SM Saa6d125e-3 Sebm024208

SEBM024208
DIESEL ENGINE
© 2004
All Rights Reserved
Printed in Japan 04-04 (01) 00-1
(8)
CONTENTS
No. of page
01 GENERAL ............................................................................................................................ 01-1
11 STRUCTURE AND FUNCTION,

MAINTENANCE STANDARD............................................ 11-1
12 TESTING AND ADJUSTING ........................................................................ 12-1
13 DISASSEMBLY AND ASSEMBLY ........................................................ 13-1
15 REPAIR AND REPLACEMENT OF PARTS ............................. 15-1
00-2 125-3 SERIES

LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Page to be newly added Add
Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
00-1 (8) 01-3 01-69 (8) 11-216 11-404
00-2 (1) 01-4 11-217 11-405
00-2-1 (8) 01-12 (5) 11-1 (7) 11-218 11-406
00-2-2 (8) 01-13 (5) 11-2 11-219 11-407
00-2-3 (8) 01-14 (5) 11-3 11-220 11-408
00-3 01-15 (8) 11-4 11-221 11-409
00-4 01-22 11-5 11-222 11-410
00-5 01-23 11-12 (5) 11-224 11-411
00-6 01-24 11-13 (5) 11-225 11-412
00-7 01-25 11-13-1 (5) 11-226 11-413
00-8 01-26 (2) 11-13-2 (5) 11-228 11-414
00-9 01-27 (2) 11-14 (2) 11-229 11-415
00-10 01-28 (2) 11-15 (2) 11-230 11-416
00-11 01-29 (2) 11-16 (7) 11-231 11-417
00-12 01-29-1 (5) 11-17 (2) 11-232 11-418
00-13 01-29-2 (5) 11-20 (5) 11-233 11-419
00-14 01-29-3 (5) 11-21 (7) 11-234 11-501
00-15 01-29-4 (5) 11-202 11-235 11-502
00-16 01-30 (8) 11-203 11-302 11-503
00-17 01-31 (5) 11-204 (1) 11-303 11-504
00-18 01-42 (8) 11-206 11-304 11-505
00-19 01-53 (5) 11-207 11-305 11-506
00-20 01-54 (5) 11-208 11-306 11-507
00-21 01-64 (5) 11-209 11-307 11-902 (7)
00-22 01-65 (5) 11-210 11-308 11-902-1 (7)
01-66 (5) 11-212 11-309 11-903 (7)
01-1 (5) 01-67 (5) 11-213 11-402 11-903-1 (8)
01-2 (8) 01-68 (7) 11-214 11-403 11-903-2 (7)
125-3 SERIES 00-2-1

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11-903-3 (7) 12-50 (7) 12-208 12-252 13-61 (1)
11-904 (5) 12-51 (8) 12-209 12-253 13-62 (1)
11-905 (5) 12-70 (8) 12-210 12-254 13-63 (1)
11-906 (5) 12-71 (8) 12-211 12-255 13-64 (1)
11-907 (6) 12-74 (5) 12-212 12-256 13-65 (1)
12-75 (5) 12-213 (2) 12-257 13-66 (1)
12-76 (7) 12-214 12-258 13-67 (1)
12-1 (5) 12-77 (7) 12-215 12-259 13-68 (1)
12-2 12-78 (8) 12-217 12-260 13-69 (1)
12-4 (7) 12-79 (8) 12-218 12-261 13-70 (1)
12-5 (4) 12-219 12-262 13-71 (1)
12-5-1 (5) 12-101 12-220 13-72 (1)
12-5-2 (7) 12-102 12-221 13-73 (1)
12-5-3 (8) 12-103 12-222 13-1 (1) 13-74 (1)
12-6 (2) 12-104 12-223 13-2 (1) 13-75 (1)
12-7 (2) 12-105 (2) 12-224 13-3 (1) 13-76 (1)
12-8 (2) 12-107 (2) 12-225 13-4 (1) 13-77 (1)
12-9 (2) 12-108 12-226 13-5 (1)
12-10 (2) 12-109 12-227 13-6 (1)
12-11 (2) 12-110 12-228 13-7 (1) 15-1 (6)
12-12 (2) 12-111 12-229 13-8 (1) 15-3
12-13 (2) 12-112 12-230 13-9 (1) 15-4
12-14 (2) 12-113 12-231 13-10 (1) 15-5
12-15 (2) 12-114 12-232 13-11 (1) 15-6
12-16 (2) 12-115 12-233 13-12 (1) 15-7
12-17 (2) 12-116 12-234 13-13 (1) 15-8
12-18 (2) 12-117 12-236 13-14 (1) 15-9
12-19 (2) 12-118 12-237 13-15 (1) 15-10
12-20 (2) 12-119 12-238 13-16 (1) 15-11
12-21 (2) 12-120 12-239 13-17 (1) 15-12
12-22 (2) 12-121 12-240 13-18 (1) 15-13
12-23 (2) 12-122 12-241 13-19 (1) 15-14
12-24 (2) 12-123 12-242 13-52 (1) 15-22
12-25 (2) 12-124 12-243 13-53 (1) 15-23
12-26 (2) 12-201 12-244 13-54 (1) 15-24
12-27 (2) 12-202 12-245 13-55 (1) 15-25
12-28 (2) 12-203 12-246 13-56 (1) 15-26
12-29 (2) 12-204 12-248 13-57 (1) 15-27
12-30 (2) 12-205 12-249 13-58 (1) 15-28
12-31 (2) 12-206 12-250 13-59 (1) 15-29
12-32 (2) 12-207 12-251 13-60 (1) 15-30
00-2-2 125-3 SERIES

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15-31
15-32 (6)
15-33 (6)
15-51
15-52
15-53
15-54
15-55
15-56
15-57
15-58
15-59
15-60
125-3 SERIES 00-2-3

(8)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
1 kg
(Set of adhesive
LT-3 Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz • Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 2g 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
pipe joints, flanges.
LG-5 790-129-9080 1 kg Can • Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil an, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
• Features: Silicone type, heat resist-
ant, vibration resistant, and impact
Three bond 419-15-18131 100 g Tube resistant sealing material
1207B • Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion

SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
• Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district
body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
• "S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container
SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material • Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
02 19 34 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
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
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 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
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 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
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 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
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 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
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
01 GENERAL
OUTLINE .....................................................................................................................................................01- 2
SPECIFICATIONS .......................................................................................................................................01- 12
GENERAL ASSEMBLY DRAWING .............................................................................................................01- 22
WEIGHT TABLE ..........................................................................................................................................01- 31
ENGINE PERFORMANCE CURVE ............................................................................................................01- 42
125-3 SERIES 01-1

(5)
GENERAL OUTLINE
OUTLINE
1. Applicable machine
In-line fuel injection pump specification
Engine Engine Serial No. Applicable machine

WA430-5 Wheel loader
SAA6D125E-3
Common rail specification
Engine Engine Serial No. Applicable machine

D65EX, PX-15 Bulldozer
SA6D125E-3 D85EX, PX-15 Bulldozer

HM300-1 Articulated dump truck
SAA6D125E-3
PC400-7 Hydraulic excavator
PC450-7 Hydraulic excavator
HD255-5 Dump truck
01-2 125-3 SERIES

(8)
GENERAL OUTLINE
2. Outline of engine
• The 125E-3 engine clears strict exhaust gas regulations (USA: EPA regulations for the year 2001, EU: reg-
ulations for the year 2002, Japan: construction equipment regulations for the year 2003). At the same time,
it is a high performance, high efficiency engine which achieves low fuel consumption, low noise, improved
exhaust gas color, and improved acceleration.
This engine has been newly developed to meet various purposes of use as the power unit for construction
equipment and industrial machinery.
• This engine is the successor to the 125E-2 engine. It is an in-line, 6-cylinder, water-cooled, direct injection
type following in the steps of the 4-cycle diesel engine configuration, while introducing various types of new
technology.
1) Electronic control high-pressure fuel injection system

Previously, the engine was a mechanical governor control type engine using a jerk type in-line injection
pump. But with this high-power engine, the whole series uses an electronic control high-pressure fuel
injection type common rail injection system. With this system, high-pressure fuel at a level of 118
MPa {1200 kg/cm2} can be injected from the low speed range to the high speed range. Furthermore,
electronic control provides the feature of being able to carry out control of the optimum injection config-
uration to match the speed and load. As a result, the engine achieves clean exhaust gas performance,
clean exhaust gas color and low fuel consumption and low noise.
2) The piston is a high-quality steel casting piston with a shaker cooling galley, a re-entrant combustion
chamber used from the 125E-2 engine, and with the Komatsu traditional minimum heat expansion. As
a result, it not only provides clean exhaust gas performance, clean exhaust gas color, and low fuel con-
sumption, but also achieves high durability and high reliability.
3) In addition, the use of the electronic control high- pressure fuel injection system explained above and
the optimization of the spray characteristics when starting in low temperatures is designed to improve
the starting performance and reduce the emission of white smoke.
4) The turbocharger is an improved version of turbocharger job proven on the 125E-2 engine, which
boasts high reliability and high performance. The improved points are the supply air recirculation port to
control the surge at the compressor end and the high efficiency design added to the turbine. As a
result, success has been achieved in providing excellent performance over a wide range from low
speed to high speed to achieve high engine performance and low fuel consumption.
5) It has been possible to use the electronic control high-pressure fuel combustion system to achieve com-
bustion with little generation of soot and a long drain interval for the oil. (This has been extended from
the conventional 250 h to 500 h.) Furthermore, a large capacity oil pan is available for the high output
specification to provide an increase in the oil drain interval.
6) With the cylinder block, the overall length, overall width, and overall height are the same as usual to
maintain the compactness. In addition, the top surface thickness has been increased to suppress the
deformation after long periods of operation to make it easier to machine the engine when rebuilding.
Furthermore, by increasing the rigidity of the main ribs to improve the basic rigidity, deformation and
vibration of the block under load has been suppressed and low noise has been achieved. This contrib-
utes to clearing various noise restrictions, in particular the European noise restrictions, which have
become strict recent years.
7) The high-pressure pump, which creates the high pressure in the common rail injection system, is 1/3 of
the size of the conventional in-line fuel injection pump. In addition, it has a flange mount instead of a
saddle mount, and is connected compactly to the timing gear case. As a result, the radiation noise is
reduced, thereby achieving low noise.
8) The air cleaner has been changed from the conventional end face seal type to a radial seal type to pre-
vent the entry of dust on the clean side caused by deformation of these parts. In addition, a 5-stage dis-
play type air cleaner clogging sensor is provided to give accurate information about the timing for
cleaning.
125-3 SERIES 01-3

GENERAL OUTLINE
9) The oil filter is a high-performance, high-efficiency combination filter which can capture not only the
large particles of dirt but also small particles. This filter system is used for all specifications
10) The fuel filter is a high-performance, high-efficiency special fuel filter which can also catch small parti-
cles of dirt. This filter system is used for all specifications and protects the electronic control high-pres-
sure fuel injection system.
11) The features of the electronically control engine have been used to the maximum limit, and the follow-
ing functions have been provided.
• Sensing is carried out for the important features of the engine (water temperature, oil pressure, fuel
injection amount, fuel injection pressure, etc.). If it is judged that the operating condition is abnormal,
the computer issues an alarm and the system is set to the emergency escape mode.
• After starting the engine in extremely low temperature, if the engine speed is raised suddenly, ex-
cessive load will be applied to the bearings before the lubricating oil has circulated sufficiently. This
will reduce the service life of the engine; in particular, excessive load will be applied to the turbo-
charger. To prevent this, a turbo protect system has been installed to limit the engine speed.
01-4 125-3 SERIES

