Saa6d125e-5 Sen00177-01d PDF

SEN00177-01
ENGINE 125E -5 SERIES

SEN00179-01
ENGINE 1SHOP MANUAL
125E-5 Series
00 Index and foreword 1

Index
Organization list of the shop manual.................................................................................................... 2

Table of contents .................................................................................................................................. 3
125E-5 Series 1
SEN00179-01 00 Index and foreword
Organization list of the shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00177-01
00 Index and foreword SEN00178-01

Index SEN00179-01 q
Foreword and general information SEN00180-01 q
01 Specification SEN00181-00
Specification and technical data SEN00182-00
10 Structure, function and maintenance standard SEN00183-00

Structure, function and maintenance standard, Part 1 SEN00184-00
20 Standard value table SEN00186-00

Standard service value table SEN00546-00 Q
30 Testing and adjusting SEN00187-00

Testing and adjusting SEN00547-00 Q
40 Troubleshooting SEN00188-00
General information on troubleshooting SEN00548-00 Q
Troubleshooting of mechanical system (S-mode) SEN00549-00 Q
Troubleshooting of electrical system (E-mode), Part 1 SEN00550-00 Q
Troubleshooting of electrical system (E-mode), Part 2 SEN00551-00 Q
2 125E-5 Series
Table of contents 1
00 Index and foreword
Index SEN00179-01
Organization list of the shop manual ....................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information SEN00180-01

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
10 Structure, function and maintenance standard

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

Lubrication system ...................................................................................................................... 4
Lubrication system diagram..................................................................................................... 4
Oil pump .................................................................................................................................. 6
125E-5 Series 3
Main relief valve....................................................................................................................... 7

EGR oil pump .......................................................................................................................... 8
Oil filter..................................................................................................................................... 9
Safety valve ............................................................................................................................. 10
Oil cooler.................................................................................................................................. 11
Fuel system ................................................................................................................................. 12
CRI system diagram ................................................................................................................ 12
Outline of CRI system.............................................................................................................. 13
Fuel piping ............................................................................................................................... 34
Fuel cooler ............................................................................................................................... 36
Fuel filter .................................................................................................................................. 37
Priming pump........................................................................................................................... 38
Engine controller cooler ........................................................................................................... 39
Cooling system............................................................................................................................ 40
Cooling system diagram .......................................................................................................... 40
Water pump ............................................................................................................................. 41
Thermostat............................................................................................................................... 43
Corrosion resistor .................................................................................................................... 45
Electrical equipment .................................................................................................................... 46
Alternator ................................................................................................................................. 46
Starting motor .......................................................................................................................... 52
Electrical intake air heater ....................................................................................................... 56
Engine controller...................................................................................................................... 57
20 Standard value table

Standard service value table SEN00546-00
Standard service value table ....................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ................................. 2
Running-in standard and performance test standard .............................................................. 5
30 Testing and adjusting

Testing and adjusting SEN00547-00
Testing and adjusting................................................................................................................... 4
Testing and adjusting tools list ................................................................................................. 4
Testing air boost pressure........................................................................................................ 6
Testing exhaust temperature ................................................................................................... 7
Adjusting valve clearance ........................................................................................................ 8
Testing compression pressure ................................................................................................. 9
Testing blow-by pressure ......................................................................................................... 11
Testing oil pressure.................................................................................................................. 12
Handling fuel system parts ...................................................................................................... 13
Releasing residual pressure in fuel system ............................................................................. 13
Testing fuel pressure................................................................................................................ 14
Reduced cylinder mode operation ........................................................................................... 15
No-injection cranking ............................................................................................................... 15
Testing leakage from pressure limiter and return rate from injector......................................... 16
Bleeding air from fuel circuit .................................................................................................... 19
Testing fuel system for leakage ............................................................................................... 21
Adjusting speed sensor ........................................................................................................... 22
Testing and adjusting alternator belt tension ........................................................................... 23
Handling controller voltage circuit............................................................................................ 24
4 125E-5 Series
40 Troubleshooting
General information on troubleshooting SEN00548-00
General information on troubleshooting ...................................................................................... 2
Points on troubleshooting ........................................................................................................ 2
Error code and failure code table ............................................................................................ 4
Troubleshooting of mechanical system (S-mode) SEN00549-00

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
S-14 Coolant temperature becomes too high (overheating).................................................... 27
S-15 Abnormal noise is made ................................................................................................. 28
S-16 Vibration is excessive ..................................................................................................... 29
Troubleshooting of electrical system (E-mode), Part 1 SEN00550-00

Troubleshooting of electrical system (E-mode), Part 1 ............................................................... 4
Information in troubleshooting table ........................................................................................ 4
E-1 Code [111/CA111] ECM Critical Internal Failure................................................................ 6
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error .............................................. 8
E-3 Code [122/CA122] Charge Air Press Sensor High Error .................................................. 10
E-4 Code [123/CA123] Charge Air Press Sensor Low Error ................................................... 12
E-5 Code [131/CA131] Throttle Sensor High Error ................................................................. 14
E-6 Code [132/CA132] Throttle Sensor Low Error .................................................................. 18
E-7 Code [135/CA135] Oil press. Sensor High Error .............................................................. 20
E-8 Code [141/CA141] Oil press. Sensor Low Error ............................................................... 22
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ...................................................... 24
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error ..................................................... 26
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error ................................................ 28
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error ................................................ 30
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error .......................................................... 31
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error.............................................. 32
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error............................................... 34
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error ......................................................... 36
E-17 Code [234/CA234] Eng. Overspeed ............................................................................... 38
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error.................................................... 40
E-19 Code [263/CA263] Fuel Temp. Sensor High Error.......................................................... 42
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error........................................................... 44
E-21 Code [271/CA271] PCV1 Short Error ............................................................................. 46
E-22 Code [272/CA272] PCV1 Open Error ............................................................................. 48
E-23 Code [273/CA273] PCV2 Short Error ............................................................................. 50
E-24 Code [274/CA274] PCV2 Open Error ............................................................................. 52
E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error ................................. 54
125E-5 Series 5
E-29 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error.................................. 62

E-30 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error.................................. 64
E-31 Code [342/CA342] Calibration Code Incompatibility ....................................................... 66
E-32 Code [351/CA351] INJ. Drive Circuit Error...................................................................... 68
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error .......................................................... 70
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error ......................................................... 72
E-35 Code [431/CA431] Idle Validation SW Low error ............................................................ 74
E-36 Code [432/CA432] Idle Validation Process error............................................................. 76
E-37 Code [441/CA441] Battery voltage low error................................................................... 76
E-38 Code [442/CA442] Battery voltage high error ................................................................. 77
Troubleshooting of electrical system (E-mode), Part 2 SEN00551-00

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 Dtalink 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
6 125E-5 Series
125E-5 Series 7
SEN00179-01
KOMATSU 125E-5 Series engine
Form No. SEN00179-01
© 2005 KOMATSU
All Rights Reserved
Printed in Japan 12-05 (01)
8
SEN00180-01
ENGINE 1SHOP MANUAL
125E-5 Series
00 Index and foreword 1

Foreword and general information
Foreword and general information .................................................................................................................. 2
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
125E-5 Series 1
Foreword and general information (Rev. 2005/11)
Safety notice 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 situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w eld in g wo rk , alw ay s wear wel din g
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to 1 Good arrangement
keep tools and removed parts. Always
2 Correct work clothes
keep the tools and parts in their correct
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water, 4 Making and checking signs
or oil on the floor. Smoke only in the areas Prohibition of operation and handling by
5
provided for smoking. Never smoke while unlicensed workers
working. 6 Safety check before starting work
3) When carrying out any operation, always Wearing protective goggles
wear safety shoes and helmet. Do not 7
(for cleaning or grinding work)
wear loose work clothes, or clothes with
Wearing shielding goggles and protectors
buttons missing. 8
(for welding work)
q Always wear safety glasses when hit-
ting parts with a hammer. 9 Good physical condition and preparation
q Always wear safety glasses when Precautions against work which you are
10
grinding parts with a grinder, etc. not used to or you are used to too much
4) When carrying out any operation with 2 or
more workers, always agree on the oper-
ating procedure before starting. Always 2. Preparations for work
inform your fellow workers before starting 1) Before adding oil or making any repairs,
any step of the operation. Before starting park the machine on hard and level
work, hang UNDER REPAIR signs in the ground, and apply the parking brake and
operator's compartment. block the wheels or tracks to prevent the
5) Only qualified workers must carry out work machine from moving.
and operation which require license or 2) Before starting work, lower the work
qualification. equipment (blade, ripper, bucket, etc.) to
6) Keep all tools in good condition, learn the the ground. If this is not possible, insert
correct way to use them, and use the the lock pin or use blocks to prevent the
proper ones of them. Before starting work, work equipment from falling. In addition,
thoroughly check the tools, machine, fork- be sure to lock all the control levers and
lift, service car, etc. hang warning signs on them.
2 125E-5 Series
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
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 cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot 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
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When l a r l y c a r e fu l t o c he c k t h a t t h ey ar e
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) 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.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
125E-5 Series 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with one rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 125E-5 Series
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
125E-5 Series 5
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
6 125E-5 Series
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

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

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
125E-5 Series 7
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

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

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

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
8 125E-5 Series
2. Standard clearance and standard value 5. Clearance limit

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

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 must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
125E-5 Series 9
Handling electric equipment and hydraulic component 1

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

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

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
10 125E-5 Series
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
splash water over the connector. The con-
nector 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 con-
nector, the pins will be short-circuited by
the water, so if any water gets in, immedi-
ately dry the connector or take other
appropriate action before passing electric-
ity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
125E-5 Series 11
3. Removing, installing, and drying connec-

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

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

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

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
12 125E-5 Series
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
3) Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.
1. Male connector
2. Female connector
q Normal locking state (Horizontal): a,
b, d
q Incomplete locking state (Diagonal): c
125E-5 Series 13
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om th e c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
14 125E-5 Series
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
125E-5 Series 15
Points to remember when handling hydraulic equipment

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

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

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

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
16 125E-5 Series
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
125E-5 Series 17
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
18 125E-5 Series
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
125E-5 Series 19
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
20 125E-5 Series
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
125E-5 Series 21
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
22 125E-5 Series
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
125E-5 Series 23
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
24 125E-5 Series
2. Table of tightening torques for split flange bolts

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

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
125E-5 Series 25
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
Thread diame-
No. of across Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolt BANJO bolt
mm Nm kgm Nm kgm
6 10 ± 2 1.02 ± 0.20 8± 2 0.81 ± 0.20
8 24 ± 4 2.45 ± 0.41 10 ± 2 1.02 ± 0.20
10 43 ± 6 4.38 ± 0.61 12 ± 2 1.22 ± 0.20
12 77 ± 12 7.85 ± 1.22 24 ± 4 2.45 ± 0.41
14 – – 36 ± 5 3.67 ± 0.51
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
26 125E-5 Series
8. 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.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
125E-5 Series 27
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

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

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
28 125E-5 Series
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
125E-5 Series 29
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
30 125E-5 Series
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
125E-5 Series 31
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to 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.
If it is desired to 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.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

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

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

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

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
32 125E-5 Series
125E-5 Series 33
SEN00180-01
© 2005 KOMATSU
All Rights Reserved
34
SEN00182-00
ENGINE 1SHOP MANUAL
125E-5 Series
01 Specification 1
Specification and technical data
Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 5
General view ........................................................................................................................................ 8
Weight table ....................................................................................................................................... 17
Engine performance curves ............................................................................................................... 18
125E-5 Series 1
SEN00182-00 01 Specification
Outline 1
1. Applicable machine
Engine Engine serial No. Applicable machine

PC400-7, PC400LC-7
Hydraulic excavator
PC450-7, PC450LC-7
SAA6D125E-5
D85EX-15, D85PX-15 Bulldozer
HM300-2 Articulated dump truck
2 125E-5 Series
2. Outline of engine
q The 125E-5 engine is a high-performance and 5) The common rail high-pressure fuel injection
high-efficiency engine, which passed strict system controlled electronically is employed
emission regulations (USA: EPA Regulations for the 125E-3 and after models. This system
for 2006, EU: Regulations for 2006, Japan: can inject the fuel at high pressure of 120 MPa
Construction machinery regulations for 2006) {1,200 kg/cm2} from the low-speed range to the
and attained low fuel consumption, low noise, high-speed range. In addition, this system can
better exhaust gas color, and high acceleration control the form of injection most properly by
performance. Accordingly, this newly devel- electronic control according to the speed and
oped engine is suitable as a power source of load. The injection system of 125E-5 is further
construction machinery and industrial machin- improved to employ multiple injection and
ery used for various purposes. increase the injection pressure up to 140 MPa
{1,400 kg/cm2}. As a result, exhaust gas of the
q The 125E-5 engine is the successor to the cleanest level in the world, good exhaust gas
125E-3 engine. While it is an in-line 6-cylinder, color, low fuel consumption, and low noise are
water-cooled, common rail direct injection, 4- realized simultaneously.
stroke diesel engine, it is equipped with the
cooled EGR system which is a new technol- 6) As the injection pressure of the common rail
ogy. injection system employed for the 125E-3
engine and after models is increased (from
1) The main components of the cooled EGR sys- 120 to 140 MPa {from 1,200 to 1,400 kg/cm2}),
tem are the EGR cooler of corrugated tube the pressure resistance of the common rail,
type made of newly developed special stain- injector, and supply pump is improved for
less steel and the EGR valve driven hydrauli- higher reliability.
cally and controlled electronically which
KOMATSU developed by itself. The cooled 7) The main fuel filter of high efficiency and the
EGR system secures the optimum EGR rate pre-fuel filter are installed as standard so that
from the low-speed range to the high-speed the low grade fuel in the market (equivalent to
range to attain both clean exhaust gas and low Class NAS13) can be used. In addition, the
fuel consumption with the bypass assist circuit delivery of the priming pump used to replace
consisting of the venturi system and bypass the filters is increased for higher serviceability.
valve which has the same function and struc-
ture as those of the EGR valve. 8) The high-quality piston made of cast iron which
has been employed for the 125E-2 engine and
2) The special EGR oil pump is employed to gen- after models is employed. This piston has a
erate high oil pressure (1.47 MPa {15 kg/cm2}) less coefficient of thermal expansion, a reen-
as the drive power source of the EGR valve trant combustion chamber, and a shaker cool-
driven hydraulically and controlled electroni- ing gallery. As a result, clean exhaust gas,
cally. good exhaust gas color, and low fuel consump-
tion are attained simultaneously, and high
3) The 125E-5 engine is equipped with the com- durability and reliability are also obtained.
bination filter system of high performance and
efficiency, which has been employed for the 9) By using the above-mentioned high-pressure
125E-3 engine, to meet the requirements of fuel injection system controlled electronically,
the EGR system and high-dispersion oil and the multiple injection and injection characteris-
capture large and small particles. In addition, tics are set most properly to improve the start-
the recommended sub-materials for operation ability and reduce the white exhaust smoke
(oil and fuel) are changed to improve the reli- when the temperature is low.
ability and durability of the engine.
10) Since the engine controller is mounted on the
4) Since the high-pressure fuel injection system engine and equipped with the automatic high-
controlled electronically is employed, less soot altitude compensation function, the engine can
is produced and the draining interval of the oil be operated at high altitude without replacing
is lengthened. (While the capacity of the oil the controller. As a result, the serviceability is
pan is not changed, the oil replacement inter- improved.
val of 500 hours is secured.)
125E-5 Series 3
11) The KTR90 turbocharger newly developed and

manufactured by KOMATSU for higher reliabil-
ity and higher performance is mounted. The
efficiency of the blower impeller is improved
and special manufacturing methods for higher
strength of the material are employed to obtain
higher efficiency and higher pressure ratio. As
a result, high performance is maintained from
the low-speed range to the high-speed range.
12) The copper sleeve at the injector mounting

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

cooled EGR system. Since its overall length,
overall width, and overall height are the same
as before, however, its compactness is main-
tained.
14) If only fuel containing sulfur more than 5,000

PPM (0.5%) is obtained in a district where the
emission regulations are not applied, the high
sulfur-content fuel specification without EGR
system is prepared.
4 125E-5 Series
Specifications 1
Engine name SAA6D125E-5

PC400-7, PC400LC-7
Applicable machine
PC450-7, PC450LC-7
Number of cylinders – Bore × Stroke mm 6 – 125 × 150
Total displacement l {cc} 11.0 {11,040}
Firing order — 1–5–3–6–2–4
Overall length mm 1,713
Dimensions
Overall width mm 1,001

Overall height (excluding exhaust pipe) mm —
Overall height (including exhaust pipe) mm 1,741
262.5 / 1,900
kW/rpm
Rated output {353 / 1,900}
{HP/rpm}
(Gross)
1,422 / 1,400
Nm/rpm
Performance
Max. torque {145 / 1,400}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 1,930 ± 25
(High idle speed)
No-load min. speed
rpm 1,000 ± 25
(Low idle speed)
g/kW·h 211
Fuel consumption ratio at rated output
{g/HP·h} {157}
Dry weight kg 1,310
Fuel injection pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil 46
l
(Refill capacity) (37)
Quantity of coolant
l
(for only engine) (21)
Alternator — 24V, 35A
Starting motor — 24V, 7.5kW
Battery — 12V, 150Ah×2
Turbocharger — KOMATSU KTR90
Air compressor — —
Others — With air-cooled aftercooler
125E-5 Series 5

Applicable machine D85EX-15, D85PX-15
Number of cylinders – Bore × Stroke mm 6 – 125 × 150
Dimensions

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

{kgm/rpm}
(Gross)
No-load max. speed
rpm 2,100 ± 50
(High idle speed)
No-load min. speed
rpm 750 (+50/0)
(Low idle speed)
g/kW·h 215
{g/HP·h} {160}
Dry weight kg 1,330
l
Quantity of coolant
l
6 125E-5 Series

Applicable machine HM300-2
Number of cylinders – Bore × Stroke mm 6–125 × 150
Dimensions

Overall height (excluding exhaust pipe) mm 1,268
Overall height (including exhaust pipe) mm —
254 / 2,000
kW/rpm
{HP/rpm}
(Gross)
1,706 / 1,400
Nm/rpm
Performance
Max. torque {174 / 1,400}

{kgm/rpm}
(Gross)
No-load max. speed
rpm 2,220 ± 50
(High idle speed)
No-load min. speed
rpm 725 (+50/0)
(Low idle speed)
g/kW·h 215
{g/HP·h} {161}
Dry weight kg 1,285
l
Quantity of coolant
l
125E-5 Series 7
General view 1
SAA6D125E-5 (Left side of engine)
Applicable machines: PC400-7, PC400LC-7, PC450-7, PC450LC-7
a The shape is subject to machine models.

a For the dimensions of each part, see the last page of the general view.
1. Center of crankshaft
2. Rear face of flywheel housing
8 125E-5 Series
SAA6D125E-5 (Front side of engine)

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

2. Center of cylinder liner
125E-5 Series 9

Applicable machines: D85EX-15, D85PX-5

10 125E-5 Series

Applicable machines: D85EX-15, D85PX-5

125E-5 Series 11

Applicable machine: HM300-2

12 125E-5 Series


125E-5 Series 13
SAA6D125E-5 (Top of engine)


14 125E-5 Series
125E-5 Series 15
Dimensions table
Unit: mm
Dimension of each part
Engine Machine
A B C D E F G H J
PC400-7, PC400LC-7
1,713 1,741 438 — — — — 1,001 —
PC450-7, PC450LC-7
SAA6D125E-5
D85EX-15, D85PX-15 1,307 1,711 387 15 15 777 949 1,004 —
HM300-2 1,681 1,268 401 178 — 530 760 1,010 718
a These dimensions are given for reference when the engine is set on a test bench.
16 125E-5 Series
Weight table 1
Unit: kg
No. Item Main parts SAA6D125E-5
1 Turbocharger KOMATSU KTR90 17
Cylinder head, valve,
2 Cylinder head assembly 15
valve spring
Cylinder block, bearing,
3 Cylinder block assembly 305
cap, cylinder liner
4 Front cover 29
PC400-7, PC400LC-7
18
PC450-7, PC450LC-7
5 Oil pan D85EX-15
21
D85PX-15
HM300-2 22
PC400-7, PC400LC-7
49
PC450-7, PC450LC-7
6 Flywheel assembly Flywheel ring gear D85EX-15
55
D85PX-15
HM300-2 23
7 Flywheel housing assembly 54
8 Crankshaft assembly Crankshaft, crank gear 106
Camshaft, cam gear,
9 Camshaft assembly 16
thrust plate
Piston and connecting rod Piston, piston ring,
10 8
assembly piston pin, connecting rod
11 Oil pump 5
12 Fuel supply pump 10
13 Water pump 10
24V, 35A 8
14 Alternator 24V, 50A 10
24V, 75A 13
24V, 7.5kW 16
15 Starting motor
24V, 11kW 18
16 EGR oil pump 6
17 EGR valve 16
18 Bypass valve 16
19 EGR cooler 9
125E-5 Series 17
Engine performance curves 1
Engine Engine serial No. Applicable machine Page

