SEN00179-00

ENGINE
1SHOP MANUAL

125E-5 Series

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00 Index and foreword

Index
Organization list of the shop manual.................................................................................................... 2
Table of contents .................................................................................................................................. 3

125E-5 Series

SEN00179-00

00 Index and foreword

Organization list of the 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

SEN00177-00

00 Index and foreword

Index
Foreword and general information

SEN00178-00
SEN00179-00
SEN00180-00

01 Specification
Specification and technical data

SEN00181-00
SEN00182-00

10 Structure, function and maintenance standard

Structure, function and maintenance standard, Part 1
Structure, function and maintenance standard, Part 2

SEN00183-00
SEN00184-00
SEN00185-00

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125E-5 Series

00 Index and foreword

SEN00179-00

Table of contents

00 Index and foreword

Index
SEN00179-00
Organization list of the shop manual .......................................................................................
2
Table of contents .....................................................................................................................
3
Foreword and general information
SEN00180-00
Safety notice............................................................................................................................
2
How to read the shop manual..................................................................................................
6
Explanation of terms for maintenance standard ......................................................................
8
Handling electric equipment and hydraulic component ........................................................... 10
How to read electric wire code ................................................................................................ 18
Method of disassembling and connecting push-pull type coupler ........................................... 21
Standard tightening torque table.............................................................................................. 24
Conversion table...................................................................................................................... 28
01 Specification
Specification and technical data
SEN00182-00
Outline .....................................................................................................................................
2
Specifications...........................................................................................................................
5
General view............................................................................................................................
8
Weight table............................................................................................................................. 17
Engine performance curves..................................................................................................... 18

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10 Structure, function and maintenance standard
Structure, function and maintenance standard, Part 1
SEN00184-00
General structure ........................................................................................................................
4
Intake and exhaust system .........................................................................................................
6
Intake and exhaust unit ...........................................................................................................
6
Air cleaner ...............................................................................................................................
8
Turbocharger ........................................................................................................................... 10
Aftercooler ............................................................................................................................... 13
EGR system ............................................................................................................................ 14
Engine unit .................................................................................................................................. 21
Cylinder head .......................................................................................................................... 21
Cylinder block .......................................................................................................................... 24
Cylinder liner............................................................................................................................ 28
Main moving parts ................................................................................................................... 29
Crankshaft ............................................................................................................................... 31
Camshaft ................................................................................................................................. 32
Cam follower and push rod...................................................................................................... 33
Piston, piston ring and piston pin............................................................................................. 34
Connecting rod ........................................................................................................................ 36
Flywheel and flywheel housing................................................................................................ 37
Vibration damper ..................................................................................................................... 40
Timing gear.............................................................................................................................. 42
Valve system ........................................................................................................................... 46
Valve and valve guide.............................................................................................................. 50
Rocker arm and shaft .............................................................................................................. 52
Crosshead and guide .............................................................................................................. 53
Structure, function and maintenance standard, Part 2
SEN00185-00
Lubrication system ......................................................................................................................
4
Lubrication system diagram.....................................................................................................
4
Oil pump ..................................................................................................................................
6
125E-5 Series

SEN00179-00

00 Index and foreword

Main relief valve.......................................................................................................................

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

7
8
9
10
11
12
12
13
34
36
37
38
39
40
40
41
43
45
46
46
52
56
57

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125E-5 Series

00 Index and foreword

SEN00179-00

www.
k
omat
s
upar
t
s
book
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om

125E-5 Series

00 Index and foreword

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KOMATSU 125E-5 Series engine

Form No. SEN00179-00

2005 KOMATSU
All Rights Reserved
Printed in Japan 09-05 (01)