GENERAL SPECIFICATIONS
SPECIFICATIONS
IN-LINE FUEL INJECTION PUMP SPECIFICATION
Engine SAA6D125E-3
Machine model WA430-5
No. of cylinders - bore x stroke mm 6 – 125 x 150
Piston displacement {cc} 11.0 {11,040}
Firing order — 1–5–3–6–2–4
Overall length mm 1,317
Overall width mm 935
Dimensions
Overall height mm 1,637

(excl. exhaust pipe)
Overall height mm —
(incl. exhaust pipe)
Rated horsepower kW/rpm 174/2,000
{HP/rpm} {237/2,000}
(Net)
Performance
Max. torque Nm/rpm 941/1,400

{kgm/rpm} {96/1,400}
(Net)
High idling speed rpm 2,250±50
Low idling speed rpm 750 +500
Min. fuel consumption ratio g/kW·h —
{g/HP·h} { }
Dry weight kg 1,200
Fuel supply pump — Bosch PE-P (PS3000)
Governor — Boxch RSV, centrifugal, all speed type
Lubricating oil amount 47
(replacement amount) (38)
Cooling water
(engine only) (21)
Alternator — 24V, 50A
Starting motor — 24V, 7.5kW
Battery — 12V 150Ah x 2
Turbocharger — SCHWITZER S400
Air compressor — —
Others — With air-cooled
aftercooler
01-12 125-3 SERIES

(5)
125-3 SERIES 01-13

(5)
COMMON RAIL SYSTEM SPECIFICATION
Engine SA6D125E-3
Machine model D65EX, PX-15 D85EX, PX-15
No. of cylinders - bore x stroke mm 6 – 125 x 150
Piston displacement {cc} 11.0 {11,040}
Firing order — 1–5–3–6–2–4
Overall length mm 1,307 1,307
Overall width mm 856 949
Dimensions
Overall height mm 1,615 1,712

(excl. exhaust pipe)
Overall height mm — —
(incl. exhaust pipe)
Rated horsepower kW/rpm 154/1,950 195/1,900
{HP/rpm} {206/1,950} {261/1,900}
(Gross) (Gross)
Performance
Max. torque Nm/rpm 1,012/1,400 1,265/1,400

{kgm/rpm} {103.2/1,400} {129/1,400}
(Gross) (Gross)
High idling speed rpm 2,100 ± 50 2,100±50
Low idling speed rpm 825 ± 25 750 +500
Min. fuel consumption ratio g/kW·h 210 214
{g/HP·h} {157} {160}
Dry weight kg 1,250 1,250
Fuel supply pump — Denso ECD-U2
Governor — Electronic control type
Lubricating oil amount 44 44
(replacement amount) (38) (38)
Cooling water
(engine only) (21) (21)
Alternator — 24V, 50A 24V, 50A
Starting motor — 24V, 7.5kW 24V, 7.5kW
Battery — 12V 140Ah x 2 12V 150Ah x 2
Turbocharger — SCHWITZER S400 SCHWITZER S400
Air compressor — — —
Others — With water-cooled With water-cooled
aftercooler aftercooler
01-14 125-3 SERIES

(5)
SAA6D125E-3
WA470-5 WA480-5 HM300-1 PC400, 450-7 HD255-5
6 – 125 x 150
11.0 {11,040}
1–5–3–6–2–4
1,442 1,442 1,665 1,718 1,550
935 935 1,045 995 958
1,637 1,637 1,217 — 1,207
— — — 1,645 —
195/2,000 202/2,000 250/2,000 259/1,850 241/2,100

{261/2,000} {271/2,000} {335/2,000} {347/1,850} {323/2,100}
(Net) (Net) (Gross) (Gross) (Gross)
1,245/1,400 1,295/1,400 1,569/1,400 1,371/1,400 1,373/1,400
{127/1,400} {132/1,400} {160/1,400} {139.8/1,400} {140/1,400}
(Net) (Net) (Gross) (Gross) (Gross)
2,170 +20
-80
2,170 +20
-80
2,200±50 1,930±50 2,420 +80
-20
750 +500 750 +500 725 +500 1,000±25 750±50
201 201 202 199 208
{150} {150} {150} {148} {153}
1,200 1,200 1,200 1,200 1,200
Denso ECD-U2
Electronic control type
47 47 47 43 44
(38) (38) (38) (37) (38)
(21) (21) (21) (21) (21)

24V, 50A 24V, 50A 24V, 75A 24V, 35A 24V, 35A
24V, 7.5kW 24V, 7.5kW 24V, 7.5kW 24V, 7.5kW 24V, 7.5kW
12V 150Ah x 2 12V 150Ah x 2 12V 150Ah x 4 12V 150Ah x 4 12V 150Ah x 4
SCHWITZER S400 SCHWITZER S400 SCHWITZER S400 SCHWITZER S400 SCHWITZER S400
— — — — SANWA SEIKI LTD.
Recyprocating sin-
gle cylinder type
With air-cooled With air-cooled With air-cooled With air-cooled With air-cooled
aftercooler aftercooler aftercooler aftercooler aftercooler
125-3 SERIES 01-15

(8)
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING

SAA6D125E-3 LEFT SIDE VIEW DRAWING + Details may differ according to the machine
(WA470-5, WA480-5) model.
01-22 125-3 SERIES

SAA6D125E-3 RIGHT SIDE VIEW DRAWING ★ Details may differ according to the machine
(WA470-5, WA480-5) model.
125-3 SERIES 01-23

SAA6D125E-3 FRONT VIEW DRAWING ★ Details may differ according to the machine
(WA470-5, WA480-5) model.
01-24 125-3 SERIES

SAA6D125E-3 REAR VIEW DRAWING ★ Details may differ according to the machine
(WA470-5, WA480-5) model.
125-3 SERIES 01-25

SAA6D125E-3 LEFT SIDE VIEW DRAWING ★ Details may differ according to the machine
(WA430-5) model.
a. Crankshaft center
b. Flywheel housing rear surface
01-26 125-3 SERIES

2
SAA6D125E-3 RIGHT SIDE VIEW DRAWING ★ Details may differ according to the machine
(WA430-5) model.
125-3 SERIES 01-27

SAA6D125E-3 REAR VIEW DRAWING ★ Details may differ according to the machine
(WA430-5) model.
b. Cylinder liner center
01-28 125-3 SERIES

2
SAA6D125E-3 FRONT VIEW DRAWING ★ Details may differ according to the machine
(WA430-5) model.
125-3 SERIES 01-29

SA6D125E-3 LEFT SIDE VIEW DRAWING ★ This drawing shows a typical model.
(D65EX, PX-15)
★ Details may differ according to the machine
model.
01-29-1 125-3 SERIES

(5)
SA6D125E-3 RIGHT SIDE VIEW DRAWING ★ This drawing shows a typical model.
(D65EX, PX-15)
model.
125-3 SERIES 01-29-2

(5)
SA6D125E-3 FRONT VIEW DRAWING ★ This drawing shows a typical model.

(D65EX, PX-15)
model.
01-29-3 125-3 SERIES

(5)
SA6D125E-3 REAR VIEW DRAWING + This drawing shows a typical model.

(D65EX, PX-15)
+ Details may differ according to the machine
model.
125-3 SERIES 01-29-4

(5)
DIMENSION TABLE + These dimensions are reference values for use

when installing to a test bench.
IN-LINE FUEL INJECTION SPECIFICATION
Dimensions for each part (mm)

Engine Machine model
A B C D E F
SAA6D125E-3 WA430-5 1,317 1,637 1,250 387 467.5 467.5
Dimensions for each part (mm)

Engine Machine model
A B C D E F
D65EX, PX-15 1,307 1,615 1,228 387 420 442
SA6D125E-3
D85EX, PX-15 1,307 1,712 1,325 387 420 470
WA470-5, 480-5 1,317 1,637 1,250 387 467.5 467.5
SAA6D125E-3 PC400, 450-7 1,341 1,645 1,203 442 415 478
HD255-5 1,550 1,241 1,240 401 440 518
01-30 125-3 SERIES

(8)
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is guided for use when transporting or handling components.
Unit:kg
No. Item Components SA6D125E-3 SAA6D125E-3
1 Turbocharger SCHWITZER S400 15 15
Cylinder head, valve, rocker arm,

2 Cylinder head assembly 16 x 6 16 x 6
valve spring
Cylinder block, main bearing cap,

3 Cylinder block assembly 370 370
cylinder liner
4 Front cover 28 28
22.4
5 Engine oil pan
26.7
55.3
(WA470/480-5)
34.2
6 Flywheel assembly Flywheel, ring gear
(WA430-5)
22.7
(HM300-1)
54 47
7 Flywheel housing
8 Crankshaft assembly Crankshaft, crankshaft gear 104 104
Camshaft, camshaft gear, thrust

9 Camshaft assembly 16 16
plate
Piston, connecting rod Piston, piston ring, piston pin,

10 7.6 x 6 (FCD) 7.6 x 6 (FCD)
assembly connecting rod
11 Oil pump 5 5
12 Fuel supply pump 13 13

13 Water pump 9.5 9.5
14 Water-cooled aftercooler 27 —
Air-cooled aftercooler
15 — 24
assembly
11
(WA470/480-5)
24 V, 50 A 11
10
16 Alternator
(HM300-1 OPT)
13
24V, 75A 13
(HM300-1)
24 V, 7.5 kW 15.5 15.5
17 Starting motor
24 V, 11 kW 18 18
125-3 SERIES 01-31

(5)
GENERAL ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE

Engine Engine Serial No. Machine model Page

WA430-5 01-64
SAA6D125E-3
Engine Engine Serial No. Machine model Page

D65EX, PX-15 01-53
SA6D125E-3 D85EX, PX-15 01-54
WA470-5 01-65
WA480-5 01-66
SAA6D125E-3 HM300-1 01-67
PC400, 450-7 01-68
HD255-5 01-69
01-42 125-3 SERIES

(8)
SA6D125E-3 (D65EX, PX-15)
Flywheel horsepower: 154 kW {206 HP} / 1,950 rpm (Gross)

Max. torque: 1,012 Nm {103.2 kgm} / 1,400 rpm (Gross)
125-3 SERIES 01-53

(5)
SA6D125E-3 (D85EX, PX-15)

Max. torque: 1,265 Nm {129 kgm} / 1,400 rpm (Gross)
01-54 125-3 SERIES

(5)
SAA6D125E-3 (WA430-5)

Max. torque: 941 Nm {96 kgm} / 1,400 rpm (Gross)
01-64 125-3 SERIES

(5)
SAA6D125E-3 (WA470-5)

125-3 SERIES 01-65

(5)
SAA6D125E-3 (WA480-5)

01-66 125-3 SERIES

(5)
SAA6D125E-3 (HM300-1)

125-3 SERIES 01-67

(5)
SAA6D125E-3 (PC400, 450-7)

Max. torque: 1,371 Nm {139.8 kgm} / 1,400 rpm (Gross)
01-68 125-3 SERIES

(7)
GENERAL
SAA6D125E-3 (HD255-5)