PC400-7, PC400LC-7
19
PC450-7, PC450LC-7
SAA6D125E-5
D85EX-15, D85PX-15 20
HM300-2 21
18 125E-5 Series
SAA6D125E-5 (Applicable machine: PC400-7, PC400LC-7, PC450-7, PC450LC-7)
Rated output: 262.5 kW {353 HP}/1,900 rpm (Gross)

Max. torque: 1,423 Nm {145 kgm}/1,400 rpm (Gross)
125E-5 Series 19
SAA6D125E-5 (Applicable machine: D85EX-15, D85PX-15)
Rated output: 199 kW {267 HP}/1,900 rpm (Gross)

20 125E-5 Series
SAA6D125E-5 (Applicable machine: HM300-2)
Rated output: 254 kW {341 HP}/2,000 rpm (Gross)

125E-5 Series 21
© 2005 KOMATSU
All Rights Reserved
22 125E-5 Series
SEN00184-00
ENGINE 1SHOP MANUAL
125E-5 Series
10 Structure, function and

maintenance standard 1
Structure, function and maintenance
standard, Part 1
General structure ............................................................................................................................................ 4
Intake and exhaust system ............................................................................................................................. 6
Intake and exhaust unit ........................................................................................................................ 6
Air cleaner ............................................................................................................................................ 8
Turbocharger...................................................................................................................................... 10
Aftercooler .......................................................................................................................................... 13
EGR system ....................................................................................................................................... 14
Engine unit .................................................................................................................................................... 21
Cylinder head ..................................................................................................................................... 21
Cylinder block..................................................................................................................................... 24
Cylinder liner ...................................................................................................................................... 28
125E-5 Series 1
SEN00184-00 10 Structure, function and maintenance standard
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
2 125E-5 Series
125E-5 Series 3
General structure 1
Common rail system specification 1
1. Cylinder block 14. Flywheel

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

27. Turbocharger 32. Common rail
28. Cylinder head 33. Fuel supply pump
29. Rocker arm 34. Cam follower
30. Push rod 35. Connecting rod cap
Engine
Name : SAA6D125E-5 (with turbocharger and air-cooled aftercooler)
Type : In-line 6-cylinder, water-cooled, direct injection, 4-stroke diesel engine
125E-5 Series 5
Intake and exhaust system 1

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

2. Diffuser
3. Intake manifold
6 125E-5 Series
SAA6D125E-5 (Right side of engine)
A : To EGR cooler
B : To turbocharger
C : From bypass valve
1. Exhaust manifold (Rear)

2. Exhaust manifold (Center)
3. Exhaust manifold (Front)
125E-5 Series 7
Air cleaner 1
FRG type (Radial seal type)
1. Inlet 6. Evacuator valve

2. Outlet 7. Dust pan
3. Guide vane 8. Guide plate (Sleeve)
4. Primary element 9. Body
5. Safety element 10. Element
Engine Applicable machines Type Evacuator valve Number of elements

PC400-7, PC400LC-7
PC450-7, PC450LC-7 1 inner element
SAA6D125E-5 FRG (Radial seal type) Automatic discharge
D85EX-15, D85PX-15 1 outer element
HM300-2
Structure Operation
q The size of the body is reduced from the con- q Air containing dust is sucked in vertically
ventional type without changing the diameter through inlet (1) and the dust is separated by
of the element. the centrifugal effect of guide vane (3).
q Since the inlet is set in the tangential direction, q More than 99.9% of the dust is removed by pri-
air is given sufficient centrifugal force by the mary element (4) and clean air is sucked in the
simple spiral guide vane, not by the guide engine through safety element (5) and outlet
plate. (2).
q The dust and water separated by guide vane
(3) swirl along the inside wall of body (9) and
enter evacuator valve (6) and then are dis-
charged out automatically.
8 125E-5 Series
125E-5 Series 9
Turbocharger 1
Model name: KTR90
10 125E-5 Series
A: Intake air inlet

B: Intake air outlet
C: Exhaust gas inlet
D: Exhaust gas outlet
E: Oil inlet
F: Oil outlet
1. Blower housing
2. V-band
3. Diffuser plate
4. Center housing
5. Shroud
6. Turbine housing
7. Blower impeller
8. Seal ring
9. Bearing metal
10. Journal bearing
11. Seal ring
12. Turbine impeller
Specifications
Model name : KOMATSU KTR90
Overall length : 268 mm
Overall width : 247 mm
Overall height : 227 mm
Weight : 17 kg
125E-5 Series 11
Unit: mm
No. Check item Criteria Remedy
Standard Repair limit Replace thrust
1 End play (Play in axial direction)
0.08 – 0.13 0.18 parts
Replace bearing
2 Radial play (Play in radial direction) 0.38 – 0.59 —
parts
Clearance between blower housing Replace bearing
3 Clearance limit (Min.): 0.01
and impeller parts
12 125E-5 Series
Aftercooler 1
Air-cooled type
SAA6D125E-5 (PC400-7, PC400LC-7, PC450-7, PC450LC-7, D85EX-15, D85PX-15, HM300-2)
a. Inlet/Outlet of intake air (Between turbocharger and air intake manifold)
1. Tank
2. Side support
3. Tube
4. Fin
125E-5 Series 13
EGR system 1
No. Component part Function

• Controls the gas flow from the exhaust system to the air intake system.
EGR valve (driven hydrau-
1 • Since the exhaust pressure (PEX) is higher than the boost pressure (PIN), the
lically)
exhaust gas flows to the air intake valve.
• Opens the bypass valve when the boost pressure (PIN) is higher than the exhaust
pressure (PEX).
2 Bypass valve
• Makes the intake air flow to the exhaust side to increase the exhaust pressure so
that the exhaust gas will be returned to the air intake side easily.
3 EGR cooler • Lowers the exhaust temperature and returns the exhaust gas to the air intake side.
4 Venturi system • Generates negative pressure with the venturi effect and takes in the exhaust gas.
• Controls the EGR according to the operating condition.
5 Each sensor
• Troubleshoots the system.
Features
q The exhaust gas is kept clean by sensing each
part of the EGR circuit and controlling the EGR
rate according to the operating condition.
q Since the EGR circuit is monitored and trouble-
shooted, a serious trouble is prevented.
14 125E-5 Series
125E-5 Series 15
a The above illustration shows the engine for HM300-2.
16 125E-5 Series
1. EGR valve
2. Bypass valve
3. EGR cooler
4. Venturi system
5. EGR valve position sensor
6. Bypass valve position sensor
7. Bypass piping
8. EGR piping
9. EGR oil pump
Operation
q The engine controller outputs signals for open-
ing EGR valve (1) most properly according to
the load on the engine to attain both clean
exhaust gas and low fuel consumption.
q If EGR valve (1) opens, a part of the exhaust
gas (EGR gas) flows from the exhaust mani-
fold through EGR piping (8) to EGR cooler (3).
q The exhaust gas cooled by EGR cooler (3)
flows through EGR valve (1) and mixes with
the intake air in venturi system (4), and then
flows in the air intake manifold.
q In the operating range where the boost pres-
sure is higher than the exhaust pressure on the
high load side, the EGR gas does not flow to
the air intake side easily. At this time, the
engine controller opens bypass valve (2).
q If bypass valve (2) opens, the intake air flows
through bypass piping (7). As a result, the
exhaust pressure rises and more EGR gas
mixes with the intake air.
125E-5 Series 17
EGR valve and bypass valve
A: Oil inlet 1. Stick prevention device

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

q The EGR valve controls the EGR gas. open by hydraulic piston (5) to an opening ratio
q This valve is driven hydraulically and its open- in proportion to the control oil pressure.
ing ratio is controlled electronically. q The valve opening ratio is sensed with position
sensor (4) installed to hydraulic piston (5) and
Operation set to the specified opening ratio by controlling
q The oil pressure (engine oil) of 1.47 MPa {15 the solenoid current.
kg/cm2} supplied to oil inlet (A) is reduced by q The bypass valve assists the EGR gas by
oil pressure control valve (2). increasing the exhaust pressure.
q Hydraulic piston (5) generates pressing force q The structure and operation of the EGR
from the reduced oil pressure. bypass valve are the same as those of the
q The control oil pressure can be changed with EGR valve.
the drive current of solenoid (3).
18 125E-5 Series
EGR cooler
A : EGR gas inlet D : Coolant outlet

B : EGR gas outlet E : Air bleeder
C : Coolant inlet
1. Heat exchange tube (Corrugated tube)
Function
q The EGR cooler cools the high-temperature
EGR gas taken out of the exhaust gas to
increase the gas density, or the EGR effi-
ciency.
Structure
q The EGR cooler is a multi-tube heat
exchanger. When the high-temperature EGR
gas flows through heat exchange tube (1), it is
cooled by the coolant flowing outside of the
tube.
q Heat exchange tube (1) is made of corrosion-
resistant stainless steel and corrugated to
increase the cooling efficiency.
125E-5 Series 19
Venturi system
A : Air inlet 1. Venturi nozzle

B : EGR gas inlet 2. Throat
3. Diffuser
Structure
q The EGR gas and intake air mix together in the
venturi system.
q The venturi system consists of throat (2), ven-
turi nozzle (1), and diffuser (3).
Operation
q The boost pressure increased by the turbo-
charger is set negative temporarily with the
venturi effect of the throat to take the EGR gas
into the intake air through venturi nozzle (1).
q When the mixture of the EGR gas and intake
air flows through diffuser (3), its pressure is
increased again to the normal level and then it
flows in the intake manifold.
20 125E-5 Series
Engine unit 1
Cylinder head 1
1. Coolant air tube

2. Cylinder head bolt
3. Injector
4. Fuel spill tube
5. Valve guide
6. Cylinder head
7. Cylinder head cover
8. Valve seat insert
9. Rocker arm housing
125E-5 Series 21
Cylinder head
q Direct injection type
q 4-valve type
q Overhead injector (Common rail system specification)
q Split-type 1-cylinder, 1-head
Valve seat
q Valve seat inserts are press fitted to both intake and exhaust valves
Head cover
q Float-type seal
22 125E-5 Series
a Order of tightening cylinder head mounting bolts

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

1st stage 98 {10}
inder head mounting bolt {9 – 11}
Tighten in order
3 (apply molybdenum dis- (1) – (6) 166.6 – 176.4
2nd stage 176.4 {18} shown above
ulfide or engine oil to {17 – 18}
underside of bolt head.) 3rd stage Retighten 120° 90 – 120°
(7) — 68.6 {7} 58.8 – 73.5 {6 – 7.5}
Tightening torque of Target (Nm {kgm}) Range (Nm {kgm})
4
injector mounting bolt 66 {6.75} 58.8 – 73.5 {6.0 – 7.5}
Tightening torque of Tighten
5 rocker arm housing 66 {6.75} 58.8 – 73.5 {6.0 – 7.5}
mounting bolt
125E-5 Series 23
Cylinder block 1
1. Cylinder block
2. Cylinder liner
3. Clevis seal
4. Liner ring (Ethylene-propylene rubber)
5. Liner ring (Silicone rubber)
6. Front seal
7. Front cover
8. Main cap bolt
9. Main bearing cap
10. Main bearing
11. Thrust bearing
12. Piston cooling nozzle
24 125E-5 Series
Cylinder block
q Crankshaft section: 7 bearings
q Camshaft section: 7 bearings
Front seal
q Single lip with dust seal
Piston cooling
q With piston cooling nozzle
Cylinder liner
q Wet type
q Machining on inside: Plateau honing
Soft nitriding process
Liner ring
q Upper : Clevis seal
q Middle : O-ring (Ethylene-propylene rubber)
q Lower : O-ring (Silicone rubber)
125E-5 Series 25
Unit: mm
Strain of cylinder head Tolerance Repair limit Correct by grind-
1
mounting surface 0 – 0.080 0.12 ing or replace
Diameter of main bearing Replace main
mounting hole +0.015 bearing cap
116
–0.010
2 Roundness of mounting
Repair limit: 0.005
hole
Replace bearing
–0.005
Thickness of main bearing 3
–0.020
Standard size Tolerance Repair limit
Inside diameter of main Replace main
3 +0.040
bearing 110 110.15 bearing
+0.010
Standard size Tolerance Correct or
Diameter of cam bushing
4 +0.030 replace cylinder
mounting hole 63
+0.000 block
Inside diameter of cam Replace cam
5 +0.070
bushing 60 60.30 bushing
0
26 125E-5 Series
Unit: mm
Procedure Target(Nm{kgm}) Range(Nm{kgm})
Tightening torque of main cap 1st stage 98 {10} 88 – 108 {9 – 11}
6
(apply engine oil to threads) 2nd stage 196 {20} 191 – 201 {19.5 – 20.5}
3rd stage Retighten 90° Retighten 90(+30/0)°
Tighten
Tightening torque of oil pan
7 — 54 {5.5} 34 – 73 {3.5 – 7.5}
mounting bolt
Tightening torque of crank pul- M16 (5 pieces) 274 {28} 245 – 309 {25 – 31.5}
8
ley mounting bolt M14 (1 piece) 176 {18} 157 – 196 {16 – 20}
Level difference between
9 underside surfaces of cylinder Repair limit: 0.35
block and flywheel housing Correct by
Level difference between reassembling
10 underside surfaces of cylinder Repair limit: 0.28
block and front cover
125E-5 Series 27
Cylinder liner 1
Unit: mm
Replace cylinder liner or
1 Projection of cylinder liner Permissible range: 0.07 – 0.15
cylinder block
Rank Standard size Tolerance Repair limit
+0.020
Inside diameter of cylinder A 125 125.20
+0.000
liner (unit)
+0.040
B 125 125.20
2 +0.021
Replace cylinder liner
Roundness of inside of cylin- (Spare liner is supplied
Repair limit: 0.08
der liner (unit) only for rank B)
Cylindricality of inside of cyl-
Repair limit: 0.08
inder liner (unit)
Outside diameter of cylinder Standard size Tolerance
liner (at counterbore portion)
(unit) 153 ±0.025
3
Interference of cylinder liner
and block (at counterbore Standard clearance: 0 – 0.113
block
portion)
Outside diameter of cylinder Standard size Tolerance
liner (at bottom of counter- +0.090 Replace cylinder liner
bore) 145
+0.040
4
Interference of cylinder liner Standard interference Interference limit
and block (at bottom of coun-
0.01 – 0.12 0.01 block
terbore)
Outside diameter of cylinder
+0.386 Replace cylinder liner
liner (at O-ring) 141
5 +0.361
Clearance between cylinder Replace cylinder liner or
Standard clearance: 0.014 – 0.079
liner and block (at O-ring) block
28 125E-5 Series
Main moving parts 1
a. Re-entrant combustion chamber
1. Piston (FCD piston) 7. Connecting rod bearing

2. Connecting rod bushing 8. Connecting rod
3. Piston pin 9. Connecting rod cap bolt
4. Crankshaft 10. Top ring
5. Crank gear (Number of teeth: 33) 11. Second ring
6. Connecting rod cap 12. Oil ring
125E-5 Series 29
Specifications Piston rings

Crankshaft: Closed die forging
: Journal, fillet
Induction hardening
Piston: Special thin ductile cast iron (FCD piston)

: Re-entrant combustion chamber
Connecting rod lubricating oil hole: Made

Piston cooling from connecting rod end: Applied
Features of FCD piston

q The FCD piston has high heat resistance.
q The FCD piston has low thermal expansion
factor and the clearance between the liner and Top ring (1) : Double-side keystone, inner cut,
it can be reduced. barrel face, hard chromium-plated
q Since the FCD piston has high strength, the Second ring (2) : Keystone, inner cut, taper face,
top ring can be installed to a higher place, and hard chromium-plated
the loss area of the combustion chamber can Oil ring (3) : With coil expander and nitrided
be reduced. surface
q The exhaust sound is low and the exhaust gas
color is better.
q The output can be heightened.
30 125E-5 Series
Crankshaft 1
Unit: mm
Standard value Repair limit Replace thrust bearing
1 End play
0.140 – 0.315 0.50 or use oversize bearing
S.T.D. 110 109.88
Outside diameter of main 0.25 U.S. 109.75 109.63
journal –0.050
0.50 U.S. 109.50 109.38 Use undersize journal
–0.070
0.75 U.S. 109.25 109.13 or replace
2
1.00 U.S. 109.00 108.88
Standard Repair limit
Roundness
0 – 0.010 0.020
Standard clearance Clearance limit
Clearance of main journal Replace main bearing
0.062 – 0.106 0.27
S.T.D. 80 79.88
Outside diameter of crank 0.25 U.S. 79.75 79.63
pin journal –0.050
0.50 U.S. 79.50 79.38 Use undersize journal
–0.070
0.75 U.S. 79.25 79.13 or replace
3
1.00 U.S. 79.00 78.88
Roundness
0 – 0.010 0.020
Clearance of crank pin jour- Standard clearance Clearance limit Replace connecting rod
nal 0.046 – 0.090 0.24 bearing
Standard Repair limit Use undersize crank-
4 Bend of crankshaft
0 – 0.09 0.20 shaft or replace
125E-5 Series 31
Camshaft 1
Unit: mm
1 End play Replace thrust plate
0.15 – 0.35 0.50
Outside diameter of cam-
–0.080 Replace
shaft journal 60
2 –0.110
Clearance of camshaft jour- Standard clearance Clearance limit
Replace cam bushing
nal 0.080 – 0.180 0.28
3 Bend of camshaft Repair limit: 0.03 (Overall swing of indicator)
Replace
4 Height of cam +0.395
52 51.73
+0.195
32 125E-5 Series
Cam follower and push rod 1
Unit: mm
Diameter of cam follower
shaft –0.040
19.8 19.73
1 –0.050
Diameter of cam follower +0.020
19.8 —
shaft hole +0.000
Outside diameter of cam –0.250
2 32 31.70
roller –0.280
Inside diameter of cam –0.262
13 12.78
roller –0.287 Replace
3
–0.364
Diameter of cam roller pin 13 12.62
–0.376
4 Radius of push rod ball end –0.00
12.7
–0.20
Radius of push rod socket –0.00
5 12.7
end –0.20
6 Bend of push rod Repair limit: 0.50 (Overall swing of indicator)
Tightening torque of cam
— 51 ± 7.4 Nm {5.25 ± 0.75 kgm} Tighten
follower shaft mounting bolt
125E-5 Series 33
Piston, piston ring and piston pin 1
34 125E-5 Series
Unit: mm
Rank Standard size Tolerance Repair limit
Replace piston
–0.090
A or S 125 124.80 (Spare piston is
1 Outside diameter of piston –0.105
supplied for only
–0.075 rank A or S)
B or L 125 124.80
–0.090
No. Measuring point Standard size Tolerance
–0.005
2 No. 1 ring 2.42
–0.025
Replace piston
Thickness of piston ring –0.010
3 No. 2 ring 2.4 ring
–0.030
–0.010
4 Oil ring 4
–0.030
2 No. 1 ring Check with groove wear gauge
(When new ring is installed,
3 No. 2 ring clearance is 0.15)
Width of piston ring groove Replace piston
2–4 +0.040
4 Oil ring 4
+0.020
Standard clear- Clearance
No. Measuring point
ance limit
Clearance between piston 2 No. 1 ring Replace piston or
ring and piston ring groove Check with groove wear gauge piston ring
3 No. 2 ring
4 Oil ring 0.030 – 0.070 0.15
2 No. 1 ring 0.37 – 0.47 2.0 Replace piston
Closed gap of piston ring 3 No. 2 ring 1.10 – 1.20 2.0 ring or cylinder
4 Oil ring 0.23 – 0.35 1.0 liner

Outside diameter of pis- Replace piston
ton pin 0 pin
48
–0.006
5 +0.045
Diameter of piston pin hole 48 Replace piston
+0.035
Clearance between piston Standard clearance Clearance limit Replace piston or
pin and piston 0.035 – 0.051 0.063 piston pin
— Weight of piston 3,000 g, Permissible range: ±60 g Replace piston
125E-5 Series 35
Connecting rod 1
Unit: mm
Inside diameter of Standard size Tolerance Repair limit Replace bushing
connecting rod small end +0.041 (Spare is half
bushing 48 48.08 worked)
+0.025
1
Clearance between Standard clearance Clearance limit
Replace bushing
connecting rod small end
0.025 – 0.047 0.10 or piston pin
bushing and piston pin
Diameter of connecting rod Standard size Tolerance
Replace connect-
2 small end bushing +0.030
53 ing rod
mounting hole +0.000
Inside diameter of Standard size Tolerance Repair limit
3 connecting rod large end +0.020 Replace bearing
bearing (crank pin journal) 80 80.12
–0.010
+0.022
Diameter of connecting rod 85 —
–0.004 Replace connect-
large end bearing mounting
Before measuring, tighten connecting rod cap mounting bolt to ing rod
4 hole
specified torque.
Thickness of connecting +0.005
2.5 — Replace bearing
rod bearing –0.004
Item Standard Repair limit
Parallelism and twist of Parallelism a 0 – 0.20 0.25 Replace connect-
5
connecting rod Twist b 0 – 0.30 0.35 ing rod
Dimension c 240 —
Tightening torque of Procedure Target (Nm {kgm}) Range (Nm {kgm})
connecting rod cap 1st stage 98 {10} 93 – 103 {9.5 – 10.5}
6 mounting bolt Retighten
(Apply engine oil to bolt 2nd stage Retighten 90° Retighten 90 (+30/0)°
threads and nut seat)
Permissible range: Dispersion of weight of connecting rods in 1
— Weight of connecting rod Replace
engine must not exceed 140 g.
a Do not use a connecting rod cap mounting bolt more than 5 times.
Each time the bolt is used, make a punch mark on its head.
36 125E-5 Series
Flywheel and flywheel housing 1

