3)

6)

Remove pump mounting bolts (6) and


bracket (7).
a Leave bolts (6) tightened by 2 3
threads to prevent the pump from falling down.
Install tool P1 with P2 and P3 and then
screw in the center bolt of P1 to remove
the gear from the shaft.
Remove remaining bolts and then remove
fuel supply pump assembly (8).
a Leave tools P1, P2 and P3 in the
installed condition.

Remove mounting nut (4) and then remove


washer (5).
a Use a magnet or the like in this operation so that washer (5) may not be
inadvertently dropped into the case.

125E-5 Series

SEN00698-02

25. Common rail and overflow tube


1) Remove common rail (1).
2) Remove spill tube (2), overflow tube (3)
and block (4).

26. Spill tube


Remove spill tube (1).

50 Disassembly and assembly

2)

Remove the mounting bolt and then


remove oil cooler assembly (4) using
guide bolt [1].

29. Engine repair stand adapter


Install tool A2.

27. Air vent tube


Remove air vent tube (2).

30. Head cover


Remove head cover (1).

28. Oil cooler assembly


1) Remove brackets (1) and (2) and drain
hose (3).

125E-5 Series

50 Disassembly and assembly

31. Injector harness


1) Fully loosen 2 harness terminal mounting
nuts (2) on the head of injector (1).
a Loosen nuts alternately.
2) Loosen bolt (3) of harness fixing holder.

32. Rocker arm and shaft assembly


1) Loosen locknut (3) and then loosen
adjustment screw (2).
2) Remove mounting bolt (4) and then
remove rocker arm and shaft assembly
(1).

33. Push rod


Remove 12 push rods (1).

125E-5 Series

SEN00698-02

34. Injector
Remove holder mounting bolt (3) of injector (1)
and then remove injector (1) along with holder
(2).
a Do not try to grip the solenoid valve at the
top of the injector using a pliers and the
like.

35. Crosshead
Remove 12 crossheads (1).

36. Injector wiring harness


1) Remove mounting bolt (2) of harness connector (1).
2) Remove holder (3) from the harness.

SEN00698-02

3)

4)

Remove harness connector (1) by pushing outward from inside of rocker housing
(4).
Remove O-ring (5) from the rocker housing.

37. Rocker arm housing


Remove rocker arm housing (1).

38. Thermostat and water pump


1) Remove thermostat case (1) and tube (2).
2) Remove water pump (3).

10

50 Disassembly and assembly

39. Cam follower cover


1) Remove oil level gauge tube (1).
2) Remove oil tube (2) and bracket (3).
3) Remove 3 cam follower covers (4).

40. Cam follower


Remove 12 mounting bolts (1) and then
remove cam followers (2).
a Remove dowel pin (3).

41. Removal of cylinder head assembly


1) Remove each set of 7 mounting bolts (2)
of cylinder head assembly (1).
2) Using eyebolt [1], lift and remove cylinder
head assembly (1).
4 Cylinder head assembly: 20 kg
3) Remove each head gasket.

125E-5 Series

50 Disassembly and assembly

42. Disassembly of cylinder head assembly


1) Using tool C, compress valve spring (3)
and remove valve cotter (4).
2) Remove upper seat (5) and valve spring (3).

3)
4)

Remove seal (7) and then remove lower


seat (8).
Raise the cylinder head and remove valve
(6).
a Apply an marking and the like to the
valve so that it may be identifiable to
which head it should be combined.

SEN00698-02

43. Setting to engine repair stand


Lift the engine and then align currently installed
tools A2 and A1 to set the engine.

44. Oil pan


Remove oil pan (1) by reversing the engine.

45. Speed sensor


Remove speed sensors (1) and (2) by turning
over the engine.
a Speed sensor (2) is not used on some
machine models.

125E-5 Series

11

SEN00698-02

50 Disassembly and assembly

46. Flywheel
1) Using slings [1], lift up flywheel (1) temporarily.
2) Remove 6 mounting bolts to remove the
flywheel from the dowel pin and then lift off
the flywheel.
4 Flywheel: 25 kg

49. EGR oil pump


Remove EGR oil pump (1).

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

48. Damper and pulley assembly


Lift the damper and pulley assembly (1) temporarily and then remove its 6 mounting bolts.
4

12

50. Front support and front cover


1) Lift up front support (1) temporarily and
then remove it by removing the mounting
bolts.
a Its shape depends on the applicable
machines.
4 Front support: 30 kg
2) Remove adjustment rod (2).
3) Lift up front cover (3) temporarily and then
remove it by removing the mounting bolts.
4 Front cover: 30 kg
4) Remove tool P and then remove the supply pump drive gear.

Damper and pulley assembly: 25 kg

125E-5 Series

50 Disassembly and assembly

51. Camshaft
1) Remove 2 mounting bolts (1).
2) Remove camshaft (2).
a When pulling out the camshaft, turn it
gently so that damages may not be
left on the cam bushing.

SEN00698-02

53. Idler gear


1) Remove mounting bolt (1) and then remove
plate (2) and oil pump idler gear (3).

2)
3)
52. Oil pump
Remove 4 mounting bolts (1) and then remove
oil pump (2).

Remove shaft (4).


Remove mounting bolt (5) and then
remove shaft (6), main idler gear (7) and
plate (8).

54. Oil suction pipe


Remove brackets (1) and then remove oil suction pipe (2).

125E-5 Series

13

SEN00698-02

50 Disassembly and assembly

55. Piston cooling nozzle


Remove mounting bolt (1) and each piston
cooling nozzle (2).

6)
56. Piston and connecting rod assembly
a Before removing the piston and connecting rod assembly, measure its end play
with dial gauge [3], if necessary.
7)

1)

2)
3)
4)
5)

14

Check the stamped No. of the connecting


rod cap.
q
The cap No. and cylinder No. must be
the same.
q
The cap No. must be stamped on the
cam side.
a If the No. is not stamped, stamp it
before removing the connecting rod.
Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
Scrub the carbon off the top wall of the cylinder liner with fine sandpaper.
Remove connecting rod cap mounting
bolts (1).
Hit connecting rod cap (2) with a plastic
hammer so lightly that the threads of the
connecting rod bolts will not be damaged
and remove connecting rod cap (2) and
connecting rod bearing as a unit.

8)

Push in and remove the piston and connecting rod assembly with a wood bar, etc.
from the oil pan side, while supporting piston (3) on the cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the connecting rod.
Remove the other piston and connecting
rod assemblies according to the above
procedure.
a Take care not to damage the sliding
portions of the pistons and bearings.
a Assemble each connecting rod and
cap temporarily so that they will not
be assembled with other ones and
keep them and the bearing together.

Disassemble the piston and connecting


rod assembly according to the following
procedure.
1] Remove 2 snap rings (4).
2] While supporting connecting rod (5),
remove piston pin (6) to disconnect
piston (7) and connecting rod.

125E-5 Series

50 Disassembly and assembly

SEN00698-02

2)

3]

Using tool D, remove piston ring (8).


a Keep the piston, connecting rod,
connecting rod bearing, piston
rings, and piston pin by each cylinder.

Insert the bolts in the bolt holes of the


main cap and remove the cap, while shaking it.

Thrust bearing (3) is assembled to


No. 7 main cap. After removing the
cap, apply a marking to the re-assembly position.

57. Crankshaft
a Before removing the crankshaft, measure its
end play with dial gauge [3], if necessary.
3)

1)

Lift off crankshaft (4).


a When removing the crankshaft, take
care so that its sliding surfaces may
not be damaged.
4 Crankshaft: 110 kg

Remove mounting bolts (2) of main cap (1).

125E-5 Series

15

SEN00698-02

16

4)

Remove upper thrust bearing (5).

5)

Remove upper bearing (6).


a Apply a marking to the assembly
positions of the main cap, main bearing, and thrust bearing. And store
them by the journal No.

50 Disassembly and assembly

58. Cylinder liner


Using tool E, pull out cylinder (1).
a Before removing the cylinder liner, measure its projection with dial gauge [3], if
necessary.

125E-5 Series

50 Disassembly and assembly

General assembly of engine


a
a

SEN00698-02

2]

The shapes, quantity, locations, etc. of the


parts depend on each applicable machine.
Take care.
Clean each part carefully, and check it for
bruise, flaw, cavity, etc. Make sure each oil or
coolant path is through.

3]

Tightening bolts by plastic-region turning angle


method
a Bolts tightened by plastic-region turning angle
method
q
Cylinder head mounting bolt
q
Main cap mounting bolt
q
Connecting rod cap mounting bolt
a If the plastic-region turning angle method is
applied, the tightened bolts have permanent
strain. Accordingly, the allowable number of
using times of each bolt is limited. Observe the
following precautions.
q
Before tightening each bolt, measure its
stem length and make sure that the length
is less than the using limit. If the stem is
longer than the using limit, it should not be
used but replaced.
q
Check each mounting bolt head for punch
marks. If there are punch marks more than
the specified numbers, replace the bolt.
1.

Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 320 kg

2)

Before inserting the cylinder liners, prepare the cylinder block according to the
following procedure.
1] Remove the rust and scales from faces
(A) and (B) with sandpaper, etc. until
the machined surfaces are exposed.

125E-5 Series

4]
5]

2.

Polish part (R) with sandpaper of


about No. 240 until it becomes a
smooth rounded surface.
If part (R) is sharp or has burrs, finish
it with a scraper or sandpaper.
Finish this surface particularly smoothly
so that it will not damage the O-ring.
If face (B) is so pitted that it cannot be
repaired, replace the cylinder block.
If faces (A) and (R) are pitted, finish
them smoothly.
Check the counterbored part and
remove burrs. If chips or dust is
present on face (C), the liner may not
fit well, resulting in coolant leakage or
insufficient liner protrusion. Thus,
they must be eliminated.
a If the counterbored part is drooping, corroded, or pitted, repair it.

Cylinder liner
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not roughened
because of rusting or pitting. If those parts
are roughened, replace the cylinder liner.
2) Install clevis seal (1), O-rings (2) and (3) to
the cylinder liner.
a Check that there is not a burr, dust,
etc. in the groove of the liner.
a Replace the O-ring and clevis seal
with new ones.
a Fit the clevis seal with the chamfered
side down. When fitting it, press it
against the seal groove all round so
that it will not be twisted.
a When installing O-rings (2) and (3),
refer to the following.
q
O-ring (2): The whole ring is black.
q
O-ring (3): The whole ring is red.
2 Clevis seal and O-ring:
Rubber lubricant (LH-50 from NOF
Corporation)

17

SEN00698-02
a
a

If LH-50 is not available, apply clean


engine oil SAE No. 30.
Since the clevis seal and O-ring are
swollen and deteriorated by oil, apply
a small amount of oil to them thinly
with a brush just before fitting them.

50 Disassembly and assembly

4)

Apply gasket sealant to the parts of the


cylinder block and cylinder liner which will
fit to the counterboared parts.
a Wipe off dirt and oil with cloth from
the contact faces of the counterboared parts of the cylinder block and
liner flange.
2 Cylinder block: Gasket sealant (LG-6)
q
Gasket sealant:
0.8 1.6 mm in diameter
q
Overlap (a) of gasket sealant: 6 6 mm
a If the applied gasket sealant is left for a
long time, its surface becomes hard.
Accordingly, install the cylinder block to
the cylinder head within 50 minutes.

5)

Insert cylinder liner (1) to the cylinder block.


a Insert cylinder liner (1) in the cylinder
block slowly, taking care not to damage the O-ring.
Push in cylinder liner (1) further by both
hands.
a If the liner does not enter the cylinder
smoothly, the O-ring may be damaged. In this case, check the cylinder
block for burrs.
Using tool F, press fit cylinder liner (1) to
the cylinder block.

6)
3)

After fitting the O-ring, check it for twist. If


it is twisted, correct it with a flexible rod
(about 10 mm in diameter).
7)

18

125E-5 Series

50 Disassembly and assembly

8)

To prevent the gasket sealant from projecting through the clearance between the
block and liner after the cylinder head is
tightened, tighten the cylinder head temporarily with the used head gasket
inserted.
a At this time, observe the following tightening torque and tightening order.
3 Temporary tightening torque:
127.5 147.1 Nm {13 15 kgm}

9)

Remove the cylinder head and wipe off


the gasket sealant projected from the
counterbored part.
a Be sure to perform steps 8) and 9)
above since the projected gasket
sealant can deform the grommet of
the head gasket.

SEN00698-02

3.