125-3 SERIES 01-69

(8)
11 STRUCTURE AND FUNCTION,
GENERAL STRUCTURE.............................. 11- 2 LUBRICATION SYSTEM
INTAKE, EXHAUST SYSTEM LUBRICATION SYSTEM DIAGRAM ....... 11-302
INTAKE, EXHAUST SYSTEM.................. 11- 12 OIL PUMP................................................ 11-303
AIR CLEANER ......................................... 11- 16 OIL FILTER .............................................. 11-306
TURBOCHARGER................................... 11- 17 OIL COOLER........................................... 11-308
AFTERCOOLER ...................................... 11- 20 FUEL SYSTEM
ENGINE BODY FUEL SYSTEM DIAGRAM ...................... 11-402
CYLINDER HEAD .................................... 11-202 OUTLINE OF CRI SYSTEM .................... 11-403
CYLINDER BLOCK.................................. 11-206 FUEL PIPING .......................................... 11-416
CYLINDER LINER ................................... 11-210 FUEL COOLER ....................................... 11-418
MAIN CIRCULATION SYSTEM ............... 11-212 FUEL FILTER........................................... 11-419
CRANKSHAFT......................................... 11-214 COOLING SYSTEM
PISTON .................................................... 11-216 COOLING SYSTEM CHART ................... 11-501
CONNECTING ROD ................................ 11-218 WATER PUMP ......................................... 11-502
FLYWHEEL AND FLYWHEEL HOUSING 11-219 THERMOSTAT......................................... 11-505
VIBRATION DAMPER.............................. 11-221 CORROSION RESISTOR ....................... 11-507
TIMING GEAR ......................................... 11-224 ELECTRICAL SYSTEM
VALVE MECHANISM ............................... 11-228 ALTERNATOR MOUNTING..................... 11-902
CAMSHAFT ............................................. 11-230 ALTERNATOR ......................................... 11-903
CAM FOLLOWER AND PUSH ROD ....... 11-231 STARTING MOTOR................................. 11-904
VALVE AND VALVE GUIDE ..................... 11-232 STARTING AID ........................................ 11-906
ROCKER ARM SHAFT ............................ 11-234
CROSSHEAD .......................................... 11-235
125-3 SERIES 11-1

(7)
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD GENERAL STRUCTURE
GENERAL STRUCTURE
GENERAL STRUCTURE
(WITH IN-LINE FUEL INJECTION PUMP ENGINE)
model.
1. Cylinder block 10. Fuel injection nozzle 19. Main bearing cap
2. Cylinder liner 11. Cylinder head cover 20. Oil strainer
3. Piston 12. Camshaft 21. Crankshaft gear
4. Connecting rod 13. Ring gear 22. Front cover
5. Piston pin 14. Flywheel 23. Front seal
6. Intake valve 15. Rear seal 24. Crankshaft pulley
7. Crosshead 16. Flywheel housing 25. Vibration damper
8. Exhaust valve 17. Oil pan
9. Rocker arm shaft 18. Crankshaft
11-2 125-3 SERIES

26. Cylinder head Engine: SA6D125E-3 (with turbocharger

27. Thermostat and aftercooler)
28. Rocker arm SAA6D125E-3 (with turbocharger and
29. Push rod air-cooled aftercooler)
30. Cam follower Type: In-line, 6-cylinders, water-cooled, direct
31. Connecting rod cap fuel injection, 4-cycle diesel engine.
32. Oil pump
125-3 SERIES 11-3

(WITH COMMON RAIL FUEL INJECTION SYSTEM ENGINE)

model.
1. Cylinder block 10. injector 19. Main bearing cap

2. Cylinder liner 11. Cylinder head cover 20. Oil strainer
3. Piston 12. Camshaft 21. Crankshaft gear
4. Connecting rod 13. Ring gear 22. Front cover
5. Piston pin 14. Flywheel 23. Front seal
6. Intake valve 15. Rear seal 24. Crankshaft pulley
7. Crosshead 16. Flywheel housing 25. Vibration damper
8. Exhaust valve 17. Oil pan
9. Rocker arm shaft 18. Crankshaft
11-4 125-3 SERIES

26. Exhaust manifold Engine: SA6D125E-3 (with turbocharger

27. Turbocharger and aftercooler)
28. Cylinder head SAA6D125E-3 (with turbocharger and
29. Rocker arm air-cooled aftercooler)
30. Push rod Type: In-line, 6-cylinders, water-cooled,
31. Intake manifold direct fuel injection,
32. Common rail 4-cycle diesel engine.
33. Fuel supply pump
34. Cam follower
35. Connecting rod cap
125-3 SERIES 11-5

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD INTAKE, EXHAUST SYSTEM
INTAKE, EXHAUST SYSTEM
INTAKE, EXHAUST SYSTEM

★ This drawing shows a typical model.
SA6D125E-3 (D65EX, PX-15) 1/2 ★ Details may differ according to the machine
model.
1. Muffler
2. Electrical intake air heater
3. Air cleaner cover
4. Air cleaner body
5. Vacuator valve
6. Intake manifold
11-12 125-3 SERIES

(5)
SA6D125E-3 (D65EX, PX-15) 2/2
7. Turbocharger A. Intake inlet

8. Exhaust manifold (front) B. Exhaust outlet
9. Exhaust manifold (center)
10. Exhaust manifold (rear)
125-3 SERIES 11-13

(5)

SAA6D125E-3 (WA430-5, WA470-5, WA480-5) 1/4 model.
1. Intake air connector

2. Electrical intake air heater
3. Intake manifold
11-13-1 125-3 SERIES

(5)
SAA6D125-3 (WA430-5, WA470-5, WA480-5) 2/4
4. Turbocharger A. Intake inlet

5. Intake air connector B. Exhaust outlet
6. Exhaust manifold (front) C. Air supply
7. Exhaust manifold (center) (between turbochager and air-cooled aftercooler)
8. Exhaust manifold (rear)
125-3 SERIES 11-13-2

(5)
SAA6D125E-3 (WA430-5, WA470-5, WA480-5) 3/4
9. Muffler
11-14 125-3 SERIES

SAA6D125E-3 (WA430-5, WA470-5, WA480-5) 4/4 .
10. Vacuator valve

11. Air cleaner cover
12. Air cleaner body
125-3 SERIES 11-15

AIR CLEANER
model.
FRG type (radial seal type)
1. Inlet 4. Dust pan 7. Primary element

2. Guide vane (sleeve) 5. Vacuator valve 8. Safety element
3. Guide vane 6. Body 9. Outlet
Engine Machine model Type Vacuator valve No. of elements

D65EX, PX-15 Inner cylinder 1,
SA6D125E-3 FRG Automatic discharge
D85EX, PX-15 Outer cylinder 1
WA430-5,
Inner cylinder 1,
SAA6D125E-3 WA470-5, WA480-5, FRG Automatic discharge
Outer cylinder 1
HM300-1, PC400, 450-7
Features Structure
• The element diameter is the same and the • Air containing dust is sucked into the tangen-
outside diameter of the body is small. tial from inlet (1). The dust is separated by
The inlet is placed in the direction of connec- the centrifugal separation effect of guide
tion, so no guide vane is used; a simple spi- vane (3). More than 99.9% of the dust is
ral guide vane can give ample centrifugal then removed by primary element (7), and
force. the clean air then passes through safety el-
• The dust pan has no guide vane and its ement (8) and outlet (9), and is sent to the
structure is simple. engine.
• The dust and water separated by guide vane
(3) circulates around the inside wall of body
(6), flies into vacuator valve (5), and is auto-
matically discharged.
11-16 125-3 SERIES

(7)
TURBOCHARGER
SCHWITZER S400
No. Name No. Name A. Air intake inlet

1 Compressor cover 16 Snap ring B. Compressed air outlet
2 Locknut 17 Journal bearing C. Exhaust inlet
3 Compressor wheel 18 Circlip D. Exhaust outlet
4 V-Clamp 19 O-ring
5 Lock nut 20 Bearing housing
6 Circlip 21 Piston ring
7 Insert 22 Turbine backplate
8 O-ring 23 V-Clamp
9 Piston ring 24 Lock nut
10 Flinger sleeve Shaft and turbine
11 Oil deflector 25 wheel assembly
12 Thrust sleeve Shaft and turbine wheel
13 Thrust bearing 26 Turbine housing
14 Snap ring
15 Journal bearing
125-3 SERIES 11-17

AFTERCOOLER
Water-cooled type ★ Details may differ according to the machine
SA6D125E-3 (D65EX, PX-15, D85EX, PX-15) model.
1. Aftercooler core A. Intake air inlet

2. Aftercooler cover B. Intake air outlet
3. Intake manifold C. Water inlet (from cylinder head)
D. Water outlet (to themostat)
11-20 125-3 SERIES

(5)
Air-cooled type ★ Details may differ according to the machine

SAA6D125E-3 (WA430-5, WA470-5, WA480-5, model.
HM300-1, PC400-7, PC450-7)
1. Tank a. Air supply

2. Side support (Turbocharger↔intake manifold)
3. Tube
4. Fin
125-3 SERIES 11-21

(7)
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD ENGINE BODY
ENGINE BODY
CYLINDER HEAD
model.
1. Cooling water air tube

2. Cylinder head bolt
3. Injector
4. Fuel spill tube
5. Valve guide
6. Cylinder head
7. Cylinder head cover
8. Valve seat insert
9. Rocker arm housing
11-202 125-3 SERIES


model.
CYLINDER HEAD
• Direct fuel injection
• 4-valve
• Injector assembled in cylinder head
(With common rail fuel injection system engine)
• Injection nozzle assembled in cylinder head
(With in-line fuel injection pump engine)
• Divided type
(1 cylinder head for 1 cylinder)
VALVE SEAT
• Press-fitted insert for intake and exhaust
CYLINDER HEAD COVER

• Floating type seal
125-3 SERIES 11-203

CYLINDER HEAD
Tightening order of cylinder head mounting bolt
MAINTENANCE STANDARD Unit:

mm
No. Item. Criteria Remedy
Standard Repair limit Repair
Distortion of cylinder head
1 by grinding or
mounting surface 0 – 0.06 0.09 replace
Applicalbe model Standard
Protrusion Replace
2 SA6D125E-3 S.T.D. 3.25 – 3.95
of nozzle sleeve
SAA6D125E-3 S.T.D. 3.25 – 3.95
Target Range
Bolt No. Order
Nm {kgm} Nm {kgm}
88 – 108
1st step 98 {10}
Tightening torque of cylinder {9 – 11}
127 – 147 Tihgten bolts
head mounting bolts (Coat the 2nd step 137 {14}
3 – {13 – 15} in accordance
thread areas with molybdenum
with bolts No.
disulfide or engine oil) Retighten Retighten with
3rd step
with 90º 90º + 030º
58 – 73
— 68 {7}
{6 – 7.5}
Target Range
Tightening torque of injector Nm {kgm} Nm {kgm}
4
mounting bolt
66{6.75} 58.8 – 73.5 {6.0 – 7.5} Retighten
Tightening torque of rocker arm
5 66{6.75} 58.8 – 73.5 {6.0 – 7.5}
housing mounting bolt
11-204 125-3 SERIES

1
CYLINDER BLOCK
1. Cylinder block 7. Front cover

2. Cylinder liner 8. Main bearing cap bolt
3. Crevice seal 9. Main bearing cap
4. Liner seal (Ethylene propylene rubber) 10. Main bearing
5. Liner seal (Silicon rubber) 11. Thrust bearing
6. Front seal 12. Piston cooling nozzle
11-206 125-3 SERIES

CYLINDER BLOCK CYLINDER LINER

• Crankshaft: 7 bearings • Wet type
• Camshaft: 7 bearings • Treatment: Plateau honing finish
Gas soft nitriding
FRONT SEAL
• Single lip with dust seal LINER SEAL
• Top: Clevis seal
PISTON COOLING • Middle: O-ring (Ethylene propylene rubber)
• With piston cooling nozzle • Bottom: O-ring (Silicon rubber)
125-3 SERIES 11-207

