SEN06495-09

ENGINE 125E -7 SERIES

 00 INDEX AND FOREWORD

125E-7 SERIES 00-1

INDEX 00 INDEX AND FOREWORD

INDEX
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
ABBREVIATION LIST ............................................................................................................................. 00-4
FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-10
HOW TO READ THE ENGINE SHOP MANUAL ............................................................................ 00-10
SAFETY NOTICE FOR OPERATION............................................................................................. 00-12
PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-20
ACTIONS IF FIRE OCCURS ......................................................................................................... 00-22
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-23
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...................................................... 00-24
PRECAUTIONS FOR DEF............................................................................................................. 00-25
STORE AdBlue/DEF ...................................................................................................................... 00-26
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-27
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-30
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-37
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-39
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-40
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-41
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-45
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-49
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-50
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-52
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-53
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-55
HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-56
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-60
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-63
CONVERSION TABLE ................................................................................................................... 00-70
01 SPECIFICATIONS .................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
ABBREVIATION LIST ............................................................................................................................. 01-3
SPECIFICATIONS .................................................................................................................................. 01-9
OUTLINE OF EXHAUST GAS REGULATION.................................................................................. 01-9
LIST OF APPLICABLE MACHINES: 125E-7.................................................................................. 01-12
SPECIFICATIONS ......................................................................................................................... 01-13
ENGINE GENERAL VIEW ............................................................................................................. 01-19
WEIGHT TABLE ............................................................................................................................ 01-43
ENGINE PERFORMANCE CURVE ............................................................................................... 01-46
10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1
CONTENTS ............................................................................................................................................ 10-2
ABBREVIATION LIST ............................................................................................................................. 10-4
UREA SCR SYSTEM............................................................................................................................ 10-10
LAYOUT DRAWING OF UREA SCR SYSTEM .............................................................................. 10-10
UREA SCR SYSTEM DIAGRAM ................................................................................................... 10-15
FUNCTION OF UREA SCR SYSTEM............................................................................................ 10-16
COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-33
ENGINE SYSTEM ................................................................................................................................ 10-42
LAYOUT OF ENGINE COMPONENTS .......................................................................................... 10-42
INTAKE AND EXHAUST SYSTEM PARTS .................................................................................... 10-44
ENGINE MAIN BODY PARTS........................................................................................................ 10-49
TURBOCHARGER SYSTEM ......................................................................................................... 10-66
LUBRICATION SYSTEM................................................................................................................ 10-90
FUEL SYSTEM .............................................................................................................................. 10-98
COOLING SYSTEM......................................................................................................................10-119
ELECTRICAL SYSTEM .......................................................................................................................10-124
COMPONENT PARTS OF ELECTRICAL SYSTEM ......................................................................10-124

00-2 125E-7 SERIES

00 INDEX AND FOREWORD INDEX

SENSOR.......................................................................................................................................10-145
20 STANDARD VALUE TABLE ...................................................................................................................... 20-1
CONTENTS ............................................................................................................................................ 20-2
ABBREVIATION LIST ............................................................................................................................. 20-3
STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-9
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18,
D85PXI-18)................................................................................................................................... 20-9
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (HM300-5, HM300-5E0)......................20-11
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (PC490LC-11, PC490LCI-11)............. 20-13
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA470-8) ......................................... 20-15
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA475-10) ....................................... 20-17
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA480-8) ......................................... 20-19
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD ................................................. 20-21
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (D85EX-18,
D85EXI-18, D85PX-18, D85PXI-18) ........................................................................................... 20-21
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (HM300-5,
HM300-5E0) ............................................................................................................................... 20-23
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (PC490LC-11,
PC490LCI-11)............................................................................................................................. 20-25
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (WA470-8) .........
................................................................................................................................................... 20-27
ENGINE OPERATION STANDARD FOR BREAK IN PERIOD AND PERFORMANCE TEST STAND-
ARD: SAA6D125E-7 (WA475-10)............................................................................................... 20-29
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (WA480-8) .........
................................................................................................................................................... 20-31
50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1
CONTENTS ............................................................................................................................................ 50-2
ABBREVIATION LIST ............................................................................................................................. 50-3
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .......................................................... 50-9
HOW TO READ THIS MANUAL....................................................................................................... 50-9
COATING MATERIALS LIST...........................................................................................................50-11
SPECIAL TOOLS LIST .................................................................................................................. 50-15
SKETCHES OF SPECIAL TOOLS................................................................................................. 50-17
ENGINE SYSTEM ................................................................................................................................ 50-20
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY............................................................. 50-20
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................50-123
REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-132
REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-135
60 MAINTENANCE STANDARD.................................................................................................................... 60-1
CONTENTS ............................................................................................................................................ 60-2
ABBREVIATION LIST ............................................................................................................................. 60-3
ENGINE SYSTEM .................................................................................................................................. 60-9
INTAKE AND EXHAUST SYSTEM PARTS ...................................................................................... 60-9
ENGINE MAIN BODY PARTS........................................................................................................ 60-10
LUBRICATION SYSTEM................................................................................................................ 60-33
COOLING SYSTEM....................................................................................................................... 60-36
INDEX..................................................................................................................................................................1

125E-7 SERIES 00-3

ABBREVIATION LIST 00 INDEX AND FOREWORD

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

00-4 125E-7 SERIES

00 INDEX AND FOREWORD ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

125E-7 SERIES 00-5

ABBREVIATION LIST 00 INDEX AND FOREWORD

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

00-6 125E-7 SERIES

00 INDEX AND FOREWORD ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actu-
system
ated, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for “International System of Units” It
SI al d' Unites (Internation- Unit is the universal unit system and “a single unit for
al unit system) a single quantity” is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

125E-7 SERIES 00-7

ABBREVIATION LIST 00 INDEX AND FOREWORD

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

00-8 125E-7 SERIES

00 INDEX AND FOREWORD ABBREVIATION LIST

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

125E-7 SERIES 00-9

HOW TO READ THE ENGINE SHOP MANUAL 00 INDEX AND FOREWORD

FOREWORD, SAFETY, BASIC INFORMATION

HOW TO READ THE ENGINE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUC-
TURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, instal-
lation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
Symbol
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
This signal indicates an extremely hazardous situation which will result in
Danger
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Warning
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.

00-10 125E-7 SERIES

00 INDEX AND FOREWORD HOW TO READ THE ENGINE SHOP MANUAL

Symbol Item Remark

This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.

Oil and coolant This signal indicates a place to supply oil, coolant, etc. and the quantity.

Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.

This symbol indicates the works which require special caution for the ma-
Safety
chine safety when assembling.

Signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE Notice
or shortening of service life may occur.
REMARK Remark This signal word contains useful information to know.

Unit
International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.

125E-7 SERIES 00-11

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

SAFETY NOTICE FOR OPERATION

• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop
manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of
the servicing and repair methods require the use of special tools designed by Komatsu for special purpo-
ses.

• The symbol mark is indicated for such matters that require special precautions. The work indicated with
this warning mark should be performed according to the instructions with special attention. Should a
hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every
necessary measures.
Safety matters
• Well organized work place
• Correct work clothes
• Observance of work standard
• Enforcement of hand signals
• Prohibition against unlicensed persons operating and handling the machine
• Safety check before starting work
• Wear of dust glasses (for cleaning or grinding work)
• Wear of welding goggles and protectors (for welding work)
• Being in good physical condition, and good preparation
• Always be alert and careful.
General precautions
k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Oper-
ation and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.

00-12 125E-7 SERIES

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

• Always wear the protective eyeglasses when hitting parts

with a hammer.
• Always wear the protective eyeglasses when grinding
parts with a grinder, etc.
• When performing any operation with multiple workers, al-
ways agree on the operating procedure before starting. Be
clear in verbal communication, and observe hand signals.
Hang “UNDER REPAIR” warning tag in the operator's
compartment Before starting work. ,&
• Work and operation which require license or qualification
should be performed by qualified workers.
• Welding repairs should be performed by trained and experienced welders. When performing welding work,
always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
• Warm up before starting the work with exercise which increases alertness and the range of motion in order
to prevent injury.
• Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe
area.
Precautions for preparatory work
• Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks
to prevent the machine from moving before adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not pos-
sible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang “UNDER REPAIR” warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks,
or stands before starting the work.
• Remove all mud and oil from the steps or other places for
going up and down on the machine. Always use the hand-
rails, ladders or steps when for going up and down on the
machine. Never jump on or off the machine. When the
scaffold is not provided, use steps or stepladder to secure
your footing. Do not use handrails, ladders, or steps if they
are damaged or deformed. Repair it or replace it immedi-
ately.

,&

Precautions during work

• For the machine with the battery disconnect switch, check before starting the work that the system operat-
ing lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.
REMARK
Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type.
For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) ter-
minal first.
• For the machine with the quick release battery terminal (-), check before starting the work that the system
operating lamp is not lit. Then, disconnect the quick release battery terminal (-).
REMARK
For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the quick release battery terminal (-).

125E-7 SERIES 00-13

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

• Release the remaining pressure from the circuit before starting the work of disconnecting and removing of
oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it
should be done slowly otherwise the oil spills.
• When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer
after the engine is shut down and start the work after the remaining pressure is released from the fuel cir-
cuit.
• The coolant and oil in the circuits are hot when the engine
is shut down. Be careful not to get scalded. Wait for the oil
and coolant to cool before performing any work on the oil
or coolant circuits.

• Before starting work, shut down the engine. When working

on or around a rotating part, in particular, shut down the
engine. When checking the machine without shutting down
the engine (measuring oil pressure, revolving speed, tem-
perature, etc.), take extreme care not to get caught in ro-
tating parts or moving parts.
• When raising a heavy component (heavier than 25 kg),
use a hoist or crane. Before starting work, check that the
slings (wire ropes, webbing slings, chains, and hooks) are
free from damage. Always use slings which have ample
capacity and install them to proper places. Operate the
hoist or crane slowly to prevent the component from hitting
any other part. Do not work with any part still raised by the
hoist or crane.
• When removing a part which is under internal pressure or
under reaction force of a spring, always leave 2 bolts in di-
agonal positions. Loosen those 2 bolts gradually and alter-
nately to release the pressure, and then remove the part.
• When removing components, do not break or damage the
electrical wiring. Damaged wiring may cause a fire.
,&
• When removing piping, do not spill the fuel or oil. If any
fuel or oil drips onto the floor, wipe it off immediately. Fuel
or oil on the floor can cause you to slip and can even cause fires.
• Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic-
ular.

00-14 125E-7 SERIES

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

• Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which
must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not
be damaged by contact with other parts when the machine is operated.
• When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and
tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In
addition, check that high pressure hoses and tubes are correctly installed.
• When assembling or installing parts, always tighten them to the specified torques. When installing protec-
tive parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are
installed correctly.
• Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
• Check that the measuring tools are correctly installed when measuring hydraulic pressure.
• Take care when removing or installing the tracks of track-type machines. Since the track shoe may sepa-
rate suddenly when you remove it, never let anyone stand at either end of the track shoe.
• If the engine is operated for a long time in a closed place
with poor ventilation, it may cause gas poisoning. Open
the windows and doors to ventilate the place well.

,&

Precautions for slinging work and making signals

• Only one appointed worker must make signals and co-workers must communicate with each other fre-
quently. The appointed signaler must make specified signals clearly at a place where he is well seen from
the operator's seat and where he can see the working condition easily. The signaler must always stand in
front of the load and guide the operator safely.
k Never stand under the load.
k Do not move a load over a person.
k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they
are not caught between the load and materials or equipment on the ground or hit by the load
even if the crane starts abruptly.
• Check the slings before starting sling work.
• Keep putting on gloves during sling work. (Put on leather gloves, if available.)
• Measure the weight of the load by the eye and check its center of gravity.
• Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are
used to sling a light load, the load may slip and fall.
• Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install
2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or
slipping of the rope from its original slinging position on the load, which can result in a danger-
ous accident.
• Hanging angle must be 60 ° or smaller as a rule.
• When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of
the hook.

125E-7 SERIES 00-15

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

REMARK
When slinging a load with 2 or more ropes, the force sub-
jected to each rope increases with the hanging angle. The
figure below shows the variation of allowable load in kN
{kg} when slinging is made with 2 ropes, each of which is
allowed to sling up to 9.8 kN {1000 kg}  vertically, at vari-
ous hanging angles. When the 2 ropes sling a load verti-
cally, they can sling up to 2000 kg of total weight. This
weight is reduced to 1000 kg when the 2 ropes make a
hanging angle of 120 °. If the 2 ropes sling a 2000 kg load
at a hanging angle of 150 °, each rope is subjected to a
force as large as 39.2 kN {4000 kg} .
• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery,
apply proper material to prevent the wire rope from slipping.
• Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch sys-
tem.
k Slinging near the tip of the hook may cause the
rope to slip off the hook during hoisting.
REMARK
The strength of the hook is maximum at its central part.

• Never use a wire rope which has breaks in strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
Precautions for slinging up
• Wind in the crane slowly until wire ropes are stretched.
When settling the wire ropes with the hand, do not grasp
them but press them from above. If you grasp them, your
fingers may be caught.
• After the wire ropes are stretched, stop the crane and
check the condition of the slung load, wire ropes, and
pads.
• If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
• Do not lift up the load at an angle.
Precautions for slinging down
• When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove the sling.
• Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified
place.
Precautions for using mobile crane
REMARK
Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
Precautions for using overhead traveling crane
k When raising a heavy component (heavier than 25 kg), use a hoist or crane.

00-16 125E-7 SERIES

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

REMARK

Weight of component whose weight is heavier than 25 kg is shown with symbol in “DISASSEMBLY AND
ASSEMBLY”.
• Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device,
ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energiz-
ing caution lamp, and check the following safety items.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Be sure to check the directions of the direction indication plate (north, south, east and west) and the
operating button.
• Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
• Do not raise or lower a load while the crane is moving longitudinally or laterally.
• Do not drag a sling.
• When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
• Consider the travel route in advance and lift up a load to a safe height.
• Place the control switch in a position where it is not an obstacle to work and passage.
• After operating the hoist, do not swing the control switch.
• Remember the position of the main switch so that you can turn off the power immediately in an emer-
gency.
• If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it
is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not
in operating condition.
• If you find an obstacle around the hoist, stop the operation.
• After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above
the floor. Do not leave the sling installed to the hook.
Selecting wire ropes
Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.
REMARK
The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.

Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing)
Nominal diameter of rope (mm) Allowable load (kN {t} )
10 8.8 {0.9}
12 12.7 {1.3}
14 17.3 {1.7}
16 22.6 {2.3}
18 28.6 {2.9}
20 35.3 {3.6}
25 55.3 {5.6}
30 79.6 {8.1}
40 141.6 {14.4}
50 221.6 {22.6}
60 318.3 {32.4}

125E-7 SERIES 00-17

SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

Precautions for disconnecting air conditioner piping

NOTICE
When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc.,
collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting
the air conditioner hoses.
REMARK
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a).
• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are col-
lecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may
lose your sight, and when it touches your skin, you may suffer from frostbite.
• When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one
wrench to fix and use the other one to loosen the nut.
Precautions for air conditioner piping
• When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.
• Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
• Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
• When removing the O-rings, use a soft tool so that the piping is not damaged.
• Check that the O-ring is not damaged or deteriorated.
• Apply compressor oil for refrigerant (R134a) to O-ring.
REMARK
Do not apply oil to the threaded portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (PAG46 or equivalent)
SANDEN SP-10

When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix
and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).

00-18 125E-7 SERIES

00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

REMARK
• The figure shows an example of fitting of O-ring.
• An O-ring is fitted to every joint of the air conditioner piping.
For tightening torques, see THE OTHER INFORMATION, “Pre-
cautions for disconnection and connection of air conditioner
piping”.

125E-7 SERIES 00-19

PRECAUTIONS TO PREVENT FIRE 00 INDEX AND FOREWORD

PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, coolant or window washer fluid
Do not bring any open flame close to fuel, oil, coolant or win-
dow washer fluid. Always observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
• Be careful not to spill fuel on overheated surfaces or on
,&
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other flammable materials into a safe
container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil. Do
not use diesel oil or gasoline.There is danger that they
may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
• Determine well-ventilated areas for storing oil and fuel. ,&
Keep the oil and fuel in the specified place and do not al-
low unauthorized persons to enter.
• When performing grinding or welding work on the machine, move any flammable materials to a safe place
before starting.
Fire caused by accumulation or attachment of flammable material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
• To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of
paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil
cooler) or on the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
Fire caused by piping
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury
or death.
Fire around the machine due to highly heated exhaust gas
Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re-
generation), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not
bring any flammable materials close to exhaust pipe outlet.

00-20 125E-7 SERIES

00 INDEX AND FOREWORD PRECAUTIONS TO PREVENT FIRE

• When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disa-
ble the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused
by KDPF regeneration.
See the Operation and Maintenance Manual for the setting procedure.
Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion
specifications.
• When taking the electrical power for the lighting equipment from the machine, follow the instructions in the
Operation and Maintenance Manual.

125E-7 SERIES 00-21

ACTIONS IF FIRE OCCURS 00 INDEX AND FOREWORD

ACTIONS IF FIRE OCCURS

• Turn the starting switch to OFF position to stop the engine.
• Use the handrails and steps to get off the machine.
• Do not jump off the machine. You may fall and suffer serious injury.
• The fumes generated by a fire contain harmful materials which have a bad influence on your body when
they are inhaled.
Do not breathe the fumes.
• After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on
your body.
Be sure to wear rubber gloves when handling the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in
the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.

00-22 125E-7 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

To prevent pollution, pay full attention to the way to dispose of waste materials.
• Always drain the oil from your machine in containers. Nev-
er drain the oil and coolant directly onto the ground or
dump into the sewage system, rivers, seas, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
batteries, and DEF.

Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the
local regulations for disposing industrial waste products.

125E-7 SERIES 00-23

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 00 INDEX AND FOREWORD

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

This machine complies with either regulation Tier4 Final (North America) or Stage IV (EU) (until 2018), Stage V
(EU) (after 2019).
This machine is equipped with the following two exhaust gas treatment systems:
• Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu-
rify exhaust gas. This process performs the combustion of soot referred to as “regeneration”.
• Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the exhaust gas
into harmless nitrogen and water. Spraying aqueous urea solution into the exhaust gas produces a reaction
between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen
oxides into nitrogen and water.
Urea SCR system is not installed to some machine models or specifications.
Either AdBlue® or DEF may be used as the aqueous urea solution for the SCR system.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).
DEF is the abbreviation for Diesel Exhaust Fluid.
Commercial DEF that is API approved and meets all the requirements defined in ISO 22241-1.
This solution will be represented as DEF throughout this manual.
About DEF
DEF is necessary for the urea SCR system. DEF is a colorless transparent 32.5% aqueous urea solution. Urea
as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertiliz-
er, etc.
If you add any additional additive agents or water to DEF and use it, the devices will not function properly, and
conformance to the exhaust gas regulations will be lost. In addition, it will cause failure of the machine.
• In Europe, use AdBlue®.
• In North America, use DEF (Diesel Exhaust Fluid) which is certified by API (American Petroleum Institute).
The certified DEF has the API DEF Certification Mark shown as follows. Look for the API DEF Certification
Mark when purchasing DEF.
API Diesel Exhaust Fluid Certification Mark is the trade
mark of API (American Petroleum Institute).

00-24 125E-7 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR DEF

PRECAUTIONS FOR DEF

GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is
used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im-
mediate action:
• If it gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes off
and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated or
begins to hurt, immediately consult a doctor for treatment.
• Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor
for treatment.
• Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doc-
tor for treatment.
• Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear
rubber gloves when you perform work handling DEF to avoid skin contact.

PRECAUTIONS FOR ADDING

Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause a
fire. Some fluids or agents added can create and emit a toxic gas.
When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face away from
the filler port during opening or refilling.

PRECAUTIONS FOR STORING

If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal up
its container for storage. When opening the container, perform it where there is good ventilation. For storage,
see “STORE AdBlue/DEF”.
Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not
exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or aluminum con-
tainer, toxic gas may develop and a chemical reaction may corrode the container.

PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE

AdBlue/DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas. Act on the base
of “Actions if fire occurs”.
If AdBlue/DEF is spilled, immediately wipe and wash the area with water. If spilled AdBlue/DEF is left unatten-
ded and the area is not wiped and cleaned, toxic gas or corrosive substance may be produced by chemical re-
actions.

THE OTHER PRECAUTIONS

When disposing of AdBlue/DEF, treat it as an industrial waste. For the waste treating method, refer to “Precau-
tions for disposing of waste materials”. It should be treated in the same way.
Never use an iron or aluminum container when disposing AdBlue/DEF fluid, because toxic gas may develop and
a chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when
handling the fluid waste of AdBlue/DEF.
Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel
or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.
Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can
cause serious damage to the environment as well as violation of laws.

125E-7 SERIES 00-25

STORE AdBlue/DEF 00 INDEX AND FOREWORD

STORE AdBlue/DEF
• If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal
up its container for storage. Only open containers in a well-ventilated area.
• Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do
not exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or alumi-
num container, toxic gas may develop and a chemical reaction may corrode the container.
• AdBlue/DEF freezes at –11 °C. The recommended temperature for storage is -5 °C or above.
The relation between the upper limit of storage temperature and the storage period of AdBlue/DEF is
shown in the table.
Temperature of storage area Storage period
Max.10 °C Up to 36 months
Max.25 °C Up to 18 months
Max.30 °C Up to 12 months
Max.35 °C Up to 6 months

*: Do not store AdBlue/DEF in the temperature of 35 °C or above.

Handling AdBlue/DEF in cold weather
• AdBlue/DEF freezes at –11 °C.
AdBlue/DEF may freeze and expand to break the devices and parts in the tank. The parts inside the tank
may be affected. Add AdBlue/DEF to the specified amount for cold weather (below the level of when AdBl-
ue/DEF may freeze).
• In cold weather, keep AdBlue/DEF or the machine installed with AdBlue/DEF in the indoors where the tem-
perature is at –11 °C or higher to prevent AdBlue/DEF in the tank from freezing.
If AdBlue/DEF or the machine installed with AdBlue/DEF cannot be stored in the indoors where the temper-
ature is at –11 °C or higher (if they are left outdoors in cold weather), AdBlue/DEF in the tank may freeze.
Drain AdBlue/DEF to prevent it from freezing.

00-26 125E-7 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is
dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or
when disassembling, or assembling the hydraulic components.
Select an appropriate workplace
• In rain or high winds, or in dusty environment, avoid adding hydraulic oil, replacing filters, or repairing the
machine.
Disassembly and maintenance work in the field
k Any component may jump out or oil may spurt out by the remaining pressure in the hydraulic circuit
and it may result in serious personal injury or death when removing and disassembling of the hy-
draulic equipment is performed.
k Release the remaining pressure from the hydraulic circuit always before performing the work.

• In the field, there is a risk of dust entering the component

during disassembling or maintenance work, and perform-
ance check is hardly performed. Replacement of the as-
sembly is recommended.
• Perform disassembling and maintenance work in the dust
proof area.

Sealing of openings (prevention of flowing out of oil)

Plug the openings of the piping and the device which have been removed to prevent foreign material from enter-
ing and oil from flowing out.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute
the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it ap-
propriately.
REMARK
Cover the places tightly with caps, tapes, or plastic bags if it is
hard to provide the plugs.

125E-7 SERIES 00-27

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD

Preventing intrusion of foreign materials during refilling

• During refilling with the hydraulic oil, do not let water enter
the electrical components.
• Clean the oil filler port and its around, refilling pump, oil
jug, or etc.
• Refilling by using an oil cleaning device is better method
since it can filtrate the contaminants accumulated in the oil
during storage.

Replacing hydraulic oil while its temperature is high

• The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are
easily discharged from the circuit. Perform the replacement while oil temperature is high.
• Old hydraulic oil needs to be drained as much as possible when replacing.
NOTICE
Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludg-
es, and the service life of the hydraulic oil is shortened.
REMARK
Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the cir-
cuit.
Avoid reusing the hydraulic oil and lubricating oil
Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine.
If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.
Flushing operation
• Flushing is required to completely dislodge the contami-
nants and sludges, and existing oil containing those inside
the hydraulic circuit after disassembling and assembling,
and when replacing the oil with the new one.
• Normally, flushing is performed twice. Primary flushing is
performed by using the flushing oil (1) and the secondary
flushing is performed by using the specified hydraulic oil.

Cleaning operation
Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic
device (pump, or control valve) or during operation of the machine.

00-28 125E-7 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

REMARK
The oil cleaning equipment can remove the ultra fine (approxi-
mately 3 μm) particles that the filter built in the hydraulic equip-
ment cannot remove. So, it is very effective device.

125E-7 SERIES 00-29

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

When performing “testing and adjusting” of the machine, “removal and installation” and “disassembly and as-
sembly” of the components, observe the following precautions.
Precautions for removal and disassembling work
• If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage
rashly.
• After disconnecting the hoses or tubes, plug them to prevent dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the matchmarks which indicate the installing position, and put matchmarks on the places where they
seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses so that installation is done to the correct installing positions.
• Check the thickness and number of shims when storing shims.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any for-
eign material from entering after removal.
• To disconnect the face seal type hose from the cylinder
tube, loosen the joint by gripping the two wrenches togeth-
er, one is the wrench (1) on the hose side, and another is
the wrench (2) on the cylinder tube reaction force point as
shown in the following figure. Use the grip strength on-
ly.Check after disconnecting the hose that the joint portion
of the cylinder and the cylinder tube is tightened to the
specified torque. Re-tighten it if the tightening torque is in-
sufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the
reaction force point of the cylinder tube, and it is a
cause of weakening of the tightening torque. It may
lead to oil leakage.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
NOTICE
When disassembling the machine, check the part number by referring to the Parts Book and use the
appropriate parts according to the usage conditions.
REMARK
The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and
transporting the machine.

00-30 125E-7 SERIES

 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

Introduction of parts for the disassembly of the face seal type hoses and tubes

Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018

Introduction of parts for the disconnection of the taper seal type hoses and
tubes

Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422

125E-7 SERIES 00-31

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

Introduction of parts for the disconnection of the split flange type hoses and
tubes

Nomi Bolt pitch (mm) Hose side Tube side

nal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
No. a b Flange (1)
(2) (3)
04 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823
05 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823
06 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032
10 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032
58.7 30.2 07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032
12
66.7 31.8 07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232
69.9 35.8 07379-01460 07371-31465 07378-11400 07000-13048 07372-51240 01643-51232
14
79.4 36.5 07379-01470 07371-51470 07378-11410 07000-13048 01010-81455 01643-31445
77.8 42.8 07379-02071 07371-32076 07378-12000 07000-12060 07372-51240 01643-51232
20
96.8 44.5 07379-02080 07371-52080 07378-12010 07000-12060 01010-81865 01643-31845
24 88.9 50.8 07379-02484 07371-12484 07378-12400 07000-12070 07372-51240 01643-51232
30 106.4 62 07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645
40 130.2 77.8 07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645

Introduction of parts for the removal of O-ring boss type joint

00-32 125E-7 SERIES

 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

Nominal No. Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234

Introduction of parts for the removal of taper pipe thread type joint

Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R1/8 07042-00108 07043-00108

02 R1/4 07042-00211 07043-00211

03 R3/8 07042-00312 07043-00312

04 R1/2 07042-00415 07043-00415

06 R3/4 07042-00617 07043-00617

10 R1 07042-01019 07043-01019
12 R11/4 07042-01222 07043-01222

14 R11/2 07042-01422 07043-01422

20 R2 07042-02026 07043-02026

Precautions for installation and assembling work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.
• Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.

125E-7 SERIES 00-33

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to
the threaded portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dust or damage.
• Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.
• Apply engine oil to the rotating parts and sliding surface.
• Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then con-
nect them securely.
• Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male
screws which receive pressure.
REMARK
If the threaded portion is difficult to degrease, you may use a seal tape.
When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the
third thread in the advancing direction of the threads seeing from the screw end.
NOTICE
If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come
off. If the sealed tip is pushed outside, it may cause oil leakage.
• To connect the face seal type hose to the cylinder tube,
tighten the joint by gripping the two wrenches together,
one is the wrench (1) on the hose side, and another is the
wrench (2) on the cylinder tube reaction force point at the
same time as shown in the following figure. Use the grip
strength only.Check after connecting the hose that the joint
portion of the cylinder and the cylinder tube is tightened to
the specified torque. Re-tighten it if the tightening torque is
insufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the
reaction force point of the cylinder tube, and it is a
cause of weakening of the tightening torque. It may
lead to oil leakage.
NOTICE
When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed,
be sure to bleed air from the hydraulic circuit before operating it for the first time according to the fol-
lowing procedure.
1. Start the engine, and run it at low idle.
2. Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximate-
ly 100 mm before the stroke end for 4 or 5 times.
3. Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke
end for 3 or 4times.

00-34 125E-7 SERIES

 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

NOTICE
After repair is finished, when operating the machine which has been stored for a long period, bleed air
from the hydraulic circuit according to the same procedure.
Precautions at the time of completion of work
Refilling of coolant or water or oil, greasing, and adding of AdBlue/DEF
• For machines with urea SCR system, fill AdBlue/DEF to the specified level before starting the engine.
• Supply the specified amount of grease to the work equipment parts.
• When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser-
voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in
the piping, and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends
to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level
again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuild-
ing the parts, by referring to TESTING AND ADJUSTING.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If there is any looseness, retighten the part.
REMARK
For the tightening torques, see “DISASSEMBLY AND ASSEMBLY”.
Test engine piping for damage and looseness
Intake and exhaust system
Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak
of air or exhaust gas from connecting portion.
If there is any looseness, damage, or gas leak, retighten or repair the part.
Cooling system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water
leak from connecting portion.
If there is any looseness, damage, or water leak, retighten or repair the part.
Fuel system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel
leak from connecting portion.
If there is any looseness, damage, or fuel leak, retighten or repair the part.
Check the exhaust equipment and its installation portion for looseness and damage.
REMARK
When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or com-
ponents of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there
is any damage, replace the part.

125E-7 SERIES 00-35

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the instal-
lation portion.
If there is any looseness, retighten the part.
Check of function of muffler in exhaust system
REMARK
When an equipment is described as an muffler in exhaust system, it is one of the followings. (The applications
or components of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Check that there is no unusual noise by comparing to it of the time when the machine was new.
If there is any unusual noise, repair KDPF or muffler, referring to “TROUBLESHOOTING” and “DISASSEMBLY
AND ASSEMBLY”.

00-36 125E-7 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

To maintain the performance of the machine over a long period, and to prevent failures or troubles before they
occur, correct “operation”, “maintenance and inspection” “troubleshooting”, and “repairs” must be performed.
This section deals particularly with correct repair procedures for mechatronics components and is aimed at im-
proving the quality of repairs. For this purpose, it describes the working procedures in “Handling of electrical
equipment”.
Handling wiring harnesses and connectors
• Wiring harnesses consist of wires connecting one compo-
nent to another component, connectors used for connect-
ing and disconnecting one wire from another wire, and pro-
tectors or tubes used for protecting the wires.
• Compared with other electrical components fitted in boxes
or cases, wiring harnesses are likely to be directly affected
by rain water, heat, or vibration. Furthermore, during in-
spection and repair operations, they are frequently re-
moved and installed again, so they are likely to suffer de-
formation or damage. For this reason, it is necessary to be
extremely careful when handling and maintenance of the
wiring harnesses.
• If AdBlue/DEF is spilled over wiring harness and connectors, it may cause corrosion and defective contact.
Be careful not to spill it over electrical equipment, wiring harness and connectors since AdBlue/DEF is
strongly corrosive to metal.
Main causes of failure in wiring harness
Defective contact of connectors (defective contact between male and female connectors)
Problems with defective contact are likely to occur because the
male connector is not properly inserted into the female connec-
tor,or because one or both of connectors are deformed or the
position is not correctly aligned, or because there is corrosion
or oxidization of the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and contact may
become normal) by connecting and disconnecting the connec-
tors approximately 10 times.

Defective crimping or soldering of connectors

The pins of the male and female connectors are attached to
wires by crimping or soldering. If excessive force is applied to
the wire, the jointed portion (1) may become loose, and it may
result in a defective connection or breakage.

125E-7 SERIES 00-37

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD

Disconnection in wiring
If the wiring harness is pulled to disconnect the connector, or
the components are lifted with a crane while the wiring harness
is still connected, or a heavy object hits the wiring harness, it
may separate the crimping of the connector, or damage the sol-
dering, or break the wiring harness.

Water entering the connector by high-pressure jetting

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed di-
rectly on the connector, water may enter the connector, de-
pending on the direction of the water jet.
Do not spray water directly on the connector.
If the connector is waterproof, intruded water is hardly drained.
Once water enters into the connector, water goes through pins
to cause short-circuit. Drying the drenched connector or take
appropriate actions before providing electricity.
Entry of water, dirt, or dust when disconnecting a con-
nector
If any water, mud or dust is stuck to the outside surface of a connector, it can enter inside the connector when
the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a
dry cloth or blow it with compressed air.
Oil, mud, or dust stuck to connector
If any oil or grease is stuck to the connector and an oil film is
formed on the mating surface of the male and female pins, the
oil prevents electricity from passing through resulting in defec-
tive contact. If any oil, grease, dirt or dust is stuck to the con-
nector, wipe it off with a dry cloth or blow it with compressed air,
and wash it with electrical contact restorer.
NOTICE
• When wiping the jointed portion of the connector, do
not apply excessive force or deform the pins.
• If there is oil or water in the compressed air, it causes
the contacts to become dirtier. Use clean air which any
oil and water has been removed from.

00-38 125E-7 SERIES

00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the
parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may
cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Select an appropriate workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign
material may enter or leaked oil may pollute the environ-
ment.
Do not discard the oil inconsiderately. Ask the customer
for disposal or bring it back to dispose it appropriately.

How to clean parts when dirt is stuck

If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than
the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material
from entering this system, the filter employs a specially high performance of filter element. If a filter oth-
er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore
Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the
shop manual.

125E-7 SERIES 00-39

PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable
system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause
a failure. Use special care to prevent entry of the foreign material when servicing the intake system.
Select an appropriate workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter it.

00-40 125E-7 SERIES

00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

REMARK
• Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.
• Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even
after the remaining pressure is released from the hydraulic tank.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold adapter (1), and push hose joint (2) into mating
adapter (3).
REMARK
• Push it in approximately 3.5 mm.
• Do not hold rubber cap portion (4).

2. While having adapter (3) inserted into hose side joint (2),
insert rubber cap (4) to adapter (3) side until it clicks.

3. Hold hose adapter (1) or hose (5), and pull it out.

REMARK
Provide an oil container to receive a quantity of hydraulic
oil which may flow out.

Connection
1. Hold hose adapter (1) or hose (5), and insert it in mating
adapter (3), aligning the axis.
REMARK
Do not hold rubber cap portion (4).

125E-7 SERIES 00-41

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD

2. After inserting the hose in the mating adapter perfectly, pull

it back to check the connecting condition.
REMARK
When the hose fitting is pulled back, the rubber cap moves
approximately 3.5 mm toward the hose, but it is not a prob-
lem.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.

2. While keeping the condition of step 1, turn lever (3) to the

right (clockwise).

3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.

00-42 125E-7 SERIES

00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.

2. While keeping the condition of step 1, push cover (3)

straight until it contacts contact surface (a) of the hexago-
nal portion on the male side.

3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.

125E-7 SERIES 00-43

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD

Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.

00-44 125E-7 SERIES

 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
00 INDEX AND FOREWORD NECTORS

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNEC-

TORS
Disconnecting connectors
1. Hold the connectors when disconnecting.
When disconnecting the connectors, always hold the con-
necting portion. If the connector is fixed with screw, loosen
the screw of the connector completely, hold the both of
male and female connectors, and pull them out in parallel.
NOTICE
Do not pull the connectors with one hand.
REMARK
If it is a lock stopper type connector, pull it out as pushing
the stopper (1) with your thumb.
2. When removing a connector from a clip
• Both of the connector and clip have stoppers (2),
which are engaged with each other when the connec-
tor is connected.
• When removing a connector from a clip, pull the con-
nector in parallel with the clip as removing stoppers.
NOTICE
If the connector is pried up and down or to the
right or left, it may break the housing.

3. Action to be taken after removing connectors

After removing the connector, cover it with plastic bags to
prevent entry of dust, dirt, oil, or water in the contact por-
tion.
NOTICE
Be sure to cover the connector with plastic bags when
leaving the machine disassembled for a long time, oth-
erwise defective contact may occur.

Connecting connectors
1. Check the connector visually.

125E-7 SERIES 00-45

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
NECTORS 00 INDEX AND FOREWORD

• Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).
• Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.
• Check that there is no damage or crack on the external surfaces of the connectors.
NOTICE
• If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is
any water intrusion into the connector, warm the inside of the connector and harness with a dry-
er. Do not overheat the connector, otherwise short circuit may occur.
• If there is any damage or breakage, replace the connector.
2. Connecting the connector securely
Position connector (1) correctly, and fit it in securely.
REMARK
If the connector is lock stopper type, insert it until it clicks.
3. Correct the protrusion of the boot and misalignment of the
wiring harness.

• If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is
misaligned or the clamp is out of position, adjust it to its correct position.
REMARK
If the protrusion of the boot and misalignment of the
wiring harness cannot be fixed, remove the clamp to
adjust them.

• If the connector clamp is removed, be sure to return it

to its original position. Check that there is no loose-
ness.

Drying wiring harness

REMARK
If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing.
If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water
gets directly on the connector, do as follows.

00-46 125E-7 SERIES

 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
00 INDEX AND FOREWORD NECTORS

1. Disconnect the connector and wipe off the water with a dry
cloth.
NOTICE
If the connector is to be blown with dry compressed
air, there is the risk that oil in the air may cause defec-
tive contact, remove oil and water in the air before
starting air blow.

2. Dry the inside of the connector with a dryer.

If water enters inside the connector, use a dryer to dry the
connector.
NOTICE
Hot air from a dryer can be used, but limit the time of
using a dryer to prevent the connector or related parts
from becoming too hot, as this will cause deformation
or damage to the connector.

3. Perform a continuity test on the connector.

After drying, leave the wiring harness disconnected, con-
nect T-adapter(1), and perform a continuity test to check
for any short circuits between pins caused by water or etc.
REMARK
After the connector is completely dried, blow the contact
restorer, and reassemble them.

Handling controller
k When performing arc welding on the machine body, disconnect all of the wiring harness connectors
connected to the controller. Fit an arc welding ground close to the welding point.

125E-7 SERIES 00-47

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
NECTORS 00 INDEX AND FOREWORD

NOTICE
• Controller has been assembled with electronic circuits
for control including microcomputers. These electronic
circuits inside of the controller must be handled with
care since they control the machine.
• Do not leave things on the controller.
• Cover the connector portion of the controller with a
tape and a plastic bag. Do not touch the connecting
portion of connector.
• Do not leave the controller in a place where it is ex-
posed to rain.
• Do not place the controller on oil, water, soil or any pla-
ces where the temperature is likely to be high even for
a short period of time (Place it on a suitable dry stand).

Precautions for troubleshooting electrical circuits

• Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
• Before performing troubleshooting, check all the related connectors for loose connection.
REMARK
Check the related connectors for their performance by disconnecting and connecting them several times.
• Be sure to connect all the disconnected connectors before proceeding to the next step.
NOTICE
If the starting switch is turned to ON position while the connectors are disconnected, an unrelated
failure beside the actual failed part may be displayed.
• When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current,
etc.), shake the related wiring harnesses and connectors several times and check that the multimeter read-
ing does not change.
NOTICE
If the value changes on the multimeter, there may be a defective contact in the circuit.

00-48 125E-7 SERIES

 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH
00 INDEX AND FOREWORD CONNECTOR

METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNEC-

TOR
Method for disconnecting Deutsch connector
While pressing locks (a) and (b) from each side respectively,
pull out female connector (2).

Method for connecting Deutsch connector

1. Push in female connector (2) horizontally, and insert it
straight until it clicks. (Arrow: x)
2. In order to check whether locks (a) and (b) are completely
inserted, insert female connector (2) by rocking it vertically
(in the arrow z direction). (Arrow: x, y, z)
REMARK
Lock (a) in the figure is pulled down (not set completely),
and lock (b) is set completely.

125E-7 SERIES 00-49

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
TYPE CONNECTOR 00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE

CONNECTOR
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMA-
TOME-2)
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1) toward you.
REMARK
If portion A does not float when lock (L2) is pressed, and if
connector (1) does not come out when it is pulled toward
you, push up portion A with a small flat-head screwdriver
while pressing lock (L2), and then pull out connector (1) to-
ward you.

Method for connecting slide lock type connector (FRAMATOME-3, FRAMA-

TOME-2)
Insert it straight until it clicks.

Method for disconnecting slide lock type connector (FRAMATOME-24)

1. Slide down lock (red) (L1).

00-50 125E-7 SERIES

 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
00 INDEX AND FOREWORD TYPE CONNECTOR

2. While pressing lock (L2), pull out connector (1).

REMARK
Lock (L2) is located behind connector (1) in the figure.

Method for connecting slide lock type connector (FRAMATOME-24)

Insert it straight until it clicks.

125E-7 SERIES 00-51

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
WITH LOCK TO PULL 00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

LOCK TO PULL
Method for disconnecting connector with lock to pull
Disconnect the connector (2) by pulling lock (B) (on the wiring
harness side) of connector (2) outward.

Method for connecting connector with lock to pull

Insert the connector securely until it “clicks”.

00-52 125E-7 SERIES

 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
00 INDEX AND FOREWORD WITH LOCK TO PUSH

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

LOCK TO PUSH
Method for disconnecting connector with lock to push (BOSCH-3)
While pressing lock (C), pull out connector (3) in the direction of the arrow.
• 114 series

• 107 series

REMARK
If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers.
While pushing up lock (C) of the connector with flat-head
screwdriver [1], pull out connector (3) in the direction of the ar-
row.

Method for connecting connector with lock to push (BOSCH-3)

Insert it straight until it clicks.

125E-7 SERIES 00-53

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
WITH LOCK TO PUSH 00 INDEX AND FOREWORD

Method for disconnecting connector with lock to push (AMP-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.

Method for connecting connector with lock to push (AMP-3)

Insert it straight until it clicks.

Method for disconnecting connector with lock to push (SUMITOMO-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.
REMARK
Pull up the connector straight.

Method for connecting connector with lock to push (SUMITOMO-3)

Insert it straight until it clicks.

Method for disconnecting connector with lock to push (SUMITOMO-4)

While pressing lock (D), pull out connector (4) in the direction
of the arrow.

Method for connecting connector with lock to push (SUMITOMO-4)

Insert it straight until it clicks.

00-54 125E-7 SERIES

 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
00 INDEX AND FOREWORD WITH HOUSING TO ROTATE

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

HOUSING TO ROTATE
Method for disconnecting connector with housing to rotate
Turn housing (H1) to the left, and pull it out.
REMARK
Housing (H1) is left on the wiring harness side.

Method for connecting connector with housing to rotate

1. Insert the connector to the end while aligning its groove to the other.
2. Turn housing (H1) clockwise until it clicks.

125E-7 SERIES 00-55

HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD

HOW TO READ ELECTRICAL WIRE CODE

In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electrical wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No. of 0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in (Table 1).
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), the symbols are not indicated on
the diagram.)
Indicates size of wire by nominal No.
0.85
Sizes (Nominal Nos.) are shown in (Table 2).
Indicates color of wire by color code.
L
Color codes are shown in (Table 3).

Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the coating. CAVS has a circular com-
pressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating.
AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material
of the coating.
(Table 1)
Temperature
Sym- Conductor ma-
Type Insulator material range (°C) in Example of use
bol terial
use
Low-voltage For large current wiring
wire for auto- AV
mobile (nominal No. 5 and above)

Thin-cover
low-voltage
General wiring
wire for auto- AVS
mobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1)
Annealed cop-
Thin-cover per for electric
low-voltage appliance For mid- to small-size excava-
wire for auto- CAVS tors
mobile (nominal No. 1.25 and lower)
(Type 2)

Heat-resistant General wiring for extremely

low-voltage Heat-resistant cross- cold weather specification
AEX -50 to +110
wire for auto- linked polyethylene Wiring at high-temperature
mobile place

00-56 125E-7 SERIES

00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE

Dimensions

(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
20 7 30 11 50 16 37 26 58 41 65
strands
Diameter of
0.18 0.32 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor
Cross-sec-
tional area 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
(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 -
Coating D

AV Standard - - - - - - - 4.6
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
50 84 41 70 85 108 127 169 217
strands
Diameter of
0.45 0.45 0.80 0.80 0.80 0.80 0.80 0.80 0.80
strand
Conductor
Cross-sec-
tional area 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
(mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard - - - - - - - - -
Coating D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
- 7 - 11 - 16
strands
Diameter of round compres- round compres-
- - round compression
strand sion sion
Conductor
Cross-sec-
tional area - 0.56 - 0.88 - 1.29
(mm2)
d (approx.) - 0.9 - 1.1 - 1.4

125E-7 SERIES 00-57

HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Coating D

CAVS Standard - 1.6 - 1.8 - 2.1

REMARK
“f” of nominal No. denotes “flexible”.
Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green and White
Br Brown LgY Light green and Yellow
BrB Brown and Black LR Blue and Red
BrR Brown and Red LW Blue and White
BrW Brown and White LY Blue and Yellow
BrY Brown and Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red and Black
GB Green and Black RG Red and Green
GL Green and Blue RL Red and Blue
Gr Gray RW Red and White
GR Green and Red RY Red and Yellow
GW Green and White Sb Sky Blue
GY Green and Yellow Y Yellow
L Blue YB Yellow and Black
LB Blue and Black YG Yellow and Green
Lg Light green YL Yellow and Blue
LgB Light green and Black YR Yellow and Red
LgR Light green and Red YW Yellow and White

REMARK
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 indicates that the background is “Green” and marking is “White”.

00-58 125E-7 SERIES

00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE

Types of circuits and color codes

Type of wire AVS, AV, CAVS AEX
Charge R WG - - - - R -
Ground B - - - - - B -
Start R - - - - - R -
Light RW RB RY RG RL - O -
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 circuit Br BrW BrR BrY BrB - - -
Lg LgR LgY LgB LgW - - -
O - - - - - - -
Others Gr - - - - - - -
P - - - - - - -
Sb - - - - - - -
Dg - - - - - - -
Ch - - - - - - -

125E-7 SERIES 00-59

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

The maintenance standard section shows the judgment criteria whether the equipment or parts should be re-
placed or can be reused when the machine is disassembled for the maintenance. The following terms are the
descriptions of the judgment criteria.
Standard dimension and tolerance
• The finished dimension of a part is slightly different from one to another actually.
• A standard dimension of a finished part is set, and an allowable difference from that dimension is set for the
part.
• The dimension set as the standard is called the standard dimension and the allowable range of difference
from this standard dimension is called “tolerance”.
• An indication example of a standard dimension and tolerance is shown in the following table.
(The standard dimension is entered on the left side and the tolerance is entered with a positive or negative
symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126

• The tolerance may be indicated in the text and a table as “standard dimension (upper limit of tolerance/
lower limit of tolerance).”
Example) 120 (-0.022/ -0.126)
• Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by
the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is deter-
mined by the tolerance.
• A dimension indication example of a shaft and hole is shown in the following table.
(The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive
or negative symbol at the center and that of the hole on the right side)
Tolerance
Standard dimension
Shaft Hole
-0.030 +0.046
60
-0.076 0

00-60 125E-7 SERIES

00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

Standard clearance and standard value

• The clearance made when new parts are assembled is
called the standard clearance, which is indicated by the
range from the minimum clearance to the maximum clear-
ance.
• When some parts are repaired, the clearance is generally
adjusted to the standard clearance.
• The values indicating performance and function of new
products or equivalent are called “standard value”, which is
indicated by a range or a target value.
• When some parts are repaired, the value of performance/
function is set to the standard value.

Standard interference
• When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller
than that of the shaft to be inserted, the difference between those diameters is called “interference”.
• Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Sub-
tract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range
between (A) and (B) is “standard interference”.
• After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the
interference is in the standard range.
Repair limit and allowable value or allowable dimension
• The dimension of parts changes due to the wear or deformation while they are used. When the dimension
changes exceeding certain value, parts cannot be used any longer. This value is called “repair limit”.
• If a part is worn to the repair limit, it must be replaced or repaired.
• The performance and function of products lower while they are used. A value with which the product can be
used without causing a problem is called “allowable value” or “allowable dimension”.
• A product whose dimension is out of the allowable value, must be repaired. However, since the allowable
values are generally estimated through various tests or experiences in most cases, the judgment must be
made in consideration of the operating condition and customer's requirement.
Allowable clearance
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those
parts cannot be used is called “allowable clearance”.
• If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.
Allowable interference
• The allowable maximum interference between the hole of a part and the shaft of another part to be assem-
bled is called “allowable interference”.
• The allowable interference shows the repair limit of the part of smaller tolerance.

125E-7 SERIES 00-61

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD

• The parts whose interferences are out of the allowable interference must be replaced or repaired.

00-62 125E-7 SERIES

00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE

STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for bolts and nuts
REMARK
Tighten the metric nuts and bolts to the torque shown in the table below unless otherwise specified.

Thread diameter Width across flats

Tightening torque (Nm {kgm} )
(mm) (mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10 to 12.5}
(*1, *2) 17
14 22 153 to 190 {15.5 to 19.5}
24
16 235 to 285 {23.5 to 29.5}
(*1) 22
18 27 320 to 400 {33 to 41}
20 30 455 to 565 {46.5 to 58}
22 32 610 to 765 {62.5 to 78}
24 36 785 to 980 {80 to 100}
27 41 1150 to 1440 {118 to 147}
30 46 1520 to 1910 {155 to 195}
33 50 1960 to 2450 {200 to 250}
36 55 2450 to 3040 {250 to 310}
39 60 2890 to 3630 {295 to 370}

*1: Split flange bolt

*2: Flanged bolt
REMARK
Tighten the flanged bolt marked with “7” on the head as shown in the following to the tightening torque shown in
the table below.

125E-7 SERIES 00-63

STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

Thread diameter Width across flats

Tightening torque (Nm {kgm} )
(mm) (mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}

REMARK
Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise
specified.

Type of bolt A B

Nominal size - Tightening torque (Nm {kgm} ) Tightening torque (Nm {kgm} )

threads per inch Range Target Range Target
1/ 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
4-20UNC

5/ 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
16-18UNC

3/ 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
8-16UNC

7/ 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
16-14UNC

1/ 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
2-13UNC

9/ 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
16-12UNC

5/ 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
8-11UNC

3/ -10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
4

7/ 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
8-9UNC

00-64 125E-7 SERIES

00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE

Type of bolt A B

Nominal size - Tightening torque (Nm {kgm} ) Tightening torque (Nm {kgm} )

threads per inch Range Target Range Target
1-8UNC 883 to 1196 {90 to 122} 1040 {106} 245 to 333 {25 to 34} 284 {29}

11/8-7UNC 1187 to 1608 {121 to 164} 1393 {142} 333 to 451 {34 to 46} 392 {40}

11/4-7UNC 1598 to 2157 {163 to 220} 1873 {191} 451 to 608 {46 to 62} 530 {54}

11/2-6UNC 2354 to 3177 {240 to 324} 2765 {282} 657 to 892 {67 to 91} 775 {79}

REMARK
Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise speci-
fied.