Crankshaft
a Cylinder block and main bearing are
selective mating parts and the prepared
spare parts ensure the required clearance.
1) Install the upper main bearing (6) to the
notch of the cylinder block while aligning
the bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.
2 Bearing inner surface:
Engine oil (EO30)

2)

Drive in the roll pin so that its projection


from the block end face may become 1.5
1.9 mm and then install upper side thrust
bearing (5).
a Install each thrust bearing with the
grooved surface on the crankshaft side.

3)

Before assembling the crankshaft, check


the following.
q
Troubles on the front side and rear
side threaded portions
(Bottom can be easily screwed in by
hand)
q
Scratches or dents on pin and main
journal
q
Presence or absence of dust inside
oil hole

10) Using dial gauge [3], measure the projection of the cylinder liner.
a When measuring projection of the
liner, fix the liner using a plate so that
it may not be lifted by the O-ring.
a Projection of cylinder liner:
0.07 0.15 mm
a If the end play is out of the standard,
correct it. For details, see Structure,
function and maintenance standard.

125E-5 Series

19

SEN00698-02

4)

5)

Lift and set crankshaft (4) to the mounting


position.
a When installing the crankshaft, take
care not to damage its sliding surfaces by, for instance, bumping
against the cylinder block.
a When replacing the crank gear, heat it
with a bearing heater set at 150C
and then fit it immediately after the
heating.
4 Crankshaft: 110 kg
2 Cylinder block journal:
Engine oil (EO30)

50 Disassembly and assembly

6)

Install main cap (1).


a When installing, make sure that the
stamped No. at center of the main
cap is aligned to the stamped journal
No. of the cylinder block.
a Install the main cap with the cast letter (F) toward the front of the engine.
2 Crankshaft journal surface:
Engine oil (EO30)

7)

Before tightening the main cap mounting


bolts, check the following items. If any of
the following conditions applies, do not
reuse that bolt but replace it.
q
Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q
Length (a) of bolt stem:
Min. 159.8 mm

Install lower main bearing (7) to the main


cap.
a Install lower main bearing (7) to the
notch of the main cap while aligning
the bearing projection to it.
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
grooved surface on the crankshaft side.

8)

Screw in main cap mounting bolts (2)


alternately until the main cap (1) is
securely fitted in its place.
9) Tighten main cap mounting bolts (2)
according to the following procedure.
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

50 Disassembly and assembly


3

SEN00698-02

Mounting bolt
1st time : 98.1 9.8 Nm {10 1 kgm}
2nd time : 196.1 4.9 Nm {20 0.5 kgm}
3rd time : Using tool J, tighten the bolt by
90 (+30/0).

4.

When not using tool J, apply mark (b)


to the main cap and bolt with paint,
then tighten the bolt by 90 (+30/0).
10) Make punch mark (c) on the mounting bolt
head.
a When a new bolt is used, do not
make a punch mark on its head.

11) Check that the crankshaft turns smoothly.


12) Measure the end play of the crankshaft
with dial gauge [3].
a End play: 0.14 0.315 mm
a If the end play is out of the standard,
correct it. For details, see Structure,
function and maintenance standard.

125E-5 Series

Piston and connecting rod assembly


a Piston and cylinder liner are selective mating parts and the prepared spare parts
ensure the required clearance.
1) Using tool D, assemble piston ring (8) in
the order of oil ring, second ring and top
ring starting from the bottom.
a Fit the top ring and second ring to the
piston with the stamped mark side up.
q
Stamp on top ring: 1R
q
Stamp on second ring: 2R
a Take the expander out of the oil ring
and fit it to the piston first and then fit
the oil ring. At this time, make sure
that the expander is fitted to the ring
groove perfectly.

2)

Set the abutment joint of each piston ring


as shown in the following figure.
a Adjust oil ring so that the joint of the
expander will be at 180 to the abutment joint of the oil ring.

21

SEN00698-02

3)
4)

Install snap ring (4) to one side of piston (7).


Heat piston (7) at 100C for 5 minutes
minimum in the heating furnace.
a When the furnace is not available,
heat it at 100C for 5 minutes minimum in hot water.

Set connecting rod (5) on piston (7).


a Set the connecting rod so that the ID
marking "6251" at the bottom of the
connecting rod comes to the left side
as the grade marking on the piston
top surface is faced toward the front
side of the engine. Then insert the
connecting rod to piston pin (6).
2 Piston boss: Engine oil (EO30)
6) Install snap ring (4) on the opposite side.
a Turn the snap ring on both sides to
make sure they are securely fitted to
the ring groove.

50 Disassembly and assembly

7)

Install upper main bearing (8) to the notch


of the connecting rod while aligning the
bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.
a Make sure that the bearing hole and
connecting rod oil hole are aligned.

8)

Install the connecting rod lower bearing


(9) to the notch of the connecting rod cap
while aligning the bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.

5)

22

125E-5 Series

50 Disassembly and assembly

9)

Set the cylinder crankshaft, to which the piston and connecting rod assembly is to be
assembled, to the bottom dead center.
10) Insert piston and connecting rod assembly
(3) in the cylinder block so that ID marking
"6251" of the connecting rod may be faced
toward the left side face of the engine.
a Make sure the abutment joint of the
piston ring is located in the position
indicated in the following figure.
2 Inner surface of connecting rod and
cylinder: Engine oil (EO30)

11) Using tool G, reduce the piston ring and


then push in the piston head with a wood
bar, etc.

125E-5 Series

SEN00698-02

12) Install connecting rod cap (2).


a Align match mark of connecting rod
(5 ) and connecting ro d cap (2).
(Above aligns the match mark to ID
marking "6251" on the opposite side.)
2 Inner surface of connecting rod cap
bearing: Engine oil (EO30)

13) Before tightening the connecting rod cap


mounting bolts, check the following items.
If any of the following conditions applies,
do not reuse that bolt but replace it.
q
Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q
Length (a) of bolt stem: Min. 84.1 mm

23

SEN00698-02

50 Disassembly and assembly

14) Tighten connecting rod cap mounting bolts


alternately until the connecting rod cap is
closely contacted.
15) Tighten connecting rod cap mounting bolts
(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.

5.

17) Turn the crankshaft to check that it rotates


normally.
18) Measure the side clearance of the connecting rod with dial gauge [3].
a Side clearance: 0.2 0.375 mm

24

Piston cooling nozzle


1) Rotate the crankshaft and set the No. 1
No. 3 pistons to the following positions for
installation of the piston cooling nozzles of
each piston.
q
Set the No. 1 piston to top: Piston
cooling nozzles of the No. 1 and No. 6
pistons can be installed.
q
Set the No. 2 piston to top: Piston
cooling nozzles of the No. 2 and No. 5
pistons can be installed.
q
Set the No. 3 piston to top: Piston
cooling nozzles of the No. 3 and No. 4
piston can be installed.
2) Set piston cooling nozzle (2) adjusting the
dowel pin position and then tighten mounting bolt (1).
3 Mounting bolt:
27 34 Nm {2.8 3.5 kgm}

125E-5 Series

50 Disassembly and assembly


a

6.

SEN00698-02

After the installation, make sure the


nozzle end is situated at center of the
cut of respective pistons.

Oil suction pipe


Install oil suction pipe (2) after attaching the Oring to it and then fix them using bracket (1).

8.

7.

Oil pump
1) Install oil pump (2) after attaching the Oring to it and then tighten 4 mounting bolts
(1).
2) Drive in the pin and then install shaft (4).

Idler gear
1) Install plate (8) to the engine block and then
install main idler gear (7) and shaft (6).
a When installing plate (8), set its
chamfered side to the front side of the
engine.
2) Matching A mark of the crankshaft gear
and A mark of main idler gear (7),
tighten mounting bolt (5).
3 Mounting bolt:
245 294 Nm {25 30 kgm}

125E-5 Series

25

SEN00698-02

9.

50 Disassembly and assembly

Idler gear
Assemble oil pump idler gear (3), attach plate
(2) to it and then tighten them using mounting
bolt (1).
3 Mounting bolt:
147 176.4 Nm {15 18 kgm}

11. Cam follower


1) Drive in dowel pin (3) to the cylinder block.
2) Tighten 6 cam followers (2) using mounting bolt (1).
3 Mounting bolt:
44 59 Nm {4.5 6 kgm}

10. Camshaft
1) Assemble camshaft (2) to the cylinder
block.
a Rotate the camshaft when assembling so that the cam bushing may not
be damaged.
a When replacing the cam gear, heat it
at 200 240C for 30 minutes minimum in an electronic oven and then
shrink fit it.
2 Camshaft journal surface:
Engine oil (EO30)
2) Matching B mark of the crankshaft gear
and B mark of the main idler gear,
tighten mounting bolt (1).

12. Cam follower cover


1) Install the O-ring and cam follower cover (4).
3 Mounting bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
2) Install brackets (3), oil tube (2) and oil
level gauge (1).

13. Water pump assembly


Fit the O-ring to water pump assembly (3) and
install them.

26

125E-5 Series

50 Disassembly and assembly

SEN00698-02

14. Thermostat and water tube


Fit the gasket and then install thermostat (1)
and tube (2).

16. Make sure that match marks (A to C) of drive


gears and idler gears are matched.
15. Fuel supply pump assembly
1) Set fuel supply pump assembly (3) and
then tighten it temporarily using 4 mounting bolts (5).
a Tighten it permanently according to
Step 43 described below.
2 Mounting bolt: Adhesive (LT-2)
2) Set the assembly by aligning C mark to
C mark of camshaft gear (2) while aligning the key groove of supply pump drive
gear (1) to the woodruff key of the shaft.
3) Fit the washer and then tighten them
using gear mounting nut (4).
3 Gear mounting nut:
127 147 Nm {13 15 kgm}
4) Install bracket (6).
3 Mounting bolt (supply pump side):
19.6 29.4 Nm {2.0 3.0 kgm}
a Leave the cylinder block side mounting bolt in temporarily tightened state
(it is to be tightened permanently in
the following Step 43).

17. Measuring backlash and end play


a Measure the backlash and end play of
each gear with dial gauge [3].
Standard backlash of each gear
Position

Range (mm)

0.105 0.325

0.105 0.325

0.116 0.359

0.105 0.337

0.082 0.389

0.076 0.366

Standard end play of each gear

125E-5 Series

Position

Range (mm)

0.05 0.17

0.05 0.21

If the end play is out of the standard, correct it. For details, see Structure, function
and maintenance standard.

27

SEN00698-02

50 Disassembly and assembly

3)
4)

5)
6)

18. Front cover


1) Using the push tool (outside diameter 120
mm), press fit oil seal (5) to the cover.
a Oil seal press fit allowance (a):
16 (+1/0) mm
2 Oil seal lip (50 80% of void lip
space): Grease (G2-LI)

19. Flywheel housing


1) Apply a string of gasket sealant 1 mm in
diameter as shown below.

2)

3)
2)

28

Install cover (2).


Using dial gauge, measure the level difference between underside faces of the cylinder block and front cover.
a Difference: 0 0.275 mm
a If the difference is out of the standard,
correct it. For details, see Structure,
function and maintenance standard.
Install adjustment rod (3).
Install front support (4).
a Its shape depends on the applicable
machines.
4 Front support: 30 kg

Sling flywheel housing (1) and then install


it to the cylinder block.
4 Flywheel housing: 80 kg
Tighten flywheel housing mounting bolts (2).

Lift front cover (1) and then install it using


the guide bolt.
a When installing, take care not to damage the oil seal.
4 Front cover: 30 kg
2 Front cover mounting surface:
Gasket sealant (LG-7)

125E-5 Series

50 Disassembly and assembly

SEN00698-02

a
a

Tighten the flywheel housing mounting bolts in the following order in 2


steps.
a The following indicates that mounting
bolts 1, 4 and 2, 9 are to be tightened
twice in 1st time.
2 Mounting bolt: Engine oil (EO30)
3 Mounting bolt:
1st time:
147 235 Nm {15 24 kgm}
2nd time:
245 309 Nm {25 31.5 kgm}

4)

After installing the flywheel housing, measure its facial runout and radial runout with
dial gauge [3].

imum on the flywheel housing including the periphery.