CYLINDER BLOCK
MAINTENANCE STANDARD Unit: mm

No. Item Criteria Remedy
Distortion of cylinder Standard Repair limit Repair by
1
head mounting surface 0 – 0.080 0.12 grinding or replace
Standard Tolerance
Inside diameter of main Replace main
bearing hole +0.015 bearing cap
116
–0.010
2 –0.005
Thickness of main bearing 3
–0.020 Replace main
Roundness of main bearing bearing
Repair limit: 0.005
hole
Standard Tolerance Repair limit
Inside diameter of main Replace main
3 +0.040
bearing 110 110.15 bearing
+0.010
Standard Tolerance
Inside diameter of cam Repair or replace
4 +0.030
bushing mounting hole 63 cylinder block
+0.000
Inside diameter of
5 +0.070 Replace
cam bushing 60 60.30
0
11-208 125-3 SERIES


Tihgtening torque of Order Target Nm{kgm} Range Nm{kgm}
main bearing cap 1st step 98{10} 88 – 108{9 – 11}
6
(Coat thread area 2nd step 196{20} 186 – 206{19 – 21}
with engine oil) 3rd step Retighten with 90º 90º – 120º
Tightening torque of Tighten
7 — 54{5.5} 34 – 73{3.5 – 7.5}
oil pan mounting bolt
Tightening torque of 245 – 309
M16 (5 bolts) 274{28}
8 crankshaft pulley {25 – 31.5}
mounting bolt M14 (1 bolt) 176{18} 157 – 196{16 – 20}
Diffrence between
lower face of
9 Repair limit : 0.35
cylinder block and
flywheel housing Repair
Diffrence between
10 lower face of Repair limit : 0.28
cylinder block and front cover
125-3 SERIES 11-209

CYLINDER LINER

Replace liner or
1 Protrusion of cylinder liner Repair limit : 0.07 – 0.15
block
Rank Standard Tolerance Repair limit
+0.020
Inside diameter of cylinder A 125 125.20
0
liner *1
Replace cylinder
2 +0.040
B 125 125.20 liner
+0.021
(only B rank
Roundness of cylinder liner *1 Repair limit : 0.08
is supplied)
Cylindricity of cylinder liner *1 Repair limit : 0.08
Outside diameter of cylinder Standard Tolerance
liner (Counter bore) *1 153 ±0.025
3
Interference between cylinder Replace liner or
Standard: 0 – 0.113
liner and block(Counter bore) *1 block
Standard Tolerance
Outside diameter of cylinder
+0.090 Replace liner
liner (Counter bore bottom) 145
+0.040
4
Interference between Standard Interference limit
Replace liner
cylinder liner and block
0.01 – 0.12 0.01 or block
(Counter bore bottom)
Standard Tolerance
Outside diameter of cylinder
+0.386 Replace liner
liner (O-ring) 141
5 +0.361
Clearance between cylinder Replace liner
Standard : 0.014 – 0.079
liner and block (O-ring) or block
*1 shows the dimension as an individual part
11-210 125-3 SERIES

MAIN CIRCULATION SYSTEM
1. Piston (FCD piston) 8. Connecting rod

2. Connecting rod bushing 9. Connecting rod cap mounting bolt
3. Piston pin 10. Top ring
4. Crankshaft 11. Second ring
5. Crankshaft gear (No. of teeth :33) 12. Oil ring
6. Connecting rod cap
7. Connecting rod bearing a. Re-entrant combustion chamber
11-212 125-3 SERIES

CRANKSHAFT : Stamp forging PISTON RING

: Induction hardening on
journal portion and Top ring Second ring Oil ring
fillet portion
PISTON
Material : FDC piston
(Thin ductile cast iron structure, re- Both surface Keystone, Hard chrome
entrant combustion chamber) keystone, inner cut, plating with
Barrel face, taper face, coil expander
• The FCD piston has the following features; Hard chrome hard chrome
(1) The FCD piston has high heat resistance. plating plating
(2) Since the FCD piston has less thermal
expansion coefficient, the clearance between it CONNECTING ROD LUBE OIL HOLE
and liner can be reduced. :Provided
(3) Since the FCD piston has high strength, the
top ring can be installed to a higher place and PISTON COOLING FROM CONNECTING ROD TIP
the combustion chamber loss area can be :Provided
reduced. Accordingly,an engine having the FCD
piston has high combustion efficiency, produces
lower noise and exhaust gas of better color, and
can output higher power.
125-3 SERIES 11-213

CRANKSHAFT

Standard Repair limit Repair by using
over size
1 End play
thrust bearing
0.140 – 0.315 0.50
or replace
STD 110 109.88
Outside diameter of main 0.25 U.S. 109.75 109.63
journal –0.050 Repair by using
0.50 U.S. 109.50 109.38
–0.070 over size bearing
0.75 U.S. 109.25 109.13 or replace
2
1.00 U.S. 109.00 108.88
Standard Repair limit
Roundness of main journal
0 – 0.010 0.020
Standard Clearance limit Replace main
Clearance of main journal
0.062 – 0.106 0.27 bearing
STD 80 79.88
Outside diameter of 0.25 U.S. 79.75 79.63
crankpin journal –0.050 Repair by using
0.50 U.S. 79.50 79.38
–0.070 undersize bearing
0.75 U.S. 79.25 79.13 or replace
3
1.00 U.S. 79.00 78.88
Roundness of crankpin Standard Repair limit
journal 0 – 0.010 0.020
Clearance of crankpin Standard Clearance limit Replace
journal 0.046 – 0.090 0.24 connecting rod
Standard Repair limit Repair by

using under
4 Bend of crankshaft
size bearing
0 – 0.09 0.20
or replace
11-214 125-3 SERIES

PISTON
11-216 125-3 SERIES


No. Check item Criteria Remedy
Rank Standard Tolerance Repair limit Replace
–0.090 piston
Outside diameter of A or S 125 124.80
1 –0.105 (supplied only
piston
–0.075 as rank A
B or L 125 124.80 or S)
–0.090
Measuring
No. Standard Tolerance
point
–0.005
2 Top ring 2.42
Thickness of piston –0.025 Replace
ring –0.010 piston ring
3 Second ring 2.4
–0.030
–0.010
4 Oil ring 4.0
–0.030
2 2 Top ring
Judge using groove wear gauge
Width of piston ring 3 Second ring Replace
3 groove +0.040 piston
4 Oil ring 4.0
+0.020
4 Measuring Clearance
No. Standard
Clearance between point limit Replace
piston ring and ring 2 Top ring piston or
Judge using groove wear gauge
groove 3 Second ring piston ring
4 Oil ring 0.030 – 0.070 0.15
2 Top ring 0.37 – 0.47 2.0 Replace
3 Second ring 0.50 – 0.60 1.5 piston ring
Piston ring gap
or cylinder
4 Oil ring 0.28 – 0.40 1.0 liner
Standard size Tolerance
Outside diameter of Replace
piston pin 0 piston pin
48
–0.006
5 Inside diameter of +0.045 Replace
48
piston pin hole +0.035 piston
Clearance between Standard Clearance limit Replace
piston pin piston or
and piston 0.035 – 0.051 0.063 piston pin
Replace
– Weight of piston 3,000g Permissible range: ± 60g
piston
125-3 SERIES 11-217

CONNECTING ROD

Inside diameter of Standard Tolerance Repair limit
Replace
bushing at connecting rod small +0.041
48 48.08 bushing
end +0.025
1
Clearance between bushing at Standard Clearance limit Replace
connecting rod small end and bushing or
piston pin 0.025 – 0.047 0.10 piston pin
Standard Tolerance Replace
Inside diameter of bushing hole
2 +0.030 connecting
at connecting rod small end 53
+0.030 rod
Inside diameter of bearing at Standard Tolerance Repair limit
Replace
3 connecting rod big end +0.020
80 80.12 bearing
(crankpin journal) –0.010
+0.022
85 — Replace
Inside diameter of bearing hole –0.004
connecting
at connecting rod big end Measure after tightening connecting rod cap with speci-
4 rod
fied torque
Thickness of connecting rod +0.005 Replace
2.5 —
bearing –0.005 bearing
Repair
Standard
limit
Replace
A : Bend 0 – 0.20 0.25
5 Bend and twist of connecting rod connecting
rod
B : Twist 0 – 0.30 0.35
Tihgtening torque of connecting Order Target Nm{kgm} Range Nm{kgm}

rod cap mounting bolt 1st step 98{10} 93 – 103(9.5 – 10.5)
6 Retighten
(Coat the bolt threads and nut
seats with engine oil) 2nd step Retighten with 90º 90º – 120º
Permissible range:
— Weight of connecting rod Replace
Variation between weights on the machine: max. 140g
11-218 125-3 SERIES

FLYWHEEL AND FLYWHEEL HOUSING

WITHOUT PTO ★ Details may differ according to the machine
model.
1. Flywheel housing No. of internal

2. Ring gear Machine No. of teeth
teeth on
3. Flywheel model on ring gear
flywheel
4. Rear seal WA470-5
137 72
WA480-5
125-3 SERIES 11-219

FLYWHEEL AND FLYWHEEL HOUSING

Face runout of flywheel
1 Repair limit: 0.35 Repair by
housing
reassem-
Radial runout of flywheel bling
2 Repair limit: 0.30
housing
Target Range
Bolt Order
Nm{kgm} Nm{kgm}
83 – 196
Tightening torque of 1st step 142{14.5}
{8.5 – 20}
3 flywheel housing M16 Retighten
mounting bolts 245 – 309
2nd step 279{28.5}
{25 – 31.5}
59 – 74
M10 – 68{7}
{6 – 7.5}
4 Face runout of flywheel Repair limit: 0.20 Repair by
reassem-
5 Radial runout of flywheel Repair limit: 0.15 bling
Tightening Target Range
Order
order Nm{kgm} Nm{kgm}
Tightening torque of
flywheel mounting bolt 127 – 166
6 1st step 147{15} Retighten
(Coat the bolt threads {13 – 17}
with engine oil) 270 – 309
2nd step 289{29.5}
{27.5 – 31.5}
11-220 125-3 SERIES

VIBRATION DAMPER
model.
1. Vibration damper
2. Pin
3. Crankshaft pulley
4. Crankshaft pulley mounting bolt
5. Vibration damper mounting bolt
125-3 SERIES 11-221

VIBRATION DAMPER

1 Visual check Not appear any cracks on the rubber part. Replace
Radial runout of vibration
2 Repair limit :0.80 Replace
damper
Face runout of vibration
3 Repair limit :0.80 Replace
damper.
Tightening torque Bolt Target Nm {kgm} Range Nm{kgm}
4 of vibration damper Retighten
M12 111{11.3} 98 – 123{10 – 12.5}
mounting bolt
11-222 125-3 SERIES

TIMING GEAR
1. Cylinder block 7. Fuel supply pump drive gear (No. of teeth: 44)
2. Water pump drive gear (No. of teeth: 22) 8. Timing gear cover
3. Main idler gear, large (No. of teeth: 57) 9. Camshaft gear (No. of teeth: 44)
4. Main idler gear, small (No. of teeth: 38) 10. Crankshaft gear (No. of teeth: 33)
5. Oil pump drive gear (No. of teeth: 21) 11. Crankshaft
6. Idler gear for oil pump (No. of teeth: 25) A,B,C: Match marks for timing gears
11-224 125-3 SERIES