Type of bolt A B

Nominal size - Tightening torque (Nm {kgm} ) Tightening torque (Nm {kgm} )

threads per inch Range Target Range Target
1/ 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
4-28UNF

5/ 34.3 to 39.2 {3.5 to 4} 34.3 {3.5} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
16-24UNF

3/ 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
8-24UNF

7/ 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
16-20UNF

1/ 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
2-20UNF

9/ 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.8 {6}
16-18UNF

5/ 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
8-18UNF

3/ 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
4-16UNF

7/ 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
8-14UNF

1-14UNF 1020 to 1373 {104 to 140} 1196 {122} 284 to 382 {29 to 39} 333 {34}

11/8-12UNF 1353 to 1844 {138 to 188} 1598 {163} 382 to 520 {39 to 53} 451 {46}

11/4-12UNF 1804 to 2432 {184 to 248} 2118 {216} 510 to 686 {52 to 70} 598 {61}

11/2-12UNF 2707 to 3658 {276 to 373} 3177 {324} 765 to 1030 {78 to 105} 892 {91}

125E-7 SERIES 00-65

STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

Table of tightening torque for O-ring boss piping joints

REMARK
Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.

Thread di- Width across Tightening torque (Nm {kgm} )

Nominal No.
ameter (mm) flats (mm) Range Target
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
- 18 59 to 98 {6.0 to 10.0} 78 {8.0}
Varies de-
03, 04 20 pending on 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 type of con- 128 to 186 {13.0 to 19.0} 157 {16.0}
nector.
10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1010 {76.0 to 103} 883 {90.0}

Table of tightening torque for O-ring boss plugs

REMARK
Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.

Thread diam- Width across Tightening torque (Nm {kgm} )

Nominal No.
eter (mm) flats (mm) Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}

00-66 125E-7 SERIES

00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE

Thread diam- Width across Tightening torque (Nm {kgm} )

Nominal No.
eter (mm) flats (mm) Range Target
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 - 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 - 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 - 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}

Table of tightening torque for hose (taper seal type and face seal type)
REMARK
• Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table un-
less otherwise specified.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).

Width Tightening torque (Nm {kgm} ) Taper seal Face seal

Nominal
across Nominal size - Thread root
No. of Thread size
flats Range Target threads per diameter(mm)
hose (mm)
(mm) inch (reference)
34 to 54 {3.5 to 5.5} 44 {4.5} - 9/ 14.3
16-18UN
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 - -
22 54 to 93 {5.5 to 9.5} 74 {7.5} - 11/ 17.5
16-16UN
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 - -
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/ -16UN 20.6
16

05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4

06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 13/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 - -
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 - -
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 - -

125E-7 SERIES 00-67

STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

Table of tightening torque for face seal joints

REMARK
• The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated
low pressure piping which is used for engine.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).
• Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.

Outside di- Tightening torque (Nm {kgm} ) Face seal

Width
ameter of Thread root diam-
across flats Nominal size -
adequate Range Target eter(mm) (refer-
(mm) threads per inch
pipe (mm) ence)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/ 14.3
16-18UN

10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/ -16UN 17.5

16

12 24 (27) 43 to 47 {4.4 to 4.8} 45 {4.6} 13/ 20.6

16-16UN

15 (16) 30 (32) 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4

22 (20) 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 13/16-12UN 30.2

Tightening torque table for bolts and nuts on 102, 107 and 114 series engines
REMARK
Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in
the following table unless otherwise specified.
Thread diameter (mm) Tightening torque (Nm {kgm} )
6 10±2 {1.02±0.20}
8 24±4 {2.45±0.41}
10 43±6 {4.38±0.61}
12 77±12 {7.85±1.22}
14 -

Tightening torque table for 102, 107, and 114 series engines (joint bolts)
REMARK
Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following
table unless otherwise specified.

00-68 125E-7 SERIES

00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE

Thread diameter (mm) Tightening torque (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}

Tightening torque table for tapered screws on 102, 107, and 114 series engines
(National taper pipe thread (NPT))
REMARK
Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the
torques shown in the following table unless otherwise specified.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque (Nm {kgm} ) Tightening torque (Nm {kgm} )
1/ 15±2 {1.53±0.20} 5±1 {0.51±0.10}
16

1/ 20±2 {2.04±0.20} 15±2 {1.53±0.20}

8

1/ 25±3 {2.55±0.31} 20±2 {2.04±0.20}

4

3/ 35±4 {3.57±0.41} 25±3 {2.55±0.31}

8

1/ 55±6 {5.61±0.61} 35±4 {3.57±0.41}

2

3/ 75±8 {7.65±0.82} 45±5 {4.59±0.51}

4

125E-7 SERIES 00-69

CONVERSION TABLE 00 INDEX AND FOREWORD

CONVERSION TABLE
Method of using the conversion table
The conversion table is provided to enable simple conversion of the numerical numbers between the different
units. For further details of the method of using the conversion table, see the examples given below.
Examples of using the conversion table to convert a unit from mm to in.
When converting 55 mm to in
1. Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A).
2. Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).
3. Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit
from mm to in. Accordingly, 55 mm = 2.165 in.
When converting 550 mm to in
1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left)
to get 55 mm.
2. Convert 55 mm to 2.165 in according to the preceding procedure.
3. The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point
one place to the right) to restore the target value. This gives 550 mm = 21.65 in
mm to in
(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 2.017 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 2.847 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 3.780 3.819 3.858 3.898

mm to in
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

00-70 125E-7 SERIES

00 INDEX AND FOREWORD CONVERSION TABLE

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
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 2.847 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

kg to lb
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

ℓ to U.S.Gal
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

ℓ to U.K.Gal
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

125E-7 SERIES 00-71

CONVERSION TABLE 00 INDEX AND FOREWORD

1 ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
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 lbft
1 kgm = 7.233 lbft
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

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

00-72 125E-7 SERIES

00 INDEX AND FOREWORD CONVERSION TABLE

1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
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 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa
is to see the number in the center column of the following table. The figures in the center of the following
table show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
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

125E-7 SERIES 00-73

CONVERSION TABLE 00 INDEX AND FOREWORD

1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-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

00-74 125E-7 SERIES

 01 SPECIFICATIONS

125E-7 SERIES 01-1

CONTENTS 01 SPECIFICATIONS

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 01-3
SPECIFICATIONS ......................................................................................................................................... 01-9
OUTLINE OF EXHAUST GAS REGULATION......................................................................................... 01-9
SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION............................... 01-10
IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION..................................01-11
LIST OF APPLICABLE MACHINES: 125E-7......................................................................................... 01-12
SPECIFICATIONS ................................................................................................................................ 01-13
SPECIFICATIONS: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18) .................... 01-13
SPECIFICATIONS: SAA6D125E-7 (HM300-5, HM300-5E0).......................................................... 01-14
SPECIFICATIONS: SAA6D125E-7 (PC490LC-11, PC490LCI-11) .................................................. 01-15
SPECIFICATIONS: SAA6D125E-7 (WA470-8)............................................................................... 01-16
SPECIFICATIONS: SAA6D125E-7 (WA475-10)............................................................................. 01-17
SPECIFICATIONS: SAA6D125E-7 (WA480-8)............................................................................... 01-18
ENGINE GENERAL VIEW .................................................................................................................... 01-19
ENGINE GENERAL VIEW: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18) ........ 01-19
ENGINE GENERAL VIEW: SAA6D125E-7 (HM300-5, HM300-5E0).............................................. 01-23
ENGINE GENERAL VIEW: SAA6D125E-7 (PC490LC-11, PC490LCI-11)...................................... 01-27
ENGINE GENERAL VIEW: SAA6D125E-7 (WA470-8) .................................................................. 01-31
ENGINE GENERAL VIEW: SAA6D125E-7 (WA475-10) ................................................................ 01-35
ENGINE GENERAL VIEW: SAA6D125E-7 (WA480-8) .................................................................. 01-39
WEIGHT TABLE ................................................................................................................................... 01-43
WEIGHT TABLE: 125E-7 ............................................................................................................... 01-43
ENGINE PERFORMANCE CURVE ...................................................................................................... 01-46
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18) ....
................................................................................................................................................... 01-46
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (HM300-5, HM300-5E0)................................ 01-47
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (PC490LC-11, PC490LCI-11) ........................ 01-48
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (WA470-8) .................................................... 01-49
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (WA475-10)................................................... 01-50
ENGINE PERFORMANCE CURVE: SAA6D125E-7 (WA480-8) .................................................... 01-51

01-2 125E-7 SERIES

01 SPECIFICATIONS ABBREVIATION LIST

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

125E-7 SERIES 01-3

ABBREVIATION LIST 01 SPECIFICATIONS

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

01-4 125E-7 SERIES

01 SPECIFICATIONS ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

125E-7 SERIES 01-5

ABBREVIATION LIST 01 SPECIFICATIONS

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actu-
system
ated, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for “International System of Units” It
SI al d' Unites (Internation- Unit is the universal unit system and “a single unit for
al unit system) a single quantity” is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

01-6 125E-7 SERIES

01 SPECIFICATIONS ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

125E-7 SERIES 01-7

ABBREVIATION LIST 01 SPECIFICATIONS

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

01-8 125E-7 SERIES

01 SPECIFICATIONS OUTLINE OF EXHAUST GAS REGULATION

SPECIFICATIONS
OUTLINE OF EXHAUST GAS REGULATION
• Diesel engines discharge the following 3 major materials
that have bad effects on the human body and environment.
NOx (nitrogen oxides): Respiratory disorder, acid rain
HC (Hydrocarbon): Photochemical smog
PM (particulate in air such as soot): Carcinogenic, respira-
tory disorder
• NOx is material which is produced at high temperature
from nitrogen (N2) and oxygen (O2) in the air. It is pro-
duced in the diesel engine because of excessive air (nitro-
gen). To reduce NOx, the combustion temperature in the
cylinder must be reduced to restrict oxidation of nitrogen.
For this purpose, the air from turbocharger (1) has been
cooled by air-cooled aftercooler (2) and recirculated (EGR
system).
• HC is the main component of the fuel. HC contained in the
blowby gas is the main part of the toxic material dis-
charged from the diesel engine, but it has been discharged
into the atmosphere.
• PM is produced by incomplete combustion of fuel, similarly
to HC. It is particles (solid matter) sticking soot, etc. Gener-
ally, if either of NOx and PM is reduced, the other increa-
ses. To reduced PM, common rail (3) is employed, and
electronically controlled high-pressure fuel injection system
is used to spray fuel finely, shorten the injection period, and improve the injection timing.
• Exhaust gas regulations are made and applied in Japan, USA, and EU. The following figure shows the his-
tory of the exhaust gas regulation in USA from Tier 1 to Tier4. (History of exhaust gas regulation by EPA
(*1) of USA (For engine rated horsepower: 130 to 560 kW))
The horizontal axis is NOx + NMHC (*2) and the vertical axis is PM. Discharge levels of both NOx + NMHC
and PM are reduced to almost 1/10 from Tier 3 to Tier 4 Final. This exhaust gas regulation is called “Tier 4
Final Regulation”.
*1: United States Environmental Protection Agency
*2: General term for hydrocarbon (HC) which highly causes
photochemical reaction.

125E-7 SERIES 01-9

OUTLINE OF EXHAUST GAS REGULATION 01 SPECIFICATIONS

SYSTEM DRAWINGS OF ENGINE CONFORMED TO TIER4 REGULATION

A: From atmosphere B: To atmosphere

1: Air cleaner 12: Engine oil pan
2: VGT 13: Engine
3: Air-cooled aftercooler 14: Mixing connector(*1)
4: Intake air heater 15: AdBlue/DEF mixing tube(*1)
5: Intake manifold 16: SCR assembly(*1)
6: Exhaust manifold 17: AdBlue/DEF tank(*1)
7: EGR valve 18: AdBlue/DEF pump(*1)
8: KCCV ventilator 19: AdBlue/DEF injector(*1)
9: KDPF 20: Engine controller
10: EGR cooler 21: Various sensors
11: Flywheel housing
*1: This may not be installed on some machine models and specifications.

01-10 125E-7 SERIES

01 SPECIFICATIONS OUTLINE OF EXHAUST GAS REGULATION

IMPROVED POINTS OF ENGINE CONFORMED TO TIER4 REGULATION

Improved points of Tier 4 Interim over Tier 3
• Increase of efficiency of EGR cooler (10) (Reduction of NOx)
• Increase of intake air (reduction of PM) in engine low speed range by variable rotation of turbocharger
(VGT)
• Oxygen density control (reduction of NOx and PM) by EGR ratio (*1) control matched to operating condition
which are attained by high-precision EGR valve (EGRV), intake air flow and temperature sensor (MAF), en-
gine controller, and sensing of various portions of EGR circui
• Fine fuel injection (reduction of PM) by increase of common rail pressure and fuel injection pressure
• Internal recirculation of blowby gas (reduction of HC) by employment of blowby reducing device (KCCV)
• Employment of soot collecting filter (KCSF) (reduction of PM)
• Control of dispersion of characteristics of injectors by engine controller
• Improvement of combustion chamber (reduction of NOx, reduction of PM, low fuel consumption)
• High altitude is recognized by ambient pressure sensor (PAMB), and fuel injection and VGT are controlled
automatically (reduction of NOx and PM at high altitude).
• Sensing of rotation of VGT (REV) (protection of VGT)
• Clogging of soot collecting filter (KCSF) is detected by differential pressure (dP) in KDPF, and engine con-
troller performs regeneration *2) as necessary (automatic regeneration) or performance of manual regener-
ation is displayed on machine monitor (maintenance of function of KDPF)
*1: EGR ratio means the ratio of EGR gas contained in the intake gas.
*2: Function to purify (burn) soot accumulated in soot collecting figure (KCSF) in KDPF.
Improved points of Tier 4 Final over Tier 4 Interim
• AdBlue/DEF is sprayed over toxic nitrogen oxides (NOx) contained in exhaust gas to be decomposed into
harmless nitrogen and water. Urea SCR system (*3) is employed for this purpose.
*3: Function to purify NOx by making ammonia in AdBlue/DEF react with NOx inside catalyst.

125E-7 SERIES 01-11

LIST OF APPLICABLE MACHINES: 125E-7 01 SPECIFICATIONS

LIST OF APPLICABLE MACHINES: 125E-7

Engine Applicable machines
D85EX–18
D85EXI–18
Bulldozer
D85PX–18
D85PXI–18
HM300–5
Articulated dump truck
SAA6D125E–7 HM300–5E0
PC490LC–11
Hydraulic excavator
PC490LCI–11
WA470–8
WA475–10 Wheel loader
WA480–8

01-12 125E-7 SERIES

01 SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS
SPECIFICATIONS: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18)
Engine model SAA6D125E–7
Number of cylinders - bore x stroke mm 6-125x150
Piston displacement ℓ{cc} 11.0{11040}
Firing order – 1–5–3–6–2–4
Overall length mm 1539
Overall width mm 1053

Dimensions Overall height (excluding

mm 1863
exhaust pipe)
Overall height (including ex-
mm –
haust pipe)

kW{HP}/min–
Rated horsepower 1{rpm}
199±6.0{266±8.0}/1900{1900}

Nm {kgm} /
Maximum torque 1272±38{130±3.9}/1400{1400}
min–1 {rpm}

Performance Max. speed with no load

min–1{rpm} 2100±50{2100±50}
(high idle speed)
Min. speed with no load
min–1{rpm} 750(+50/0){750(+50/0)}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 159±4.8{119±3.6}
rated point
Dry weight kg 1325
Fuel injection system – High pressure common rail type
Fuel injection system control – Electronic control type
Lubricating oil quantity (refill capacity) ℓ 47(38)
Coolant level ℓ 22
Alternator – 24 V, 90 A
Starting motor – 24 V, 7.5 kW or 11 kW
Turbocharger – KOMATSU, Model KTR85V

125E-7 SERIES 01-13

SPECIFICATIONS 01 SPECIFICATIONS

SPECIFICATIONS: SAA6D125E-7 (HM300-5, HM300-5E0)

Engine model SAA6D125E–7
Number of cylinders - bore x stroke mm 6-125x150
Piston displacement ℓ{cc} 11.0{11040}
Firing order – 1–5–3–6–2–4
Overall length mm 1415
Overall width mm 975

Dimensions Overall height (excluding

mm 1304
exhaust pipe)
Overall height (including
mm –
exhaust pipe)

kW{HP}/min–
Rated horsepower 1{rpm}
248±7.4{333±9.9}/2000{2000}

Nm {kgm} /
Maximum torque 1677±50{171±5.1}/1400{1400}
min–1 {rpm}

Performance Max. speed with no load

min–1{rpm} 2220±50{2220±50}
(high idle speed)
Min. speed with no load
min–1{rpm} 725(+50/0){725(+50/0)}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 216(+5/0){161(+5/0)}
rated point
Dry weight kg 1334
Fuel injection system – High pressure common rail type
Fuel injection system control – Electronic control type
Lubricating oil quantity (refill capacity) ℓ 47(38)
Coolant level ℓ 22
Alternator – 24 V, 90 A or 140 A
Starting motor – 24 V, 7.5 kW or 11 kW
Turbocharger – KOMATSU, Model KTR85V

01-14 125E-7 SERIES

01 SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS: SAA6D125E-7 (PC490LC-11, PC490LCI-11)

Engine model SAA6D125E–7
Number of cylinders - bore x stroke mm 6-125x150
Piston displacement ℓ{cc} 11.0{11040}
Firing order – 1–5–3–6–2–4
Overall length mm 1469
Overall width mm 1045

Dimensions Overall height (excluding

mm 1306
exhaust pipe)
Overall height (including ex-
mm –
haust pipe)

kW{HP}/min–
Rated horsepower 1{rpm}
270±8.1{362±10.9}/1900{1900}

Nm {kgm} /
Maximum torque 1510±45{154±4.6}/1400{1400}
min–1 {rpm}

Performance Max. speed with no load

min–1{rpm} 1930±25{1930±25}
(high idle speed)
Min. speed with no load
min–1{rpm} 1000±25{1000±25}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 210.7{157.2}
rated point
Dry weight kg 1316
Fuel injection system – High pressure common rail type
Fuel injection system control – Electronic control type
Lubricating oil quantity (refill capacity) ℓ 46(37)
Coolant level ℓ 22
Alternator – 24 V, 90 A
Starting motor – 24 V, 7.5 kW or 11 kW
Turbocharger – KOMATSU, Model KTR85V

125E-7 SERIES 01-15

SPECIFICATIONS 01 SPECIFICATIONS

SPECIFICATIONS: SAA6D125E-7 (WA470-8)

Engine model SAA6D125E–7
Number of cylinders - bore x stroke mm 6-125x150
Piston displacement ℓ{cc} 11.0{11040}
Firing order – 1–5–3–6–2–4
Overall length mm 1410
Overall width mm 998

Dimensions Overall height (excluding

mm 1261
exhaust pipe)
Overall height (including ex-
mm –
haust pipe)

kW{HP}/min–
Rated horsepower 1{rpm}
204±6.1{273.5±8.2}/2000{2000}

Nm {kgm} /
Maximum torque 1307±39{133.2±4.0}/1450{1450}
min–1 {rpm}

Performance Max. speed with no load

min–1{rpm} 2170±50{2170±50}
(high idle speed)
Min. speed with no load
min–1{rpm} 800(+50/0){800(+50/0)}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 220{164}
rated point
Dry weight kg 1325
Fuel injection system – High pressure common rail type
Fuel injection system control – Electronic control type
Lubricating oil quantity (refill capacity) ℓ 47(38)
Coolant level ℓ 22
Alternator – 24 V, 90 A or 140 A
Starting motor – 24 V, 7.5 kW or 11 kW
Turbocharger – KOMATSU, Model KTR85V

01-16 125E-7 SERIES

01 SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS: SAA6D125E-7 (WA475-10)

Engine model SAA6D125E–7
Number of cylinders - bore x stroke mm 6-125x150
Piston displacement ℓ{cc} 11.0{11040}
Firing order – 1–5–3–6–2–4
Overall length mm 1434
Overall width mm 998

Dimensions Overall height (excluding

mm 1261
exhaust pipe)
Overall height (including ex-
mm –
haust pipe)

kW{HP}/min–
Rated horsepower 1{rpm}
217±6.5{291.0±8.7}/1600{1600}

Nm {kgm} /
Maximum torque 1528±46{155.8±4.7}/1330{1330}
min–1 {rpm}

Performance Max. speed with no load

min–1{rpm} 1890±50{1890±50}
(high idle speed)
Min. speed with no load
min–1{rpm} 700(+50/0){700(+50/0)}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 207{154}
rated point
Dry weight kg 1380
Fuel injection system – High pressure common rail type
Fuel injection system control – Electronic control type
Lubricating oil quantity (refill capacity) ℓ 47(38)
Coolant level ℓ 22
Alternator – 24 V, 90 A, or 140 A
Starting motor – 24 V, 11 kW
Turbocharger – KOMATSU, Model KTR75V

125E-7 SERIES 01-17

SPECIFICATIONS 01 SPECIFICATIONS

SPECIFICATIONS: SAA6D125E-7 (WA480-8)

Engine model SAA6D125E–7
Number of cylinders - bore x stroke mm 6-125x150
Piston displacement ℓ{cc} 11.0{11040}
Firing order – 1–5–3–6–2–4
Overall length mm 1410
Overall width mm 998

Dimensions Overall height (excluding

mm 1261
exhaust pipe)
Overall height (including ex-
mm –
haust pipe)

kW{HP}/min–
Rated horsepower 1{rpm}
224±6.8 {300±9.1}/2000 {2000}

Nm{kgm}/min–
Maximum torque 1{rpm}
1359±41 {138.7±4.2}/1400{1400}

Performance Max. speed with no load

min–1{rpm} 2190±50 {2190±50}
(high idle speed)
Min. speed with no load
min–1{rpm} 800 (+50/0) {800 (+50/0)}
(low idle speed)
Fuel consumption ratio at
g/kWh{g/HPh} 220{164}
rated point
Dry weight kg 1370
Fuel injection system – High pressure common rail type
Fuel injection system control – Electronic control type
Lubricating oil quantity (refill capacity) ℓ 47(38)
Coolant level ℓ 22
Alternator – 24 V, 90 A or 140 A
Starting motor – 24 V, 7.5 kW or 11 kW
Turbocharger – KOMATSU, Model KTR85V

01-18 125E-7 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18,
D85PXI-18)
Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A): 1539 mm

125E-7 SERIES 01-19

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-20 125E-7 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1863 mm
Dimension (C): 392 mm
Dimension (D): 1053 mm

125E-7 SERIES 01-21

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-22 125E-7 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D125E-7 (HM300-5, HM300-5E0)

Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 1415 mm

125E-7 SERIES 01-23

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-24 125E-7 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B) : 1304 mm
Dimension (C) : 403 mm
Dimension (D) : 975 mm

125E-7 SERIES 01-25

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-26 125E-7 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D125E-7 (PC490LC-11, PC490LCI-11)

Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A) : 1469 mm

125E-7 SERIES 01-27

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-28 125E-7 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B) : 1306 mm
Dimension (C) : 441 mm
Dimension (D) : 1045 mm

125E-7 SERIES 01-29

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-30 125E-7 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D125E-7 (WA470-8)

Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A): 1410 mm

125E-7 SERIES 01-31

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-32 125E-7 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1261 mm
Dimension (C): 390 mm
Dimension (D): 998 mm

125E-7 SERIES 01-33

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-34 125E-7 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D125E-7 (WA475-10)

Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A): 1434 mm

125E-7 SERIES 01-35

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-36 125E-7 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front side view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1261 mm
Dimension (C): 390 mm
Dimension (D): 998 mm

125E-7 SERIES 01-37

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear side view

1: Center of crankshaft
2: Center of cylinder

01-38 125E-7 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

ENGINE GENERAL VIEW: SAA6D125E-7 (WA480-8)

Left side view

1: Center of crankshaft
2: Rear face of flywheel housing
Dimension (A): 1410 mm

125E-7 SERIES 01-39

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Right side view

1: Center of crankshaft
2: Rear face of flywheel housing

01-40 125E-7 SERIES

01 SPECIFICATIONS ENGINE GENERAL VIEW

Front view

1: Center of crankshaft
2: Center of cylinder
Dimension (B): 1261 mm
Dimension (C): 390 mm
Dimension (D): 998 mm

125E-7 SERIES 01-41

ENGINE GENERAL VIEW 01 SPECIFICATIONS

Rear view

1: Center of crankshaft
2: Center of cylinder

01-42 125E-7 SERIES

01 SPECIFICATIONS WEIGHT TABLE

WEIGHT TABLE
WEIGHT TABLE: 125E-7
Unit: kg
Item Component parts, specifications SAA6D125E–7
Turbocharger (VGT) VGT manufactured by KOMATSU 27
Cylinder head assem-
Cylinder head, valve, and valve spring 15
bly
Cylinder block assem- Cylinder block, main bearing, and main
269
bly bearing cap
Front cover – 34
PC490LC–11
18
PC490LCI–11
D85EX–18
D85EXI–18
D85PX–18
Engine oil pan – D85PXI–18
HM300–5 22
HM300–5E0
WA470–8
WA475-10
WA480–8
HM300–5
23
HM300–5E0
WA470–8
27
WA480–8
WA475-10 33
Flywheel assembly Flywheel and ring gear PC490LC–11
51
PC490LCI–11
D85EX–18
D85EXI–18
56
D85PX–18
D85PXI–18
HM300–5
HM300–5E0
47
WA470–8
WA480–8
D85EX–18
Flywheel housing as- D85EXI–18
–
sembly 64
D85PX–18
D85PXI–18
PC490LC–11
70
PC490LCI–11
WA475-10 78

125E-7 SERIES 01-43

WEIGHT TABLE 01 SPECIFICATIONS

Unit: kg
Item Component parts, specifications SAA6D125E–7
Crankshaft assembly Crankshaft and crank gear 103
Camshaft assembly Camshaft, cam gear, and thrust plate 16
Piston and connecting Piston, piston ring, piston pin, and con-
8
rod assembly necting rod
Engine oil pump – 5
Supply pump – 15
Water pump – 10
D85EX–18
D85EXI–18
D85PX–18
D85PXI–18
HM300–5
24 V, 90 A HM300–5E0 19
PC490LC–11
PC490LCI–11
Alternator
WA470–8
WA475-10
WA480–8
HM300–5
HM300–5E0
24 V, 140 A WA470–8 17
WA475-10
WA480–8
24 V, 7.5 kW 16
Starting motor
24 V, 11 kW 18
Engine boost oil pump – 5
EGR Valve – 11
EGR cooler – 11
WA480–8 57
WA475-10 61
WA470–8 71
D85EX–18
D85EXI–18
KDPF – D85PX–18
D85PXI–18
75
HM300–5
HM300–5E0
PC490LC–11
PC490LCI–11
KCCV ventilator – 3

01-44 125E-7 SERIES

01 SPECIFICATIONS WEIGHT TABLE

Unit: kg
Item Component parts, specifications SAA6D125E–7
WA475-10 44
WA480–8 47
D85EX–18
D85EXI–18
D85PX–18 68
SCR assembly – D85PXI–18
WA470–8
HM300–5
69
HM300–5E0
PC490LC–11
70
PC490LCI–11

125E-7 SERIES 01-45

ENGINE PERFORMANCE CURVE 01 SPECIFICATIONS

ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE: SAA6D125E-7 (D85EX-18, D85EXI-18,
D85PX-18, D85PXI-18)
Rated horsepower: 199±6.0 kW {266±8.0 HP} /1900 min-1 {1900 rpm} (Gross)
Max. torque: 1272±38 Nm {130±3.9 kgm} /1400 min-1 {1400 rpm} (Gross)

01-46 125E-7 SERIES

01 SPECIFICATIONS ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE: SAA6D125E-7 (HM300-5, HM300-5E0)

Rated horsepower: 248±7.4 kW {333±9.9 HP} /2000 min-1 {2000 rpm} (Gross)
Max. torque: 1677±50 Nm {171±5.1 kgm} /1400 min-1 {1400 rpm} (Gross)

1800
1600
1400

Torque (Nm)
1200
1000
800
600
400
200
0
-200
280
260
240
220
Flywheel horsepower (kW)

200
180
160
140
120
100
80
60
40
20
0

Engine speed (min-1)

$(

125E-7 SERIES 01-47

ENGINE PERFORMANCE CURVE 01 SPECIFICATIONS

ENGINE PERFORMANCE CURVE: SAA6D125E-7 (PC490LC-11, PC490LCI-11)

Rated horsepower: 270±8.1 kW{362±10.9 HP}/1900 min-1 {1900 rpm} (Gross)
Max. torque: 1510±45 Nm {154±4.6 kgm} /1400 min-1 {1400 rpm} (Gross)

1600

1400

1200

Torque (Nm)
1000

800

600

400

200

0
300
280
260
240
Flywheel horsepower (kW)

220
200
180
160
140
120
100
80
60
40
20
0

Engine speed (min-1)

$(

01-48 125E-7 SERIES

01 SPECIFICATIONS ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE: SAA6D125E-7 (WA470-8)

Rated horsepower: 204±6.1 kW {273.5±8.2 HP} /2000 min-1 {2000 rpm} (Gross)
Max. torque: 1307±39 Nm {133.2±4.0 kgm} /1450 min-1 {1450 rpm} (Gross)

125E-7 SERIES 01-49

ENGINE PERFORMANCE CURVE 01 SPECIFICATIONS

ENGINE PERFORMANCE CURVE: SAA6D125E-7 (WA475-10)

Rated horsepower: 217±6.5 kW {291.0±8.7 HP} /1600 min-1 {1600 rpm} (Gross)
Maximum torque: 1528±46 Nm {155.8±4.7 kgm} /1330 min-1 {1330 rpm} (Gross)

1600

1400

1200

Torque (Nm)
1000

800

600

400

200

0
260
240
220
200
Flywheel horsepower (kW)

180
160
140
120
100
80
60
40
20
0

Engine speed (min-1)

*

01-50 125E-7 SERIES

01 SPECIFICATIONS ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE: SAA6D125E-7 (WA480-8)

Rated horsepower: 224±6.8 kW {301±9.1 HP} /2000 min-1 {2000 rpm} (Gross)
Max. torque: 1359±41 Nm {138.7±4.2 kgm} /1400 min-1 {1400 rpm} (Gross)

1600

1400

1200

Torque (Nm)
1000

800

600

400

200

0
280
260
240
220
200
Flywheel horsepower (kW)

180
160
140
120
100
80
60
40
20
0

Engine speed (min-1)

$((

125E-7 SERIES 01-51

 10 STRUCTURE AND FUNCTION

125E-7 SERIES 10-1

CONTENTS 10 STRUCTURE AND FUNCTION

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 10-4
UREA SCR SYSTEM................................................................................................................................... 10-10
LAYOUT DRAWING OF UREA SCR SYSTEM ..................................................................................... 10-10
UREA SCR SYSTEM DIAGRAM .......................................................................................................... 10-15
FUNCTION OF UREA SCR SYSTEM................................................................................................... 10-16
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM ............................................................................ 10-16
INDUCEMENT STRATEGY ........................................................................................................... 10-19
COMPONENT PARTS OF UREA SCR SYSTEM.................................................................................. 10-33
AdBlue/DEF MIXING TUBE ........................................................................................................... 10-33
SCR ASSEMBLY ........................................................................................................................... 10-34
AdBlue/DEF TANK ......................................................................................................................... 10-36
AdBlue/DEF PUMP ........................................................................................................................ 10-38
AdBlue/DEF INJECTOR................................................................................................................. 10-39
AdBlue/DEF HOSE ........................................................................................................................ 10-40
AdBlue/DEF TANK HEATING VALVE............................................................................................. 10-41
ENGINE SYSTEM ....................................................................................................................................... 10-42
LAYOUT OF ENGINE COMPONENTS ................................................................................................. 10-42
LAYOUT DRAWING OF ENGINE COMPONENTS ........................................................................ 10-42
INTAKE AND EXHAUST SYSTEM PARTS ........................................................................................... 10-44
LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM.......................................................... 10-44
INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM................................................................ 10-45
FUNCTION OF INTAKE AND EXHAUST SYSTEM ....................................................................... 10-45
AIR CLEANER ............................................................................................................................... 10-47
ENGINE MAIN BODY PARTS............................................................................................................... 10-49
CYLINDER HEAD .......................................................................................................................... 10-49
CYLINDER BLOCK........................................................................................................................ 10-51
MAIN MOVING PARTS .................................................................................................................. 10-54
VIBRATION DAMPER.................................................................................................................... 10-57
TIMING GEAR ............................................................................................................................... 10-59
FRONT COVER............................................................................................................................. 10-61
VALVE SYSTEM ............................................................................................................................ 10-62
FLYWHEEL AND FLYWHEEL HOUSING ...................................................................................... 10-65
TURBOCHARGER SYSTEM ................................................................................................................ 10-66
CIRCUIT DIAGRAM OF VGT SYSTEM ......................................................................................... 10-66
FUNCTION OF VGT SYSTEM....................................................................................................... 10-67
VGT ............................................................................................................................................... 10-69
EGR SYSTEM ............................................................................................................................... 10-73
EGR VALVE ................................................................................................................................... 10-76
EGR COOLER ............................................................................................................................... 10-78
MIXING CONNECTOR .................................................................................................................. 10-79
KCCV SYSTEM ............................................................................................................................. 10-80
KCCV VENTILATOR ...................................................................................................................... 10-84
KDPF ............................................................................................................................................. 10-86
LUBRICATION SYSTEM....................................................................................................................... 10-90
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS............................................................. 10-90
LUBRICATION SYSTEM CIRCUIT DIAGRAM............................................................................... 10-91
ENGINE OIL PUMP ....................................................................................................................... 10-92
ENGINE BOOST OIL PUMP.......................................................................................................... 10-93
ENGINE OIL FILTER ..................................................................................................................... 10-94
ENGINE OIL COOLER .................................................................................................................. 10-95
ENGINE OIL PAN .......................................................................................................................... 10-97
FUEL SYSTEM ..................................................................................................................................... 10-98
LAYOUT DRAWING OF FUEL SYSTEM PARTS ........................................................................... 10-98
FUEL SYSTEM CIRCUIT DIAGRAM ............................................................................................. 10-99
FUNCTION OF FUEL SYSTEM ....................................................................................................10-100
OPERATION OF FUEL SYSTEM..................................................................................................10-100

10-2 125E-7 SERIES

10 STRUCTURE AND FUNCTION CONTENTS

CRI SYSTEM ................................................................................................................................10-101

SUPPLY PUMP.............................................................................................................................10-105
COMMON RAIL ............................................................................................................................10-108
INJECTOR .................................................................................................................................... 10-111
FUEL DOSING SYSTEM ..............................................................................................................10-115
FUEL PREFILTER ........................................................................................................................10-117
FUEL MAIN FILTER......................................................................................................................10-118
COOLING SYSTEM.............................................................................................................................10-119
LAYOUT DRAWING OF COOLING SYSTEM PARTS...................................................................10-119
COOLING SYSTEM CIRCUIT DIAGRAM .....................................................................................10-120
WATER PUMP ..............................................................................................................................10-121
THERMOSTAT..............................................................................................................................10-122
ELECTRICAL SYSTEM ..............................................................................................................................10-124
COMPONENT PARTS OF ELECTRICAL SYSTEM .............................................................................10-124
ALTERNATOR ..............................................................................................................................10-124
ALTERNATOR MOUNTING ..........................................................................................................10-128
STARTING MOTOR ......................................................................................................................10-129
ENGINE WIRING HARNESS........................................................................................................10-133
ENGINE CONTROLLER ...............................................................................................................10-135
FUEL FEED PUMP .......................................................................................................................10-143
FUEL FEED PUMP SWITCH ........................................................................................................10-144
SENSOR..............................................................................................................................................10-145
LAYOUT DRAWING OF ENGINE SENSOR .................................................................................10-145
STRUCTURE OF AMBIENT PRESSURE SENSOR .....................................................................10-149
FUNCTION OF AMBIENT PRESSURE SENSOR ........................................................................10-149
STRUCTURE OF ENGINE OIL PRESSURE SENSOR ................................................................10-150
FUNCTION OF ENGINE OIL PRESSURE SENSOR ....................................................................10-150
STRUCTURE OF CHARGE PRESSURE SENSOR......................................................................10-151
FUNCTION OF CHARGE PRESSURE SENSOR .........................................................................10-151
STRUCTURE OF CHARGE TEMPERATURE SENSOR...............................................................10-152
FUNCTION OF CHARGE TEMPERATURE SENSOR ..................................................................10-152
STRUCTURE OF COOLANT TEMPERATURE SENSOR.............................................................10-153
FUNCTION OF COOLANT TEMPERATURE SENSOR ................................................................10-153
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR ............................................................10-154
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR ...............................................................10-154
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR .............................................................10-155
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR.................................................................10-155
STRUCTURE OF COMMON RAIL PRESSURE SENSOR ...........................................................10-156
FUNCTION OF COMMON RAIL PRESSURE SENSOR ...............................................................10-156
STRUCTURE OF EGR VALVE LIFT SENSOR .............................................................................10-157
FUNCTION OF EGR VALVE LIFT SENSOR.................................................................................10-157
STRUCTURE OF VGT SPEED SENSOR.....................................................................................10-158
FUNCTION OF VGT SPEED SENSOR ........................................................................................10-158
STRUCTURE OF VGT POSITION SENSOR ................................................................................10-159
FUNCTION OF VGT POSITION SENSOR ...................................................................................10-159
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR .........................................10-160
FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR.............................................10-160
STRUCTURE OF DOSING FUEL PRESSURE SENSOR.............................................................10-161
FUNCTION OF DOSING FUEL PRESSURE SENSOR ................................................................10-161
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR .....10-162
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR .........10-162
STRUCTURE OF CRANKCASE PRESSURE SENSOR...............................................................10-163
FUNCTION OF CRANKCASE PRESSURE SENSOR ..................................................................10-163
STRUCTURE OF ENGINE OIL LEVEL SENSOR.........................................................................10-164
FUNCTION OF ENGINE OIL LEVEL SENSOR ............................................................................10-164
STRUCTURE OF AIR CLEANER CLOGGING SENSOR .............................................................10-165
FUNCTION OF AIR CLEANER CLOGGING SENSOR .................................................................10-165

125E-7 SERIES 10-3

ABBREVIATION LIST 10 STRUCTURE AND FUNCTION

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

10-4 125E-7 SERIES

10 STRUCTURE AND FUNCTION ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

125E-7 SERIES 10-5

ABBREVIATION LIST 10 STRUCTURE AND FUNCTION

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

10-6 125E-7 SERIES

10 STRUCTURE AND FUNCTION ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actu-
system
ated, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for “International System of Units” It
SI al d' Unites (Internation- Unit is the universal unit system and “a single unit for
al unit system) a single quantity” is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

125E-7 SERIES 10-7

ABBREVIATION LIST 10 STRUCTURE AND FUNCTION

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

10-8 125E-7 SERIES

10 STRUCTURE AND FUNCTION ABBREVIATION LIST

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

125E-7 SERIES 10-9

LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

UREA SCR SYSTEM

SCR
Abbreviation for Selective Catalytic Reduction

LAYOUT DRAWING OF UREA SCR SYSTEM

REMARK
The figure shows PC400, Model 11 as an example.

10-10 125E-7 SERIES

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UREA SCR SYSTEM

1: AdBlue/DEF tank 6: SCR assembly

2: Oil filler port 7: AdBlue/DEF injector
3: AdBlue/DEF return hose 8: AdBlue/DEF tank heating valve
4: AdBlue/DEF pump 9: AdBlue/DEF tank coolant inlet hose
5: AdBlue/DEF pressure hose 10: AdBlue/DEF suction hose

125E-7 SERIES 10-11

LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

11: KDPF 13: AdBlue/DEF injector coolant hose

12: AdBlue/DEF mixing tube 14: AdBlue/DEF tank coolant outlet hose

10-12 125E-7 SERIES

10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UREA SCR SYSTEM

Detailed drawing of SCR assembly

1: Turbocharger outlet NOx sensor 4: SCR outlet NOx sensor

2: Ammonia sensor 5: SCR outlet temperature sensor
3: SCR temperature sensor
Detailed drawing of AdBlue/DEF tank

1: AdBlue/DEF tank sensor

125E-7 SERIES 10-13

LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Layout drawing of engine room temperature sensor

1: Engine room temperature sensor

Layout drawing of ambient temperature sensor

1: Ambient temperature sensor

10-14 125E-7 SERIES

10 STRUCTURE AND FUNCTION UREA SCR SYSTEM DIAGRAM

UREA SCR SYSTEM DIAGRAM

1

4 7 8 17

2 5 6 15 18 19 20
9 16 26
3 A
11 12 13 B 21 23 24
10 27
14 22 25
28

29

30
35
37 32
A
B
36
39
40 38 33

34 31
A4P15760

A: Coolant inlet B: Coolant outlet

1: Mass air flow and temperature sensor 21: Ammonia sensor
2: Engine 22: Ammonia sensor controller
3: Engine controller 23: SCR temperature sensor
4: KDPF assembly 24: SCR outlet temperature sensor
5: KDOC unit 25: SCR temperature sensor controller
6: KCSF unit 26: SCR outlet NOx sensor
7: KDPF differential pressure sensor 27: SCR outlet NOx sensor controller
8: KDPF outlet pressure sensor 28: Smart sensor
9: Turbocharger outlet NOx sensor 29: Ambient temperature sensor
10: Turbocharger outlet NOx sensor controller 30: Engine room temperature sensor (*1)
11: KDOC inlet temperature sensor 31: AdBlue/DEF system
12: KDOC outlet temperature sensor 32: AdBlue/DEF tank heating valve
13: KDPF outlet temperature sensor 33: AdBlue/DEF tank
14: KDPF temperature sensor controller 34: AdBlue/DEF tank sensor
15: AdBlue/DEF mixing tube 35: AdBlue/DEF suction line
16: AdBlue/DEF injector 36: AdBlue/DEF return line
17: SCR assembly 37: AdBlue/DEF pressure line
18: Upstream SCR catalyst 38: AdBlue/DEF pump
19: Downstream SCR catalyst 39: AdBlue/DEF line heater relay
20: Ammonia oxidation catalyst 40: Machine monitor
*1: There are some machine models which are not equipped with it.

125E-7 SERIES 10-15

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

1: Engine 5: AdBlue/DEF injector

2: Engine controller 6: KDPF
3: AdBlue/DEF pump 7: SCR catalyst
4: AdBlue/DEF tank 8: Ammonia oxidation catalyst
• Urea SCR system is a device which converts toxic nitrogen oxides (NOx) in the exhaust gas into harmless
nitrogen and water.
• By spraying AdBlue/DEF into the exhaust gas, it decomposes and hydrolyzes to form ammonia (NH3) and
the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water.

FUNCTION OF AdBlue/DEF SUPPLY SYSTEM

1: AdBlue/DEF tank 5
2: AdBlue/DEF suction hose
6
3: AdBlue/DEF pump
4
3A: Flow control valve
3B: Pump
3C: AdBlue/DEF filter
3D: Pressure sensor 2
4: AdBlue/DEF return hose
1
5: AdBlue/DEF pressure hose
6: AdBlue/DEF injector 3A 3D
P
• AdBlue/DEF supply system consists of AdBlue/DEF tank
3C
(1), AdBlue/DEF hoses (2), (4), (5), AdBlue/DEF pump (3),
and AdBlue/DEF injector (6).
3B 3
• The AdBlue/DEF supply system is a part of the Komatsu
Urea SCR system and its function is to provide
AdBlue/DEF into the SCR Catalyst Assembly.
A4P15761
• However, the comprising devices, such as the AdBlue/DEF
pump, may not start functioning till certain conditions are
fulfilled.
• The AdBlue/DEF system has heating systems to thaw and prevent AdBlue/DEF from freezing because
AdBlue/DEF freezes at -11 °C.

10-16 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Function of AdBlue/DEF injection system

• The AdBlue/DEF pump pressurizes AdBlue/DEF and delivers it into the AdBlue/DEF mixing tube through
the AdBlue/DEF injector.
• The amount of AdBlue/DEF injection is controlled by the Engine Controller.
• The amount of AdBlue/DEF injection is calculated based on the information of the turbocharger outlet NOx
sensor, the SCR catalyst temperature sensor, the SCR outlet temperature sensor, the ammonia sensor, the
SCR outlet NOx sensor and the exhaust gas flow rate.
• AdBlue/DEF injection is also controlled by the system temperature because Urea SCR systems are not ef-
fective in low temperature. For the monitoring of the system temperature, the KDPF outlet temperature sen-
sor is used in addition to the SCR temperature sensors.
• If any abnormality is detected in any of the sensors that are used for the calculation of the amount of AdBl-
ue/DEF injection and the monitoring of the system temperature, the Engine Controller commands termina-
tion of AdBlue/DEF injection. When this occurs, alerts will be activated and failure codes will be registered.
• Some abnormalities may cause large amount of urea precipitation inside the AdBlue/DEF mixing tube and
result in deposit of urea on the inner surfaces. If it continues and urea deposit accumulates AdBlue/DEF
injection can be blocked at the AdBlue/DEF injector or the exhaust gas flow can be choked in the passag-
es.
Function of purge system
• The AdBlue/DEF purging is incorporated to purge remain- 5
ing AdBlue/DEF in the AdBlue/DEF injector, AdBlue/DEF
hoses and the AdBlue/DEF pump to prevent AdBlue/DEF 6
from solidifying inside by precipitation or freezing. 4
• The AdBlue/DEF purging is activated automatically when
the engine is shut down or the ambient temperature falls
so low that the heating systems is not capable of maintain-
ing fluidity of AdBlue/DEF.
2
• In the case of the AdBlue/DEF purging of the engine shut-
down, the purging operation continues several minutes af-
1
ter the engine stops. Once the purging operation com-
pletes, the Engine Controller shuts itself down automatical- 3A 3D
ly. P
NOTICE
3C

Do not turn the battery disconnect switch to OFF position

3B 3
till the System Operating Lamp in the battery box goes out.
The System Operating Lamp will go out when the system
shuts itself down after the purging operation completes.
A4P15762

Function of heating system

• Thawing control system has the thawing mode and freeze prevention mode.
• Thawing mode is the function to thaw the frozen AdBlue/DEF.
• After starting engine, if the engine controller judges that AdBlue/DEF must be thawed, this function au-
tomatically heats the system.
• At this time, pressure control of AdBlue/DEF pump and injection of AdBlue/DEF are not performed until
the thawing is completed.
• Freeze prevention mode is the function to keep AdBlue/DEF warm to prevent it from freezing.
• This function automatically heats the system to prevent it from freezing while operating the machine, if
engine controller judges that AdBlue/DEF could be frozen.
• This function stops the pressure control of AdBlue/DEF pump and injection of AdBlue/DEF if it judges
that AdBlue/DEF is frozen while operating the machine.

125E-7 SERIES 10-17

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

• Thawing and freeze prevention are controlled by sensor, and the control sensors vary by devices which
AdBlue/DEF system consists of. The following table shows the relationship between the object devices of
thawing control, heating system, and control sensors for each mode.

Object devices of thawing control, heating system, and control sensors for each mode
When the engine room temperature sensor is equipped
Heating system Thawing mode Freeze prevention mode
AdBlue/DEF suction and purge
hose Ambient temperature Ambient temperature
Heater around hose
AdBlue/DEF pressure hose (low- sensor sensor
temperature side)
AdBlue/DEF pressure hose (high- Engine room temperature Engine room temperature
Heater around hose
temperature side) sensor sensor
AdBlue/DEF pump tem- Ambient temperature
AdBlue/DEF pump Pump built-in heater
perature sensor sensor
AdBlue/DEF tank temper- AdBlue/DEF tank temper-
AdBlue/DEF tank Circulation of coolant
ature sensor ature sensor

When the engine room temperature sensor is not equipped

Heating system Thawing mode Freeze prevention mode
AdBlue/DEF suction and purge
hose Ambient temperature Ambient temperature
Heater around hose
sensor sensor
AdBlue/DEF pressure hose
AdBlue/DEF pump tem- Ambient temperature
AdBlue/DEF pump Pump built-in heater
perature sensor sensor
AdBlue/DEF tank temper- AdBlue/DEF tank temper-
AdBlue/DEF tank Circulation of coolant
ature sensor ature sensor

10-18 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

INDUCEMENT STRATEGY
• The purpose of inducement is to prompt the operator to perform maintenance or repair on the emissions
control system.
• Inducement strategy is a control action to ensure prompt correction of various failures in the engine emis-
sions control system. It requires actions to limit engine performance and defines required indication such as
warning lamps and messages, as well as alarms while the control actions are imposed.
The warning steps of Inducement are different between for North America and for European Union.
• The categories of abnormalities that have triggered Inducement are displayed on the “SCR Information”
screen of the machine monitor.

INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-

COMES LOW (FOR NORTH AMERICA)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
• The Inducement strategy progresses in 5 levels from Warning, Escalated Warning, Mild Inducement, Se-
vere Inducement and Final Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank. Final Inducement starts at 1 hour after the start of Severe Inducement
if the machine continues its operation without adding AdBlue/DEF into the tank, and reduces the engine
speed to low idle and keeps it at low idle.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
Red
10% CA3497
1: DEF low
1 Warning (The bottom level warning No sound (AdBlue/DEF No deration
two grada- appears. level low error
tions light on) 1)

5%
2: Without Red
(Within the CA3498
Escalated treatment, en- Triplet (*4)
2 Warning gradation of gine power (AdBlue/DEF No deration
Short intermit-
the second will be derat- level low error
(Warning 2) tently (*5)
from the bot- ed. 2)
tom )
Red

2.5%
Mild Induce- CA1673
ment (The grada- 3: Engine
Long intermit- (AdBlue/DEF Torque: over
3 tion of the end power is un-
(Inducement Red tently level low error 25%
of the bottom der deration.
1) 3)
lights on)

125E-7 SERIES 10-19

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
Red

CA1673
Severe In- 0% 4: Engine Torque: 50%
ducement CA3547
(All grada- power is un-
4 Continuously (AdBlue/DEF and
(Inducement tions lights der heavy de- Red
2) off) ration. level low error RPM: 40%
4)

Red

Not remaining CA1673

Final Induce- in the tank CA3547
ment (*6) 5: Engine is Engine speed
5 running at low Continuously AS00ZK is fixed to low
(Inducement (All grada- idle. Red (AdBlue/DEF idle
3) tions lights level low error
off) 5)

*1: It is shown the value of Monitoring ID 19111: “AdBlue/DEF Level Corrected”.

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR
UREA SCR SYSTEM”.
*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*4: Construction equipment with crawler
*5: Construction equipment with wheel
*6: After progressed “Severe Inducement” the status advances to “Final Inducement” with in 1 hour.

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE UREA SCR

SYSTEM DEVICES (FOR NORTH AMERICA)
• AdBlue/DEF system caution lamp lights up on machine monitor, and an action level is displayed when an
abnormality occurs in quality in AdBlue/DEF or in urea SCR system. In addition to the caution by the AdBl-
ue/DEF system caution lamp, alarm sounds as time passes after the abnormality occurred. Then, induce-
ment strategy starts so that the engine output is lowered.
• The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Informa-
tion” screen of the machine monitor.
• The table shows warning indications and engine power derations by each Inducement strategy status.