Move the crankshaft either in the front
or rear side in order to prevent errors
due to the end play.
Make sure after rotating the crankshaft by a turn that the gauge pointer
is returned to the position where it
had been situated when the crankshaft was started to turn.
The gauge pointer deflects in both
sides right and left. Thus, reasonable care must be exercised to avoid
misreading of the pointer when the
gauge is provided in the top, bottom,
left and right side of the measured
end face.
Facial runout: Max. 0.20 mm

Measurement of radial runout of flywheel


housing
Like in measurement of the facial runout, set
dial gauge [3] so that its probe may contact
against the flywheel housing centering location
at a right angle.
a In measurement of radial runout, errors
due to end play of the crankshaft do not
occur. As for other points, however, the
precautions noted for the facial runout
remain applicable to the radial runout
as they are.
a Radial runout: Max. 0.20 mm

Measurement of facial runout of flywheel


housing
1] Apply the magnet stand to the crankshaft end face.
2] Set dial gauge [3] so that its probe
may contact against the flywheel
housing end face at a right angle.
3] Rotate the crankshaft by a turn to
read the difference between the maximum and minimum values indicated
by the gauge pointer.
a Measurement shall be conducted at
eight equally distanced positions min125E-5 Series

29

SEN00698-02

5)

Using dial gauge [3], measure the level


difference between underside faces of the
cylinder block and flywheel housing.
a Difference: 0 0.35 mm
a If the difference is out of the standard,
correct it. For details, see Structure,
function and maintenance standard.

50 Disassembly and assembly


a

1)

Never remove inside plastic cylinder


(3) of the standard spare seal before
installing the seal.
Set the large inside diameter side (b)
of plastic inside cylinder (3) to the end
of crankshaft (4).
a Take care not to mistake the direction of the plastic inside cylinder.

20. Rear oil seal


a Check the Teflon seal (Laydown lip seal)
by checking the wear of the crankshaft
and replace it with the Standard seal or
Sleeved seal.
a If the crankshaft is worn to the degree of
luster (If wear which you feel with your finger is less than 10 mm) and does not have
any flaw, install the standard seal. In other
cases, install the sleeved seal.
a The left one in the following figure is the
standard seal and the right one is the
sleeved seal.

2)
3)

Hold the metal ring of seal (1) by both


hands and push it in firmly.
After pushing in the seal, remove
plastic inside cylinder (3).
a When removing the inside cylinder, take care not to damage the
seal lip.

Procedure for installing standard seal


a Before installing the seal, check that
the end corners and lip sliding surfaces of crankshaft (4) are free from
flaw, burr, and rust of the housing.
a When installing the seal, do not apply
oil or grease to the shaft and seal lip
(a). Wipe off the oil from the shaft.

30

125E-5 Series

50 Disassembly and assembly

4)

SEN00698-02

Tighten bolts (N3 and N4) evenly to press


fit seal (1) until the end of tool N1 reaches
the end of crankshaft (4).
a First tighten tool N1 until it is contacted
against bolt N3 (bolt stem 45 mm) and
then further tighten the tool with bolt N4
(bolt stem 25 mm).
a When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool set, etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.

Procedure for installing sleeved seal


a Before installing the seal, make sure
that the end corners and lip sliding surfaces of crankshaft (4) are free from
flaws, burrs, and rusts of the housing.
a When installing the seal, do not apply
oil or grease to the shaft, sleeve (1),
and seal lip (a). Wipe off the oil from
the shaft.
a Handle the seal and sleeve as an
assembly and don't separate them
from each other.

1)

2)

Set the sleeve of the seal to the end


of the crankshaft, and then tighten
bolt N3 evenly to press fit sleeve and
seal assembly (2) until the end face of
tool N2 reaches the end of crankshaft
(4).

3)

Remove tool N2 and then replace it


with tool N1.
Tighten bolt N4 evenly to press fit
sleeve and seal assembly (2) until the
end face of tool N1 reaches the end
of crankshaft (4).
a After press fitting the seal, remove
the red sealant layer from its
periphery.

4)

Set sleeve and seal assembly (2) to


tool N2.
2 Inside sleeve:
Gasket sealant (LG-7)

125E-5 Series

31

SEN00698-02

50 Disassembly and assembly

21. Flywheel
1) Using sling [1], lift up flywheel (1) and then
install it aligning to the dowel pin.
2) Tighten mounting bolts (2) in the following
order in 2 steps.
2 Mounting bolt: Engine oil (EO30)
3 Mounting bolt
1st time:
147 19.6 Nm {15 2.0 kgm}
2nd time:
289.1 19.6 Nm {29.5 2.0 kgm}

3)

32

Using dial gauge [3], measure the facial


and radial runout.
a Facial runout : Max. 0.20 mm
a Radial runout: Max. 0.15 mm

22. Speed sensor


a Before installing the sensor, make sure its
tip is free from steel chips or flaws.
1) Install speed sensor (1).
3 Mounting bolt:
4.9 7.9 Nm {0.5 0.8 kgm}
2) Install speed sensor (2).
1] Screw in speed sensor (2) until its tip
lightly touches the tooth tip of ring
gear (3).
2 Threads:Gasket sealant
(Hydraulic sealant
from Loctite)
2] Rotate speed sensor (2) in the opposite direction by 1/2 2/3 turns.
a Clearance (a) will become 0.75
1 mm.
3] Tighten nut (4) while fixing sensor (2).
3 Nut: 69 74 Nm {7 7.5 kgm}

125E-5 Series

50 Disassembly and assembly

SEN00698-02

25. Oil pan


1) Reverse the engine.
2) Apply gasket sealant of 5 mm in diameter
along the entire inside periphery of oil pan
(1) mounting bolt hole and then tighten the
mounting bolt.
2 Mating face: Gasket sealant (LG-7)

23. EGR oil pump


Install the O-ring and EGR oil pump (1).

26. Removal from engine repair stand


1) Reverse the engine.
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

SEN00698-02

27. Setting the engine


Set engine (1) on a rigid and stable stands [1].

50 Disassembly and assembly

29. Installation of cylinder head assembly


1) Check that the cylinder head mounting
face and inside of the cylinder are free
from foreign matter and then set cylinder
head gasket (1).
a When fitting the gasket, check that
the grommets are fitted correctly.

28. Assembly of cylinder head assembly


1) Assemble valve (6).
2 Valve stem: Engine oil (EO30)
2) Raise the cylinder head and then install
lower seat (8) and seal (7).
2)

3)
4)

34

Before tightening the cylinder head


mounting bolts, check the following items.
If any of the following conditions applies,
do not reuse that bolt but replace it.
q
Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q
Length (a) of bolt stem:
Min. 171.4 mm

Assemble valve spring (3) and upper


sheet (5).
Using tool C, compress the valve spring
and install valve cotter (4).
a Hit the valve stem lightly with a plastic
hammer to make sure that the valve
cotter is fitted to the groove of the
valve stem.

125E-5 Series

50 Disassembly and assembly

3)

SEN00698-02

Using sling [1], lift and set cylinder head


assembly (2) to the cylinder block.
4 Cylinder head assembly: 20 kg

4)

Tighten the cylinder head assembly


mounting bolts and auxiliary bolts.
1] Tighten the mounting bolts in the
order of 1 to 6 shown in the figure.
2 Mounting bolt:
Molybdenum disulfide lubricant (LM-P) or engine oil
(EO30)
3 Mounting bolt
1st time : 98.1 9.8 Nm {10
1 kgm}
2nd time: 166.6 176.4 Nm
{17 18 kgm}
(Target: 176.4 Nm
{18 kgm})
3rd time : Using tool J, tighten
the bolt by 90 120
(Target: 120).

2]

3]

125E-5 Series

When not using tool J, apply


marking (b) to the cylinder head
and bolt with paint, then tighten
the bolt by 90 120 (Target:
120).
Mark a punch mark (C) on its head to
show the number of tightening times.
a When a new bolt is used, do not
make a punch mark on its head.

Tighten the auxiliary cylinder head


bolt (following figure 7).
3 Auxiliary bolt:
66.2 7.4 Nm {6.75 0.75 kgm}

35

SEN00698-02

30. Rocker arm housing


1) Install gasket (1) and then install rocker
arm housing (2).
2) Tighten mounting bolts (3).
3 Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}

50 Disassembly and assembly

32. Crosshead
1) Set crosshead (1) and then loosen locknut
(2) to return adjustment screw (3) to its
original position.
2) Using your finger, lightly hold down the
crosshead (1) face contacting the rocker
arm to maintain contact between the push
rod side valve stem and crosshead (1).
3) Screw in adjustment screw (3) until crosshead (1) comes in contact with another
valve stem.
4) As they are contacted, further screw in the
adjustment screw by 20 and then tighten
locknut (2) from that state.
2 Crosshead guide and crosshead
top face: Engine oil (EO30)
3 Locknut:
58.7 5.9 Nm {6.0 0.6 kgm}

31. Injector harness connector


1) Install O-ring (4) to harness connector (1).
2 O-ring: Engine oil (EO30)
2) Insert harness connector (1) to rocker
housing (3) and then tighten them with
mounting bolt (2).
3) Fit in harness to holder (3).

36

125E-5 Series

50 Disassembly and assembly

33. Injector
a Check that the inside of the injector sleeve
is free from dirt.
1) Install common rail (9) temporarily.

SEN00698-02

4)

5)

6)

7)
2)

3)

Install gasket (6) and O-rings (7) and (8) to


injector (1).
2 O-ring: Engine oil (EO30)

Insert holder (2) to injector (1). Continue


from that state, insert inlet connector (5) to
the high-pressure pipe insertion hole
through the rocker housing.

125E-5 Series

8)

Fit the ball washer to bolt (3) and tighten


holder (2) temporarily.
2 Spherical part of washer:
Engine oil (EO30)
Locate high-pressure sleeve (4) to inlet
connector (5) and then tighten them temporarily.
a Tighten the common rail side sleeve
nut temporarily, too.
Tighten holder (2) with bolt (3) permanently.
a Tighten bolt (3) while pulling the tube
of the high-pressure pipe in the opposite direction of the injector.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
After tightening the holder, remove the
high-pressure sleeve (4) from the inlet
connector (5) and then install the other
injectors in order according to the above
procedure.
Remove the temporarily installed common
rail.

34. Push rod


Install push rod (1).
a Check that the push rod end is placed in
the cam follower socket.

37

SEN00698-02

35. Rocker arm and shaft assembly


1) Set rocker arm and shaft assembly (1).
a When installing the rocker arm shaft,
be sure to set its side with a larger
mounting hole diameter to the bottom
and to direct ball plug (6) side toward
the front side of the engine.
2) Before tightening mounting bolts (4),
check that the ball of adjustment screw (2)
is fitted to socket (5) of the push rod.
a Install the mounting bolt after cleaning
its oil hole.
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}

36. Injector wiring harness


1) Tighten mounting bolts (3) of the harness
fixing holder.
3 Mounting bolt:
27.0 34.0 Nm {2.8 3.5 kgm}
2) Tighten 2 harness terminal mounting nuts
(2) to injector (1).
a Tighten the nuts alternately.
3 Mounting nut:
2.0 2.4 Nm {0.2 0.24 kgm}

38

50 Disassembly and assembly

37. Adjusting valve clearance


a Adjust the clearance between the crosshead and rocker arm to the following
value.
a Valve clearance (in cold state)
Unit: mm

1)

2)

Intake valve

Exhaust valve

0.33

0.71

Rotate the engine and adjust the valve


clearance of each cylinder in the firing
order of 1 5 3 6 2 4.
Rotate the crankshaft forward and match
stamped line of 1.6 TOP on vibration
damper (1) to pointer (2), watching the
movement of the valve.

Insert clearance gauge l between rocker


arm (3) and crosshead (4) and screw in
adjustment screw (5) until the gauge
becomes movable. Then tighten the locknut.
3 Locknut:
58.8 73.5 Nm {6 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.

125E-5 Series

50 Disassembly and assembly

38. Head cover


Fit the O-ring and install head cover (1).
a Take care so that O-ring may not be twisted.
3 Mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}

SEN00698-02

41. Oil cooler assembly


1) Fit the gasket to oil cooler assembly (4)
and then install them using guide bolt [1].

2)

Install drain hose (3) and brackets (2) and


(1).