125-3 SERIES 11-225

TIMING GEAR
MAINTENANCE STANDARD Unit :mm

Measuring
Gears Standard Repair limit
point
Crankshaft gear and
A 0.116 – 0.359
main idler gear (Large)
Main idler gear (Small)
B 0.105 – 0.325
and camshaft gear
Camshaft gear and fuel
Backlash of each C 0.105 – 0.325
— supply pump drive gear Replace
gears
Main idler gear (Large) 0.6
a and water pump drive 0.076 – 0.366
gear
Main idler gear (Large)
b 0.105 – 0.337
and oil pump idler gear
Oil pump idler gear and
c 0.082 – 0.389
oil pump drive gear
Clearance Standard Tolerance Standard Clearance
between main size Shaft Hole clearance limit
1
idler gear bush- +0.165 +0.115
47.5 0.025 – 0.060 0.20
ing and shaft +0.140 +0.100 Replace
Clearance bushing
between oil –0.025 +0.065
2 35 0.025 – 0.105 0.20
pump idler gear –0.040 0
and shaft
End play of main Standard Repair limit
3 Replace
idler gear 0.05 – 0.17 0.4
thrust
End play of oil
4 0.05 – 0.21 0.4 bearing
pump idler gear
11-226 125-3 SERIES

VALVE MECHANISM
1. Rocker arm shaft 8. Locknut 14. Adjustment screw

2. Cam roller 9. Crosshead 15. Locknut
3. Cam roller pin 10. Upper valve spring seat 16. Rocker arm
4. Engine speed output gear 11. Intake valve 17. Push rod
(No. of teegh: 14) 12. Valve spring 18. Cam follower
5. Camshaft 13. Lower valve spring seat 19. Valve cotter
6. Camshaft gear (No. of teeth : 44) (Intake and exhaust) 20. Exhaust valve
7. Adjustment screw 21. Valve stem seal
(Intake and exhaust)
11-228 125-3 SERIES

No. 1 cylinder intake side No. 1 cylinder exhaust side
CAMSHAFT VALVE TIMING

• Stamp forging
• Journal portion, cam portion:
Induction hardening
List of part (related to valve) to be set in place
Parts set in IN EX
Crosshead 6150-42-5610 6150-42-5610
Valve 6150-42-4110 6150-42-4210
Valve spring 6150-41-4450 6150-41-4450
(Color code) (White) (White)
Spring seat
6150-41-4430 6150-41-4430
(Lower)
Valve guide 6150-11-1370 6150-11-1370
Stem seal 6150-41-4570 6150-41-4570
125-3 SERIES 11-229

CAMSHAFT

Standard Repair limit Replace thrust
1 End play
0.15 – 0.35 0.50 plate
Standard Tolerance
Outside diameter of
–0.080 Replace
camshaft journal 60
2 –0.110
Clearance of camshaft Standard Clearance limit
Replace cam bushing
journal 0.080 – 0.180 0.28
3 Bend of camshaft Repair limit: 0.03 (Total indicator reading)
Replace
4 Cam height +0.395
52 51.73
+0.195
11-230 125-3 SERIES

CAM FOLLOWER AND PUSH ROD

Outside diameter of cam follower shaft –0.040
19.8 19.73
1 –0.050
Inside diameter of cam follower shaft +0.020
19.8
hole 0
–0.250
2 Outside diameter of cam roller 32 31.70
–0.280
–0.262
Inside diameter of cam roller 13 12.78
–0.287 Replace
3
–0.364
Outside diameter of cam roller pin 13 12.62
–0.376
Standard Tolerance
4 Radius of push rod ball end 0
12.7
–0.20
0
5 Radius of push rod socket end 12.7
–0.20
6 Bend of push rod Repair limit: 0.50 (Total indicator reading)
Tightening torque of cam follower
7 51±7.4Nm{5.25±0.75kgm} Retighten
housing mounting bolt
125-3 SERIES 11-231

VALVE AND VALVE GUIDE
11-232 125-3 SERIES


Valve Standard Tolerance Repair limit Replace
Amount of valve
1 Intake 1.88 ±0.10 2.51 valve or
sinking
Exhaust 1.20 ±0.10 1.90 valve seat
Valve Standard Repair limit
Thickness of
2 Intake 2.10 1.7 Replace
valve lip
Exhaust 1.50 1.2
Valve Standard Tolerance
Repair or
3 Valve seat angle Intake 30º ±0º15'
replace
Exhaust 45º ±0º15'
–0.045
Outside diameter Intake 9
–0.065 Replace
of valve stem
–0.050
Exhaust 9
–0.070
+0.015
Before inserting 9
Inside diameter –0.003
4 Replace
of valve guide +0.009
After inserting 9
–0.011
Clearance Valve Standard Clearance limit
Replace
between Intake 0.034 – 0.074 0.22 valve guide on
valve guide
Exhaust 0.039 – 0.079 0.24 valve stem
and valve stem
Bend of valve
Repair limit: 0.01 (Total indicated runout for 100 mm) Replace
stem
Protrusion of Standard size Tolerance
5 Repair
valve guide 20 ±0.2
Valve Color code Free length Repair limit
Free lengh of
Intake White 75.2 —
valve spring
Exhaust White 75.2 —
Color Installed
Valve Installed load Repair limit
code length
6 Installed load of 520±25 N 468 N Replace
Intake White 56.0
valve spring {53.0±2.6 kg} {47.7 kg}
520±25 N 468 N
Exhaust White 56.0
{53.0±2.6 kg} {47.7 kg}
Squarence of
Repair limit: 2º (for both end)
valve spring
125-3 SERIES 11-233

ROCKER ARM SHAFT
Standard Tolerance
Outside diameter of Replace
rocker arm shaft –0.053 rocker arm shaft
28.6
–0.066
Inside diameter of +0.033 Replace
28.6
rocker arm shaft hole –0.027 rocker arm
1
Standard Clearance limit Replace rocker
Clearance between rocker arm
arm or rocker arm
shaft and rocker arm 0.026 – 0.099 0.130 shaft
Replace
Bend of rocker arm shaft Repair limit :0.20 (Total indicated runout)
rocker arm shaft
Tightening torque of rocker
2 53 – 65Nm (5.4 – 6.6kgm) Retighten
arm adjustment nut
Valve clearance
3 Intake 0.33 ±0.02 Adjust
(at hot or cold)
Exhaust 0.71 ±0.02
11-234 125-3 SERIES

CROSSHEAD

Inside diameter of crosshead +0.075
11 11.18
1 +0.025 Replace
+0.011
Outside diameter of crosshead guide 11 10.95
0
2 Protrusion of crosshead guide 45.5 ±0.25 — Repair
Tightening torque of crosshead
3 66±7.4 Nm{6.7±0.75 kgm} Retighten
lock nut
125-3 SERIES 11-235

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD LUBRICATION SYSTEM
LUBRICATION SYSTEM
LUBRICATION SYSTEM DIAGRAM

model.
1. Oil pan 8. Safety valve 15. Intake, exhaust valve

2. Oil strainer 9. Crankshaft 16. Timing gear
3. Oil pump 10. Piston cooling nozzle 17. Turbocharger
4. Relief valve 11. Piston 18. Fuel supply pump assembly
5. Oil cooler 12. Camshaft
6. Thermo valve 13. Cam follower W. Cooling water
7. Oil filter 14. Rocker arm
11-302 125-3 SERIES

OIL PUMP
1. Pump drive gear (No.of teeth :21) OIL PUMP

2. Bushing • Type: Gear pump
3. Pump cover • Pump speed: Engine speed x 1.571
4. Drive gear
5. Pump body MAIN RELIEFE VALVE
6. Drive shaft +0.1
• Set pressure: 0.7 0 MPa
7. Main relief valve {7 +10 kg/cm2}
8. Valve spring
9. Retainer
10. Driven shaft
11. Bushing
12. Driven gear
125-3 SERIES 11-303

OIL PUMP

Tolerance
Standard Standard Clearance
size Gear Body clearance limit
Axial clearance of
1 thickness depth
pump gear
0 +0.065 0.03 –
47 0.10 Replace
–0.025 +0.040 0.09
gear
Standard Tolerance Standard Clearance
Radial clearance of size Gear O.D. Gear I.D. clearance limit
2
pump gear –0.15 +0.060 0.03 –
51.4 0.13
–0.21 +0.600 0.10
Tolerance Standard
Standard interfer- Clearance
Interference size ence or limit
Shaft Hole
3 between pump drive clearance Replace
gear and drive shaft
+0.106 +0.065 0.023 –
18 —
+0.088 +0.047 0.059
Clearance
+0.106 +0.173 0.040 – Replace
4 between drive shaft 18
+0.088 +0.146 0.085 bushing
and cover bushing
Interference
+0.106 +0.063 0.025 –
5 between pump gear 18 — Replace
+0.088 +0.028 0.078
and drive shaft
Clearance
–0.006 +0.061 0.040 – Replace
6 between drive shaft 18
–0.024 +0.034 0.085 bushing
and body bushing
Clearance between +0.090 +0.129 0.012 –
7 18 — Replace
driven shaft and body +0.070 +0.102 0.059
Clearance
+0.090 +0.147 0.032 – Replace
8 between driven shaft 18
+0.070 +0.122 0.077 bushing
and gear bushing
Interference between +0.090 +0.040 0.030 –
9 18 — Replace
driven shaft and cover +0.070 +0.020 0.068
11-304 125-3 SERIES

MAIN RELIFE VALVE

+0.1 +1
1 Relief valve set pressure 0.7 0 MPa {7 0 kg/cm2}
Standard Tolerance Standard Clearance
Clearance size Shaft Hole clearance limit
2
between valve and body –0.040 +0.043 0.040–
16
–0.060 0 0.103 Replace
Standard size Repair limit
Installed Installed Installed
Free length Free length
3 Relief valve spring length load length
120 N 110 N
48.8 38.8
{12.2 kg} {11.2 kg}
125-3 SERIES 11-305

OIL FILTER
Remote mounting type model.
1. Safety valve Oil filter

2. Filter head • Filtration area: 0.42 m2 (Full-flow)
3. Cartridge
Safety valve
A. Oil inlet • Set pressure: 245 ± 20 kPa
B. Oil outlet {2.5 ± 0.2 kg/cm2}
11-306 125-3 SERIES

SAFETY VALVE
1. Safety valve
2. Filter head
3. Spring
4. Cap
MAINTENANCE STANDARD Unit :mm

1 Safety valve set pressure 245 ± 20 kPa {2.5 ± 0.2 kg/cm2} Replace
125-3 SERIES 11-307

OIL COOLER
1. Thermostat housing THERMOSTAT FUNCTION

2. Thermostat • Valve cracking temperature: 85 ± 1.5ºC
3. Cooler cover • Full opening temperature: 100ºC
4. Cooler element • Full opening left: Min.8 mm
5. Strainer
a. Water drain port Oil cooler

b. Oil inlet • Effective area: 0.575m2
c. To engine each part
d. Water inlet
11-308 125-3 SERIES

OIL COOLER

Lift of Min.11 (Check after immersion in a hot oil bath of 100ºC
thermostat valve for 4 or 5 minutes.)
1 Opening and Valve must be close fully when immersed in a hot oil bath (85ºC) Replace
closing of valve for 4 or 5 minutes after being immersed in a hot oil bath (100ºC)
in thermostat to fully open the valve.
125-3 SERIES 11-309

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD FUEL SYSTEM
FUEL SYSTEM
FUEL SYSTEM DIAGRAM

CRI SYSTEM ★ CRI is short for Common Rail Injection. Hereinaf-
ter called CRI.
1. Fuel tank 3. Fuel filter

2. Fuel supply pump assembly 4. Overflow valve
2A. PCV 5. Common rail
2B. High-pressure pump 6. Pressure limiter
2C. Priming pump 7. Flow damper
2D. Feed pump 8. Injector assembly
2E. Bypass valve 9. Fuel cooler
2F. G revolution sensor 10. ECU (Engine Control Unit)
11. NE revolution sensor
11-402 125-3 SERIES