10-20 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Yellow

1: Please
inspect and CA3571
1 Warning 1 hour maintain No sound No indication No deration
SCR sys- Yellow CB3571
tem.

Yellow

2: Without Triplet (*6) AS00R2

Escalated treatment,
2 Warning 2 hours engine Short inter- CA3571 (Warning 2 No deration
power will Yellow mittently CB3571 (SCR Device
(Warning 2)
be derated. (*7) Abnormality))

Red

AS00R3
Mild In- 3: Engine
ducement power is Long inter- CA3571 (Inducement Torque: over
3 3 hours 1(SCR De-
(Induce- under dera- Red mittently CB3571 25%
tion. vice Abnor-
ment 1)
mality))

Red

4: Engine AS00R4 Torque:

Severe In-
ducement power is CA3571 (Inducement 50%
Continu-
4 4 hours under 2 (SCR De-
(Induce- Red ously CB3571 and
heavy dera- vice Abnor-
ment 2) tion. RPM: 40%
mality))

125E-7 SERIES 10-21

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

AS00R5
Final In- Engine
ducement 5: Engine is CA3571 (Inducement
Until repair- Continu- speed is
5 running at 3 (SCR De-
(Induce- ing Red ously CB3571 fixed to low
low idle. vice Abnor-
ment 3) idle
mality))

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYS-

TEM BY THE UREA SCR SYSTEM (FOR NORTH AMERICA)
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. It has 5 levels to-
tally which is the same as that, but it has different display on the machine monitor, and engine power dera-
tion (torque lowering ratio is 25% or more) and alarm starts from “Warning”.
• The table shows warning indications and engine power derations by each Inducement strategy status.

10-22 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

1: Please
inspect and CA4151
Long inter- Torque: over
1 Warning 1 hour maintain No indication
Red mittently CB4151 25%
SCR sys-
tem.

Red

2: Without Yellow
Triplet (*6) AS00R2
Escalated treatment,
2 Warning 2 hours engine Short inter- CA4151 (Warning 2 Torque: over
power will mittently CB4151 (SCR Device 25%
(Warning 2)
be derated. (*7) Abnormality))

Red

Red

Red AS00R3
Mild In- 3: Engine
ducement power is Long inter- CA4151 (Inducement Torque: over
3 3 hours 1 (SCR De-
(Induce- under dera- mittently CB4151 25%
tion. vice Abnor-
ment 1)
mality))
Red

125E-7 SERIES 10-23

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

4: Engine Red AS00R4 Torque:

Severe In-
ducement power is CA4151 (Inducement 50%
Continu-
4 4 hours under 2 (SCR De-
(Induce- ously CB4151 and
heavy de- vice Abnor-
ment 2) ration. RPM: 40%
mality))
Red

Red

Red AS00R5
Final In- Engine
ducement 5: Engine CA4151 (Inducement
Until repair- Continu- speed is
5 is running 3 (SCR De-
(Induce- ing ously CB4151 fixed to low
at low idle. vice Abnor-
ment 3) idle
mality))
Red

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing” stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel

10-24 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR NORTH

AMERICA)
• Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea
SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Mild Inducement” through
the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full engine pow-
er.
• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed, but “Temporary Restoration from Inducement” is turned off whenever the system advan-
ces to “Final Inducement” even if either 30 minutes or 3 operations are not used up. All the abnormalities of
the Urea SCR system need to be corrected to regain another restoration capability.
• If all the abnormalities of the Urea SCR system are not corrected when the system is in “Severe Induce-
ment”, the system advances to “Final Inducement” in 1 hour after “Severe Inducement” started and engine
speed will be fixed to low idle to disable practical machine operation.
• To activate Temporary Restoration, follow the procedures described below.
REMARK
For the operating procedure on this function, refer to “TEMPORARY RESTORATION FROM INDUCE-
MENT” on the OPERATION section in the Operation and Maintenance Manual.

INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40

HOURS (FOR NORTH AMERICA)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated and starts from “Severe Inducement”.
• The duration of “Severe Inducement” in the recurrence is limited to 30 minutes. If the abnormalities are not
corrected while Inducement is in “Severe Inducement (30 minutes)”, Inducement will advance to “Final In-
ducement” and engine speed will be fixed to low idle to disable practical machine operation.

INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-

COMES LOW (FOR EUROPEAN UNION)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
• The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low-Level Induce-
ment, and Severe Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
• The table shows warning indications and engine power derations by each Inducement strategy status.

125E-7 SERIES 10-25

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
Red
10% CA3497
1: DEF low
1 Warning (The bottom level warning No sound (AdBlue/DEF No deration
two grada- appears. level low error
tions light on) 1)

5%
2: Without Red
(Within the CA3498
Continuous treatment, en- Triplet (*4)
2 Warning gradation of gine power (AdBlue/DEF No deration
Short intermit-
the second will be derat- level low error
(Warning 2) tently (*5)
from the bot- ed. 2)
tom )
Red

2.5%
Low-Level In- CA1673
ducement (The grada- 3: Engine
Long intermit- (AdBlue/DEF Torque: over
3 tion of the end power is un-
(Inducement Red tently level low error 25%
of the bottom der deration.
1) 3)
lights on)

Red

CA1673
Severe In- 0% 4: Engine Torque: 50%
ducement CA3547
(All grada- power is un-
4 Continuously (AdBlue/DEF and
(Inducement tions lights der heavy de- Red
2) off) ration. level low error RPM: 40%
4)

*1: It is shown the value of Monitoring ID 19111: “AdBlue/DEF Level Corrected”.

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR
UREA SCR SYSTEM”.
*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*4: Construction equipment with crawler
*5: Construction equipment with wheel

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE AdBlue/DEF

QUALITY OR IN THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• AdBlue/DEF system caution lamp lights up on machine monitor, and an action level is displayed when an
abnormality occurs in quality in AdBlue/DEF or in urea SCR system. In addition to the caution by the AdBl-
ue/DEF system caution lamp, alarm sounds as time passes after the abnormality occurred. Then, induce-
ment strategy starts so that the engine output is lowered.

10-26 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

• The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Informa-
tion” screen of the machine monitor.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor
AdBlue/DE
Elapsed F system Failure code Engine de-
Status Message of caution Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- lamp for abnormali-
dible alert ment strategy
mation ty (*2),(*3)
(Action lev- status (*4)
el)
Yellow

1: Please
inspect and CA3571
1 Warning 5 hours maintain No sound No indication No deration
SCR sys- Yellow CB3571
tem.

Yellow

2: Without Triplet (*6) AS00R2

Continuous treatment,
2 Warning 10 hours engine Short inter- CA3571 (Warning 2 No deration
power will Yellow mittently CB3571 (SCR Device
(Warning 2)
be derated. (*7) Abnormality))

Red

AS00R3
Low-Level 3: Engine
Inducement power is Long inter- CA3571 (Inducement Torque: over
3 20 hours 1 (SCR De-
(Induce- under dera- Red mittently CB3571 25%
tion. vice Abnor-
ment 1)
mality))

Red

4: Engine AS00R4 Torque:

Severe In-
ducement power is CA3571 (Inducement 50%
Until repair- Continu-
4 under 2 (SCR De-
(Induce- ing Red ously CB3571 and
heavy dera- vice Abnor-
ment 2) tion. RPM: 40%
mality))

125E-7 SERIES 10-27

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing” stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. It has 4 levels to-
tally which is the same as that, but it has different display on the machine monitor, and engine power dera-
tion (torque lowering ratio is 25% or more) and alarm starts from “Warning”.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

1: Please
inspect and CA4151
Long inter- Torque: over
1 Warning 5 hours maintain No indication
Red mittently CB4151 25%
SCR sys-
tem.

Red

2: Without Yellow
Triplet (*6) AS00R2
Continuous treatment,
2 Warning 10 hours engine Short inter- CA4151 (Warning 2 Torque: over
power will mittently CB4151 (SCR Device 25%
(Warning 2)
be derated. (*7) Abnormality))

Red

10-28 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

Red AS00R3
Low-Level 3: Engine
Inducement power is Long inter- CA4151 (Inducement Torque: over
3 20 hours 1 (SCR De-
(Induce- under dera- mittently CB4151 25%
tion. vice Abnor-
ment 1)
mality))
Red

Red

4: Engine Red AS00R4 Torque:

Severe In-
ducement power is CA4151 (Inducement 50%
Until repair- Continu-
4 under 2 (SCR De-
(Induce- ing ously CB4151 and
heavy dera- vice Abnor-
ment 2) tion. RPM: 40%
mality))
Red

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel

125E-7 SERIES 10-29

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE EGR SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• The Inducement strategy is different if Inducement is triggered by abnormalities in EGR. It has 4 levels to-
tally which is the same as that, but it has different display on the machine monitor, and engine power dera-
tion (torque lowering ratio is 25% or more) and alarm starts from “Warning”.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

1: Please
inspect and CA2271
Long inter- Torque: over
1 Warning 5 hours maintain No indication
Red mittently CB2271 25%
SCR sys-
tem.

Red

2: Without Yellow
Triplet (*6) AS00R2
Continuous treatment,
2 Warning 10 hours engine Short inter- CA2271 (Warning 2 Torque: over
power will mittently CB2271 (SCR Device 25%
(Warning 2)
be derated. (*7) Abnormality))

Red

Red

Red AS00R3
Low-Level 3: Engine
Inducement power is Long inter- CA2271 (Inducement Torque: over
3 20 hours 1 (SCR De-
(Induce- under dera- mittently CB2271 25%
tion. vice Abnor-
ment 1)
mality))
Red

10-30 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

4: Engine Red AS00R4 Torque:

Severe In-
ducement power is CA2271 (Inducement 50%
Until repair- Continu-
4 under 2 (SCR De-
(Induce- ing ously CB2271 and
heavy dera- vice Abnor-
ment 2) tion. RPM: 40%
mality))
Red

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel

FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR EURO-

PEAN UNION)
• Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea
SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Low-Level Inducement”
through the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full en-
gine power.
• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed. All the abnormalities of the Urea SCR system need to be corrected to regain another re-
storation capability.
• To activate Temporary Restoration, follow the procedures described below.

125E-7 SERIES 10-31

FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

REMARK
For the operating procedure on this function, refer to “TEMPORARY RESTORATION FROM INDUCE-
MENT” on the OPERATION section in the Operation and Maintenance Manual.

INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40

HOURS (FOR EUROPEAN UNION)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated.
• Inducement in the recurrence resumes counting time at the time when the previous abnormalities were cor-
rected if the previous Inducement is in “Warning”, “Continuous Warning” or “Low-Level Inducement”. The
alerts resume the previous Inducement.
• If the time the previous abnormalities were corrected is in “Severe Inducement”, Inducement in the recur-
rence starts from “Low-Level Inducement” but the remaining time to “Severe Inducement” is 1 hour or 2
hours depending on abnormalities. If the 1 hour or 2 hours are used up without correcting the new abnor-
malities, Inducement will advance to “Severe Inducement” and engine power will be derated heavily.

10-32 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

COMPONENT PARTS OF UREA SCR SYSTEM

SCR
Abbreviation for Selective Catalytic Reduction

AdBlue/DEF MIXING TUBE

STRUCTURE OF AdBlue/DEF MIXING TUBE
REMARK
The shape is subject to machine models.

A: Exhaust gas inlet (from KDPF) B: Exhaust gas outlet (to SCR)
1: V clamp 4: AdBlue/DEF mixing tube (connector)
2: AdBlue/DEF injector 5: AdBlue/DEF mixing tube (tube)
3: Gasket for AdBlue/DEF injector

FUNCTION OF AdBlue/DEF MIXING TUBE

It mixes AdBlue/DEF injected from AdBlue/DEF injector with exhaust gas, and decomposes it to ammonia which
is needed to purge NOx from SCR assembly.

125E-7 SERIES 10-33

COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

SCR ASSEMBLY
SCR
Abbreviation for Selective Catalytic Reduction

STRUCTURE OF SCR ASSEMBLY

REMARK
The shape is subject to machine models.

10-34 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

18

20

14 15 16 17 19
A4P15765

A: From AdBlue/DEF mixing tube C: Water drain

B: To exhaust pipe
1: Inlet unit 11: SCR outlet NOx sensor
2: Upstream SCR catalyst unit 12: Water drain port
3: Downstream SCR catalyst unit 13: Hanger plate
4: Ammonia sensor 14: Rectifying plate
5: SCR temperature sensor 15: Upstream SCR catalyst
6: Temperature sensor controller 16: Downstream SCR catalyst
7: Sensor bracket 17: Ammonia oxidation catalyst
8: Sensor bracket band 18: Catalyzer holding mat
9: Outlet unit 19: Water dam
10: SCR outlet temperature sensor 20: Water baffle
• SCR assembly consists of the following: The inlet unit (1) which introduces the exhaust gas and equalize
the distribution of flow speed, the upstream SCR catalyst unit (2) which stores upstream SCR catalyst, the
downstream SCR catalyst unit (3) which stores downstream SCR catalyst and ammonia oxidation catalyst,
the outlet unit (9) which discharges the exhaust gas and as well as prevents rainwater from entering
through outlet into downstream SCR catalyst unit (3).
• Ammonia oxidation catalyst (17) oxidizes ammonia to water and nitrogen to prevent ammonia which is sup-
plied to SCR assembly from being released out because SCR catalysts (15) and (16) cannot completely
consume it.
• Each 1 piece of SCR temperature sensor (5), SCR outlet temperature sensor (10), ammonia sensor (4),
and SCR outlet NOx sensor (11) are installed. These sensors are usable for various troubleshooting, such
as they are used to control the feedback of denitration efficiency or they monitor that SCR catalyst properly
functions or not.
• Rectifying plate (14) equalizes the distribution of exhaust gas flow speed.
• SCR catalysts (15) and (16) use the ceramic honeycomb.
• The catalyzer holding mat (18) is made of a specific fiber and protects the ceramic catalyst against vibra-
tions by the engine and the machine body. It also restrains the temperature of outer periphery of SCR as-
sembly from becoming high caused by a heat transfer of the ceramics during operation.
• Water dam (19) is located at the upstream side of the outlet and prevents rainwater from entering into
downstream SCR catalyst unit (3).
• Water baffle (20) is located at the downstream side of the outlet and prevents rainwater at outlet from
splashing over the detection part of NOx sensor.

125E-7 SERIES 10-35

COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

AdBlue/DEF TANK
STRUCTURE OF AdBlue/DEF TANK

A: Coolant inlet D: From AdBlue/DEF pump

B: Coolant outlet E: To breather
C: To AdBlue/DEF pump
1: Sensor flange assembly 5: AdBlue/DEF tank sensor
2: Cap 6: AdBlue/DEF tank filter
3: Sight gauge 7: Drain plug
4: AdBlue/DEF tank

10-36 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

AdBlue/DEF TANK SENSOR

STRUCTURE OF AdBlue/DEF TANK SENSOR
REMARK
The shape is subject to machine models.

1: Connector 4: Level sensing part

2: Cover 5: Concentration Sensing part
3: Temperature sensing part

FUNCTION OF AdBlue/DEF TANK SENSOR

• This sensor is installed to AdBlue/DEF tank and outputs AdBlue/DEF level, AdBlue/DEF concentration, and
AdBlue/DEF temperature through CAN communication.
• AdBlue/DEF level and AdBlue/DEF concentration are measured by using ultrasonic wave.
• When the tank is frozen or empty, AdBlue/DEF level and AdBlue/DEF concentration are not measured.

125E-7 SERIES 10-37

COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

AdBlue/DEF PUMP
STRUCTURE OF AdBlue/DEF PUMP
A: Suction from AdBlue/DEF tank
B: Return to AdBlue/DEF tank
C: Pressurized sending to AdBlue/DEF injector
1: AdBlue/DEF pump
2: AdBlue/DEF inlet connector
3: AdBlue/DEF return connector (*1)
4: AdBlue/DEF outlet connector
5: Electric connector
6: AdBlue/DEF filter cap
7: AdBlue/DEF filter (built-in)
*1: There are some machine models which are not equipped
with check valve.

• The followings are built-in: The filter to collect the dust in

AdBlue/DEF, the valve to switch the flow direction when
purging, and the heater to thaw AdBlue/DEF when it is fro-
zen.
• It sucks AdBlue/DEF from AdBlue/DEF tank, pressurizes it
to 900 kPa {9.18 kg/cm2} , and sends it to AdBlue/DEF in- 2 3 4
jector.
• To prevent wrong connection of connectors, the return
connectors are white and can be distinguished from oth-
ers. The sizes of inlet connector and outlet connector are
different and they cannot be connected each other.
P

A4P15769

10-38 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

AdBlue/DEF INJECTOR
STRUCTURE OF AdBlue/DEF INJECTOR
A: Pressurized sending from AdBlue/DEF pump
B: Coolant inlet
C: Coolant outlet
1: AdBlue/DEF injector
2: AdBlue/DEF inlet connector
3: Coolant inlet connector
4: Coolant outlet connector
5: Electric connector

FUNCTION OF AdBlue/DEF INJECTOR

• It injects AdBlue/DEF which is pressurized by AdBlue/DEF pump into AdBlue/DEF mixing tube.
• The injection amount is controlled by the valve opening or closing time while the pressure is constant.
• It circulates the engine coolant to prevent it from being heated by the heat from the exhaust pipe.

OPERATION OF AdBlue/DEF INJECTOR

Principle of injection of the injector is described. Following fig-
ure shows the state of injection.
1. Engine controller sends the electrical signal to control
AdBlue/DEF injector.
2. Solenoid (4) moves seal ball (2), and seal ball (2) leaves
from injection port (1) to make opening state.
Pressurized AdBlue/DEF by AdBlue/DEF pump is injected.
3. When the electrical signal is not sent, seal ball (2) closes
injection port (1) with spring force (3), so AdBlue/DEF is
not injected.

125E-7 SERIES 10-39

COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

AdBlue/DEF HOSE
STRUCTURE OF AdBlue/DEF HOSE

1: Connector 5: Insulation tape

2: Housing 6: Heating wire
3: Coupling 7: Nylon tube
4: Corrugated tube
• It is used as AdBlue/DEF piping between AdBlue/DEF tank and AdBlue/DEF pump or between AdBlue/DEF
pump and AdBlue/DEF injector.
• The shape of the engaging portion between AdBlue/DEF tank and AdBlue/DEF pump or AdBlue/DEF injec-
tor pin is based on 3/8 inches or 5/16 inches of SAE J2044. It can be disconnected or connected with one
touch.
• There are 2 types of hose end shape such as straight shape and 90 deg. elbow shape.
• There are 2 types of nylon tubes of its outside diameter 5 mm and 8 mm. Choose the suitable one accord-
ing to the model and the part to use.

FUNCTION OF AdBlue/DEF HOSE

• In the cold weather, the specified current flows in the heating wire immediately after the engine is started. It
heats nylon tube and thaws AdBlue/DEF which has frozen in the nylon tube.
• It also keeps temperature constant to prevent AdBlue/DEF from freezing again while machine is operated.

10-40 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

AdBlue/DEF TANK HEATING VALVE

STRUCTURE OF AdBlue/DEF TANK HEATING VALVE

A: Engine coolant inlet B: Engine coolant outlet

1: Solenoid 5: Plunger
2: Solenoid core 6: Diaphragm
3: Solenoid coil 7: Valve
4: Spring

FUNCTION OF AdBlue/DEF TANK HEATING VALVE

• AdBlue/DEF tank heating valve thaws AdBlue/DEF tank, and opening/closing of the valve (7) is done by
solenoid (1).
• The opening position of valve is fixed and the control is only for opening/closing. When the solenoid (1) is
de-energized, the valve is closed.
• Diaphragm (6) prevents entering of engine coolant into solenoid (1).

OPERATION OF AdBlue/DEF TANK HEATING VALVE

1. When solenoid coil (3) is energized, solenoid core (2) is magnetized and pull plunger (5) to open valve (7)
which is directly connected to plunger (5).
2. When solenoid coil (3) is de-energized, solenoid core (2) loses pulling force and plunger (5) is pushed down
by spring (4) and valve (7) is closed.

125E-7 SERIES 10-41

LAYOUT OF ENGINE COMPONENTS 10 STRUCTURE AND FUNCTION

ENGINE SYSTEM
LAYOUT OF ENGINE COMPONENTS
LAYOUT DRAWING OF ENGINE COMPONENTS
REMARK
The shape is subject to machine models.
Sectional view

1: Cylinder block 11: Cylinder head cover

2: Cylinder liner 12: Camshaft
3: Piston 13: Ring gear
4: Connecting rod 14: Flywheel
5: Piston pin 15: Rear oil seal
6: Crosshead 16: Flywheel housing
7: Intake valve 17: Engine oil pan
8: Exhaust valve 18: Crankshaft
9: Rocker arm shaft 19: Main bearing cap
10: Injector 20: Oil strainer

10-42 125E-7 SERIES

10 STRUCTURE AND FUNCTION LAYOUT OF ENGINE COMPONENTS

21: Crankshaft gear 24: Crankshaft pulley

22: Front cover 25: Vibration damper
23: Front oil seal
General view

26: Exhaust manifold 31: Intake manifold

27: Turbocharger 32: Common rail
28: Cylinder head 33: Supply pump
29: Rocker arm 34: Cam follower
30: Push rod 35: Connecting rod cap

125E-7 SERIES 10-43

INTAKE AND EXHAUST SYSTEM PARTS 10 STRUCTURE AND FUNCTION

INTAKE AND EXHAUST SYSTEM PARTS

LAYOUT DRAWING OF INTAKE AND EXHAUST SYSTEM
REMARK
The shape is subject to machine models.

A: KDPF D: From air cleaner

B: From aftercooler E: To aftercooler
C: To intake manifold
1: VGT 4: Exhaust manifold
2: EGR valve 5: EGR cooler
3: Intake connector 6: Mixing connector

10-44 125E-7 SERIES

10 STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM PARTS

INTAKE AND EXHAUST SYSTEM CIRCUIT DIAGRAM

A: From atmosphere B: To atmosphere

1: Air cleaner 9: KDPF
2: VGT 10: EGR cooler
3: Air-cooled aftercooler 11: Flywheel housing
4: Intake air heater 12: Engine oil pan
5: Intake manifold 13: Engine
6: Exhaust manifold 14: Mixing connector
7: EGR valve 15: AdBlue/DEF mixing tube
8: KCCV ventilator 16: SCR assembly

FUNCTION OF INTAKE AND EXHAUST SYSTEM

• This engine is equipped with VGT (Variable Geometry Turbocharger), EGR system (EGR valve, EGR cool-
er) which recirculate a part of exhaust gas to the combustion chamber to reduce generation of NOx, KDPF
(KOMATSU Diesel Particulate Filter) which is an exhaust gas purifying device, and KCCV (KOMATSU
Closed Crankcase Ventilation) which recirculate the blowby gas.
• Since clean air is required to maintain the engine performance, the engine is damaged and its performance
is degraded, if it takes dirt or dust into it.
• Air is sucked into the engine through air cleaner (1), VGT (2), and air-cooled aftercooler (3).
Also, since VGT is equipped with the variable mechanism which is not installed to conventional turbocharg-
er, foreign material can damage VGT largely. Accordingly, cleaner or replace the air cleaner element ac-
cording to the procedure in Operation and Maintenance Manual, and take extreme care that foreign materi-
al does not enter.
• The intake air is sucked into the compressor side of VGT (2) through air cleaner (1). The air turbocharged
by VGT (2) is cooled by air-cooled aftercooler (3). Then, the air flows through mixing connector (14) and
intake manifold (5) into the cylinders and is used for combustion.

125E-7 SERIES 10-45

INTAKE AND EXHAUST SYSTEM PARTS 10 STRUCTURE AND FUNCTION

• The exhaust gas flows through exhaust manifold (6) to the turbine of VGT (2) and drives the turbine wheel
with its energy.
• To attain both clean exhaust gas and low fuel consumption, EGR system outputs signals from the engine
controller so that EGR valve (7) opens properly according to the engine load.
• When EGR valve (7) opens, a part of the exhaust gas (EGR gas) flows through exhaust manifold (6) and
EGR piping to EGR cooler.
• The exhaust gas cooled by EGR cooler (10) flows through EGR valve (7) and mixes with the intake air in
mixing connector (14), and then flows in intake manifold (5).
• KDPF (9) is installed to conform with the exhaust gas regulations and composed of KDOC (oxidation cata-
lyst) and KCSF (soot collecting filter).
• KDPF collects particulate soot contained in the exhaust gas of the engine to clean the exhaust gas.
• AdBlue/DEF mixing tube (15) mixes AdBlue/DEF injected by AdBlue/DEF injector with the exhaust gas to
hydrolyze the exhaust gas into ammonia at high temperature.(*1)
• SCR assembly (16) makes the ammonia decomposed in AdBlue/DEF mixing tube (15) react chemically
with toxic nitrogen oxides (NOx) contained in the exhaust gas in the catalyst, and decomposes them into
harmless nitrogen and water.(*1)
*1: This may not be installed on some machine models and specifications.

10-46 125E-7 SERIES

10 STRUCTURE AND FUNCTION INTAKE AND EXHAUST SYSTEM PARTS

AIR CLEANER
STRUCTURE OF AIR CLEANER
REMARK
The shape is subject to machine models.
General view and sectional view

1: Vacuator valve 5: Mass air flow and temperature sensor mounting

2: Inlet portion

3: Air cleaner clogging sensor or dust indicator mount- 6: Rectifying wire net
ing portion 7: Outer element
4: Outlet 8: Inner element

SPECIFICATIONS OF AIR CLEANER

Type: Cycropac type
Filtering area (outer cylinder): 14.7 m2
Filtering area (inner cylinder): 1.85 m2

OPERATION OF AIR CLEANER

1. Since inlet (2) is placed in the tangential direction, the intake air swirls along the body and generates a cen-
trifugal force.
2. The dust in the intake air is separated by the centrifugal separation effect.
3. Outer element (7) removes dust 99.9 % or more, and only clean air passes through inner element (8) and
rectifying wire net (6), and is sucked into engine through outlet (4).
4. Rectifying wire net (6) rectifies the intake air flow and the air flow to the temperature sensor which have
large effects on control of the engine.

125E-7 SERIES 10-47

INTAKE AND EXHAUST SYSTEM PARTS 10 STRUCTURE AND FUNCTION

5. The dust removed during the air intake process is automatically discharged out through vacuator valve (1)
when the engine stops.

10-48 125E-7 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

ENGINE MAIN BODY PARTS

CYLINDER HEAD
STRUCTURE OF CYLINDER HEAD
REMARK
The shape is subject to machine models.
General view and sectional view

1: Coolant air tube 6: Cylinder head

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

125E-7 SERIES 10-49

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

SPECIFICATIONS OF CYLINDER HEAD

Cylinder head
Direct fuel injection type
4-valve
Overhead injector (common rail specification)
Split-type 1-cylinder head, 1-head
Valve seat
Press-fitted valve seat inserts on both intake and exhaust sides
Head cover
Float type seal

10-50 125E-7 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

CYLINDER BLOCK
STRUCTURE OF CYLINDER BLOCK
REMARK
The shape is subject to machine models.
General view and sectional view

1: Cylinder block 7: Front cover

2: Cylinder liner 8: Main bearing cap bolt
3: Clevis seal 9: Main bearing cap
4: Liner ring (ethylene-propylene rubber) 10: Main bearing
5: Liner ring (Silicon rubber) 11: Thrust bearing
6: Front seal 12: Piston cooling nozzle

125E-7 SERIES 10-51

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

Sectional view

SPECIFICATIONS OF CYLINDER BLOCK

Cylinder block
Crankshaft portion: 7 bearings
Camshaft portion: 7 bearings
Front seal
Single lip with dust seal
Piston cooling
With piston cooling nozzle
Cylinder liner
Wet type
Inside wall finish: Plateau honing and nitrocarburizing
Liner ring
Top: Clevis seal

10-52 125E-7 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

Middle: Liner ring (ethylene-propylene rubber)

Lower: Liner ring (silicon rubber)

125E-7 SERIES 10-53

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

MAIN MOVING PARTS

STRUCTURE OF MAIN MOVING PARTS
REMARK
The shape is subject to machine models.
Sectional view

1: Piston 6: Connecting rod cap

2: Connecting rod bushing 7: Connecting rod bearing
3: Piston pin 8: Connecting rod
4: Crankshaft 9: Connecting rod cap bolt
5: Crankshaft gear (number teeth: 33)

10-54 125E-7 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

10: Top ring 12: Oil ring

11: Second ring

SPECIFICATIONS OF MAIN MOVING PARTS

Crankshaft: Closed-die forged, journal portions and fillet portions are induction-hardened
Piston: Thin structure of ductile special cast iron (FCD piston), with re-entrant combustion chamber
With connecting rod lubrication hole
With piston cooling from connecting rod end

FEATURES OF FCD PISTON

• It has a high heat resistance.
• Since the coefficient of thermal expansion factor is small, the clearance between the liner and piston can be
reduced.
• Since the strength is high, the top ring can be installed to an upper position, thus the combustion chamber
loss area can be reduced and high combustion efficiency is obtained.
• It generates low noise and better exhaust gas color.
• High output can be obtained.

125E-7 SERIES 10-55

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

PISTON RING
STRUCTURE OF PISTON RING
Sectional view
1: Top ring
2: Second ring
3: Oil ring

Structure
Top ring (1) is a keystone, inner cut, barrel face, hard chrome plated ring.
Second ring (2) is a keystone, inner cut, taper face, hard chrome plated ring.
Oil ring (3) is a coil spring loaded and surface nitrided ring.

10-56 125E-7 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

VIBRATION DAMPER
STRUCTURE OF VIBRATION DAMPER
REMARK
The shape is subject to machine models.
General view

1: Vibration damper 3: Damper bolt

2: Dowel pin

125E-7 SERIES 10-57

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

Sectional view

1: Vibration damper 4: Crankshaft pulley mounting bolt:

2: Dowel pin (for positioning damper) 5: Vibration damper mounting bolt
3: Crankshaft pulley

FUNCTION OF VIBRATION DAMPER

Vibration damper (1) absorbs torsional vibration acting on the crankshaft and prevents breakage of the crank-
shaft and abnormal wear of the shaft and gears.

10-58 125E-7 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

TIMING GEAR
STRUCTURE OF TIMING GEAR
REMARK
The shape is subject to machine models.
General view

A: Match mark of crankshaft gear and large main idler C: Match mark of camshaft gear and supply pump
gear gear
B: Match mark of small main idler gear and camshaft
gear
1: Cylinder block

125E-7 SERIES 10-59

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

Sectional view

2: Water pump drive gear (number of teeth: 22) 8: Injection drive gear (number of teeth: 44)
3: Large main idler gear (number of teeth: 57) 9: Front cover
4: EGR oil pump drive gear (number of teeth: 20) 10: Camshaft gear (number of teeth: 44)
5: Small main idler gear (number of teeth: 38) 11: Crankshaft gear (number teeth: 33)
6: Engine oil pump drive gear (number of teeth: 21) 12: Crankshaft
7: Engine oil pump idler gear (number of teeth: 25)

10-60 125E-7 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

FRONT COVER
STRUCTURE OF FRONT COVER
REMARK
The shape is subject to machine models.
General view

A: Engine boost oil pump mounting hole B: Installation position of VGT control EPC valve
1: Front cover

125E-7 SERIES 10-61

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

VALVE SYSTEM
STRUCTURE OF VALVE SYSTEM
General view and sectional view

1: Rocker arm shaft 4: Camshaft

2: Cam roller 5: Camshaft gear
3: Cam roller pin

10-62 125E-7 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

Sectional view

A: Intake side of No. 1 cylinder B: Exhaust side of No. 1 cylinder

6: Adjustment screw 14: Lock nut
7: Lock nut 15: Rocker arm
8: Crosshead 16: Push rod
9: Valve seat (upper) 17: Cam follower
10: Intake valve 18: Valve cotter
11: Valve spring 19: Exhaust valve
12: Valve spring seat (lower) (both IN and EX) 20: Valve stem seal (both IN and EX)
13: Adjustment screw

125E-7 SERIES 10-63

ENGINE MAIN BODY PARTS 10 STRUCTURE AND FUNCTION

Valve timing
A: Intake valve OPEN
B: Exhaust valve CLOSE
C: Exhaust valve OPEN
D: Intake valve CLOSE
R: Rotation direction
T.D.C: Top dead center
B.D.C: Bottom dead center

SPECIFICATIONS OF VALVE SYSTEM

Camshaft: Closed die forging
Journal portion, cam portion: Induction hardening

10-64 125E-7 SERIES

10 STRUCTURE AND FUNCTION ENGINE MAIN BODY PARTS

FLYWHEEL AND FLYWHEEL HOUSING

STRUCTURE OF FLYWHEEL AND FLYWHEEL HOUSING
REMARK
The shape is subject to machine models.
General view and sectional view

1: Flywheel housing 3: Flywheel

2: Ring gear 4: Rear seal

SPECIFICATIONS OF FLYWHEEL AND FLYWHEEL HOUSING

Number of teeth of ring gear: 148
Number of internal teeth of flywheel: -

125E-7 SERIES 10-65

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

TURBOCHARGER SYSTEM
CIRCUIT DIAGRAM OF VGT SYSTEM

C: Blower impeller T: Turbine impeller

1: Air Cleaner 7: Engine controller
2: Mass air flow and temperature sensor 8: EPC valve (for VGT)
3: VGT 9: KDPF
4: VGT speed sensor 10: SCR assembly(*1)
5: VGT position sensor 11: EGR system (EGR cooler, EGR valve)
6: Hydraulic actuator 12: EGR valve lift sensor
*1: This may not be installed on some machine models and specifications.

10-66 125E-7 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

FUNCTION OF VGT SYSTEM

VGT Control System

C: Blower impeller T: Turbine impeller

1: Air cleaner 8: EPC valve (for VGT)
2: Mass air flow and temperature sensor 9: KDPF
3: VGT 10:AdBlue/DEF mixing tube(*1)
4: VGT speed sensor 11:SCR assembly(*1)
5: VGT position sensor 12: EGR system (EGR cooler, EGR valve)
6: Hydraulic actuator 13: EGR valve lift sensor
7: Engine controller
*1: This may not be installed on some machine models and specifications.
• Engine controller (7) processes the data of VGT position sensor (5), intake air flow and temperature sensor
(2), VGT speed sensor, etc. and sends the result to hydraulic actuator (6) via oil pressure controlled by EPC
valve to move the piston.
• High altitude is recognized by the ambient pressure sensor, and the fuel injection and VGT are controlled
automatically to secure better response at high altitude.
• The rotation of VGT is controlled to protect VGT from overspeed.
Lubrication
• The lubricating oil cooled by the engine oil cooler is supplied through the feed pipe to VGT.
• The oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing.
• The return oil flows through the return pipe connected to under the bearing housing and falls into the engine
oil pan.
Cooling
• The coolant from the cylinder block flows into the center housing to cool VGT.

125E-7 SERIES 10-67

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

• The return coolant flows from the center housing to the radiator.

10-68 125E-7 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

VGT
VGT
Abbreviation for Variable Geometry Turbocharger

STRUCTURE OF VGT
REMARK
The shape is subject to machine models.
General view, sectional view

A: Intake air inlet C: Exhaust inlet

B: Intake air outlet D: Exhaust outlet

125E-7 SERIES 10-69

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

1: Blower housing 7: Nozzle ring

2: VGT speed sensor 8: Push rod
3: Hydraulic actuator 9: Shaft
4: Turbine housing 10: Blower impeller
5: Plate 11: Turbine impeller
6: Vane 12: Piston

FUNCTION OF VGT

C: Blower impeller T: Turbine impeller

1: Air cleaner 5: SCR assembly(*1)
2: VGT 6: EGR cooler
3: KDPF 7: EGR valve
4: AdBlue/DEF mixing tube(*1)
*1: This may not be installed on some machine models and specifications.
• The exhaust gas regulations are applied to the exhaust gas from the engine running at low speed, as well
as at high speed. To meet this, the EGR ratio is improved. (EGR ratio = Ratio of amount of EGR to amount
of fresh suction air)
• To attain high EGR ratio, turbine inlet pressure (P3) must be set higher than boost pressure (P2) (P3 > P2).
For this reason, the variable turbocharger (VGT) is employed, in which the exhaust gas pressure acting on
turbine impeller (T) is adjustable.
Also, since the boost pressure increases more quickly, generation of particulate caused by lack of oxygen
during low-speed operation (rotation) is reduced.
• The shaft joined to turbine impeller (T) drives blower impeller (C) and sends much air to the cylinder for
combustion.
If VGT (2) sends more air, the fuel injection rate can be increased, thus the engine output is increased.
In addition, the air cooled by aftercooler becomes dense, that is, more oxygen is supplied, thus the fuel in-
jection rate can be increased and the engine output is increased.
NOTICE
Adequate amount of clean high quality oil is required to maintain VGT performance. Be sure to use Ko-
matsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.
REMARK
It sounds like air is leaking from VGT or a boost pipe, but it is not abnormal.

10-70 125E-7 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

OPERATION OF VGT

1. The exhaust gas enters (C) of turbine housing (4) and flows out through portion (P) and (D). Portion (P) is
surrounded by plate (5) fixed to turbine housing, nozzle ring (7), and vanes (6).
The area of its passage is changed by sliding push rod (8) to the right or left.
2. Hydraulic actuator (3) moves piston (12) in the actuator up and down with the hydraulic pressure controlled
by EPC valve installed to the front cover, and slides push rod (8) to the right and left.
3. The exhaust gas flowing through vanes (6) rotates blower impeller (10) through shaft (9) joined to turbine
impeller (11). As the result, the blower impeller works as a compressor, and the intake air entering through
(A) is compressed and discharge through (B).
4. When the exhaust gas pressure at inlet (C) of turbine housing (4) is low (engine speed is in low range),
push rod (8) slides to the right and narrows portion (P).
5. The exhaust gas acting on turbine impeller (11) increases, the turbocharger speed increases, and more air
(oxygen) is taken in.
VGT speed sensor (2) detects the rotation of the turbocharger.
When nozzle ring is “closed”
1. During low speed operation (rotation), exhaust gas inlet
passage (P) is narrow (L1). (It is not fully closed, however.)
2. If the turbine inlet pressure increases while the nozzle ring
is closed, the turbine inflow speed increases, and accord-
ingly the turbocharger speed increases.

125E-7 SERIES 10-71

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

When nozzle ring is “open”

1. During high speed operation (rotation), exhaust gas inlet
passage (P) is wide (L2).
2. As the engine speed increases and the turbine inlet pres-
sure (exhaust gas pressure) increases exhaust gas inlet
passage (P) is widened (L2) so that the exhaust gas acts
on turbine impeller (11) efficiently.
REMARK
• Nozzle ring (7), vanes (6), and push rod (8) are all-in-one
unit, and it slides only and does not rotate.
• Hydraulic actuator (3) is equipped with VGT position sen-
sor. VGT position sensor is calibrated together with the vari-
able mechanism of VGT and the result is written in the
memory in VGT position sensor. Accordingly, if any of hy-
draulic actuator (3), VGT position sensor, and VGT unit
fails, whole VGT must be replaced.
Operation of hydraulic actuator
1. Hydraulic actuator (1) is controlled by EPC valve (2) instal-
led to the front cover and driven hydraulically.
2. The hydraulic pressure supplied by engine boost oil pump
(3) is used for this purpose.
3. The position of hydraulic actuator (1) is fed back to engine
controller by the signals from VGT position sensor (4).

10-72 125E-7 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

EGR SYSTEM
EGR
Abbreviation for Exhaust Gas Recirculation

LAYOUT DRAWING OF EGR SYSTEM

REMARK
The shape is subject to machine models.

1: VGT 5: Exhaust manifold

2: EGR valve 6: EGR cooler
3: Intake connector 7: Mixing connector
4: Intake manifold

125E-7 SERIES 10-73

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF EGR SYSTEM

• EGR valve (hydraulically driven) (2) controls the gas flowing from the exhaust section to the intake section.
Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows to the intake section.
• EGR cooler (6) cools the exhaust gas.
Engine coolant is used to cool the exhaust gas.
• Mixing connector (7) returns the air from the air-cooled aftercooler and the exhaust gas from EGR valve (2)
to the intake section.
• Exhaust gas is always clean with this system which controls EGR circuit based on information sent from
sensor installed to each part to obtain EGR rate according to the operating condition. (EGR ratio means the
ratio of EGR gas contained in the intake gas.)
• Monitors EGR circuit for troubleshooting with sensor installed to each part to prevent a serious failure from
occurring.

CIRCUIT DIAGRAM OF EGR SYSTEM

C: Blower impeller T: Turbine impeller

1: Air cleaner 11: Hydraulic actuator (power piston)
2:VGT 12: EPC valve (for EGR valve)
3: KDPF 13: EGR valve lift sensor
4:AdBlue/DEF mixing tube(*1) 14: Exhaust manifold
5:SCR assembly(*1) 15: Engine boost oil pump
6: Ambient pressure sensor 16: Intake manifold
7: After cooler 17: Charge (boost) pressure and temperature sensor
8: EGR cooler 18: Engine controller
9:EGR unit 19: Mixing connector
10: EGR valve
*1: This may not be installed on some machine models and specifications.

10-74 125E-7 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

OPERATION OF EGR SYSTEM

1. The engine controller outputs signals in order to open EGR valve (10) most properly in accordance with the
engine load, so that both of the clean exhausting gas and low fuel consumption can be achieved.
2. When EGR valve (10) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (14) into
EGR cooler (8) through the EGR piping.
3. The exhaust gas cooled by EGR cooler (8) flows through EGR valve (10), merges with the supply air in the
mixing connector (19), and flows into the air intake manifold (16).

125E-7 SERIES 10-75

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

EGR VALVE
EGR
Abbreviation for Exhaust Gas Recirculation

STRUCTURE OF EGR VALVE

REMARK
The shape is subject to machine models.
Sectional view

A: EGR gas inlet (from EGR cooler) C: Servo drive oil inlet
B: EGR gas outlet (to intake manifold) D: Servo drive oil outlet
1: Valve 5: Spring
2: Spring 6: EGR valve lift sensor
3: Power piston 7: EPC valve (for EGR)
4: Spool
Structure
• EGR valve consists of the EGR gas flow control mechanism and EPC valve.
• EPC valve (1 pieces) is installed to control EGR valve.
REMARK
EPC valve for controlling VGT is installed to the front cover.

10-76 125E-7 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

OPERATION OF EGR VALVE

1. The oil from the engine boost oil pump flows in port (C) of
EGR valve. The control pressure from EPC valve solenoid
enters port (E).
2. Spool (4) is moved to the right by the reaction force of
spring (5), and valve (1) is closed by the reaction for spring
(2). Accordingly, the exhaust gas from EGR cooler does
not flow to the intake side.
3. To open valve (1), the control pressure from EPC valve en-
ters port (E) first. The position of spool (4) is determined by
the balance of the control pressure and spring (5).
4. Since the notch of power piston (3) opens, the oil from the
engine boost oil pump flows through port (C) and pushes
power piston (3) to the left.
5. The oil from the engine boost oil pump acts on power piston (3) and generates force (Fp).
6. When force (Fp) increases more than reaction force (Fs) of spring (2), EGR valve (1) opens and the ex-
haust gas flows to the intake side.
7. Reaction force (Fs) of spring (2) and force (Fp) of power piston are balanced since the engine controller
controls the control pressure with EPC valve solenoid.
8. Since the servo mechanism is applied, external force applied to valve (1) does not act on spool (4) which is
in contact with power piston (3).
9. EGR valve lift sensor senses the displacement of spool (4).

125E-7 SERIES 10-77

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

EGR COOLER
EGR
Abbreviation for Exhaust Gas Recirculation

STRUCTURE OF EGR COOLER

REMARK
The shape is subject to machine models.
General view, sectional view

A: EGR gas inlet D: Coolant outlet

B: EGR gas outlet (to EGR valve) E: Air vent
C: Coolant inlet F: Air vent
1: Header plate 3: Inner fin
2: Flat tube 4: Case

OPERATION OF EGR COOLER

• EGR gas enters through (A) and flows through flat tubes (2) (9 pieces).
• Coolant enters through (C), flows outside of flat tubes (2) in case (4), and goes out through (D).
• Flat tube (2) has inner fins (3), thus EGR gas is cooled efficiently and discharged through EGR gas outlet
(B).

10-78 125E-7 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

MIXING CONNECTOR
STRUCTURE OF MIXING CONNECTOR
General view

A: Air inlet C: To cylinder head (EGR gas and air)

B: EGR gas inlet
1: Intake manifold 3: Intake connector
2: Mixing connector 4: Electric air heater

FUNCTION OF MIXING CONNECTOR

This connector mixes EGR gas and air.

125E-7 SERIES 10-79

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

KCCV SYSTEM
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation

LAYOUT DRAWING OF KCCV SYSTEM

REMARK
The shape is subject to machine models.

A: Blowby gas C: Removed engine oil (to engine oil pan)

B: Blowby gas from which engine oil is removed (to
VGT)
1: KCCV ventilator 3: Check valve
2: VGT 4: CDR valve

FUNCTION OF KCCV SYSTEM

• In the past, blowby gas (A) was allowed to be released into the atmosphere in the past, but now it is restric-
ted by emission regulations.
• Blowby gas (A) contains ingredients of the engine oil. A filter is installed to KCCV ventilator (1) to remove
the engine oil to prevent the following possible problems if it is recirculated to VGT (2) as it is.
• Deterioration of turbocharger and aftercooler performance caused by sticking engine oil
• Abnormal combustion in engine

10-80 125E-7 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

• Malfunction of each sensor caused by sticking engine oil

FORMING OF CONDENSED WATER AND EMULSION IN KCCV SYSTEM

A: Inside of KCCV piping C: Back of head cover

B: inside of breather D: Dipstick
1: Air Cleaner 5: Breather
2: VGT 6: KCCV ventilator
3: Aftercooler 7: Engine oil pan
4: Engine

125E-7 SERIES 10-81

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

Outline of forming of condensed water and emulsion in KCCV system

• If low-load operation is continued while the ambient tem-
perature is low, moisture in the blowby gas does not evap-
orate but condenses, and is returned to engine oil pan (7)
through KCCV ventilator (6).
The flow of this phenomenon is as follows;
1. Moisture in blowby gas condenses in KCCV piping
(A).
2. The condensed water flows into engine oil pan (7)
through the drain circuit.
3. The water evaporates in engine oil pan (7).
4. When the water vapor condenses again inside the en-
gine where the temperature is relatively low, it is
mixed with oil and clouded sediment is produced.
This sediment is called mayonnaise sludge (*1).
5. If the temperature of various parts does not increase
because of light-load operation, mayonnaise sludge
(*1) is accumulated.
• Mayonnaise sludge (*1) is produced inside breather (B),
on back of head cover (C), dipstick (D), etc. where the
temperature is low and condensation occurs easily.
• Mayonnaise sludge (*1) is eliminated when loaded opera-
tion is continued and the engine oil temperature increases.
• Mixing of water condensed from the blowby gas into the oil
is not problem. However, if the engine coolant is mixed in,
the cause of coolant leakage must be removed.
*1: Emulsion made from oil and water which looks like mayon-
naise

10-82 125E-7 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

OPERATION OF KCCV SYSTEM

Drawing on the left shows the conventional flow of blowby gas. Drawing on the right shows the flow of blowby
gas which is sucked in KCCV ventilator and recirculated.

A: Blowby gas C: Engine oil

B: Clean gas
1: Air cleaner 5: Breather
2: Turbocharger 6: KCCV ventilator
3: Aftercooler 7: Engine oil pan
4: Cylinder block (crankcase) 8: VGT
1. This system removes engine oil (C) from blowby gas (A) in cylinder block (4) by using the filter in KCCV
ventilator (6), and recirculate clean gas (B) to the air intake side of VGT (8).
2. Separated engine oil (C) is drained to engine oil pan (7) through the check valve.

125E-7 SERIES 10-83

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

KCCV VENTILATOR
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation

STRUCTURE OF KCCV VENTILATOR

REMARK
The shape is subject to machine models.
General view and sectional view

A: Blowby gas inlet (engine breather) C: Oil drain port (to engine oil pan)
B: Blowby gas outlet (to VGT intake side) D: Coolant passage
1: Case 4: Impactor
2: CDR valve 5: Filter
3: Relief valve 6: Crankcase pressure sensor
Structure
• Filter (5) is classified by the working direction for filter replacement into the top load type (removed upward)
and bottom load type (removed downward).
• The top load type (removed upward) and bottom load type (removed downward) are different from each
other in the position of the crankcase pressure sensor.
In the top load type (removed upward), the crankcase pressure sensor is installed to the blowby gas inlet
piping.
In the bottom load type (removed downward), the crankcase pressure sensor is installed to the top of
KCCV ventilator.

10-84 125E-7 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

FUNCTION OF KCCV VENTILATOR

• If the blowby gas is returned to the intake side of VGT and crankcase pressure becomes negative, the dust
may be sucked in through crank seal.
The pressure inside the crankcase is controlled by CDR valve (2) to prevent this to occur.
• Crankcase pressure may increase and oil leakage may occur if filter (5) of KCCV ventilator is clogged.
Thus, crankcase pressure sensor (3) detects the clogging of filter (6).
• Keep KCCV ventilator warm with warmed-up engine coolant to prevent the blowby gas passage from being
clogged due to freeze.
• Relief valve (3) inside case (1) operates to bypass the blowby gas and protect both KCCV ventilator and
the engine when filter (5) is blocked.

OPERATION OF KCCV VENTILATOR

1. When blowby gas enters blowby gas inlet (A) and passes through the hole of impactor (4) in filter (5), large
particles in the oil mist are separated.
2. Small particles in the oil mist are separated by filter (5).
3. The separated oil oozes out from the bottom of the filter (5), and flows to oil drain port (C), and then flows to
the engine oil pan.
4. The crankcase pressure sensor senses the crankcase pressure (blowby gas pressure).
If the engine controller detects filter clogging by detected value of crankcase pressure sensor, it displays
failure code CA555. If the pressure increases further, it displays failure code CA556.
5. Relief valve (3) is installed in case (1) and operates when filter (5) is blocked.
6. When the crankcase pressure becomes negative, CDR valve (2) operates for it not to become excessively
negative.

CDR VALVE
CDR
Abbreviation for Crankcase Depression Regulator

OPERATION OF CDR VALVE

1. Spring (2) normally pushes up diaphragm (1), and the
blowby gas flows from crankcase side (A) into turbocharg-
er side (air intake side) (B).
2. As the intake air at turbochaeger side (air intake side) (B)
increases, pressure on crankcase side (P1) decreases.
3. The reaction force of spring (2) is overwhelmed by ambient
pressure (P2). Diaphragm (1) shuts the passage and tem-
porarily blocks the flow.
4. When the blowby gas accumulates in the crankcase, pres-
sure (P1) on the crankcase side increases, and it pushes
up diaphragm (1) again and blowby gas starts to flow.