39. Air vent tube


Fit a gasket on both sides and then install air
vent tube (2).
3 Joint bolt: 9.8 12.7 Nm {1.0 1.3 kgm}
40. Spill tube
Fit a gasket on both sides and then install spill
tube (1).
3 Joint bolt: 9.8 12.7 Nm {1.0 1.3 kgm}

42. Common rail and overflow tube


1) Install block (4) and then install overflow
tube (3) and spill tube (2).
2) Install common rail (1).
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}

125E-5 Series

39

SEN00698-02

50 Disassembly and assembly

43. Installation of high-pressure pipe between


fuel supply pump and common rail
1) Tighten high-pressure pipes (3) and (4) by
hand first, and then tighten them permanently.
3 Sleeve nut
(Pump side):
39.2 49 Nm {4 5 kgm}
(Common rail side):
39.2 58.8 Nm {4 6 kgm}
2) Tighten supply pump mounting bolts (2)
permanently.
3) Tighten the cylinder block side mounting
bolt of bracket (1) permanently.
4) Install the splash prevention cover on both
ends of the high-pressure pipe.
a Face the common rail side slit downward and the supply side slit toward
the cylinder block.
5) Tighten lubrication tube (12) by hand.
6) Tighten and install clamp (10) by hand
first, and then tighten it permanently.
7) Tighten and install brackets (6) and (5) by
hand first, and then tighten them permanently.
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}
9) Tighten and install clamp (11) by hand
first, and then tighten it permanently.
3 Clamp (11) mounting bolt:
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.
3 Clamp (7) mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}

40

125E-5 Series

50 Disassembly and assembly

44. Engine controller cooler


1) Install engine controller cooler (1).
3 Joint bolt:
14.8 19.6 Nm {1.5 2.0 kgm}
2) Install fuel hose (2).
3 Fuel hose:
84 132 Nm {8.5 13.5 kgm}

45. Air intake manifold


1) Fit the gasket and then install air intake
manifold (2) temporarily.
4 Air intake manifold: 25 kg

2)

Tighten the mounting bolts in the order of


given below.
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}

125E-5 Series

SEN00698-02

3)

Install bracket (1).

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
housing assembly (4) in order to eliminate
clearance in (b) (between front hanger
and air housing) and part (a) (between air
housing and diffuser). Then tighten every
bolt.

4)
5)

Install brackets (5), (6), (7) and (8).


Install oil filler port (9).

41

SEN00698-02

47. EGR valve


1) Install tube (5) with clamp (4) temporarily.
2) Fit the gasket and then install EGR valve
(3) with bolts (2) temporarily.
a Tighten it permanently according to
Step 56. described below.
3) Install oil inlet tube (1).
a Make sure when installing the tube
that it is free from twist or interference.
3 Sleeve nut:
24 27 Nm {2.4 2.7 kgm}
4) Tighten clamp (4).

50 Disassembly and assembly

4)

Install clamps (2) and (1).

49. Bypass tube


1) Fit the gasket and then install bypass tube
(1) temporarily.
2) Adjust the angle between the bypass
valve and bypass tube and then tighten
their mounting bolt permanently.
3 Bypass valve mounting bolt:
59 74 Nm {6 7.5 kgm}

48. Bypass valve


1) Fit the gasket and then install bypass
valve (8) with bolt (7) temporarily.
a Tighten it permanently according to
Step 49. described below.
2) Install oil inlet tube (6).
a Make sure when installing the tube
that it is free from twist or interference.
3 Sleeve nut:
24 27 Nm {2.4 2.7 kgm}
3) Install drain tubes (5) and (4).
a Make sure when installing the tubes
that they are free from twist or interference.
3 Joint bolt:
24.5 34.3 Nm {2.5 3.5 kgm}

42

50. High-pressure pipe


a Before installing the high-pressure pipe,
check it for the following defects. If there is
any of these defects, it can cause fuel
leakage. Accordingly, replace the highpressure pipe.
q
Check the taper seal of the connecting
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q
Check part (d) (end of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.

125E-5 Series

50 Disassembly and assembly

1)

2)

3)
4)

Install high-pressure pipes (3), (4), (5), (6),


(7) and (8).
a Mounting angle of the high-pressure
injection pipe is adjusted before the
installation of the injector.
3 Sleeve nut (on both sides):
39.2 49 Nm {4 5 kgm}
Tighten bracket (9) and clamp (10) by
hand first, and then tighten them permanently.
3 Mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
Install clamps (11), (12), (13) and (14) by
tightening them by hand.
Install 6 each of the splash prevention
covers (15) and (16).
Direct the slit on the injector side downward and that on the common rail side
toward the cylinder block.

SEN00698-02

5)

6)

Install bracket (17).


3 Clamp tightening torque:
11.8 14.7 Nm {1.2 1.5 kgm}
Tighten clamps (11), (12), (13), and (14)
permanently.
3 Mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}

51. Lubrication tube and bracket


1) Install lubrication tube (3).
3 Sleeve nut:
24 27 Nm {2.4 2.7 kgm}
2) Install brackets (1) and (2).

125E-5 Series

43

SEN00698-02

52. Fuel tube


Install fuel tubes (1) and (2) and clamp (3) temporarily.
a Tighten them permanently after installing
the fuel filter.

53. Fuel filter


1) Install fuel filter (4) with the 4 bolts.
2) Tighten permanently above fuel tubes (1)
and (2) and clamp (3) that are currently
temporarily installed.
3 Joint bolt (for both tubes (1) and (2)):
24.5 34.3 Nm {2.5 3.5 kgm}

44

50 Disassembly and assembly

54. Oil filter and oil tube


1) Install oil filter (2) temporarily with the 4
bolts.
2) Install the O-ring and then install oil tube
(1) temporarily.
3) Tighten the bottom flange of oil tube (1)
permanently and then tighten the top
flange permanently.
4) Tighten 4 oil filter (2) mounting bolts permanently.

55. Turbocharger and exhaust manifold assembly


1) Lift turbocharger and exhaust manifold
assembly (1), fit the gasket to the assembly and then install them temporarily.
4 Turbocharger and manifold assembly: 40 kg
2) After tightening bolts (2), (3) and (4), and
then tighten remaining bolts.
3 Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}

125E-5 Series

50 Disassembly and assembly

3)
4)

SEN00698-02

Fit the gasket and then connect lubrication


tube (2).
Fit the gasket and then connect EGR
bypass tube (1).

4)
5)
6)
56. EGR tube
1) Fit the gasket, adjust its angle to the EGR
valve and then install EGR tube (5) temporarily.
2) Tighten EGR tube mounting bolt (4) and
EGR valve mounting bolt.
3 EGR valve mounting bolt:
59 74 Nm {6 7.5 kgm}
3) Fit the gasket and then install EGR gas
pressure sensor tube (3).
4) Install clamps (2) and (1).

7)

Install air vent tube (4).


Fit the gasket and O-ring, and then install
coolant tube (3).
Fit the gasket and install exhaust gas discharge tube (2).
3 Mounting bolt:
59 74 Nm {6.0 7.5 kgm}
Fit the gasket and install drain tube (1).

58. Water pump suction tube


Fit the gasket and install tube (1).

57. EGR cooler


1) Install EGR cooler (9) with the 4 bolts.
2) Fit the gasket and then connect EGR tube
(7).
a Clamp (8) is to be tightened together.
3) Fit the O-ring, install coolant tube (6) and
then tighten the clamp of rubber hose (5).

125E-5 Series

45

SEN00698-02

59. Alternator
1) Hang V-belt on the pulley of alternator (5)
and tighten mounting bolt (2) and lock bolt
(3) temporarily.
2) Adjust the belt tension with V-belt tension
adjustment nut and tighten mounting bolt
(2) and lock bolt (3).
3) Check the belt tension and then tighten
locknut (4).
4) Install cover (1).

60. Starting motor


Set starting motor (2) and then tighten 3
mounting bolts (1).

61. Heat shielding plate


Install the heat shielding plate to EGR and
EGR pipe.
62. Harness assembly
Locate the harness in the specified position,
connect the harness connectors to the specified counterparts and then fix them using the
clamp.

46

50 Disassembly and assembly

63. Tightening torque for sensor


Use the following tightening torque when
removal and installation or replacement of the
sensor.
Sensor name
Fuel
temperature

Tightening torque
23 3 Nm {2.35 0.3 kgm}

Boost pressure 5.5 0.5 Nm {0.56 0.05 kgm}


Intake air
temperature

23 3 Nm {2.35 0.3 kgm}

Coolant
temperature

23 3 Nm {2.35 0.3 kgm}

EGR gas
pressure

23 3 Nm {2.35 0.3 kgm}

Engine oil
pressure

23 3 Nm {2.35 0.3 kgm}

Atmospheric
pressure

4.5 0.5 Nm {0.46 0.05 kgm}


(Hexagonal head bolt and hexagonal socket head bolt)

Fuel pressure

Never disassemble.

64. Checking for fuel leakage


a If fuel supply pump (2), common rail (1), or
high-pressure pipe is removed and
installed, after assembling the engine,
check for fuel leakage according to the following procedure.

1)

2)

Clean and degrease the engine and the


parts around it in advance so that you can
test it easily for fuel leakage.
Spray color checker (developer) over the
fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.

125E-5 Series

50 Disassembly and assembly

3)

4)
5)

6)
7)

8)

9)

SEN00698-02

Check the fuel piping and devices for fuel


leakage.
a Check mainly around the high-pressure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
Run the engine at low idle.
Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pressure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
Run the engine at high idle.
Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pressure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
Run the engine at high idle and load it.
a When checking while the components
to be checked are mounted on the
machine, stall the torque converter or
relieve the hydraulic pump.
Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pressure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
a If no fuel leakage is detected, check
is completed.

125E-5 Series

47

SEN00698-02

KOMATSU 125E-5 Series engine


Form No. SEN00698-02

2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)

48

SEN00699-03

ENGINE
1SHOP MANUAL

125E-5 Series

50 Disassembly and assembly1


Disassembly and assembly, Part 2
(EGR-less)
Disassembly and assembly, Part 2 (EGR-less) .............................................................................................. 2
General disassembly of engine............................................................................................................ 2
General assembly of engine .............................................................................................................. 16

125E-5 Series

SEN00699-03

50 Disassembly and assembly

Disassembly and assembly, Part 2 (EGR-less)


General disassembly of engine 1
a

The shapes, quantity, locations, etc. of the


parts depend on each applicable machine.
Take care.

1.

Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean it
generally and carefully for accurate inspection
of its parts and quick disassembly and assembly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.

2.

Setting engine assembly


1) Place engine assembly (1) on stable block
[1] so that it will not tip over.
a The weight depends on each applicable machine.
4

2)

4.

Wiring harness assembly


Disconnect the connectors and clamps and
remove wiring harness assembly (1).

5.

Starting motor assembly


Remove 3 mounting bolts (1) and starting
motor assembly (2).

Engine assembly: 1,250 kg

Drain the engine coolant and engine oil.


a The quantity of the engine oil
depends on each applicable machine.
6

3.

Engine oil: Approx. 40 l

Muffler, air cleaner and related parts


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

125E-5 Series

50 Disassembly and assembly

6.

SEN00699-03

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 adjustment nut, and remove V-belt (5).
4) Remove mounting bolt (2), fixing bolt (3)
and alternator assembly (6).
5) Remove plate (7) and bracket (8).
a These parts depend on each applicable
machine.

9.

Exhaust manifold assembly


Sling exhaust manifold assembly (1), remove
18 mounting bolts (2), and remove the exhaust
manifold assembly.
4

7.

Exhaust manifold assembly: 35 kg

Water pump suction tube


Remove tube (1).

10. Thermostat housing assembly


1) Remove connector (1).
2) Remove thermostat housing assembly (2).

8.

Turbocharger assembly
1) Remove bracket (1).
2) Remove the 5 clamps and turbocharger
lubricating oil inlet tube (2).
3) Remove the tube bracket and turbocharger outlet tube (3).
4) Remove 4 mounting bolts (4) and turbocharger assembly (5).

125E-5 Series

SEN00699-03

11. Water pump assembly


1) Remove connector (1).
2) Remove 3 mounting bolts (2) and water
pump assembly (3).

50 Disassembly and assembly

14. Fuel filters


1) Remove cover (1).
2) Remove the joint bolt and tubes (2) and
(3).
3) Remove the joint bolt and hose (4).
4) Remove the 2 clamps, joint bolt and tube
(5).
5) Remove clamp (6), joint bolt and tubes (7)
and (8).
6) Remove fuel filters (9) and (10).

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).

125E-5 Series

50 Disassembly and assembly

16. Engine controller cooler assembly and


block
1) Remove the 5 mounting bolts and engine
controller cooler assembly (1).
2) Remove the joint bolt and tubes (2) and
(3).
3) Remove block (4).

17. Electric priming pump and block


a Electric priming pump is not set for some
models.
1) Disconnect wiring harness connector (1).
2) Remove the joint bolt and hoses (2) and
(3).
3) Remove the joint bolt and tube (4).
4) Remove the joint bolt, loosen the sleeve
nut, and remove tube (5).
5) Remove Electric priming pump (6).
6) Remove block (7).

SEN00699-03

18. Bracket
1) Remove wiring harness (1).
2) Remove brackets (2) and (3).

19. Air connector, electrical intake air heater


and front hanger
1) Remove the 6 mounting bolts, air connector (1) and electrical intake air heater (2).
2) Remove plates (3) and (4).
3) Remove front hanger (5).