Without PTO
1. Flywheel housing
Number of
2. Ring gear Applicable machine
Number of teeth
internal teeth of
3. Flywheel of ring gear
flywheel
4. Rear seal
PC400-7, PC400LC-7
PC450-7, PC450LC-7 148 —
D85EX-15, D85PX-15
HM300-2 137 —
125E-5 Series 37
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
38 125E-5 Series
Unit: mm
Facial runout of flywheel
1 Repair limit: 0.35
housing Correct by reas-
Radial runout of flywheel sembling
2 Repair limit: 0.30
housing
Bolt Procedure Target (Nm{kgm}) Range (Nm{kgm})
Tightening torque of fly- 1st stage 191 {19.5} 147 – 235 {15 – 24}
3 wheel housing mounting M16 Tighten
bolt 2nd stage 279 {28.5} 245 – 309 {25 – 31.5}
M10 — 69 {7} 59 – 74 {6 – 7.5}
4 Facial runout of flywheel Repair limit: 0.20 Correct by reas-
5 Radial runout of flywheel Repair limit: 0.15 sembling
Tightening torque for fly- Procedure Target (Nm{kgm}) Range (Nm{kgm})
wheel mounting bolt 1st stage 147 {15} 127 – 167 {13 – 17} Tighten
6
(Apply engine oil to
threads) 2nd stage 289 {29.5} 270 – 309 {27.5 – 31.5}
a Do not use a flywheel mounting bolt more than

5 times.
Each time the bolt is used, make a punch mark
on its head.
125E-5 Series 39
Vibration damper 1
1. Vibration damper
2. Pin
3. Crank pulley
4. Crank pulley mounting bolt
5. Vibration damper mounting bolt
40 125E-5 Series
Unit: mm
1 Outside check Rubber parts must be free from cracking and flaking.
2 Radial runout of damper Repair limit: 0.80 Replace
3 Facial runout of damper Repair limit: 0.80
Tightening torque of vibra- Bolt Target (Nm {kgm}) Range (Nm {kgm})
4 Tighten
tion damper mounting bolt M12 111 {11.3} 98 – 213 {10 – 12.5}
125E-5 Series 41
Timing gear 1
1. Cylinder block 8. Oil pump idler gear (Number of teeth: 25)

2. Water pump drive gear (Number of teeth: 22) 9. Injection drive gear (Number of teeth: 44)
3. Main idler gear (Number of teeth: 57) 10. Timing gear cover
4. EGR oil pump drive gear (Number of teeth: 20) 11. Camshaft gear (Number of teeth: 44)
5. Idler gear, medium (Number of teeth: 38) 12. Crankshaft gear (Number of teeth: 33)
6. Main idler gear, small (Number of teeth: 38) 13. Crankshaft
7. Oil pump drive gear (Number of teeth: 21) A, B, C: Timing gear mating marks
42 125E-5 Series
125E-5 Series 43
Unit: mm
Position Check parts Standard Repair limit
Crank gear and main idler gear
A 0.116 – 0.359
(large)
Main idler gear (small) and cam
B 0.105 – 0.325
gear
Cam gear and fuel supply pump
C 0.105 – 0.325
— Backlash of each gear gear Replace
0.6
Main idler gear (large) and water
a 0.076 – 0.366
pump gear
Main idler gear (large) and oil
b 0.105 – 0.337
pump idler gear
Oil pump idler gear and oil pump
c 0.082 – 0.389
drive gear
Tolerance Standard Clearance
Standard size
Clearance between main Shaft Hole clearance limit
1
idler gear bushing and shaft +0.165 +0.115 0.025 –
47.5 0.20 Replace
+0.140 +0.100 0.060 bushing
Clearance between oil
–0.025 +0.065 0.025 –
2 pump idler gear bushing 35 0.20
–0.040 +0.000 0.105
and shaft
3 End play of main idler gear Replace
0.05 – 0.17 0.4
thrust bear-
End play of oil pump idler ing
4 0.05 – 0.21 0.4
gear
44 125E-5 Series
125E-5 Series 45
Valve system 1
1. Rocker arm shaft 11. Valve spring

2. Cam roller 12. Valve spring seat (lower) (both IN and EX)
3. Cam roller pin 13. Adjustment screw
4. Camshaft 14. Locknut
5. Cam gear (Number of teeth: 44) 15. Rocker arm
6. Adjustment screw 16. Push rod
7. Locknut 17. Cam follower
8. Cross head 18. Valve cotter
9. Valve seat (upper) 19. Exhaust valve
10. Intake valve 20. Valve stem seal (both IN and EX)
46 125E-5 Series
A: No.1 cylinder intake side

B: No.1 cylinder exhaust side
Camshaft: Closed die forging

Journal and cam sections: Induction hardening
125E-5 Series 47
Parts related to valves

Part IN EX
Cross head 6150-42-5610 6150-42-5610
Valve 6150-42-4110 6150-42-4210
Valve spring 6251-41-4450 6251-41-4450
(Color code) (Light blue) (Light blue)
Valve spring seat
6150-41-4430 6150-41-4430
(lower)
Valve rotator — —
Valve guide 6150-11-1370 6150-11-1370
Valve stem seal 6150-41-4570 6150-41-4570
Valve timing
48 125E-5 Series
125E-5 Series 49
Valve and valve guide 1
Unit: mm
Valve Standard size Tolerance Repair limit
Replace valve or
1 Sinking distance of valve Intake 1.88 ±0.10 2.51
valve seat
Exhaust 1.20 ±0.10 1.90
Valve Standard size Repair limit
2 Thickness of valve lip Intake 2.10 1.7 Replace valve
Exhaust 1.50 1.2
Intake Exhaust Correct or replace
3 Valve seat angle
Standard 30° ± 15' 45° ± 15' valve or valve seat
Valve Standard size Tolerance
–0.045
Intake 9
Diameter of valve stem –0.065 Replace valve
–0.050
Exhaust 9
–0.070
Before head is Intake/Exhaust +0.015
9
4 Inside diameter of valve press fitted valve –0.003 Replace valve
guide After head is Intake/Exhaust +0.009 guide
9
press fitted valve –0.011
Valve Standard clearance Clearance limit
Clearance between valve Replace valve or
Intake 0.034 – 0.074 0.22
guide and stem valve guide
Exhaust 0.039 – 0.079 0.24
Bend of valve stem Repair limit: 0.01 (Overall swing of indicator in 100 mm) Replace
50 125E-5 Series
Unit: mm
Driving height of valve Standard Tolerance
5 Correct
guide 20 ±0.2
Valve Color code Standard size Repair limit
Free length of valve spring Intake Light blue 76.2 —
Exhaust Light blue 76.2 —
Standard Allowable
Installed
Valve Color code load load
length
(N {kg}) (N {kg}) Replace valve
6 Installed load of valve
519.8 ± 26 spring
spring Intake Light blue 56.0 468 {47.7}
{53.0 ± 2.7}
519.8 ± 26
Exhaust Light blue 56.0 468 {47.7}
{53.0 ± 2.7}
Perpendicularity of valve
Repair limit: 2° (both sides)
spring
125E-5 Series 51
SEN00184-00
Rocker arm and shaft 1
Unit: mm
Diameter of rocker arm Replace rocker
shaft –0.053 arm and shaft
28.6
–0.066
Diameter of rocker arm +0.033 Replace rocker
28.6
shaft hole –0.027 arm
1
Standard clearance Clearance limit Replace rocker
Clearance between rocker
arm or rocker arm
arm shaft and rocker arm 0.026 – 0.099 0.13 shaft
Replace rocker
Bend of rocker arm shaft Repair limit: 0.20 (Overall swing of indicator)
arm shaft
Tightening torque of locknut Target (Nm {kg}) Range (Nm {kg})
2 of rocker arm adjustment Tighten
screw 59 {6.0} 53 – 65 {5.4 – 6.6}
Valve Standard Tolerance

Valve clearance
3 Intake side 0.33 Adjust
(Both when hot and cold) ±0.02
Exhaust side 0.71
52
Crosshead and guide 1
Unit: mm
Inside diameter of cross-
head +0.075
11 11.18
1 +0.025 Replace
Outside diameter of cross- +0.011
11 10.95
head guide +0.000
Projection of crosshead
2 45.5 ±0.25 — Correct
guide
125E-5 Series 53
© 2005 KOMATSU
All Rights Reserved
54 125E-5 Series
SEN00185-00
ENGINE 1SHOP MANUAL
125E-5 Series
10 Structure, function and

maintenance standard 1
Structure, function and maintenance
standard, Part 2
Lubrication system .......................................................................................................................................... 4
Lubrication system diagram ................................................................................................................. 4
Oil pump............................................................................................................................................... 6
Main relief valve ................................................................................................................................... 7
EGR oil pump....................................................................................................................................... 8
Oil filter ................................................................................................................................................. 9
Safety valve........................................................................................................................................ 10
Oil cooler .............................................................................................................................................11
Fuel system................................................................................................................................................... 12
CRI system diagram........................................................................................................................... 12
Outline of CRI system ........................................................................................................................ 13
125E-5 Series 1
Fuel piping.......................................................................................................................................... 34
Fuel cooler.......................................................................................................................................... 36
Fuel filter............................................................................................................................................. 37
Priming pump ..................................................................................................................................... 38
Engine controller cooler...................................................................................................................... 39
Cooling system.............................................................................................................................................. 40
Cooling system diagram..................................................................................................................... 40
Water pump ........................................................................................................................................ 41
Thermostat ......................................................................................................................................... 43
Corrosion resistor ............................................................................................................................... 45
Electrical equipment...................................................................................................................................... 46
Alternator............................................................................................................................................ 46
Starting motor ..................................................................................................................................... 52
Electrical intake air heater .................................................................................................................. 56
Engine controller ................................................................................................................................ 57
2 125E-5 Series
125E-5 Series 3
Lubrication system 1
Lubrication system diagram 1
a The layout of the oil filter, shapes of the oil pan and piping, etc. are subject to machine models.
4 125E-5 Series
W: Coolant
1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil pump relief valve
5. Oil cooler
6. Thermo-valve
7. Oil filter
8. Safety valve
9. Crankshaft
10. Piston cooling nozzle
11. Piston
12. Camshaft
13. Cam follower
14. Rocker arm
15. Air intake valve and exhaust valve
16. Timing gear
17. Turbocharger
18. Fuel supply pump
19. EGR oil pump
20. EGR oil pump relief valve
21. EGR valve
22. Bypass valve
23. Main gallery
125E-5 Series 5
Oil pump 1
1. Oil pump drive gear (Number of teeth: 21) Oil pump gear
2. Bushing Type: Gear pump
3. Pump cover Speed: Engine speed × 1.571
4. Drive gear
5. Pump body Main relief valve
6. Drive shaft Cracking pressure:
7. Main relief valve 1.33 – 1.53 MPa {13.6 – 15.6 kg/cm2}
8. Valve spring
9. Retainer
10. Drive shaft
11. Bushing
12. Driven gear
6 125E-5 Series
Main relief valve 1
Unit: mm
Cracking pressure of Correct or
1
relief valve Standard: 1.33 – 1.53 MPa {13.6 – 15.6 kg/cm2} replace spring
Tolerance
Standard size Standard clearance
Clearance between valve Shaft Hole
2 Replace
and body
–0.040 +0.043
16 0.040 – 0.103
–0.060 0
Standard size Repair limit
Free length Installed length Standard load Free length Allowable load
3 Relief valve spring Replace
120 N 110 N
48.8 38.8
{12.2 kg} {11.2 kg}
125E-5 Series 7
EGR oil pump 1
A: From main gallery Specifications

B: To EGR valve and bypass valve Oil pump
C: Rotation direction Type: Gear pump
Speed: Engine speed × 1.1
1. Pump cover
2. Driven gear Main relief valve
3. Pump body Cracking pressure:
4. Drive gear 1.43 ± 0.1 MPa {14.6 ± 1.0 kg/cm2}
5. Pump drive gear (Number of teeth: 20)
6. Main relief valve
7. Main valve spring
8 125E-5 Series
Oil filter 1
Remote mount type
A: Oil inlet Specifications

B: Oil outlet Oil filter
Filtration area: 0.44 m2 (Full-flow)
1. Safety valve
2. Filter head Safety valve
3. Cartridge Cracking pressure: 343 ± 19 kPa {3.5 ± 0.2 kg/cm2}
125E-5 Series 9
Safety valve 1
1. Safety valve
2. Filter head
3. Spring
4. Cap
Unit: mm
Cracking pressure of safety
1 Standard: 343 ± 19 kPa {3.5 ± 0.2 kg/cm2} Replace
valve
10 125E-5 Series
Oil cooler 1

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

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

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

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

fuel supplied by the fuel supply pump to the
cylinders through the common rail.
q The solenoid valve in the injector opens and
closes the nozzle needle valve to start and fin-
ish injection.
125E-5 Series 13
2. Control system
q The engine controller calculates and controls

the energizing timing and energizing period of
the injector with the signals from the sensors
installed to the machine to inject proper quan-
tity of fuel in proper timing.
q The control system is roughly divided by the
electric parts into the sensors, computer, and
actuators.
14 125E-5 Series
Structure and operation of CRI system
q The CRI system consists of the fuel supply q If the TWV is turned on (energized), the fuel
pump, common rail, injector, engine controller circuit is so changed that the high-pressure
to control them, and sensors. fuel in the control chamber will flow through the
q The fuel supply pump generates fuel pressure orifice. As a result, the needle valve is raised
in the common rail. The fuel pressure is con- to start fuel injection by the nozzle cracking
trolled by the fuel discharge rate of the supply pressure of the high-pressure fuel on the noz-
pump. zle side.
q The discharge rate is controlled by turning on q If the TWV is turned off (de-energized), the fuel
and off the PCV (pressure control valve) of the circuit is so changed that the high-pressure
fuel supply pump according to the electric sig- fuel will be applied to the control chamber
nals from the engine controller. through the orifice. As a result, the needle
q The common rail receives the pressurized fuel valve lowers and finishes fuel injection.
from the fuel supply pump and distributes it to q Accordingly, the fuel injection timing and fuel
the cylinders. injection rate are controlled respectively by the
q The fuel pressure is sensed by the common timing to turn on the TWV and the length of the
rail fuel pressure sensor installed to the com- turn-on time of the TWV.
mon rail.
q A feedback control is applied so that the actual
fuel pressure will match to the command pres-
sure set according to the engine speed and the
load on the engine.
q The fuel pressure in the common rail is applied
to the nozzle side of the injector and to the
control chamber through the fuel injection pipe
of each cylinder.
q The injector controls the fuel injection rate and
fuel injection timing by turning on and off the
TWV (2-way solenoid valve).
125E-5 Series 15
Structure and operation of component parts 1

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

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

q The fuel supply pump consists of priming to the common rail is the same as the number
pump (7), feed pump (8), and high-pressure of the times of fuel injection, the common rail
pumps (4) and (6). fuel pressure is smooth and stable.
q The function of the fuel supply pump is to gen- q The fuel fed by high-pressure pumps (4) and
erate common rail fuel pressure by controlling (6) to the common rail is divided as follows.
the fuel delivery. q No. 1 high-pressure pump (on the drive gear
side) (4) compensates for drop in the common
Structure rail fuel pressure caused by fuel injection into
q High-pressure pumps (4) and (6) have the the No. 1, 3, and 5 cylinders.
pressure feed systems similar to those of the q No. 2 high-pressure pump (on the feed pump
conventional in-line fuel injection pump and the side) (6) compensates for drop in the common
PCVs (pressure control valves) for each cylin- rail fuel pressure caused by fuel injection into
der to control the fuel delivery. the No. 2, 4, and 6 cylinders.
q By employing the 3-head cam, the necessary
number of the cylinders of high-pressure
pumps (4) and (6) is reduced to 1/3 of the
engine cylinders.
16 125E-5 Series
Operation
q (A): During the lowering stroke of the plunger,

the PCV is open and the low-pressure fuel
is sucked in the plunger chamber through
the PCV.
q (B): While the PCV is not energized and is
open after the plunger starts the rising
stroke, the sucked fuel is returned through
the PCV without being pressurized.
q (C): If the PCV is energized and closed in the
timing for the necessary delivery, the return
passage is closed and the pressure in the
plunger chamber rises. Accordingly, the
fuel is fed through the delivery valve (check
valve) to the common rail. That is, the
quantity of the fuel corresponding to the
plunger lift after the PCV is closed is the
delivery. The delivery is changed and the
common rail fuel pressure is controlled by
changing the opening timing of the PCV.
q (D): After the cam passes the maximum lift
point, the plunger starts the lowering
stroke and the pressure in it lowers. At
this time, the delivery valve closes to stop
feeding the fuel. Since the PCV is de-
energized, it opens and the low-pressure
fuel is sucked in the plunger chamber, or
the state of (A) starts again.
125E-5 Series 17
1) PCV (Pressure control valve) 2) Feed pump

q The PCV adjusts the fuel delivery from the fuel q The feed pump built in the fuel supply pump
supply pump to adjust the common rail fuel assembly draws the fuel from the fuel tank and
pressure. The delivery from the fuel supply sends it through the fuel filter to the high-pres-
pump to the common rail is decided by the tim- sure pump chamber.
ing of energizing the PCV. q The outer and inner rotors of the feed pump
are rotated by the camshaft.
q The fuel is sucked in on the suction side and
discharged on the delivery side according to
the increase and decrease of the spaces
between the outer and inner rotors.
18 125E-5 Series
2. Common rail
Structure Operation
q Common rail (4) distributes the high-pressure When fuel is not injected
fuel from the high-pressure pump to the injec-
q Piston (2) is in contact with stopper (1) (initial
tors of the cylinders.
position).
q Common rail (4) is equipped with common rail
q The fuel for static leakage is supplied through
fuel pressure sensor (2), flow dampers (1), and
orifice (a) of piston (2) and clearance in the
pressure limiter (3).
sliding parts.
q The fuel injection pipes are connected to flow
dampers (1) to send the high-pressure fuel to
When fuel is injected
the injectors.
q The fuel pressure is applied to piston (2),
q The piping of the pressure limiter (3) is
which compresses spring (3) and moves to the
returned to the fuel tank.
right.
q The fuel for static leakage is supplied through
orifice (a) of piston (2) and clearance in the
sliding parts.
When fuel is stopped
q If the fuel flows out abnormally because of a
burst of the piping, etc., piston (2) moves to the
right stroke end.
q The tip of piston (2) contacts seat (b) to stop
the fuel.
q Once the fuel is stopped, piston (2) does not
return to the initial position until the engine is
stopped.
1) Flow damper
Function
q The flow dampers damp the pressure pulses in
the high pressure piping and supply the fuel to
the injectors with stable pressure.
q If excessive fuel flows out, the flow dampers
block the fuel passage to prevent abnormal
outflow of the fuel.
q If the fuel flows out abnormally, high pressure
is applied to the piston, which moves to the
right until it reaches the seat to stop the fuel.
125E-5 Series 19
2) Pressure limiter 3) Common rail fuel pressure sensor

q If abnormally high pressure is generated, the q The common rail fuel pressure sensor is
pressure limiter opens to release that pres- installed to the common rail to sense the fuel
sure. pressure.
q If the common rail fuel pressure reaches about q This sensor is a semiconductor pressure sen-
200 MPa {2,040 kg/cm2}, the pressure limiter sor, which utilizes the phenomenon that the
operates (opens). electric resistance of silicon changes according
q If the common rail fuel pressure lowers to 30 to pressure applied to it.
MPa {310 kg/cm2}, the pressure limiter resets
itself (closes) to maintain the pressure.
q Under the normal condition, the pressure lim-
iter does not reset itself (close) until the engine
is stopped.
1. Ball
2. Housing
3. Spring
4. Body
5. Guide
20 125E-5 Series
3. Injector
Outline
q The function of the injector is to inject the high-
pressure fuel from the common rail into each
combustion chamber of the engine in the opti-
mum timing, by the optimum quantity, at the
optimum injection rate, and under the optimum
spray condition.
q The TWV (2-way solenoid valve) controls the
start and finish of fuel injection by controlling
the pressure in the control chamber.
q The orifice limits the opening speed of the noz-
zle and controls the fuel injection rate.
q The hydraulic piston transmits the force gener-
ated by the pressure in the control chamber to
the needle valve of the nozzle.
q The nozzle sprays the fuel.
125E-5 Series 21
Structure
1. Inlet connector 7. Orifice (in)