125E-7 SERIES 10-85

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

KDPF
KDPF
Abbreviation for KOMATSU Diesel Particulate Filter

STRUCTURE OF KDPF
REMARK
The shape is subject to machine models.
General view

A: From VGT B: To AdBlue/DEF mixing connector

1: Outlet unit 8: KDPF differential pressure sensor port
2: KCSF unit 9: KDPF differential pressure sensor
3: Temperature sensor controller 10: KDPF differential pressure sensor port
4: KDOC unit 11: KDPF outlet temperature sensor
5: Inlet unit 12: Hanger bracket
6: KDOC inlet temperature sensor 13: Sensor bracket
7: KDOC outlet temperature sensor 14: Sensor bracket band
Structure
• KDPF consists of inlet unit (5) to introduce the exhaust gas, KDOC unit (4) to store the oxidation catalyst,
KCSF unit (2) to store the soot collecting filter equipped with catalyst, and outlet unit (1) to discharge the
exhaust gas.
• KDOC unit (4) consists of ceramic honeycomb equipped with the oxidation catalyst.
• The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramics
under the vibration condition of the engine and machine body.

10-86 125E-7 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

This mat also thermally insulates the periphery of KDPF from the ceramics which becomes high tempera-
ture during operation.
• KCSF unit (2) consists of ceramic honeycomb equipped with the oxidation catalyst, similarly to KDOC unit
(4).
The inside of KCSF unit (2) consists of many cells partitioned by ceramic walls. The cells blocked on the
inlet side and those blocked on the outlet side are arranged alternately to collect soot.
• KDPF is equipped with KDPF temperature sensor (assembly of KDOC inlet temperature sensor, KDOC out-
let temperature sensor, and KDPF outlet temperature sensor) and the differential pressure sensor (assem-
bly of KDPF differential pressure sensor and KDPF outlet pressure sensor).
Combination of temperatures detected by these 3 temperature sensors is used to monitor that KCSF unit
(6) and KDOC unit (7) are functioning normally, and to troubleshoot various components.
The differential pressure sensor monitors accumulation of soot in KCSF unit (2) by sensing the pressure
difference between both sides of KCSF unit (2), and uses the obtained data for troubleshooting of various
components, similarly to the temperature sensor.

FUNCTION OF KDPF
A: Flow of exhaust gas
1: KDOC (oxidation catalyst)
2: KCSF
3: Seal (ceramic made)
4: Cell
5: Ceramics honeycomb
• KDPF purifies the exhaust gas by catching large amount of
chainlike soot or PM (Particulate Matter such as soot)
which is contained in the engine exhaust gas.
• KDOC (oxidation catalyst) (1) oxidizes NO (nitrogen mon-
oxide) contained in the exhaust gas into NO 2 (nitrogen di-
oxide), and regenerates (*1) KCSF(2).
• KCSF (2) captures soot.
• Accumulated soot in KCSF (2) in operation range where
the temperature of exhaust gas is relatively high state is
naturally oxidized and burnt away by the effect of KDOC
(oxidation catalyst) (1). (This is called “passive regenera-
tion”)
REMARK
“Passive regeneration” cannot be performed if the light
load operation and low temperature state of the exhaust
gas continue. Accumulated soot is gradually increased.
• Engine controller always monitors 2 soot accumulation values and compares them. One is presumed soot
accumulation based on the engine operating conditions, and the other is the calculated soot accumulation
based on the signal from the differential pressure sensor which is attached to KCSF (2).
• If the amount of accumulated soot and the temperature of engine exhaust gas exceed the specified level,
engine controller performs “automatic regeneration” to burn (oxydize) the soot.
While performing automatic regeneration, the engine controller calculates the exhaust gas temperature at
KDOC inlet and exhaust gas volume, and controls the engine to raise the temperature of engine exhaust
gas. (This is called “exhaust gas temperature raise control”)
The temperature of engine exhaust gas at KDOC inlet is controlled by the fuel amount injected from the fuel
doser installed at the turbocharger outlet part,and exhaust gas volume is controlled by VGT.
The engine controller enhances the oxidation power in KDOC (1) by raising the temperature of engine ex-
haust gas automatically, and improves combustion efficiency of soot captured in KCSF (2).

125E-7 SERIES 10-87

TURBOCHARGER SYSTEM 10 STRUCTURE AND FUNCTION

REMARK
When regeneration function on the machine monitor is disabled, or outside air temperature is extremely
low, or continuous light load operation is carried out, relatively low exhaust temperature continues. In such
case, “automatic regeneration” is not performed and the amount of soot accumulation is increased.
• If “automatic regeneration” is not performed due to the excess amount of accumulated soot in KCSF (2),
perform “manual stationary regeneration” to burn (oxydize) the soot and reduce the amount of soot inside
KCSF (2).
REMARK
Excessive amount of the soot interferes the flow of exhaust gas to worsen fuel consumption and engine
combustion state. It may lead to other failures.
If the amount of soot increases further, “manual stationary regeneration” cannot be performed safely. This
will result in a KDPF failure and replacement is unavoidable. Make sure to follow the procedures in the Op-
eration and Maintenance Manual when performing “manual stationary regeneration”
*1: Soot purification (oxidation) treatment

TYPES OF REGENERATION FUNCTIONS

Regeneration means to purify (oxidize) the soot accumulated on the soot collecting filter (KCSF) in KDPF or
maintain the urea SCR system normal.
Passive regeneration
When the exhaust temperature of the engine is relatively high, the oxidation power of soot in the exhaust gas
components is increased by the catalysis of KDOC to oxidize (burn) the soot accumulated in KCSF naturally.
Active regeneration (engine exhaust temperature rise control + fuel dosing)
• Automatic regeneration
• When soot is accumulated more than a certain level or the urea SCR system makes a request to main-
tain itself normal, the engine enters the exhaust temperature rise control mode (*1) and performs fuel
dosing (*2) and starts regeneration automatically.
The automatic regeneration is also performed by the direction from the engine controller at a set time
after the previous regeneration, regardless of soot accumulation in KCSF.
*1: Control to increase the engine exhaust temperature by controlling the fuel injection timing or VGT.
*2: Fuel injection performed to accelerate regeneration by increasing the exhaust temperature.
• Manual stationary regeneration
• When the exhaust temperature does not reach a certain level, depending on the operating condition of
the machine, or when the operator disables regeneration, the automatic regeneration is not performed
and accumulated soot in KCSF increases. Also, when the automatic regeneration is performed upon
receiving a request from the urea SCR system, the exhaust temperature may not reach a certain level,
depending on the operating condition of the machine. In these cases, a request for the manual station-
ary regeneration request is displayed on the machine monitor, and the operator must perform regener-
ation by the operation on the machine monitor screen.
In addition, when the engine controller is replaced or ash in KCSF is washed, a serviceman performs
regeneration by the operation on the machine monitor screen (“active regeneration for service”).

10-88 125E-7 SERIES

10 STRUCTURE AND FUNCTION TURBOCHARGER SYSTEM

NOTICE
• For the procedure to start and stop the regeneration of KDPF, see the Operation and Maintenance
Manual for each machine.
• Always use ultra low-sulfur diesel fuel. If any fuel other than the specified one is used, it can cause a
failure in KDPF.
• Always use specified Komatsu genuine engine oil applicable to KDPF. If any oil other than the speci-
fied one is used, it can clog KDPF quickly, and that can increase fuel consumption and cause a fail-
ure in KDPF.
• Do not modify KDPF body and exhaust pipe. If modification is made, KDPF cannot operate normally
and may have trouble.
• Do not give strong impacts to KDPF by standing on it, dropping it, or hitting it, etc. KDPF has ceram-
ic parts in it, and they may be broken by a strong impact.
• During the “automatic regeneration” and the “manual stationary regeneration”, especially at low
temperature, white smoke may be discharged through the exhaust pipe outlet for a short time. This
phenomenon is not abnormal. Be sure to perform regeneration in a well-ventilated area, since car-
bon monoxide may be generated.
• During the “automatic regeneration” and the “manual stationary regeneration”, the temperature of
the exhaust gas discharged from the exhaust pipe may increase above 650 °C. To prevent a fire,
check that there is no combustible around the exhaust pipe. Also, check that there is no person in
the blow-out direction of the exhaust gas and confirm the safety around the machine.
REMARK
• If the mixing ratio of the bio-fuel in the diesel fuel is high, the regeneration of KDPF may become more fre-
quent.
• Even when soot is not accumulated much, the engine controller may start “automatic regeneration”. This is
automatic regeneration to maintain the function of KDPF or urea SCR system normal, and is not an abnor-
mal operation. Automatic regeneration to maintain the function of urea SCR system normal or manual sta-
tionary regeneration takes approximately 1 hour.
• During the “automatic regeneration” and the “manual stationary regeneration”, VGT operates automatically
and the engine sound changes. Also, the exhaust gas flow rate in KDPF changes, and accordingly the ex-
haust sound changes. These phenomena are not abnormal.
• During the “automatic regeneration” and the “manual stationary regeneration”, the exhaust pipe may smell
different from usual. This is not abnormal phenomenon.
• KDPF has “KDPF dry operation” function to prevent excessive accumulation of unburnt fuel in KDPF when
operation is continued at relatively low temperature for long hours.This is a function that the engine control-
ler increases the engine exhaust temperature automatically and performs dry operation of KCSF when the
set condition is satisfied. When the automatic dry operation is insufficient for the treatment, manual station-
ary regeneration may be required.
• The standard temperature of KDPF is shown below.
KDOC In (KDOC inlet KDOC Out (KDOC out- KDPF Out (KDPF outlet
temperature sensor) let temperature sensor) temperature sensor)
While regeneration is not performed
100 to 250 °C
(idling state)
While regeneration is performed (ther-
100 to 250 °C 400 to 550 °C
mal mode)

125E-7 SERIES 10-89

LUBRICATION SYSTEM 10 STRUCTURE AND FUNCTION

LUBRICATION SYSTEM
LAYOUT DRAWING OF LUBRICATION SYSTEM PARTS
REMARK
The shape is subject to machine models.

1: EGR valve 4: VGT

2: Engine oil pan 5: Engine oil filter
3: Engine boost oil pump

10-90 125E-7 SERIES

10 STRUCTURE AND FUNCTION LUBRICATION SYSTEM

LUBRICATION SYSTEM CIRCUIT DIAGRAM

1: Strainer 10: Engine boost oil pump

2: Engine oil pump 11: Relief valve
3: Relief valve 12: EPC valve (for VGT)
4: Engine oil cooler 13: VGT
5: Engine oil filter 14: EPC valve (for EGR valve)
6: Safety valve 15: EGR valve
7: VGT lubrication 16: Piston cooling gallery
8: Main gallery lubrication 17: Piston lubrication
9: Lubrication of each bearing 18: Engine oil pan

125E-7 SERIES 10-91

LUBRICATION SYSTEM 10 STRUCTURE AND FUNCTION

ENGINE OIL PUMP

STRUCTURE OF ENGINE OIL PUMP
REMARK
The shape is subject to machine models.
General view and sectional view

1: Engine oil pump drive gear (number of teeth: 21) 7: Relief valve
2: Bushing 8: Valve spring
3: Pump cover 9: Retainer
4: Drive gear 10: Driven shaft
5: Pump body 11: Bushing
6: Drive shaft 12: Driven gear

SPECIFICATIONS OF ENGINE OIL PUMP

Engine oil pump
Type: Gear pump
Speed: Engine speed x 1.571
Relief valve
Cracking pressure: 0.65 to 0.8 MPa {6.63 to 8.16 kg/cm2} 

FUNCTION OF ENGINE OIL PUMP

The engine oil pump pressure-feeds engine oil to lubricate the inside of the engine.

10-92 125E-7 SERIES

10 STRUCTURE AND FUNCTION LUBRICATION SYSTEM

ENGINE BOOST OIL PUMP

STRUCTURE OF ENGINE BOOST OIL PUMP
REMARK
The shape is subject to machine models.
General view and sectional view

a: Center of drive shaft c: Suction opening

b: Discharge opening
1: Relief valve

SPECIFICATIONS OF ENGINE BOOST OIL PUMP

Engine boost oil pump
Type: Gear pump
Speed: Engine speed x 1.1
Relief valve
Cracking pressure: 1.43±0.1 MPa {14.6±1 kg/cm2} 

FUNCTION OF ENGINE BOOST OIL PUMP

• The engine boost oil pump pressure-feeds engine oil to drive EGR valve and VGT.
• This pump is installed in the circuit from the main gallery to EGR valve and VGT circuit, and driven with the
power from the main idler gear.
• This pump supplies hydraulic pressure to the 4 circuits of EGR valve drive, EGR valve control, VGT drive,
and VGT control.

125E-7 SERIES 10-93

LUBRICATION SYSTEM 10 STRUCTURE AND FUNCTION

ENGINE OIL FILTER

STRUCTURE OF ENGINE OIL FILTER
REMARK
The shape is subject to machine models.
General view and sectional view

A: Engine oil inlet B: Engine oil outlet

1: Safety valve 3: Cartridge
2: Filter head

SPECIFICATIONS OF ENGINE OIL FILTER

Filtering area of engine oil filter: 0.44 m2 (full flow)
Cracking pressure of safety valve: 343±19 kPa {3.5±0.2 kg/cm2} 

10-94 125E-7 SERIES

10 STRUCTURE AND FUNCTION LUBRICATION SYSTEM

ENGINE OIL COOLER

STRUCTURE OF ENGINE OIL COOLER
REMARK
The shape is subject to machine models.
General view and sectional view

a: Water drain c: To each portion of engine (oil)

b: Engine Oil inlet d: Water inlet
1: Thermostat cover 4: Cooler element
2: Thermostat (thermo valve) 5: Strainer
3: Cooler cover

SPECIFICATIONS OF ENGINE OIL COOLER

Heat dissipation area: 0.575 m2

125E-7 SERIES 10-95

LUBRICATION SYSTEM 10 STRUCTURE AND FUNCTION

OIL COOLER THERMO VALVE

STRUCTURE OF OIL COOLER THERMO VALVE
General view and sectional view

1: Piston 5: Spring
2: Valve 6: Seat
3: Holder 7: Pellet
4: Spring

SPECIFICATIONS OF OIL COOLER THERMO VALVE

Cracking temperature: 71 °C
Full open temperature: 90 °C
Full open lift: Min.8 mm

FUNCTION OF OIL COOLER THERMO VALVE

This valve is installed in the engine oil cooler, and prevents the engine oil from flowing into the cooler element
until the engine oil reaches a certain temperature.

10-96 125E-7 SERIES

10 STRUCTURE AND FUNCTION LUBRICATION SYSTEM

ENGINE OIL PAN

STRUCTURE OF ENGINE OIL PAN
REMARK
The shape is subject to machine models.

1: Engine oil pan 3: Oil level sensor

2: Dipstick

125E-7 SERIES 10-97

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

FUEL SYSTEM
LAYOUT DRAWING OF FUEL SYSTEM PARTS
REMARK
The shape is subject to machine models.

1: Injector 5: Common rail

2: Pressure limiter 6: High-pressure pipe
3: Feed pump 7: Main filter
4: Supply pump

10-98 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM

FUEL SYSTEM CIRCUIT DIAGRAM

1: Fuel tank 7: Flow damper

2: Supply pump assembly 8: Injector assembly
2A: PCV 9: Fuel cooler
2B: High-pressure pump 10: Engine controller
2C: Priming pump 11: NE speed sensor
2D: Feed pump 12: Fuel feed pump
2E: Bypass valve 13: Check valve
2F: G speed sensor 14: Fuel prefilter
3: Fuel filter 15: Fuel doser solenoid valve assembly
4: Overflow valve 15A: Fuel doser solenoid valve 1
5: Common rail 15B: Fuel doser solenoid valve 2
6: Pressure limiter 15C: Fuel dosing pressure sensor

125E-7 SERIES 10-99

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

16: Fuel doser 17: Relief valve

FUNCTION OF FUEL SYSTEM

• The fuel injection system is high-pressure common rail type and is controlled electronically.
The high-pressure common rail type consists of 3 main components of supply pump (high-pressure fuel
pump) (2), common rail (5), and injector (8).
• Fuel injection is performed by injector (8) driven by solenoid.
• Engine controller (10) controls fuel injection rate and injection timing by driving the solenoid in injector (8).

OPERATION OF FUEL SYSTEM

1. Supply pump (2) sends high-pressure fuel to common rail (5).
The high-pressure fuel is stored in common rail (5).
2. The fuel sucked up by feed pump (2D) is discharged to main filter (3) through prefilter (14) equipped with
water separator.
3. The fuel discharged onto main filter (3) is filtered, and flows in supply pump (2).
4. The fuel flowing into supply pump (2) is pressurized high by 2 plungers.
5. Common rail (5) stores high-pressure fuel and distributes it to the supply lines for each injector (8).
6. Common rail (5) has a common rail pressure sensor. Engine controller (10) controls the discharged volume
of supply pump (2), while monitoring the pressure supplied from supply pump (2) to common rail (5).
7. Common rail (5) has pressure limiter (6) (common rail pressure relief). When the pressure in common rail
(5) exceeds the set pressure, pressure limiter (6) releases the pressure.
8. The fuel released by pressure limiter (6) is returned to fuel tank (1) through the connected fuel return circuit.
9. High-pressure fuel flows in injector (8). The solenoid is driven and raise the internal needle to inject the fuel.
10. During active regeneration of KDPF, the fuel doser supplies fuel to the piping for increasing the exhaust gas
temperature in KDOC.

10-100 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM

CRI SYSTEM
CRI
Abbreviation for Common Rail Injection

OUTLINE OF CRI SYSTEM

• CRI system senses the condition of the engine (engine speed, accelerator position, coolant temperature,
etc.) with various sensors.
The engine controller in this system totally controls the fuel injection rate, fuel injection timing, fuel injection
pressure, etc. according to those data, and operates the engine under the optimum condition.
• The engine controller self-checks the main components and notifies any abnormality with the self-diagnosis
function and alarm function.
It also has the failsafe function to stop the engine, depending on the abnormal portion, and the backup
function to make it possible to operate the machine without stopping by changing the control method.

STRUCTURE OF CRI SYSTEM

• The CRI system consists of the supply pump, common rail, injector, and engine controller and sensors to
control those components.
• The supply pump generates common rail fuel pressure.
The discharged volume is controlled by turning ON/OFF PCV (discharged volume control valve) of the sup-
ply pump according to the electrical signals from the engine controller.
• The common rail receives the fuel pressure generated by the supply pump, and distributes it to the cylin-
ders.
• The fuel pressure is sensed by the common rail pressure sensor installed to the common rail.
• The common rail fuel pressure is applied to the nozzle side of the injector and to the control chamber
through the fuel injection pipe of each cylinder.
• The injector controls the fuel injection rate and fuel injection timing by turning ON/OFF TWV (Two-Way sol-
enoid Valve).

125E-7 SERIES 10-101

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

• CRI system can be divided by function into the fuel system and control system.

FUNCTION OF FUEL SYSTEM OF CRI SYSTEM

• High-pressure fuel from the supply pump is distributed
through the common rail to the cylinders.
• The solenoid valve in the injector controls start and finish
of injection by opening and closing the nozzle needle
valve.

10-102 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM

CONTROL FUNCTION OF CRI SYSTEM

• CRI system controls the fuel injection rate and fuel injection timing more properly than the mechanical gov-
ernor and timer used for the conventional fuel injection pump.
• The engine controller controls this system by the signals from the sensors installed to the engine and ma-
chine.
• The engine controller controls power ON timing and power ON period to inject fuel in the optimum timing by
the optimum amount.

FUEL INJECTION RATE CONTROL FUNCTION

The fuel injection rate control function is used instead of the function of the conventional mechanical governor. It
controls the fuel injection rate properly from the engine speed and throttle position signal.

125E-7 SERIES 10-103

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

FUEL INJECTION TIMING CONTROL FUNCTION

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

FUEL INJECTION PRESSURE CONTROL FUNCTION

(Common rail fuel pressure control function)
• The fuel injection pressure control function (common rail fuel pressure control function) measures the fuel
pressure with the common rail pressure sensor and feeds it back to the engine controller to control the vol-
ume discharged from the supply pump.
• The pressure feedback control is performed so that the fuel injection rate matches with the optimum (com-
mand) value which is set according to the engine speed and fuel injection rate.

OPERATION OF CRI CONTROL SYSTEM

1. When TWV (Two-Way solenoid Valve) is turned ON (energized), the fuel circuit is so changed that the high-
pressure fuel in the control chamber flows out through the orifice, and the needle valve is raised by the noz-
zle cracking force generated by the high-pressure fuel on the nozzle side, and then fuel injection starts.
The fuel injection timing is controlled electronically by the energization timing of TWV.
2. When TWV is turned OFF (de-energized), the fuel circuit is so changed that the high-pressure fuel acts on
the control chamber, and the needle valve lowers and finishes fuel injection.
The fuel injection rate is controlled electronically by the energization period of TWV.

10-104 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM

SUPPLY PUMP
STRUCTURE OF SUPPLY PUMP
Sectional view

1: 3-lobe cam 6: No. 2 high-pressure pump (feed pump side)

2: Overflow valve 7: Priming pump
3: Drive gear 8: Feed pump
4: No. 1 high-pressure pump (drive gear side) 9: Gear for Bkup speed sensor (G sensor)
5: PCV (pomp control valve)
Structure
• The supply pump consists of priming pump (7), feed pump (8), and high-pressure pumps (4) and (6).
• In each cylinder of high-pressure pumps (4) and (6), the pressure-feed system similar to the conventional
in-line fuel injection pump and the PCV (pump control valve) (5) are arranged.
• By employing 3-lobe cam (1), the necessary number of cylinders in high-pressure pumps (4) and (6) is re-
duced to 1/3 of the number of the engine cylinders.
Also, since the pressure feed rate to the common rail is the same as the number of fuel injection, the fuel
pressure in the common rail is stabilized.
• The fuel pressure-fed from high-pressure pumps (4) and (6) is divided as follows;
• No. 1 high-pressure pump (drive gear side) compensates for reduction of common rail fuel pressure
caused by fuel injection into No. 1, 3, and 5 cylinders.
• No. 2 high-pressure pump (feed pump side) compensates for reduction of common rail fuel pressure in
No. 2, 4, and 6 cylinders.

FUNCTION OF SUPPLY PUMP

• The supply pump controls the fuel discharged volume to generate the common rail fuel pressure.

125E-7 SERIES 10-105

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF SUPPLY PUMP

1. During lowering stroke (A) of the plunger, PCV is open and low-pressure fuel is sucked into plunger cham-
ber through PCV.
2. If PCV is not energized and is open even in rising stroke (B), the sucked fuel is returned to the overflow
valve via PCV without being pressurized.
3. When PCV is energized in timing (C) matched with the necessary discharged volume, the return passage is
closed and the pressure in the plunger chamber increases.
Accordingly, the fuel is pressure-sent to the common rail through the delivery valve (check valve).
That is, the amount for the plunger lift after PCV is closed is the discharged volume, which varies with the
opening time of PCV (pre-stroke of the plunger). The common rail fuel pressure is controlled in this way.
4. When the cam passes over the maximum lift, the plunger starts lowering stroke (D), and the pressure in the
plunger chamber decreases.
At this time, the delivery valve closes and pressure feeding of fuel stops.
Since PCV is de-energized, it opens and the low-pressure fuel is sucked into the plunger chamber, that is
the state becomes (A).

10-106 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM

PCV (Pump control valve)

PCV adjusts the fuel discharged from the supply pump to ad-
just the common rail fuel pressure. The amount discharged
from the supply pump to the common rails is determined by the
energizing timing of PCV.

Feed pump
1. The feed pump built in the supply pump sucks in fuel from
the fuel tank and sends it through the fuel filter to the high-
pressure pump chamber.
2. The feed pump rotor is driven with the camshaft, and the
outer rotor and inner rotor start rotation.
3. As the space made between the outer rotor and inner rotor
increases and decreases, the fuel is sucked in on the suc-
tion side, and discharged on the discharge side.

125E-7 SERIES 10-107

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

COMMON RAIL
STRUCTURE OF COMMON RAIL
General view
1: Flow damper
2: Common rail pressure sensor
3: Pressure limiter
4: Common rail

Structure
• Common rail (4) distributes the high-pressure fuel generated by the high-pressure pump to the injectors of
the cylinders.
• Common rail (4) is equipped with common rail pressure sensor (2), flow damper (1), and pressure limiter
(3).
• The fuel injection pipe is connected to flow damper (1), which feeds the high-pressure fuel to the injectors.
• The piping of pressure limiter (3) returns to the fuel tank.

10-108 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM

FLOW DAMPER
FUNCTION OF FLOW DAMPER
• The flow damper reduces the pressure pulsation in the high-pressure piping and supplies fuel at constant
pressure to the injector.
• If excessive fuel should flow out, the flow damper cuts off the fuel passage to prevent abnormal outflow of
fuel.

OPERATION OF FLOW DAMPER

When normal
1. In the initial position, piston (2) is in contact with stopper
(1).
Fuel for the static leak is supplied through clearance be-
tween orifice (a) of piston (2) and the sliding portion.

2. When the fuel is injected, piston (2) compresses spring (3)

with the fuel pressure and moves to the right.
Fuel for the dynamic leak is supplied through orifice (a) of
piston (2) and the clearance in the sliding portion.

When fuel flows out abnormally

1. If fuel flows out abnormally because of a burst in piping,
etc., piston (2) moves to the right stroke end.
2. The end of piston (2) touches seat (b) to stop the fuel.
3. Once the fuel is stopped, pin (2) does not return to the ini-
tial position until the engine is stopped.

125E-7 SERIES 10-109

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

PRESSURE LIMITER
STRUCTURE OF PRESSURE LIMITER
Sectional view
1: Ball
2: Housing
3: Spring
4: Body
5: Guide

FUNCTION OF PRESSURE LIMITER

• The pressure limiter releases abnormal high pressure.
• The pressure limiter operates (cracks) when the common rail fuel pressure reaches approximately
230 MPa {2340 kg/cm2} .
• The pressure limiter restores (opens) and maintains the pressure when the pressure decreases to 30 MPa 
{310 kg/cm2} .
• Under the normal condition, the pressure limiter does not restore (open) while the engine is running.

COMMON RAIL PRESSURE SENSOR

FUNCTION OF COMMON RAIL PRESSURE SENSOR
• The common rail pressure sensor is installed to the com-
mon rail to sense fuel pressure.
• This is a semi-conductor pressure sensor which uses the
property of piezoelectric element that its electrical resist-
ance varies with pressure applied to it.

10-110 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM

INJECTOR
STRUCTURE OF INJECTOR
Sectional view

1: Inlet connector 8: Pressure control chamber

2: Terminal 9: Control piston
3: Upper body 10: Spring
4: Solenoid 11: Pressure pin
5: Valve body 12: Nozzle assembly
6: Orifice (out) 13: QR code tag
7: Orifice (in)

125E-7 SERIES 10-111

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

Structure
The injector consists of the nozzle, orifice that determines the fuel injection rate, hydraulic piston pin, and two-
way solenoid valve, similarly to the former models.

10-112 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM

FUNCTION OF INJECTOR

• The injector injects and sprays high-pressure fuel in the common rail into the combustion chamber of the
engine in the optimum timing, by the optimum amount of fuel, at the optimum injection rate, and in the opti-
mum spray state, according to the signals from the engine controller.
• The TWV (Two-Way solenoid Valve) controls the start and finish of fuel injection by controlling the pressure
in the control chamber.
• The hydraulic piston transfers the force caused by the control chamber pressure to the needle valve.
• The nozzle sprays the fuel.

125E-7 SERIES 10-113

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF INJECTOR

A: No fuel injection C: Finish of fuel injection

B: Start of fuel injection D: High-pressure fuel in common rail
1: Nozzle 5: Valve body
2: Control piston 6: Solenoid
3: Orifice (in) 7: Spring
4: Orifice (out) 8: Pressure control chamber
No fuel injection (A)
1. When solenoid (6) is not energized, valve body (5) is pressed down by spring (7).
2. Since high-pressure fuel (D) is applied to pressure control chamber (8), nozzle (1) is closed and injects no
fuel.
Start of fuel injection (B)
1. When solenoid (6) is energized, valve body (5) is pulled up by the electromagnetic force, and the fuel pas-
sage opens.
2. Since the fuel in pressure control chamber (8) flows out through orifices (3) and (4), nozzle (1) moves up
and starts fuel injection.
3. The fuel injecting rate is gradually increased by the orifices (3) and (4).
4. The maximum fuel injecting rate is achieved by keeping energizing the solenoid (6)
Finish of fuel injection (C)
1. When solenoid (6) is de-energized, valve body (5) is pressed down by spring (7), and the fuel passage
closes.
2. Since high-pressure fuel (D) is applied suddenly to pressure control chamber (8), nozzle (1) is closed, and
fuel injection is finished.

10-114 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM

FUEL DOSING SYSTEM

LAYOUT DRAWING OF FUEL DOSING SYSTEM

1: Fuel doser 4: Fuel dosing pressure sensor

2: Fuel doser solenoid valve 1 5: Fuel feed pump
3: Fuel doser solenoid valve 2

OUTLINE OF FUEL DOSING SYSTEM

A: From prefilter
B: To fuel tank
1: Fuel doser
2: Fuel doser solenoid valve 1
3: Fuel doser solenoid valve 2
4: Fuel dosing pressure sensor
5: Fuel feed pump
• During active regeneration of KDPF, fuel is supplied to the
piping for increasing the exhaust gas temperature in
KDOC.
• During active regeneration, fuel doser solenoid valve (2) opens and the fuel pressurized by feed pump (5)
flows into fuel doser (1).
• After active regeneration is finished, fuel doser solenoid valve (2) closes and stops supplying fuel. At the
same time, the remaining pressure opens fuel doser solenoid valve 2 (3), and the fuel is drained.

125E-7 SERIES 10-115

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

FUEL DOSER
STRUCTURE OF FUEL DOSER
General view
A: Fuel inlet
B: Coolant inlet
C: Coolant outlet
1: Fuel doser

FUNCTION OF FUEL DOSER

• The fuel injection rate of fuel dozer (1) is calculated by the engine controller to obtain proper KDOC outlet
temperature.
• Fuel doser (1) is driven by PWM control to inject the calculated amount of fuel, according to the pressure
sensed by the dosing fuel pressure sensor.

FUEL DOSER SOLENOID VALVE AND DOSER FUEL PRESSURE SENSOR

STRUCTURE OF FUEL DOSER SOLENOID VALVE AND DOSER FUEL PRES-
SURE SENSOR
General view
A: Fuel inlet
B: Fuel outlet (to fuel doser)
C: Fuel outlet (drain)
1: Fuel doser solenoid valve 1
2: Fuel doser solenoid valve 2
3: Fuel dosing pressure sensor

FUNCTION OF FUEL DOSER SOLENOID VALVE AND DOSER FUEL PRESSURE

SENSOR
• Fuel doser solenoid valves (1) and (2) and doser fuel pressure sensor (3) are assembled as a fuel doser
solenoid valve assembly.
• A mesh filter is installed to fuel inlet (A) of the fuel doser solenoid valve assembly.
• The fuel pressure supplied to the fuel doser is measured by doser fuel pressure sensor (3).
• After active regeneration is finished, fuel doser solenoid valve (1) closes and stops supplying fuel.
At the same time, the remaining pressure opens fuel doser solenoid valve (2) and the fuel is drained.

10-116 125E-7 SERIES

10 STRUCTURE AND FUNCTION FUEL SYSTEM

FUEL PREFILTER
STRUCTURE OF FUEL PREFILTER
REMARK
The shape is subject to machine models.
General view and sectional view

A: Fuel inlet B: Fuel outlet

1: Air bleeder plug 3: Cartridge
2: Filter head

125E-7 SERIES 10-117

FUEL SYSTEM 10 STRUCTURE AND FUNCTION

FUEL MAIN FILTER

STRUCTURE OF FUEL MAIN FILTER
REMARK
The shape is subject to machine models.
General view and sectional view

A: Fuel inlet B: Fuel outlet

1: Air bleeder plug 3: Cartridge
2: Filter head

10-118 125E-7 SERIES

10 STRUCTURE AND FUNCTION COOLING SYSTEM

COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM PARTS
REMARK
The shape is subject to machine models.

A: From radiator B: To radiator

1: VGT 3: Engine oill cooler
2: Water pump 4: EGR cooler

125E-7 SERIES 10-119

COOLING SYSTEM 10 STRUCTURE AND FUNCTION

COOLING SYSTEM CIRCUIT DIAGRAM

a: Flow when thermostat is open b: Flow when thermostat is closed

1: Radiator 10: Coolant temperature sensor
2: Thermostat 11: Fuel doser
3: Cylinder head 12: KCCV
4: VGT 13: AdBlue/DEF injector
5: EGR cooler 14: Distribution block
6: Cylinder block 15: Air conditioner unit (heater section)
7: Engine oil cooler 16: AdBlue/DEF tank heating valve
8: Water pump 17: AdBlue/DEF tank
9: Water manifold

10-120 125E-7 SERIES

10 STRUCTURE AND FUNCTION COOLING SYSTEM

WATER PUMP
STRUCTURE OF WATER PUMP
REMARK
The shape is subject to machine models.
General view

A: To radiator (coolant) D: From radiator (coolant)

B: From each portion of engine (coolant) E: From engine oil pump (Engine oil)
C: To each portion of engine through water pump F: To each portion of engine (Engine oil)
(coolant)
1: Thermostat 4: Oil cooler
2: Thermostat housing 5: Water drain valve
3: Water pump

125E-7 SERIES 10-121

COOLING SYSTEM 10 STRUCTURE AND FUNCTION

THERMOSTAT
STRUCTURE OF THERMOSTAT
REMARK
The shape is subject to machine models.
General view and sectional view

A: To radiator B: To water pump

1: Thermostat 2: Thermostat housing

SPECIFICATIONS OF THERMOSTAT
Cracking temperature: 76.5±2 °C
Full open temperature: 90 °C
Valve lift: Min.9 mm

10-122 125E-7 SERIES

10 STRUCTURE AND FUNCTION COOLING SYSTEM

OPERATION OF THERMOSTAT
When coolant is cold (valve is closed)
While coolant (C) temperature is lower than the cracking tem-
perature of the thermostat, valve (1) is closed and coolant (C)
does not flow from the cylinder block and cylinder head to the
radiator but flows into water pump.

When coolant is hot (valve is open)

When coolant (C) temperature reaches the cracking tempera-
ture, heat sensing portion (2) inflates and raises valve (1), and
coolant (C) from the cylinder block and cylinder head flows into
radiator (B).

125E-7 SERIES 10-123

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

ELECTRICAL SYSTEM
COMPONENT PARTS OF ELECTRICAL SYSTEM
ALTERNATOR
STRUCTURE OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE, 90A)
REMARK
The shape is subject to machine models.
General view and circuit diagram

1: Alternator 6: Internal wiring diagram

2: Alternator pulley 6A: Initial excitation resistance
3: Terminal B 6B: Regulator
4: Terminal E 6C: Field coil
5: Terminal R

10-124 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM

SPECIFICATIONS OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,

90A)
Type: Open type manufactured by NIKKO DENKI (brushless)
Specifications: 24 V, 90 A
Number of pulley grooves: 8
Pulley outside diameter: 80 mm
Weight: 19 kg

125E-7 SERIES 10-125

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

STRUCTURE OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,

140A)
REMARK
The shape is subject to machine models.
General view and circuit diagram

1: Alternator (body) 6A: Initial excitation resistance

2: Alternator pulley 6B: Regulator
3: Terminal R 6C: Field coil
4: Terminal B 6D: Condenser
5: Terminal E 6E: stator
6: Internal wiring diagram 6F: Rectifying diode

SPECIFICATIONS OF ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE,

140A)
Type: Open type manufactured by NIKKO DENKI (brushless)
Specifications: 24 V, 140 A
Number of pulley grooves: 8

10-126 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM

Pulley outside diameter: 85 mm

Weight: 16.5 kg

125E-7 SERIES 10-127

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

ALTERNATOR MOUNTING
STRUCTURE OF ALTERNATOR MOUNTING
REMARK
The shape is subject to machine models.
General view

1: Alternator 4: Alternator belt

2: Alternator bracket 5: Auto-tensioner
3: Crankshaft pulley
REMARK
Auto-tensioner (5) automatically adjusts the tension of alternator belt (4) at a constant level.

10-128 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM

STARTING MOTOR
STRUCTURE OF STARTER MOTOR WITH BUILT-IN SAFETY RELAY (7.5kW)
REMARK
The shape is subject to machine models.
General view and circuit diagram

S: To starting switch terminal C R: To alternator terminal R

1: Pinion 4: Terminal B
2: Starting motor (body) 5: Terminal C
3: Magnetic switch 6: Safety relay

125E-7 SERIES 10-129

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

7: External wiring diagram 7B: Starting motor

7A: Safety relay section 8: Connector type

SPECIFICATIONS OF STARTER MOTOR BUILT IN SAFETY RELAY (7.5kW)

Type: Manufactured by NIKKO DENKI, water-resistant, oil-resistant
Specifications: 24 V, 7.5 kW
Number of teeth of pinion: 12
Weight: 16 kg
Connector type: A

10-130 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM

STRUCTURE OF STARTER MOTOR WITH BUILT-IN SAFETY RELAY (11kW)

REMARK
The shape is subject to machine models.
General view and circuit diagram

S: To starting switch terminal C R: To alternator terminal R

1: Pinion 5: Terminal C
2: Starting motor (body) 6: Safety relay
3: Magnetic switch 7: External wiring diagram
4: Terminal B 7A: Safety relay section

125E-7 SERIES 10-131

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

7B: Starting motor 8: Connector type

SPECIFICATIONS OF STARTER MOTOR BUILT IN SAFETY RELAY (11kW)

Type: Manufactured by NIKKO DENKI, water-resistant, oil-resistant
Specifications: 24 V, 11 kW
Number of teeth of pinion: 12
Weight: 18 kg
Connector type: A

10-132 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM

ENGINE WIRING HARNESS

STRUCTURE OF ENGINE WIRING HARNESS
REMARK
The shape is subject to machine models.
General view

No. Sensor Connector label name

1 Engine oil pressure sensor POIL
2 EGR valve lift sensor SEGR
3 Fuel doser solenoid valve connector 1 DSOV1
4 VGT position sensor SVGT
5 VGT speed sensor VGT_REV
6 Dosing fuel pressure sensor PDOSER
7 Fuel doser solenoid valve connector 2 DSOV2
8 Ambient pressure sensor PAMB

125E-7 SERIES 10-133

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

No. Sensor Connector label name

9 Coolant temperature sensor TWTR
10 Engine wiring harness intermediate connector OEM
11 Common rail pressure sensor: PFUEL
12 NE (crankshaft) speed sensor NE
13 Engine controller connector 2 J2
14 Engine controller connector 1 J1
15 Charge pressure sensor PIM
16 Supply pump 1 connector PCV2
17 Bkup (camshaft) speed sensor G
18 Supply pump 2 connector PCV1

10-134 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM

ENGINE CONTROLLER
STRUCTURE OF ENGINE CONTROLLER
General view

FUNCTION OF ENGINE CONTROLLER

• The employed engine controller is jointly developed by Komatsu and Cummins.
• The engine controller calculates the input signals from sensors installed to various portions, and outputs
them to control the engine properly.
• The engine controller commonly possesses the information of other controllers mounted on the machine
through the network (CAN) and controls the engine and machine properly.
• Since the engine controller is mounted on the engine, its field serviceability is improved.
• It is mounted through rubber vibration isolators to reduce the vibration transmitted to it.

125E-7 SERIES 10-135

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

ENGINE CONTROLLER SYSTEM DIAGRAM

10-136 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM

INPUT AND OUTPUT SIGNALS OF ENGINE CONTROLLER

Delphi96Pin “J1 connector”
Pin No. Signal name Input/Output
Ground/Shield/
1 Injector #1 (-)
Return
Ground/Shield/
2 Injector #2 (-)
Return
Ground/Shield/
3 Injector #3 (-)
Return
4 (*1) -
5 Fuel doser (+) Output
6 Fuel doser solenoid valve 2 Output
7 Fuel feed pump Output
8 Fuel doser solenoid valve 1 Output
9 Sensor power supply relay Output
10 (*1) -
11 (*1) -
12 (*1) -
13 EGR valve solenoid (+) Output
14 PCV2 (+) Output
15 (*1) -
Ground/Shield/
16 Turbocharger speed (-)
Return
17 Turbocharger speed (+) Input
18 Engine Bkup speed sensor Input
19 (*1) -
20 (*1) -
21 (*1) -
22 (*1) -
23 PCV1 (+) Output
PCV1 (-) Ground/Shield/
24
Return
25 Injector #1 (+) Output
26 Injector #2 (+) Output
27 Injector #3 (+) Output
28 (*1) -
Ground/Shield/
29 Fuel doser (-)
Return
Ground/Shield/
30 GND
Return
31 Engine NE speed sensor Input
32 Mass air flow (MAF) sensor Input

125E-7 SERIES 10-137

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input/Output

33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 Dosing fuel pressure sensor Input
38 (*1) -
39 (*1) -
40 (*1) -
41 (*1) -
42 (*1) -
43 (*1) -
44 Ambient pressure sensor Input
45 Charge pressure sensor Input
46 (*1) -
47 (*1) -
Ground/Shield/
48 PCV2 (-)
Return
49 Injector #4 (+) Output
50 Injector #5 (+) Output
51 Injector #6 (+) Output
52 (*1) -
53 (*1) -
Ground/Shield/
54 GND
Return
Ground/Shield/
55 GND
Return
Ground/Shield/
56 GND
Return
Ground/Shield/
57 GND
Return
Ground/Shield/
58 GND
Return
59 (*1) -
60 (*1) -
61 Intake air temperature sensor Input
62 Charge temperature sensor Input
63 Crankcase pressure sensor Input
64 (*1) -
65 (*1) -
66 (*1) -
67 VGT position sensor Input

10-138 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM

Pin No. Signal name Input/Output

68 (*1) -
69 (*1) -
70 Datalink3 (+) (KOMNET/r) Communication
71 (*1) -
72 (*1) -
Ground/Shield/
73 Injector #4 (-)
Return
Ground/Shield/
74 Injector #5 (-)
Return
Ground/Shield/
75 Injector #6 (-)
Return
Ground/Shield/
76 EGR valve solenoid (-)
Return
77 (*1) -
78 Sensor 5 V power supply Power supply
79 Sensor 5 V power supply Power supply
80 Sensor 12 V power supply Power supply
81 Sensor 5 V power supply Power supply
82 Sensor 5 V power supply Power supply
83 Coolant temperature sensor Input
84 (*1) -
85 Engine oil pressure sensor Input
86 (*1) -
87 Common rail pressure sensor Input
88 EGR valve lift sensor Input
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 Datalink3 (-) (KOMNET/r) Communication
95 (*1) -
96 (*1) -

*1: Never connect these pins. Malfunctions or failures may occur.

Delphi96Pin “J2 connector”
Pin No. Signal name Input/Output
1 Power supply (+24 V, continuous) Power supply
Ground/Shield/
2 VGT solenoid (-)
Return
3 AdBlue/DEF line heater relay 1 Output

125E-7 SERIES 10-139

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input/Output

4 (*1) -
5 ACC (Key SW) Input
6 AdBlue/DEF pump temperature sensor/ AdBlue/DEF pump driver Input/ Output
7 AdBlue/DEF line heater relay 2 Output
8 Sensor 5 V power supply Power supply
9 Sensor 5 V power supply Power supply
10 Throttle sensor Input
11 (*1) -
12 (*1) -
13 (*1) -
14 (*1) -
15 (*1) -
16 AdBlue/DEF pump pressure sensor Input
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
21 Datalink4 (+) (Sensor controller) Communication
22 Datalink4 (+) (KOMNET/c) Communication
23 (*1) -
24 (*1) -
25 Power supply (+24 V, continuous) Power supply
26 Power supply (+24 V, continuous) Power supply
27 Power supply (+24 V, continuous) Power supply
28 Power supply (+24 V, continuous) Power supply
29 (*1) -
30 (*1) -
31 (*1) -
Ground/Shield/
32 GND
Return
Ground/Shield/
33 GND
Return
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 AdBlue/DEF line heater 2 Input
39 AdBlue/DEF line heater 1 Input
40 (*1) -

10-140 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM

Pin No. Signal name Input/Output

41 KDPF differential pressure sensor Input
42 KDPF outlet pressure sensor Input
(*1): Machine equipped with fuel control dial
43 -
Idle validation switch 2: Machine with accelerator pedal
(*1): Machine equipped with fuel control dial
44 -
Idle validation switch 1: Machine with accelerator pedal
45 Datalink4 (-) (Sensor controller) Communication
46 Datalink4 (-) (KOMNET/c) Communication
47 (*1) -
48 System operating lamp Output
Ground/Shield/
49 Power GND
Return
Ground/Shield/
50 Power GND
Return
Ground/Shield/
51 Power GND
Return
Ground/Shield/
52 Power GND
Return
Ground/Shield/
53 AdBlue/DEF injector (-)
Return
Ground/Shield/
54 GND
Return
55 (*1) -
56 Ambient temperature sensor Input
Ground/Shield/
57 GND
Return
58 (*1) -
59 (*1) -
60 (*1) -
Ground/Shield/
61 GND
Return
62 (*1) -
63 (*1) -
64 (*1) -
65 Engine room temperature sensor Input
66 (*1) -
67 (*1) -
68 (*1) -
69 (*1) -
70 (*1) -
71 (*1) -
72 (*1) -

125E-7 SERIES 10-141

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input/Output

Ground/Shield/
73 Power GND
Return
74 (*1) -
75 Intake air heater relay Output
76 (*1) -
77 AdBlue/DEF injector (+) Output
78 (*1) -
79 AdBlue/DEF pump voltage Output
80 VGT solenoid (+) Output
81 AdBlue/DEF FCV Output
82 AdBlue/DEF tank heating valve Output
83 AdBlue/DEF pump heater relay Output
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
88 (*1) -
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 (*1) -
95 (*1) -
96 (*1) -

*1: Never connect these pins. Malfunctions or failures may occur.

10-142 125E-7 SERIES

10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ELECTRICAL SYSTEM

FUEL FEED PUMP

STRUCTURE OF FUEL FEED PUMP
General view

A: Fuel inlet B: Fuel outlet

1: Body 3: Bracket
2: Rubber 4: Connector

FUNCTION OF FUEL FEED PUMP

The fuel feed pump is controlled and driven by the engine controller or fuel feed pump switch in the following
cases.
• Increase the fuel pressure during fuel dosing process. (Controlled by engine controller)
• Bleed air from the fuel line (on engine side). (Controlled by fuel feed pump switch)

125E-7 SERIES 10-143

COMPONENT PARTS OF ELECTRICAL SYSTEM 10 STRUCTURE AND FUNCTION

FUEL FEED PUMP SWITCH

STRUCTURE OF FUEL FEED PUMP SWITCH
General view

1: Body 3: LED lamp

2: Toggle switch 4: Connector

FUNCTION OF FUEL FEED PUMP SWITCH

• This switch receives signals from the engine controller and drives the fuel feed pump.
• The fuel feed pump is driven to bleed air from the fuel line by operating the toggle switch, when the fuel
filter is replaced, etc.
Air in the fuel line is bled by driving the fuel feed pump for the set time of the built-in timer.
• When the starting switch is at OFF position, the fuel feed pump is driven in the following pattern; Pump is
driven (30 seconds) → Pump is stopped (10 seconds). After 10 cycles of this pattern, the pump is stopped
automatically.

10-144 125E-7 SERIES

10 STRUCTURE AND FUNCTION SENSOR

SENSOR
LAYOUT DRAWING OF ENGINE SENSOR
REMARK
The figure shows PC400, Model 11 as an example.
General view

125E-7 SERIES 10-145

SENSOR 10 STRUCTURE AND FUNCTION

1: Air cleaner clogging sensor 6: SCR temperature sensor

2: Mass air flow and temperature sensor 7: SCR outlet NOX sensor
3: Crankcase pressure sensor 8: Ammonia sensor
4: KDPF differential pressure and outlet pressure sen- 9: EGR valve lift sensor
sor
5: KDPF temperature sensor

10-146 125E-7 SERIES

10 STRUCTURE AND FUNCTION SENSOR

Detailed drawing 1

10: Bkup speed sensor 13: Engine oil level sensor

11: Engine oil pressure sensor 14: Charge pressure sensor
12: Common rail pressure sensor 15: NE speed sensor

125E-7 SERIES 10-147

SENSOR 10 STRUCTURE AND FUNCTION

Detailed drawing 2

16: Charge temperature sensor 20: VGT speed sensor

17: Ambient pressure sensor 21: Turbocharger outlet NOX sensor
18: Fuel dosing pressure sensor 22: Coolant temperature sensor
19: VGT position sensor

10-148 125E-7 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF AMBIENT PRESSURE SENSOR

Ambient pressure sensor is attached to the air intake cover part on the top of engine.
General view

1: Connector (FRAMATOME-3P) 2: Sensor

FUNCTION OF AMBIENT PRESSURE SENSOR

It detects ambient pressure and outputs a variable voltage.
Output characteristics

125E-7 SERIES 10-149

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF ENGINE OIL PRESSURE SENSOR

Engine oil pressure sensor is attached to the cylinder block.
General view

1: O-ring 3: Connector
2: Sensor

FUNCTION OF ENGINE OIL PRESSURE SENSOR

It detects engine oil pressure and outputs a corresponding variable voltage.

10-150 125E-7 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF CHARGE PRESSURE SENSOR

Charge pressure sensor is attached to the intake manifold of engine.
General view

1: O-ring 3: Connector
2: Sensor

FUNCTION OF CHARGE PRESSURE SENSOR

It detects engine air intake pressure and outputs signal as a variable voltage for pressure.

125E-7 SERIES 10-151

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF CHARGE TEMPERATURE SENSOR

General view

FUNCTION OF CHARGE TEMPERATURE SENSOR

It converts the temperature variation into the resistance variation and outputs the corresponding signals.

10-152 125E-7 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF COOLANT TEMPERATURE SENSOR

Coolant temperature sensor is attached to the cylinder head of engine.
General view

1: Connector (DELPHI-2P/PACKRD-2P) 3: O-ring

2: Sensor

FUNCTION OF COOLANT TEMPERATURE SENSOR

It converts the temperature variation into the resistance variation and outputs the corresponding signals.

125E-7 SERIES 10-153

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR

NE (crankshaft) speed sensor is attached to the crankshaft pulley part of engine front cover.
General view

1: O-ring 3: Connector
2: Sensor

FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR

It outputs pulse voltage by the rotation of the gear.

10-154 125E-7 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR

General view

FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR

• Just the same as NE speed sensor, it detects passing
pulse of 0 to 5 V which is generated by the changes of
magnetic lines in the sensor.
• Disc shape gear in the center of camshaft of the high pres-
sure pump has notches (concaved cut-out) by 120 ° inter-
val.
Furthermore, extra notch is cut. Accordingly, 7 pulses per 2
engine rotations are outputted.
• The combination of NE speed sensor pulse and Bkup
speed sensor pulse is recognized as a first cylinder stand-
ard pulse.

125E-7 SERIES 10-155

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF COMMON RAIL PRESSURE SENSOR

Common rail pressure sensor is attached to the common rail of engine.
General view

1: Connector 2: Sensor

FUNCTION OF COMMON RAIL PRESSURE SENSOR

It detects fuel pressure and outputs a variable voltage.