20. Diffuser air housing assembly


Remove the 8 mounting bolts and lift off diffuser and air housing assembly (1).
4

125E-5 Series

Diffuser and air housing assembly: 40 kg

SEN00699-03

21. Bracket
1) Remove the 2 mounting bolts and bracket
(1).
2) Remove the 4 mounting bolts and bracket
(2).

22. Spill pipe


Remove 6 joint bolts (1) and spill pipe (2).

50 Disassembly and assembly

23. High-pressure pipe


1) Remove high-pressure pipe clamp mounting bolt (1).
2) Remove the 2 mounting bolts and bracket
(2).

3)
4)
5)
6)

7)

Remove high-pressure pipe clamp (3).


Remove 10 high-pressure pipe clamps
(4).
Remove 6 brackets (5).
Remove the pin, 6 splash prevention covers (6) on the injector side and 6 splash
prevention covers (7) on the common rail
side.
Remove 6 high-pressure pipes (8).

125E-5 Series

50 Disassembly and assembly

24. Air intake manifold


Sling air intake manifold (1), remove the 24
mounting bolts, and remove the air intake manifold.
4

Air intake manifold: 40 kg

25. Common rail


1) Remove the pin, 2 splash prevention covers (1) on the common rail side and 2
splash prevention covers (2) on the fuel
supply pump side.
2) Remove high-pressure pipe clamps (3),
(4), (5) and (6) and high-pressure pipes
(7) and (8).
3) Remove the joint bolt and tube (9).
4) Remove common rail (10).
5) Remove the 4 mounting bolts and bracket
(11).

125E-5 Series

SEN00699-03

26. Fuel supply pump assembly


1) Remove cover (1).
2) Rotate the crankshaft forward and set
intermediate point (a) between stamped
2/5 TOP and 3/4 TOP on damper (2) to
pointer (3) (stamped 1/6 TOP comes
almost directly under).
a Make sure at this point that the forcing tap of the drive gear is aligned to
the bolt hole at the top of cover (1).
(If not, rotate the crankshaft 1 more
turn.)
a At this point, the key of the shaft is
turned clockwise by 15 from the top.

3)

Remove mounting nut (4) and then remove


washer (5).
a Use a magnet or the like in this operation so that washer (5) may not be
inadvertently dropped into the case.

SEN00699-03

4)

5)

6)

Remove pump mounting bolts (6) and


bracket (7).
a Leave bolts (6) tightened by 2 3
threads to prevent the pump from falling down.
Install tool P1 with P2 and P3 and then
screw in the center bolt of P1 to remove
the gear from the shaft.
Remove remaining bolts and then remove
fuel supply pump assembly (8).
a Leave tools P1, P2 and P3 in the
installed condition.

50 Disassembly and assembly

28. Injector wiring harness


1) Fully loosen 2 wiring harness terminal
mounting nuts (2) on the head of injector
(1).
a Loosen nuts alternately.
2) Loosen bolt (3) of harness fixing holder.

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).

27. Tube and head cover


1) Remove 6 joint bolts (1) and tube (2).
2) Remove the mounting bolts and head covers (3).

30. Push rods


Remove 12 push rods (1).

125E-5 Series

50 Disassembly and assembly

31. Injector
Remove holder mounting bolts (3) of injector
(1) and then remove injector (1) and holder (2)
together.
a Never hold the solenoid valve at the top of
the injector with pliers, etc.

32. Crosshead
Remove 12 crossheads (1).

33. Injector wiring harness


1) Remove mounting bolt (2) of wiring harness connector (1).
2) Remove holder (3) from the wiring harness.

125E-5 Series

SEN00699-03

3)

4)

Press out wiring harness connector (1)


from inside of rocker housing (4) to
remove it.
Remove O-ring (5) from the rocker housing.

34. Rocker arm housing


Remove rocker arm housing (1).

35. Cam follower cover


1) Remove 3 cam follower covers (1).
2) Remove oil level gauge tube (2).

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36. Cam follower


Remove 12 mounting bolts (1) and 6 cam followers (2).
a Remove dowel pin (3).

37. Removal of cylinder head assembly


1) Remove 7 mounting bolts (2) each from
cylinder head assembly (1).
2) Using eyebolts [1], lift off cylinder head
assembly (1).
4 Cylinder head assembly: 20 kg
3)

50 Disassembly and assembly

38. Disassembly of cylinder head assembly


1) Using tool C, compress valve spring (3)
and remove valve cotter (4).
2) Remove upper seat (5) and valve spring
(3).

3)
4)

Remove seal (7) and lower seat (8).


Raise the cylinder head and remove valve
(6).
a Make marks for combinations of the
valves and heads.

Remove each head gasket.

39. Setting to engine repair stand


Sling the engine, install tool A2, and set the
engine while matching tool A2 to tool A1.

10

125E-5 Series

50 Disassembly and assembly

40. Oil pan


Reverse the engine and remove oil pan (1).

SEN00699-03

43. Flywheel housing


1) Install slings [1] to the right and left of
housing (1) and sling the housing.
2) Remove the 10 mounting bolts, remove
the housing from the dowel pins, and lift it
off.
4

Flywheel housing: 80 kg

41. Speed sensors


Reverse the engine and remove speed sensors (1) and (2).
a Speed sensor (2) may not be installed,
depending on each applicable machine.
44. Damper and pulley assembly
Sling damper and pulley assembly (1), remove
the 6 mounting bolts, and lift off the assembly.
4 Damper and pulley assembly: 25 kg

42. Flywheel
1) Install sling [1] to flywheel (1) and lift it up.
2) Remove the 6 mounting bolts, remove the
flywheel from the dowel pins, and lift it off.
4

125E-5 Series

Flywheel: 25 kg

11

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45. Front support and front cover


1) Sling front support (1), remove the mounting bolts, and lift off the front support.
a The shape depends on the applicable
machine.
3 Front support: 30 kg
2) Sling front cover (2), remove the mounting
bolts, and lift off the front cover.
3 Front cover: 30 kg
3) Remove tool P and supply pump drive
gear.

50 Disassembly and assembly

47. Oil pump


Remove 4 mounting bolts (1) and then remove
oil pump (2).

48. Idler gear


1) Remove mounting bolt (1) and then remove
plate (2) and oil pump idler gear (3).
2) Remove shaft (4).
3) Remove mounting bolt (5) and then
remove shaft (6), main idler gear (7) and
plate (8).
46. Camshaft
1) Remove 2 mounting bolts (1).
2) Remove camshaft (2).
a When pulling out the camshaft, turn it
gently so that damages may not be
left on the cam bushing.

12

125E-5 Series

50 Disassembly and assembly

49. Oil suction pipe


Remove brackets (1) and then remove oil suction pipe (2).

50. Piston cooling nozzle


Remove mounting bolt (1) and each piston
cooling nozzle (2).

SEN00699-03

51. Piston and connecting rod assembly


a Before removing the piston and connecting rod assembly, measure its end play
with dial gauge [3], if necessary.

1)

2)
3)
4)
5)

125E-5 Series

Check the stamped No. of the connecting


rod cap.
q
The cap No. and cylinder No. must be
the same.
q
The cap No. must be stamped on the
cam side.
a If the No. is not stamped, stamp it
before removing the connecting rod.
Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
Scrub the carbon off the top wall of the cylinder liner with fine sandpaper.
Remove connecting rod cap mounting
bolts (1).
Hit connecting rod cap (2) with a plastic
hammer so lightly that the threads of the
connecting rod bolts will not be damaged
and remove connecting rod cap (2) and
connecting rod bearing as a unit.

13

SEN00699-03

6)

7)

50 Disassembly and assembly

Push in and remove the piston and connecting rod assembly with a wood bar, etc.
from the oil pan side, while supporting piston (3) on the cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the connecting rod.
Remove the other piston and connecting
rod assemblies according to the above
procedure.
a Take care not to damage the sliding
portions of the pistons and bearings.
a Assemble each connecting rod and
cap temporarily so that they will not
be assembled with other ones and
keep them and the bearing together.

3]

Using tool D, remove piston ring (8).


a Keep the piston, connecting rod,
connecting rod bearing, piston
rings, and piston pin by each cylinder.

52. Crankshaft
a Before removing the crankshaft, measure its
end play with dial gauge [3], if necessary.

8)

14

Disassemble the piston and connecting


rod assembly according to the following
procedure.
1] Remove 2 snap rings (4).
2] While supporting connecting rod (5),
remove piston pin (6) to disconnect
piston (7) and connecting rod.

1)
2)

Remove mounting bolts (2) of main cap (1).


Insert the bolts in the bolt holes of the
main cap and remove the cap, while shaking it.

125E-5 Series

50 Disassembly and assembly


a

3)

4)

Thrust bearing (3) is assembled to


No. 7 main cap. After removing the
cap, apply a marking to the re-assembly position.

Lift off crankshaft (4).


a When removing the crankshaft, take
care so that its sliding surfaces may
not be damaged.
4 Crankshaft: 110 kg

SEN00699-03

5)

Remove upper bearing (6).


a Apply a marking to the assembly
positions of the main cap, main bearing, and thrust bearing. And store
them by the journal No.

53. Cylinder liner


Using tool E, pull out cylinder (1).
a Before removing the cylinder liner, measure its projection with dial gauge [3], if
necessary.

Remove upper thrust bearing (5).

125E-5 Series

15

SEN00699-03

General assembly of engine


a
a

50 Disassembly and assembly

2]

The shapes, quantity, locations, etc. of the


parts depend on each applicable machine.
Take care.
Clean each part carefully, and check it for
bruise, flaw, cavity, etc. Make sure each oil or
coolant path is through.

3]

Tightening bolts by plastic-region turning angle


method
a Bolts tightened by plastic-region turning angle
method
q
Cylinder head mounting bolt
q
Main cap mounting bolt
q
Connecting rod cap mounting bolt
a If the plastic-region turning angle method is
applied, the tightened bolts have permanent
strain. Accordingly, the allowable number of
using times of each bolt is limited. Observe the
following precautions.
q
Before tightening each bolt, measure its
stem length and make sure that the length
is less than the using limit. If the stem is
longer than the using limit, it should not be
used but replaced.
q
Check each mounting bolt head for punch
marks. If there are punch marks more than
the specified numbers, replace the bolt.
1.

Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 320 kg

2)

16

Before inserting the cylinder liners, prepare the cylinder block according to the
following procedure.
1] Remove the rust and scales from faces
(A) and (B) with sandpaper, etc. until
the machined surfaces are exposed.

4]
5]

2.

Polish part (R) with sandpaper of


about No. 240 until it becomes a
smooth rounded surface.
If part (R) is sharp or has burrs, finish
it with a scraper or sandpaper.
Finish this surface particularly smoothly
so that it will not damage the O-ring.
If face (B) is so pitted that it cannot be
repaired, replace the cylinder block.
If faces (A) and (R) are pitted, finish
them smoothly.
Check the counterbored part and
remove burrs. If chips or dust is
present on face (C), the liner may not
fit well, resulting in coolant leakage or
insufficient liner protrusion. Thus,
they must be eliminated.
a If the counterbored part is drooping, corroded, or pitted, repair it.

Cylinder liner
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not roughened
because of rusting or pitting. If those parts
are roughened, replace the cylinder liner.
2) Install clevis seal (1), O-rings (2) and (3) to
the cylinder liner.
a Check that there is not a burr, dust,
etc. in the groove of the liner.
a Replace the O-ring and clevis seal
with new ones.
a Fit the clevis seal with the chamfered
side down. When fitting it, press it
against the seal groove all round so
that it will not be twisted.
a When installing O-rings (2) and (3),
refer to the following.
q
O-ring (2): The whole ring is black.
q
O-ring (3): The whole ring is red.
2 Clevis seal and O-ring:
Rubber lubricant (LH-50 from NOF
Corporation)

125E-5 Series

50 Disassembly and assembly


a
a

If LH-50 is not available, apply clean


engine oil SAE No. 30.
Since the clevis seal and O-ring are
swollen and deteriorated by oil, apply
a small amount of oil to them thinly
with a brush just before fitting them.

SEN00699-03

4)

Apply gasket sealant to the parts of the


cylinder block and cylinder liner which will
fit to the counterboared parts.
a Wipe off dirt and oil with cloth from
the contact faces of the counterboared parts of the cylinder block and
liner flange.
2 Cylinder block: Gasket sealant (LG-6)
q
Gasket sealant:
0.8 1.6 mm in diameter
q
Overlap (a) of gasket sealant: 6 6 mm
a If the applied gasket sealant is left for a
long time, its surface becomes hard.
Accordingly, install the cylinder block to
the cylinder head within 50 minutes.