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

fice to control the fuel injection rate, hydraulic
piston section, and 2-way solenoid valve sec-
tion.
22 125E-5 Series
A: No fuel injection C: Finish of fuel injection

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

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

q While solenoid (6) is not energized, valve body q If solenoid (6) is de-energized, valve body (5)
(5) is pressed down by spring (7). is lowered by spring (7) and the fuel passage is
q Since the high-pressure fuel is applied from closed.
the common rail to pressure control chamber q At this time, the high-pressure fuel in the com-
(8), nozzle (1) is closed and the fuel is not mon rail is applied to pressure control chamber
injected. (8) suddenly and nozzle (1) is closed quickly,
fuel injection is finished sharply.
2) Start of fuel injection (B)
q If solenoid (6) is energized, valve body (5) is
pulled up by the electromagnetic force and the
fuel passage is opened.
q Since the fuel in pressure control chamber (8)
flows out through orifices (3) and (4), nozzle
(1) rises and fuel injection pump starts.
q The fuel injection rate is increased gradually by
the function of orifices (3) and (4).
q If solenoid (6) is kept energized, the fuel injec-
tion rate is increased to the maximum.
125E-5 Series 23
Electric circuit diagram
k Since high voltage (118 V) is applied to the

wiring harnesses connected to the engine
controller, COMMON 1 and COMMON 2 of
the supply pump, and TWV #1 – #6 of the
injector, take care not get an electric shock.
24 125E-5 Series
Various controls
q The CRI system controls the fuel injection rate

and fuel injection timing more properly than the 2. Fuel injection timing control function
mechanical governor or timer of the conven- q The fuel injection timing control function is
tional fuel injection pump. employed instead of the function of the con-
q For the control of the system, calculations nec- ventional timer. It controls the fuel injection
essary to the engine controller are performed timing most properly from the engine speed
fr om th e si gn als se nt fr om the s en so rs and fuel injection rate.
installed to the engine and machine.
q The energizing timing and energizing period of
the injector are so controlled that the optimum 3. Fuel injection pressure control function
quantity of fuel will be injected in the optimum (Common rail fuel pressure control function)
timing.
q The fuel injection pressure control function
(common rail fuel pressure control function) is
a function of measuring the fuel pressure with
1. Fuel injection rate control function the common rail fuel pressure sensor and
q The fuel injection rate control function is
feeding it back to the engine controller to con-
employed instead of the function of the con-
trol the delivery of the fuel supply pump.
ventional governor. It controls the fuel injection
q This function performs pressure feedback con-
according to the signals of engine speed and
trol so that the fuel injection pressure will be
accelerator angle so that the fuel injection rate
the same as the optimum value (command
will be most proper.
value) set according to the engine speed and
fuel injection rate.
125E-5 Series 25
4. Various sensors
a Nos. 1 – 13 in the above illustration correspond to title Nos. 1) – 13).

a The above illustration shows the engine for HM300-2.
26 125E-5 Series
125E-5 Series 27
1) EGR inlet pressure sensor 2) Atmospheric pressure sensor

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

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

teristics of the atmospheric pressure sensor.
28 125E-5 Series
3) EGR valve position sensor
4) Bypass valve position sensor (Applicable machine: HM300-2)

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

teristics of the position sensor.
125E-5 Series 29
5) Common rail pressure sensor 7) Fuel temperature sensor

q The fuel temperature sensor senses the fuel
6) NE speed sensor (Crank angle sensor) temperature and sends it to the engine control-
q If the signal hole made on the flywheel passes ler. The sensor unit is a thermistor the resis-
the sensor, the magnetic line of force changes. tance of which changes according to the
q If the magnetic line of force changes, the out- temperature.
put of the Hall element sensor changes linearly q The engine controller applies voltage to the
and it is converted into pulse of 0 – 5 V by the thermistor and senses the temperature by the
wave form shaping circuit in the sensor, and voltage divided by the resistance in the com-
then output. puter and the resistance of the thermistor.
8) Engine controller
9) Oil pressure sensor
30 125E-5 Series
10) Bkup speed sensor (G sensor) 11) Charge pressure sensor

(Cylinder No. sensor) q This sensor is used to sense the charge pres-
q Similarly to the NE speed sensor, this sensor sure (boost pressure).
utilizes the pulses of 0 – 5 V generated by the
change of the magnetic line of force crossing
the sensor unit.
q The disc gear installed to the central part of the
camshaft of the high-pressure pump has teeth
(cut parts) around it at intervals of 120°C.
q In addition to the above teeth, one more tooth
is installed. Accordingly, 7 pulses are gener-
ated every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is rec-
ognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.
A: Mounting screw: M6
Tightening torque: 5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}
1. Sensor
2. O-ring

teristics of the charge pressure sensor.
125E-5 Series 31
12) Charge temperature sensor 13) Coolant temperature sensor

q The charge temperature sensor senses the q The coolant temperature sensor senses the
intake air temperature (boost temperature) and coolant temperature and sends it to the engine
sends it to the engine controller. controller.
q The sensor unit is a thermistor the resistance q The sensor unit is a thermistor the resistance
of which changes according to the tempera- of which changes according to the tempera-
ture. The engine controller applies voltage to ture. The engine controller applies voltage to
the thermistor and senses the temperature by the thermistor and senses the temperature by
the voltage divided by the resistance in the the voltage divided by the resistance in the
computer and the resistance of the thermistor. computer and the resistance of the thermistor.
32 125E-5 Series
125E-5 Series 33
Fuel piping 1
1. Fuel injection pipe (No. 1 cylinder)

7. Fuel return pipe
8. Common rail
9. Priming pump
10. Feed pump
11. Oil inlet pipe (for pump lubricating oil)
12. High pressure pump
13. Fuel supply pump drive gear
(Number of teeth: 44)
14. Overflow valve
15. PCV
34 125E-5 Series
A: Fuel inlet
B: To fuel filter
C: From fuel filter
D: To injector
E: Fuel return (between overflow valve and fuel
tank)
F: Fuel return (between injector and fuel tank)
G: Engine oil (to fuel supply pump)
Specifications
Fuel supply pump
Manufacturer: DENSO CORPORATION
Model: DENSO ECD-U2
Lubrication method: Forced lubrication with engine oil
125E-5 Series 35
Fuel cooler 1
A: From fuel tank

B: To fuel supply pump
1. Mount bracket
2. Core
Specifications
Cooling method: Cooling with air
Type of core: AL-CFT-1
Heat dissipation surface: 3.31 m2
36 125E-5 Series
Fuel filter 1
Main fuel filter
A: Fuel inlet
B: Fuel outlet
1. Air bleeding plug

2. Filter head
3. Cartridge
Specifications
Filtration area: 1.0 m2
125E-5 Series 37
Priming pump 1
1. Spring 9. Valve stopper

2. Cover 10. Packing
3. Shaft 11. Check valve body
4. Bushing 12. Lever pin
5. Diaphragm 13. E-ring
6. Diaphragm cover 14. Washer
7. Body 15. Bolt
8. Check valve 16. Lever
38 125E-5 Series
Engine controller cooler 1
A: Fuel IN (From feed pump of fuel supply pump)

B: Fuel OUT (Main fuel filter)
1. Engine controller
2. Engine controller cooler
Outline
q The fuel is circulated as refrigerant through
engine controller cooler (2) to prevent engine
controller (1) from overheating.
q The fuel is not circuited in some applicable
machines.
125E-5 Series 39
Cooling system 1
Cooling system diagram 1
A: Oil inlet 8. Cylinder liner

B: Oil outlet 9. Piston
C: Exhaust gas inlet 10. Cylinder block
D: Exhaust gas outlet 11. Oil cooler
12. Air compressor
1. Radiator 13. EGR cooler
2. Thermostat
3. Water pump
4. Coolant temperature gauge
5. Water manifold (made one with cylinder block)
6. Corrosion resistor
7. Cylinder head
40 125E-5 Series
Water pump 1
Mounting
A: To radiator (Coolant) 1. Thermostat

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

b. Coolant temperature gauge pickup port
c. Water drain valve
125E-5 Series 41
a. From thermostat
b. From radiator
c. To each part of engine
1. Water pump drive gear (Number of teeth: 22)

2. Pump shaft
3. Ball bearing
4. Pump body
5. Water seal
6. Impeller
7. Pump cover
Water pump
Type: Centrifugal, gear-driven
Speed: Engine speed × 1.5
Unit: mm
Tolerance Standard inter- Replace
Standard size
Interference of impeller Shaft Hole ference Usually, impeller needs to be
8
and shaft +0.018 –0.020 replaced (Outside diameter of
15.9 0.025 – 0.068 shaft changes little)
+0.005 –0.050
Interference of drive gear +0.015 –0.023 Replace (Usually, gear needs to
9 20.0 0.025 – 0.068
and shaft +0.002 –0.053 be replaced)
Clearance between impel-
10 Standard clearance: 0.30 – 1.10 (including end play)
ler and body Replace
11 Wear of water seal ring Limits of size: 1.5
42 125E-5 Series
Thermostat 1
Mounting
a. To radiator
b. To water pump
1. Thermostat
2. Thermostat housing
125E-5 Series 43
1. Fuel tank 1. Thermostat 8. Sleeve

A: When cold (Fully closed) 2. Seal 9. Flange
B: When hot (Fully open) 3. Valve
4. Body Function of thermostat (before
a. To water pump (bypass) 5. Piston installed)
b. To radiator 6. Heat sensing portion Opening temperature: 76.5°C
c. From engine 7. Inflating portion Full opening temperature: 90°C
Valve lift: Min. 10 mm
Unit: mm
Min. 10 mm (Check after soaking in oil tank at 90°C for 4 – 5 minutes.
1 Full opening lift of thermostat When valve full open (at 90°C is soaked in oil tank at full closing tempera- Replace
ture (71°C , it must close fully in 4 – 5 minutes.
44 125E-5 Series
Corrosion resistor 1
A: Coolant inlet Corrosion resistor

B: Coolant outlet Filtration area: 0.5 m2
1. Head
2. Cartridge
3. Element (Paper)
4. Element (Chemical)
5. Spring
125E-5 Series 45
Electrical equipment 1
Alternator 1
1. Alternator with built-in regulator (Open type, 35 A)
1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Initial excitation resistor
3. Terminal B 6B. Regulator
4. Terminal R 6C. Field coil
5. Terminal E
Pulley
Weight
Engine Applicable machine Type Specification Number Outside
diameter (kg)
of stages
(mm)
PC400-7, PC400LC-7 Open type (brushless),
SAA6D125E-5 24V, 35A 2 93 8.0
PC450-7, PC450LC-7 manufactured by NIKKO DENKI
46 125E-5 Series
1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Initial excitation resistor
3. Terminal B 6B. Regulator
4. Terminal R 6C. Field coil
5. Terminal E
Pulley
Weight
diameter (kg)
of stages
(mm)
PC400-7, PC400LC-7
PC450-7, PC450LC-7
Open type (brushless),
SAA6D125E-5 HM300-2 24V, 50A 2 75 10
manufactured by NIKKO DENKI
D85EX-15
D85PX-15
125E-5 Series 47
a. Load
1. Alternator
2. Alternator pulley
3. Terminal R
4. Terminal E
5. Terminal B
6. Internal electric circuit diagram
6A. Alternator
6B. Regulator
Pulley
Weight
diameter (kg)
of stages
(mm)
HM300-2
Open type, manufactured by
SAA6D125E-5 D85EX-15 24V, 75A 2 95 13
SAWAFUJI DENKI
D85PX-15
48 125E-5 Series
Alternator mounting
SAA6D125E-5 (D85EX-15, D85PX-15)
2. Alternator drive belt
3. Crank pulley
4. Adjustment bolt
125E-5 Series 49
SAA6D125E-5 (PC400-7, PC400LC-7, PC450-7, PC450LC-7)
2. Alternator drive belt
3. Crank pulley
4. Adjustment bolt
50 125E-5 Series
125E-5 Series 51
Starting motor 1
Starting motor with built-in safety relay (7.5 kW)
52 125E-5 Series
1. Pinion gear
2. Starting motor (body)
3. Magnetic switch
4. External electric circuit diagram [2P connector (male)]
4A. Safety relay
4B. Starting motor
5. External electric circuit diagram [3P connector (male)]
5A. Safety relay
5B. Starting motor
6. Specifications of connector
Type A: 2P connector (male)
Type B: 2P dust-proof connector (male)
Type C: 3P dust-proof connector (male)
Type D: 2P connector (male)
B, C, R, S, E: Terminals
Applicable Number of Type of

Engine Type Specification Weight (kg)
machine pinion teeth connector
Waterproof, oilproof, manufactured
SAA6D125E-5 All machines 24V, 7.5kW 12 20 D
by NIKKO DENKI
125E-5 Series 53
Starting motor with built-in safety relay (11 kW)
54 125E-5 Series
1. Pinion gear
2. Starting motor
3. Magnetic switch
4. External electric circuit diagram
4A. Safety relay
4B. Starting motor
5. Specifications of connector
Type A: 2P connector (male)
Type B: Dust-proof connector (male)
B, C, R, S, E: Terminals
Applicable Number of Type of

Engine Type Specification Weight (kg)
machine pinion teeth connector
All machines Waterproof, oilproof, manufactured
SAA6D125E-5 24V, 11kW 12 18 A
(if equipped) by NIKKO DENKI
125E-5 Series 55
Electrical intake air heater 1

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

Rated voltage: 22 V (DC)
Rated current: 111 A
56 125E-5 Series
Engine controller 1
Features
Mounting of engine controller on engine
q Since the engine controller is mounted on the
engine, the operator can service it easily in the
field.
q The engine controller cooler (if equipped) is
prepared to cool the engine controller with the
fuel to secure the reliability of the mounted
engine controller.
q Vibrations are damped by the vibration-proof
rubber.
Unified specifications of engine controller

q Engine controller CM850 developed by the
cooperation between KOMATSU and CUM-
MINS is employed.
125E-5 Series 57
SEN00185-00
© 2005 KOMATSU
All Rights Reserved
58
SEN00546-00
ENGINE 1SHOP MANUAL
125E-5 Series
20 Standard value table 1

Standard service value table
Standard service value table ........................................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ............................................. 2
Running-in standard and performance test standard ........................................................................... 5
125E-5 Series 1
SEN00546-00 20 Standard value table
Standard service value table 1

Standard service value table for testing, adjusting, and troubleshooting1
Engine SAA6D125E-5
D85EX-15
Machine model
D85PX-15
Performance Category
Standard value Judgement

Item Measurement conditions Unit
for new machine criteria
High idle rpm 2,100 ± 25 2,100 ± 25

Speed
Low idle rpm 750 (+50/0) 750 (+50/0)
Necessary speed for At 0°C (Without starting aid) rpm Min. 100 —
starting At –20°C (With starting aid) rpm Min. 85 —
kPa Max. 3.72 7.47
Air intake resistance Whole speed range
{mmH2O} {Max. 380} {762}
kPa Min. 93 73
Air boost pressure At rated output
{mmHg} {Min. 700} {550}
Air intake and exhaust system
kPa Min. 93 73
Exhaust pressure At rated output
{mmHg} {Min. 700} {550}
Exhaust temperature Whole speed range (20°C) °C 650 700
%
Max. 25
At sudden acceleration (Low o High) (Bosch —
{Max. 2.5}
index)
Exhaust gas color Bosch
At rated output Max. 1.5 —
index
Bosch
At high idle Max. 1.0 —
index
Intake valve mm 0.33 —
Valve clearance
Exhaust valve mm 0.71 —
Compression pres- Engine oil temperature: 40 – 60°C MPa Min. 2.9 2.0
sure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 30} {20}
Body
At rated output kPa Max. 0.98 1.96

Blow-by pressure
Engine coolant temperature: Min. 70°C {mmH2O} {Max. 100} {200}
At rated output
SAE0W30E0S MPa 0.29 – 0.69 0.18
Engine oil temperature:
{kg/cm2} {3.0 – 7.0} {1.8}
Lubrication system
Min. 80°C SAE5W40E0S

Oil pressure SAE10W30DH
At low idle SAE15W40DH MPa Min. 0.05 0.03
Engine oil temperature: SAE30DH {kg/cm2} {Min. 0.5} {0.3}
Min. 80°C
Oil temperature Whole speed range (In oil pan) °C 90 – 110 120
Ratio to fuel consumption at continuous
Oil consumption % Max. 0.3 1.0
rated output
Function of radiator kPa
Cracking pressure (Differential pressure) — —
pressure valve {kg/cm2}
Cooling system
Fan speed At rated speed rpm — —

Deflection under finger pressure of 98 N
Fan belt tension mm — —
{10 kg}
Alternator belt ten- Deflection under finger pressure of 98 N
mm 13 – 16 13 – 16
sion {10 kg}
2 125E-5 Series
Engine SAA6D125E-5
PC400, 400LC-7
Machine model
PC450, 450LC-7

High idle rpm 1,930 ± 50 1,930 ± 50

Speed
Low idle rpm 1,000 ± 25 1,000 ± 25
kPa Max. 3.72 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 133 107
{mmHg} {Min. 1,000} {800}
kPa Min. 133 107

{mmHg} {Min. 1,000} {800}
Exhaust temperature Whole speed range (20°C) °C Max. 700 700
%
Max. 25
{Max. 2.5}
index)
index
Bosch
index
Valve clearance
Body

Blow-by pressure
At rated output
SAE0W30E0S MPa 0.29 – 0.69 0.18
{kg/cm2} {3.0 – 7.0} {1.8}
Lubrication system

Min. 80°C
rated output
Cooling system

{10 kg}
mm 13 – 16 13 – 16
sion {10 kg}
125E-5 Series 3
Engine SAA6D125E-5
Machine model HM300-2

High idle rpm 2,220 ± 50 2,220 ± 50

Speed
Low idle rpm 725 (+50/0) 725 (+50/0)
kPa Max. 3.72 7.47
{mmH2O} {Max. 380} {762}
kPa Min. 107 87
{mmHg} {Min. 800} {650}
kPa Min. 107 87

{mmHg} {Min. 800} {650}
Exhaust temperature Whole speed range (20°C) °C Max. 700 700
%
Max. 25
{Max. 2.5}
index)
index
Bosch
index
Valve clearance
Body

Blow-by pressure
At rated output
SAE0W30E0S MPa 0.29 – 0.69 0.18
{kg/cm2} {3.0 – 7.0} {1.8}
Lubrication system

Min. 80°C
rated output
Cooling system

{10 kg}
mm 13 – 16 13 – 16
sion {10 kg}
4 125E-5 Series
Running-in standard and performance test standard 1
Running-in standard
Engine SAA6D125E-5
D85EX-15
Machine model
D85PX-15
Procedure
Item
1 2 3 4 5
Running time min. 2 8 2 3 5
Speed rpm 750 950 1,140 1,425 1,900
Dynamometer
N {kg} 0 {0} 275 {28} 697 {71} 1,115 {114} 1,394 {142}
load
Output kW {HP} 0 {0} 20 {26.6} 60 {80} 119 {160} 199 {266}
a This table shows the values when the fan is not installed.
a The dynamometer load in this table shows the value when the dynamometer arm is 716 mm long.
Performance test standard
Engine SAA6D125E-5
D85EX-15
Machine model
D85PX-15
Max. speed at no Min. speed at no
Test item Rated output Max. torque
load load
Specification
value —
(Gross value)
Speed rpm 1,900 1,400 2,100 ± 50 70 (+50/0)
Dynamometer N 1,354 – 1,432 1,727 – 1,834
— —
load {kg} {138 – 146} {176 – 187}
Output kW 199
— — —
(Gross value) {HP} {266}
Torque Nm 1,272
— — —
(Gross value) {kgm} {130}
Fuel consumption sec/300cc — — — —
Coolant
°C 80 – 90 80 – 90 80 – 90 80 – 90
temperature
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
Lubricating oil kPa 290 – 540 190 – 540 290 – 540
—
pressure {kg/cm2} {3.0 – 5.5} {2.0 – 5.5} {3.0 – 5.5}
Exhaust
°C Max. 650 Max. 650 — —
temperature
a This table shows the standard values obtained by using the JIS correction coefficients.
a Since the output and torque in this table are the standard values when the fan is not installed, they are
different from the specification values.
a This table shows the standard values when the air cleaner and the muffler are installed and no load is
applied to the alternator.
a Use ASTM No. 1 or No. 2 diesel fuel as fuel.
a Use SAE15W-40 as lubricating oil.
125E-5 Series 5
Running-in standard
Engine SAA6D125E-5
PC400, 400LC-7
Machine model
PC450, 450LC-7
Procedure
Item
1 2 3 4 5
Speed rpm 1,000 1,000 1,200 1,500 1,900
Dynamometer
N {kg} 0 {0} 353 {36} 875 {89} 1,400 {143} 1,893 {193}
load
Output kW {HP} 0 {0} 26 {35.5} 79 {106} 158 {211} 262.5 {352}
Engine SAA6D125E-5
PC400, 400LC-7
Machine model
PC450, 450LC-7
load load
Specification
value —
(Gross value)
Speed rpm 1,900 1,400 1,930 ± 50 1,000 ± 25
Dynamometer N 1,785 – 1,900 1,920 – 2,050
— —
load {kg} {182 – 194} {196 – 209}
Output kW 262.5
— — —
Torque Nm 1,422
— — —
Coolant
°C 80 – 90 80 – 90 80 – 90 80 – 90
temperature
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
—
pressure {kg/cm2} {3.0 – 5.5} {2.0 – 5.5} {3.0 – 5.5}
Exhaust
°C Max. 700 Max. 700 — —
temperature
6 125E-5 Series
Running-in standard
Engine SAA6D125E-5
Procedure
Item
1 2 3 4 5
Speed rpm 725 1,000 1,200 1,500 2,000
Dynamometer
N {kg} 0 {0} 343 {35} 850 {87} 1,354 {138} 1,692 {173}
load
Output kW {HP} 0 {0} 25 {34.5} 76 {103} 152 {204} 254 {340}
Engine SAA6D125E-5
load load
Specification
value —
(Gross value)
Speed rpm 2,000 1,400 2,220 ± 50 725 (+50/0)
Dynamometer N 1,650 – 1,750 2,320 – 2,450
— —
load {kg} {168 – 178} {236 – 250}
Output kW 254
— — —
Torque Nm 1,706
— — —
Coolant
°C 80 – 90 80 – 90 80 – 90 80 – 90
temperature
Lubricating oil
°C 90 – 110 90 – 110 90 – 110 90 – 110
temperature
—
pressure {kg/cm2} {3.0 – 5.5} {2.0 – 5.5} {3.0 – 5.5}
Exhaust
°C Max. 700 Max. 750 — —
temperature
125E-5 Series 7
SEN00546-00
© 2005 KOMATSU
All Rights Reserved
8
SEN00547-00
ENGINE 1SHOP MANUAL
125E-5 Series
30 Testing and adjusting 1