OUTLINE OF CRI SYSTEM

OUTLINE
The CRI system detects the condition of the engine (engine speed, accelerator angle, cooling water tempera-
ture, etc.) from various sensors, and uses a microcomputer to carry out overall control of the fuel injection
amount, fuel injection timing, and fuel injection pressure to operate the engine under the optimum conditions.
The computer also carries out self-diagnosis of the main components, and if any abnormality is found, it carries
out diagnosis and sends an alarm to inform the operator. It also has a fail-safe function to stop the engine
according to the location of the abnormality and a backup function to switch the control method to make it possi-
ble to continue operation.
STRUCTURE
The CRI system can be divided in terms of function into the fuel system and control system.
1. Fuel system
The high-pressure fuel generated by the fuel supply pump goes from the common rail and is distributed to each
cylinder. The start and finish of injection is controlled by opening or closing the nozzle needle valve by using an
electromagnetic valve inside the injector.
2. Control system
The ECU (Engine Control Unit) carries out control by calculating the length of time and the timing of sending
current to the injector by using the signals from the sensors installed to the engine and various parts of the
machine so that it injects a suitable amount at the suitable injection timing.
The control system and electrical components can be broadly divided into the sensors, computer, and actua-
tors.
125-3 SERIES 11-403

STRUCTURE AND FUNCTION OF CRI SYSTEM

The CRI system consists of the fuel supply pump, common rail, and injectors, and the ECU and sensors that
control them.
The fuel supply pump generates fuel pressure inside the common rail. The fuel pressure is controlled by the
amount of fuel discharged from the supply pump. The amount of fuel discharged is controlled by sending an
electrical signal from the ECU to switch the PCV (discharge control valve) of the fuel supply pump ON-OFF.
The common rail accepts the fuel pressure generated by the fuel supply pump and distributes it to the cylinders.
The fuel pressure is detected by the common rail fuel pressure sensor installed in the common rail. It carries
out feed back control to ensure that the actual pressure value matches the command pressure value set in
accordance with the engine speed and engine load.
The fuel pressure of the common rail passes through the fuel injection pipes of each cylinder and is applied to
the control chamber and the nozzle of the injector.
The injector controls the amount of fuel injection and the fuel injection timing. It controls by switching the TWV
(Two-Way electromagnetic Valve) ON-OFF. When the TWV is turned ON (conducts electricity), the fuel circuit is
switched so that the high-pressure fuel in the control chamber passes through the orifice and flows out. The
needle valve goes up because of the nozzle cracking pressure actuated by the high-pressure fuel at the nozzle
end, and fuel injection is started. When the TWV is switched OFF (no current flows), the control chamber
becomes a fuel circuit with the high-pressure fuel applied through the orifice, so the needle valve goes down
and fuel injection is completed.
Therefore, the fuel injection timing is controlled electronically by the timing of the electricity passing through the
TWV, and the amount of fuel injected is controlled by the amount of time that electricity passes through the
TWV.
11-404 125-3 SERIES

STRUCTURE AND FUNCTION OF COMPONENTS
1. Fuel supply pump
1) Outline
The fuel supply pump consists of the priming pump, feed pump, and high-pressure pump. Its function gener-
ates the fuel pressure inside the common rail by the control of the fuel discharge amount.
2) Structure
With the high-pressure pump, pump control valves (discharge amount control valves) are installed to each cylin-
der to control the force feed system and fuel discharge amount in the same way as the conventional in-line fuel
injection pump.
By employing cams with 3 protrusions, the necessary number of high-pressure pumps (cylinders) is reduced to
1/3 of the number of engine cylinders. In addition, the force feed to the common rail is the same number of
times as the number of times of fuel injection, so it is possible to obtain a smooth and stable common rail pres-
sure.
The fuel force fed from the high-pressure pump to the common rail is divided as follows for each pump.
The No. 1 high-pressure pump (drive gear side) (4) covers the drop in the pressure inside the common rail
because of the fuel injection of the No. 1, No. 3, and No.5 cylinders, while the No. 2 high-pressure pump (feed
pump side) (6) covers the drop in the pressure inside the No.2, No.4 and No.6 cylinders of common rail in the
same way.
1. 3-protrusion type cam 6. No.2 high-pressure pump

2. Overflow valve 7. Priming pump
3. Drive gear 8. Feed pump
4. No.1 high-pressure pump 9. G revolution sensor gear
5. PCV (discharge control valve)
125-3 SERIES 11-405

3) Operation
A. During the down stroke of the plunger, the PCV is open, so the low-pressure fuel passes through the
PCV and is sucked into the plunger chamber.
B. Even when the plunger enters the up stroke while there is no electricity flowing to the PCV and it remains
open, the fuel taken in passes through the PCV, so the pressure does not rise and it is returned.
C. When electricity is sent to the PCV to close the valve with timing matching the necessary discharge
amount, the return passage is cut off, and the pressure in the plunger chamber rises. Therefore, the fuel
passage through the delivery valve (check valve) and is force fed to the common rail.
In other words, when the PCV is closed, the plunger lift becomes the amount of discharge, and by chang-
ing the timing of closing the PCV (plunger prestroke), the discharge amount changes and the common
rail fuel pressure is controlled.
D. When the cam passes the maximum lift, the plunger enters the down stroke and the pressure inside the
plunger chamber goes down. When this happens, the delivery valve closes and stops the force feed of
fuel. In addition, the flow of current to the PCV is stopped, so the PCV opens and low-pressure fuel is
sucked into the plunger chamber. In other words, it returns to the condition in A.
11-406 125-3 SERIES

4) PCV (discharge control valve)

The PCV acts to adjust the fuel discharge amount from the fuel supply pump to adjust the common rail fuel
pressure. The discharge amount sent to the common rail from the fuel supply pump is determined by the timing
of the electric current sent to the PCV.
5) Feed pump
The feed pump is built into the fuel supply pump assembly. It sucks up the fuel from the fuel tank, sends it
through the fuel filter, and into the high-pressure pump chamber. The feed pump rotor is driven by the cam-
shaft, and when the outer/inner rotors start to turn respectively, fuel is sucked in at the suction side and sent
out at the discharge size according to the change in the size of space created by the outer/inner rotors.
2. Common rail
1) Structure
The common rail acts to distribute the high-pressure
fuel generated by the high-pressure pump and send
it to the injector of each cylinder. The common rail is
equipped with a common rail fuel pressure sensor,
flow damper, and pressure limiter.
The flow damper is equipped with a fuel injection
pipe and sends high-pressure fuel to the injector.
The piping of the pressure limiter is arranged to
return to the fuel tank.
125-3 SERIES 11-407

2) Flow damper
The flow damper reduces the pressure pulses inside
the high-pressure piping and acts to supply fuel at a
stable pressure to the injector. If any excess fuel
flow out, it acts to shut off the fuel passage and pre-
vent any abnormal outflow of fuel.
If any abnormal outflow is generated, high pressure
bears on the piston, so the piston and ball move to
the right as shown in the diagram and come into
contact with the seat. As a result, the fuel passage
is shut off.
3) Pressure limiter
The pressure limiter opens if any abnormal high
pressure is generated, and acts to allow the pres-
sure to escape. It is actuated (opens) if the fuel
pressure in the common rail reaches approx. 140
MPa {1,430 kg/cm2}, and when the pressure goes
down to approx. 30 MPa {310 kg/cm2}, it is restored
(closes) and acts to maintain the pressure.
11-408 125-3 SERIES

4) Common rail fuel pressure sensor

The common rail fuel pressure sensor is installed to the common rail and detects the fuel pressure. The sensor
is a semi-conductor pressure sensor. This uses the characteristic of silicon, which changes the electrical resis-
tance if pressure is applied to it.
3. Injector
1) Outline
The function of the injectors is to inject high-pressure fuel from the common rail according to the signal from the
ECU into the injection chamber of the engine at the optimum fuel injection timing, fuel injection amount, fuel
injection ratio and spray condition.
The TWV (Two-Way electromagnetic Valve) controls the pressure in the control chamber in order to control the
start and finish of the fuel injection.
The orifice controls the angle of opening of the nozzle to control the fuel injection ratio.
The hydraulic piston transmits force to the needle valve of the nozzle according to the pressure in the control
chamber.
The nozzle acts to spray out the fuel.
When fuel injection starts (TWV ON) When fuel injection finishes (TWV OFF)
125-3 SERIES 11-409

2) Structure
The injector consists of a conventional nozzle, 2-way electromagnetic valve, hydraulic piston, and orifice which
controls the fuel injection ratio.
1. Inlet connector 5. Outer body 10. Control chamber

2. Terminal 6. Inner valve Valve assembly 11. Command piston
3. Upper body 7. Valve body 12. Spring
4. Solenoid 8. OUT orifice 13. Pressure pin
9. IN orifice 14. Nozzle assembly
11-410 125-3 SERIES

3) Operation
The TWV of the injector is a 2-way valve and consists of inner valve (fixed) (4) and outer valve (variable) (3). It
is precisely joined to the same shaft. It forms both the inner and outer seats, and when the TWV is switched
ON/OFF, one of the two seats is selected to open.
i) No injection of fuel
When no electric current is being sent to the solenoid, outer valve (3) is pushed down by the valve spring and
the fuel pressure, and outer seat (5) is closed. High pressure from the common rail is applied to control cham-
ber (7), so nozzle (8) is closed and there is no fuel injection.
ii) Start of fuel injection

When electric current starts to flow to the TWV, outer valve (3) is pulled up by the electromagnetic force and
outer seat (5) opens. As a result, fuel flows out from the control chamber through orifices (2) and (6), the nozzle
needle goes up, and fuel injection starts. Because of the action of orifices (2) and (6), the fuel injection ratio is
gradually raised. If electric current continues to be sent, the maximum fuel injection ratio is reached.
iii) Completion of fuel injection

When the flow of electric current to the TWV is stopped, outer valve (3) goes down under the force of the valve
spring and the fuel pressure, and outer seat (5) closes. When this happens, the high-pressure fuel in the com-
mon rail is suddenly applied to the control chamber, so the nozzle is suddenly closed and a sharp completion of
the fuel injection is obtained.
No injection of fuel Start of fuel injection Completion of fuel injection
1. Hydraulic piston 7. Control chamber

2. Orifice 1 8. Nozzle
3. Outer valve
4. Inner valve A. Common rail (always at high pressure)
5. Outer seat (18 to 130 MPa{180 to 1,330 kg/cm2})
6. Orifice 2 B. Leak
125-3 SERIES 11-411

4) Electric circuit diagram
High voltage (118V) is applied to the wiring harnesses connected to the ECU and EDU COMMON1,
COMMON2, and TWV #1 to #6, so be careful to avoid electrocution.
11-412 125-3 SERIES

4. Sensors and relays

NE revolution sensor (crank angle)
1) NE revolution sensor (crank angle sensor)
When the signal hole in the flywheel passes the sen-
sor, the line of magnetic force passing through the
coil changes and an AC voltage is generated in the
coil.
Signal holes are provided in the flywheel every 7.5o,
but there are 3 places where there is no hole, so
there is a total of 45 signal holes. Therefore, for
every 2 turns of the engine, 90 pulses are output.
From this signal, the engine speed and the crank
angle for every 7.5o is detected.
2) G revolution sensor (cylinder judgement sensor)

In the same way as the NE revolution sensor, the
change in the line of magnetic force passing through G revolution sensor (cylinder judgement)
the coil is used to generate an AC voltage.
The disc-shaped gear provided in the center of the
camshaft of the high-pressure pump has teeth cut (a
notch is made) every 120o, and in addition, there is
an extra tooth at one point. Therefore, for every 2
turns of the engine, 7 pulses are output.
The combination of the NE revolution sensor pulse
and G revolution sensor pulse is recognized as the
No. 1 cylinder standard pulse.
125-3 SERIES 11-413