10-156 125E-7 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF EGR VALVE LIFT SENSOR

EGR valve lift sensor is attached to the EGR valve of engine.
General view

1: O-ring (small) 3: Sensor

2: O-ring (big) 4: Connector

FUNCTION OF EGR VALVE LIFT SENSOR

It detects EGR valve opening position and outputs a corresponding variable voltage.
Output characteristics
The relation between stroke and output voltage is shown in the
following graph.

125E-7 SERIES 10-157

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF VGT SPEED SENSOR

VGT speed sensor is attached to VGT of engine.
General view

1: Sensor 3: Connector
2: O-ring

FUNCTION OF VGT SPEED SENSOR

It outputs pulse voltage by the rotation of VGT turbine.

10-158 125E-7 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF VGT POSITION SENSOR

VGT position sensor is attached to VGT of engine.
General view

1: O-ring (small) 3: Sensor

2: O-ring (big) 4: Connector

FUNCTION OF VGT POSITION SENSOR

It detects the position of nozzle ring which is built in VGT and outputs a corresponding variable voltage.
Output characteristics
The relation between stroke and output voltage is shown in fol-
lowing graph.

125E-7 SERIES 10-159

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR

“Mass air flow” is sometimes described as “MAF (Mass Air Flow)”.
Mass air flow and temperature sensor is attached to the outlet side of air cleaner.
General view

1: Connector (SUMITOMO-4P) 3: Sensor

2: O-ring

FUNCTION OF MASS AIR FLOW AND TEMPERATURE SENSOR

It converts the variations of mass air flow and temperature into the pulse voltage and the resistance variation
and outputs the corresponding signals.

10-160 125E-7 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF DOSING FUEL PRESSURE SENSOR

This sensor is installed to the fuel doser solenoid valve assembly.
General view

1: O-ring 3: Connector
2: Sensor

FUNCTION OF DOSING FUEL PRESSURE SENSOR

It detects the pressure of the fuel supplied and outputs the corresponding variable voltage.

125E-7 SERIES 10-161

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE

SENSOR
KDPF differential pressure and outlet pressure sensor is attached to KDPF.
General view

1: High-pressure port 3: Connector

2: Low-pressure port 4: Sensor

FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE

SENSOR
• It detects KDPF inlet pressure and outlet pressure and outputs a corresponding variable voltage.
• Differential pressure indicates the difference between KDPF inlet pressure detected at high-pressure port
(1) and KDPF outlet pressure detected at low-pressure port (2).
• KDPF outlet pressure detected at low-presser port (2) is outputted as an outlet pressure.

10-162 125E-7 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF CRANKCASE PRESSURE SENSOR

Crankcase pressure sensor is attached to the inlet port side of KCCV head part.
General view

1: Connector (FRAMATOME-3P) 3: O-ring

2: Sensor

FUNCTION OF CRANKCASE PRESSURE SENSOR

It detects crankcase pressure (blowby gas pressure) and outputs a corresponding variable voltage.

125E-7 SERIES 10-163

SENSOR 10 STRUCTURE AND FUNCTION

STRUCTURE OF ENGINE OIL LEVEL SENSOR

Engine oil level sensor is attached to the side of engine oil pan.
General view

1: Connector (DT-2P) 3: Float

2: Bracket 4: Switch

FUNCTION OF ENGINE OIL LEVEL SENSOR

As the oil goes blow specified level, float drops and turns “OFF” the switch.

10-164 125E-7 SERIES

10 STRUCTURE AND FUNCTION SENSOR

STRUCTURE OF AIR CLEANER CLOGGING SENSOR

Air cleaner clogging sensor is attached to the air cleaner outlet side.
General view

1: Adapter 3: Indicator
2: Hood 4: Connector (DT-2P)

FUNCTION OF AIR CLEANER CLOGGING SENSOR

The switch turns “ON” when the air cleaner is clogged and pressure goes below the specified pressure (nega-
tive pressure).

125E-7 SERIES 10-165

 20 STANDARD VALUE TABLE

125E-7 SERIES 20-1

CONTENTS 20 STANDARD VALUE TABLE

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 20-3
STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-9
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18)
............................................................................................................................................................ 20-9
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (HM300-5, HM300-5E0).............................20-11
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (PC490LC-11, PC490LCI-11).................... 20-13
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA470-8) ................................................ 20-15
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA475-10) .............................................. 20-17
STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA480-8) ................................................ 20-19
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD ........................................................ 20-21
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (D85EX-18,
D85EXI-18, D85PX-18, D85PXI-18) .................................................................................................. 20-21
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (HM300-5,
HM300-5E0) ...................................................................................................................................... 20-23
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (PC490LC-11,
PC490LCI-11).................................................................................................................................... 20-25
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (WA470-8) ...... 20-27
ENGINE OPERATION STANDARD FOR BREAK IN PERIOD AND PERFORMANCE TEST STANDARD:
SAA6D125E-7 (WA475-10) ............................................................................................................... 20-29
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD: SAA6D125E-7 (WA480-8) ...... 20-31

20-2 125E-7 SERIES

20 STANDARD VALUE TABLE ABBREVIATION LIST

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

125E-7 SERIES 20-3

ABBREVIATION LIST 20 STANDARD VALUE TABLE

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

20-4 125E-7 SERIES

20 STANDARD VALUE TABLE ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

125E-7 SERIES 20-5

ABBREVIATION LIST 20 STANDARD VALUE TABLE

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actu-
system
ated, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for “International System of Units” It
SI al d' Unites (Internation- Unit is the universal unit system and “a single unit for
al unit system) a single quantity” is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

20-6 125E-7 SERIES

20 STANDARD VALUE TABLE ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

125E-7 SERIES 20-7

ABBREVIATION LIST 20 STANDARD VALUE TABLE

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

20-8 125E-7 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (D85EX-18,
20 STANDARD VALUE TABLE D85EXI-18, D85PX-18, D85PXI-18)

STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (D85EX-18,
D85EXI-18, D85PX-18, D85PXI-18)
Performance
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
Max. speed
with no load 2100 ± 50 –
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 °C Min. speed with
no load (Low 750 (+50/0) –
idle)

Air intake and exhaust system

Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine

Air intake re- kPa Max. 3.73 7.47

Whole speed range
sistance {mmH2O} {Max. 380} {762}
kPa Min. 113 87
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 850} {650}
Exhaust tem-
Whole speed range (20 °C) °C Max. 650 650
perature
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 °C Max. 1.5 2.5
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- Max. 0.5 0.5
let)

Valve clear- Intake valve 0.33 –

mm
ance Exhaust valve 0.71 –
Min. 1.43 1.43
At Max. speed with no load (High idle)
EGR valve, MPa {Min. 14.6} {14.6}
VGT oil pres-
sure {kg/cm2} Min. 1.18 1.18
At Min. speed with no load (Low idle)
{Min. 12.0} {12.0}

Main body
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.9 2.0

pressure • Engine speed: 200 to 250 rpm {kg/cm2} {Min. 30} {20}

125E-7 SERIES 20-9

STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (D85EX-18,
D85EXI-18, D85PX-18, D85PXI-18) 20 STANDARD VALUE TABLE

Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine

Blowby pres- At rated horsepower (when KCCV is disconnec- kPa Max. 1.96 3.92
sure ted) {mmH2O} {Max. 200} {400}

Lubrication system
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
• Engine oil temperature: At rated horse- 0.29 to 0.69 0.18
Min. 80 ºC power {3.0 to 7.0} {1.8}
Engine oil • Engine oil (*1) MPa
pressure EOS5W30-LA At Min. speed {kg/cm2} Min. 0.08 0.05
EOS5W40-LA with no load
EO10W30-LA (Low idle) {Min. 0.8} {0.5}
EO15W40-LA
Engine oil tem-
Whole speed range (engine oil pan) °C 90 to 110 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 0.3
tion • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
Automatic adjust- Automatic adjust-
Alternator belt Deflection when pressed with finger at 98 N  ment ment
mm
tension {10 kg} 
(Auto-tensioner) (Auto-tensioner)

20-10 125E-7 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (HM300-5,
20 STANDARD VALUE TABLE HM300-5E0)

STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (HM300-5,

HM300-5E0)
Performance
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
Max. speed
with no load 2220 ± 50 –
Engine coolant temperature: 59 (High idle)
Engine speed rpm
to 102 °C Min. speed with
no load (Low 725 (+50/0) –
idle)

Air intake and exhaust system

Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine

Air intake re- kPa Max. 3.73 7.47

Whole speed range
sistance {mmH2O} {Max. 380} {762}
kPa Min. 140 113
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 1050} {850}
Exhaust tem-
Whole speed range (20 °C) °C Max. 650 650
perature
Engine outlet
• Engine coolant tempera- (between VGT
ture: 59 to 102 °C Max. 1.5 2.5
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- Max. 0.5 0.5
let)

Valve clear- Intake valve 0.33 –

mm
ance Exhaust valve 0.71 –
Min. 1.43 1.43
At Max. speed with no load (High idle)
EGR valve, MPa {Min. 14.6} {14.6}
VGT oil pres-
sure {kg/cm2} Min. 1.18 1.18
At Min. speed with no load (Low idle)
{Min. 12.0} {12.0}

Main body
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.9 2.0

pressure • Engine speed: 200 to 250 rpm {kg/cm2} {Min. 30} {20}

Blowby pres- At rated horsepower (when KCCV is disconnec- kPa Max. 1.96 3.92
sure ted) {mmH2O} {Max. 200} {400}

125E-7 SERIES 20-11

STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (HM300-5,
HM300-5E0) 20 STANDARD VALUE TABLE

Lubrication system
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
• Engine oil temperature: At rated horse- 0.29 to 0.69 Min. 0.18
Min. 80 ºC power {3.0 to 7.0} Min. {1.8}
Engine oil • Engine oil (*1) MPa
pressure EOS5W30-LA At Min. speed {kg/cm2} Min. 0.08 Min. 0.05
EOS5W40-LA with no load
EO10W30-LA (Low idle) {Min. 0.8} Min. {0.5}
EO15W40-LA
Engine oil tem-
Whole speed range (engine oil pan) °C 90 to 110 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 0.3
tion • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
Automatic adjust- Automatic adjust-
Alternator belt Deflection when pressed with finger at 98 N  ment ment
mm
tension {10 kg} 
(Auto-tensioner) (Auto-tensioner)

20-12 125E-7 SERIES

 STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7
20 STANDARD VALUE TABLE (PC490LC-11, PC490LCI-11)

STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (PC490LC-11,

PC490LCI-11)
Performance
Engine SAA6D125E–7
Standard value
Item Test condition Unit Failure criterion
for new machine
Max. speed
with no load 1930 ± 25 –
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 100 °C Min. speed with
no load (Low 1000 ± 25 –
idle)

Air intake and exhaust system

Engine SAA6D125E–7
Standard value
Item Test condition Unit Failure criterion
for new machine

Air intake re- kPa Max. 3.73 7.47

Whole speed range
sistance {mmH2O} {Max. 380} {762}
kPa Min. 147 120
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 1100} {900}
Exhaust tem-
Whole speed range (20 °C) °C Max. 650 650
perature
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 100 °C Max. 1.5 2.5
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- Max. 0.5 0.5
let)

Valve clear- Intake valve 0.33 –

mm
ance Exhaust valve 0.71 –
Min. 1.43 1.43
At Max. speed with no load (High idle)
EGR valve, MPa {Min. 14.6} {14.6}
VGT oil pres-
sure {kg/cm2} Min. 1.18 1.18
At Min. speed with no load (Low idle)
{Min. 12.0} {12.0}

Main body
Engine SAA6D125E–7
Standard value
Item Test condition Unit Failure criterion
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.9 2.0

pressure • Engine speed: 200 to 250 rpm {kg/cm2} {Min. 30} {20}

Blowby pres- At rated horsepower (when KCCV is disconnec- kPa Max. 1.96 3.92
sure ted) {mmH2O} {Max. 200} {400}

125E-7 SERIES 20-13

STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7
(PC490LC-11, PC490LCI-11) 20 STANDARD VALUE TABLE

Lubrication system
Engine SAA6D125E–7
Standard value
Item Test condition Unit Failure criterion
for new machine
• Engine oil temperature: At rated horse- 0.29 to 0.69 0.18
Min. 80 ºC power {3.0 to 7.0} {1.8}
Engine oil • Engine oil (*1) MPa
pressure EOS5W30–LA At Min. speed {kg/cm2} Min. 0.08 0.05
EOS5W40–LA with no load
EO10W30–LA (Low idle) {Min. 0.8} {0.5}
EO15W40–LA
Engine oil tem-
Whole speed range (engine oil pan) °C 90 to 110 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 0.3
tion • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D125E–7
Standard value
Item Test condition Unit Failure criterion
for new machine
Automatic adjust- Automatic adjust-
Alternator belt Deflection when pressed with finger at 98 N  ment ment
mm
tension {10 kg} 
(Auto-tensioner) (Auto-tensioner)

20-14 125E-7 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA470-8)

STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA470-8)

Performance
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
Max. speed
with no load 2170 ± 50 –
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 102 °C Min. speed with
no load (Low 800 (+50/0) –
idle)

Air intake and exhaust system

Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine

Air intake re- kPa Max. 3.73 7.47

Whole speed range
sistance {mmH2O} {Max. 380} {762}
kPa Min. 113 87
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 850} {650}
Exhaust tem-
Whole speed range (20 °C) °C Max. 650 650
perature
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 102 °C Max. 1.5 2.5
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- Max. 0.5 0.5
let)

Valve clear- Intake valve 0.33 –

mm
ance Exhaust valve 0.71 –
Min. 1.43 1.43
At Max. speed with no load (High idle)
EGR valve, MPa {Min. 14.6} {14.6}
VGT oil pres-
sure {kg/cm2} Min. 1.18 1.18
At Min. speed with no load (Low idle)
{Min. 12.0} {12.0}

Main body
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.9 2.0

pressure • Engine speed: 200 to 250 rpm {kg/cm2} {Min. 30} {20}

Blowby pres- At rated horsepower (when KCCV is disconnec- kPa Max. 1.96 3.92
sure ted) {mmH2O} {Max. 200} {400}

125E-7 SERIES 20-15

STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA470-8) 20 STANDARD VALUE TABLE

Lubrication system
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
• Engine oil temperature: At rated horse- 0.29 to 0.69 0.18
Min. 80 ºC power {3.0 to 7.0} {1.8}
Engine oil • Engine oil (*1) MPa
pressure EOS5W30-LA At Min. speed {kg/cm2} Min. 0.08 0.05
EOS5W40-LA with no load
EO10W30-LA (Low idle) {Min. 0.8} {0.5}
EO15W40-LA
Engine oil tem-
Whole speed range (engine oil pan) °C 90 to 110 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 0.3
tion • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
Automatic adjust- Automatic adjust-
Alternator belt Deflection when pressed with finger at 98 N  ment ment
mm
tension {10 kg} 
(Auto-tensioner) (Auto-tensioner)

20-16 125E-7 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA475-10)

STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA475-10)

Performance
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
Max. speed
with no load 1890 ± 50 –
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 102 °C Min. speed with
no load (Low 700 (+50/0) –
idle)

Air intake and exhaust system

Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine

Air intake re- kPa Max. 3.73 7.47

Whole speed range
sistance {mmH2O} {Max. 380} {762}
kPa Min. 106 87
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 800} {650}
Exhaust tem-
Whole speed range (20 ˚C) °C Max. 640 640
perature
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 102 °C Max. 1.5 2.5
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- Max. 0.5 0.5
let)

Valve clear- Intake valve 0.33 –

mm
ance Exhaust valve 0.71 –
Min. 1.43 1.43
At Max. speed with no load (High idle)
EGR valve, MPa {Min. 14.6} {14.6}
VGT oil pres-
sure {kg/cm2} Min. 1.18 1.18
At Min. speed with no load (Low idle)
{Min. 12.0} {12.0}

Main body
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.9 2.0

pressure • Engine speed: 200 to 280 rpm (reference) {kg/cm2} {Min. 30} {20}
• At rated horsepower (when KCCV is dis-
Blowby pres- kPa Max. 2.45 3.92
connected)
sure {mmH2O} {Max. 250} {400}
• Engine coolant temperature: 60 to 100 °C

125E-7 SERIES 20-17

STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA475-10) 20 STANDARD VALUE TABLE

Lubrication system
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
• Engine oil temperature: At rated horse- 0.29 to 0.69 0.18
Min. 80 ºC power {3.0 to 7.0} {1.8}
Engine oil • Engine oil (*1) MPa
pressure EOS5W30-LA At Min. speed {kg/cm2} Min. 0.08 0.05
EOS5W40-LA with no load
EO10W30-LA (Low idle) {Min. 0.8} {0.5}
EO15W40-LA
Engine oil tem-
Whole speed range (engine oil pan) °C 90 to 110 120
perature

Oil consump- • At continuous rated horsepower

％ Max. 0.15 0.3
tion • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
Automatic adjust- Automatic adjust-
Alternator belt Deflection when pushed with finger at approxi- ment ment
mm
tension mately 98 N {10 kg}
(Auto-tensioner) (Auto-tensioner)

20-18 125E-7 SERIES

20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA480-8)

STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA480-8)

Performance
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
Max. speed
with no load 2190 ± 50 –
Engine coolant temperature: 60 (High idle)
Engine speed rpm
to 102 °C Min. speed with
no load (Low 800 (+50/0) –
idle)

Air intake and exhaust system

Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine

Air intake re- kPa Max. 3.73 7.47

Whole speed range
sistance {mmH2O} {Max. 380} {762}
kPa Min. 127 100
Boost pressure At rated horsepower (gauge pressure)
{mmHg} {Min. 950} {750}
Exhaust tem-
Whole speed range (20 °C) °C Max. 650 650
perature
Engine outlet
• Engine coolant tempera- (between VGT
ture: 60 to 102 °C Max. 1.5 2.5
and KDPF in-
Exhaust gas let) Bosch in-
• At rated horsepower
color dex
• After it is kept for 5 sec- SCR outlet (ex-
onds at normal condition haust pipe out- Max. 0.5 0.5
let)

Valve clear- Intake valve 0.33 –

mm
ance Exhaust valve 0.71 –
Min. 1.43 1.43
At Max. speed with no load (High idle)
EGR valve, MPa {Min. 14.6} {14.6}
VGT oil pres-
sure {kg/cm2} Min. 1.18 1.18
At Min. speed with no load (Low idle)
{Min. 12.0} {12.0}

Main body
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.9 2.0

pressure • Engine speed: 200 to 250 rpm {kg/cm2} {Min. 30} {20}

Blowby pres- At rated horsepower (when KCCV is disconnec- kPa Max. 1.96 3.92
sure ted) {mmH2O} {Max. 200} {400}

125E-7 SERIES 20-19

STANDARD VALUE TABLE FOR ENGINE: SAA6D125E-7 (WA480-8) 20 STANDARD VALUE TABLE

Lubrication system
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
• Engine oil temperature: At rated horse- 0.29 to 0.69 0.18
Min. 80 ºC power {3.0 to 7.0} {1.8}
Engine oil • Engine oil (*1) MPa
pressure EOS5W30-LA At Min. speed {kg/cm2} Min. 0.08 0.05
EOS5W40-LA with no load
EO10W30-LA (Low idle) {Min. 0.8} {0.5}
EO15W40-LA
Engine oil tem-
Whole speed range (engine oil pan) °C 90 to 110 120
perature

Oil consump- • At continuous rated horsepower

% Max. 0.15 0.3
tion • Ratio to fuel consumption

*1: KES diesel engine oil

Electrical system
Engine SAA6D125E-7
Standard value
Item Test condition Unit Failure criterion
for new machine
Automatic adjust- Automatic adjust-
Alternator belt Deflection when pressed with finger at 98 N  ment ment
mm
tension {10 kg} 
(Auto-tensioner) (Auto-tensioner)

20-20 125E-7 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18)

RUNNING-IN STANDARD AND PERFORMANCE TEST

STANDARD
RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18)
Running-in standard
Engine SAA6D125E-7
Procedure
Item
1 2 3 4 5
Running time min 2 8 2 3 5
Engine speed rpm 750 950 1140 1425 1900
Dynamometer load N {kg} 0 {0} 275 {28} 697 {71} 1115 {114} 1394 {142}
Output kW{HP} 0 {0} 20 {26.6} 60 {80} 119 {160} 199 {266}

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

Performance test standard

Engine SAA6D125E-7
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
1272 Nm/
Specification value 199 kW/1900 rpm 1400 rpm
- 2100±50 rpm 750 (+50/0) rpm
(Gross value) {266 HP/1900 rpm} {130 kgm/
1400 rpm}
Engine speed rpm 1900 1400 2100 ± 50 750 (+50/0)
N 1354 to 1432 1727 to 1834
Dynamometer load - -
{kg} {138 to 146} {176 to 187}
199
Output (Gross value) kW{HP} - - -
{266}
Nm 1272
Torque (Gross value) - - -
{kgm} {130}
sec/300
Fuel consumption - - - -
cc
Coolant temperature °C 80 to 90 80 to 90 80 to 90 80 to 90
Lubricating oil tem-
°C 90 to 110 90 to 110 90 to 110 90 to 110
perature

Lubricating oil pres- kPa 290 to 690 190 to 540 290 to 690 Min. 80
sure {kg/cm2} {3.0 to 7.0} {2.0 to 5.5} {3.0 to 7.0} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 650 - -

125E-7 SERIES 20-21

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18) 20 STANDARD VALUE TABLE

REMARK
• This table shows the standard values obtained by using the JIS correction coefficients.
• Output and torque in this table shows the values when the fan is not installed, and these values differ from
specification values.
• This table shows the standard values when the air cleaner, KDPF, and the SCR are installed and no load is
applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

20-22 125E-7 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D125E-7 (HM300-5, HM300-5E0)

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D125E-7 (HM300-5, HM300-5E0)
Running-in standard
Engine SAA6D125E-7
Procedure
Item
1 2 3 4 5
Running time min 2 8 2 3 5
Engine speed rpm 725 1000 1200 1500 2000
Dynamometer load N {kg}  0 {0} 330 {34} 826 {84} 1321 {135} 1646 {168}
Output kW {HP} 0 {0} 25 {33} 74 {100} 149 {200} 248 {333}

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

Performance test standard

Engine SAA6D125E-7
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
1677 Nm/
Specification value 248 kW/2000 rpm 1400 rpm
- 2220±50 rpm 725(+50/0) rpm
(Gross value) {333 HP/2000 rpm} {171 kgm/
1400 rpm}
Engine speed rpm 2000 1400 2220±50 725(+50/0)
N 1579 to 1695 2274 to 2410
Dynamometer load - -
{kg} {163 to 173} {232 to 246}
248
Output (Gross value) kW{HP} - - -
{333}
Nm 1677
Torque (Gross value) - - -
{kgm} {171}
Fuel consumption sec/300cc - - - -
Coolant temperature °C 80 to 90 80 to 90 80 to 90 80 to 90
Lubricating oil tem-
°C 90 to 110 90 to 110 90 to 110 90 to 110
perature

Lubricating oil pres- kPa 290 to 690 190 to 540 290 to 690 Min. 80
sure {kg/cm2} {3.0 to 7.0} {2.0 to 5.5} {3.0 to 7.0} {Min.0.8}
Exhaust temperature °C Max. 650 Max. 650 - -

125E-7 SERIES 20-23

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D125E-7 (HM300-5, HM300-5E0) 20 STANDARD VALUE TABLE

REMARK
• This table shows the standard values obtained by using the JIS correction coefficients.
• Output and torque in this table show the values when the fan is not installed, and these values differ from
specification values.
• This table shows the standard values when the air cleaner, the KDPF, and the SCR are installed and no load
is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• For running-in, use EO15W40-LA as lubricating oil.

20-24 125E-7 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D125E-7 (PC490LC-11, PC490LCI-11)

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D125E-7 (PC490LC-11, PC490LCI-11)
Running–in standard
Engine SAA6D125E–7
Procedure
Item
1 2 3 4 5
Running time min 2 8 2 3 5
Engine speed rpm 1000 1000 1140 1425 1900
Dynamometer load N {kg}  0 {0} 360 {37} 947 {97} 1516 {155} 1895 {193}
Output kW {HP} 0 {0} 27 {36} 81 {109} 162 {217} 270 {362}

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

Performance test standard

Engine SAA6D125E–7
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
1510 Nm/
Specification value 270 kW/1900 rpm 1400 rpm
– 1930±25 rpm 1000±25 rpm
(Gross value) {362 HP/1900 rpm} {154 kgm/
1400 rpm}
Engine speed rpm 1900 1400 1930±25 1000 ± 25
N 1838 to 1952 2045 to 2172
Dynamometer load – –
{kg} {187 to 199} {209 to 221}
270
Output (Gross value) kW{HP} – – –
{362}
Nm 1510
Torque (Gross value) – – –
{kgm} {154}
Fuel consumption sec/300cc – – – –
Coolant temperature °C 80 to 90 80 to 90 80 to 90 80 to 90
Lubricating oil tem-
°C 90 to 110 90 to 110 90 to 110 90 to 110
perature

Lubricating oil pres- kPa 290 to 690 190 to 540 290 to 690 Min. 80
sure {kg/cm2} {3.0 to 7.0} {2.0 to 5.5} {3.0 to 7.0} {Min.0.8}
Exhaust temperature °C Max. 650 Max. 650 – –

125E-7 SERIES 20-25

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D125E-7 (PC490LC-11, PC490LCI-11) 20 STANDARD VALUE TABLE

REMARK
• This table shows the standard values obtained by using the JIS correction coefficients.
• Output and torque in this table show the values when the fan is not installed, and these values differ from
specification values.
• This table shows the standard values when the air cleaner, the KDPF, and the SCR are installed and no load
is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low–sulfur diesel fuel.
• For running–in, use EO15W40–LA as lubricating oil.

20-26 125E-7 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D125E-7 (WA470-8)

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D125E-7 (WA470-8)
Running-in standard
Engine SAA6D125E-7
Procedure
Item
1 2 3 4 5
Running time min 2 8 2 3 5
Engine speed rpm 800 1000 1200 1500 2000
Dynamometer load N {kg} 0 {0} 272 {28} 680 {69} 1088 {111} 1360 {139}
kW
Output 0 {0} 20 {27} 61 {82} 122 {164} 204 {273.5}
{HP}

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

Performance test standard

Engine SAA6D125E-7
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
1307 Nm/
204 kW/2000 rpm
Specification value 1450 rpm
- {273.5 HP/ 2170±50 rpm 800 (+50/0) rpm
(Gross value) {133.2 kgm/
2000 rpm}
1450 rpm}
Engine speed rpm 2000 1450 2170±50 800 (+50/0)
N 1319 to 1401 1769 to 1879
Dynamometer load - -
{kg} {135 to 143} {180 to 192}
kW 204
Output (Gross value) - - -
{HP} {273.5}
Nm 1307
Torque (Gross value) - - -
{kgm} {133.2}
sec/300
Fuel consumption - - - -
cc
Coolant temperature °C 80 to 90 80 to 90 80 to 90 80 to 90
Lubricating oil tem-
°C 90 to 110 90 to 110 90 to 110 90 to 110
perature

Lubricating oil pres- kPa 290 to 690 190 to 540 290 to 690 Min. 80
sure {kg/cm2} {3.0 to 7.0} {2.0 to 5.5} {3.0 to 7.0} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 650 - -

125E-7 SERIES 20-27

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D125E-7 (WA470-8) 20 STANDARD VALUE TABLE

REMARK
• This table shows the standard values obtained by using the JIS correction coefficients.
• Output and torque in this table shows the values when the fan is not installed, and these values differ from
specification values.
• This table shows the standard values when the air cleaner, KDPF, and the SCR are installed and no load is
applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

20-28 125E-7 SERIES

 ENGINE OPERATION STANDARD FOR BREAK IN PERIOD AND PER-
20 STANDARD VALUE TABLE FORMANCE TEST STANDARD: SAA6D125E-7 (WA475-10)

ENGINE OPERATION STANDARD FOR BREAK IN PERIOD AND PER-

FORMANCE TEST STANDARD: SAA6D125E-7 (WA475-10)
Engine operation standard for break in period
Engine SAA6D125E-7
Step
Item
1 2 3 4 5
Operation time min 2 8 2 3 5
Engine speed rpm 700 800 1000 1200 1600
Dynamometer load N {kg} 0 {0} 452 {46} 904 {92} 1446 {148} 1807 {184}
Output kW {HP} 0 {0} 27 {36} 68 {91} 130 {175} 217 {291}

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

Performance test standard

Engine SAA6D125E-7
At rated horsepow- Max. speed with Min. speed with no
Test item Maximum torque
er no load load
1528 Nm / 1330
217 kW /1600 rpm
Specification value rpm
– {291.0 HP / 1600 1890 ± 50 rpm 700 (+50/0) rpm
(Gross value) {155.8kgm / 1330
rpm}
rpm
Engine speed rpm 1600 1330 1890 ± 50 700 (+50/0)
N 1754 to 1863 2069 to 2197
Dynamometer load –– –
{kg} {179 to 190} {211 to 224}
kW 217
Output (Gross value) – – –
{HP} {291.0}
Nm 1528
Torque (Gross value) – – –
{kgm} {155.8}
sec / 300
Fuel consumption – – – –
cc
Coolant temperature °C 80 to 90 80 to 90 80 to 90 80 to 90
Lubrication oil tem-
°C 90 to 110 90 to 110 90 to 110 90 to 110
perature

Lubrication oil pres- kPa 290 to 690 190 to 540 290 to 690 Min. 80
sure {kg/cm2} {3.0 to 7.0} {2.0 to 5.5} {3.0 to 7.0} {Min. 0.8}
Exhaust gas tempera-
ture (inlet of turbo- °C Max. 600 Max. 640 – –
charger)

125E-7 SERIES 20-29

ENGINE OPERATION STANDARD FOR BREAK IN PERIOD AND PER-
FORMANCE TEST STANDARD: SAA6D125E-7 (WA475-10) 20 STANDARD VALUE TABLE

REMARK
• This table shows the standard values using JIS correction coefficients.
• The output and torque shown in this table are standard values when fans are not installed and are different
from the specification values.
• This table shows the standard values when the air cleaner is installed, KDPF, and the SCR is installed and
no load is applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as lubrication oil for break-in operation.

20-30 125E-7 SERIES

 RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
20 STANDARD VALUE TABLE SAA6D125E-7 (WA480-8)

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:

SAA6D125E-7 (WA480-8)
Running-in standard
Engine SAA6D125E-7
Procedure
Item
1 2 3 4 5
Running time min 2 8 2 3 5
Engine speed rpm 800 1000 1200 1500 2000
Dynamometer load N {kg} 0 {0} 299 {30} 747 {76} 1196 {122} 1495 {152}
kW
Output 0 {0} 22 {30} 67 {90} 134 {180} 224 {300}
{HP}

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

Performance test standard

Engine SAA6D125E-7
Max. speed with Min. speed with no
Test item Rated horsepower Max. torque
no load load
1359 Nm/
Specification value 224 kW/2000 rpm 1400 rpm
- 2190±50 rpm 800 (+50/0) rpm
(Gross value) {300 HP/2000 rpm} {138.7 kgm/
1400 rpm}
Engine speed rpm 2000 1400 2190±50 800 (+50/0)
N 1450 to 1539 1841 to 1955
Dynamometer load - -
{kg} {147 to 156} {188 to 199}
kW 224
Output (Gross value) - - -
{HP} {300}
Nm 1359
Torque (Gross value) - - -
{kgm} {138.7}
sec/300
Fuel consumption - - - -
cc
Coolant temperature °C 80 to 90 80 to 90 80 to 90 80 to 90
Lubricating oil tem-
°C 90 to 110 90 to 110 90 to 110 90 to 110
perature

Lubricating oil pres- kPa 290 to 690 190 to 540 290 to 690 Min. 80
sure {kg/cm2} {3.0 to 7.0} {2.0 to 5.5} {3.0 to 7.0} {Min. 0.8}
Exhaust temperature °C Max. 650 Max. 650 - -

125E-7 SERIES 20-31

RUNNING-IN STANDARD AND PERFORMANCE TEST STANDARD:
SAA6D125E-7 (WA480-8) 20 STANDARD VALUE TABLE

REMARK
• This table shows the standard values obtained by using the JIS correction coefficients.
• Output and torque in this table shows the values when the fan is not installed, and these values differ from
specification values.
• This table shows the standard values when the air cleaner, KDPF, and the SCR are installed and no load is
applied to the alternator.
• The loads for the dynamometer in this table shows the value when the dynamometer arm is 716 mm long.
• Use ultra low-sulfur diesel fuel.
• Use EO15W40-LA as running-in lubricating oil.

20-32 125E-7 SERIES

 50 DISASSEMBLY AND ASSEMBLY

125E-7 SERIES 50-1

 50 DISASSEMBLY AND ASSEM-
CONTENTS BLY

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 50-3
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ................................................................. 50-9
HOW TO READ THIS MANUAL.............................................................................................................. 50-9
COATING MATERIALS LIST..................................................................................................................50-11
SPECIAL TOOLS LIST ......................................................................................................................... 50-15
SKETCHES OF SPECIAL TOOLS........................................................................................................ 50-17
ENGINE SYSTEM ....................................................................................................................................... 50-20
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY.................................................................... 50-20
METHOD FOR DISASSEMBLING ENGINE GENERALLY............................................................. 50-21
METHOD FOR ASSEMBLING ENGINE GENERALLY .................................................................. 50-58
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY ........................................................................50-123
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY ............................................................50-123
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY ...........................................................50-125
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .........................................................................50-132
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .............................................................50-132
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL ............................................................50-133
REMOVE AND INSTALL ENGINE REAR OIL SEAL............................................................................50-135
METHOD FOR REMOVING ENGINE REAR OIL SEAL................................................................50-135
METHOD FOR INSTALLING ENGINE REAR OIL SEAL...............................................................50-136

50-2 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY ABBREVIATION LIST

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

125E-7 SERIES 50-3

 50 DISASSEMBLY AND ASSEM-
ABBREVIATION LIST BLY

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

50-4 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

125E-7 SERIES 50-5

 50 DISASSEMBLY AND ASSEM-
ABBREVIATION LIST BLY

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actu-
system
ated, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for “International System of Units” It
SI al d' Unites (Internation- Unit is the universal unit system and “a single unit for
al unit system) a single quantity” is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

50-6 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

125E-7 SERIES 50-7

 50 DISASSEMBLY AND ASSEM-
ABBREVIATION LIST BLY

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

50-8 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY HOW TO READ THIS MANUAL

RELATED INFORMATION ON DISASSEMBLY AND AS-

SEMBLY
HOW TO READ THIS MANUAL
This section describes the special tools, work procedures, and safety precautions necessary for removal, instal-
lation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
Reading the special tools list
• The special tools required for removal and installation work are described in the list as symbols such as
A1, ..., X1. Part number, part name, necessity, and quantity are described.
• Details of the special tools are on “SPECIAL TOOLS LIST”. Details of sketches are on “SKETCHES OF
SPECIAL TOOLS”. Special tools required for a specified work is also described in each work procedures.
• The symbols used in the table of special tools indicate the following meanings.
■: Not substitutable, and work cannot be performed without the tool.
●: Very useful tools to use which can be substituted with commercially available tools.
Reading the work procedures
All the necessary information for the work procedure, the precautions and prior knowledge relating to the work
procedures is described step by step.
Reading the symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
This signal indicates an extremely hazardous situation which will result in
Danger
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Warning
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.
This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.
This signal indicates a place to supply oil, coolant, etc. and the quantity.
Oil and coolant
(*1)

Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.

*1:For places to supply oil, coolant, etc. and their quantities, see SPECIFICATIONS “TABLE OF FUEL, COOL-
ANT, AND LUBRICANTS”.
Reading the signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE NOTICE
or shortening of service life may occur.

125E-7 SERIES 50-9

 50 DISASSEMBLY AND ASSEM-
HOW TO READ THIS MANUAL BLY

Symbol Item Remark

REMARK Remarks This signal word contains useful information to know.

Reading the unit

International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.

50-10 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY COATING MATERIALS LIST

COATING MATERIALS LIST

Coating materials which are not listed below, use the equivalent of products shown in this manual.

Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions, and cork plugs from falling off.
• Use for plastic (except polyethylene, pol-
20 g Polyethy- ypropylene, tetrafluoroethylene and vinyl
LT-1B 790-129-9050 (contained lene con- chloride), rubber, metal, and non-metal
2 pieces) tainer parts which require immediate and
strong adhesion.
• Features: Resistance to heat and chemi-
Polyethy- cals
LT-2 790-129-9180 50 g lene con-
tainer • Use to keep bolts and plugs from com-
ing loose and as sealant.
790-129-9060 Adhesive
Set of adhe- 1 kg • Use to bond and seal metal, glass and
LT-3 Pail
sive and hard- Hardener plastics.
ener 500 g
Polyethy-
LT-4 790-129-9040 250 g lene con- • Use to seal plugs for blank holes.
tainer
Holts • Heat-resistant seal used to repair en-
790-129-9120 75 g Tube
MH705 gines
• Instantaneous adhesive
Polyethy-
• Curing time: From 5 sec. to 3 min.
LT-1D 790-129-9140 50 g lene con-
tainer • Use to bond mainly metals, rubbers,
plastics, and woods.
• Instantaneous adhesive

Aron Alpha Polyethy- • Quick-curing type (max. strength is ob-

790-129-9130 2 g lene con- tained after 30 minutes)
201 tainer • Use to bond rubbers, plastics, and met-
als.
• General-purpose instantaneous adhe-
sive with excellent resistance to heat
Loctite
428-99-80070 20 cc Tube and impact
499
• Use for the bushing mounting faces of
axle supports.

Polyethy- • Features: Resistance to heat and chemi-

Loctite
79A-129-9110 50 cc lene con- cals
648-50 tainer • Use to bond high-temperature fit parts.

125E-7 SERIES 50-11

 50 DISASSEMBLY AND ASSEM-
COATING MATERIALS LIST BLY

Liquid gasket
Komatsu code Part No. Capacity Container Main features and applications
• Use to seal various threaded parts, pipe
Polyethy- joints, and flanges.
LG-5 790-129-9080 1 kg lene con-
tainer • Use to seal taper plugs, elbows, and nip-
ples for hydraulic piping.
• Features: Silicon-based heat and cold-
resistant
LG-6 790-129-9160 200 g Tube • Use to seal flange surface and threaded
parts
• Use to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-curing
sealant
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake
manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based heat, vibration,
THREEBOND 419-15-18131 100 g Tube and shock-resistant
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the cir-
LG-9 cle gear top seal which is not clamped
THREEBOND 790-129-9310 200 g Tube by bolts, gaps in the weld which must be
1206D
caulked, etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when insert-
THREEBOND 790-129-9320 200 g Tube ing radiator hoses
1206E • Can be coated with paint.

LG-11 • Feature: Can be used together with solid

gaskets.
THREEBOND 790-129-9330 200 g Tube
• Use for covers of the transmission case
1121
and steering case etc.
THREEBOND
790-129-9090 100 g Tube • Liquid gasket used to repair engine
1211

Molybdenum disulfide lubricant

Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent galling and seizure of
press-fitted parts, shrinkage-fitted parts,
LM-P — 200 g Tube and threaded parts.
• Use to lubricate linkages, bearings, etc.
• Spray type
• Thin molybdenum disulfide films are
made on metal surfaces to prevent the
LM-S — 190 g Pail
metals from galling.
• Use for the drive shaft splines, needle
bearings, various link pins, bolts, etc.

50-12 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY COATING MATERIALS LIST

Seizure prevention compound

Komatsu code Part No. Capacity Container Main features and applications
• Feature: Seizure and galling prevention
compound with metallic super-fine-grain,
LC-G etc.
— — Pail
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust mani-
fold and the turbocharger, etc.

Grease
Komatsu code Part No. Capacity Container Main features and applications
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI • Lithium grease with extreme pressure lu-
G0-LI (*)
SYGA-16CNLI Various Various brication performance, general purpose
*: For cold dis- type.
tricts SYG0-400LI-A
(*)
SYG0-16CNLI
(*)
• Use for parts under heavy load.

Molybdenum Bellows-
• Caution: Do not use this grease for roll-
SYG2-400M 400 gx 10 ing bearings like swing circle bearings,
disulfide type con-
grease SYG2-400M-A 400 gx 20 tainer etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Pail • Caution: Use this grease for work equip-
ment pins only when installing them, but
do not use it afterwards.
Hyper white SYG2-400T-A
grease • Higher seizure resistance, heat resist-
SYG2-16CNT Bellows-
ance, and waterproof than molybdenum
G2-T SYG0-400T-A 400 g type con-
disulfide grease
G0-T(*) (*) 16 kg tainer
Pail
• Not so conspicuous on machine since
*: For cold dis- SYG0-16CNT color is white.
tricts (*)
Biogrease SYG2-400B
G2-B SYGA-16CNB
Bellows- • Since this grease is bacterially biode-
G2-BT (*) SYG2-400BT 400 g type con- gradable in short period, the impact on
*: For use at (*) tainer microorganisms, animals, and plants is
16 kg
high tempera- SY- Pail kept to the minimum.
ture and under GA-16CNBT
high load (*)
• Feature: Silicon-based grease with wider
G2-S operating temperature range and superi-
THREEBOND — 200 g Tube or thermal oxidative stability to prevent
1855
deterioration of rubber and plastic.
• Use for oil seals of the transmission, etc.

125E-7 SERIES 50-13

 50 DISASSEMBLY AND ASSEM-
COATING MATERIALS LIST BLY

Komatsu code Part No. Capacity Container Main features and applications
• Feature: Urea (organic) grease with heat
resistance and long service life, inclu-
G2-U-SENS sion type.
427-12-11871 2 kg Pail
Grease • Use for rubber, bearing and oil seal in
damper.
• Caution: Do not mix with lithium grease.

Primer
Komatsu code Part No. Capacity Container Main features and applications
Loctite Glass con- • Use to accelerate hardening of instanta-
428-99-80080 100 mℓ
712 tainer neous adhesive.
SUNSTAR • Use as primer for cab side (Expira-
Glass con-

For adhered window glass

Paint Surface 22M-54–27260 150 mℓ tion date: 4 months after its produc-
tainer
Primer 435-98 tion date)
SUNSTAR • Use as primer for black ceramic-coat-
PRIMER ed glass surface and for hard poly-
22M-54-27240 150 mℓ Steel can
435-41 for carbonate-coated surface (Expiration
glass date: 6 days after its production date)
SUNSTAR • Use as primer for sash (alumite sur-
sash primer 22M-54-27250 900 mℓ Steel can face treatment) (Expiration date:6
GP-402 months after its production date)

Adhesive
Komatsu code Part No. Capacity Container Main features and applications
Polyethy- • Use as adhesive for glass (Expiration
For adhered window glass

Sika Japan Si-

20Y-54-39850 310 mℓ lene con- date: 6 months after its production
kaflex 256HV
tainer date)
SUNSTAR Ecocart • Use as adhesive for glass (Expiration
Penguin Super 22M-54-27210 320 mℓ (special date: 6 months after its production
560 container) date)
SUNSTAR Ecocart • Use as adhesive for glass (Expiration
Penguin Seal 416–926–6950 320 mℓ (special date: 6 months after its production
#560 container) date)

Caulking material
Komatsu code Part No. Capacity Container Main features and applications
SUNSTAR Polyethy- • Use to seal for joint between glasses
For adhered window glass

Penguin Seal 417-926-3920 320 mℓ lene con- (Expiration date: 4 months after its
No.2505 tainer production date)
Polyethy-
SEKISUI Sili- • Use to seal front window (Expiration
20Y-54-55130 333 mℓ lene con-
cone Sealant date: 6 months after its production)
tainer
GE TOSHIBA • Translucent white seal used for joint
SILICONES 22M-54-27220 333 mℓ Cartridge between glasses (Expiration date: 12
TOSSEAL381 months after its production date)

50-14 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY SPECIAL TOOLS LIST

SPECIAL TOOLS LIST

How to read the tools list
• Part Number:
Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
• Necessity
■: Not substitutable, and work cannot be performed without the tool.
●: Tools extremely useful if available or tools that can be substituted with commercially available tool.
• New/Redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
• Sketch
○: Tools marked with ○ in the sketch column have the sketches.
Sketches are introduced in “Sketches of special tools”, and all sketches of “79*T-***-***”are described.

New/Redesign
Necessity

Sketch
Sym-

Q'ty
Work Part No. Part name Details of work
bol

Disassembly and as- 1 790-501-2001 Engine repair stand ■ 1

sembly of engine as- A Setting of cylinder block
sembly 2 790-901-1240 Adapter ■ 1

Removal and installa- Removal and installation

tion of cylinder head B 795-102-2103 Spring pusher ■ 1 of cylinder head valve as-
valve spring sembly
Removal and installa- Removal and installation
C 795-100-1191 Piston ring tool ■ 1
tion of piston ring of piston ring
Removal of cylinder lin-
D 795-220-1000 Cylinder liner puller ■ 1 Removal of cylinder liner
er
Installation of cylinder
E 795-225-1520 Cylinder liner driver ■ 1 Press fit of cylinder liner
liner
Measurement of protru- Measurement of protru-
F 795-790-4100 Depth gauge ■ 1
sion of cylinder liner sion of cylinder liner
Installation of piston as- Insertion of piston as-
G 795-921-1110 Piston holder ■ 1
sembly sembly
Measurement of protru- Measurement of protru-
H 795-502-1121 Gauge holder ■ 1
sion of piston head sion of piston head
Adjusting valve clear-
J 795-125-1360 Feeler gauge ● 1 Adjusting valve clearance
ance
Angle tightening of con-
necting rod cap, main
Angle tightening of bolt K 790-331-1110 Wrench ● 1
cap bolt, and cylinder
head bolt
Removal of engine front Removal of engine front
Oil seal puller assem-
oil seal and engine rear L 795-931-1100 ● 1 oil seal and engine rear
bly
oil seal oil seal
1 795T-621-3410 Push tool ■ 1 ○
Installation of engine Press fit of engine front
M 2 01010-61650 Bolt ■ 3
front oil seal oil seal
3 01643-31645 Washer ■ 9

125E-7 SERIES 50-15

 50 DISASSEMBLY AND ASSEM-
SPECIAL TOOLS LIST BLY

New/Redesign
Necessity

Sketch
Sym-

Q'ty
Work Part No. Part name Details of work
bol

1 795T-421-1340 Push tool ■ 1 ○

Press fit of standard oil
2 01010-61635 Bolt ■ 3
seal (with guide)
3 01643-31645 Washer ■ 3
4 795-931-1220 Push tool ■ 1
Installation of engine
N 5 01010-41650 Bolt ■ 3
rear oil seal
6 01643-31645 Washer ■ 3 Press fit of sleeved oil
7 795T-421-1340 Push tool ■ 1 ○ seal
8 01010-61645 Bolt ■ 3
9 01643-31645 Washer ■ 9
1 795-630-5500 Standard puller ■ 1
Removal of supply Removal of supply pump
P 2 01010-81090 Bolt ■ 2
pump drive gear
3 01643-31032 Washer ■ 2
Installation of oil seal for
Press fit of oil seal in
valve stem in cylinder Q 795T-411-1510 Screwdriver ■ 1 N ○
valve system
head
Press fit of exhaust con-
1 795T-621-2820 Push tool ■ 1 N ○
nector seal
Installation of exhaust
S Measurement of exhaust
connector
2 795T-621-3310 Installer ■ 1 N ○ connector installed di-
mensions

50-16 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS

k Komatsu does not take any responsibility for special tools manufactured according to these sketch-
es.
M1 Push tool

N1 Push tool

125E-7 SERIES 50-17

 50 DISASSEMBLY AND ASSEM-
SKETCHES OF SPECIAL TOOLS BLY

N7 Push tool

Q Screwdriver

50-18 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY SKETCHES OF SPECIAL TOOLS

S1 Push tool

S2 Installer

125E-7 SERIES 50-19

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

ENGINE SYSTEM
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY
NOTICE
• Before starting your work, check the shapes, quantity, locations, etc. of the parts depending on the
machine model.
• Before disassembling the engine, check its parts for cracking, damage, etc. and clean it thoroughly
and carefully for accurate inspection of its parts and quick disassembly and assembly.
• Before cleaning the engine, carefully seal the openings or remove electric parts and wiring connec-
tors so that water does not enter them.
• Clean every parts throughly and check them for dent, scratch and void. Also check that passages of
oil and coolant is not clogged, and then assemble them.

50-20 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

METHOD FOR DISASSEMBLING ENGINE GENERALLY

Engine Preparation Starting

- Set it on motor A
assembly assembly
blocks
- Drain the
coolant
- Drain the Alternator B
oil

Oil tube for VGT, Exhaust

VGT hydraulic EGR cooler manifold Air bent tube C
actuator assembly

Wiring Oil cooler

harness D
assembly assembly

Oil filter

Fuel prefilter

High-pressure
Mixing Fuel spill fuel pipes between
Fuel filter the common rail E
connector tube
and injectors

Fuel doser
solenoid valve
assembly

KCCV
ventilator

EGR valve
assembly

Engine Engine
controller F
controller cooler

Supply pump Oil level

G
assembly gauge

Fuel block H

C4E14165

125E-7 SERIES 50-21

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

D Flywheel K

Damper
pulley L

Boost pump,
EPC valve

Intake Rocker arm,

Engine repair Cylinder Fuel injector Shaft
E I
manifold stand head cover harness assembly

Thermostat
Common rail housing,
Water pump

Front hanger

Cam follower Cam follower

cover

Speed
F
sensor

Engine oil
G pressure
sensor

Engine
H oil pan, J
Oil strainer

C4E14166

50-22 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

K K

L L

Push rod

Rocker arm Cylinder

I Fuel injector head M
housing assembly

Cylinder
Crosshead head
disassembly

Fuel injector
harness
connector

J J

C4E14167

125E-7 SERIES 50-23

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Flywheel Engine rear

K housing oil seal

Front Piston,
L Front cover Camshaft Connecting Crankshaft N
support rod assembly

Piston,
Idle gear Connecting
(Small) rod assembly
(Disassembly)

Engine oil
M
pump

Idle gear
(Large)

Engine front
oil seal

N Cylinder liner

Piston
J cooling
nozzle

C4E14168

50-24 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Preparatory work
1. Set the engine assembly (1) on a rigid and stable stand
[1].

4 Engine assembly (1): 

1800 kg
REMARK
The weight of the engine assembly (1) depends on the
machine model.
2. Drain the coolant and engine oil.

6 Engine oil: 
Approximately 40 ℓ
REMARK
The engine oil amount depends on the machine model.
Starting motor assembly
3. Remove the mounting bolts (1), and remove the starting
motor assembly (2).