Testing and adjusting
Testing and adjusting ...................................................................................................................................... 4
Testing and adjusting tools list ............................................................................................................. 4
Testing air boost pressure .................................................................................................................... 6
Testing exhaust temperature................................................................................................................ 7
Adjusting valve clearance .................................................................................................................... 8
Testing compression pressure ............................................................................................................. 9
Testing blow-by pressure ....................................................................................................................11
Testing oil pressure ............................................................................................................................ 12
Handling fuel system parts ................................................................................................................. 13
Releasing residual pressure in fuel system........................................................................................ 13
Testing fuel pressure .......................................................................................................................... 14
Reduced cylinder mode operation ..................................................................................................... 15
No-injection cranking.......................................................................................................................... 15
Testing leakage from pressure limiter and return rate from injector ................................................... 16
Bleeding air from fuel circuit............................................................................................................... 19
Testing fuel system for leakage.......................................................................................................... 21
125E-5 Series 1
SEN00547-00 30 Testing and adjusting
Adjusting speed sensor ...................................................................................................................... 22

Testing and adjusting alternator belt tension ...................................................................................... 23
Handling controller voltage circuit ...................................................................................................... 24
2 125E-5 Series
125E-5 Series 3
Testing and adjusting 1

Testing and adjusting tools list 1
Sym-
Testing and adjusting item Part No. Part name Q'ty Remarks
bol
–101 – 200 kPa {–760 – 1,500
799-201-2202 Boost gauge kit 1
Testing air boost pressure A mmHg}
799-401-2220 Hose 1 I-coupler type (if necessary)
Testing exhaust
B 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
temperature
Commercially Intake: 0.33mm
Adjusting valve clearance C Clearance gauge 1
available Exhaust: 0.71mm
1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}
Testing compression
D (Setting) Adapter 1
pressure 2 For 125E-5
6217-71-6112 Gasket 1
Testing blow-by pressure E 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
Pressure gauge: 2.5, 5.9, 39.2, 58.8
799-101-5002 Hydraulic tester 1
MPa {25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 58.8 MPa {600 kg/
Testing oil pressure F 790-261-1204 Digital hydraulic tester 1
cm2}
2 799-401-2320 Hydraulic tester 1
cm2}
Pressure gauge: 2.5, 5.9, 39.2, 58.8
799-101-5002 Hydraulic tester 1
MPa {25, 60, 400, 600 kg/cm2}
1
790-261-1204 Digital hydraulic tester 1
Testing fuel pressure G cm2}
2 799-401-2320 Hydraulic tester 1
cm2}
3 (Setting) Adapter 1 8 x 1.25 mm o R1/8
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Inside diameter of joint: 10 mm
Commercially
3 Hose 1 φ 5 mm x 2 – 3 m
available
Testing leakage from
pressure limiter and return H 4 Commercially
Hose 1 φ 15 mm x 2 – 3 m
rate from injector available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
4 125E-5 Series
Sym-
Testing and adjusting item Part No. Part name Q'ty Remarks
bol
799-601-4130 T-adapter — For Ne sensor
799-601-4330 Socket — For Bkup sensor
799-601-4240 Socket — For atmospheric pressure sensor
799-601-4250 Socket — For boost pressure sensor
799-601-4180 T-adapter — For EGR gas sensor
799-601-9420 T-adapter — For common rail pressure
799-601-4150 T-adapter — For oil pressure sensor
795-799-5540 T-adapter — For boost temperature sensor
For coolant temperature sensor
795-799-5530 T-adapter —
For fuel temperature sensor
Troubleshooting for
For EGR valve solenoid
controllers, J 799-601-9020 T-adapter —
For bypass valve solenoid
sensors, and actuators
For EGR valve solenoid
799-601-9030 T-adapter —
For bypass valve stroke sensor
799-601-9430 T-adapter — For supply pump PCV
799-601-9020 T-adapter — For injector
799-601-4260 T-adapter — For controller (4-pole)
799-601-9320 T-box —
For 24-pole type
799-601-9310 Plate —
799-601-4350 T-box — For 60-pole type
125E-5 Series 5
Testing air boost pressure 1

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

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

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

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

nect it to gauge [2].
3. Run the engine at the rated output and test the

air boost pressure.
a When testing with the engine mounted on
the machine, test on the condition
described in the shop manual for the
machine.
6 125E-5 Series
Testing exhaust temperature 1

a Testing tools for exhaust temperature

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

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

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

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

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

nut (4).
3 Locknut:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.
2. Rotate the crankshaft forward to bring the

stamped “1.6TOP“ line (a) of the damper to
pointer (2) and set the No. 1 cylinder to the
compression top dead center.
a Rotate the crankshaft with the mounting
bolt of the crankshaft pulley (width across
flats: 24 mm), and be sure to rotate it only
forward to prevent the bolt from loosening.
a When the No. 1 cylinder is at the compres-
sion top dead center, the rocker arm of the
No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, rotate the crankshaft
one more turn. 6. After adjusting the No. 1 cylinder, rotate the
crankshaft forward by 120° and adjust the
clearance of each cylinder according to the fir-
ing order.
a Firing order: 1-5-3-6-2-4
7. After finishing adjustment, return the removed

parts.
3 Cylinder head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
8 125E-5 Series
Testing compression pressure 1 a Pass a wire, etc. under the fuel path pro-
jected sideways and pull up the injector
a Testing tools for compression pressure (Do not pry the injector top up).

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

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the
engine is warmed up
(Engine oil temperature: 40 – 60°C).
1. Remove cylinder head cover (1) of the cylinder 4. Install adapter D2 to the mounting hole on the
to be tested for compression pressure. injector and the compression gauge D1.
a Fit the gasket to the adapter end without
fail
a Fix the adapter with the injector holder.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
5. Install rocker arm assembly (2) and adjust the

valve clearance.
3 Rocker arm assembly mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a See "Adjusting valve clearance".
2. Bring the cylinder to be tested to the compres-
sion top dead center and remove rocker arm
assembly (2).
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-pres-
sure tube, loosen all center clamps.
a Disconnect the terminal of the injector wir-
ing harness on the injector side and the
bracket on the rocker housing side and
pull them outside the rocker arm housing
(Loosen the 2 terminal nuts alternately).
125E-5 Series 9
6. Connect the INSITE (bench test tool) to the 3 Rocker arm assembly mounting
engine and set the engine in the no-injection bolt:
cranking mode. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
k If the engine is not set in the no-injec-
tion cranking mode, it will start and will a Adjust the valve clearance. For
be dangerous. Accordingly, be sure to details, see "Adjusting valve clear-
set the engine in this mode. ance".
7. Rotate the engine with the starting motor and 3 Cylinder head cover mounting bolt:
measure the compression pressure. 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
a Read the pressure gauge pointer when it
is stabilized.

a Install the injector, injector wiring harness,
and fuel high-pressure tube according to
the following procedure.
1) Install the O-ring and gasket to injector
(11).
2) Fit holder (12) to injector (11) to tempo-
rarily assemble them as a unit to the cylin-
der head.
3) Fit mounting bolt (13) to spherical washer
(14) to tighten them to the cylinder head.
2 Spherical part of washer:
Engine oil (SAE30DH)
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
4) Install wiring harness (15) to the rocker
arm housing and fix it with mounting bolt
(16).
5) Insert wiring harness (15) into holder (17).
6) Alternately tighten 2 nuts at wiring harness
(15) end to injector (11).
3 Nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm}
7) Tighten tube (18) to injector (11).
3 Sleeve nut:
39.2 – 49.0 Nm {4 – 5 kgm}
8) Tighten the clamping bolt of the fuel pip-
ing.
3 Clamping bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
10 125E-5 Series
Testing blow-by pressure 1

a Testing tool for blow-by pressure

E 799-201-1504 Blow-by checker
1. Install nozzle [1] of blow-by checker E to the

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

[3].
3. Run the engine at the rated output and test the

blow-by pressure.
machine.

125E-5 Series 11
Testing oil pressure 1

a Testing tools for oil pressure

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

cylinder block.

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

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

and test the oil pressure.
machine.
12 125E-5 Series
Handling fuel system parts 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. a The pressure in both low-pressure circuit and
sticks to any part, wash that part thoroughly high-pressure circuit lowers to a safety level
with clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is tested and its parts are
cartridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at least 30 seconds after stop-
vent foreign matter from entering it. ping the engine until the residual pressure
If a filter other than the genuine one is used, in the fuel circuit is released. (Do not start
the fuel system may have a trouble. Accord- the work just after stopping the engine
ingly, never use such a filter. since there is residual pressure.)
125E-5 Series 13
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
range, it is normal.
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
G High idle
2 799-401-2320 Hydraulic tester {1.5 – 3 kg/cm2}
3 (Setting) Adapter
a Test only the fuel pressure in the low-pressure

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

fuel filter head.

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

tester G1 and connect it to hydraulic tester G2.
14 125E-5 Series
Reduced cylinder mode No-injection cranking 1

operation 1 a No-injection cranking means to crank the
a Reduced cylinder mode operation means to engine with the starting motor while all the
run the engine with the fuel injectors of 1 or injections are stopped electrically. The pur-
more cylinders disabled electrically to reduce pose and effect of this operation are as follows.
the number of effective cylinders. The pur- q Before the engine is started after it or the
poses and effects of this operation are as fol- engine unit has been stored for a long period,
lows. the no-injection cranking is performed to lubri-
1. This operation is used to find out a cylinder cate the engine parts and protect them from
which does not output power normally (or, seizure.
combustion in it is abnormal). a Perform the no-injection operation with the
2. When a cylinder is selected for the reduced engine mounted on the machine or connected
cylinder mode operation, if the engine speed to INSITE (bench test tool).
and output do not change from the normal a Before performing, see "Testing method" in the
operation (all-cylinder operation), that cylinder shop manual for the machine or INSITE
has 1 or more defects. (bench test tool).
The possible defects are as follows.
q Leakage from the cylinder head gasket
q Defective injection
q Defective piston, piston ring, or cylinder
liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
a Perform the reduced cylinder mode opera-
tion with the engine mounted on the
machine or connected to INSITE (bench
test tool).
a Before performing, see "Testing method"
in the shop manual for the machine or
INSITE (bench test tool).
125E-5 Series 15
Testing leakage from pressure limiter and return rate from injector 1
a The locations of the fuel circuit parts are sub- 1. Preparation work
ject to machine models (The figure shows the 1) Remove tube (3) between common rail (1)
engine for PC400/400LC-7 and PC450/450LC- and return block (2).
7).
a Testing tools for leakage from pressure limiter
and return rate from injector

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

fuel flowing out during the test. 2) Insert spacer H1 on return block (2) side
and tighten the removed joint bolt again.
a Be sure to fit the gaskets to both ends
of the spacer.
16 125E-5 Series
3) 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.
4) Connect test hose H3 to the end of joint
H2.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
5) After finishing testing, stop the engine.
3. Testing return rate from injector

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

1) Lay test hose H3 so that it will not slacken
and put its end in the oil pan.
2) Connect INSITE (bench test tool) to the
engine and set it so that it can check the
engine speed.
3) Start the engine and keep its speed to
1,600 rpm with no load.
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 lim-
2) Connect test hose H4 to the return block
iter is in the following range, it is nor-
(2) side.
mal.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
Engine speed Leakage from coming off.
(rpm) (cc/min) 3) Lay test hose H4 so that it will not slacken
1,600 Max. 10 and put its end in the oil pan.
125E-5 Series 17
4. Work after finishing testing
After finishing all testing, remove the testing

tools and return the removed parts.
4) Connect INSITE (bench test tool) to the

engine and set it so that it can check the
engine speed.
5) Run the engine at the rated output.
6) 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 injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit

(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
7) After finishing testing, stop the engine.
18 125E-5 Series
Bleeding air from fuel circuit 1
a If fuel is used up or if a fuel circuit part is

removed and installed, bleed air from the fuel
circuit according to the following procedure.
a The locations of the fuel circuit parts are sub-
ject to machine models (The figure shows the
engine for PC400/400LC-7 and PC450/450LC-
7).
1. Remove fuel pre-fuel filter (1) and fill it with

fuel.
a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the pre-fuel filter, and then
add fuel through part (b) (holes around the
central hole).
a After filling the pre-fuel filter with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the pre-fuel filter but fill it with the
fuel by operating priming pump (4).
a Do not add fuel to fuel main filter (2) exter-
nally.
125E-5 Series 19
2. Install pre-fuel filter (1) to the filter head. 5. Loosen air bleeder (6) of the fuel supply pump
a Apply engine oil thinly over the packing on and operate priming pump (4) 90 – 100 times.
the pre-fuel filter side. a Operate the priming pump until the fuel
a After the packing of the pre-fuel filter flows out of the air bleeder and tighten the
touches the sealing face of the filter head, air bleeder. Then, operate the priming
tighten the fuel filter 3/4 turns. pump several times more until it becomes
heavy.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
6. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically if the engine is cranked.
a If the engine does not start, there may be
still air in the low-pressure circuit. In this
case, repeat the above procedure from
step 3.
3. Remove air bleeding plug (4) of the fuel main

filter and operate priming pump (4).
a Operate the priming pump until the fuel
flows out of the plug hole and install the
plug.
3 Air bleeding plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4. Loosen air bleeding plug (5) of the fuel main fil-

ter (2) and operate priming pump (4).
a Operate the priming pump until the fuel
flows out of the plug hole and install the
plug.
3 Air bleeding plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
20 125E-5 Series
Testing fuel system for leakage 1 9. Inspect the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the high- a Inspect mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
its parts, test it for fuel leakage according a If no fuel leakage is detected, inspection is
to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
1. Spray color checker (developer) over the fuel

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

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

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

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

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

a When testing the engine mounted on the
machine, stall the torque converter or
relieve the oil from the hydraulic pump.
125E-5 Series 21
Adjusting speed sensor 1

a The Ne speed sensor and Bkup speed sensor
for the common rail fuel injection system can-
not be adjusted.
a Adjust speed sensor (1), which detects the sig-
nal of the flywheel ring gear to use it for the
electronic system on the machine side, accord-
ing to the following procedure.
1. Remove speed sensor (1) and check that its tip

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

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

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

3 Nut: 69 – 74 Nm {7.0 – 7.5 kgm}
22 125E-5 Series
Testing and adjusting alternator Separately installed fan type (D85EX/PX-15)

belt tension 1
Testing
Separately installed fan type
Press the intermediate point of the belt between
(Other than D85EX/PX-15)
alternator pulley and crankshaft pulley with a finger
and measure deflection (a) of the belt.
Testing a Pressing force: Approx. 58.8 N {Approx. 6 kg}
Press the intermediate point of the belt between a Deflection (a): 13 – 16 mm
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
Adjusting
a If the deflection is out of the standard range,
adjust it according to the following procedure.
Adjusting 1. Loosen locknut (1) and loosen rocknut (2) and

a If the deflection is out of the standard range, bolts (3) and (4).
2. Move alternator (6) with adjustment nut (5) to
1. Loosen locknut (1) and bolts (2) and (3). adjust the tension of belt (7).
2. Move alternator (5) with adjustment nut (4) to 3. Tighten bolts (4) and (3) and tighten locknut
adjust the tension of belt (6). (2), and then tighten locknut (1).
3 Bolt (4): 107.8 – 147 Nm {11 – 15 kgm}
3. Tighten bolts (3) and (2) and tighten locknut 3 Bolt (3): 28.4 – 32.4 Nm {2.9 – 3.3 kgm}
(1). a After adjusting, test the belt tension again.
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 23
Simultaneous fan drive type Handling controller voltage

circuit 1
Testing
1. When disconnecting or connecting a connector
Press the intermediate point of the belt between
between the engine controller and engine, be
alternator pulley and fan pulley with a finger and
sure to turn the starting switch OFF.
measure deflection (a) of the belt.
a Pressing force: Approx. 58.8 N {Approx. 6 kg}
2. If a T-adapter is inserted in or connected to a
a Deflection (a): 13 – 16 mm
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.
Adjusting
a If the deflection is out of the standard range,
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.
24 125E-5 Series
125E-5 Series 25
SEN00547-00
© 2005 KOMATSU
All Rights Reserved
26
SEN00548-00
ENGINE 1SHOP MANUAL
125E-5 Series
40 Troubleshooting 1
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points on troubleshooting..................................................................................................................... 2
Error code and failure code table ......................................................................................................... 4
125E-5 Series 1
SEN00548-00 40 Troubleshooting
General information on troubleshooting 1

Points on troubleshooting 1
k When troubleshooting a machine, stop it in a level ground, and check that the lock pin, chocks,
and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals,
and do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so be sure to wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not 3. Check before troubleshooting

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

Even if the failure is repaired, if the root cause
of the failure is not repaired, the same failure
will occur again. To prevent this, always inves-
tigate why the problem occurred. Then,
remove the root cause.
125E-5 Series 3
Error code and failure code table 1
INSITE Machine failure

Failure phenomenon
error code code
111 CA111 ECM Critical Internal Failure
115 CA115 Eng. Ne and Bkup Speed Sensor Error
122 CA122 Charge Air Press Sensor High Error
123 CA123 Charge Air Press Sensor Low Error
131 CA131 Throttle Sensor High Error
132 CA132 Throttle Sensor Low Error
135 CA135 Oil press. Sensor High Error
141 CA141 Oil press. Sensor Low Error
144 CA144 Coolant Temp. Sensor High Error
145 CA145 Coolant Temp. Sensor Low Error
153 CA153 Charge Air Temp. Sensor High Error
154 CA154 Charge Air Temp. Sensor Low Error
187 CA187 Sensor Sup. 2 Volt. Low Error
221 CA221 Ambient Air Press. Sensor High Error
222 CA222 Ambient Air Press. Sensor Low Error
227 CA227 Sensor Sup. 2 Volt. High Error
234 CA234 Eng. Overspeed
238 CA238 Ne Speed Sensor Sup. Volt. Error
263 CA263 Fuel Temp. Sensor High Error
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
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
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
4 125E-5 Series
INSITE Machine failure

Failure phenomenon
error code code
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
1625 CA1625 EGR Valve Servo Error 2
1626 CA1626 Bypass Valve Solenoid Current High Error
1627 CA1627 Bypass Valve Solenoid Current Low Error
1628 CA1628 Bypass Valve Servo Error 1
1629 CA1629 Bypass Valve Servo Error 2
1631 CA1631 BP valve Lift Position Sensor High Error
1632 CA1632 BP valve Lift Position Sensor Low Error
1633 CA1633 KOMNET Dtalink Timeout Error
1642 CA1642 EGR Inlet Press Sensor Low Error
1653 CA1653 EGR Inlet Press Sensor High Error
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
2272 CA2272 EGR Valve Lift Position Sensor Low Error
2351 CA2351 EGR Valve Solenoid Current High Error
2352 CA2352 EGR Valve Solenoid Current Low Error
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 Engine Overheat
(415) B@BAZG Eng. Oil press. Low Speed Derate
a INSITE error code:

An error code of 3 or 4 digits displayed on the INSITE (bench test tool) when the occurrence condition of
the failure is confirmed with the INSITE.
a Machine failure code:
An error code of 5 or 6 digits displayed on the machine monitor when the occurrence condition of the
failure is confirmed with the machine monitor, etc. on the machine side.
125E-5 Series 5
SEN00548-00
© 2005 KOMATSU
All Rights Reserved
6
SEN00549-00
ENGINE 1SHOP MANUAL
125E-5 Series
Troubleshooting of mechanical system
(S-mode)
Troubleshooting of mechanical system (S-mode)........................................................................................... 4
Method of using troubleshooting charts ............................................................................................... 4
S-1 Starting performance is poor ......................................................................................................... 8
S-2 Engine does not start................................................................................................................... 10
S-3 Engine does not pick up smoothly............................................................................................... 14
S-4 Engine stops during operations ................................................................................................... 15
S-5 Engine does not rotate smoothly ................................................................................................. 16
S-6 Engine lacks output (or lacks power)........................................................................................... 17
S-7 Exhaust smoke is black (incomplete combustion)....................................................................... 18
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................... 20
S-9 Oil becomes contaminated quickly .............................................................................................. 21
S-10 Fuel consumption is excessive.................................................................................................. 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 23
S-12 Oil pressure drops ..................................................................................................................... 24
125E-5 Series 1
S-13 Oil level rises (Entry of coolant or fuel) ...................................................................................... 25

S-14 Coolant temperature becomes too high (overheating) .............................................................. 27
S-15 Abnormal noise is made ............................................................................................................ 28
S-16 Vibration is excessive ................................................................................................................ 29
2 125E-5 Series
125E-5 Series 3
Troubleshooting of mechanical system (S-mode) 1

Method of using troubleshooting charts 1
The troubleshooting chart consists of the “questions“, “check items“, “causes“, and “troubleshooting“ blocks.
The questions and check items are used to pinpoint high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the
most probable one to make final confirmation according to the troubleshooting procedure.
Questions:
Items to be drawn from the user or operator. They correspond to A and B in the chart on the right.
The items in A are basic ones. The items in B can be drawn from the user or operator, depending on their
level.
Check items:
Simple check items used by the serviceman to narrow the causes. They correspond to C in the chart on the
right.
Causes:
Items to be narrowed from the questions and check items.
The serviceman narrows down the probable causes from A, B, and C.
Troubleshooting:
Items used to find out the true cause by verifying the narrowed causes finally in order from the most probable
one by applying troubleshooting tools or direct inspection.
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, and w.
E: Causes to be referred to for questions and check items
Q: Causes related to questions and check items
w: Causes highly probable among ones marked with Q
a When narrowing the “causes“, apply the items marked with w before those marked with Q.
When narrowing the “causes“, do not apply the items marked with E (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
4 125E-5 Series
125E-5 Series 5
<Example of troubleshooting> Exhaust smoke is black

Let us assume that when “Color of exhaust gas is black“ occurs, the relevant items of [questions] and [check
items] are the following 3 symptoms: [Color of exhaust gas gradually became black], [Power was lost gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
6 125E-5 Series
6 items of [causes] have causal relationship with these 3 items of [questions] and [check items].
Let us explain the method of using this causal relationship in “Step 1“ to “Step 3“ in the figure below to narrow
the [causes] to lead to [troubleshooting].
125E-5 Series 7
S-1 Starting performance is poor 1

General causes why starting performance is poor Causes
q Defective electrical system
Cracked EGR cooler (Coolant in exhaust pipe)

q Insufficient supply of fuel
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Insufficient intake of air
Defective contact of valve and valve seat

q
Defective alternator (generator section)

Defective alternator (regulator section)
q Improper selection of fuel
Stuck, seized supply pump plunger

Coolant in exhaust pipe
Defective intake air heater system

q
Defective or deteriorated battery

Clogged feed pump gauze filter
a The common rail fuel injection system (CRI) recog-
Clogged air cleaner element

nizes the fuel injection timing electrically. Accordingly,
Clogged fuel filter, element

Worn piston ring, cylinder
even if the starting operation is carried out, the engine
may not start until the crankshaft revolves 2 turns at
Defective injector
maximum. This phenomenon does not indicate a trou-
ble, however.
Confirm recent repair history

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

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

of some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When EGR cooler outlet gas piping is removed, coolant containing antifreeze
flows out (*1) q
When compression pressure is measured, it is found to be low q q

When air is bled from fuel system, air comes out q
Troubleshooting
Inspect fuel filter, strainer directly q

Inspect feed pump gauze filter directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*2)“ in q
E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed
does not change q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 – 30 V between alternator terminal B and terminal E with Yes q
engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
8 125E-5 Series
*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of the EGR cooler outlet gas piping and check that the coolant flows out. A
little condensate produced from cooled exhaust gas may flow out. If it is colorless and transparent, how-
ever, it is not a problem.
*2: Code [559/CA559] and code [2249/CA2249] in E-mode
125E-5 Series 9
S-2 Engine does not start 1

a) Engine does not turn Causes
General causes why engine does not turn
Cracked EGR cooler (Coolant in exhaust pipe)
Defective starting motor (safety relay section)

q Internal parts of engine seized
o See “S-4 Engine stops during operations“
Defective connection of battery terminal
Defective starting motor (motor section)

q Water hammer caused by coolant which entered cylinder
q Defective electrical system
Defective or deteriorated battery
Defective steering circuit wiring

q Problem in drive devices on applicable machine side
o Requires troubleshooting on applicable machine side.
Broken flywheel ring gear
Defective starting switch

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

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

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

Inspect flywheel ring gear directly q
Carry out troubleshooting

Troubleshooting
There is not voltage (20 – 30 V) between battery relay terminal B

q
and terminal E
When terminal B and terminal C of starting switch are connected,
Turn starting switch OFF, q
engine starts
connect cord, and carry out
troubleshooting at ON When terminal B and terminal C at safety relay outlet are con-
nected, engine starts q
Even if terminal B and terminal C at safety relay outlet are con-

q
nected, engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy —
10 125E-5 Series

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

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

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

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

Seized, abnormally worn feed pump
Defective operation of flow damper

Broken supply pump shaft, key
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Questions
Degree of use of
Operated for long period E E E
machine
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w E E
Replacement of filters has not been carried out according to Operation and
w w E Q
Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is not fuel in it w w
Check items
Fuel is leaking from fuel piping w

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

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

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

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

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

q Lack of rotating force due to defective electrical system

q Insufficient intake of air
Defective intake air heater system

Improper selection of fuel
Clogged injector, defective spray

q

Worn piston ring, cylinder liner
Defective, deteriorated battery

Clogged fuel filter, strainer

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

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

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

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

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

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

q Defective condition of fuel spray

q Controller is controlling in derate mode

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

electrical system)
(Large leakage from injector)

EGR valve is stuck open

q
Improper valve clearance

(There is much EGR gas and intake of air is insuffi-
cient)
Stuck EGR valve

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

Non-specified fuel is being used w w w w
Replacement of filters has not been carried out according to Operation and w w w
Maintenance Manual
When exhaust manifold is touched immediately after starting engine, tempera-
Q w
ture of some cylinders is low
Blue under light load w
Color of exhaust gas
Black w Q w w
Check items

When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is
Q w w
applied
There is hunting from engine (rotation is irregular) Q Q w Q

Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)“ in q
E-mode
Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
Carry out troubleshooting according to “No-pressure feed by supply pump (*2)“ q
in E-mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q q
does not change
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy

14 125E-5 Series
S-4 Engine stops during operations 1

General causes why engine stops during operations Causes
Seized parts inside engine
Broken dynamic valve system (valve, rocker arm, etc.)

q
Broken auxiliary equipment (pump, compressor, etc.)
Problem in drive devices on applicable machine side

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

side
o Requires troubleshooting on applicable machine
Broken, seized piston, connecting rod

side.
Broken, seized crankshaft bearing
Broken supply pump shaft, key

Leaking, clogged fuel piping
Broken, seized feed pump

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

stopped
Engine stopped slowly w Q Q
There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Maintenance Manual w w
Fuel level monitor indicates low level (if monitor is installed) w

Metal particles are found when oil is drained w w Q Q
Check items
Does not turn at all w w

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

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

Troubleshooting
Inspect gear train directly q

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

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

q
q Defective speed sensor
(Error at degree that it is not indicated)
q Defective EGR valve
q Defective bypass valve
Clogged injector, defective spray (dirt in injector)
Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness
Defective operation of bypass valve
Defective operation of EGR valve

Low setting of low idle speed

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

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

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

Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)“ in E-mode q
Carry out troubleshooting according to “Abnormality in bypass valve servo (*2)“ in E-
q
mode
Troubleshooting

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

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

General causes why engine lacks output Causes
Defective fuel temperature sensor, wiring harness

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

Defective drive of injector (signal, solenoid)

q Defective spray condition of fuel


Air leakage from air intake piping

o See “S-14 Coolant temperature becomes

Leaking, clogged fuel piping

too high (Overheating)“

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

Gradually Q Q Q Q Q Q Q
w
Maintenance Manual
Oil must be added more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Black w w
Color of exhaust gas color
w
Check items

High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops when load is w w Q
applied
Engine does not pick up smoothly and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q

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

Carry out troubleshooting according to “No-pressure feed by supply pump (*1)“
in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed q q
does not change
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to “Abnormality in charge pressure sensor
q
(*2)“ in E-mode
Carry out troubleshooting according to “Abnormality in fuel temperature sensor
(*3)“ in E-mode q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy

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

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

q

q Excessive injection of fuel

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


o See “S-14 Coolant temperature becomes too high

(Overheating)“
Improper fuel injection pressure

Controller is controlling in derate mode (limiting

q
EGR gas piping is clogged
Crushed, clogged muffler

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

Clogged, seized injector
cal system)
EGR valve is stuck open (There is much EGR gas
Stuck EGR valve

q
and intake of air is insufficient)
q EGR gas piping is clogged (Entry of exhaust gas into
air intake at acceleration or deceleration)
Degree of use of
machine
Suddenly became black w Q Q Q Q
Questions
Color of exhaust gas Gradually became black

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

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

When turbocharger is rotated by hand, it is fount to be heavy q
Carry out troubleshooting according to “Abnormality in EGR valve servo (*1)“ in E- q
mode
Inspect EGR gas piping directly (*2) q
Troubleshooting

When muffler is removed, exhaust color improves q
Carry out troubleshooting according to “No-pressure feed by supply pump (*3)“ in E-
q q
mode
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q
not change
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor
q
(*4)“ in E-mode
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
18 125E-5 Series

*2: EGR gas piping
Remove EGR gas piping (2) and confirm for internal clogging

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

General causes why oil consumption is excessive Causes
q Abnormal consumption of oil
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

q Long-time operation of engine at low idle or high
Worn, damaged valve (stem, guide, seal)

idle (Do not run engine at idle for more than 20
minutes continuously)
Dust sucked in from intake system
Oil leakage from EGR valve stem

Clogged breather, breather hose
q External leakage of oil
Worn seal at turbocharger end
Oil leakage from oil drain plug

Wear of parts in lubrication system
Worn, damaged rear oil seal

q
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of use of
Questions

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

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

When intake manifold is removed, inside is found to be dirty abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

When EGR valve is removed, exhaust port is found to be dirty with oil q
Inspect breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20 125E-5 Series
S-9 Oil becomes contaminated quickly 1

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

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
Clogged breather, breather hose

Operation under excessive load

q
Defective oil filter safety valve

Worn valve, valve guide
Worn EGR valve guide
Exhaust smoke is bad

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

Oil must be added more frequently Q w
Even when engine oil temperature rises, oil filter clogging monitor indicates clogging w Q
(if monitor is installed)
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items

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

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

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

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

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

Defective feed pump oil seal
Defective spray by injector

Degree of use of
Questions
machine Operated for long period E E E
More than for other machines of same model Q Q Q Q

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

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

Troubleshooting
Inspect feed pump oil seal directly q

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

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

q
Broken hydraulic oil cooler or power train oil cooler

q Internal leakage in cooling system
Insufficient protrusion of cylinder liner

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

Cracks inside cylinder block

Degree of use of
Questions
Operated for long period E E

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

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

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

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

General causes why oil pressure drops Causes
q Leakage, clogging, wear or lubrication system
Defective oil pressure sensor, wiring harness

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

q Improper selection of fuel (improper viscosity)
q Deterioration of oil due to overheating
Clogged, broken pipe in oil pan
Defective oil pump relief valve
Leaking EGR hydraulic piping

Clogged strainer in oil pan
Defective EGR oil pump

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

Coolant, fuel in oil
Clogged oil filter

Degree of use of
Operated for long period E E E E
Questions
machine
Oil pressure monitor indicates low oil pressure (if monitor is installed) Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Mainte- w
nance Manual
Indicates pressure drop at low idle w Q Q
Oil pressure monitor Indicates pressure drop at low, high idle Q w w w Q Q Q
(if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q Q
Oil level monitor indicates oil level drop (if monitor is installed) w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w w
Check items
Oil is milky or smells of diesel oil w

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

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

Relief valve of EGR oil pump is damaged, oil leaks from it q
Inspect EGR hydraulic piping directly q
Carry out troubleshooting according to “Abnormality in oil pressure sensor (*1)“ in E- q
mode
If oil level sensor is replaced, oil pressure monitor indicates normally q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
Remedy —
24 125E-5 Series
S-13 Oil level rises (Entry of coolant or fuel) 1

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

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

a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in
Damaged cylinder liner O-ring, holes caused by pitting

coolant“
Cracked EGR cooler (Entry of coolant)

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

Worn, damaged rear oil seal
Cracks inside cylinder block
Defective thermostat seat

Defects in supply pump
Questions

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q w
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q w
When engine is started, drops of water come from muffler Q Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bub-
w Q
bles appear, or coolant spurts back
Check items
Exhaust smoke is white Q Q

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

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

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

General causes why coolant temperature becomes too Causes
high
Damaged cylinder liner O-ring, hole caused by pitting

q Lack of cooling air (deformation, damage of fan)
Rise in power train oil temperature on applicable

q Drop in heat dissipation efficiency
External leakage of coolant from EGR cooler

q Problem in coolant circulation system
q Rise in oil temperature in power train
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

o Carry out troubleshooting on applicable machine

side
Defective operation of thermostat
Slipping fan belt, worn fan pulley

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

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

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

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

Inspect cylinder liner directly q

Inspect oil cooler directly q

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

When operation of thermostat is carried out, it does not open at cracking temper-
ature q
Temperature difference between upper and lower tanks of radiator is slight q

Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy —
125E-5 Series 27
S-15 Abnormal noise is made 1

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

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

q
Leakage of air between turbocharger and cylinder head

q Air sucked in from intake system
a Judge if the noise is an internal noise or an external
Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger
noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
(abnormality in coolant temperature sensor)

Excessive wear of piston ring, cylinder liner
while it is not warmed up sufficiently. Accordingly, the
engine sound becomes a little larger. This does not
Removed, seized gear train bushing

indicate abnormality, however.
Cracked, leaking EGR gas piping

a When the engine is accelerated, it is operated in the
Improper fuel injection timing

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

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

cate abnormality, however.

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

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

Inspect EGR gas piping directly q
When muffler is removed, abnormal noise disappears q
Troubleshooting

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed q q
does not change
Abnormal noise is heard only when engine is started q
Confirm with INSITE or with monitoring function on applicable machine side q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
28 125E-5 Series
S-16 Vibration is excessive 1

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

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

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

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

Improper gear train backlash

Worn camshaft bushing
Questions

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

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

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

Inspect camshaft bushing directly q
Confirm with INSITE or with monitoring function on applicable machine side q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect front support spigot joint portion directly q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Remedy
125E-5 Series 29
SEN00549-00
© 2005 KOMATSU
All Rights Reserved
30
SEN00550-00
ENGINE 1SHOP MANUAL
125E-5 Series
Troubleshooting of electrical system
(E-mode), Part 1
Troubleshooting of electrical system (E-mode), Part 1 ................................................................................... 4
Information in troubleshooting table ..................................................................................................... 4
E-1 Code [111/CA111] ECM Critical Internal Failure ............................................................................ 6
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error........................................................... 8
E-3 Code [122/CA122] Charge Air Press Sensor High Error ............................................................. 10
E-4 Code [123/CA123] Charge Air Press Sensor Low Error.............................................................. 12
E-5 Code [131/CA131] Throttle Sensor High Error ............................................................................ 14
E-6 Code [132/CA132] Throttle Sensor Low Error............................................................................. 18
E-7 Code [135/CA135] Oil press. Sensor High Error ......................................................................... 20
E-8 Code [141/CA141] Oil press. Sensor Low Error.......................................................................... 22
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ................................................................. 24
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error................................................................ 26
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error........................................................... 28
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error ........................................................... 30
125E-5 Series 1
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error..................................................................... 31

E-14 Code [221/CA221] Ambient Air Press. Sensor High Error......................................................... 32
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error ......................................................... 34
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error .................................................................... 36
E-17 Code [234/CA234] Eng. Overspeed .......................................................................................... 38
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error............................................................... 40
E-19 Code [263/CA263] Fuel Temp. Sensor High Error..................................................................... 42
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error ..................................................................... 44
E-21 Code [271/CA271] PCV1 Short Error ........................................................................................ 46
E-22 Code [272/CA272] PCV1 Open Error ........................................................................................ 48
E-23 Code [273/CA273] PCV2 Short Error ........................................................................................ 50
E-24 Code [274/CA274] PCV2 Open Error ........................................................................................ 52
E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error ............................................ 54
E-31 Code [342/CA342] Calibration Code Incompatibility.................................................................. 66
E-32 Code [351/CA351] INJ. Drive Circuit Error ................................................................................ 68
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error..................................................................... 70
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error .................................................................... 72
E-35 Code [431/CA431] Idle Validation SW Low error ....................................................................... 74
E-36 Code [432/CA432] Idle Validation Process error ....................................................................... 76
E-37 Code [441/CA441] Battery voltage low error ............................................................................. 76
E-38 Code [442/CA442] Battery voltage high error............................................................................ 77
2 125E-5 Series
125E-5 Series 3
Troubleshooting of electrical system (E-mode), Part 1 1

Information in troubleshooting table 1
a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
User code Failure code

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

<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is
broken.
• Ground fault
Wiring harness which is not connected to chassis ground
circuit is in contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source
2 (24 V) circuit is in contact with power source (24 V) circuit.
• Short circuit
Independent wiring harnesses are in contact with each
Possible causes other abnormally.
and standard Possible causes of trouble
value in normal (Given numbers are reference
state numbers, which do not indicate <Precautions for troubleshooting>
priority) (1) Method of indicating connector No. and handling of T-
adapter
Insert or connect T-adapter as explained below for trou-
bleshooting, unless otherwise specified.
3
• If connector No. has no marks of “male“ and “female“,
disconnect connector and insert T-adapters in both
male side and female side.
• If connector No. has marks of “male“ and “female“,
disconnect connector and connect T-adapter to only
male side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester
as explained below for troubleshooting, unless otherwise
4 specified.
• Connect positive (+) lead to pin No. or wiring harness
entered on front side.
• Connect negative (–) lead to pin No. or wiring harness
entered on rear side.
4 125E-5 Series
Related circuit diagram
This drawing is a part of the electric circuit diagram related

to troubleshooting.
• Connector No.: Indicates (Model – Number of pins) and
(Color).
• “Connector No. and pin No.“ from each branching/merg-
ing point: Shows the ends of branch or source of merging
within the parts of the same wiring harness.
• Arrow (⇔): Roughly shows the location on the machine.
125E-5 Series 5
E-1 Code [111/CA111] ECM Critical Internal Failure 1
Error code Failure code

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

Check fuse or circuit breaker on machine side directly for defect.
1 Defective fuse (If fuse is broken or circuit breaker is turned OFF, circuit probably
has ground fault.)
a Prepare with starting switch OFF, then carry out troubleshoot-
Disconnection in wiring har- ing without turning starting switch ON.
ness (Disconnection in wiring Wiring harness between E03 (female) (3), Resis-
2 Max. 1 z
or defective contact in connec- (4) – battery (+) tance
tor) Wiring harness between E03 (female) (1), Resis-
Possible causes Max. 1 z
and standard (2) – chassis ground tance
value in normal a Prepare with starting switch OFF, then carry out troubleshoot-
state ing without turning starting switch ON.
Ground fault in wiring harness Wiring harness between E03 (female) (3), Resis- Min.
3
(Short circuit with GND circuit) (4) – battery (+) and chassis ground tance 1 Mz
Wiring harness between E03 (female) (1), Resis- Min.
(2) – chassis ground tance 1 Mz
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
4 Defective engine controller
E03 Voltage
Between (3), (4) – (1), (2) 20 – 30 V
6 125E-5 Series
Circuit diagram related to controller power supply
125E-5 Series 7
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error 1

Trouble Eng. Ne and Bkup Speed Sensor Error
115 CA115
Contents of
• Abnormality occurred in Ne speed sensor circuit and Bkup speed sensor circuit simultaneously.
trouble
Action of
controller
Problem that
• Engine cannot be started (if engine has been stopped).
appears on
• Engine stops (if engine has been running).
machine
Related
information