5)

Insert cylinder liner (1) to the cylinder block.


a Insert cylinder liner (1) in the cylinder
block slowly, taking care not to damage the O-ring.
Push in cylinder liner (1) further by both
hands.
a If the liner does not enter the cylinder
smoothly, the O-ring may be damaged. In this case, check the cylinder
block for burrs.
Using tool F, press fit cylinder liner (1) to
the cylinder block.

6)
3)

After fitting the O-ring, check it for twist. If


it is twisted, correct it with a flexible rod
(about 10 mm in diameter).
7)

125E-5 Series

17

SEN00699-03

8)

To prevent the gasket sealant from projecting through the clearance between the
block and liner after the cylinder head is
tightened, tighten the cylinder head temporarily with the used head gasket
inserted.
a At this time, observe the following tightening torque and tightening order.
3 Temporary tightening torque:
127.5 147.1 Nm {13 15 kgm}

9)

Remove the cylinder head and wipe off


the gasket sealant projected from the
counterbored part.
a Be sure to perform steps 8) and 9)
above since the projected gasket
sealant can deform the grommet of
the head gasket.

50 Disassembly and assembly

3.

Crankshaft
a Cylinder block and main bearing are
selective mating parts and the prepared
spare parts ensure the required clearance.
1) Install the upper main bearing (6) to the
notch of the cylinder block while aligning
the bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.
2 Bearing inner surface:
Engine oil (EO30-DH)

2)

Drive in the roll pin so that its projection


from the block end face may become 1.5
1.9 mm and then install upper side thrust
bearing (5).
a Install each thrust bearing with the
grooved surface on the crankshaft side.

3)

Before assembling the crankshaft, check


the following.
q
Troubles on the front side and rear
side threaded portions
(Bottom can be easily screwed in by
hand)
q
Scratches or dents on pin and main
journal
q
Presence or absence of dust inside
oil hole

10) Using dial gauge [3], measure the projection of the cylinder liner.
a When measuring projection of the
liner, fix the liner using a plate so that
it may not be lifted by the O-ring.
a Projection of cylinder liner:
0.07 0.15 mm
a If the end play is out of the standard,
correct it. For details, see Structure,
function and maintenance standard.

18

125E-5 Series

50 Disassembly and assembly

4)

5)

Lift and set crankshaft (4) to the mounting


position.
a When installing the crankshaft, take
care not to damage its sliding surfaces by, for in stance, bumping
against the cylinder block.
a When replacing the crank gear, heat it
with a bearing heater set at 150C
and then fit it immediately after the
heating.
4 Crankshaft: 110 kg
2 Cylinder block journal:
Engine oil (EO30-DH)

SEN00699-03

6)

Install main cap (1).


a When installing, make sure that the
stamped No. at center of the main
cap is aligned to the stamped journal
No. of the cylinder block.
a Install the main cap with the cast letter (F) toward the front of the engine.
2 Crankshaft journal surface:
Engine oil (EO30-DH)

7)

Before tightening the main cap mounting


bolts, check the following items. If any of
the following conditions applies, do not
reuse that bolt but replace it.
q
Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q
Length (a) of bolt stem:
Min. 159.8 mm

Install lower main bearing (7) to the main


cap.
a Install lower main bearing (7) to the
notch of the main cap while aligning
the bearing projection to it.
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
grooved surface on the crankshaft side.

8)

Screw in main cap mounting bolts (2)


alternately until the main cap (1) is
securely fitted in its place.
9) Tighten main cap mounting bolts (2)
according to the following procedure.
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-DH)

125E-5 Series

19

SEN00699-03
3

50 Disassembly and assembly

Mounting bolt
1st time : 98.1 9.8 Nm {10 1 kgm}
2nd time : 196.1 4.9 Nm {20 0.5 kgm}
3rd time : Using tool J, tighten the bolt by
90 (+30/0).

4.

When not using tool J, apply mark (b)


to the main cap and bolt with paint,
then tighten the bolt by 90 (+30/0).
10) Make punch mark (c) on the mounting bolt
head.
a When a new bolt is used, do not
make a punch mark on its head.

11) Check that the crankshaft turns smoothly.


12) Measure the end play of the crankshaft
with dial gauge [3].
a End play: 0.14 0.315 mm
a If the end play is out of the standard,
correct it. For details, see Structure,
function and maintenance standard.

20

Piston and connecting rod assembly


a Piston and cylinder liner are selective mating parts and the prepared spare parts
ensure the required clearance.
1) Using tool D, assemble piston ring (8) in
the order of oil ring, second ring and top
ring starting from the bottom.
a Fit the top ring and second ring to the
piston with the stamped mark side up.
q
Stamp on top ring: 1R
q
Stamp on second ring: 2R
a Take the expander out of the oil ring
and fit it to the piston first and then fit
the oil ring. At this time, make sure
that the expander is fitted to the ring
groove perfectly.

2)

Set the abutment joint of each piston ring


as shown in the following figure.
a Adjust oil ring so that the joint of the
expander will be at 180 to the abutment joint of the oil ring.

125E-5 Series

50 Disassembly and assembly

3)
4)

Install snap ring (4) to one side of piston (7).


Heat piston (7) at 100C for 5 minutes
minimum in the heating furnace.
a When the furnace is not available,
heat it at 100C for 5 minutes minimum in hot water.

Set connecting rod (5) on piston (7).


a Set the connecting rod so that the ID
marking "6251" at the bottom of the
connecting rod comes to the left side
as the grade marking on the piston
top surface is faced toward the front
side of the engine. Then insert the
connecting rod to piston pin (6).
2 Piston boss: Engine oil (EO30-DH)
6) Install snap ring (4) on the opposite side.
a Turn the snap ring on both sides to
make sure they are securely fitted to
the ring groove.

SEN00699-03

7)

Install upper main bearing (8) to the notch


of the connecting rod while aligning the
bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.
a Make sure that the bearing hole and
connecting rod oil hole are aligned.

8)

Install the connecting rod lower bearing


(9) to the notch of the connecting rod cap
while aligning the bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.

5)

125E-5 Series

21

SEN00699-03

9)

Set the cylinder crankshaft, to which the piston and connecting rod assembly is to be
assembled, to the bottom dead center.
10) Insert piston and connecting rod assembly
(3) in the cylinder block so that ID marking
"6251" of the connecting rod may be faced
toward the left side face of the engine.
a Make sure the abutment joint of the
piston ring is located in the position
indicated in the following figure.
2 Inner surface of connecting rod and
cylinder: Engine oil (EO30-DH)

11) Using tool G, reduce the piston ring and


then push in the piston head with a wood
bar, etc.

22

50 Disassembly and assembly

12) Install connecting rod cap (2).


a Align match mark of connecting rod
(5 ) and connecting ro d cap (2).
(Above aligns the match mark to ID
marking "6251" on the opposite side.)
2 Inner surface of connecting rod cap
bearing: Engine oil (EO30-DH)

13) Before tightening the connecting rod cap


mounting bolts, check the following items.
If any of the following conditions applies,
do not reuse that bolt but replace it.
q
Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q
Length (a) of bolt stem: Min. 84.1 mm

125E-5 Series

50 Disassembly and assembly

SEN00699-03

14) Tighten connecting rod cap mounting bolts


alternately until the connecting rod cap is
closely contacted.
15) Tighten connecting rod cap mounting bolts
(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.

5.

17) Turn the crankshaft to check that it rotates


normally.
18) Measure the side clearance of the connecting rod with dial gauge [3].
a Side clearance: 0.2 0.375 mm

125E-5 Series

Piston cooling nozzle


1) Rotate the crankshaft and set the No. 1
No. 3 pistons to the following positions for
installation of the piston cooling nozzles of
each piston.
q
Set the No. 1 piston to top: Piston
cooling nozzles of the No. 1 and No. 6
pistons can be installed.
q
Set the No. 2 piston to top: Piston
cooling nozzles of the No. 2 and No. 5
pistons can be installed.
q
Set the No. 3 piston to top: Piston
cooling nozzles of the No. 3 and No. 4
piston can be installed.
2) Set piston cooling nozzle (2) adjusting the
dowel pin position and then tighten mounting bolt (1).
3 Mounting bolt:
27 34 Nm {2.8 3.5 kgm}

23

SEN00699-03
a

6.

50 Disassembly and assembly

After the installation, make sure the


nozzle end is situated at center of the
cut of respective pistons.

Oil suction pipe


Install oil suction pipe (2) after attaching the Oring to it and then fix them using bracket (1).

8.

7.

24

Oil pump
1) Install oil pump (2) after attaching the Oring to it and then tighten 4 mounting bolts
(1).
2) Drive in the pin and then install shaft (4).

Idler gear
1) Install plate (8) to the engine block and then
install main idler gear (7) and shaft (6).
a When installing plate (8), set its
chamfered side to the front side of the
engine.
2) Matching A mark of the crankshaft gear
and A mark of main idler gear (7),
tighten mounting bolt (5).
3 Mounting bolt:
245 294 Nm {25 30 kgm}

125E-5 Series

50 Disassembly and assembly

9.

SEN00699-03

Idler gear
Assemble oil pump idler gear (3), attach plate
(2) to it and then tighten them using mounting
bolt (1).
3 Mounting bolt:
147 176.4 Nm {15 18 kgm}

11. Cam follower


1) Drive in dowel ring (3) to the cylinder block.
2) Tighten 6 cam followers (2) using mounting bolt (1).
3 Mounting bolt:
44 59 Nm {4.5 6 kgm}

10. Camshaft
1) Assemble camshaft (2) to the cylinder
block.
a Rotate the camshaft when assembling so that the cam bushing may not
be damaged.
a When replacing the cam gear, heat it
at 200 240C for 30 minutes minimum in an electronic oven and then
shrink fit it.
2 Camshaft journal surface:
Engine oil (EO30-DH)
2) Matching B mark of the crankshaft gear
and B mark of the main idler gear,
tighten mounting bolt (1).

12. Cam follower cover


Install the O-ring and cam follower cover (1).
3 Mounting bolt:
9.8 12.7 Nm {1.0 1.3 kgm}

13. Water pump assembly


Fit the O-ring to water pump assembly (3) and
install them temporarily.

125E-5 Series

25

SEN00699-03

14. Fuel supply pump assembly


1) Set fuel supply pump assembly (3) and
then tighten it temporarily using 4 mounting bolts (5).
a Tighten it permanently according to
Step 39. described below.
2 Mounting bolt: Adhesive (LT-2)
2) Set the assembly by aligning C mark to
C mark of camshaft gear (2) while aligning the key groove of supply pump drive
gear (1) to the woodruff key of the shaft.
3) Fit the washer and then tighten them
using gear mounting nut (4).
3 Gear mounting nut:
127 147 Nm {13 15 kgm}
4) Install bracket (6).
3 Mounting bolt (supply pump side):
19.6 29.4 Nm {2.0 3.0 kgm}
a Leave the cylinder block side mounting bolt in temporarily tightened state
(it is to be tightened permanently in
the following Step 39.).

50 Disassembly and assembly

15. Make sure that match marks (A to C) of drive


gears and idler gears are matched.

16. Measuring backlash and end play


a Measure the backlash and end play of
each gear with dial gauge [3].
Standard backlash of each gear
Position

Range (mm)

0.105 0.325

0.105 0.325

0.116 0.359

0.105 0.337

0.082 0.389

0.076 0.366

Standard end play of each gear

26

Position

Range (mm)

0.05 0.17

0.05 0.21

If the end play is out of the standard, correct it. For details, see Structure, function
and maintenance standard.

125E-5 Series

50 Disassembly and assembly

SEN00699-03

2)

3)
4)

5)

17. Front cover


1) Using the push tool (outside diameter 120
mm), press fit oil seal (5) to the cover.
a Oil seal press fit allowance (a):
16 (+1/0) mm
2 Oil seal lip (50 80% of void lip
space): Grease (G2-LI)

18. Flywheel housing


1) Apply a string of gasket sealant 1 mm in
diameter as shown below.

2)

3)

125E-5 Series

Lift front cover (2) and then install it using


the guide bolt.
a When installing, take care not to damage the oil seal.
4 Front cover: 30 kg
2 Front cover mounting surface:
Gasket sealant (LG-7)
Install cover (3).
Using dial gauge, measure the level difference between underside faces of the cylinder block and front cover.
a Difference: 0 0.275 mm
a If the difference is out of the standard,
correct it. For details, see Structure,
function and maintenance standard.
Install front support (1).
a Its shape depends on the applicable
machines.
4 Front support: 30 kg

Sling flywheel housing (1) and then install


it to the cylinder block.
4 Flywheel housing: 80 kg
Tighten flywheel housing mounting bolts (2).