Alternator assembly
4. Remove the alternator belt (1), and set the wrench [1] to
the portion (a) (width across flats12.7 mm) of the auto-ten-
sioner (2).
1) Set the wrench [1] to the part (a) (width across flats
12.7 mm) of the auto-tensioner assembly (2).
2) Rotate the wrench [1] counterclockwise when seen
from the front of the engine, and remove the alternator
belt (1).
k Firmly set the wrench [1] to the portion (a) of
the auto-tensioner (2), and then rotate it. (Since
the spring force of the auto-tensioner (2) is
strong, the wrench may come off and is very
dangerous if it is turned when not attached se-
curely.)
k After removal of the alternator belt (1), return
the auto-tensioner assembly (2) slowly and
carefully.
k Be careful not to get your fingers caught be-
tween the pulley and alternator belt (1) during
work.

125E-7 SERIES 50-25

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

5. Remove the auto-tensioner (2) from the auto-tensioner

tensioner bracket (5).
6. Remove the alternator assembly (4) from the auto-tension-
er bracket (5).
7. Remove the auto-tensioner bracket (5) from the front cover
and cylinder block.

Oil tube for VGT hydraulic actuator

8. Disconnect EPC valve connector VGT-SOL (1).

9. Disconnect the oil tube (2) for VGT hydraulic actuator.

EGR cooler
10. Disconnect VGT oil drain tube (1).
11. Disconnect the air vent tube (2) and EGR coolant tubes (3)
and (3a).

12. Disconnect EGR air vent tubes (4) (2 pieces).

50-26 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

13. Disconnect the air heat insulation plate (5) and EGR piping
(6).
REMARK
Installation of the heat insulation plate (5) depends on the
machine model.

14. Remove EGR piping (7) and EGR cooler (8).

15. Remove the bracket (9).

VGT and exhaust manifold assembly

16. Remove the cover (1) for the fuel doser solenoid valve as-
sembly.

17. Disconnect the connector TWTR (2), and remove the

bracket (3).
18. Remove the clamp, and disconnect the coolant tube (4).

125E-7 SERIES 50-27

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

19. Disconnect the following connectors.

(7): SVGT
(8): VGT-REV

20. Disconnect the following hoses and tubes.

1) Remove the clamps. and disconnect the coolant tube
(5) and fuel hose (6) for the fuel doser.
2) Remove the cover (5a) and disconnect VGT wiring
harnesses (5b) (2 pieces) from wiring harness bracket
(5c).
3) Remove NOx sensor (6a).

21. Remove the bracket (9).

22. Remove the brackets (10) (3 pieces) and wiring harness

clamp bracket (11).

50-28 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

23. Remove the clamp and disconnect VGT lubricating oil tube
(12).

24. Remove the bracket (13a).

25. Remove the clamp and disconnect VGT coolant return

tube (14).

26. Sling VGT and exhaust manifold assembly (15) and re-
move mounting bolts (16) (18 pieces).
27. Sling VGT and exhaust manifold assembly (15) and re-
move it.

4 VGT and exhaust manifold assembly (15): 

65 kg

125E-7 SERIES 50-29

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Air vent tube

28. Remove the air vent tube (1).

Wiring harness assembly

29. Disconnect the connectors shown below.
(7): PCV1
(8): PCV2
(9): G
(10): PO1L
(11): SEGR
(12): EGR-SOL

(4): PDOSER
(5a): SOV1
(5b): SOV2
(6): Fuel injector connectors CN1 through CN6 (on each
cylinder head)

(1): PAMB
(2): SVGT (Disconnect connector from holder.)
(3): VGT-REV (Disconnect connector from holder.)

50-30 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

30. Remove the engine controller cover (14).

REMARK
The engine controller cover (14) varies in response to the
machine model.

31. Remove the fixing bolts (20) (3 pieces) for the wiring har-
ness assembly.
32. Disconnect the connectors shown below.
(15): PFUEL
(16): NE
(17): ECMJ1
(18): ECMJ2
33. Remove the wiring harness assembly (19).

Oil filter
34. Remove the clamps (1) (2 pieces), and disconnect the
head tubes (2) (2 pieces).
35. Remove the mounting bolts on the oil filter head side, and
remove the oil filter and head assembly (3).
36. Remove the upper bracket (4) and lower bracket (5).

125E-7 SERIES 50-31

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Fuel prefilter
37. Disconnect the head tubes (1) (2 pieces).
38. Remove the mounting bolts on the fuel prefilter head side
and remove the fuel prefilter and head assembly (2).

39. Remove the bracket (3).

Fuel filter
REMARK
The mounting position of the fuel prefilter may vary in response to the machine model compared with
that on the machine side.
40. Disconnect the fuel filter head tubes (1), (2), (3), and (4).
41. Remove the fuel filter and head assembly (5).

Fuel doser solenoid valve assembly

42. Remove the fuel doser solenoid valve assembly (1).

50-32 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

KCCV ventilator
43. Disconnect the upper hoses (1) (2 pieces) and coolant
tube (2).
44. Disconnect the coolant tube (3) and lower drain hose (4).
45. Remove KCCV ventilator (5).
REMARK
The mounting position of KCCV ventilator (5) may vary in
response to the machine model compared with that on the
machine side.

EGR valve
46. Remove EGR valve oil drain tube (1a).
47. Remove the oil tube (1b) for EGR valve hydraulic actuator.
48. Remove EGR valve (2).

Mixing connector
49. Remove the bracket (1).

125E-7 SERIES 50-33

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

50. Sling the mixing connector (2) and remove the mounting
bolts.
51. Sling the mixing connector (2) and remove it.

4 Mixing connector (2): 

35 kg

Fuel spill tube

52. Disconnect the fuel spill tube (1).

Fuel high-pressure pipe between common rail and injector

53. Remove the bracket (1).

54. Remove the clamp (2).

55. Remove the fuel spray prevention caps (3).

50-34 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

56. Remove the clamps (4) (10 pieces).

57. Disconnect the fuel high-pressure pipes (5) (6 pieces).

Air intake manifold

58. Remove the bracket (1) and oil filler pipe (2).
REMARK
The shapes of (1) and (2) mentioned above depend on the
machine model.

59. Sling the air intake manifold (3) and remove the mounting
bolts (24 pieces).
60. Sling the air intake manifold (3) and remove it.

4 Air intake manifold (3): 

30 kg

Engine controller
61. Disconnect the ground cable (1).
62. Remove the mounting bolts, and remove engine controller
(2).

125E-7 SERIES 50-35

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Engine controller cooler

63. Remove the wiring harness clamps (1) (2 pieces).
64. Remove the mounting bolts (4 pieces), and remove the en-
gine controller cooler (2).

Fuel high-pressure pipe between supply pump and common rail

65. Remove the clamps (4) (3 pieces).
66. Remove the fuel spray prevention cap (5) of the common
rail fuel high-pressure pipe.
67. Disconnect the common rail fuel high-pressure pipes (6) (2
pieces).
68. Disconnect the overflow tube (7).
69. Disconnect the fuel hose (8) for the fuel doser pump.

70. Sling the bracket (9).

71. Remove the mounting bolts and sling bracket (9) and re-
move it.
REMARK
Remove the bracket with fuel doser pump (10) attached.

4 Bracket (9): 
25 kg

50-36 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Common rail
72. Remove the mounting bolts (1) (2 pieces), and remove the
common rail (2).
73. Remove the mounting bolts (3) (4 pieces), and remove the
bracket (4).

Supply pump assembly

74. Disconnect the lubricating oil tube (1).
75. Disconnect the fuel tube (1a).

76. Remove the cover (2).

77. Rotate the crankshaft in the normal direction (counter-
clockwise seeing from the flywheel side) to set the center
point (a) between stamps 2/5TOP and 3/4TOP of the
damper (3) to pointer (4).
REMARK
• The stamp of 1/6 TOP is almost at the bottom.
• At this time, check that the forcing tap of the drive gear
aligns with the mounting bolt hole of the cover (2). (If it
is not, rotate the crankshaft one more turn.)
• At this position, the key of the supply pump shaft is ro-
tated clockwise by 15 ° from the top.

125E-7 SERIES 50-37

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

78. Remove the mounting nut (5).

79. Install the tools P1, P2, and P3 and tighten the center bolt
of P1 to pull out the supply pump drive gear from the shaft.
NOTICE
Keep the tools P1, P2, and P3 installed to prevent re-
moval of the supply pump drive gear.

80. Remove the bracket (6).

81. Remove the mounting bolts (7) (4 pieces), and remove the
supply pump assembly (8).
NOTICE
Keep the tools P1, P2, and P3 installed to prevent re-
moval of the supply pump drive gear.

Fuel block
82. Remove the fuel block (1).
83. Remove the bracket (2).

50-38 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Dipstick
84. Remove the oil level gauge (1).
REMARK
Put a matchmark between the dipstick pipe (1) and cylin-
der block to indicate the mounting position of the dipstick
pipe.
The installation position depends on the machine model.

Oil cooler assembly

85. Remove the drain hose. (1a)

86. Remove the mounting bolts and remove oil cooler assem-
bly (1) with the guide bolt [1].

Cylinder head cover

87. Remove the cylinder head covers (1).

125E-7 SERIES 50-39

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Fuel injector wiring harness

88. Fully loosen the capture nuts (2) (2 pieces) on the head of
fuel injector (1).
REMARK
Loosen the capture nuts (2) alternately.
89. Loosen the mounting bolt (3) of the wiring harness fixing
holder.

Rocker arm and shaft assembly

90. Loosen the lock nut (3) and fully loosen the adjustment
screw (2).
91. Remove the mounting bolt (4), and remove the rocker arm
and shaft assembly (1).

Push rod
92. Remove the push rods (1) (12 pieces).

Fuel injector
93. Remove the holder mounting bolt (3) of the fuel injector (1)
and remove the fuel injector (1) and holder (2) together.
NOTICE
• Note the cylinder number for the removed fuel in-
jectors and store them in order.
• Never grip the solenoid valve at the top of fuel in-
jector (1) with pliers, etc.
• Be careful not to damage or remove QR code tab
(4) on the top of fuel injector (1).

50-40 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Crosshead
94. Remove the crossheads (1) (12 pieces).

Fuel injector wiring harness connector

95. Remove the mounting bolts (2) for the fuel injector wiring
harness connector (1).
96. Remove the wiring harness from holder (3), and remove
the holder (3) from the rocker housing (4).

97. Push the fuel injector wiring harness connector (1) from in-
side of the rocker housing (4) toward the outside to re-
move it.
98. Remove O-ring (5) from the rocker housing.

Rocker arm housing

99. Remove the rocker arm housing (1).

125E-7 SERIES 50-41

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Thermostat housing, water pump

100. Pull out the pin (1).

101. Push up the connector tube (2) with the bar [1].

REMARK
Apply the bar [1] to the flange of the connector tube (2) to
pry the tube up.
102. Disconnect the connector (6).
103. Remove thermostat housing (3).

REMARK
The shape of the thermostat housing (3) depends on the
machine model.

104. Remove the bolts (6) (3 pieces), and remove the water
pump (4).
REMARK
This procedure is for the engine installed to other than
WA475-10.

50-42 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

105. Remove the reamer bolt (5) and bolts (6) (2 pieces), and
remove the water pump (4).
REMARK
This procedure is for the engine installed to WA475-10.
NOTICE
For WA475-10-mounted engine, remove the bolts (6) (2
pieces) while the reamer bolt (5) is completely re-
moved.
(If the bolts are removed in an incorrect order, the
reamer bolt (5) may seize.)

Front hanger
106. Disconnect the coolant tube (1).
107. Remove the mounting bolts and remove the front hanger
(2).

125E-7 SERIES 50-43

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Cam follower cover

108. Remove the cam follower covers (1) (3 pieces).

Cam follower
109. Remove the mounting bolts (1) (12 pieces), and remove
the cam followers (2) (6 pieces).
110. Remove the dowel pin (3).

50-44 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Cylinder head assembly (removal)

111. Remove the mounting bolts (2) (7 pieces each) of the cyl-
inder head assembly (1).
112. Sling the cylinder head assembly (1) with the eyebolt [1],
and remove it.

4 Cylinder head assembly (1): 

20 kg
113. Remove the cylinder head gaskets (3) (6 pieces).

Cylinder head assembly (disassembly)

114. Compress the valve spring (1) with the tool B, and remove
the valve cotter (2).
115. Remove the upper seat (3) and valve spring (1).

125E-7 SERIES 50-45

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

116. Remove the oil seal (4) and remove the lower seat (5).
117. Put the cylinder head sideways and remove the valve (6).

REMARK
Check and record the combinations of the valves and cyl-
inder heads.

Engine repair stand (installation)

118. Install the tool A2.

119. Sling the engine with the lifting tools, set the previously in-
stalled tool A2 to the tool A1, and then tighten the mount-
ing bolts.

50-46 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Speed sensor
120. Remove the speed sensor (1).

Engine oil pressure sensor

121. Remove the engine oil pressure sensor (1).

Engine coolant temperature sensor

122. Remove the engine oil coolant temperature sensor (1).

Engine oil pan and oil strainer

123. Turn the engine sideways, and sling engine oil pan (1) with
the lifting tool [5].
124. Remove the mounting bolts, sling the engine oil pan (1),
and then remove it.

4 Engine oil pan (1): 

25 kg

125E-7 SERIES 50-47

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

125. Remove the mounting bolts, and then remove the bracket
(3) and oil strainer (2).

Flywheel
126. Sling the flywheel (1) with the eyebolt [1].
127. Remove the mounting bolts (6 pieces), and pull out the
dowel pin part.
128. Pull out the flywheel (1) with the guide bolt [2], sling it, and
remove it.

4 Flywheel (1): 
50 kg

Flywheel housing
129. Sling the flywheel housing (1) with the eyebolt [1].
130. Remove the mounting bolts (2) (10 pieces).
131. Pull the flywheel housing (1) off the dowel pin of the cylin-
der block.

4 Flywheel housing (1): 

70 kg

Engine rear oil seal

132. Remove the engine rear oil seal (1) from the flywheel
housing.

50-48 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Damper and pulley assembly

133. Sling the damper and pulley assembly (1) with the lifting
tool [1].
134. Remove the mounting bolts (6 pieces).
135. Sling the dumper and pulley assembly (1) with the guide
bolt [2], and remove it.

4 Damper and pulley assembly (1): 

25 kg

Front support
136. Sling the front support bracket (1) with the eyebolt [1].
137. Remove the mounting bolts, and then sling front support
bracket (1) and remove it.

4 Front support bracket (1): 

50 kg
REMARK
The shape of the front support bracket (1) depends on the
machine model.

Boost pump and EPC valve

138. Remove the boost pump (1).
139. Remove EPC valve (2).

125E-7 SERIES 50-49

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Front cover
140. Remove the mounting bolts (1) (4 pieces) on the back.
141. Sling the front cover (2) with the eyebolt [1].
142. Remove the mounting bolts, and then sling the front cover
(2) and remove it.

4 Front cover (2): 

35 kg
143. Remove the tools P1, P2, and P3 that remained installed
to prevent removal of the supply pump gear, and remove
the supply pump gear.

Engine front oil seal

144. Remove the engine front oil seal (1) from the front cover.

Camshaft
145. Remove the mounting bolts (1) (2 pieces), and remove the
camshaft (2).
REMARK
Remove the camshaft (2) while it is rotated to prevent
damage of the cam bushing.

50-50 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Idler gear (small)

146. Remove the mounting bolt (1), and remove the plate (2)
and idler gear (3).

147. Remove the shaft (4).

Engine oil pump

148. Remove the mounting bolts (1) (4 pieces), and remove the
engine oil pump (2).

125E-7 SERIES 50-51

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Idler gear (large)

149. Remove the mounting bolt (1), and remove the shaft (2),
idler gear (3), and plate (4).

Piston cooling nozzle

150. Remove the mounting bolt (1) and remove the piston cool-
ing nozzle (2) of each cylinder.

Piston and connecting rod assembly (removal)

151. Measure the end play at the large end (a) of the connect-
ing rod with the dial gauge [1], and then remove the piston
and connecting rod assembly.

50-52 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

152. Remove the carbon from the upper wall of the cylinder lin-
er with fine sandpaper.
153. Rotate the crankshaft to set the piston to be removed at
the bottom dead center.
154. Check that the identification stamps (b) exist on the cam-
shaft side of the connecting rod and cap.
REMARK
• The stamps on the connecting rod and cap must be the
same.
• If there are no stamps, stamp on them before disas-
sembling.
155. Remove the mounting bolts (1) (2 pieces) of the connect-
ing rod cap.
156. Remove the connecting rod cap (2) and connecting rod
bearing together while you lightly hit the cap with a plastic
hammer
REMARK
To hit it with the plastic hammer, do not damage the exter-
nal threads of the mounting bolts (1).

157. Push in the connecting rod end (c) with the wooden rod [2]
from the engine oil pan side, and take out the piston and
connecting rod assembly (3) on the cylinder head side.
REMARK
To take out the connecting rod, take care not to scratch the
inside wall of the cylinder liner with its corners.
158. Follow the same procedure to remove the other piston and
connecting rod assembly .
REMARK
• When it is stored, implement the measures to protect
the sliding surfaces of the piston, connecting rod bear-
ing, etc.
• Assemble the connecting rod and cap loosely and
store them together with the connecting rod bearing to
prevent any mistake that may occur during reassembly.

125E-7 SERIES 50-53

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Piston and connecting rod assembly (disassembly)

159. Remove the snap rings (1) (2 pieces) with the tool [1].
160. Support the connecting rod (2) by hand, pull out the piston
pin (3), and then disconnect the piston (4) from the con-
necting rod (2).

161. Remove the piston ring (5) with the tool C.

REMARK
Store the parts (piston, connecting rod, connecting rod
bearings, piston rings, and piston pin) in a set for each cyl-
inder No.

50-54 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Crankshaft
162. Measure the end play with the dial gauge [1], and then re-
move the crankshaft (1).

163. Remove the main cap mounting bolts (2) (2 pieces each),
and remove the main caps (3) to (9).
164. Insert the mounting bolts (2) into the bolt holes of the main
cap and remove the main cap while you rock it.
165. Remove the lower thrust bearing (10). (Only for the main
cap (9) of No. 7)
REMARK
Check the mounting position of the lower thrust bearing
(10), and record it.

166. Remove the lower main bearing (11) from each main cap.

125E-7 SERIES 50-55

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

167. Sling the crankshaft (1) with the bolts [2], and remove it.

REMARK
To remove the crankshaft (1), be careful not to damage its
journals.

4 Crankshaft (1): 
110 kg

168. Remove the upper thrust bearing (12). (Only for the journal
of No. 7)
REMARK
Check the mounting position of the upper thrust bearing
(12), and record it.

169. Remove the upper main bearing (13) from each main jour-
nal.
REMARK
Discriminate the parts (main caps, main bearings, thrust
bearings) to indicate the positions to be installed, and then
store them in group by every cylinder number.

50-56 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Cylinder liner
170. Measure the projection of the cylinder liner (1) with the
plate [1] and tool F, and then remove the cylinder liner.
171. Remove the cylinder liner (1) with the tool D.

125E-7 SERIES 50-57

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

METHOD FOR ASSEMBLING ENGINE GENERALLY

Piston
cooling
nozzle

Piston,
Cylinder Connecting Idle gear
Cylinder liner Crankshaft rod assembly Camshaft A
block (large)
(Installation)

Piston,
Connecting Engine oil
rod assembly pump
(Assembly)

Idle gear
(small)

Speed
sensor

Coolant
temperature
sensor
C4E14169

50-58 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Thermostat
housing, C
Water pump

Front hanger D

Cam follower Oil level Supply pump

A Cam follower Front cover E
cover gauge assembly

B B

C C

Oil cooler
assembly F

Damper, Engine Cylinder head

Engine front Engine repair
assembly
E oil seal Pulley oil pan, stand G
assembly Oil strainer (Assembly)

Boost pump, Cylinder head

assembly
EPC valve (Assembly)

Front support
bracket

Flywheel Engine rear

B Flywheel
housing oil seal
C4E14170

125E-7 SERIES 50-59

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

C C

F F

Fuel injector
harness
connector

Rocker arm Rocker arm, Fuel injector Cylinder

G Crosshead Shaft H
housing assembly harness head cover

Fuel injector

Push rod

C4E14171

50-60 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Oil tube for

F EGR cooler VGT hydraulic K
actuator

VGT, Exhaust
Exhaust
manifold L
assembly connector

H Fuel block M

High-pressure KCCV
fuel pipes between
Common rail supply pump and ventilator N
common rail assembly

Fuel doser
solenoid valve O
assembly

Fuel filter
P
assembly

High-pressure
Intake fuel pipes between Fuel spill Mixing Fuel prefilter
manifold common rail tube connector assembly Q
and fuel injectors

Oil filter
R
assembly

EGR valve S
assembly

Engine Engine
controller controller T
cooler cooler

I I

J J

C4E14172

125E-7 SERIES 50-61

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Wiring Check after

Q harness
assembly assembling

I Alternator

Starting
J motor
assembly

C4E14173

50-62 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

REMARK
• Tighten the following bolts by the torque plus angle method.
Cylinder head mounting bolt
Main cap mounting bolt
Connecting rod cap mounting bolt
• If a bolt is tightened by the torque plus angle method, permanent strain remains in it, thus the number of
times of repeated use for the bolt is limited. Accordingly, observe the following before tightening.
1. Measure the stem length the bolt, and check that the length does not exceed the allowable limit. If a bolt
is longer than the allowable limit, do not reuse it but replace it.
2. If the number of punch marks on the head of a bolt exceeds the specified quantity, do not reuse that
bolt, and replace it with a new one.
Cylinder block
1. Install the tool A2 to the cylinder block (1).
2. Sling the cylinder block (1) and set the tool A2 to the tool
A1.

4 Cylinder block (1): 

320 kg

Cylinder liner
3. Follow the procedure described below to securely perform the preparatory work before installation of the
cylinder liner.
1) Remove rust and scales from the surfaces (A) and (B)
with a sandpaper, etc. until the machined surfaces are
exposed.
2) Polish the part (R) until it is smoothed with sandpaper
(No. 240 or equivalent).
If the portion (R) is sharp or has any burr, polish it with
a scraper or sandpaper.
Finish this face particularly smoothly not to scratch the
O-ring.
3) If the surface (B) is pitted and cannot be repaired, re-
place the cylinder block with a new one.
4) If the surface (A) and portion (R) are pitted, finish them smoothly.

125E-7 SERIES 50-63

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

5) Check the counterbore portion, and remove burrs or sharp edge if any. Also, remove chips and dust on
the surface (C), otherwise the insufficient contact will cause a water leakage or insufficient protrusion of
cylinder liner.
REMARK
• If the counter bore portion is drooped, corroded, or pitted, repair it additionally.
• Check that the periphery of the cylinder liner and O-ring grooves are not corroded or pitted.
• If any failure is found, replace the part with a new one.
4. Install the clevis seal (1), O-rings (2) and (3) to the cylinder
liner.
REMARK
• Check that the grooves of the cylinder liner are free
from burr, sharp edge, and dirt.
• Replace the clevis seal and O-rings with new ones.
• Install the clevis seal (1) with the chamfered side down.
Press up the clevis seal all around the groove not to be
twisted when it is installed.
• See the indication below and install O-rings (2) and (3).
O-ring (2): Whole body is black
O-ring (3): Whole body is red
• Since engine oil causes the clevis seal and O-ring to
swell and deteriorate, apply a small amount of engine

2 Clevis seal, O-ring: 

oil with a brush just before installing them.

Rubber lubricant (DISPANOL LH-50 manufac-

tured by NOF), clean engine oil

5. After installing the O-ring, check it for twisting. If the O-ring

is twisted, straighten it with the smooth rod [1] (outside di-
ameterapproximately 10 mm).

6. Apply liquid gasket to the fitting part of the cylinder block

counter bore and cylinder liner.
REMARK
Remove dirt, oil, etc. from the contact faces of the cylinder
block counter bore and cylinder liner flange.
2 Cylinder block: 
Liquid gasket (LG-6)
Liquid gasket bead diameter: 0.8 to 1.6 mm
Overlap of the liquid gasket (a): 6±6 mm

50-64 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

k If the liquid gasket is left for a long period of time after being applied, its surface becomes hard-
ened. Accordingly, complete installation of the cylinder liner to the cylinder block within 50 mi-
nutes.
7. Insert the cylinder liner (4) into the cylinder block.
REMARK
Insert the cylinder liner (4) slowly not to damage the outside of O-rings.
8. Push the cylinder liner (4) further into the cylinder block with both hands.
REMARK
If the cylinder liner (4) does not enter smoothly, the periphery of the O-rings may be broken. In this case,
check the cylinder block for existence of burrs and sharp edge.
9. Press fit the cylinder liner (4) into the cylinder block with
the tool E.

10. Tighten the cylinder head lightly with a used cylinder head
gasket.
REMARK
• This work is required to prevent the liquid gasket from
projecting between the cylinder block and cylinder liner.
• Observe the following temporary tightening torque and
tightening order for the mounting bolts.
3 Mounting bolt: 
127.5 to 147.1 Nm {13 to 15 kgm} 
11. Remove the cylinder head and wipe off the excessive liq-
uid gasket which projected from the counter bore portion.
NOTICE
Be sure to perform steps 10. and 11. since the projected excessive liquid gasket can deform the
grommet of the head gasket.
12. Measure the projection of cylinder liner (4) with the plate
[1] and tool F.
Projection of cylinder liner: 0.07 to 0.15 mm
REMARK
If it is out of the standard value, take actions by referring to
“MAINTENANCE STANDARD”.

Crankshaft

125E-7 SERIES 50-65

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

REMARK
The cylinder block and main bearing are fitting selective parts. (The spare parts are prepared to secure
the standard clearance.)
13. Drive the roll pin (1) into the cylinder block and adjust their
protrusion to the following. (Only for the journal of No. 7)
Protrusion of the roll pin (1): 1.5 to 1.9 mm
14. Install the upper main bearing (2) while fitting its protrusion
(b) to notch (a) of the cylinder block.
REMARK
• Check that the oil hole (C) of the upper main bearing
(2) is aligned to the oil hole of the cylinder block.
• Check that no foreign material sticks to the back of the
upper main bearing (2) before installing.
2 Upper main bearing inner surface (2): 
Engine oil
15. Install the upper thrust bearing (3). (Only for the journal of
No. 7)
REMARK
Install the upper thrust bearing (3) with the grooved face
directed toward the crankshaft.
2 Upper thrust bearing (3): 
Engine oil
16. Before installing the crankshaft, check the following.
• The thread portions at the front and rear of the crankshaft are free from defects. (The bolts can be
screwed in smoothly by hand.)
• The crank pin and main journal are free from scratches or dent.
• Inside of the oil hole is free from dirt.
17. Sling the crankshaft (4) and set it to the mounting position
with the bolts [1].

4 Crankshaft (4): 
110 kg
NOTICE
When replacing the crankshaft gear, heat the crank-
shaft gear with a bearing heater to 150°C, and fit it
quickly.
18. When installing, take care not to damage the journal of the
crankshaft (4) by hitting it against the cylinder block.
2 Journal of the crankshaft (4): 
Engine oil

50-66 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

19. Drive the roll pin (5) into the main cap. (Only for the journal
of No. 7)
Protrusion of the roll pin (5): 1.5 to 1.9 mm
20. Install the lower main bearing (6) to the main cap.
REMARK
• Install the lower main bearing (6) while fitting its protru-
sion to the notch of the main cap.
• Check that no foreign material sticks to the back of the
lower main bearing (6) before installing.
2 Lower main bearing (6): 
Engine oil
21. Install the lower thrust bearing (7). (Only for the journal of No. 7)
REMARK
Install the lower thrust bearing (7) with the grooved face directed toward the crankshaft.
2 Lower thrust bearing (7): 
Engine oil
22. Install the main cap (8).
2 Crankshaft journal: 
Engine oil
1) Check that the stamped No. at the center of the main
cap is the same as the journal No. of the cylinder
block.
2) Install the main cap (8) with the embossed letter (F) at
the portion (c) directed toward the front of the engine.

23. Check the main cap mounting bolts for the following. If the
following applies to a bolt, do not reuse that bolt but re-
place it.
Number of tightening times: 6 (5 punch marks at the bolt
head)
Bolt stem length allowable limit (d): Min. : 159.8 mm

125E-7 SERIES 50-67

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

24. Tighten the main cap mounting bolts (9) alternately to fit
the main cap (8) completely.

25. Follow the procedure described below to tighten the main cap mounting bolts (9).
Tighten the mounting bolts (9) in order from the center to the outside.
2 Threaded portion of the mounting bolt (9) and washer: 
Engine oil
3 Mounting bolt (9) 1st time: 
98.1±9.8 Nm {10±1 kgm} 
3 2nd time: 
196.1±4.9 Nm {20±0.5 kgm} 
3rd time:Retighten the bolt with the tool K by 90 ° (+30 °/0)
REMARK
When the tool K is not used, put the paint marks (e) on the
main cap and mounting bolt, and retighten the bolt by 90 °
(+30 °/0).
26. Put 1 punch mark (f) on the head of mounting bolt.
REMARK
When a new bolt is used, do not put punch mark (f).
27. Rotate the crankshaft (4) and check that it rotates smooth-
ly.
28. Measure the end play of the crankshaft (4) with the dial
gauge [1].
End play of the crankshaft (4): 0.14 to 0.315 mm
REMARK
If it is out of the standard value, refer to “MAINTENANCE
STANDARD” to take actions.

Piston and connecting rod (assembly)

50-68 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

REMARK
The piston and cylinder liner are fitting selective parts. (The spare parts are prepared to secure the
standard clearance.)
29. Install the piston rings (1) with the tool C. (Install the oil
ring, 2nd ring, and top ring in order from the bottom)
REMARK
• Install the top ring and 2nd ring to the piston with the
stamped side up.
Stamping mark on top ring: 1H
Stamping mark on 2nd ring: 2R
• When installing the oil ring, take out the expander from
inside and fit it to the piston, and then install the oil
ring. At this time, make sure that the expander is set-
tled in the ring groove completely.

30. Set the abutment joints of the piston rings at the position
shown in the figure.
REMARK
Set the expander joint in the oil ring to the position of 180 °
from the abutment joint of the oil ring.

31. Install the snap ring (3) to either side of the piston (2).
32. Heat the piston (2) with the electric furnace at 100 °C for at
least 5 minutes.
REMARK
If there is no electric furnace, heat the piston with hot wa-
ter (100 °C) for 5 minute or longer.

125E-7 SERIES 50-69

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

33. Set the connecting rod (4) to the piston (2).

REMARK
Set the grade stamp (F) at the portion (a) on the side of
the piston (2) to the front side and set the distinction stamp
at the portion (b) on the side of the large end of the con-
necting rod (4) to the left side.

34. Insert the piston pin (5) into the piston (2).
2 Piston boss: 
Engine oil
35. Install the snap ring (3) on the opposite side.
REMARK
Rotate the right and left snap rings (3) to check that they
are fitted to the ring grooves completely.

36. Install the upper connecting rod bearing (6) while setting
its projection (d) to the notch (c) of the connecting rod (4).
REMARK
• Check that no foreign material sticks to the back of the
upper connecting rod bearing (6) before installing.
• Install the upper connecting rod bearing (6) while set-
ting the oil hole (f) to the oil hole (e) of the upper con-
necting rod (4).

50-70 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

37. Install the lower connecting rod bearing (8) while setting
the projection (h) to the notch (g) of the connecting rod cap
(7).
REMARK
Check that no foreign material sticks to the back of lower
connecting rod bearing (8) before installing.

Piston and connecting rod assembly (installation)

38. Rotate the crankshaft to set the crankpin of the piston to
be installed to the bottom dead center.
39. Insert the piston and connecting rod assembly (1) in the
cylinder block.
REMARK
• Set the grade stamp (F) at the portion (a) on the side of
the piston to the front side of the engine and set the
distinction stamp at the portion (b) on the side of the
large end of the connecting rod to the left side (cam-
shaft side).
• Set the abutment joints of the piston rings at the posi-
tion shown in the figure.
2 Inside surface of the upper connecting rod bearing
and inside wall of the cylinder: 
Engine oil

125E-7 SERIES 50-71

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

40. Retract the piston rings with the tool G, and push in the
head of piston and the connecting rod assembly (1) with
the wooden rod [1].
REMARK
When you push in the piston and connecting rod assembly
(1), support the large end of the connecting rod and guide
it to the crankpin with the hand on the opposite side to pre-
vent scratching.

41. Install the connecting rod cap (2).

2 Lower connecting rod bearings inner surface: 
Engine oil
42. Match the distinction stamps (c) of the connecting rod (3)
and connecting rod cap (2).

43. Install the connecting rod cap mounting bolts (4).

44. Check the connecting rod cap mounting bolts for the fol-
lowing. If the following applies to a bolt, do not reuse that
bolt but replace it.
Number of tightening times: 6 (5 punch marks at the bolt
head)
Bolt stem length allowable limit (d): Min. : 84.1 mm

50-72 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

45. Tighten connecting rod cap mounting bolts (4) alternately

to fit the connecting rod cap completely.
46. Follow the procedure described below to tighten the con-
necting rod cap mounting bolts (4).
3 Mounting bolt (4) 1st time: : 
98.1±4.9 Nm {10±0.5 kgm} 
2nd time: retighten bolt with the tool K by 90 ° (+30 °/0)
REMARK
When the tool K is not used, put paint marks (e) on the
main cap and mounting bolt, and retighten the bolt by 90 °
(+30 °/0).
47. Put 1 punch mark (f) on the head of mounting bolt.
REMARK
When a new bolt is used, do not put the punch mark (f).

48. Rotate the crankshaft and check that it rotates smoothly.

49. Measure the side clearance of the large end (g) of the con-
necting rod with the dial gauge [2].
Side clearance of the connecting rod large end (g): 0.2 to
0.375 mm

50. Measure the protrusion of the piston head from the top
surface of cylinder block with the tool H and dial gauge [2].
REMARK
• Press the piston head, eliminate the oil clearance of
the crank pin, and then measure the protrusion.
• Use the dial gauge [2] after setting it to zero on the top
surface of cylinder block.
Protrusion of piston head: 0.984 to 1.335 mm

Piston cooling nozzle

51. Rotate the crankshaft to the following position to install each piston cooling nozzle.
No. 1 at top: No. 1 and No. 6 can be installed
No. 2 at top: No. 2 and No. 5 can be installed
No. 3 at top: No. 3 and No. 4 can be installed

125E-7 SERIES 50-73

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

52. While matching the dowel pin position, set the piston cool-
ing nozzle (2) and tighten the mounting bolt (1).
3 Mounting bolt (1): 
27 to 34 Nm {2.8 to 3.5 kgm} 
REMARK
After installing each piston cooling nozzle (2), check that
its end is at the center of the notch of the piston.

Idler gear (large)

53. Install the plate (4) to the engine block,
54. Install the idler gear (3) and shaft (2), and install the
mounting bolt (1).
REMARK
• Check V-groove distinction on the side of the shaft (2)
before installing it.
• Install the plate (4) with the chamfered side directed to-
ward the front of the engine.

55. Match the timing marks (A) of the crankshaft gear (5) and
idler gear (3), and then tighten the mounting bolt (1).
3 Mounting bolt (1): 
245 to 294 Nm {25 to 30 kgm} 

50-74 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Engine oil pump

56. Fit O-ring, install the engine oil pump (2), and install the
mounting bolts (1) (4 pieces).

Idler gear (small)

57. Drive in the pin, and install the shaft (4).
REMARK
Check V-groove distinction on the mating face of the shaft
(4) with the plate (2) before installing it.
58. Install the idler gear (3) and plate (2), and lightly tighten
the mounting bolt (1).
59. Mesh the idler gear (3) with the engine oil pump gear prop-
erly and tighten the mounting bolt (1).
3 Mounting bolt (1): 
147.0 to 176.4 Nm {15 to 18 kgm} 

Camshaft
60. Install the camshaft (2) to the cylinder block.
REMARK
• Install the camshaft (2) while it is rotated not to scratch
the cam bushing.
• When the cam gear was replaced, heat the new cam
gear at 220 to 240 °C for less than 30 minutes with an
electric oven, and install it by shrink-fit.
2 Journal surface of the camshaft (2): 
Engine oil
61. Match the timing marks (B) of the crankshaft gear and idler
gear (small), and then tighten the mounting bolt (1).

125E-7 SERIES 50-75

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Cam follower
62. Drive the dowel pins (3) into the cylinder block.
63. Install the cam follower assemblies (2) (6pieces) and tight-
en the mounting bolts (1).
3 Mounting bolt (1): 
44 to 59 Nm {4.5 to 6.0 kgm} 

Cam follower cover

64. Install O-ring and install the cam follower cover (1).
REMARK
Install O-ring not to twist it.
3 Mounting bolt: 
9.8 to 12.7 Nm {1.0 to 1.3 kgm} 

Dipstick
65. Install the collar onto the dipstick pipe (1) and fix it with the
nut (2).
3 Nut (2): 
44 to 59 Nm {4.5 to 6.0 kgm} 
REMARK
• Be careful about the oil gauge mounting position since
it varies in response to the model.
• Match the marks put on the cylinder block and dipstick
pipe when the dipstick pipe is removed.

50-76 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Thermostat housing, water pump

66. Install the O-ring to the water pump (4), and tighten them
lightly with the bolts (6) (3 pieces).
REMARK
• This procedure is for the engine installed to other than
WA475-10.
• Before you install the water pump (4), supply engine oil
to the bearing chamber.

125E-7 SERIES 50-77

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

67. Install the O-ring to the water pump (4), and tighten them
lightly with the reamer bolt (5) and bolts (6) (2 pieces).
REMARK
• This procedure is for the engine installed to WA475-10.
• Before you install the water pump (4), supply engine oil
to the bearing chamber.
NOTICE
For WA475-10-mounted engine, tighten the reamer bolt
(5), and then tighten the bolts (6) (2 pieces).
(If the bolts are tightened in an incorrect order, the
reamer bolt (5) may seize.)

50-78 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

68. Install O-ring to the connector tube (2) and install them to
the thermostat housing (3).
REMARK
The shape of the thermostat housing (3) depends on the
machine model, so be careful.
69. Install the thermostat (5) and gasket to the thermostat
housing (3).
70. Install the thermostat housing (3) while the connector tube
(2) is pushed up, and then tighten the thermostat housing
mounting bolt.
71. Push the connector tube (2) into the water pump with the
bar [1] and fix it with the pin (1).
REMARK
Apply the bar [1] to the flange of the connector tube (2) to
pry the tube up.

72. Tighten the water pump mounting bolts (6) (3 pieces) to

the specified torque.
REMARK
This procedure is for the engine installed to other than
WA475-10.

125E-7 SERIES 50-79

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

73. Tighten the reamer bolt (5) and bolts (6) (2 pieces) to the
specified torque.
REMARK
This procedure is for the engine installed to WA475-10.
NOTICE
For WA475-10-mounted engine, tighten the reamer bolt
(5), and then tighten the bolts (6) (2 pieces).
(If the bolts are tightened in an incorrect order, the
reamer bolt (5) may seize.)

74. Install O-ring to the connector (6) and tighten the mounting
bolts to the specified torque while positioning the connec-
tor.

Front hanger
75. Install the front hanger (2).
76. Install the coolant tube (1).

50-80 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Supply pump assembly

77. Set the supply pump assembly (1) onto the front support,
and tighten the mounting bolts (2) (4 pieces) lightly. (Install
the fuel high-pressure pipe between the common rail and
supply pump, and then tighten the supply pump mounting
bolt to the specified torque.)
2 Mounting bolt (2): 
Liquid adhesive (LT-2)
78. Match the keyway of the supply pump drive gear (3) with
the woodruff key of the shaft.
79. At the same time, match the timing marks (C) on the sup-
ply pump drive gear (3) and cam gear (4), and then tighten
the mounting nut (5).
3 Mounting nut (5): 
176 to 196 Nm {18 to 20 kgm} 

125E-7 SERIES 50-81

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

80. Install the bracket (6).

3 Mounting bolt of the bracket (6) (supply pump
side) : 
19.6 to 29.4 Nm {2.0 to 3.0 kgm} 
REMARK
• Lightly tighten the mounting bolt (7) on the cylinder
block side in advance. (After tightening the supply
pump to the specified torque, tighten the bracket
mounting bolt to the specified torque.)
• Check that the timing marks (A), (B), and (C) of each
drive gear and idler gear are matched securely.

50-82 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

81. Measure the backlash and end play of each gear with the
dial gauge [1].
• Standard backlash of each gear
(a): 0.105 to 0.325 mm
(b): 0.105 to 0.325 mm
(c): 0.116 to 0.359 mm
(d): 0.105 to 0.337 mm
(e): 0.082 to 0.38 mm
(f) *1: 0.076 to 0.366 mm
(f) *2: 0.043 to 0.372 mm
*1: Indicates the value other than that for WA475-10-
mounted engine.
*2: Indicates the value for WA475-10-mounted engine.
• Standard end play of each gear
(g): 0.07 to 0.15 mm
(h): 0.10 to 0.25 mm
(j): 0 to 0.06 mm
(k): 0.04 to 0.38 mm
(m): 0.05 to 0.21 mm
(n): 0.030 to 0.094 mm
REMARK
If it is out of the standard value, refer to “MAINTENANCE STANDARD” to take actions.
Front cover
82. Apply liquid gasket to the front cover mounting face (a) as
shown in the figure on the right.
2 Mounting surface (a) of the front cover (1): 
Liquid gasket (LG-7)
Liquid gasket bead diameter at (a): 3 to 5 mm

125E-7 SERIES 50-83

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

83. Sling the front cover (1) with the eyebolt [1] and install it
with the guide bolt [3].

4 Front cover (1): 

35 kg
REMARK
Length of the mounting bolts
*1: 95 mm
*2: 80 mm
84. Install the cover (2).
3 Mounting bolt: 
98 to 123 Nm {10.0 to 12.5 kgm} 

85. Measure the bottom level difference between the cylinder

block (5) and front cover (1) at the part (a) with the dial
gauge [2].
Difference in level at bottom: 0 to 0.275 mm
REMARK
If it is out of the standard value, refer to “MAINTENANCE
STANDARD” to take actions.

86. Install the mounting bolts (3) (4 pieces) on the back.

3 Mounting bolt (3): 
59 to 74 Nm {6.0 to 7.5 kgm} 

50-84 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Engine front oil seal

87. Check that crankshaft end surface corners, sliding surfa-
ces of oil seal lip, and front cover are free from scratch,
burrs, sharp edge, rust, etc.
88. Set the engine front oil seal (2) to the front cover (1), and
then use a plastic hammer to press fit the seal until the oil
seal lip (a) fits on to the crankshaft (3).
REMARK
• Take care not to install the engine front oil seal (2) in a
wrong direction.
• When the engine front oil seal (2) is press fitted, hit its
periphery evenly not to deform it.
• Take care that the oil seal lip (a) is not caught in the
crankshaft (3) while press fitting.
2 Engine front oil seal (2) (50 to 80% full of hollow
part of lip): 
Grease (G2-LI)

89. Install the tool M1 and tighten the tools M2 (bolts) (3

pieces) evenly until they reach the end to press fit the en-
gine front oil seal (2) into the front cover (1).
REMARK
Do not attach the tools M3 (washer) to the tools M2 (bolt).
90. Remove the tools M2 (bolt) (3 pieces) and install the tools
M3 (washer) (3 pieces) to those tools M2 (bolt) respective-
ly.
91. Install the tools M2 (bolt) (3 pieces) again and tighten them
evenly until the end face of tool M1 reaches the end face
of the front cover (1) to press-fit the engine front oil seal
(2).
Press-fit distance (c) between the end surface of the front
cover (1) and engine front oil seal (2): 19 mm
Press-fit distance (c) of the engine front oil seal (2) from
end face of the crank shaft (3): 9.2 (+1/0) mm

125E-7 SERIES 50-85

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Boost pump and EPC valve

92. Install O-rings (3 pieces) and EPC valve (2).
3 Mounting bolt: 
9.8 to 12.7 Nm {1.0 to 1.3 kgm} 
93. Install O-rings (3 pieces) and boost pump (1).
94. Check that there is the embossed mark (T4) at the part (a)
of the boost pump (1).

Front support bracket

95. Sling the front support bracket (1) with the eyebolt [1], and
install the mounting bolt.

4 Front support bracket (1): 

50 kg
2 Mounting bolt of the front support bracket (1): 
Liquid adhesive (LT-2)
3 Mounting bolt of the front support bracket (1): 
59 to 74 Nm {6.0 to 7.5 kgm} 
REMARK
• The front support bracket (1) differs depending on the
machine model.
• The front support mounting bolt differs depending on
the machine model.
Damper and pulley assembly
96. Sling the damper and pulley assembly (1) with the lifting
tool [1] and install it with the guide bolt [2].

4 Damper and pulley assembly (1): 

25 kg
k Install them with mounting bolts.
3 Mounting bolt (1 piece) (width across flats: 22
mm): 
157 to 196 Nm {16 to 20 kgm} 
3 Mounting bolt (5 pieces) (width across flats: 24
mm): 
245 to 309 Nm {25.0 to 31.5 kgm} 

50-86 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Flywheel housing
97. Apply liquid gasket to the flywheel housing mounting sur-
face (a) as shown in the figure on the right.
Liquid gasket bead diameter at (a): 1 mm
2 Flywheel housing mounting surface (a): 
Liquid gasket (LG-7)

98. Sling the flywheel housing (1) with the eyebolt [1], and in-
stall it to the cylinder block.
REMARK
Align it with the dowel pin, and install it.

4 Flywheel housing (1): 

70 kg
99. Tighten the mounting bolt (2).
Tighten the mounting bolts in order in the figure on the
right.
REMARK
• When you tighten the bolt at the first time, tighten the

2 Threaded portion and seat surface of the

mounting bolts (1), (4) and (2), (9) twice.

mounting bolt: 
Engine oil
3 Mounting bolt (1st time): 
147 to 235 Nm {15 to 24 kgm} 
3 Mounting bolt (2nd time): 
245 to 309 Nm {25.0 to 31.5 kgm} 
Use the torque wrench. (Do not use the impact
wrench.)
100. Follow the procedure described below to measure the facial runout of flywheel housing.
1) Install the magnet stand of the dial gauge [3] to the
end face of the crankshaft.
2) Set the dial gauge [3] to enable its probe to hit the end
face of the flywheel housing perpendicularly.
3) Rotate the crankshaft 1 turn on the damper side and
read the difference between the maximum and mini-
mum readings of the gauge pointer.

125E-7 SERIES 50-87

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

REMARK
• Measure at 8 or more points equally spaced peripherally on the end face of the flywheel housing.
• Push the crankshaft to the front or rear to prevent an error due to the end play.
• After the crankshaft is rotated by 1 turn, check that the dial gauge pointer indicates the value at the
start of rotation.
• Since the gauge pointer moves to both of right and left, take care not to misread it when the gauge
is at the top, bottom, right, and left position.
Facial runout: 0.20 mm or less
101. Follow the procedure described below to measure the radial runout of flywheel housing.
1) Similarly to the setting for the facial runout measure-
ment of the flywheel housing, set the probe of dial
gauge [3] perpendicularly to the spigot joint part to
measure the radial runout.
REMARK
During the radial runout measurement, no error is
caused by the end play of the crankshaft, but the other
precautions for facial runout measurement must be
observed.
Radial runout: 0.20 mm or less

2) Measure the bottom level difference between the cyl-

inder block (3) and flywheel housing (1) at the portion
(b) with the dial gauge [3].
Difference in level at bottom: 0 to 0.35 mm
REMARK
If it is out of the standard value, take actions by refer-
ring to “MAINTENANCE STANDARD”.

Engine rear oil seal

102. Selection of oil seal

REMARK
In the figure, left side shows the standard oil seal, and right
side shows the sleeved oil seal.
1) Check the wear of the crankshaft and select the type
of the Teflon seal (lay-down lip seal) to install, “stand-
ard oil seal” or “sleeved oil seal”, depending on the
wear of the crankshaft.
2) When the crankshaft is worn to a degree of luster (you
can feel the wear with the pad of your finger and the
wear depth is a maximum of 10 μm) and there are no
scratches, install the standard oil seal. In other cases, install sleeved oil seal.

50-88 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

103. Installation of standard oil seal

REMARK
• Clean, degrease, and dry the contacting surface
against the flywheel housing.
• Before installing the oil seal, check that the end face
corners of crankshaft (4), oil seal lip sliding surfaces,
and housing are free from a scratch, burr, sharp edge,
rust, etc.
• When installing the engine rear oil seal, do not apply oil
or grease to the crankshaft and the hatched area of the
oil seal lip (b). Wipe off oil thoroughly from the crank-
shaft in advance.
• Spare the standard engine rear oil seal (2) has the in-
stallation guide (6). Never remove that guide before in-
stalling the engine rear oil seal.
1) Place large inside diameter side (c) of installation
guide (6) of engine rear oil seal (2) to the end of
crankshaft (4).
REMARK
Take care not to install engine rear oil seal (2) in a
wrong direction.

2) Push in the outer case end surface of the engine rear

oil seal (2) evenly.
3) Push in the engine rear oil seal (2) to a degree that it
does not come off the housing, and then remove the
installation guide (6).
REMARK
When removing installation guide (6), take care not to
scratch the oil seal lip.

4) Install tool N1 and tighten tools N2 (bolt) (3 pieces)

evenly until they reach the end to press-fit engine rear
oil seal (2).
NOTICE
• Do not attach the tools N3 (washer) to the tools
M2 (bolt).
• When press-fitting the engine rear oil seal, take
care not to scratch the oil seal lip with a tool,
etc.
5) Remove the tools N2 (bolt) and fit 1 each of the tools
N3 (washer) to the tools N2 (bolt).
6) Install the tools N2 (bolt) (3 pieces) to the tool N1 again and tighten them evenly until the end face of
tool N1 reaches the end face of the crankshaft (4) to press-fit the engine rear oil seal (2).

125E-7 SERIES 50-89

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Press-fitting distance (d) of the engine rear oil seal (2) from the end face of the crank shaft (4): 
16.3±0.2 mm
NOTICE
• When press-fitting the engine rear oil seal (2), take care not to scratch the oil seal lip with a
tool, etc.
• After press-fitting the engine rear oil seal (2), remove the red sealant layer from its periphery.
104. Installing the sleeved oil seal

NOTICE
• Clean, degrease, and dry the contacting surface against the flywheel housing.
• Check that the end face corners of the crankshaft, oil seal lip sliding surfaces, and housing are
free from a scratch, burr, sharp edge, rust, etc.
1) Do not apply oil or grease to the crankshaft, inside
surface of sleeve (5), and the hatched area of the en-
gine rear oil seal lip (b). Wipe off oil thoroughly from
the crankshaft in advance.
2) Handle the engine rear oil seal and sleeve (5) as an
assembly and never separate them from each other.

3) Set the sleeve and engine rear oil seal assembly (2) to
tool N4.
2 Sleeve inner cylinder surface: 
Liquid gasket (LG-7)

4) Put the sleeve (5) of the sleeve and engine rear oil
seal assembly (2) to the end face of the crankshaft
(4), evenly tighten the tools N5 (bolts) (3 pieces) of the
tool N4, and press-fit the sleeve and engine rear oil
seal assembly (2).
REMARK
Install 1 each of tools N6 (washer) to tools N5 (bolt)
and tighten tools N5 (bolt) until they reach the end.
5) Replace tool N4 with tool N7 and tighten tools N8
(bolt) (3 pieces) evenly until they reach the end to
press-fit sleeve and engine rear oil seal assembly (2).
REMARK
Do not fit tools N9 (washer) to tools N8 (bolt).
6) Remove tools N8 (bolt) and fit 3 each of tools N9 (washer) to tools N8 (bolt).