3) Water temperature sensor

The water temperature sensor detects the tempera-
ture of the engine cooling water and sends it to the
ECU. The sensor uses a thermistor which changes
the resistance value according to the temperature.
It applies voltage to the thermistor and detects with
the voltage divided into the resistance value inside
the computer and the resistance value of the ther-
mistor.
4) Fuel temperature sensor

The fuel temperature sensor detects the tempera-
ture of the fuel and sends it to the ECU. The sensor
uses a thermistor which changes the resistance
value according to the temperature. It applies volt-
age to the thermistor and detects with the voltage
divided into the resistance value inside the computer
and the resistance value of the thermistor.
11-414 125-3 SERIES

Controls
The CRI system control of the fuel injection amount and fuel injection timing is carried out more suitably than on
the mechanical governor and timer used in conventional fuel injection pumps.
The system control carries out the necessary calculation in the ECU from the signal from the sensors installed
to the engine and machine, and controls the timing and length of time that electricity is sent to the injector so
that it can carry out the optimum fuel injection at the optimum fuel injection timing.
1. Control function for fuel injection amount

The function to control the fuel injection amount replaces the conventional function of the governor. It functions
to control the fuel injection so that the optimum fuel injection amount is injected, based on the signal from the
engine speed and accelerator angle.
2. Control function for fuel injection timing

The function to control the fuel injection timing replaces the conventional function of the timer. It functions to
control the fuel injection so that the optimum fuel injection timing is carried out, based on the signal from the
engine speed and fuel injection amount.
3. Control function for fuel injection pressure (common rail fuel pressure control function)
The function to control the fuel injection pressure (common rail fuel pressure control function) measures the fuel
pressure with the common rail fuel pressure sensor. This function feeds back to the ECU and controls the
amount of fuel discharged from the fuel supply pump.
It controls the pressure feedback so that it matches the optimum value (command value) set according to the
engine speed and fuel injection amount.
125-3 SERIES 11-415

FUEL PIPING
model.
1. Fuel injection pipe (No. 1 cylinder) 9. Priming pump

2. Fuel injection pipe (No. 2 cylinder) 10. Feed pump
3. Fuel injection pipe (No. 3 cylinder) 11. Oil inlet pipe (for pump lubrication oil)
4. Fuel injection pipe (No. 4 cylinder) 12. High-pressure pump
5. Fuel injection pipe (No. 5 cylinder) 13. Fuel supply pump drive gear (No. of teeth: 44)
6. Fuel injection pipe (No. 6 cylinder) 14. Overflow valve
7. Fuel return pipe 15. PCV
8. Common rail
11-416 125-3 SERIES

A. Fuel inlet Fuel supply pump

B. To fuel filter • Maker: Nihon Denso
C. From fuel filter • Type: Denso ECD-U2
D. To injector • Lubrication method: Forced lubrication
E. Fuel return (between overflow valve and fuel tank) using engine oil
F. Fuel return (between injector and fuel tank)
G. Engine oil (to fuel supply pump)
125-3 SERIES 11-417

FUEL COOLER
model.
1. Mount bracket Specifications

2. Core
• Cooling method: Air cooled
A. From fuel tank • Core type: AL-CFT-1
B. To fuel supply pump • Heat dissipation surface: 3.31m2
11-418 125-3 SERIES

FUEL FILTER
model.
1. Air bleed plug Specifications

2. Filter head
3. Cartridge • Filtering area: 1.0 m2
A. Fuel inlet
B. Fuel outlet
125-3 SERIES 11-419

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
COOLING SYSTEM CHART

model.
1. Radiator 7. Cylinder head

2. Thermostat 8. Cylinder liner
3. Water pump 9. Piston
4. Water temperature gauge 10. Cylinder block
5. Water manifold (Integrated with cylinder block) 11. Oil cooler
6. Corrosion resistor 12. Air compressor
A. Lubrication oil
B. Cooling water (water manifold to cylinder block)
125-3 SERIES 11-501

WATER PUMP
MOUNTING ★ Details may differ according to the machine
model.
1. Thermostat A. To radiator (coolant)

2. Housing cover B. From engine each part (coolant)
3. Thermostat housing C. To engine each part thru oil cooler (coolant)
4. Water pump D. From radiator (coolant)
5. Oil cooler E. From oil pump (oil)
F. To engine each part (oil)
a. Outlet for car heater

b. Water temperature gauge pick-up
c. Coolant drain plug
11-502 125-3 SERIES

WATER PUMP
WATER PUMP
1. Water pump drive gear
(No. of teeth: 22) Type: Centrifugal gear drive.
2. Pump shaft Pump speed: Engine speed x 1.5
3. Ball bearing
4. Pump body
5. Water seal
6. Impeller
7. Pump cover
a. From thermostat
b. From radiator
c. To engine each part
125-3 SERIES 11-503

WATER PUMP

Standard Tolerance Standard
Interference between size Shaft Hole interference Replace
1
impeller and shaft +0.018 –0.020 0.025 – impeller
15.9
+0.005 –0.050 0.068
Interference
+0.015 –0.023 0.025 – Replace
2 between drive 20.0
+0.002 –0.053 0.068 gear
gear and shaft
Clearance
3 between impeller Standard : 0.30 – 1.10 (Including end play)
and body
Repair limit Replace

Abrasion of seal A: 1.5
4
ring in water seal
11-504 125-3 SERIES

THERMOSTAT
MOUNTING model.
1. Thermostat
2. Thermostat housing
a. To radiator
b. To water pump
125-3 SERIES 11-505

THERMOSTAT
Cool (full close) Warm (full open)
1. Thermostat 7. Expander Function

2. Seal 8. Sleeve • Opening temperature: 71ºC
3. Valve 9. Flang • Full opening temperature: 90ºC
4. Body a. To water pump (bypass) • Valve lift: Min. 10 mm
5. Piston b. To radiator
6. Sensor c. From engine

No. Check item Criteria Remedy
Lift of thermostat to fully Min. 10 mm
open position (soak the valve in oil bath at 90ºC for 4 to 5 minutes to check)
1 Check that the valve closes fully when the water temperature Replace
Opening/closing of has gone down to 71°C from 90°C when the valve was fully
thermostat open.
(Soak the valve in a water bath for 4 to 5 minutes to check)
11-506 125-3 SERIES

CORROSION RESISTOR
1. Head CORROSION RESISTOR

2. Cartridge • Filtration area: 0.5 m2
3. Element (Paper)
4. Element (Chemicals)
5. Spring
A. Water inlet
B. Water outlet
125-3 SERIES 11-507

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
ALTERNATOR MOUNTING
SA6D125E-3 model.
SAA6D125E-3 (WA430-5, WA470-5, WA480-5)
1. Alternator pulley
2. Alternator drive belt
3. Clankshaft pulley
4. Adjusting bolt
11-902 125-3 SERIES

(7)
SAA6D125E-3 (HM300-1, PC400-7, PC450-7) ★ Details may differ according to the machine
model.
1. Alternator pulley
2. Alternator drive belt
3. Crankshaft pulley
4. Adjusting bolt
5. Fan pulley
125-3 SERIES 11-902-1

(7)
ALTERNATOR
WITH BUILT-IN REGULATOR (OPEN TYPE, 35A)
1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Primary energized resistance
3. Terminal B 6B. Regulator
4. Terminal R 6C. Field coil
5. Terminal E
Pulley
Specifica- Outside Weight
Engine Machine model Type No . of
tion diameter (kg)
steps
(mm)
Nikko Denki
SAA6D125E-3 PC400-7, PC450-7 Open type 24V, 35A 2 93 8
(brushless)
125-3 SERIES 11-903

(7)

2. Alternator pulley 6A. Primary energized resistance
3. Terminal B 6B. Regulator
4. Terminal R 6C. Field coil
5. Terminal E
Pulley
Specifica- Outside Weight
Engine Machine model Type No . of
tion diameter (kg)
steps
(mm)
D65EX, PX-15,
SA6D125E-3 24V, 50A 2 75 11
D85EX, PX-15 Nikko Denki
WA430-5, Open type
SAA6D125E-3 WA470-5, WA480-5, (brushless) 24V, 50A 2 75 11
HD255-5
11-903-1 125-3 SERIES

(8)

2. Alternator pulley 6A. Alternator
3. Terminal R 6B. Regulator
4. Terminal E
5. Terminal B a. Load
Pulley
Weight
Engine Machine model Type Specification Outside
No. of steps (kg)
diameter (mm)
D65EX, PX-15,
SA6D125E-3 Sawafuji 24V, 75A 2 95 13
D85EX, PX-15
Denki,
WA430-5 24V, 75A 2 95 13
SAA6D125E-3 Open type
HM300-1 24V, 75A 2 95 13
125-3 SERIES 11-903-2

(5)

2. Alternator pulley 6A. Alternator
3. Terminal R 6B. Regulator
4. Terminal E
5. Terminal B a. Load
Pulley
Weight
Engine Machine model Type Specification Outside
No. of steps (kg)
diameter (mm)
D65EX, PX-15,
SA6D125E-3 Sawafuji 24V, 75A 2 95 13
D85EX, PX-15
Denki,
WA430-5 24V, 75A 2 95 13
SAA6D125E-3 Open type
HM300-1 24V, 75A 2 95 13
11-903-3 125-3 SERIES

(7)
STARTING MOTOR
BUILT-IN SAFETY RELAY TYPE (7.5kW) model.
1. Pinion gear 5. External wiring diagram B.C.R.S.E : Terminal

2. Starting motor (body) [3-pin connector type (male)]
3. Magnetic switch 5A. Safety relay portion
4. External wiring diagram 5B. Starting motor portion
[2-pin connector type) (male)] 6. Connector specitication
4A. Safety relay portion A Type : 2-pin connector (male)
4B. Starting motor portion B Type : 2-pin drip-proof connector (male)
C Type : 3-pin drip-proof connector (male)
D Type : 2-pin connector
No. of Weight Connector

Engine Machine model Type Specification
pinion teeth (kg) type
SA6D125E-3 Nikko Denki 24V, 7.5kW 12 18 D
All machine Waterproof,
SAA6D125E-3 oilproof type 24V, 7.5kW 12 20 D
11-904 125-3 SERIES

(5)
BUILT-IN SAFETY RELAY TYPE (11kW) ★ Details may differ according to the machine
model.
1. Pinion gear 5. Connector specification B.C.R.S.E : Terminal

2. Starting motor (body) A Type : 2-pin connector (male)
3. Magnetic switch B Type : 2-pin drip-proof connector (male)
4. External wiring diagram
4A. Safety relay portion
4B. Starting motor portion
No. of Weight Connector

Engine Machine model Type Specification
pinion teeth (kg) type
All machine
SA6D125E-3 Nikko Denki 24V, 11kW 12 18 —
(option)
Waterproof,
All machine oilproof type
SAA6D125E-3 24V, 11kW 12 18 A
(option)
125-3 SERIES 11-905

(5)
STARTING AID
ELECTRICAL INTAKE AIR HEATER
For SA6D140E-3
1. Body
2. Heater coil
3. Connection circuit diagram (using 6 heaters)

• Rated voltage: DC22 V
• Rated current: 27.3 A (total: 164A with 6)
11-906 125-3 SERIES

(5)
SAA6D125E-3
1. Terminal
2. Body
3. Heater coil
4. Wiring diagram

• Rated voltage: DC22 V
• Rated current: 111 A
125-3 SERIES 11-907

(6)
12 TESTING AND ADJUSTING,
TROUBLESHOOTING
TESTING AND ADJUSTING DATA .............................................................................................................12- 4