Defective Ne speed sensor
1 Carry out troubleshooting for code [689/CA689].
system
Defective Bkup speed sensor
2 Carry out troubleshooting for code [778/CA778].
system
Possible causes Defective mount of Ne speed Check mount of Ne speed sensor directly for defect (defective
3
and standard sensor installation of sensor, internal of flywheel, etc.)
value in normal Defective mount of Bkup Check mount of Bkup speed sensor directly for defect (defective
state 4
speed sensor installation of sensor, internal of supply pump, etc.)
Defective connection (Wrong Check Ne speed sensor and Bkup speed sensor directly for
5
connection) defective connection (wrong connection).
If causes 1 – 5 are not detected, engine controller may be defec-
6 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be car-
ried out.)
8 125E-5 Series
125E-5 Series 9
E-3 Code [122/CA122] Charge Air Press Sensor High Error 1

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

Defective sensor power supply If code [187/CA187] or [227/CA227] is indicated, carry out trou-
1
system bleshooting for it first.
Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
Defective charge pressure PIM Voltage
2 sensor Between (1) – (3) Power supply 4.75 – 5.25V
(Internal trouble)
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and
controller, too, for another cause of trouble, and then judge.
Possible causes ing without turning starting switch ON.
and standard Disconnection in wiring har- Wiring harness between ENG (female) Resis-
value in normal Max. 1 z
ness (37) – PIM (female) (1) and chassis ground tance
state 3
(Disconnection in wiring or Wiring harness between ENG (female) Resis-
defective contact in connector) Max. 1 z
(44) – PIM (female) (2) and chassis ground tance
Wiring harness between ENG (female) Resis-
Max. 1 z
(47) – PIM (female) (3) and chassis ground tance
ing without turning starting switch ON.
Wiring harness between ENG (female) Resis- Min.
Ground fault in wiring harness (37) – PIM (female) (1) tance 1 Mz
4
(Short circuit with GND circuit) Wiring harness between ENG (female) Resis- Min.
(44) – PIM (female) (2) tance 1 Mz
(47) – PIM (female) (3) tance 1 Mz
10 125E-5 Series

Wiring harness between ENG (female)
(37) – PIM (female) (1) and wiring harness Resis- Min.
between ENG (female) (44) – PIM (female) tance 1 Mz
(2)
Short circuit in wiring harness Wiring harness between ENG (female)
Possible causes 5
(With another wiring harness) (37) – PIM (female) (1) and wiring harness Resis- Min.
and standard between ENG (female) (47) – PIM (female) tance 1 Mz
value in normal (3)
state
(44) – PIM (female) (2) and wiring harness Resis- Min.
between ENG (female) (47) – PIM (female) tance 1 Mz
(3)
or start engine and carry out troubleshooting.
ENG Voltage
Between (37) – (47) Power supply 4.75 – 5.25V
Circuit diagram related to charge pressure sensor
125E-5 Series 11
E-4 Code [123/CA123] Charge Air Press Sensor Low Error 1

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

and standard
value in normal Carry out troubleshooting for E-3 Code [122/CA122].
state
12 125E-5 Series
125E-5 Series 13
E-5 Code [131/CA131] Throttle Sensor High Error 1

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

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

Defective sensor power supply If code [2185/CA2185] or [2186/CA2186] is indicated, carry out
1
system troubleshooting for it first.
AS1 Accelerator pedal Voltage
All range
Between (1) – (3) 4.75 – 5.25V
(Power supply)
Defective accelerator pedal (13 ± 2% of source
2 Released
(Internal trouble) voltage)
Between (2) – (3)
(77 ± 2% of source
Pressed
voltage)
Possible causes controller, too, for another cause of trouble, and then judge.
and standard
Disconnection in wiring har- Wiring harness between E02 (female) (22) Resis-
Max. 1 z
ness – AS1 (female) (1) tance
3
(Disconnection in wiring or Wiring harness between E02 (female) (9) – Resis-
AS1 (female) (2) tance
Wiring harness between E02 (female) (23) Resis-
Max. 1 z
– AS1 (female) (3) tance
Wiring harness between E02 (female) (22) Resis- Min.
Ground fault in wiring harness – AS1 (female) (1) and chassis ground tance 1 Mz
4
(Short circuit with GND circuit) Wiring harness between E02 (female) (9) – Resis- Min.
AS1 (female) (2) and chassis ground tance 1 Mz
– AS1 (female) (3) and chassis ground tance 1 Mz
14 125E-5 Series

Possible causes E02 Accelerator pedal Voltage
and standard All range
value in normal Between (22) – (23) 4.75 – 5.25V
5 Defective engine controller (Power supply)
state
(13 ± 2% of source
Released
voltage)
Between (9) – (23)
(77 ± 2% of source
Pressed
voltage)
Circuit diagram related to throttle sensor of accelerator pedal type (Case of HM300-2)
125E-5 Series 15
Throttle sensor of fuel control dial type (Case of PC400/400LC/450/450LC-7)

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

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

2
(Internal trouble) Between (1) – (3) 4.0 – 6.0 kz
Between (2) – (1) 0.25 – 5.0 kz
Between (2) – (3) 0.25 – 5.0 kz
Max. 1 z
ness – P20 (female) (1) tance
3
Possible causes (Disconnection in wiring or Wiring harness between E02 (female) (9) – Resis-
and standard P20 (female) (2) tance
value in normal Wiring harness between E02 (female) (23) Resis-
state Max. 1 z
– P20 (female) (3) tance
Ground fault in wiring harness – P20 (female) (1) and chassis ground tance 1 Mz
4
(Short circuit with GND circuit) Wiring harness between E02 (female) (9) – Resis- Min.
P20 (female) (2) and chassis ground tance 1 Mz
– P20 (female) (3) and chassis ground tance 1 Mz
5 Defective engine controller E02 Voltage
Between (9) – (23) Signal 0.5 – 4.5V
16 125E-5 Series
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC400/400LC/450/450LC-7)
125E-5 Series 17
E-6 Code [132/CA132] Throttle Sensor Low Error 1

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

and standard
state
18 125E-5 Series
125E-5 Series 19
E-7 Code [135/CA135] Oil press. Sensor High Error 1

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

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

Resis-
and standard (37) – POIL (female) (1) and chassis Max. 1 z
Disconnection in wiring har- tance
value in normal ground
ness
state 3 Wiring harness between ENG (female)
(Disconnection in wiring or Resis-
defective contact in connector) (47) – POIL (female) (2) and chassis Max. 1 z
tance
ground
Resis-
(13) – POIL (female) (3) and chassis Max. 1 z
tance
ground
Ground fault in wiring harness (37) – POIL (female) (1) tance 1 Mz
3
(47) – POIL (female) (2) tance 1 Mz
(13) – POIL (female) (3) tance 1 Mz
20 125E-5 Series

(37) – POIL (female) (1) and wiring har- Resis- Min.
ness between ENG (female) (47) – POIL tance 1 Mz
(female) (2)
Possible causes 4
(With another wiring harness) (37) – POIL (female) (1) and wiring har- Resis- Min.
and standard ness between ENG (female) (13) – POIL tance 1 Mz
value in normal (female) (3)
state
(47) – POIL (female) (2) and wiring har- Resis- Min.
ness between ENG (female) (13) – POIL tance 1 Mz
(female) (3)
ENG Voltage
Circuit diagram related to oil pressure sensor
125E-5 Series 21
E-8 Code [141/CA141] Oil press. Sensor Low Error 1

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

and standard
state
22 125E-5 Series
125E-5 Series 23
E-9 Code [144/CA144] Coolant Temp. Sensor High Error 1

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

Defective coolant temperature ing without turning starting switch ON.
1
sensor (Internal trouble) TWTR (male) Coolant temperature Resistance
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
ness (Disconnection in wiring Wiring harness between ENG (female) Resis-
2 Max. 1 z
Possible causes or defective contact in connec- (15) – TWTR (female) (A) tance
and standard tor) Wiring harness between ENG (female) Resis-
(38) – TWTR (female) (B) tance
state
Ground fault in wiring harness
3
(15) – TWTR (female) (A) and chassis
tance 1 Mz
ground
ENG (female) Coolant temperature Resistance
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
24 125E-5 Series
Circuit diagram related to coolant temperature sensor
125E-5 Series 25
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error 1

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

and standard
value in normal Carry out troubleshooting E-9 Code [144/CA144].
state
26 125E-5 Series
125E-5 Series 27
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error 1

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

Intake air tempera-
Defective charge temperature TIM (male) Resistance
1 ture
sensor (Internal trouble)
Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) –
All range Min. 1 Mz
chassis ground
Possible causes
and standard 2 Max. 1 z
or defective contact in connec- (23) – TIM (female) (A) tance
value in normal
tor) Wiring harness between ENG (female) Resis-
state Max. 1 z
(47) – TIM (female) (B) tance
Ground fault in wiring harness ing without turning starting switch ON.
3
(23) – TIM (female) (A) and chassis ground tance 1 Mz
4 Defective engine controller Intake air tempera-
ENG (female) Resistance
ture
Between (23) – (47) 10 – 100°C 0.5 – 20 kz
28 125E-5 Series
Circuit diagram related to charge temperature sensor
125E-5 Series 29
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error 1

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

and standard
state
30 125E-5 Series
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error 1

Trouble Sensor Sup. 2 Volt. Low Error
187 CA187
Contents of
• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally low.
trouble
• Operates Bkup speed sensor with signals of Ne speed sensor.
• Sets oil pressure sensor to default value (250 kPa) and continues operation.
• Sets atmospheric pressure sensor to default value (52.44 kPa) and continues operation.
Action of
• Fixes charge pressure sensor value (400 kPa) and continues operation.
controller
• Sets EGR inlet pressure sensor to default value (102 kPa) and continues operation.
• Limits output of EGR valve lift sensor and closes EGR valve and bypass valve.
• Limits output of bypass valve lift sensor and closes EGR valve and bypass valve.
Problem that
appears on • Output drops.
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting

and standard
state
125E-5 Series 31
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error 1

Trouble Ambient Air Press. Sensor High Error
221 CA221
Contents of
• Signal voltage in atmospheric pressure sensor circuit is abnormally high.
trouble
Action of • Sets atmospheric pressure sensor to default value (52.44 kPa {0.52 kg/cm2}) and continues opera-
controller tion.
Problem that
machine
Related
information

1
PAMB Voltage
Defective atmospheric pres-
2 sure sensor
(Internal trouble) Between (2) – (3) Signal
Possible causes
and standard Disconnection in wiring har- Wiring harness between ENG (female) Resis-
Max. 1 z
value in normal ness (37) – PAMB (female) (1) tance
3
state (Disconnection in wiring or Wiring harness between ENG (female) (3) Resis-
– PAMB (female) (2) tance
Max. 1 z
(38) – PAMB (female) (3) tance
Resis- Min.
(37) – PAMB (female) (1) and chassis
tance 1 Mz
Ground fault in wiring harness ground
4
(Short circuit with GND circuit) Wiring harness between ENG (female) (3) Resis- Min.
– PAMB (female) (2) and chassis ground tance 1 Mz
Resis- Min.
(38) – PAMB (female) (3) and chassis
tance 1 Mz
ground
32 125E-5 Series

(37) – PAMB (female) (1) and wiring har- Resis- Min.
ness between ENG (female) (3) – PAMB tance 1 Mz
(female) (2)
5
(With another wiring harness) (37) – PAMB (female) (1) and wiring har- Resis- Min.
Possible causes
and standard ness between ENG (female) (38) – PAMB tance 1 Mz
value in normal (female) (3)
state Wiring harness between ENG (female) (3)
– PAMB (female) (2) and wiring harness Resis- Min.
between ENG (female) (38) – PAMB tance 1 Mz
(female) (3)
6 Defective engine controller ENG Voltage
Between (37) – (38) 4.75 – 5.25V
Between (3) – (38)
Circuit diagram related to atmospheric pressure sensor
125E-5 Series 33
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error 1

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

and standard
state
34 125E-5 Series
125E-5 Series 35
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error 1

Trouble Sensor Sup. 2 Volt. High Error
227 CA227
Contents of
• Signal voltage in sensor power supply 2 (5 V) circuit is abnormally high.
trouble
• Operates Bkup speed sensor with signals of Ne speed sensor.
• Sets oil pressure sensor to default value (250 kPa) and continues operation.
• Sets atmospheric pressure sensor to default value (52.44 kPa) and continues operation.
Action of
• Fixes charge pressure sensor value (400 kPa) and continues operation.
controller
• Sets EGR inlet pressure sensor to default value (102 kPa) and continues operation.
• Limits output of EGR valve lift sensor and closes EGR valve and bypass valve.
• Limits output of bypass valve lift sensor and closes EGR valve and bypass valve.
Problem that
machine
Related
information

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

PAMB connector
pressure sensor
Defective sensor (Internal trou- at right in order. If
2 error code disap- Charge pressure
ble) PIM connector
pears when a device sensor
is disconnected, that EGR inlet pressure
device has a defect PEVA connector
sensor
in it.
Possible causes EGR valve lift sensor SEGR connector
and standard
Bypass valve lift
value in normal SBP connector
sensor
state
ness Wiring harness between ENG (female) Resis-
3 Max. 1 z
(Disconnection in wiring or (37) – each sensor (female) tance
defective contact in connector) Wiring harness between ENG (female) Resis-
Max. 1 z
(47) – each sensor (female) tance
Resis- Min.
Ground fault in wiring harness (37) – each sensor (female) and chassis
4 tance 1 Mz
(Short circuit with GND circuit) ground
Resis- Min.
(47) – each sensor (female) and chassis
tance 1 Mz
ground
36 125E-5 Series

Possible causes 5
(With another wiring harness) (37) – each sensor (female) and Resis- Min.
and standard Wiring harness between ENG (female) tance 1 Mz
value in normal (47) – each sensor (female)
state
ENG Voltage
Between (37) – (47) 4.75 – 5.25V
Circuit diagram related to sensor power supply 2 (5 V)
125E-5 Series 37
E-17 Code [234/CA234] Eng. Overspeed 1

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

Possible causes it.
and standard Way of use may be improper. Teach proper way of use to opera-
value in normal 2 Improper way of use
tor.
state
If causes 1 and 2 are not detected, engine controller may be
3 Defective engine controller defective. (Since trouble is in system, troubleshooting cannot be
carried out.)
38 125E-5 Series
125E-5 Series 39
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error 1

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

Disconnect devices
Defective Ne speed sensor at right in order. If
1 error code disap-
(Internal trouble)
pears when a device Ne speed sensor NE connector
is disconnected, that
device has a defect
in it.
2 Max. 1 z
or defective contact in connec- (16) – NE (female) (1) tance
Possible causes
Max. 1 z
and standard (48) – NE (female) (2) tance
Ground fault in wiring harness Wiring harness between ENG (female) Resis- Min.
3
(Short circuit with GND circuit) (16) – NE (female) (1) and chassis ground tance 1 Mz
(48) – NE (female) (2) and chassis ground tance 1 Mz
Short circuit in wiring harness
4 Wiring harness between ENG (female)
(with another wiring harness) Resis- Min.
(16) – NE (female) (1) and between ENG
tance 1 Mz
(female) (48) – NE (female) (2)
ENG Voltage
Between (16) – (48) 4.75 – 5.25 V
40 125E-5 Series
Circuit diagram related to Ne speed sensor power supply
125E-5 Series 41
E-19 Code [263/CA263] Fuel Temp. Sensor High Error 1

Trouble Fuel Temp. Sensor High Error
263 CA263
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally high.
trouble
Action of
• Fixes fuel temperature (90°C) and continues operation.
controller
Problem that
appears on
machine
Related
information

Defective fuel temperature ing without turning starting switch ON.
1 sensor
TFUEL (male) Fuel temperature Resistance
(Internal trouble)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
2 Max. 1 z
Possible causes (Disconnection in wiring or (30) – TFUEL (female) (A) tance
and standard defective contact in connector) Wiring harness between ENG (female) Resis-
(47) – TFUEL (female) (B) tance
state
Ground fault in wiring harness Resis- Min.
3 (30) – TFUEL (female) (A) and chassis
(Short circuit with GND circuit) tance 1 Mz
ground
ENG (female) Fuel temperature Resistance
Between (30) – (47) 10 – 100°C 0.6 – 20 kz
42 125E-5 Series
Circuit diagram related to fuel temperature sensor
125E-5 Series 43
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error 1

Trouble Fuel Temp. Sensor Low Error
265 CA265
Contents of
• Signal voltage in fuel temperature sensor circuit is abnormally low.
trouble
Action of
• Fixes fuel temperature (90°C) and continues operation.
controller
Problem that
appears on
machine
Related
information

and standard
state
44 125E-5 Series
125E-5 Series 45
E-21 Code [271/CA271] PCV1 Short Error 1

Trouble PCV1 Short Error
271 CA271
Contents of
• There is short circuit in PCV1 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump PCV1 PCV1 (male) Resistance
1
(Internal trouble) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) – chassis
Min. 1 Mz
ground
Ground fault in wiring harness Wiring harness between ENG (female) (4) Resis- Min.
2
(Short circuit with GND circuit) – PCV1 (female) (1) tance 1 Mz
Possible causes
Wiring harness between ENG (female) (5) Resis- Min.
and standard
– PCV1 (female) (2) tance 1 Mz
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
Hot short (Short circuit with Wiring harness between ENG (female) (4)
3 Voltage Max. 1V
24V circuit) in wiring harness – PCV1 (female) (1) and chassis ground
Wiring harness between ENG (female) (5)
Voltage Max. 1V
– PCV1 (female) (2) and chassis ground
Between (4) – (5) 2.3 – 5.3 z
Min. 1 Mz
ground
46 125E-5 Series
Circuit diagram related to supply pump PCV1
125E-5 Series 47
E-22 Code [272/CA272] PCV1 Open Error 1

Trouble PCV1 Open Error
272 CA272
Contents of
• There is disconnection in PCV1 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
(Internal disconnection) Between (1) – (2) 2.3 – 5.3 z
Min. 1 Mz
ground
ness Wiring harness between ENG (female) (4) Resis-
2 Max. 1 z
(Disconnection in wiring or – PCV1 (female) (1) tance
Possible causes defective contact in connector) Wiring harness between ENG (female) (5) Resis-
and standard Max. 1 z
– PCV1 (female) (2) tance
value in normal
state a Prepare with starting switch OFF, then carry out troubleshoot-
3
(Short circuit with GND circuit) – PCV1 (female) (1) and chassis ground tance 1 Mz
– PCV1 (female) (2) and chassis ground tance 1 Mz
Between (4) – (5) 2.3 – 5.3 z
Between (4) (5) – chassis
Min. 1 Mz
ground
48 125E-5 Series
125E-5 Series 49
E-23 Code [273/CA273] PCV2 Short Error 1

Trouble PCV2 Short Error
273 CA273
Contents of
• There is short circuit in PCV2 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
ground
2
(Short circuit with GND circuit) – PCV2 (female) (1) and chassis ground tance 1 Mz
Possible causes Wiring harness between ENG (female) Resis- Min.
and standard (10) – PCV2 (female) (2) tance 1 Mz
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state and carry out troubleshooting.
Hot short (Short circuit with Voltage Max. 1V
3 – PCV2 (female) (1) and chassis ground
24V circuit) in wiring harness
(10) – PCV2 (female) (2) and chassis Voltage Max. 1V
ground
Between (9) – (10) 2.3 – 5.3 z
Min. 1 Mz
ground
50 125E-5 Series
125E-5 Series 51
E-24 Code [274/CA274] PCV2 Open Error 1

Trouble PCV2 Open Error
274 CA274
Contents of
• There is disconnection in PCV2 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

Defective supply pump PCV2 ing without turning starting switch ON.
1
(Internal disconnection) PCV2 (male) Resistance
Between (1) – (2) 2.3 – 5.3 z
ness Wiring harness between ENG (female) (9) Resis-
2 Max. 1 z
(Disconnection in wiring or – PCV2 (female) (1) tance
Max. 1 z
Possible causes (10) – PCV2 (female) (2) tance
and standard a Prepare with starting switch OFF, then carry out troubleshoot-
value in normal ing without turning starting switch ON.
state
3 – PCV2 (female) (1) and chassis ground tance 1 Mz
(Short circuit with GND circuit)
Resis- Min.
(10) – PCV2 (female) (2) and chassis
tance 1 Mz
ground
Between (9) – (10) 2.3 – 5.3 z
Min. 1 Mz
ground
52 125E-5 Series
125E-5 Series 53
E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error 1

Trouble Injector #1 (L/B #1) System Open/Short Error
322 CA322
Contents of
• There is disconnection or short circuit in injector #1 circuit.
trouble
Action of
controller
Problem that
• Output drops.
appears on
• Rotation is unstable.
machine
Related
information