50-90 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

7) Install the tools N8 (bolt) (3 pieces) to the tool N7

again and tighten them evenly until the end face of
tool N7 reaches the end face of the crankshaft (4) to
press-fit the engine rear oil seal assembly (2).
Press-fitting distance (e) of the sleeve and engine rear
oil seal assembly (2) from the end surface of the
crankshaft (4): 16.3±0.2 mm
REMARK
• When press-fitting the engine rear oil seal (2), take
care not to scratch the oil seal lip with a tool, etc.
• After press fitting the sleeve and engine rear oil
seal assembly (2), remove the red sealant layer
from its periphery.
Flywheel
105. Sling the flywheel (1) with the eyebolt [1], align it with the
dowel pin part, and then install it with the guide bolt [2].

4 Flywheel (1): 
50 kg
2 Threaded portion and seat surface of the mounting
bolt: 
Engine oil
106. Tighten the mounting bolt in accordance with the proce-
dure described below.
3 Mounting bolt (1st time): 
147±19.6 Nm {15±2.0 kgm} 
3 Mounting bolt (2nd time): 
289.1±19.6 Nm {29.5±2.0 kgm} 
REMARK
Impact wrench is not allowed to use at the second time.

125E-7 SERIES 50-91

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

107. Measure the facial runout and radial runout with the dial
gauge [3].
Facial runout: 0.20 mm or less
Radial runout: 0.15 mm or less

Engine coolant temperature sensor

108. Attach the gasket and install the cover (2).
109. Install the engine coolant temperature sensor (1), plug (3),
and joint (4).
3 Engine coolant temperature sensor (1): 
23±3 Nm {2.3±0.3 kgm} 
3 Plug (3): 
34.3 to 44.1 Nm {3.5 to 4.5 kgm} 
3 Joint (4): 
59 to 98 Nm {6.0 to 10.0 kgm} 
REMARK
The shapes of the plug (3) and joint (4) may vary in response to the machine model.
110. Install O-ring to the connector (1), and install them to the
cylinder block.
111. Install the eye joint (2) to the connector (1).
REMARK
The shape the eye joint (2) may vary in response to the
machine model.
3 Joint bolt of the eye joint (2): 
24.5 to 34.3 Nm {2.5 to 3.5 kgm} 
REMARK
Install the seal washers at the front and rear of the eye
joint (2).

50-92 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Speed sensor
112. Install the speed sensor (1).
3 Mounting bolt (2): 
4.9 to 7.9 Nm {0.5 to 0.8 kgm} 

Engine oil pressure sensor

113. Install the engine oil pressure sensor (1).
3 Engine oil pressure sensor (1): 
23±3 Nm {2.3±0.3 kgm} 

Engine oil pan and oil strainer

114. Install the O-ring and oil strainer (2).
115. For the oil strainer (2), temporarily assemble the bracket
(3), determine the position, and then tighten the mounting
bolt.
116. Put the engine sideways

117. Sling the engine oil pan (1) with the lifting tools [5], fit the
gasket, and then install the engine oil pan.
REMARK
• Be careful about the oil pan (1) since its shape varies
in response to the machine model.
• Install the gasket while the bead faces the oil pan.
REMARK
Apply liquid gasket (LG-7) to the gasket at the following lo-
cations.
• 6 clinching parts of the gasket
• Mating faces of the cylinder block and front cover
• Mating faces of the cylinder block and flywheel housing
Install the engine oil pan (1) with the guide bolt.

125E-7 SERIES 50-93

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

4 Engine oil pan (1): 

25 kg
Engine repair stand
118. Set the engine upward.
119. Sling the engine with the lifting tool, and remove the en-
gine from the tool A1.

4 Engine (1): 
820 kg

120. Set the engine (1) on the rigid and stable block [1].

NOTICE
Do not tilt the engine, but fix it.

121. Remove the tool A2 from the engine.

Cylinder head assembly (assembly)

122. Put the cylinder head sideways and install the valve (6).

2 Valve (6) (valve stem): 

Engine oil

50-94 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

123. Turn the cylinder head upward and install the lower seat
(5).
124. Install the oil seal with the tool Q until the driving-in dis-
tance (a) reaches the value indicated below.
Driven-in distance (a): 23.4±0.5 mm
REMARK
The oil seal (4) is of the type that has the back pressure lip
(4a).

125. Install the valve spring (1) and upper seat (3).
126. Compress the valve spring (1) with the tool B, and install
the valve cotter (2).
REMARK
Hit the valve stem lightly with a plastic hammer to check
that the valve cotter is securely fitted to the groove of the
valve stem.

125E-7 SERIES 50-95

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Cylinder head assembly (installation)

127. Check that there is no dust or foreign material on the cylin-
der head mounting face and inside the cylinders, and fit
the cylinder head gasket (3) (6 pieces).
REMARK
Check that the grommet of the cylinder head gasket (3)
has no peeling or omission.

128. Check the cylinder head mounting bolts for the following. If
the following applies to a bolt, do not reuse that bolt but re-
place it.
Number of tightening times: 6 (5 punch marks at the bolt
head)
Bolt stem length allowable limit (a): Min. 171.4 mm

129. Sling the cylinder head assembly (1) with the eyebolt [1],
align it with the dowel pin, and install it.

4 Cylinder head assembly (1): 

20 kg
130. Tighten the mounting bolts and auxiliary bolt of the cylinder
head assembly.

50-96 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

1) Tighten the mounting bolts (1) to (6) in order in the fig-

ure on the right.
2 Threaded portion and seat surface of the
mounting bolt: 
Lubricant containing molybdenum disulfide
(LM-P) or engine oil
3 Mounting bolt (1st time): 
98.1±9.8 Nm {10±1 kgm} 
3 Mounting bolt (2nd time): 
166.6 to 176.4 Nm {17 to 18 kgm} 
(Target: 176.4 Nm {18 kgm} )
3rd time: Retighten the bolt with the tool K by 90 to
120 ° (target: 120 °).
REMARK
When the tool K is not used, put the marks (b) on the
cylinder head and mounting bolt with paint, and then
retighten the mounting bolt by 90 to 120 ° (target:
120 °).

2) Put the punch mark (c) (1 piece) on the mounting bolt

head.
REMARK
When a new bolt is used, do not put the punch mark
(c).

3) Tighten the cylinder head mounting auxiliary bolt (7).

3 Cylinder head mounting auxiliary bolt (7): 
58.8 to 73.5 Nm {6.0 to 7.5 kgm} 

125E-7 SERIES 50-97

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Rocker arm housing

131. Fit the gasket (1) and install the rocker arm housing (2).
132. Tighten the mounting bolt (3).
Mounting bolt (3)58.8 to 73.5 Nm {6.0 to 7.5 kgm} 

Fuel injector wiring harness connector

133. Install O-ring (4) to the fuel injector wiring harness connec-
tor (1).
2 O-ring (4): 
Engine oil
134. Insert the fuel injector wiring harness connector (1) in the
rocker housing (3) and tighten the mounting bolt (2).
2 Mounting bolt (2): 
Liquid adhesive (LT-2)

135. Fit the wiring harness to the holder (5).

Crosshead
136. Set the crosshead (1), loosen the lock nut (2), and loosen
the adjustment screw (3).
137. Hold the rocker arm contacting surface of the crossheads
(1) lightly with your fingers to keep the crosshead (1) in
contact with the valve stem on the push rod side.
138. Tighten the adjustment screw (3) until the crossheads (1)
touches the other valve stem.
139. After the adjustment screw (3) touches the valve stem,
tighten it further by 20 ° and then tighten the lock nut (2).
2 Crosshead guide, crosshead top: 
Engine oil
3 Lock nut (2): 
58.7±5.9 Nm {6.0±0.6 kgm} 

50-98 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Fuel injector
140. Install the bracket (1).

141. Install the common rail (2) loosely.

REMARK
For positioning of the fuel injector

142. Install the gasket (6), O-rings (7) and (8) to the fuel injector
(1).
REMARK
Check that there is no dust or dirt inside of the fuel injector
sleeve.
2 O-rings (7) and (8): 
Engine oil
NOTICE
• Install the fuel injectors to their correct positions in
accordance with the cylinder numbers that were re-
corded at removal.
• Be careful not to damage QR code tab (9) at the top
of the fuel injector (1).
• Do not remove QR code tab (9).
143. Install the holder (2) to the fuel injector (1), face the fuel
high-pressure pipe mounting part (5) toward the fuel high-
pressure pipe insertion hole, and then install the fuel injec-
tor (1).

125E-7 SERIES 50-99

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

144. Install the spherical washer to the mounting bolt (3) and
tighten the holder (2) lightly.
2 Spherical washer: 
Engine oil
145. Align the fuel high-pressure sleeve (4) with the fuel high-
pressure pipe mounting part (5), and lightly tighten it.
REMARK
Lightly tighten the sleeve nut on the common rail side.
146. Tighten the mounting bolt (3) of the holder (2) to the speci-
fied torque.
REMARK
While the tube of the fuel high-pressure pipe is pulled in the opposite direction of the fuel injector (1), tight-
en the mounting bolt (3).
3 Mounting bolt (3): 
58.8 to 73.5 Nm {6.0 to 7.5 kgm} 
147. Follow the same procedure to install the other fuel injectors.
148. After tightening the holder (2), remove the fuel high-pressure pipe sleeve (4) from the inlet connector (5).
149. Remove the common rail installed loosely in the above steps.
Push rod
150. Install the push rods (1) (12 pieces).
Check that the end of the push rod (1) is securely fitted to
the socket of the cam follower.

Rocker arm and shaft assembly

151. Set the rocker arm and shaft assembly (1) to the rocker
housing.
NOTICE
• Install the rocker arm and shaft assembly (1) while
the larger mounting hole end faces down and the
ball plug (6) end faces toward the front side of the
engine.
• Securely clean the oil hole of the mounting bolt (4),
and install it.
152. Check that the ball of the adjustment screw (2) is fitted in
the socket of the push rod (5) securely.
153. Tighten the mounting bolt (4).

3 Mounting bolt (4): 

58.8 to 73.5 Nm {6.0 to 7.5 kgm} 

50-100 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Fuel injector wiring harness

154. Tighten the mounting bolt (3) of the wiring harness fixing
holder.
3 Mounting bolt (3): 
27.0 to 34.0 Nm {2.8 to 3.5 kgm} 
155. Set the wiring harnesses terminal to the head of the fuel
injector (1) and install the capture nuts (2) (2 pieces).
REMARK
• The wiring harness terminal plate can be installed in
only one direction.
• Tighten the capture nuts (2) alternately.
3 Capture nut (2): 
2.0 to 2.4 Nm {0.20 to 0.24 kgm} 
156. Follow the procedure described below to adjust the valve clearance.
1) As for the valve clearance, adjust the clearance between the crosshead and rocker arm to the following
values.
• Valve clearance (when the engine is cold)
Intake valve: 0.33 mm
Exhaust valve: 0.71 mm
REMARK
Rotate the crankshaft and adjust the valve clearance of each cylinder in the firing order of 1, 5, 3, 6, 2
and 4.
2) Rotate the crankshaft in the normal direction (counter-
clockwise seeing from the flywheel side) to set
1/6TOP stamp (a) of the damper (1) to the pointer (2),
while watching the movement of the valves.

3) Set the tool J between the rocker arm (3) and cross-
head (4).
4) Tighten the adjustment screw (5) and tighten the lock
nut (6) under the condition that the tool J moves heav-
ily.
3 Lock nut (6): 
58.8 to 73.5 Nm {6.0 to 7.5 kgm} 
5) After tightening the lock nut (6), check the valve clear-
ance again.

125E-7 SERIES 50-101

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Cylinder head cover

157. Install O-ring, and install the cylinder head covers (1).

REMARK
When installing O-ring, do not twist it.
3 Mounting bolt of cylinder head cover (1): 
9.8±1.0 Nm {1.0±0.1 kgm} 
158. Install the oil filler pipe (2).

REMARK
Be careful about the shape and mounting position of the oil
filler pipe since they vary in response to the machine mod-
el.
Oil cooler assembly
159. Install the drain hose (1a).

160. Fit the gasket to the oil cooler assembly (1) and install
them with the guide bolts [1].

Fuel block
161. Install the bracket (1).
162. Install the fuel block (2).

REMARK
The shape of the fuel block (2) varies in response to the
machine model.

50-102 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Common rail
163. Install the common rail (2) and tighten the mounting bolts
(1).
3 Mounting bolt (1): 
59 to 74 Nm {6.0 to 7.5 kgm} 

164. Sling the bracket (3) and install it.

4 Bracket (3): 
25 kg
NOTICE
Install the bracket (3) while the fuel doser pump (4) is
attached.
165. Install the fuel tubes (5) and (6).

3 Joint bolt of the fuel tube (5) (supply pump side) : 

14.8 to 19.6 Nm {1.5 to 2.0 kgm} 
3 Sleeve nut of the fuel tube (5) (fuel block side): 
43 to 47 Nm {4.4 to 4.8 kgm} 
3 Sleeve nut of the fuel tube (6) (fuel block side): 
84 to 132 Nm {8.5 to 13.5 kgm} 
3 Joint bolt of the fuel tube (6) (fuel doser pump side) : 
11.6 to 13.6 Nm {1.2 to 1.4 kgm} 
Fuel high-pressure pipe between the supply pump and common rail
166. If the taper seal part of the fuel high-pressure pipe con-
necting part has any of the following problems, replace the
fuel high-pressure pipe with a new one since fuel may
leak.
REMARK
• There is the visible lengthwise slit (b) or spot (c) in the
range (a) of 2 mm from the end.
• Level difference caused by fatigue which is felt with nail
in the taper seal end part (d) of 2 mm from end.

125E-7 SERIES 50-103

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

167. Tighten the fuel high-pressure pipes (1) and (2).

168. Install the clamps and brackets for the above mentioned
fuel high-pressure pipes (1) and (2), and finger-tighten
them.
169. Install the lubricating oil tube (5), and finger-tighten it.
170. Tighten the sleeve nuts of the fuel high-pressure pipes (1)
and (2) to the specified torque.
3 Sleeve nut: Supply pump side: 
39.2 to 44.1 Nm {4.0 to 4.5 kgm} 
3 Sleeve nut: Common rail side: 
39.2 to 44.1 Nm {4.0 to 4.5 kgm} 
171. Tighten the mounting bolts (3) of the supply pump to the
specified torque.
NOTICE
When reusing the mounting bolts (3), apply adhesive
(LT-2) to the threaded portion of the bolt.
2 Mounting bolt (3): 
Liquid adhesive (LT-2)
3 Mounting bolt (3): 
59 to 74 Nm {6.0 to 7.5 kgm} 
172. Tighten the mounting bolts (2 pieces) on the supply pump
side of the bracket (4) to the specified torque.
3 Supply pump side mounting bolt: 
19.6 to 29.4 Nm {2.0 to 3.0 kgm} 
173. Tighten the mounting bolts (6) and mounting bolts (7) for
the bracket (7a) to the specified torque in this order.
174. Install the fuel spray prevention caps (8) and (9).
When installing the fuel spray prevention caps, turn their
slits in the direction shown below.
Fuel spray prevention cap (8): Cylinder block side
Fuel spray prevention cap (9): Downward
175. Finger-tighten the brackets (10), (11), (12), (13), and (14)
to install them.
176. Finger-fasten the clamps (15) and (16) to install them.
177. Tighten the clamps (15) and (16) to the specified torque.

3 Mounting bolts of the clamps (15) and (16): 

11.8 to 14.7 Nm {1.2 to 1.5 kgm} 
178. Tighten the mounting bolt (17) of the bracket (14) to the
specified torque.
179. Tighten the mounting bolt (18) of the bracket (12) to the specified torque.
180. Tighten the mounting bolt (19) of the bracket (13) to the specified torque.
181. Tighten the mounting bolt (20) to the specified torque.
182. Tighten the lubricating oil tube (5) to the specified torque.

3 Joint bolt of the lubrication oil tube (5) (supply pump side): 
7.9 to 12.7 Nm {0.8 to 1.3 kgm} 

50-104 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

3 Joint bolt of the lubricating oil tube (5) (cylinder block side) : 
9.8 to 12.7 Nm {1.0 to 1.3 kgm} 
183. Tighten the mounting bolt (21) of the bracket (10) to the specified torque.
184. Tighten the mounting bolt (22) of the bracket (11) to the specified torque.
Engine controller cooler
185. Install the engine controller cooler (1).
186. Install the overflow tube (2).

3 Joint bolt on the common rail side: 

17.7 to 22.6 Nm {1.8 to 2.3 kgm} 

Engine controller
187. Install the engine controller (2).
188. Install the ground cable (1).
189. Install the wiring harness clamps (3) (2 pieces).

Air intake manifold

190. Fit the gasket and install the air intake manifold (3) loosely.

4 Air intake manifold (3): 

30 kg

191. Tighten the mounting bolts in the order shown in the figure
below.
3 Mounting bolt: 
59 to 74 Nm {6.0 to 7.5 kgm} 

125E-7 SERIES 50-105

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

192. Install the oil filler pipe (2) and bracket (1).

REMARK
The shape varies in response to the machine model.

Fuel high-pressure pipe between the common rail and fuel injector
193. If the taper seal part of the fuel high-pressure pipe con-
necting part has any of the following problems, replace the
fuel high-pressure pipe with a new one since fuel may
leak.
REMARK
• There is the visible lengthwise slit (b) or spot (c) in the
range (a) of 2 mm from the end.
• Level difference caused by fatigue which is felt with nail
in the taper seal end part (d) of 2 mm from end.

194. Install the fuel high-pressure pipes (1) (6 pieces), and

tighten them to the specified torque.
REMARK
The mounting angle of the inlet connector has been adjus-
ted at the installation of the fuel injector.
3 Sleeve nut: Supply pump side: 
39.2 to 44.1 Nm {4.0 to 4.5 kgm} 
3 Sleeve nut: Common rail side: 
39.2 to 44.1 Nm {4.0 to 4.5 kgm} 
195. Install the bracket and clamps (2) to (6) loosely, and then
tighten the clamps to the specified torque.
3 Clamping bolt: 
11.8 to 14.7 Nm {1.2 to 1.5 kgm} 
196. Tighten the mounting bolts for brackets (2) through (6) to
the specified torque.
197. Install all the clamps (7) to (10) loosely.
198. Install the clamp (11) to the bracket (12) loosely, and then
tighten clamp (11) to the specified torque.
REMARK
The clamp (11) is on the back of the bracket (12) and used
to fix 6 fuel high-pressure pipes.
3 Clamping bolt: 
11.8 to 14.7 Nm {1.2 to 1.5 kgm} 
199. Lightly fasten the bracket (12).
200. Tighten the clamps (7) to (10) to the specified torque.

50-106 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

3 Clamping bolt: 
11.8 to 14.7 Nm {1.2 to 1.5 kgm} 
201. Install the fuel spray prevention caps (13) to both ends of the fuel high-pressure pipe.

NOTICE
Install the fuel spray prevention cap with the slit of the cap on the cylinder head side facing down-
ward and with the slit of the cap on the common rail side facing to the cylinder block.
Fuel spill tube
202. Fit the gaskets to both sides and install the spill tube (1).

3 Mounting bolt: 
9.8 to 12.7 Nm {1.0 to 1.3 kgm} 

Mixing connector
203. Install the gasket, sling the mixing connector (2), and in-
stall it.

4 Mixing connector (2): 

35 kg

204. Install the bracket (1).

REMARK
The shape of the bracket (1) varies in response to the ma-
chine model.

EGR valve
205. Install EGR valve (2).
206. Fit the gasket, and install EGR valve oil drain tube (1a).
207. Fit O-ring, and install the oil tube (1b) for EGR valve hy-
draulic actuator.

125E-7 SERIES 50-107

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

KCCV ventilator
208. Install KCCV ventilator (5).
209. Install the coolant tube (3) and lower drain hose (4).
210. Install the upper hoses (1) (2 pieces) and coolant tube (2).

REMARK
The mounting position of KCCV ventilator (5) may vary in
response to the machine model compared with that on the
machine side.

211. Install the drain hose (4), and then check for the items de-
scribed below.
1) Install the check valve (6) in the direction shown in the
figure.
2) Check that the black part (a) on the lower side of the
check valve (6) is aligned with the cylinder block side.
REMARK
The dimensions in the figure indicate the color-coded
parts.

Fuel doser solenoid valve assembly

212. Install the fuel doser solenoid valve assembly (1).

50-108 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Fuel filter
213. Install the fuel filter and head assembly (5).
214. Install the fuel filter and head tubes (4), (3), (2), and (1).

3 Joint bolt of the fuel filter head tubes (4), (3), and
(1) : 
24.5 to 34.3 Nm {2.5 to 3.5 kgm} 
3 Joint bolt of the tube (2): 
7.8 to 9.8 Nm {0.8 to 1.0 kgm} 

Fuel prefilter
215. Install the bracket (3).

REMARK
The mounting position of the fuel prefilter may vary in re-
sponse to the machine model compared with that on the
machine side.

216. Install the fuel filter and head assembly (2).

217. Install the head tubes (1) (2 pieces).

Oil filter
218. Install the lower bracket (5) and upper bracket (4).

125E-7 SERIES 50-109

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

219. Install the oil filter and head assembly (3) loosely.
220. Fit O-rings, and install the head tubes (2) (2 pieces) loose-
ly.
221. After tightening the bolts for the lower flange of the head
tube (2) to the specified torque, tighten the bolts for the up-
per flange to the specified torque.
222. Tighten the bolts for the oil filter and head assembly (3) to
the specified torque.
223. Install the clamp (1).

NOTICE
Face the slit of the clamps (1) outward of the clamps.
Wiring harness assembly
224. Route the wiring harness assembly (19) in the specified
position, connect the wiring harness connectors to their
mating connectors, and then fix them with the clamps.
225. Connect the following connectors.
(18): ECMJ2
(17): ECMJ1
(16): NE
(15): PFUEL
NOTICE
Fasten the connectors ECMJ1 (17) and ECMJ2 (18)
with the connector clamp, and fix them with the bolts
(20) and (21).
3 Bolts (20) and (21): 
8 to 10 Nm {0.81 to 1.02 kgm} 
226. Install the engine controller cover (14).

REMARK
The shape of the engine controller cover (14) varies in re-
sponse to the machine model.

227. Connect the following connectors.

(1): PAMB
(2): SVGT (Connect connector to holder.)
(3): VGT-REV (Connect connector to holder.)

50-110 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

(4): PDOSER
(5a): SOV1
(5b): SOV2
(6): Fuel injector connectors CN1 through CN6 (on each
cylinder head)

(7): PCV1
(8): PCV2
(9): G
(10): PO1L
(11): SEGR
(12): EGR-SOL

Air vent tube

228. Fit the gaskets to both sides and install the air vent tube
(1).
3 Mounting bolt: 
9.8 to 12.7 Nm {1.0 to 1.3 kgm} 

VGT and exhaust manifold assembly

229. Install the rings (19) to the manifolds (17) and (18) at both
ends.
2 Both ends (a) of the manifolds (17) and (18): 
Heat-resistant seal (Holts MH705 or equivalent)
230. Install the manifolds (17) and (18) to the intermediate
manifold (16).
NOTICE
Install them to secure the dimension (b) at the inser-
tion part is as follows.
Dimension (b) at the insertion part: 5 mm
231. Fit the gasket, and install VGT to the exhaust manifold.

2 Threaded portion of the mounting nut: 

Seizure prevention compound (LC-G)
3 Mounting bolt: 
68.6 to 73.5 Nm {7.0 to 7.5 kgm} 

125E-7 SERIES 50-111

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

232. Sling VGT and exhaust manifold assembly (15), fit the
gasket, and install them loosely.

4 VGT and exhaust manifold assembly (15): 

65 kg

233. Tighten the mounting bolts at (A), (B), and (C) of the ex-
haust manifold.
234. Tighten the remaining mounting bolts.

3 Mounting bolt (16): 

58.8 to 73.5 Nm {6.0 to 7.5 kgm} 

235. Install VGT coolant tube (14), and then install the clamp.
Coolant tube (14)
3 Nut on VGT side: 
35 to 65 Nm {3.5 to 6.5 kgm} 
3 Joint bolt on the cylinder block side: 
24.5 to 34.3 Nm {2.5 to 3.5 kgm} 

236. Install the bracket (13 a).

50-112 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

237. Install VGT lubricating oil tube (12), and then install the
clamp.
3 Sleeve nut of VGT lubricating oil tube (12) (cylinder
block side): 
24 to 27 Nm {2.4 to 2.7 kgm} 

238. Install the wiring harness clamp bracket (13) and install the
brackets (10) (2 pieces), (11) (1 piece), and (12) (1 piece).

239. Install the bracket (9).

240. Connect the following connectors.

(7): SVGT
(8): VGT-REV
241. Install the following hoses and tubes.

125E-7 SERIES 50-113

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

1) Install VGT wiring harnesses (5b) (2 pieces) to har-

ness bracket (5c).
2) Install the cover (5 a).
3) Install the coolant tube (5) and fuel hose (6) for fuel
doser, and then install the clamps.
3 Fuel hose (6) for fuel doser: 
14.7±4.9 Nm {1.5±0.5 kgm} 
3 Joint bolt of the coolant tube (5): 
24.5 to 34.3 Nm {2.5 to 3.5 kgm} 
242. Install the coolant tube (4) and install the clamp.

3 Joint bolt of the coolant tube (4): 

24.5 to 34.3 Nm {2.5 to 3.5 kgm} 
243. Install the bracket (3) and connect the connector TWTR
(2).

244. Install the cover (1) for the fuel doser solenoid valve as-
sembly.
245. Install NOx sensor controller (1a).
246. Install NOx sensor cover (1b).
247. Install the prefilter covers (1c) and (1d).

Exhaust connector
When the exhaust connector assembly was removed, fol-
low the procedure described below to install it.
(10): Exhaust connector
(11): Seal ring
(12): Seal
(13): VGT housing
(14): Fuel doser
(15): Turbocharger outlet NOx sensor

248. Install the seal (12) to VGT housing (13) with the tool S1.

REMARK
• Install the seal (12) in the direction of the arrow.
• Drive in the tool S1 until it reaches the flange surface
(c) of VGT housing (13).
• At this time, the clearance (d) between VGT housing
(13) and seal (12) is 3 mm.
249. Install the seal ring (11) to the exhaust connector (10).

50-114 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

250. Fix the exhaust connector (10) and tool S2 with the mount-
ing bolts [1], and install them to VGT housing (13).
REMARK
Install the exhaust connector (10) in the direction of the ar-
row.
251. Press in the tool S2 until its end face reaches the flange
surface (c) of VGT housing (13).
252. Fix VGT housing (13) and tool S2 with the mounting bolts
[2].
REMARK
This is prevent slanted installation of the exhaust connec-
tor (10).
253. Tighten the mounting bolts of the exhaust connector (10)
while the tool S2 is installed, and fix it.
254. Check that the dimensions (e) and (f) are within the follow-
ing value.
Dimension (e): 159 mm
Dimension (f): 19 mm
255. Remove the tool S2.

REMARK
Tightening torques of the parts related to the exhaust con-
nector (10)
3 Plug (15): 
2.9 to 5.9 Nm {0.3 to 0.6 kgm} 
3 Mounting bolt (16): 
44.1 to 53.9 Nm {4.5 to 5.5 kgm} 
3 Mounting bolt (17): 
68.6 to 73.5 Nm {7.0 to 7.5 kgm} 
3 Turbocharger outlet NOx sensor (18): 
50±10 Nm {5.1±1 kgm} 

125E-7 SERIES 50-115

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

Fuel doser
256. Follow the procedure described below to remove the soot
(a) from the fuel dose (2).

1) Press the cloth [1] with a generous amount of diesel

fuel against the soot accumulated at the fuel doser in-
jection port end, to soak the soot into the fuel.

2) After the fuel soaks into the soot, wipe off excessive
fuel with the cloth [1].

50-116 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

3) Clean the injection port end with the brush [2] to re-
move the soot.

REMARK
• Clean the injection port with the brush [2] and cloth
[1] until soot is completely removed from the injec-
tion port.
• Use the nylon brush [2] for cleaning. (Do not use a
wire brush because it will damage the injection
port.)
• Use only diesel fuel for cleaning.
REMARK
Cleaned injection port end
A: Cleaning is completed (no soot remains at injec-
tion port)
B: Cleaning is not completed (soot remains at in-
jection port)

125E-7 SERIES 50-117

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

4) Install the heat insulator (4) to the fuel doser (2).

5) Set the mounting bolts (5) to the fuel doser (2), fit the
gasket (3), and install them to the exhaust connector.
3 Mounting bolt (5) (width across flats: 
8.5 to 9.5 Nm {0.87 to 0.97 kgm} 
NOTICE
• Tighten the fuel doser mounting bolts to the
specified torque, and tighten them alternately
again.
• For the heat insulator (4), gasket (3), and
mounting bolt (5), use new parts.
• Install the gasket (3) while the stepped portion
(convex portion) faces toward the exhaust con-
nector side.

EGR cooler
257. Install the bracket (9).

258. Install EGR cooler (8).

259. Fit the gasket and install EGR piping (7).

3 Mounting bolt: 
59 to 74 Nm {6.0 to 7.5 kgm} 

50-118 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

260. Install the gasket, loosely install EGR piping (6) and clamp
(6a), and then tighten EGR piping (6) and clamp (6a) to
the specified torque in this order.
261. Install the heat insulation plate (5).

REMARK
Installation of the heat insulation plate (5) depends on the
machine model.

262. Install EGR air vent tubes (4) (2 pieces).

3 Joint bolt: 
19.6 to 29.4 Nm {2.0 to 3.0 kgm} 

263. Fit the gaskets and O-rings, and then install EGR coolant
tubes (3) and (3a).
264. Install the air vent tube (2).

3 Joint bolt: 
19.6 to 29.4 Nm {2.0 to 3.0 kgm} 
265. Fit the gasket, install the oil drain tube (1) for VGT, and
then install the clamps.

Oil tube for VGT hydraulic actuator

266. Fit the O-ring, install the oil tube (2) (2 pieces) for VGT hy-
draulic actuator, and then install the clamps.
3 Sleeve nut on the front cover side: 
24 to 27 Nm {2.4 to 2.7 kgm} 
3 Joint bolt on VGT side: 
24.5 to 34.3 Nm {2.5 to 3.5 kgm} 

125E-7 SERIES 50-119

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

267. Connect EPC valve connector VGT-SOL (1).

Alternator assembly
268. Install the auto-tensioner bracket (5) to the front cover.
269. Install the alternator assembly (4) to the auto-tensioner
bracket (5).
270. Install the auto-tensioner (2) to the auto-tensioner tension-
er bracket (5).
3 Mounting bolt of the auto-tensioner (2): 
45 to 55 Nm {4.6 to 5.6 kgm} 
271. Follow the procedure described below to install the alter-
nator belt (1).
1) Set the wrench [1] to the part (a) (width across flats
12.7 mm) of the auto-tensioner assembly (2).
2) Turn the wrench [1] counterclockwise when seen from
the front of the engine, and install the alternator belt
(1).
k Firmly set the wrench [1] to the portion (a) of
the auto-tensioner (2), and then rotate it. (Since
the spring force of the auto-tensioner (2) is
strong, the wrench may come off and is very
dangerous if it is turned when not attached se-
curely.)
k Install the alternator belt (1), and then return
the auto-tensioner assembly (2) slowly and
carefully.
k Be careful not to get your fingers caught be-
tween the pulley and alternator belt (1) during
work.
NOTICE
Check that the alternator belt (1) is fitted correctly and securely in the pulley groove.
Starting motor assembly
272. Install the starting motor assembly (2), and install the
mounting bolts (1).
REMARK
Connect the connector and wiring harness to the specified
positions.

50-120 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY

Check after assembling

273. When reinstalling or replacing the sensors, tighten their mounting bolt to the following torque.

Sensor name Tightening torque

NE (crankshaft) speed (hexagonal socket head bolt) 4.9 to 7.9 Nm {0.5 to 0.8 kgm} 
Engine oil pressure 23±3 Nm {2.3±0.3 kgm} 
Crankcase oil pressure (hexagonal socket head bolt) 2.0 to 2.5 Nm {0.2 to 0.3 kgm} 
Ambient pressure (hexagonal socket head bolt) 4.1 to 9.5 Nm {0.4 to 1.0 kgm} 
Coolant temperature 23±3 Nm {2.3±0.3 kgm} 
Charge temperature 23±3 Nm {2.3±0.3 kgm} 
Engine oil level (hexagonal socket head bolt) 11.8 to 14.7 Nm {1.2 to 1.5 kgm} 
Air cleaner clogged 0.98 to 1.27 Nm {0.10 to 0.13 kgm} 
Charge pressure 23±3 Nm {2.3±0.3 kgm} 
NOx sensor 50±10 Nm {5.1±1 kgm} 
274. Checking for fuel leakage
If the supply pump (1), common rail (2), or high-pressure
fuel pipe (3) or (4) is removed, installed or replaced, follow
the procedure described below to check for the fuel leak-
age after installing the engine.
NOTICE
Clean the engine and the parts around it, and degrease
them in advance to easily find the leakage if any.
1) Spray the color checker (developer) over the connect-
ing part of the supply pump, common rail, fuel injector,
and fuel high-pressure pipe.
2) Start the engine, keep its speed at 1000 rpm or below, and stop it when its speed is stabilized.
3) Check the fuel piping and component for fuel leakage.
REMARK
• Check the high-pressure fuel circuit part coated with the color checker (developer) and their periph-
eries for fuel leakage.
• If there is a fuel leakage, repair it, and perform the testing again from step 2).
4) Start the engine, and run it at low idle.
5) Check the fuel piping and component for fuel leakage.
REMARK
• Check the high-pressure fuel circuit part coated with the color checker (developer) and their periph-
eries for fuel leakage.
• If there is a fuel leakage, repair it, and perform the testing again from step 2).
6) Start the engine, and keep it running at high idle.
7) Check the fuel piping and component for fuel leakage.
REMARK
• Check the high-pressure fuel circuit part coated with the color checker (developer) and their periph-
eries for fuel leakage.
• If there is a fuel leakage, repair it, and perform the testing again from step 2).
8) Start the engine and keep it running at high idle, and apply a load to the engine.

125E-7 SERIES 50-121

 50 DISASSEMBLY AND ASSEM-
DISASSEMBLE AND ASSEMBLE ENGINE GENERALLY BLY

NOTICE
When the engine is mounted on the machine, stall the torque converter or relieve the hydraulic
pump.
9) Check the fuel piping and component for fuel leakage.
REMARK
• Check the high-pressure fuel circuit part coated with the color checker (developer) and their periph-
eries for fuel leakage.
• If there is a fuel leakage, repair it, and perform the testing again from step 2).
• When no fuel leakage is detected, the inspection is completed.
275. When any of the fuel injectors or the engine controller is replaced, write the compensation values with IN-
SITE.

50-122 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY

REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY

METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY
Harness connector, Fuel tube
1. Disconnect the following connectors.
(1): PCV1
(2): PCV2
(3): G

Pump piping
2. Disconnect fuel tubes (4) and (5).
3. Disconnect fuel tube (7).
4. Disconnect lubricating oil tube (8).
5. Remove fuel spray prevention cap (9) and loosen the
clamp of fuel high-pressure pipe.
6. Loosen the sleeve nuts of fuel high-pressure pipes (10) (2
pieces), and disconnect 2 high-pressure pipes from the
supply pump (26).
REMARK
Loosen the sleeve nuts on the common rail side, as well.
KCCV ventilator
7. Disconnect upper hoses (11) (2 pieces), coolant tubes (12)
(2 pieces), and lower drain hose (13).
8. Remove KCCV ventilator (13a).

125E-7 SERIES 50-123

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY BLY

Fuel filter assembly

9. Disconnect fuel filter head tubes (14), (15), (16), and (17).
10. Remove fuel filter and head assembly (18).
Supply pump drive gear
11. Remove cover (19).
12. Rotate the crankshaft in the normal direction (counter-
clockwise seeing from the flywheel side) to set center point
(a) between stamp line 2/5TOP and 3/4TOP of damper
(20) to pointer (21). (Stamp line 1/6TOP comes bottom.)
REMARK
• At this time, check that the forcing tap of the drive gear
aligns with the mounting bolt hole of cover (19). (If it is
not, rotate the crankshaft one more turn.)
• At this position, the key of the supply pump shaft is ro-
tated clockwise by 15 ° from the top.
13. Remove mounting nut (22).
14. Install tools P1, P2, and P3 and tighten the center bolt of
P1 to pull out the supply pump drive gear from the shaft.
REMARK
Keep tools P1, P2, and P3 installed to prevent the supply
pump drive gear from coming off.

Supply pump assembly

15. Remove bracket (23) and loosen the mounting bolts for
bracket (24).
16. Remove mounting bolts (25) (4 pieces), and remove sup-
ply pump assembly (26).
REMARK
Keep tools P1, P2, and P3 installed to prevent the supply
pump drive gear from coming off.

50-124 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY

METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY

Supply pump drive gear
1. Set key (22a) of the supply pump shaft almost upward.

2. Match the keyway (a) of supply pump drive gear (30) with
key (22a) of the shaft.

125E-7 SERIES 50-125

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY BLY

3. At the same time, match timing marks (C) on supply pump

drive gear (30) and cam gear (31), and then tighten mount-
ing nut (22).
REMARK
• Rotate the crankshaft in the normal direction (counter-
clockwise seeing from the flywheel side) to set center
point (a) between stamp line 2/5TOP and 3/4TOP of
damper (20) to pointer (21). (Stamp line 1/6TOP comes
bottom.)
• At this time, check that the forcing tap of the drive gear
aligns with the mounting bolt hole of cover (19). (If it is
not, rotate the crankshaft one more turn.)
• At this position, the key of the supply pump shaft is ro-
tated clockwise by 15 ° from the top.
3 Mounting nut(22) : 
176 to 196 Nm {18 to 20 kgm} 
4. Install cover (19).
3 Mounting bolt of cover (19) : 
98 to 123 Nm {10.0 to 12.5 kgm} 

50-126 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY

Supply pump
5. Finger-tighten mounting bolts (25) (4 pieces) of the supply
pump.
6. Install brackets (23) and (24), and then finger-tighten the
mounting bolts.

7. Install and finger-tighten high-pressure fuel pipes (30) and

(31).
8. Install and finger-tighten clamps and brackets for the
above-mentioned high-pressure fuel pipes (30) and (31).
9. Install and finger-tighten lubricating oil tube (32).
10. Tighten mounting bolts (25) (4 pieces) of the supply pump
to the specified torque.
3 Mounting bolt (25) : 
59 to 74 Nm {6.0 to 7.5 kgm} 
REMARK
When reusing mounting bolts (25), apply liquid adhesive
(LT-2) to the threaded part of bolt.

125E-7 SERIES 50-127

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY BLY

11. Tighten the mounting bolts (2 pieces) for bracket (23) on

the supply pump side to the specified torque.
3 Supply pump side mounting bolt : 
19.6 to 29.4 Nm {2.0 to 3.0 kgm} 
12. Tighten mounting bolt (33) and mounting bolts (34) for
bracket (24) to the specified torque in this order.
13. Install fuel spray prevention caps (35) and (36).
REMARK
When installing the fuel spray prevention caps, turn their
slits in the direction shown below.
Fuel spray prevention cap (35): Cylinder block side
Fuel spray prevention cap (36): Downward
14. Install and finger-tighten brackets (37), (38), (39), (40), and
(41).
15. Install and finger-tighten clamps (42) and (43).
16. Loosen clamps (42) and (43) to the specified torque.
3 Clamps (42), (43) mounting bolt : 
11.8 to 14.7 Nm {1.2 to 1.5 kgm} 
17. Tighten mounting bolts (44) of bracket (41) to the specified torque.
18. Tighten mounting bolts (45) of bracket (39) to the specified torque.
19. Tighten mounting bolts (46) of bracket (40) to the specified torque.
20. Tighten mounting bolts (47) to the specified torque.
21. Tighten lubricating oil tube (32) to the specified torque.
3 Joint bolt of lubricating oil tube (32) (supply pump side) : 
7.9 to 12.7 Nm {0.8 to 1.3 kgm} 
3 Joint bolt of lubricating oil tube (32) (cylinder block side) : 
9.8 to 12.7 Nm {1.0 to 1.3 kgm} 
22. Tighten mounting bolts (48) of bracket (37) to the specified torque.
23. Tighten mounting bolts (49) of bracket (38) to the specified torque.
KCCV ventilator
24. Install KCCV ventilator (13a).

50-128 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY

25. Install upper hoses (11) (2 pieces), coolant tubes (12) (2

pieces), and lower drain hose (13).
NOTICE
• Install check valve (13a) in the direction shown in
the figure.
• Hatched area (a) at lower side of check valve (13a)
must be on the cylinder block side.

Fuel filter assembly

26. Install fuel filter and head assembly (18).
27. Install the fuel filter and head tubes (17), (16), (15), and
(14).

Pump piping
28. Install fuel high-pressure pipe (10) (2 pieces), and tighten
the sleeve nuts to the specified torque.
3 Sleeve nut of fuel high-pressure pipe (10) (supply
pump side) : 
39.2 to 44.1 Nm {4.0 to 4.5 kgm} 
3 Sleeve nut of fuel high-pressure pipe (10) (com-
mon rail side) : 
39.2 to 44.1 Nm {4.0 to 4.5 kgm} 
29. Tighten the mounting bolts of fuel high-pressure pipe
clamp to the specified torque.
30. Install fuel spray prevention caps (9).
31. Install lubricating oil tube (8).
3 Joint bolt (supply pump side) : 
7.9 to 12.7 Nm {0.8 to 1.3 kgm} 
32. Install fuel tube (7).

125E-7 SERIES 50-129

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY BLY

3 Joint bolt of fuel tube (7) : 

14.8 to 19.6 Nm {1.5 to 2.0 kgm} 
Wiring harness connector and fuel tube
33. Install fuel tubes (4) and (5).
3 Fuel tube (4), (5) Joint bolt (supply pump side) : 
14.8 to 19.6 Nm {1.5 to 2.0 kgm} 
34. Install wiring harness connectors (1), (2), and (3).

Check for fuel leakage

REMARK
• If supply pump (27), common rail (28), or high-pressure
fuel pipe (29) or (30) is removed and installed or re-
placed, check for fuel leakage according to the follow-
ing procedure after installing the engine.
• Clean and degrease the engine and the parts around it
in advance so that you may easily find fuel leakage.
35. Spray color checker (developer) over the joint of the sup-
ply pump, common rail, fuel injector, and fuel high-pres-
sure pipe.
36. Start the engine, keep its speed at 1000 rpm or below, and
stop it when its speed is stabilized.
37. Check the fuel piping and component for fuel leakage.
REMARK
• Check the high-pressure fuel circuit part coated with the color checker (developer) and their peripheries
for fuel leakage.
• If any fuel leakage is detected, repair it and perform the inspection again from step 36.
38. Start the engine and keep its speed at low idle.
39. Check the fuel piping and component for fuel leakage.
REMARK
• Check the high-pressure fuel circuit part coated with the color checker (developer) and their peripheries
for fuel leakage.
• If any fuel leakage is detected, repair it and perform the inspection again from step 36.
40. Start the engine and keep its speed at high idle.
41. Check the fuel piping and component for fuel leakage.
REMARK
• Check the high-pressure fuel circuit part coated with the color checker (developer) and their peripheries
for fuel leakage.
• If any fuel leakage is detected, repair it and perform the inspection again from step 36.
42. Start the engine and keep its speed at high idle and apply a load on the engine.
REMARK
When checking while the engine is mounted on the machine, stall the torque converter or relieve the hy-
draulic pump.

50-130 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY

43. Check the fuel piping and component for fuel leakage.
REMARK
• Check the high-pressure fuel circuit part coated with the color checker (developer) and their peripheries
for fuel leakage.
• If any fuel leakage is detected, repair it and perform the inspection again from step 36.
When no fuel leakage is detected, the inspection is completed.

125E-7 SERIES 50-131

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE FRONT OIL SEAL BLY

REMOVE AND INSTALL ENGINE FRONT OIL SEAL

METHOD FOR REMOVING ENGINE FRONT OIL SEAL
Alternator belt
1. Set wrench [1] to part (a) (width across flats 12.7 mm) of
auto-tensioner (2).
2. Turn wrench [1] anticlockwise when seen from the front of
engine, and remove alternator belt (1).
k Be sure that wrench [1] is set securely to part (a) of
auto-tensioner (2) before turning it. (Since the
spring force of auto-tensioner (2) is strong, the
wrench may come off and is very dangerous if it is
turned when not attached securely.)
k After removing alternator belt (1), return auto-ten-
sioner (2) slowly and carefully.
k Be careful not to get your fingers caught between
the pulley and alternator belt (1) during work.
Damper and pulley assembly
3. By using lifting tool [2], sling damper and pulley assembly
(6).
4. Remove 6 mounting bolts.
5. By using guide bolt [3], pull out dumper and pulley assem-
bly (6), and then sling it, and remove it.

4 Damper and pulley assembly (6) : 

25 kg

Engine front oil seal

NOTICE
• Before removing engine front oil seal (2), drive in it lightly to eliminate the stick.
• Take care not to scratch the contact faces of the oil seal between front cover (1) and crankshaft (3).
• If it is difficult to remove engine front oil seal (2), take following procedure.
6. Make several holes of approx. 3 mm diameter to engine
front oil seal (2).

50-132 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ENGINE FRONT OIL SEAL

7. Change the tip of tool L to the drill type, and insert it in the
hole made in previous section.
8. Pull slide hammer [SH] of tool L toward you, and remove
engine front oil seal (2) by using impact power.
REMARK
Perform above evenly at several places so that engine
front oil seal (2) does not incline.

METHOD FOR INSTALLING ENGINE FRONT OIL SEAL

Front oil seal
1. Install engine front oil seal (2) according to the following
procedure.
REMARK
Check that crankshaft end surface corners, sliding surfa-
ces of oil seal lip, and front cover are free from scratch,
burrs, sharp edge, rust, etc.
1) Set engine front oil seal (2) to front cover (1) and
press-fit it with a plastic hammer until oil seal lip (a)
enters in crankshaft (3).
NOTICE
• Take care not to install engine front oil seal (2)
in a wrong direction.
• When press-fitting engine front oil seal (2), hit
its periphery evenly so that it does not be de-
formed.
• Take care that oil seal lip (a) does not be
caught in crankshaft (3) while press-fitting.
2 Engine front oil seal (2) (50 to 80% full of hol-
low part of lip): 
Grease (G2-LI)

2) Install tool M1 and tighten tools M2 (bolts) (3 pieces)

evenly until they reach the end to press-fit engine front
oil seal (2) to front cover (1).
k Do not fit tools M3 (washer) to tools M2 (bolt).
3) Remove tools M2 (bolt) (3 pieces) and install tools M3
(washer) (3 pieces) to those tools M2 (bolt) respec-
tively.

125E-7 SERIES 50-133

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE FRONT OIL SEAL BLY

4) Install tools M2 (bolt) (3 pieces) again and tighten

them evenly until the end face of tool M1 reaches the
end face of front cover (1) to press-fit engine front oil
seal (2).
Press-fitting distance (b) of engine front oil seal (2)
from end face of front cover (1) : 19 mm
Press-fitting distance (c) of engine front oil seal (2)
from end face of crank shaft (3) : 9.2 (+1/0) mm

Damper pulley assembly

2. By using lifting tool [2], sling damper and pulley assembly
(6).
3. By using guide bolt [3], install the dumper and pulley.
4. Install them with 6 mounting bolts.
REMARK
There are 2 types of the mounting bolts for damper and
pulley assembly (6).
3 Mounting bolt (1 piece) (width across flats: 22
mm) : 
157 to 196 Nm {16 to 20 kgm} 
3 Mounting bolt (5 piece) (width across flats: 24
mm) : 
245 to 309 Nm {25.0 to 31.5 kgm} 
Alternator belt
5. Install alternator belt (1) according to the following procedure.
1) Set wrench [1] to part (a) (width across flats 12.7 mm) of auto-tensioner (2).
2) Turn wrench [1] anticlockwise when seen from the
front of engine, and install alternator belt (1).
k Be sure that wrench [1] is set securely to part
(c) of auto-tensioner (2) before turning it.
(Since the spring force of auto-tensioner (2) is
strong, the wrench may come off and is very
dangerous if it is turned when not attached se-
curely.)
k After installing alternator belt (1), return auto-
tensioner (2) slowly and carefully.
k Be careful not to get your fingers caught be-
tween the pulley and alternator belt (1) during
work.
3) Check that alternator belt (1) is fitted correctly and securely in the pulley groove.

50-134 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ENGINE REAR OIL SEAL

REMOVE AND INSTALL ENGINE REAR OIL SEAL

METHOD FOR REMOVING ENGINE REAR OIL SEAL
Flywheel
1. By using eyebolt [1], sling flywheel (1).
2. Remove 6 mounting bolts and pull out the dowel pin part.
3. By using guide bolt [2], pull out flywheel (1), sling it, and
remove it.

4 Flywheel (1): 
50 kg

Engine rear oil seal

NOTICE
• Before removing engine rear oil seal (2), drive in it lightly to eliminate the stick.
• Take care not to scratch the contact faces of the oil seal between flywheel housing (3) and crank-
shaft (4).
• If it is difficult to remove engine rear oil seal (2), take following procedure.
4. Removal of standard oil seal
1) Make several holes of approx. 3 mm diameter to en-
gine rear oil seal (2).
REMARK
Remove all the chips.
2) Change the tip of tool L to the drill type, and insert it in
the hole made in previous section.
3) Pull slide hammer [SH] of tool L toward you, and re-
move engine rear oil seal (2) by using impact power.
REMARK
Perform above evenly at several places so that engine
rear oil seal (2) does not incline.

125E-7 SERIES 50-135

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE REAR OIL SEAL BLY

5. Removal of sleeved oil seal

1) Replace the tip of tool L with the hook type tip and
hitch it to outer case (a) of engine rear oil seal (2).
2) Pull slide hammer [SH] of tool L toward you, and re-
move engine rear oil seal (2) by using impact power.
REMARK
Perform above evenly at several places so that engine
rear oil seal (2) does not incline.
3) Cut and remove sleeve (5) with a chisel and a ham-
mer.
REMARK
• Be careful not to damage crankshaft (4).
• Remove all the chips.

METHOD FOR INSTALLING ENGINE REAR OIL SEAL

Oil seal
1. Select the oil seal according to the following procedure.
1) Check the wear of the crankshaft and select the type
of the Teflon seal (lay-down lip seal) to install, “stand-
ard oil seal” or “sleeved oil seal”, depending on the
wear of the crankshaft.
2) When the crankshaft is worn to a degree of luster (you
can feel the wear with the pad of your finger and the
wear depth is a maximum of 10μm) and there are no
scratches, install the standard oil seal. In other cases,
install sleeved oil seal.
3) In the figure, left side shows the standard oil seal, and
right side shows the sleeved oil seal.