27

SEN00699-03

50 Disassembly and assembly

a
a

Tighten the flywheel housing mounting bolts in the following order in 2


steps.
a The following indicates that mounting
bolts 1, 4 and 2, 9 are to be tightened
twice in 1st time.
2 Mounting bolt: Engine oil (EO30DH)
3 Mounting bolt:
1st time:
147 235 Nm {15 24 kgm}
2nd time:
245 309 Nm {25 31.5 kgm}

4)

After installing the flywheel housing, measure its facial runout and radial runout with
dial gauge [3].

imum on the flywheel housing including the periphery.


Move the crankshaft either in the front
or rear side in order to prevent errors
due to the end play.
Make sure after rotating the crankshaft by a turn that the gauge pointer
is returned to the position where it
had been situated when the crankshaft was started to turn.
The gauge pointer deflects in both
sides right and left. Thus, reasonable care must be exercised to avoid
misreading of the pointer when the
gauge is provided in the top, bottom,
left and right side of the measured
end face.
Facial runout: Max. 0.20 mm

Measurement of radial runout of flywheel


housing
Like in measurement of the facial runout, set
dial gauge [3] so that its probe may contact
against the flywheel housing centering location
at a right angle.
a In measurement of radial runout, errors
due to end play of the crankshaft do not
occur. As for other points, however, the
precautions noted for the facial runout
remain applicable to the radial runout
as they are.
a Radial runout: Max. 0.20 mm

Measurement of facial runout of flywheel


housing
1] Apply the magnet stand to the crankshaft end face.
2] Set dial gauge [3] so that its probe
may contact against the flywheel
housing end face at a right angle.
3] Rotate the crankshaft by a turn to
read the difference between the maximum and minimum values indicated
by the gauge pointer.
a Measurement shall be conducted at
eight equally distanced positions min-

28

125E-5 Series

50 Disassembly and assembly

5)

Using dial gauge [3], measure the level


difference between underside faces of the
cylinder block and flywheel housing.
a Difference: 0 0.35 mm
a If the difference is out of the standard,
correct it. For details, see Structure,
function and maintenance standard.

SEN00699-03
a

1)

Never remove inside plastic cylinder


(3) of the standard spare seal before
installing the seal.
Set the large inside diameter side (b)
of plastic inside cylinder (3) to the end
of crankshaft (4).
a Take care not to mistake the direction of the plastic inside cylinder.

19. Rear oil seal


a Check the Teflon seal (Laydown lip seal)
by checking the wear of the crankshaft
and replace it with the Standard seal or
Sleeved seal.
a If the crankshaft is worn to the degree of
luster (If wear which you feel with your finger is less than 10 mm) and does not have
any flaw, install the standard seal. In other
cases, install the sleeved seal.
a The left one in the following figure is the
standard seal and the right one is the
sleeved seal.
2)
3)

Hold the metal ring of seal (1) by both


hands and push it in firmly.
After pushing in the seal, remove
plastic inside cylinder (3).
a When removing the inside cylinder, take care not to damage the
seal lip.

Procedure for installing standard seal


a Before installing the seal, check that
the end corners and lip sliding surfaces of crankshaft (4) are free from
flaw, burr, and rust of the housing.
a When installing the seal, do not apply
oil or grease to the shaft and seal lip
(a). Wipe off the oil from the shaft.

125E-5 Series

29

SEN00699-03

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.

Procedure for installing sleeved seal


a Before installing the seal, make sure
that the end corners and lip sliding surfaces of crankshaft (4) are free from
flaws, burrs, and rusts of the housing.
a When installing the seal, do not apply
oil or grease to the shaft, sleeve (1),
and seal lip (a). Wipe off the oil from
the shaft.
a Handle the seal and sleeve as an
assembly and don't separate them
from each other.

1)

30

50 Disassembly and assembly

2)

Set the sleeve of the seal to the end


of the crankshaft, and then tighten
bolt N3 evenly to press fit sleeve and
seal assembly (2) until the end face of
tool N2 reaches the end of crankshaft
(4).

3)

Remove tool N2 and then replace it


with tool N1.
Tighten bolt N4 evenly to press fit
sleeve and seal assembly (2) until the
end face of tool N1 reaches the end
of crankshaft (4).
a After press fitting the seal, remove
the red sealant layer from its
periphery.

4)

Set sleeve and seal assembly (2) to


tool N2.
2 Inside sleeve:
Gasket sealant (LG-7)

125E-5 Series

50 Disassembly and assembly

SEN00699-03

20. Flywheel
1) Using sling [1], lift up flywheel (1) and then
install it aligning to the dowel pin.
2) Tighten mounting bolts (2) in the following
order in 2 steps.
2 Mounting bolt: Engine oil (EO30DH)
3 Mounting bolt
1st time:
147 19.6 Nm {15 2.0 kgm}
2nd time:
289.1 19.6 Nm {29.5 2.0 kgm}

3)

Using dial gauge [3], measure the facial


and radial runout.
a Facial runout : Max. 0.20 mm
a Radial runout: Max. 0.15 mm

125E-5 Series

21. 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}
2) Install speed sensor (2).
1] Screw in speed sensor (2) until its tip
lightly touches the tooth tip of ring
gear (3).
2 Threads:Gasket sealant
(Hydraulic sealant
from Loctite)
2] Rotate speed sensor (2) in the opposite direction by 1/2 2/3 turns.
a Clearance (a) will become 0.75
1 mm.
3] Tighten nut (4) while fixing sensor (2).
3 Nut: 69 74 Nm {7 7.5 kgm}

31

SEN00699-03

50 Disassembly and assembly

23. 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)

24. Removal from engine repair stand


1) Reverse the engine.
2) Disconnect tool A1 from tool A2.
3) Remove tool A2 from the engine.

22. 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}

25. Setting the engine


Set engine (1) on a rigid and stable stands [1].

32

125E-5 Series

50 Disassembly and assembly

26. Assembly of cylinder head assembly


1) Assemble valve (6).
2 Valve stem: Engine oil (EO30-DH)
2) Raise the cylinder head and then install
lower seat (8) and seal (7).

3)
4)

Assemble valve spring (3) and upper


sheet (5).
Using tool C, compress the valve spring
and install valve cotter (4).
a Hit the valve stem lightly with a plastic
hammer to make sure that the valve
cotter is fitted to the groove of the
valve stem.

125E-5 Series

SEN00699-03

27. Installation of cylinder head assembly


1) Check that the cylinder head mounting
face and inside of the cylinder are free
from foreign matter and then set cylinder
head gasket (1).
a When fitting the gasket, check that
the grommets are fitted correctly.

2)

Before tightening the cylinder head


mounting bolts, check the following items.
If any of the following conditions applies,
do not reuse that bolt but replace it.
q
Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q
Length (a) of bolt stem:
Min. 171.4 mm

33

SEN00699-03

3)

50 Disassembly and assembly

Using sling [1], lift and set cylinder head


assembly (2) to the cylinder block.
4 Cylinder head assembly: 20 kg

4)

Tighten the cylinder head assembly


mounting bolts and auxiliary bolts.
1] Tighten the mounting bolts in the
order of 1 to 6 shown in the figure.
2 Mounting bolt:
Molybdenum disulfide lubricant (LM-P) or engine oil
(EO30-DH)
3 Mounting bolt
1st time : 98.1 9.8 Nm {10
1 kgm}
2nd time: 166.6 176.4 Nm
{17 18 kgm}
(Target: 176.4 Nm
{18 kgm})
3rd time : Using tool J, tighten
the bolt by 90 120
(Target: 120).

2]

3]

34

When not using tool J, apply


marking (b) to the cylinder head
and bolt with paint, then tighten
the bolt by 90 120 (Target:
120).
Mark a punch mark (C) on its head to
show the number of tightening times.
a When a new bolt is used, do not
make a punch mark on its head.

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

50 Disassembly and assembly

28. Rocker arm housing


1) Install gasket (1) and then install rocker
arm housing (2).
2) Tighten mounting bolts (3).
3 Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}

SEN00699-03

30. Crosshead
1) Set crosshead (1) and then loosen locknut
(2) to return adjustment screw (3) to its
original position.
2) Using your finger, lightly hold down the
crosshead (1) face contacting the rocker
arm to maintain contact between the push
rod side valve stem and crosshead (1).
3) Screw in adjustment screw (3) until crosshead (1) comes in contact with another
valve stem.
4) As they are contacted, further screw in the
adjustment screw by 20 and then tighten
locknut (2) from that state.
2 Crosshead guide and crosshead
top face: Engine oil (EO30-DH)
3 Locknut:
58.7 5.9 Nm {6.0 0.6 kgm}

29. Injector harness connector


1) Install O-ring (4) to harness connector (1).
2 O-ring: Engine oil (EO30-DH)
2) Insert harness connector (1) to rocker
housing (3) and then tighten them with
mounting bolt (2).
3) Fit in harness to holder (3).

125E-5 Series

35

SEN00699-03

31. Injector
a Check that the inside of the injector sleeve
is free from dirt.
1) Fit bracket (5) and install common rail (6)
temporarily.

50 Disassembly and assembly

4)

5)

6)

7)

2)

3)

36

Install gasket (6) and O-rings (7) and (8) to


injector (1).
2 O-ring: Engine oil (EO30-DH)

Insert holder (2) to injector (1). Continue


from that state, insert inlet connector (5) to
the high-pressure pipe insertion hole
through the rocker housing.

8)

Fit the ball washer to bolt (3) and tighten


holder (2) temporarily.
2 Spherical part of washer:
Engine oil (EO30-DH)
Locate high-pressure sleeve (4) to inlet
connector (5) and then tighten them temporarily.
a Tighten the common rail side sleeve
nut temporarily, too.
Tighten holder (2) with bolt (3) permanently.
a Tighten bolt (3) while pulling the tube
of the high-pressure pipe in the opposite direction of the injector.
3 Holder mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
After tightening the holder, remove the
high-pressure sleeve (4) from the inlet
connector (5) and then install the other
injectors in order according to the above
procedure.
Remove the temporarily installed common
rail.

32. Push rod


Install push rod (1).
a Check that the push rod end is placed in
the cam follower socket.

125E-5 Series

50 Disassembly and assembly

33. Rocker arm and shaft assembly


1) Set rocker arm and shaft assembly (1).
a When installing the rocker arm shaft,
be sure to set its side with a larger
mounting hole diameter to the bottom
and to direct ball plug (6) side toward
the front side of the engine.
2) Before tightening mounting bolts (4),
check that the ball of adjustment screw (2)
is fitted to socket (5) of the push rod.
a Install the mounting bolt after cleaning
its oil hole.
3 Mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}

34. Injector harness


1) Tighten mounting bolts (3) of the harness
fixing holder.
3 Mounting bolt:
27.0 34.0 Nm {2.8 3.5 kgm}
2) Tighten 2 harness capture nuts (2) to
injector (1).
a Tighten the nuts alternately.
3 Mounting nut:
2.0 2.4 Nm {0.2 0.24 kgm}

125E-5 Series

SEN00699-03

35. Adjusting valve clearance


a Adjust the clearance between the crosshead and rocker arm to the following
value.
a Valve clearance (in cold state)
Unit: mm

1)

2)

Intake valve

Exhaust valve

0.33

0.71

Rotate the engine and adjust the valve


clearance of each cylinder in the firing
order of 1 5 3 6 2 4.
Rotate the crankshaft forward and match
stamped line of 1.6 TOP on vibration
damper (1) to pointer (2), watching the
movement of the valve.

Insert clearance gauge l between rocker


arm (3) and crosshead (4) and screw in
adjustment screw (5) until the gauge
becomes movable. Then tighten the locknut.
3 Locknut:
58.8 73.5 Nm {6 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.