Defective injector #1 CN1 (male) Resistance
1
Min. 1 Mz
ground
2 Max. 1 z
(Disconnection in wiring or (45) – CN1 (female) (1) tance
(53) – CN1 (female) (2) tance
and standard
Resis- Min.
Ground fault in wiring harness (45) – CN1 (female) (1) and chassis
3 tance 1 Mz
Resis- Min.
(53) – CN1 (female) (2) and chassis
tance 1 Mz
ground
Between (45) – (53) 0.4 – 1.1 z
Min. 1 Mz
ground
54 125E-5 Series
Circuit diagram related to injector #1
125E-5 Series 55

323 CA323
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine
Related
information

Defective injector #5 (Internal CN5 (male) Resistance
1
trouble) Between (1) – (2) 0.4 – 1.1 z
Min. 1 Mz
ground
2 Max. 1 z
or defective contact in connec- (46) – CN5 (female) (1) tance
and standard
Resis- Min.
3 tance 1 Mz
Resis- Min.
tance 1 Mz
ground
Between (46) – (60) 0.4 – 1.1 z
Min. 1 Mz
ground
56 125E-5 Series
125E-5 Series 57

324 CA324
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
and standard
Resis- Min.
3 tance 1 Mz
Resis- Min.
tance 1 Mz
ground
Between (55) – (52) 0.4 – 1.1 z
Min. 1 Mz
ground
58 125E-5 Series
125E-5 Series 59

325 CA325
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
and standard
Resis- Min.
3 tance 1 Mz
Resis- Min.
tance 1 Mz
ground
Between (57) – (59) 0.4 – 1.1 z
Min. 1 Mz
ground
60 125E-5 Series
125E-5 Series 61

331 CA331
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
and standard
Resis- Min.
3 tance 1 Mz
Resis- Min.
tance 1 Mz
ground
Between (54) – (51) 0.4 – 1.1 z
Min. 1 Mz
ground
62 125E-5 Series
125E-5 Series 63

332 CA332
Contents of
trouble
Action of
controller
Problem that
• Output drops.
appears on
machine
Related
information

1
Min. 1 Mz
ground
2 Max. 1 z
and standard
Resis- Min.
3 tance 1 Mz
Resis- Min.
tance 1 Mz
ground
Between (56) – (58) 0.4 – 1.1 z
Min. 1 Mz
ground
64 125E-5 Series
125E-5 Series 65
E-31 Code [342/CA342] Calibration Code Incompatibility 1

Trouble Calibration Code Incompatibility
342 CA342
Contents of
• Matching error occurred in engine controller data.
trouble
Action of
controller
Problem that
appears on • Engine continues operation normally, but it may stop during operation or may not be able to start.
machine
Related
information

and standard
state
66 125E-5 Series
125E-5 Series 67
E-32 Code [351/CA351] INJ. Drive Circuit Error 1

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

If another failure code (code of abnormality in injector system) is
indicated, carry out troubleshooting for it.
Check fuse or circuit breaker on machine side directly for defect.
2 Defective fuse (If fuse is broken or circuit breaker is turned OFF, circuit probably
has ground fault.)
ness (Disconnection in wiring Wiring harness between E03 (female) (3), Resis-
3 Max. 1 z
or defective contact in connec- (4) – battery (+) tance
Possible causes
tor) Wiring harness between E03 (female) (1), Resis-
and standard Max. 1 z
value in normal (2) – chassis ground tance
Ground fault in wiring harness Wiring harness between E03 (female) (3), Resis- Min.
4
(Short circuit with GND circuit) (4) – battery (+) and chassis ground tance 1 Mz
Wiring harness between E03 (female) (1), Resis- Min.
(2) – chassis ground tance 1 Mz
E03 Voltage
Between (3), (4) – (1), (2) 20 – 30 V
68 125E-5 Series
Circuit diagram related to controller power supply
125E-5 Series 69
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error 1

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

and standard
state
70 125E-5 Series
125E-5 Series 71
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error 1

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

it.
Disconnect devices
Defective sensor (Internal trou- at right in order. If
2 error code disap-
ble) Common rail pres-
pears when a device PFUEL connector
sure sensor
device has a defect
in it.
3 Max. 1 z
(Disconnection in wiring or (33) – PFUEL (female) (1) tance
and standard (47) – PFUEL (female) (3) tance
Resis- Min.
Ground fault in wiring harness (33) – PFUEL (female) (1) and chassis
4 tance 1 Mz
Wiring harness between CE01 (female)
Resis- Min.
(47) – PFUEL (female) (3) and chassis
tance 1 Mz
ground
5
(With another wiring harness) (33) – PFUEL (female) (1) and Resis- Min.
wiring harness between ENG (female) (47) tance 1 Mz
– PFUEL (female) (3)
ENG Voltage
Between (33) – (47) 4.75 – 5.25V
72 125E-5 Series
Circuit diagram related to sensor power supply 1 (5 V)
125E-5 Series 73
E-35 Code [431/CA431] Idle Validation SW Low error 1


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

AS1 Signal name Voltage
Defective accelerator pedal Between (5) – (4) Signal 1
1 See Fig. 1
(Internal trouble) Between (6) – (4) Signal 2
Max. 1 z
ness – AS1 (female) (4) tance
2
(Disconnection in wiring or Wiring harness between E02 (female) (11) Resis-
Possible causes
and standard Wiring harness between E02 (female) (1) – Resis-
Max. 1 z
value in normal AS1 (female) (6) tance
Ground fault in wiring harness – AS1 (female) (4) and chassis ground tance 1 Mz
3
(Short circuit with GND circuit) Wiring harness between E02 (female) (11) Resis- Min.
Wiring harness between E02 (female) (1) – Resis- Min.
AS1 (female) (6) and chassis ground tance 1 Mz
Wiring harness between E02 (female) (32)
Hot short (Short circuit with Voltage Max. 1V
– AS1 (female) (4) and chassis ground
4 24V circuit)
in wiring harness Wiring harness between E02 (female) (11)
Voltage Max. 1V
– AS1 (female) (5) and chassis ground
Wiring harness between E02 (female) (1) –
Voltage Max. 1V
AS1 (female) (6) and chassis ground
74 125E-5 Series
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal 5 Defective engine controller E02 Signal name Voltage
state Between (11) – (32) Signal 1
See Fig. 1
Between (1) – (32) Signal 2
Fig. 1
Pedal: Stroke of accelerator pedal

Output voltage: Output voltage (%)
Sig1: Signal voltage of throttle sensor
Sig2: Signal voltage of idle validation switch 1
Sig3: Signal voltage of idle validation switch 2
Lo: Switch circuit closed
Hi: Switch circuit open
Switch gap: Area where signals of Switch 1 and
Switch 2 overlap
125E-5 Series 75
E-36 Code [432/CA432] Idle Validation Process error 1

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

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

Trouble Battery voltage low error
441 CA441
Contents of
• Power supply voltage is abnormally low.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
76 125E-5 Series
E-38 Code [442/CA442] Battery voltage high error 1

Trouble Battery voltage high error
442 CA442
Contents of
• Power supply voltage is abnormally high.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
125E-5 Series 77
SEN00550-00
© 2005 KOMATSU
All Rights Reserved
78
SEN00551-00
ENGINE 1SHOP MANUAL
125E-5 Series
Troubleshooting of electrical system
(E-mode), Part 2
Troubleshooting of electrical system (E-mode), Part 2 ................................................................................... 3
E-39 Code [449/CA449] Rail Press. Very High Error ........................................................................... 3
E-40 Code [451/CA451] Rail Press. Sensor High Error ....................................................................... 4
E-41 Code [452/CA452] Rail Press. Sensor Low Error........................................................................ 6
E-42 Code [553/CA553] Rail Press. High Error ................................................................................... 6
E-43 Code [554/CA554] Rail Press Sensor In Range Error................................................................. 7
E-44 Code [559/CA559] Rail Press. Low Error .................................................................................... 8
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error ...................................................................... 12
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error........................................................ 14
E-47 Code [757/CA757] All Persistent Data Lost Error...................................................................... 15
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error................................................................... 16
E-49 Code [1228/CA1228] EGR Valve Servo Error 1 ........................................................................ 18
E-50 Code [1625/CA1625] EGR Valve Servo Error 2 ........................................................................ 19
E-51 Code [1626/CA1626] Bypass Valve Solenoid Current High Error ............................................. 20
125E-5 Series 1
E-52 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error .............................................. 22
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1 .................................................................... 23
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2 .................................................................... 24
E-55 Code [1631/CA1631] BP valve Lift Position Sensor High Error................................................. 26
E-56 Code [1632/CA1632] BP valve Lift Position Sensor Low Error ................................................. 28
E-57 Code [1633/CA1633] KOMNET Dtalink Timeout Error .............................................................. 28
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error ......................................................... 29
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error......................................................... 30
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ........................................................ 32
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error......................................................... 36
E-62 Code [2249/CA2249] Rail Press. Very Low Error ...................................................................... 37
E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error ............................................. 38
E-64 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error .............................................. 40
E-65 Code [2351/CA2351] EGR Valve Solenoid Current High Error ................................................. 42
E-66 Code [2352/CA2352] EGR Valve Solenoid Current Low Error .................................................. 44
E-67 Code [2555/CA2555] Grid Heater Relay Volt. Low Error........................................................... 45
E-68 Code [2556/CA2556] Grid Heater Relay Volt. High Error .......................................................... 46
E-69 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate.............................................................. 48
E-70 Code [(146)/B@BCNS] Eng. Overheat...................................................................................... 48
E-71 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate....................................................... 49
2 125E-5 Series
Troubleshooting of electrical system (E-mode), Part 2 1

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

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

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

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

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

(33) – PFUEL (female) (1) and Resis- Min.
5
(With another wiring harness) (33) – PFUEL (female) (1) and Resis- Min.
Possible causes
and standard wiring harness between ENG (female) (47) tance 1 Mz
value in normal – PFUEL (female) (3)
state Wiring harness between ENG (female)
(25) – PFUEL (female) (2) and Resis- Min.
6 Defective engine controller ENG Voltage
Between (33) – (47) 4.75 – 5.25V
Between (25) – (47) 0.25 – 4.6V
Circuit diagram related to common rail pressure sensor
125E-5 Series 5
E-41 Code [452/CA452] Rail Press. Sensor Low Error 1

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

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

Trouble Rail Press. High Error
553 CA553
Contents of
• Common rail pressure sensor circuit detected abnormally high pressure (level 1).
trouble
Action of
controller
Problem that
machine
Related
information

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

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

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

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

it.
2 Use of improper fuel Check fuel used directly (for high viscosity).
a For contents of troubleshooting, see Note 1. For check of pres-
sure in fuel low-pressure circuit, see Testing and adjusting,
Defective low-pressure circuit "Testing fuel pressure".
3
device
Pressure in fuel low-pressure
Min. 0.15 MPa {Min. 1.5 kg/cm2}
circuit
4 Clogging of filter or strainer a For contents of troubleshooting, see Note 2.
Supply pump PCV may have electric trouble. Carry out trouble-
Defective electrical system of
5 shooting for following codes [271/CA271] (E-21), [272/CA272]
supply pump PCV
(E-22), [273/CA273] (E-23),[274/CA274] (E-24).
Defective common rail pres- Common rail pressure sensor may be defective. Check wiring
Possible causes 6
sure sensor harness for damage.
and standard
value in normal a For testing of leakage from pressure limiter, see Testing and
state adjusting, "Testing leakage from pressure limiter and return
7 Defective pressure limiter rate from injector".
Leakage from pressure limiter Max. 10 cc/min (at 1,600 rpm)
a For testing of return rate (spill) from injector, see Testing and
adjusting, "Testing leakage from pressure limiter and return
rate from injector".
Speed at rated operation
Return (Spill) limit from injector
(at stall)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-
pressure feed“.
8 125E-5 Series
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
125E-5 Series 9
Check sheet for no-pressure feed
Model Work No.

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

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

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

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

Checking condition Unit Measured value Good NG
(Reference value)
11 Leakage through pressure limiter No-load, 1,600 rpm cc/min Max. 10
Equivalent to rating <By models>
cc/min 960
1,600 rpm
cc/min 1,020
1,700 rpm
Speed:
12 Return rate from injector cc/min 1,080
1,800 rpm
Return rate:
cc/min 1,140
1,900 rpm
cc/min 1,200
2,000 rpm
10 125E-5 Series
*1 – *10:
When inspecting with INSITE (bench test tool), see Operation and Maintenance Manual (Testing
method).
When inspecting with the monitoring function of the machine, use the codes specified for each machine
model.
Equivalent to rating <By models>:
When inspecting the engine unit on the bench, operate it under a load equivalent to the rating. When
the engine is installed to the machine, however, the operation load equivalent to the rating depends on
the machine model.
125E-5 Series 11
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error 1

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

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

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

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

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

Trouble All Persistent Data Lost Error
757 CA757
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
machine
Related
information

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

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

1
Disconnection in wiring har- Wiring harness between ENG (female) Resis-
Max. 1 z
ness (37) – G (female) (1) tance
2
(47) – G (female) (2) tance
Max. 1 z
(26) – G (female) (3) tance
Ground fault in wiring harness (37) – G (female) (1) and chassis ground tance 1 Mz
3
(47) – G (female) (2) and chassis ground tance 1 Mz
and standard (26) – G (female) (3) and chassis ground tance 1 Mz
Resis- Min.
(37) – G (female) (1) and between ENG
tance 1 Mz
(female) (47) – G (female) (2)
4 Wiring harness between ENG (female)
(With another wiring harness) Resis- Min.
tance 1 Mz
Resis- Min.
tance 1 Mz
Check Bkup speed sensor directly for defective mount (defective
Defective mount of sensor or
5 clearance) or check rotation sensing part (in supply pump)
defective rotation sensing part
directly for defect.
If causes 1 – 5 are not detected, engine Bkup speed sensor may
Defective engine Bkup speed
6 be defective. (Since trouble is in system, troubleshooting cannot
sensor
be carried out.)
ried out.)
16 125E-5 Series
Circuit diagram related to engine Bkup speed sensor
125E-5 Series 17
E-49 Code [1228/CA1228] EGR Valve Servo Error 1 1

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

it.
a For check of engine oil pressure, see Testing and adjusting,
"Testing engine oil pressure".
Engine Engine oil pressure
Defective engine oil pressure
2 Low idle 0.08MPa {0.8kg/cm2}
system (main circuit)
High idle 0.21MPa {2.1kg/cm2}
Possible causes If engine oil pressure is abnormal, carry out troubleshooting for
and standard mechanical system (S-12 Oil pressure lowers).
value in normal
Defective oil pump for EGR
state 3 Check oil pump and relief valve for EGR valve circuit directly.
valve
Defective oil feed piping for
4 Check oil feed piping for EGR valve circuit directly.
EGR valve
Defective oil return piping for
5 Check oil return piping for EGR valve circuit directly.
EGR valve
6 Defective EGR valve Check mechanical section of EGR valve directly.
ried out.)
18 125E-5 Series
E-50 Code [1625/CA1625] EGR Valve Servo Error 2 1

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

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

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

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

Trouble Bypass Valve Solenoid Current Low Error
1627 CA1627
Contents of
• There is disconnection in drive circuit of bypass valve solenoid.
trouble
Problem that
machine
Related
information

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

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

it.
a For check of engine oil pressure, see Testing and adjusting,
"Testing engine oil pressure".
Engine Engine oil pressure
Defective engine oil pressure
2 Low idle 0.08MPa {0.8kg/cm2}
system (main circuit)
High idle 0.21MPa {2.1kg/cm2}
Possible causes If engine oil pressure is abnormal, carry out troubleshooting for
and standard mechanical system (S-12 Oil pressure lowers).
value in normal
Defective oil pump for bypass
state 3 Check oil pump and relief valve for bypass valve circuit directly.
valve
Defective oil feed piping for
4 Check oil feed piping for bypass valve circuit directly.
bypass valve
Defective oil return piping for
5 Check oil return piping for bypass valve circuit directly.
bypass valve
6 Defective bypass valve Check mechanical section of bypass valve directly.
ried out.)
125E-5 Series 23
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2 1

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

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

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

If code [187/CA187] or [227/CA227] is indicated, carry out trou-
1 Defective sensor power supply
bleshooting for it first.
SBP Voltage
Defective bypass valve lift sen-
2 Between (1) – (2) Power supply 4.75 – 5.25V
sor (Internal trouble)
Possible causes Disconnection in wiring har- Wiring harness between ENG (female) Resis-
Max. 1 z
and standard ness (37) – SBP (female) (1) tance
3
value in normal (Disconnection in wiring or Wiring harness between ENG (female) Resis-
state (38) – SBP (female) (2) tance
Max. 1 z
(29) – SBP (female) (3), (4) tance
Resis- Min.
(37) – SBP (female) (1) and chassis
tance 1 Mz
ground
4
(38) – SBP (female) (2) and chassis
tance 1 Mz
ground
Resis- Min.
(29) – SBP (female) (3), (4) and chassis
tance 1 Mz
ground
26 125E-5 Series

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

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

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

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

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

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

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

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

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

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


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

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

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

Disconnect devices
Defective fuel control dial at right in order. If
1 error code disap-
(Internal trouble)
pears when a device Fuel control dial P20 connector
device has a defect
in it.
ness (Disconnection in wiring Wiring harness between E02 (female) (22) Resis-
2 Max. 1 z
or defective contact in connec- – P20 (female) (1) tance
tor) Wiring harness between E02 (female) (23) Resis-
Possible causes
Max. 1 z
and standard – P20 (female) (3) tance
3
(Short circuit with GND circuit) – P20 (female) (1) and chassis ground tance 1 Mz
– P20 (female) (3) and chassis ground tance 1 Mz
4 Wiring harness between E02 (female) (22)
– P20 (female) (1) and between E02
tance 1 Mz
(female) (23) – P20 (female) (3)
E02 Voltage
Between (22) – (23) 4.75 – 5.25 V
34 125E-5 Series
Circuit diagram related to throttle sensor of fuel control dial type (Case of PC400/400LC/450/450LC-7)
125E-5 Series 35
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error 1

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

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

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

and standard
state
125E-5 Series 37
E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error 1

Trouble EGR Valve Lift Position Sensor High Error
2271 CA2271
Contents of
• Signal voltage in EGR valve lift sensor circuit is abnormally high.
trouble
Problem that
machine
Related
information

SEGR Voltage
Defective EGR valve lift sensor
2 Between (1) – (2) Power supply 4.75 – 5.25 V
(Internal trouble)
Possible causes Wiring harness between ENG (female)

Resis-
and standard (37) – SEGR (female) (1) and chassis Max. 1 z
Disconnection in wiring har- tance
value in normal ground
ness (Disconnection in wiring
state 3
or defective contact in connec- Wiring harness between ENG (female) Resis-
tor) (47) – SEGR (female) (2) and chassis Max. 1 z
tance
ground
Resis-
(19) – SEGR (female) (3), (4) and chassis Max. 1 z
tance
ground
Ground fault in wiring harness (37) – SEGR (female) (1) tance 1 Mz
4
(47) – SEGR (female) (2) tance 1 Mz
(19) – SEGR (female) (3), (4) tance 1 Mz
38 125E-5 Series

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

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

Trouble EGR Valve Lift Position Sensor Low Error
2272 CA2272
Contents of
• Signal voltage in EGR valve lift sensor circuit is abnormally low.
trouble
Problem that
machine
Related
information

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

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

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

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

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

Trouble Grid Heater Relay Volt. Low Error
2555 CA2555
Contents of
• There is disconnection in intake air heater relay.
trouble
Action of
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related
information

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

Trouble Grid Heater Relay Volt. High Error
2556 CA2556
Contents of
• There is short circuit in intake air heater relay.
trouble
Action of
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related • Condition for driving heater relay depends on machine.
information • Different machine models may have different connector Nos.

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

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

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

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

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

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

state machine side
125E-5 Series 49
SEN00551-00
© 2005 KOMATSU
All Rights Reserved
50

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SEN00177-01

ENGINE 125E -5 SERIES

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Organization list of the shop manual.................................................................................................... 2

Organization list of the shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00177-01

00 Index and foreword SEN00178-01

10 Structure, function and maintenance standard SEN00183-00

20 Standard value table SEN00186-00

30 Testing and adjusting SEN00187-00

Foreword and general information SEN00180-01

10 Structure, function and maintenance standard

Structure, function and maintenance standard, Part 2 SEN00185-00

Main relief valve....................................................................................................................... 7

20 Standard value table

30 Testing and adjusting

Troubleshooting of mechanical system (S-mode) SEN00549-00

Troubleshooting of electrical system (E-mode), Part 1 SEN00550-00

E-29 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error.................................. 62

Troubleshooting of electrical system (E-mode), Part 2 SEN00551-00

KOMATSU 125E-5 Series engine

Form No. SEN00179-01

ENGINE 1SHOP MANUAL

00 Index and foreword 1

Foreword and general information (Rev. 2005/11)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips

q When removing a connector from a

3] Action to take after removing connec-

4) Drying wiring harness

5. Points to remember when troubleshooting

Points to remember when handling hydraulic equipment

1. Be careful of the operating environment.

2. Disassembly and maintenance work in the