50-136 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ENGINE REAR OIL SEAL

Flywheel
2. Sling flywheel (1) by using eyebolt [1], and install it by us-
ing guide bolt [2] while aligning the dowel pin part

4 Flywheel (1) : 
50 kg
2 Threaded part and seat of mounting bolt: 
Engine oil
3. Tighten the mounting bolts according to the following pro-
cedure.
3 Mounting bolt 1st time: 
147±19.6 Nm {15±2.0 kgm} 
Mounting bolt 2nd time: 289.1±19.6 Nm {29.5±2.0 kgm} 
REMARK
From the second time, impact wrench is not allowed to
use.

4. By using dial gauge [3], measure the facial runout and ra-
dial runout.
Facial runout: Max. : 0.20 mm
Radial runout: Max. : 0.15 mm
5. Installation of standard oil seal
1) Clean, degrease, and dry the contacting surface
against the flywheel housing.
2) Before installing the oil seal, check that the end face
corners of crankshaft (4), oil seal lip sliding surfaces,
and housing are free from a scratch, burr, sharp edge,
rust, etc.
3) When installing the engine rear oil seal, do not apply
oil or grease to the hatched portions of the crankshaft
and oil seal lip (b). Thoroughly wipe off oil and grease
from the crankshaft.

125E-7 SERIES 50-137

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE REAR OIL SEAL BLY

4) Spare standard engine rear oil seal (2) has installation

guide (6). Never remove that guide before installing
the engine rear oil seal.

5) Place large inside diameter side (c) of installation

guide (6) of engine rear oil seal (2) to the end of
crankshaft (4).
REMARK
Take care not to install engine rear oil seal (2) in a
wrong direction.
6) Push in the outer case end face of engine rear seal (2)
evenly.

7) Push in engine rear oil seal (2) to a degree that it does

not come off the housing, and then remove installation
guide (6).
REMARK
When removing installation guide (6), take care not to
scratch the oil seal lip.

8) Install tool N1 and tighten tools N2 (bolt) (3 pieces)

evenly until they reach the end to press-fit engine rear
oil seal (2).
REMARK
• Do not fit tools N3 (washer) to tools M2 (bolt).
• When press-fitting the engine rear oil seal, take
care not to scratch the oil seal lip with a tool, etc.
9) Remove tools N2 (bolt) and fit 1 each of tools N3
(washer) to tools N2 (bolt).
10) Install tools N2 (bolt) (3 pieces) to tool N1 again and
tighten them evenly until the end face of tool N1 rea-
ches the end face of crankshaft (4) to press-fit engine rear oil seal (2).
Press-fitting distance (d) of engine rear oil seal (2) from end face of crankshaft (4): 16.3±0.2 mm
REMARK
• When press-fitting engine rear oil seal (2), take care not to scratch the oil seal lip with a tool, etc.
• After press-fitting engine rear oil seal (2), remove the red sealant layer from its periphery.
6. Installation of sleeved oil seal

50-138 125E-7 SERIES

50 DISASSEMBLY AND ASSEM-
BLY REMOVE AND INSTALL ENGINE REAR OIL SEAL

1) Clean, degrease, and dry the contacting surface against the flywheel housing.
2) Check that the end face corners of the crankshaft, oil seal lip sliding surfaces, and housing are free
from a scratch, burr, sharp edge, rust, etc.
3) Do not apply oil or grease to the hatched portions of
the crankshaft, inner cylinder of sleeve (5), and engine
rear oil seal lip (b). Thoroughly wipe off oil and grease
from the crankshaft.
4) Handle the engine rear oil seal and sleeve (5) as an
assembly and never separate them from each other.

5) Set sleeve and engine rear oil seal assembly (2) to

tool N4.
2 Sleeve inner cylinder surface: 
Liquid gasket (LG-7)

6) Put sleeve (5) of sleeve and engine rear oil seal as-
sembly (2) to the end face of crankshaft (4) and even-
ly tighten tools N5 (bolt) (3 pieces) of tool N4 to press-
fit sleeve and engine rear oil seal assembly (2).
7) Install 1 each of tools N6 (washer) to tools N5 (bolt)
and tighten tools N5 (bolt) until they reach the end.

8) Replace tool N4 with tool N7 and tighten tools N8

(bolt) (3 pieces) evenly until they reach the end to
press-fit sleeve and engine rear oil seal assembly (2).
REMARK
Do not fit tools N9 (washer) to tools N8 (bolt).
9) Remove tools N8 (bolt) and fit 3 each of tools N9
(washer) to tools N8 (bolt).
10) Install tools N8 (bolt) (3 pieces) to tool N7 again and
tighten them evenly until the end face of tool N7 rea-
ches the end face of crankshaft (4) to press-fit engine
rear oil seal assembly (2).
Press-fitting distance (e) of sleeve, engine rear oil seal assembly (2) from end face of crankshaft (4): 
16.3±0.2 mm

125E-7 SERIES 50-139

 50 DISASSEMBLY AND ASSEM-
REMOVE AND INSTALL ENGINE REAR OIL SEAL BLY

REMARK
• When press-fitting engine rear oil seal (2), take care not to scratch the oil seal lip with a tool, etc.
• After press-fitting sleeve and engine rear oil seal (2), remove the red sealant layer from its periph-
ery.

50-140 125E-7 SERIES

 60 MAINTENANCE STANDARD

125E-7 SERIES 60-1

CONTENTS 60 MAINTENANCE STANDARD

CONTENTS
ABBREVIATION LIST .................................................................................................................................... 60-3
ENGINE SYSTEM ......................................................................................................................................... 60-9
INTAKE AND EXHAUST SYSTEM PARTS ............................................................................................. 60-9
MAINTENANCE STANDARD OF VGT............................................................................................. 60-9
ENGINE MAIN BODY PARTS............................................................................................................... 60-10
MAINTENANCE STANDARD OF CYLINDER HEAD ..................................................................... 60-10
MAINTENANCE STANDARD OF CYLINDER BLOCK ................................................................... 60-12
MAINTENANCE STANDARD OF CYLINDER LINER..................................................................... 60-14
MAINTENANCE STANDARD OF CRANKSHAFT .......................................................................... 60-16
MAINTENANCE STANDARD OF CAM FOLLOWER AND PUSH ROD ......................................... 60-17
MAINTENANCE STANDARD OF PISTON..................................................................................... 60-19
MAINTENANCE STANDARD OF CONROD .................................................................................. 60-21
MAINTENANCE STANDARD OF VIBRATION DAMPER ............................................................... 60-23
MAINTENANCE STANDARD OF TIMING GEAR........................................................................... 60-24
MAINTENANCE STANDARD OF CAMSHAFT .............................................................................. 60-26
MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE....................................................... 60-27
MAINTENANCE STANDARD OF ROCKER ARM .......................................................................... 60-29
MAINTENANCE STANDARD OF CROSSHEAD AND GUIDE ....................................................... 60-30
MAINTENANCE STANDARD OF FLYWHEEL ............................................................................... 60-31
LUBRICATION SYSTEM....................................................................................................................... 60-33
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE OIL PUMP ................................... 60-33
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE BOOST OIL PUMP ...................... 60-34
MAINTENANCE STANDARD OF SAFETY VALVE OF ENGINE OIL FILTER ................................ 60-35
COOLING SYSTEM.............................................................................................................................. 60-36
MAINTENANCE STANDARD OF ENGINE OIL COOLER.............................................................. 60-36
MAINTENANCE STANDARD OF WATER PUMP .......................................................................... 60-37
MAINTENANCE STANDARD OF THERMOSTAT .......................................................................... 60-38

60-2 125E-7 SERIES

60 MAINTENANCE STANDARD ABBREVIATION LIST

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

125E-7 SERIES 60-3

ABBREVIATION LIST 60 MAINTENANCE STANDARD

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

60-4 125E-7 SERIES

60 MAINTENANCE STANDARD ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

125E-7 SERIES 60-5

ABBREVIATION LIST 60 MAINTENANCE STANDARD

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actu-
system
ated, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for “International System of Units” It
SI al d' Unites (Internation- Unit is the universal unit system and “a single unit for
al unit system) a single quantity” is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

60-6 125E-7 SERIES

60 MAINTENANCE STANDARD ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

125E-7 SERIES 60-7

ABBREVIATION LIST 60 MAINTENANCE STANDARD

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

60-8 125E-7 SERIES

60 MAINTENANCE STANDARD INTAKE AND EXHAUST SYSTEM PARTS

ENGINE SYSTEM
INTAKE AND EXHAUST SYSTEM PARTS
MAINTENANCE STANDARD OF VGT

Unit: mm
No. Item Criteria Remedy
When compressor wheel and turbine wheel are moved lightly
1 Radial play with the fingers toward the housing, both of them must not touch
the housing.
Replace VGT
2 End play (axial play) 0.06 to 0.11 assembly (in-
cluding hy-
Perform active regeneration for service. At this time, if KDOC in-
draulic actuator
let temperature remains at approximately 250 °C or below and
Operation check of VGT and VGT posi-
VGT solenoid current remains at 1000 mA or below, VGT is de-
3 (Operation check of nozzle tion sensor)
fective. (Approximate time taken for manual stationary regenera-
ring)
tion depends on accumulation of soot. See failure code
CA2639.)

125E-7 SERIES 60-9

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF CYLINDER HEAD

REMARK
Tightening order of cylinder head mounting bolts
• Tighten cylinder head mounting bolts in the order of (1) to (7).
Unit: mm
No. Item Criteria Remedy
Tolerance Repair limit Repair by
Strain of cylinder head
1 grinding or re-
mounting face 0 to 0.06 0.09 place
Repair limit Replace nozzle
2 Protrusion of nozzle
3.20 to 3.90 sleeve

Bolt Procedure Target Range

88.2 to
98  Nm 
1st step 107.8 Nm {9 to
{10 kgm} 
11 kgm} 
Tightening torque of cylin-
der head mounting bolt 166.6 to
(1) to (6) 176.4  Nm  Tighten in or-
2nd step 176.4 Nm {17
3 (Apply molybdenum disul- {18 kgm}  der in above
to 18 kgm} 
fide or engine oil to under- figure
side of bolt head.) Retighten
3rd step 90 to 120 °
120 °
58.8 to
68.6 Nm 
(7) - 73.5 Nm {6 to
{7 kgm} 
7.5 kgm} 

60-10 125E-7 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

Unit: mm
No. Item Criteria Remedy
Target Range
Tightening torque of injec-
4 58.8 to 73.5 Nm {6.0 to
tor mounting bolt 66  Nm {6.75 kgm} 
7.5 kgm}  Retighten
Tightening torque of rocker 58.8 to 73.5 Nm {6.0 to
5 66  Nm {6.75 kgm} 
arm housing mounting bolt 7.5 kgm} 

125E-7 SERIES 60-11

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF CYLINDER BLOCK

Unit: mm
No. Item Criteria Remedy
Tolerance Allowable value Repair by
Strain of cylinder head
1 grinding or re-
mounting face 0 to 0.080 0.12 place
Standard dimension Tolerance
Inside diameter of main Replace main
bearing mounting hole +0.015 bearing cap
116
-0.010
2 Roundness of mounting
Repair limit: 0.005
hole
Replace bear-
-0.005 ing
Main method thickness 3
-0.020
Standard dimension Tolerance Repair limit
Inside diameter of main Replace main
3 +0.040
bearing 110 110.15 bearing
+0.010
Standard dimension Tolerance
Repair or re-
Inside diameter of cam
4 +0.030 place cylinder
bushing mounting hole 63 block
0
Standard dimension Tolerance Repair limit
Inside diameter of cam Replace cam
5 +0.070
bushing 60 60.30 bushing
0

60-12 125E-7 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

Unit: mm
No. Item Criteria Remedy
Procedure Target Range
88 to 108 Nm {9 to
1st step 98  Nm {10 kgm} 
Tightening torque of main 11 kgm} 
6 bearing cap (Apply engine 191 to 201 Nm  Retighten
oil to thread portion) 2nd step 196  Nm {20 kgm} 
{19.5 to 20.5 kgm} 
Retighten 90
3rd step Retighten 90 °
(+30/0) °

Unit: mm
No. Item Criteria Remedy
Procedure Target Range
Tightening torque of engine
7 34 to 73 Nm {3.5 to
oil pan mounting bolt - 54  Nm {5.5 kgm} 
7.5 kgm} 
245 to 309 Nm {25 Retighten
M16 (5 pcs.) 274  Nm {28 kgm} 
Tightening torque of crank- to 31.5 kgm} 
8
shaft pulley mounting bolt 157 to 196 Nm {6 to
M14 (1 pc.) 176  Nm {18 kgm} 
20 kgm} 
Level difference of bottom
9 between cylinder block and Repair limit: 0.35
flywheel housing Reassemble
Level difference of bottom and repair
10 between cylinder block and Repair limit: 0.28
front cover

125E-7 SERIES 60-13

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF CYLINDER LINER

Unit: mm
No. Item Criteria Remedy
Replace cylin-
1 Protrusion of liner Allowable range: 0.07 to 0.15 der liner or cyl-
inder block
Standard di-
Rank Tolerance Repair limit
mension

Inside diameter of cylinder +0.020

A 125 125.20
liner (when not installed) 0
+0.040
2 B 125 125.20 Replace cylin-
+0.021
der liner (Re-
Roundness of inside diam- pair only when
Repair limit: 0.08 rank is B)
eter (when not installed)
Cylindricity of inside diam-
Repair limit: 0.08
eter (when not installed)
Outside diameter of cylin- Standard dimension Tolerance
der liner (counterbore por-
tion) (when not installed) 153 ±0.025
3
Interference of cylinder lin- Replace cylin-
er and block (counterbore Standard clearance: 0 to 0.113 der liner or
portion) block
Outside diameter of cylin- +0.090 Replace cylin-
der liner (counterbore low- 145
+0.040 der liner
er portion)
4
Interference of cylinder lin- Standard interference Allowable interference Replace cylin-
er and block (counterbore der liner or
lower portion) 0.01 to 0.12 0.01 block

60-14 125E-7 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

Unit: mm
No. Item Criteria Remedy
Standard dimension Tolerance
Outside diameter of cylin- Replace cylin-
der liner (O-ring portion) +0.386 der liner
141
5 +0.361
Clearance between cylin- Replace cylin-
der liner and block (O-ring Standard clearance: 0.014 to 0.079 der liner or
portion) block
Protrusion on the upper Replace cylin-
6 Not crushed or damaged
surface of cylinder liner der liner

125E-7 SERIES 60-15

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF CRANKSHAFT

Unit: mm
No. Item Criteria Remedy
Standard value Repair limit Replace thrust
1 End play bearing or over
0.140 to 0.315 0.50 size repair
Standard dimension Tolerance Repair limit
STD 110 109.88

Outside diameter of main 0.25U.S. 109.75 109.63

journal -0.050
0.50U.S. 109.50 109.38 Under size re-
-0.070
0.75U.S. 109.25 109.13 pair or replace
2
1.00U.S. 109.00 108.88
Standard Repair limit
Roundness
0 to 0.010 0.020
Standard clearance Allowable clearance Replace main
Clearance in main journal
0.062 to 0.106 0.27 bearing

Standard dimension Tolerance Repair limit

STD 80 79.88

Outside diameter of crank- 0.25U.S. 79.75 79.63

pin journal -0.050
0.50U.S. 79.50 79.38 Under size re-
-0.070
0.75U.S. 79.25 79.13 pair or replace
3
1.00U.S. 79.00 78.88
Standard Repair limit
Roundness
0 to 0.010 0.020
Standard clearance Allowable clearance Replace con-
Clearance in crankpin jour-
necting rod
nal 0.046 to 0.090 0.24 bearing
Standard Repair limit Under size re-
4 Bend of crankshaft
0 to 0.09 0.20 pair or replace

60-16 125E-7 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF CAM FOLLOWER AND PUSH ROD

125E-7 SERIES 60-17

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

Unit: mm
No. Item Criteria Remedy
Standard dimension Tolerance Repair limit
Outside diameter of cam
follower shaft -0.040
19.8 19.73
1 -0.050

Inside diameter of cam fol- +0.020

19.8 -
lower shaft hole 0

Outside diameter of cam +0.250

2 32 31.70
roller +0.280

Inside diameter of cam roll- -0.262

13 12.78
er -0.287 Replace
3
Outside diameter of cam -0.364
13 12.62
roller pin -0.376
Standard dimension Tolerance
Radius of push rod ball
4 0
end 12.7
-0.20

Radius of push rod socket 0

5 12.7
end -0.20
6 Bend of push rod Repair limit: 0.50 (total runout by indicator)
Tightening torque of cam
- follower shaft mounting 51±7.4 Nm {5.25±0.75 kgm}  Retighten
bolt

60-18 125E-7 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF PISTON

Unit: mm
No. Item Criteria Remedy
Standard di-
Rank Tolerance Repair limit
mension
Replace piston
-0.090 (Repair only
1 Outside diameter of piston A or S 125 124.80
-0.105 when rank is A
or S)
-0.075
B or L 125 124.80
-0.090
Standard dimension Tolerance
Replace top
Top ring thickness -0.005
2.42 ring
-0.025
Judge by groove wear gauge (*1)
Top ring groove width Replace piston
(Clearance when new ring is fitted: 0.15)
2
Clearance between top Standard clearance Allowable clearance Replace piston
ring and top ring groove Judge by groove wear gauge (*1) or top ring

Replace top
Closed gap of top ring 0.37 to 0.47 2.0 ring or cylinder
liner
Standard dimension Tolerance
Replace 2nd
2nd ring thickness -0.010
2.4 ring
-0.030
Judge by groove wear gauge (*1) Replace piston
2nd ring groove width
(Clearance when new ring is fitted: 0.15)
3
Clearance between 2nd Standard clearance Allowable clearance Replace piston
ring and 2nd ring groove Judge by groove wear gauge (*1) or 2nd ring

Replace sec-
Closed gap of 2nd ring 1.10 to 1.20 2.0 ond ring or cyl-
inder liner

125E-7 SERIES 60-19

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

Unit: mm
No. Item Criteria Remedy
Standard dimension Tolerance
Oil ring thickness -0.010 Replace oil ring
4
-0.030
+0.040 Replace piston
Oil ring groove width 3
4 +0.020

Clearance between oil ring Standard clearance Allowable clearance Replace piston
and oil ring groove 0.030 to 0.070 0.15 or oil ring

Replace oil ring

Closed gap of oil ring 0.23 to 0.35 1.0
or cylinder liner
Standard dimension Tolerance
Outside diameter of piston Replace piston
pin 0 pin
48
-0.006
5 Inside diameter of piston +0.045
48 Replace piston
pin hole +0.035

Clearance between piston Standard clearance Allowable clearance Replace piston

pin and piston 0.035 to 0.051 0.063 or piston pin

- Weigh of piston 2986 g Allowable range: ±60 g Replace piston

*1: Part No. of groove wear gauge is 795-901-1130.

60-20 125E-7 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF CONROD

Unit: mm
No. Item Criteria Remedy
Standard dimension Tolerance Repair limit Replace bush-
Inside diameter of connect- ing (Spare
ing rod small end bushing +0.041 bushing is half
48 48.08
1 +0.025 finished)
Clearance between con- Standard clearance Allowable clearance Replace bush-
necting rod small end ing or piston
bushing and piston pin 0.025 to 0.047 0.10 pin
Standard dimension Tolerance
Inside diameter of connect-
Replace con-
2 ing rod small end bushing +0.030
53 necting rod
mounting hole
0

Inside diameter of connect- Standard dimension Tolerance Repair limit

ing rod big end bearing Replace bear-
3 +0.020
80 80.12 ing
(Crankpin journal) -0.010
+0.022
Inside diameter of connect- 85 -
-0.004 Replace con-
ing rod big end bearing
necting rod
mounting hole
4 Tighten connecting rod cap to specified torque, then measure.

Connecting rod bearing +0.005 Replace bear-

2.5 -
thickness -0.004 ing

Item Standard Repair limit

Parallelism and distortion Parallelism a 0 to 0.20 0.25 Replace con-

5
of connecting rod Distortion b 0 to 0.30 0.35 necting rod

Dimension c 240 -

125E-7 SERIES 60-21

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

Unit: mm
No. Item Criteria Remedy
Tightening torque of con- Procedure Target Range
necting rod cap mounting
93 to 103 Nm {9.5
bolt 1st step 98  Nm {10 kgm} 
6 to 10.5 kgm}  Retighten
(Apply engine oil to thread
portion of bolt and seat of Retighten 90
2nd step Retighten 90 °
nut) (+30/0) °

Allowable range: Dispersion of weight in 1 machine must be

- Weight of connecting rod Replace
Max. 140 g

REMARK
• Limit the reuse of the connecting rod cap mounting bolt to 5 times.
• Make a punch mark on the bolt each time it is used.

60-22 125E-7 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF VIBRATION DAMPER

No. Item Criteria Remedy

1 Appearance check No breakage Replace
Bolt Target Range
Tightening torque of vibra-
2 98 to 213 Nm {10 to Retighten
tion damper mounting bolt M12 111  Nm {11.3 kgm} 
12.5 kgm} 

125E-7 SERIES 60-23

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF TIMING GEAR

Unit: mm
No. Item Judgment criteria Remedy
Posi-
Judging point Standard Repair limit
tion
Crankshaft gear and main idler 0.116 to
A
gear (large) 0.359
Main idler gear (small) and cam- 0.105 to
B
shaft gear 0.325
Camshaft gear and injection drive 0.082 to
C
Standard backlash of gear 0.389
– Replace
each gear 0.076 to
0.6
Main idler gear (large) and water 0.366 (*1)
a
pump drive gear 0.043 to
0.372 (*2)
Main idler gear (large) and engine 0.105 to
b
oil pump idler gear 0.337
Engine oil pump idler gear and en- 0.082 to
c
gine oil pump drive gear 0.389

60-24 125E-7 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

Unit: mm
No. Item Judgment criteria Remedy

Standard di- Tolerance Standard Allowable

Clearance between mensions Shaft Hole clearance clearance
1 main idler gear bushing
and shaft +0.014 +0.063 0.025 to Replace the
47.6 0.20
+0.001 +0.039 0.062 bushing
Clearance between en- -0.025 +0.065 0.025 to
2 gine oil pump idler gear 35 0.20
-0.041 0 0.106
bushing and shaft

End play of main idler Standard Repair limit

3 Replace
gear 0.05 to 0.17 0.4
thrust bear-
End play of engine oil ing
4 0.05 to 0.21 0.4
pump idler gear

*1: Shows the values other than the engine which is installed to WA475-10.
*2: Shows the values of the engine which is installed to WA475-10.

125E-7 SERIES 60-25

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF CAMSHAFT

Unit: mm
No. Item Criteria Remedy
Standard Repair limit Replace thrust
1 End play
0.10 to 0.25 0.50 plate

Standard dimension Tolerance

Outside diameter of cam-
-0.080 Replace
shaft journal 60
2 -0.110

Clearance in camshaft Standard clearance Allowable clearance Replace cam

journal 0.080 to 0.180 0.28 bushing

3 Bend of camshaft Repair limit: 0.03 (total runout by indicator)

Standard dimension Tolerance Repair limit
Replace
4 Cam height +0.395
52 51.73
+0.195

60-26 125E-7 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF VALVE AND VALVE GUIDE

Unit: mm
No. Item Criteria Remedy
Standard di-
Valve Tolerance Repair limit
mension
Replace valve
1 Valve recess
Intake valve 1.88 ±0.10 2.51 or valve seat
Exhaust valve 1.20 ±0.10 1.90
Standard dimen-
Valve Repair limit
sion
2 Valve lip thickness Replace valve
Intake valve 2.10 1.7
Exhaust valve 1.50 1.2
Intake valve Exhaust valve Repair or re-
3 Valve seat angle Standard place valve or
30 ° ± 15' 45 ° ± 15' valve seat

125E-7 SERIES 60-27

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

Unit: mm
No. Item Criteria Remedy
Standard dimen-
Valve Tolerance
sion

Outside diameter of valve -0.045

Intake valve 9 Replace valve
stem -0.065
-0.050
Exhaust valve 9
-0.070

Before press Intake and ex- +0.015

4 9
fitting of head haust valve -0.003
Inside diameter of valve Replace valve
guide +0.009 guide
After press fit- Intake and ex-
9
ting of head haust valve -0.011
Valve Standard clearance Allowable clearance
Clearance between valve Replace valve
Intake valve 0.034 to 0.074 0.22
guide and stem or valve guide
Exhaust valve 0.039 to 0.079 0.24
Bend of valve stem Repair limit: 0.01 (total runout by indicator for 100 mm) Replace

Driven height of valve Standard Tolerance

5 Repair
guide 20 ±0.2
Standard di-
Valve Color cord Repair limit
mension
Free height of valve spring
Intake Pale blue 76.2 -
Exhaust Pale blue 76.2 -
Installed Standard Allowable
Valve Color cord
height load load
519.8±26 N
Replace valve
6   468  N 
Intake Pale blue 56.0 spring
Installed load of valve {53.0±2.7 {47.7 kg} 
spring  kg} 
519.8±26 N
  468  N 
Exhaust Pale blue 56.0
{53.0±2.7 {47.7 kg} 
 kg} 
Perpendicularity of valve
Repair limit: 2 ° (both sides)
spring

60-28 125E-7 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF ROCKER ARM

Unit: mm
No. Item Criteria Remedy
Standard dimension Tolerance
Outside diameter of rocker Replace rocker
arm shaft -0.053 arm shaft
28.6
-0.066

Inside diameter of rocker +0.032 Replace rocker

28.6
1 arm shaft hole -0.030 arm

Standard clearance Allowable clearance Replace rocker

Clearance between rocker
arm or rocker
arm shaft and rocker arm 0.023 to 0.098 0.13 arm shaft
Replace rocker
Bend of rocker arm shaft Repair limit: 0.20 (total runout by indicator)
arm shaft
Tightening torque of rocker Target Range
2 arm adjustment screw lock Retighten
nut 59  Nm {6.0 kgm}  53 to 65 Nm {5.4 to 6.6 kgm} 

Valve Standard Tolerance

Valve clearance (both hot
3 Intake side 0.33 Adjust
and cold states) ±0.02
Exhaust side 0.71

125E-7 SERIES 60-29

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF CROSSHEAD AND GUIDE

Unit: mm
No. Item Criteria Remedy
Standard dimension Tolerance Repair limit
Crosshead inside diameter +0.075
11 11.18
1 +0.025 Replace

Crosshead outside diame- +0.011

11 10.95
ter 0
Protrusion of crosshead
2 45.5 ±0.25 - Repair
guide

60-30 125E-7 SERIES

60 MAINTENANCE STANDARD ENGINE MAIN BODY PARTS

MAINTENANCE STANDARD OF FLYWHEEL

A: Tightening order of flywheel mounting bolts

B: Tightening order of flywheel housing mounting bolts
Unit: mm
No. Item Criteria Remedy
Facial runout of flywheel
1 Repair limit: 0.35
housing Reassemble
Radial runout of flywheel and repair
2 Repair limit: 0.30
housing

125E-7 SERIES 60-31

ENGINE MAIN BODY PARTS 60 MAINTENANCE STANDARD

Unit: mm
No. Item Criteria Remedy
Bolt Procedure Target Range
147 to
191  Nm 
1st step 235 Nm {15 to
{19.5 kgm} 
Tightening torque of fly- 24 kgm} 
M16
3 wheel housing mounting 245 to Retighten
bolt 279  Nm 
2nd step 309 Nm {25 to
{28.5 kgm} 
31.5 kgm} 
69  Nm  59 to 74 Nm {6
M10 -
{7 kgm}  to 7.5 kgm} 
4 Facial runout of flywheel Repair limit: 0.20 Reassemble
5 Radial runout of flywheel Repair limit: 0.15 and repair

Procedure Target Range

Tightening torque of fly-
127 to 167 Nm {13 to
wheel mounting bolt (Apply 1st step 147  Nm {15 kgm} 
6 17 kgm}  Retighten
engine oil to thread por-
tion) 270 to 309 Nm {27.5 to
2nd step 289  Nm {29.5 kgm} 
31.5 kgm} 

REMARK
Limit the reuse of the flywheel mounting bolt to 5 times.
Make a punch mark on the bolt each time it is used.

60-32 125E-7 SERIES

60 MAINTENANCE STANDARD LUBRICATION SYSTEM

LUBRICATION SYSTEM
MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE OIL PUMP

No. Item Criteria Remedy

Relief valve cracking pres- Repair or re-
1 Standard: 0.65 to 0.8 MPa {6.63 to 8.16 kg/cm2} 
sure place spring

125E-7 SERIES 60-33

LUBRICATION SYSTEM 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF RELIEF VALVE OF ENGINE BOOST OIL PUMP

No. Item Criteria Remedy

Relief valve cracking pres- Repair or re-
1 Standard: 1.33 to 1.53 MPa {13.6 to 15.6 kg/cm2} 
sure place spring

60-34 125E-7 SERIES

60 MAINTENANCE STANDARD LUBRICATION SYSTEM

MAINTENANCE STANDARD OF SAFETY VALVE OF ENGINE OIL FILTER

No. Item Criteria Remedy

Cracking pressure of safe-
1 Standard: 343±19 kPa {3.5±0.2 kg/cm2}  Replace
ty valve

125E-7 SERIES 60-35

COOLING SYSTEM 60 MAINTENANCE STANDARD

COOLING SYSTEM
MAINTENANCE STANDARD OF ENGINE OIL COOLER
REMARK
The shape is subject to machine models.

No. Item Criteria Remedy

Full open lift of oil cooler
Min. 8 mm (when soaked in oil at 90 °C for 4 to 5 minutes)
thermo valve
1 Valve must close fully in 4 to 5 minutes when soaked in oil at full Replace
Opening and closing of oil
close temperature (71 °C) from oil at full open temperature
cooler thermo valve
(90 °C).

60-36 125E-7 SERIES

60 MAINTENANCE STANDARD COOLING SYSTEM

MAINTENANCE STANDARD OF WATER PUMP

Unit: mm
No. Item Judgment criteria Remedy
1 Standard di- Tolerance Standard inter- Replace
(*1) mensions Shaft Hole ference
Replace the
Interference of impeller +0.018 -0.027 impeller nor-
and shaft 15.9 mally (outside
1 +0.005 -0.044
0.032 to 0.062 diameter does
(*2) 0 -0.045 not almost
15.5 change)
-0.013 -0.062
Replace
Interference of drive gear +0.015 -0.023
2 20.0 0.025 to 0.068 (Replace the
and shaft +0.002 -0.053
gear normally)
Clearance between the im-
3 Standard clearance： 0.5 to 1.3 (including end play)
peller and body Replace
4 Wear of water seal ring Limit of dimension: 1.5

*1: Shows the values when the top of shaft has no stamp.
*2: Shows the values when the top of shaft has the stamp “B”.

125E-7 SERIES 60-37

COOLING SYSTEM 60 MAINTENANCE STANDARD

MAINTENANCE STANDARD OF THERMOSTAT

No. Item Criteria Remedy

Min. 9 mm (when valve is soaked in oil at 90 °C for 4 to 5 mi-
Full open lift of thermostat
nutes)
1 Valve must close fully in 4 to 5 minutes when soaked in oil at full Replace
Opening/closing of thermo-
close temperature (76.5 °C) from oil at full open temperature
stat
(90 °C).

60-38 125E-7 SERIES

INDEX

INDEX
A C
Abbreviation List.......... 00-4,01-3,10-4,20-3,50-3,60-3 Cam follower / Push rod - Maintenance standard........
Actions if fire occurs............................................00-22 .....................................................................60-17
Actions taken to meet exhaust gas regulations.. 00-24 CDR valve...........................................................10-85
AdBlue/DEF - Store............................................ 00-26 CDR valve - Operation........................................10-85
AdBlue/DEF hose............................................... 10-40 Charge pressure sensor - Function.................. 10-151
AdBlue/DEF hose - Function.............................. 10-40 Charge pressure sensor - Structure..................10-151
AdBlue/DEF hose - Structure..............................10-40 Charge temperature sensor - Function............. 10-152
AdBlue/DEF injector............................................10-39 Charge temperature sensor - Structure............ 10-152
AdBlue/DEF injector - Function...........................10-39 Coating materials list...........................................50-11
AdBlue/DEF injector - Operation.........................10-39 Common rail......................................................10-108
AdBlue/DEF injector - Structure..........................10-39 Common rail - Structure....................................10-108
AdBlue/DEF mixing tube.....................................10-33 Common rail pressure sensor........................... 10-110
AdBlue/DEF mixing tube - Function....................10-33 Common rail pressure sensor - Function.....................
AdBlue/DEF mixing tube - Structure................... 10-33 ....................................................... 10-110,10-156
AdBlue/DEF pump.............................................. 10-38 Common rail pressure sensor - Structure......... 10-156
AdBlue/DEF pump - Structure............................ 10-38 Component parts of electrical system...............10-124
AdBlue/DEF supply system - Function............... 10-16 Component parts of urea SCR system............... 10-33
AdBlue/DEF tank................................................ 10-36 Connecting rod - Maintenance standard.............60-21
AdBlue/DEF tank - Structure...............................10-36 Connector - Precautions for disconnection and con-
AdBlue/DEF tank heating valve.......................... 10-41 nection......................................................... 00-45
AdBlue/DEF tank heating valve - Function......... 10-41 Connector with housing to rotate - Disconnect/
AdBlue/DEF tank heating valve - Operation....... 10-41 Connect....................................................... 00-55
AdBlue/DEF tank heating valve - Structure........ 10-41 Connector with lock to push - Disconnect/Connect......
AdBlue/DEF tank sensor.....................................10-37 .....................................................................00-53
AdBlue/DEF tank sensor - Function....................10-37 Conversion table................................................. 00-70
AdBlue/DEF tank sensor - Structure...................10-37 Coolant temperature sensor - Function............ 10-153
Air cleaner...........................................................10-47 Coolant temperature sensor - Structure............10-153
Air cleaner - Operation........................................10-47 Cooling system....................................... 10-119,60-36
Air cleaner - Specifications................................. 10-47 Cooling system - Circuit diagram...................... 10-120
Air cleaner - Structure......................................... 10-47 Cooling system parts - Layout drawing............. 10-119
Air cleaner clogging sensor - Function..............10-165 Crankcase pressure sensor - Function............. 10-163
Air cleaner clogging sensor - Structure.............10-165 Crankcase pressure sensor - Structure............ 10-163
Alternator.......................................................... 10-124 Crankshaft - Maintenance standard....................60-16
Alternator mounting...........................................10-128 CRI control system - Operation.........................10-104
Alternator mounting - Structure.........................10-128 CRI system....................................................... 10-101
Alternator with built-in regulator (open type, 140 A) - CRI system - Function...................................... 10-103
Specifications.............................................10-126 CRI system - Outline.........................................10-101
Alternator with built-in regulator (open type, 140 A) - CRI system - Structure......................................10-101
Structure.................................................... 10-126 Crosshead / Guide - Maintenance standard....... 60-30
Alternator with built-in regulator (open type, 90 A) - Cylinder block..................................................... 10-51
Specifications.............................................10-125 Cylinder block - Maintenance standard...............60-12
Alternator with built-in regulator (open type, 90 A) - Cylinder block - Specifications............................ 10-52
Structure.................................................... 10-124 Cylinder block - Structure....................................10-51
Ambient pressure sensor - Function................. 10-149 Cylinder head......................................................10-49
Ambient pressure sensor - Structure................ 10-149 Cylinder head - Maintenance standard............... 60-10
Assembly and disassembly - Related information 50-9 Cylinder head - Specifications............................ 10-50
Cylinder head - Structure.................................... 10-49
B Cylinder liner - Maintenance standard................ 60-14

Bkup (camshaft) speed sensor - Function........ 10-155

Bkup (camshaft) speed sensor - Structure....... 10-155
D
Deutsch connector - Disconnect/Connect...........00-49
Dosing fuel pressure sensor - Function............ 10-161
Dosing fuel pressure sensor - Structure........... 10-161

1
 INDEX

E Engine performance curve: SAA6D125E-7

(WA475-10)..................................................01-50
EGR cooler......................................................... 10-78 Engine rear oil seal - Installation.......................50-136
EGR cooler - Operation...................................... 10-78 Engine rear oil seal - Removal..........................50-135
EGR cooler - Structure........................................10-78 Engine rear oil seal - Remove/Install................ 50-135
EGR system........................................................10-73 Engine sensors - Layout drawing......................10-145
EGR system - Circuit diagram............................ 10-74 Engine shop manual - How to read.....................00-10
EGR system - Function.......................................10-74 Engine system.................................. 10-42,50-20,60-9
EGR system - Layout drawing............................ 10-73 Engine wiring harness.......................................10-133
EGR system - Operation.....................................10-75 Engine wiring harness - Structure.....................10-133
EGR valve...........................................................10-76 Exhaust gas regulation - Outline...........................01-9
EGR valve - Operation........................................10-77
EGR valve - Structure......................................... 10-76 F
EGR valve lift sensor - Function....................... 10-157
EGR valve lift sensor - Structure.......................10-157 FCD piston - Features.........................................10-55
Electrical system............................................... 10-124 Flow damper..................................................... 10-109
Engine - General disassemble............................50-21 Flow damper - Function.................................... 10-109
Engine - General disassembly and assembly.....50-20 Flow damper - Operation.................................. 10-109
Engine - Generally assemble..............................50-58 Flywheel - Maintenance standard....................... 60-31
Engine - Standard value table...............................20-9 Flywheel / Flywheel housing - Specifications......10-65
Engine boost oil pump........................................ 10-93 Flywheel and flywheel housing........................... 10-65
Engine boost oil pump - Function....................... 10-93 Flywheel and flywheel housing - Structure......... 10-65
Engine boost oil pump - Specifications............... 10-93 Foreword, Safety, Basic information................... 00-10
Engine boost oil pump - Structure.......................10-93 Front cover..........................................................10-61
Engine components - Layout.............................. 10-42 Front cover - Structure........................................ 10-61
Engine components - Layout drawing.................10-42 Fuel doser......................................................... 10-116
Engine controller............................................... 10-135 Fuel doser - Function........................................ 10-116
Engine controller - Function.............................. 10-135 Fuel doser - Structure....................................... 10-116
Engine controller - Input and output signals......10-137 Fuel doser solenoid valve / Doser fuel pressure sen-
Engine controller - Structure............................. 10-135 sor - Function............................................. 10-116
Engine controller - System diagram..................10-136 Fuel doser solenoid valve / Doser fuel pressure sen-
Engine front oil seal - Installation...................... 50-133 sor - Structure............................................ 10-116
Engine front oil seal - Removal......................... 50-132 Fuel doser solenoid valve and doser fuel pressure
Engine front oil seal - Remove/Install............... 50-132 sensor........................................................ 10-116
Engine general view............................................01-19 Fuel dosing system........................................... 10-115
Engine general view: SAA6D125E-7 (WA475-10)....... Fuel dozing - Layout drawing............................ 10-115
.....................................................................01-35 Fuel dozing - Outline......................................... 10-115
Engine main body parts............................ 10-49,60-10 Fuel feed pump................................................. 10-143
Engine oil cooler................................................. 10-95 Fuel feed pump - Function................................ 10-143
Engine oil cooler - Specifications........................ 10-95 Fuel feed pump - Structure............................... 10-143
Engine oil cooler - Structure................................10-95 Fuel feed pump switch...................................... 10-144
Engine oil filter.................................................... 10-94 Fuel feed pump switch - Function..................... 10-144
Engine oil filter - Specifications........................... 10-94 Fuel feed pump switch - Structure.................... 10-144
Engine oil filter - Structure...................................10-94 Fuel injection pressure control - Function......... 10-104
Engine oil level sensor - Function..................... 10-164 Fuel injection rate control - Function.................10-103
Engine oil level sensor - Structure.................... 10-164 Fuel injection timing control - Function............. 10-104
Engine oil pan..................................................... 10-97 Fuel main filter...................................................10-118
Engine oil pan - Structure................................... 10-97 Fuel main filter - Structure.................................10-118
Engine oil pressure sensor - Function.............. 10-150 Fuel prefilter...................................................... 10-117
Engine oil pressure sensor - Structure..............10-150 Fuel prefilter - Structure.................................... 10-117
Engine oil pump.................................................. 10-92 Fuel system.........................................................10-98
Engine oil pump - Function................................. 10-92 Fuel system - Circuit diagram............................. 10-99
Engine oil pump - Specifications.........................10-92 Fuel system - Function......................................10-100
Engine oil pump - Structure................................ 10-92 Fuel system - Operation....................................10-100
Engine operation standard for break in period and Fuel system equipment - Precautions for handling......
performance test standard: SAA6D125E-7 .....................................................................00-39
(WA470-8)....................................................20-29 Fuel system of CRI system - Function.............. 10-102
Engine performance curve..................................01-46 Fuel system parts - Layout drawing.................... 10-98

2
INDEX

G KCCV ventilator - Operation............................... 10-85

KCCV ventilator - Structure.................................10-84
General character and precautions for handling.00-25 KDPF.................................................................. 10-86
KDPF - Function................................................. 10-87
H KDPF - Structure.................................................10-86
KDPF differential pressure and outlet pressure sen-
How to read electrical wire code......................... 00-56 sor - Function.............................................10-162
How to read this manual....................................... 50-9 KDPF differential pressure and outlet pressure sen-
sor - Structure............................................ 10-162
I
Improved points of engine conformed to Tier 4 regula- L
tion............................................................... 01-11 List of applicable machines: 125E-7................... 01-12
Inducement strategy........................................... 10-19 Lubrication system....................................10-90,60-33
Inducement strategy for abnormality recurrence with- Lubrication system - Circuit diagram...................10-91
in 40 hours (For European Union)............... 10-32 Lubrication system parts - Layout drawing......... 10-90
Inducement strategy for abnormality recurrence with-
in 40 hours (For North America).................. 10-25
Inducement strategy when abnormality is found in the
M
AdBlue/DEF quality or in the Urea SCR system Main moving parts...............................................10-54
devices (For European Union).....................10-26 Main moving parts - Specifications..................... 10-55
Inducement strategy when abnormality is found in the Main moving parts - Structure.............................10-54
EGR system by the Urea SCR system devices Maintenance standard of camshaft.....................60-26
(For European Union).................................. 10-30 Maintenance standard of timing gear..................60-24
Inducement strategy when abnormality is found in the Maintenance standard of water pump.................60-37
KDPF system by the Urea SCR system (For Mass air flow and temperature sensor - Function........
North America).............................................10-22 ...................................................................10-160
Inducement strategy when abnormality is found in the Mass air flow and temperature sensor - Structure.......
KDPF system by the urea SCR system devices ...................................................................10-160
(For European Union).................................. 10-28 Method for disconnecting and connecting connector
Inducement strategy when abnormality is found in the with lock to pull............................................ 00-52
urea SCR system devices (For North America).... Mixing connector.................................................10-79
.....................................................................10-20 Mixing connector - Function................................10-79
Inducement strategy when the AdBlue/DEF level in Mixing connector - Structure............................... 10-79
the tank becomes low (For European Union).......
.....................................................................10-25 N
Inducement strategy when the AdBlue/DEF level in
the tank becomes low (For North America). 10-19 NE (crankshaft) speed sensor - Function......... 10-154
Injector...............................................................10-111 NE (crankshaft) speed sensor - Structure.........10-154
Injector - Function............................................. 10-113
Injector - Operation........................................... 10-114 O
Injector - Structure............................................. 10-111
Intake and exhaust system - Function................ 10-45 Oil cooler - Maintenance standard...................... 60-36
Intake and exhaust systems - Circuit diagram.... 10-45 Oil cooler thermo valve....................................... 10-96
Intake and exhaust systems - Layout drawing....10-44 Oil cooler thermo valve - Function...................... 10-96
Intake and exhaust systems parts.............. 10-44,60-9 Oil cooler thermo valve - Specifications..............10-96
Intake system equipment - Precautions for handling... Oil cooler thermo valve - Structure..................... 10-96
.....................................................................00-40
P
K Piping - Precautions for disconnection and connec-
KCCV system......................................................10-80 tion............................................................... 00-30
KCCV system - Forming of condensed water and Piston - Maintenance standard........................... 60-19
emulsion...................................................... 10-81 Piston ring........................................................... 10-56
KCCV system - Function.....................................10-80 Piston ring - Structure......................................... 10-56
KCCV system - Layout drawing.......................... 10-80 Precautions for adding........................................ 00-25
KCCV system - Operation...................................10-83 Precautions for DEF............................................00-25
KCCV ventilator.................................................. 10-84 Precautions for disposing of waste materials......00-23
KCCV ventilator - Function................................. 10-85 Precautions for fire hazard and leakage............. 00-25

3
 INDEX

Precautions for handling electrical equipment.... 00-37 Sensor...............................................................10-145

Precautions for handling hydraulic equipment.... 00-27 Slide lock type connector - Disconnect/Connect.00-50
Precautions for storing........................................ 00-25 Special tools - List...............................................50-15
Precautions to prevent fire.................................. 00-20 Special tools - Sketches......................................50-17
Pressure limiter................................................. 10-110 Specification............................................... 01-9,01-13
Pressure limiter - Function................................ 10-110 Specifications: SAA6D125E-7 (HM300-5,
Pressure limiter - Structure............................... 10-110 HM300-5E0)................................................ 01-14
Push-pull type coupler - Disconnect/Connect..... 00-41 Specifications: SAA6D125E-7 (PC490LC-11,
PC490LCI-11).............................................. 01-15
R Specifications: SAA6D125E-7 (WA470-8).......... 01-16
Specifications: SAA6D125E-7 (WA475-10)........ 01-17
Relief valve of engine boost oil pump - Maintenance Specifications: SAA6D125E-7 (WA480–8)......... 01-18
standard.......................................................60-34 Specifications: SAA6D125E–7 (D85EX–18, D85EXI–
Relief valve of engine oil pump - Maintenance stand- 18, D85PX–18, D85PXI–18)........................01-13
ard................................................................60-33 Standard tightening torque table.........................00-63
Rocker arm - Maintenance standard...................60-29 Standard value table for engine - SAA6D125E-7
Running-in standard and performance test standard... (D85EX-18, D85EXI-18, D85PX-18, D85PXI-18).
.....................................................................20-21 .......................................................................20-9
Standard value table for engine - SAA6D125E-7
S (HM300-5, HM300-5E0)...............................20-11
Standard value table for engine - SAA6D125E-7
SAA6D125E-7 (D85EX-18, D85EXI-18, D85PX-18, (WA480-8)....................................................20-19
D85PXI-18) - Running-in standard and perform- Standard value table for engine -
ance test standard....................................... 20-21 SAA6D125E-7(WA470-8).................. 20-15,20-17
SAA6D125E-7 (HM300-5, HM300-5E0) - Engine gen- Standard value table for engine - SAA6D125E–7
eral view.......................................................01-23 (PC490LC-11, PC490LCI-11)...................... 20-13
SAA6D125E-7 (HM300-5, HM300-5E0) - Running-in Starting motor................................................... 10-129
standard and performance test standard.....20-23 Starting motor (11 kw) with built-in safety relay -
SAA6D125E-7 (PC490LC-11, PC490LCI-11) - Engine Structure.................................................... 10-131
performance curve.......................................01-48 Starting motor (7.5 kw) with built-in safety relay -
SAA6D125E-7 (PC490LC-11, PC490LCI-11) - Run- Structure.................................................... 10-129
ning–in standard and performance test standard. Starting motor with built-in safety relay (11 kW) -
.....................................................................20-25 Specifications.............................................10-132
SAA6D125E-7 (WA470-8) - Running-in standard and Starting motor with built-in safety relay (7.5 kW) -
performance test standard...........................20-27 Specifications.............................................10-130
SAA6D125E-7(WA480-8) - Running-in standard and Supply pump..................................................... 10-105
performance test standard...........................20-31 Supply pump - Function.................................... 10-105
SAA6D125E–7 (D85EX–18, D85EXI–18, D85PX–18, Supply pump - Operation.................................. 10-106
D85PXI–18) – Engine general view.............01-19 Supply pump - Structure................................... 10-105
SAA6D125E–7 (D85EX–18, D85EXI–18, D85PX–18, Supply pump as an unit - Installation method... 50-125
D85PXI–18) – Engine performance curve... 01-46 Supply pump as an unit - Removal method...... 50-123
SAA6D125E–7 (HM300-5, HM300-5E0) – Engine Supply pump assembly - Remove/Install..........50-123
performance curve.......................................01-47
SAA6D125E–7 (PC490LC–11, PC490LCI–11) – En-
gine general view.........................................01-27 T
SAA6D125E–7 (WA470–8) – Engine general view...... Temporary restoration from Inducement (For Europe-
.....................................................................01-31 an Union) - Function.................................... 10-31
SAA6D125E–7 (WA470–8) – Engine performance Temporary restoration from Inducement (For North
curve............................................................ 01-49 America) - Function..................................... 10-25
SAA6D125E–7 (WA480–8) – Engine general view...... Terms for maintenance standard - Explanation.. 00-60
.....................................................................01-39 The other precautions......................................... 00-25
SAA6D125E–7 (WA480–8) – Engine performance Thermostat........................................................10-122
curve............................................................ 01-51 Thermostat - Maintenance standard................... 60-38
Safety notice for operation.................................. 00-12 Thermostat - Operation.....................................10-123
Safety valve of engine oil filter - Maintenance stand- Thermostat - Specifications.............................. 10-122
ard................................................................60-35 Thermostat - Structure...................................... 10-122
SCR assembly.................................................... 10-34 Tier 4 engine - System diagram.......................... 01-10
SCR assembly - Structure.................................. 10-34 Timing gear......................................................... 10-59

4
INDEX

Timing gear - Structure....................................... 10-59

Turbocharger system.......................................... 10-66
Type 1 push-pull type coupler - Disconnect/Connect...
.....................................................................00-41
Type 2 push-pull type coupler - Disconnect/Connect...
.....................................................................00-42
Type 3 push-pull type coupler - Disconnect/Connect...
.....................................................................00-43
Types of regeneration - Function........................ 10-88

U
Urea SCR system............................................... 10-10
Urea SCR system - Function.............................. 10-16
Urea SCR system - Layout drawing....................10-10
Urea SCR system - System diagram.................. 10-15

V
Valve and valve guide - Maintenance standard.. 60-27
Valve system.......................................................10-62
Valve system - Specifications............................. 10-64
Valve system - Structure..................................... 10-62
VGT.....................................................................10-69
VGT - Function....................................................10-70
VGT - Maintenance standard................................60-9
VGT - Operation..................................................10-71
VGT - Structure...................................................10-69
VGT position sensor - Function........................ 10-159
VGT position sensor - Structure........................10-159
VGT speed sensor - Function........................... 10-158
VGT speed sensor - Structure.......................... 10-158
VGT system - Circuit diagram.............................10-66
VGT system - Function....................................... 10-67
Vibration damper.................................................10-57
Vibration damper - Function................................10-58
Vibration damper - Maintenance standard..........60-23
Vibration damper - Structure...............................10-57

W
Water pump.......................................................10-121
Water pump - Structure.....................................10-121
Weight table........................................................ 01-43
Weight table: 125E-7.......................................... 01-43

5
125E-7 SERIES ENGINE
Form No. SEN06495-09

©2019 KOMATSU
All Rights Reserved
Printed in Japan 7-2019