37

SEN00699-03

36. Head cover and tube


1) Fit the O-ring and install head cover (3).
a Install the O-ring without twisting it.
3 Mounting bolt:
9.8 1 Nm {1.0 0.1 kgm}
2) Fit the gaskets on both sides, install tube
(2), and tighten joint bolt (1).
3 Joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}

50 Disassembly and assembly

38. Common rail


Install common rail (5).
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}

37. Oil level gauge tube


Install oil level gauge tube (2).
3 Sleeve nut:
44.1 58.8 Nm {4.5 6.0 kgm}

38

125E-5 Series

50 Disassembly and assembly

SEN00699-03

39. Installation of high-pressure pipes between


fuel supply pump and common rail
1) Tighten high-pressure pipes (3) and (4) by
hand first, and then tighten them permanently.
3 Sleeve nut
(Pump side):
39.2 49 Nm {4 5 kgm}
(Common rail side):
39.2 58.8 Nm {4 6 kgm}
2) Tighten supply pump mounting bolts (2)
permanently.
3) Tighten the cylinder block side mounting
bolt of bracket (1) permanently.
4) Install the splash prevention cover on both
ends of the high-pressure pipe.
a Face the common rail side slit downward and the supply side slit toward
the cylinder block.
5) Tighten lubrication tube (12) by hand.
6) Tighten and install clamp (10) by hand
first, and then tighten it permanently.
7) Tighten and install brackets (6) and (5) by
hand first, and then tighten them permanently.
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}
9) Tighten and install clamp (11) by hand
first, and then tighten it permanently.
3 Clamp (11) mounting bolt:
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.
3 Clamp (7) mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}

125E-5 Series

39

SEN00699-03

50 Disassembly and assembly

40. Air intake manifold


1) Fit the gasket and install air intake manifold (1) temporarily.
4

2)

Air intake manifold: 40 kg

41. High-pressure pipes


a Before installing each high-pressure pipe,
check it for the following defects. If there is
any of these defects, it can cause fuel leakage.
Accordingly, replace the high-pressure pipe.
q
Check the taper seal of the connecting part
(Part a: Part of 2 mm from the end) for visible
lengthwise slit b and dent c.
q
Check part d (end of the taper seal: Part at 2
mm from the end) for stepped-type wear
(fatigue) which your nail can feel.

Tighten the mounting bolts in the numeric


order shown below.
3 Mounting bolt:
59 74 Nm {6 7.5 kgm}

1)

2)

3)

4)

40

Install 6 high-pressure pipes (8).


a The installed angle of the high-pressure pipes was set when the injectors
were installed.
3 Sleeve nut (for both sides):
39.2 49 Nm {4 5 kgm}
Tighten 6 brackets (5) and 10 high-pressure pipe clamps (4) with your fingers and
then tighten them permanently.
3 Clamp mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}
Install 6 each of scatter prevention covers
(6) and (7).
a Direct the slit on the injector side
down and that on the common rail
side toward the cylinder block.
Set high-pressure pipe clamp (3) to the
high-pressure pipes.

125E-5 Series

50 Disassembly and assembly

5)
6)

Install bracket (2) and tighten the 2 mounting bolts.


Tighten 7 high-pressure pipe clamp
mounting bolts (1).
3 Clamp mounting bolt:
11.8 14.7 Nm {1.2 1.5 kgm}

42. Spill pipe


Fit the gasket to both ends of spill pipe (2),
install them, and tighten joint bolt (1).
3 Joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}

SEN00699-03

44. Diffuser and air housing assembly


Fit the gasket and install diffuser and air housing assembly temporarily.
4

Diffuser and air housing assembly: 40 kg

Fix the front hanger first and then tighten


the mounting bolts permanently.

45. Front hanger, electrical intake air heater


and air connector
1) Fit the gasket and install front hanger (5).
2) Install plates (4) and (3) and tighten 6 diffuser and air housing assembly mounting
bolts and 4 plate mounting bolts.
3) Fit the gasket, install electrical intake air
heater (2) and air connector (1), and
tighten the 6 mounting bolts.

43. Bracket
1) Install bracket (2).
2) Install bracket (1).

125E-5 Series

41

SEN00699-03

50 Disassembly and assembly

46. Brackets
1) Install brackets (3) and (2).
2) Install wiring harness (1).

47. Electric priming pump and block


a Electric priming pump is not set for some
models.
1) Install block (7).
2) Install electric priming pump (6) and
bracket together.
3) Install the tube and hose according to the
following procedure.
1] Install hose (3) and tube (4) temporarily.
2] Install tube (5) temporarily.
3] Tighten the joint bolts of tube (4) and
hose (3).
3 Joint bolt
(Block side):
24.5 34.3 Nm {2.5 3.5 kgm}
(Supply pump side):
14.8 19.6 Nm {1.5 2.0 kgm}
4] Tighten the joint bolt and sleeve nut of
tube (5).
3 Joint bolt:
14.8 19.6 Nm {1.5 2.0 kgm}
3 Sleeve nut:
43 47 Nm {4.4 4.8 kgm}
5] Install hose (2) and tighten the joint
bolts.
3 Joint bolt
(Block side):
19.6 29.4 Nm {2.0 3.0 kgm}
(Electric priming pump):
17.6 22.6 Nm {1.8 2.3 kgm}
a When tightening the joint bolt on
the electric priming pump side,
fix the hexagonal part of the
priming pump.
6] Connect connector (1).

42

48. Overflow tube, spill tube and engine controller cooler assembly
1) Install block (4).
2) Install tube (3).
3 Joint bolts:
(Block side):
24.5 34.3 Nm {2.5 3.5 kgm}
(Cylinder head side):
9.8 12.7 Nm {1.0 1.3 kgm}
3) Install tube (2) temporarily.
4) Install engine controller cooler assembly
(1).

49. Brackets
Install brackets (1), (2), (3), (4), (5), (6) and (7).

125E-5 Series

50 Disassembly and assembly

50. Fuel filters


1) Install fuel filters (9) and (10).
2) Install tubes (7) and (8) and clamp (6).
3 Joint bolts (for both tubes (7) (8)):
24.5 34.3 Nm {2.5 3.5 kgm}
3 Clamp (6) mounting bolt:
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}
6) Install cover (1).

SEN00699-03

52. Oil cooler assembly


Fit the gasket to oil cooler assembly (1) and
install them by using the guide bolts.

53. Water pump assembly


1) Fit the O-ring, install water pump assembly (3), and tighten mounting bolts (2).
2) Fit the gasket and install connector (1).

51. Oil filter


1) Install oil filter (4) with the 4 bolts temporarily.
2) Fit the O-ring and install oil tubes (2) and
(3).
3) Tighten the lower flanges of oil tubes (2)
and (3) permanently and then tighten the
upper flanges permanently.
4) Tighten the 4 mounting bolts of oil filter (4)
permanently.
5) Install clamp (1).

125E-5 Series

54. Thermostat housing assembly


1) Fit the gasket and install thermostat housing assembly (2).
2) Fit the gasket and install connector (1).

43

SEN00699-03

50 Disassembly and assembly

55. Exhaust manifold assembly


1) Sling exhaust manifold assembly (1), fit
the gasket, and tighten mounting bolts (2)
temporarily
4

2)

Exhaust manifold assembly: 35 kg

56. Turbocharger assembly


1) Fit the gasket, install turbocharger assembly (6), and tighten mounting bolts (5).
3 Mounting bolt:
44.1 49 Nm {4.5 5.0 kgm}
2) Fit the gasket and install turbocharger outlet tube (4) and tube bracket.
3) Fit the gasket and install turbocharger
lubricating oil inlet tube (3) and 5 clamps.
3 Sleeve nut (Cylinder block side):
40 44 Nm {4.1 4.5 kgm}
4) Install brackets (2) and (1).

Tighten bolts (3), (4) and (5) first and then


tighten the other bolts.
3 Mounting bolt:
58.8 73.5 Nm {6 7.5 kgm}

57. Water pump suction tube


Fit the gasket and install suction tube (1).

44

125E-5 Series

50 Disassembly and assembly

58. Alternator assembly


1) Install bracket (8) and plate (7).
2) Install V-belt (5) to the pulley of alternator
assembly (6) and secure the alternator
assembly with mounting bolt (2) and fixing
bolt (3).
3) Adjust the belt tension with the V-belt tension adjustment nut and tighten mounting
bolt (2) and fixing bolt (3).
a Adjust the V-belt tension so that the
belt will be deflected by 13 16 mm
when it is pressed with a force of
about 6 kg by the center between the
crankshaft pulley and alternator pulley.
3 Mounting bolt (2):
107.8 147 Nm {11 15 kgm}
3 Mounting bolt (3):
28.4 38.2 Nm {2.9 3.9 kgm}
4) Check the belt tension and tighten the
locknut.
5) Tighten nut (4).
6) Install cover (1).

SEN00699-03

60. Wiring harness assembly


Install wiring harness assembly (1), connect
each connector, and install each clamp.

61. Air cleaner, muffler and heat insulation


plate
1) Install the air cleaner.
2) Install the muffler and the drain tube.
3) Install the heat insulation plate.

59. Starting motor assembly


Fit the gasket, install starting motor assembly
(2), and tighten mounting bolts (1).

125E-5 Series

45

SEN00699-03

50 Disassembly and assembly

62. Tightening torque for sensor


Use the following tightening torque when
removal and installation or replacement of the
sensor.
Sensor name
Fuel
temperature

5)

Tightening torque
23 3 Nm {2.35 0.3 kgm}

Boost pressure 5.5 0.5 Nm {0.56 0.05 kgm}


Intake air
temperature

23 3 Nm {2.35 0.3 kgm}

Coolant
temperature

23 3 Nm {2.35 0.3 kgm}

Engine oil
pressure

23 3 Nm {2.35 0.3 kgm}

Atmospheric
pressure

4.5 0.5 Nm {0.46 0.05 kgm}


(Hexagonal head bolt and hexagonal socket head bolt)

Fuel pressure

Never disassemble.

6)
7)

8)

9)
63. Checking for fuel leakage
a If fuel supply pump (2), common rail (1), or
high-pressure pipe is removed and
installed, after assembling the engine,
check for fuel leakage according to the following procedure.

1)

2)
3)

4)

46

Check the fuel piping and devices for fuel


leakage.
a Check mainly around the high-pressure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
Run the engine at high idle.
Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pressure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
Run the engine at high idle and load it.
a When checking while the components
to be checked are mounted on the
machine, stall the torque converter or
relieve the hydraulic pump.
Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pressure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
a If no fuel leakage is detected, check
is completed.

Clean and degrease the engine and the


parts around it in advance so that you can
test it easily for fuel leakage.
Spray color checker (developer) over the
fuel supply pump, common rail, fuel injector, and joints of the high-pressure piping.
Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pressure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
Run the engine at low idle.
125E-5 Series

50 Disassembly and assembly

125E-5 Series

SEN00699-03

47

SEN00699-03

KOMATSU 125E-5 Series engine


Form No. SEN00699-03

2010 KOMATSU
All Rights Reserved
Printed in Japan 04-10

48

SEN00700-00

ENGINE
1SHOP MANUAL

125E-5 Series

50 Disassembly and assembly1


Disassembly and assembly, Part 3
Disassembly and assembly, Part 3 ................................................................................................................. 2
Removal and installation of fuel supply pump unit ............................................................................... 2
Replacement of oil seal of engine mounted on machine ..................................................................... 4

125E-5 Series

SEN00700-00

50 Disassembly and assembly

Disassembly and assembly, Part 3


Removal and installation of fuel
supply pump unit
1

7.

Remove cover (16).

8.

Rotate the crankshaft forward and set intermediate point (a) between stamped 2/5 TOP and
3/4 TOP on damper (17) to pointer (18).
(Stamped 1/6 TOP comes almost directly bottom)
a At this time, check that the forcing tap of
the drive gear is aligned to the mounting
bolt hole of cover (16).
(If not, rotate the crankshaft one more
turn.)
a At this point, the key of the shaft is turned
clockwise by 15 from the top.

9.

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 inadvertently dropped into the case.

Removal
1. Disconnect sensor connectors (1), (2) and (3).
2.

Remove clamps (4) and (5) and then remove


fuel tube (6).
[*1]

3.

Remove clamps (7), (8) and (9) and then


remove splash prevention covers (10) and
(11).
[*2]

4.

Remove high-pressure pipes (12) and (13).

[*3]
5.

Remove lubrication tube (14).

6.

Remove fuel tube (15).

[*4]

125E-5 Series

50 Disassembly and assembly

SEN00700-00

10. Loosen mounting bolts (21) and then remove


the mounting bolt on the cylinder block side of
bracket (22).
[*6]
a Leave bolts (21) tightened by 2 3
threads to prevent the pump from falling
down.

Installation
a Carry out installation in the reverse order to
removal.
[*1]
3 Joint bolt of tube (6):
24.5 34.3 Nm {2.5 3.5 kgm}

11. Install tool P1 with P2 and P3 and then screw


in the center bolt of P1 to remove the gear from
the shaft.

[*2]
1) Tighten clamps (7), (8), and (9) by hand first,
and then tighten them permanently.
3 Clamp mounting bolt:
11.8 4.7 Nm {1.2 1.5 kgm}
2) Face the pump side slit of the splash prevention cover to the cylinder block side and the
comm