STANDARD VALUE TABLE FOR ELECTRICAL PARTS ............................................................................12- 6
TESTING AND ADJUSTING TOOL LIST....................................................................................................12- 8
MEASURING INTAKE AIR PRESSURE (BOOT PRESSURE) ........................................................12- 9
MEASURING EXHAUST TEMPERATURE......................................................................................12- 10
ADJUSTING VALVE CLEARANCE ..................................................................................................12- 12
MEASURING COMPRESSION PRESSURE ...................................................................................12- 14
MEASURING BLOW-BY PRESSURE..............................................................................................12- 16
MEASURING ENGINE OIL PRESSURE..........................................................................................12- 17
MEASURING FUEL PRESSURE .....................................................................................................12- 18
ADJUSTING ENGINE SPEED SENSOR .........................................................................................12- 19
TESTING AND ADJUSTING FUEL INJECTION TIMING ................................................................12- 20
HANDLING EQUIPMENT IN FUEL SYSTEM ..................................................................................12- 26
RELEASING REMAINING PRESSURE IN FUEL SYSTEM ............................................................12- 26
BLEEDING AIR FROM FUEL CIRCUIT ...........................................................................................12- 27
REDUCED CYLINDER MODE OPERATION FOR ENGINE............................................................12- 29
CHECKING FOR LEAKAGE IN FUEL SYSTEM..............................................................................12- 30
ADJUSTING ENGINE STOP MOTOR LEVER.................................................................................12- 31
CALIBRATION DATA.............................................................................................................................12- 50
PERFORMANCE TEST
RUN-IN STANDARD.........................................................................................................................12- 70
PERFORMANCE TEST STANDARDS.............................................................................................12- 74
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).....................................................................12-101
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) ............................................................12-201
125-3 SERIES 12-1

(5)
k When carrying out testing and adjusting, or troubleshooting, stop the machine on level ground, fit safety
pins, block the wheels, and apply the parking brake.
k When carrying out operations with two or more workers, always use signals, and do not allow any unautho-
rized person near the machine.
k When-checking the water level, if the radiator cap is removed when the engine is hot, boiling water will spurt
out and may cause burns, so always wait for the engine to cool down before checking the water level.
k Be extremely careful not to touch any hot parts.
k Be extremely careful not to get caught in the fan or any other rotating parts.
k When removing the plugs or caps from places under hydraulic pressure, water pressure, or air pressure,
release the internal pressure first. Fit the measuring tools securely before carrying out any testing, adjusting,
or troubleshooting.
a When using the standard values table for judgement in testing, adjusting or troubleshooting, it is necessary
to be careful of the following points.
1. The standard values for the new machines in the standard values table are values given as reference from
the standards for machines shipped from the factory. They should be used as values for estimating wear dur-
ing operation or as target values when carrying out repairs.
2. The failure judgement standard values in the standard values table are values using estimated values based
on the results of various tests and standard values for machines shipped from the factory. Use these values
for reference together with the repair and operation history of the machine when judging failures.
3. Do not use this standard values table as a standard for judging claims.
12-2 125-3 SERIES

TESTING AND ADJUSTING TESTING AND ADJUSTING DATA
TESTING AND ADJUSTING DATA

Engine model SAA6D125E-3

Machine model WA430-5
Standard Permissible
Item Condition, etc Unit
value value
High idling speed rpm 2,250 +500 2,250 +500
Performance
Engine speed
Low idling speed rpm 770 +500 770 +500
Necessary starting 0ºC(Without starting aid) rpm Min.100 —

speed
–20ºC(With starting aid) rpm Min.85 —
kPa Max.2.94 7.47
Intake resistance At all speed
{mmH2O} {300} {762}
kPa Min.80 60
Boost pressure At rated horsepower
{mmHg} {600} {450}
Exhaust pressure kPa Min.80 73
Intake and exhaust system
At rated horsepower
(Turbine inlet press.) {mmHg} {600} {550}
Exhaust temperature All speed
ºC Max.650 700
(Turbine inlet temp.) (At 20ºC)
Quick acceleration Bosch
Max.4.5 6.5
(Low idle → high idle) index
Bosch
Exhaust gas color At rated horsepower Max.1.0 2.0
index
Bosch
High idling speed Max.1.0 2.0
index
Valve clearance Intake valve mm 0.33 —

(Whel engine is hot
or cold) Exhaust valve mm 0.71 —
Oil temperature:40 – 60ºC

Engine body
Compression pressure MPa Min. 2.9 2.0

(Engine speed:
(SAE30 or SAE15W-40) {kg/cm2} {30} {20}
150 – 200 rpm)
Blow-by pressure At rated horsepower kPa Max. 0.98 1.96
(SAE30 or SAE15W-40) (Water temp:Min.70ºC) {mmH2O} {100} {200}
At rated horsepower MPa 0.39 – 0.69 0.21
SAE30 or SAE15-40 oil {kg/cm2} {4.0 – 7.0} {2.1}
MPa 0.34 – 0.64 0.18
Oil pressure SAE10W oil
Lubrication system
{kg/cm2} {3.5 – 6.5} {1.8}

(Oil temperature:
At low idling MPa Min. 0.15 0.08
min.80ºC)
SAE30 or SAE15W-40 oil {kg/cm2} {1.5} {0.8}
MPa Min. 0.10 0.07
SAE10W oil
{kg/cm2} {1.0} {0.7}
All speed
Oil temperature ºC 90 – 110 120
(Oil in oil pan)
At continuous rated
Oil consumption ratio % Max.0.5 1.0
(Ratio to fuel consumption)
MPa
Cooling system Fuel system
Fuel injection pressure Nozzle tester — —

{kg/cm2}
Fuel injection timing B.T.D.C. degree 8±1 —
Opening pressure kPa

Radiator pressure valve — —
(Differential pressure) {kg/cm2}
Fan speed At rated engine speed rpm — —
Deflects when pushed
Fan belt tension mm — —
with a force of 59 N {6 kg}
12-4 125-3 SERIES

(7)
Standard Permissible Standard Permissible Standard Permissible Standard Permissible

value value value value value value value value
Performance
Engine body
Lubrication system
125-3 SERIES 12-5

Engine model SA6D125E-3

Machine model D65EX, PX-15 D85EX, PX-15
Standard Permissible Standard Permissible
value value value value
High idling speed rpm 2,100±50 2,100±50 2,100±50 2,100±50
Performance
Engine speed
Low idling speed rpm 825±25 825±25 750 +500 750 +500
Necessary starting 0ºC(Without starting aid) rpm Min.100 — Min.100 —

speed
–20ºC(With starting aid) rpm Min.85 — Min.85 —
kPa Max.3.72 7.47 Max.3.72 7.47
{mmH2O} {380} {762} {380} {762}
kPa Min.80 60 Min.80 60
{mmHg} {600} {450} {600} {450}
Exhaust pressure kPa Min.80 73 Min.80 73
At rated horsepower
(Turbine inlet press.) {mmHg} {600} {550} {600} {550}
ºC Max.650 700 Max.650 700
Max.4.5 6.5 Max.4.5 6.5
Bosch
Exhaust gas color At rated horsepower Max.1.5 2.5 Max.1.5 2.5
index
Bosch
High idling speed Max.1.0 2.0 Max.1.0 2.0
index
Valve clearance Intake valve mm 0.33 — 0.33 —

(Whel engine is hot
or cold) Exhaust valve mm 0.71 — 0.71 —

Engine body
Compression pressure MPa Min. 2.9 2.0 Min. 2.9 2.0

(Engine speed:
(SAE30 or SAE15W-40) {kg/cm2} {30} {20} {30} {20}
150 – 200 rpm)
Blow-by pressure At rated horsepower kPa Max. 0.98 1.96 Max. 0.98 1.96
(SAE30 or SAE15W-40) (Water temp:Min.70ºC) {mmH2O} {100} {200} {100} {200}
At rated horsepower MPa 0.39 – 0.69 0.21 0.39 – 0.69 0.21
SAE30 or SAE15-40 oil {kg/cm2} {4.0 – 7.0} {2.1} {4.0 – 7.0} {2.1}
MPa 0.34 – 0.64 0.18 0.34 – 0.64 0.18
Lubrication system
{kg/cm2} {3.5 – 6.5} {1.8} {3.5 – 6.5} {1.8}

(Oil temperature:
At low idling MPa Min. 0.15 0.08 Min. 0.15 0.08
min.80ºC)
SAE30 or SAE15W-40 oil {kg/cm2} {1.5} {0.8} {1.5} {0.8}
MPa Min. 0.10 0.07 Min. 0.10 0.07
SAE10W oil
{kg/cm2} {1.0} {0.7} {1.0} {0.7}
All speed
Oil temperature ºC 90 – 110 120 90 – 110 120
(Oil in oil pan)
At continuous rated
Oil consumption ratio % Max.0.5 1.0 Max.0.5 1.0
MPa
Fuel injection pressure Nozzle tester — — — —

{kg/cm2}
Fuel injection timing B.T.D.C. degree — — — —

Radiator pressure valve — — — —
Fan speed At rated engine speed rpm — — — —
Fan belt tension mm — — — —
12-5-1 125-3 SERIES

(5)
SAA6D125E-3
WA470-5 WA480-5 HM300-1 PC400, 450-7
Standard Permissible Standard Permissible Standard Permissible Standard Permissible
value value value value value value value value
2,170 +20 2,170 +20 2,170 +20 2,170 +20 2,170 +20 2,170 +20 1,930±50 1,930±50
Performance
–80 –80 –80 –80 –80 –80
750 +500 750 +500 750 +500 750 +500 750 +500 750 +500 1,000±25 1,000±25
Min.100 — Min.100 — Min.100 — Min.100 —
Min.85 — Min.85 — Min.85 — Min.85 —

Max.2.94 7.47 Max.2.94 7.47 Max.2.94 7.47 Max.2.94 7.47
{300} {762} {300} {762} {300} {762} {300} {762}
Min.80 60 Min.80 60 Min.80 60 Min.107 87
{600} {450} {600} {450} {600} {450} {800} {650}
Min.80 73 Min.80 73 Min.80 73 Min.93 80

{600} {550} {600} {550} {600} {550} {700} {600}
Max.650 700 Max.650 700 Max.650 700 Max.700 700
Max.4.5 6.5 Max.4.5 6.5 Max.4.5 6.5 Max.4.0 6.0
Max.1.5 2.5 Max.1.5 2.5 Max.1.5 2.5 Max.1.5 2.5
Max.1.0 2.0 Max.1.0 2.0 Max.1.0 2.0 Max.1.0 2.0
0.33 — 0.33 — 0.33 — 0.33 —
0.71 — 0.71 — 0.71 — 0.71 —
Engine body
Min. 2.9 2.0 Min. 2.9 2.0 Min. 2.9 2.0 Min. 2.9 2.0
{30} {20} {30} {20} {30} {20} {30} {20}
Max. 0.98 1.96 Max. 0.98 1.96 Max. 0.98 1.96 Max. 1.18 1.96
{100} {200} {100} {200} {100} {200} {120} {200}
0.39 – 0.69 0.21 0.39 – 0.69 0.21 0.39 – 0.69 0.21 0.39 – 0.69 0.21
{4.0 – 7.0} {2.1} {4.0 – 7.0} {2.1} {4.0 – 7.0} {2.1} {4.0 – 7.0} {2.1}
0.34 – 0.64 0.18 0.34 – 0.64 0.18 0.34 – 0.64 0.18 0.34 – 0.64 0.18
Lubrication system
{3.5 – 6.5} {1.8} {3.5 – 6.5} {1.8} {3.5 – 6.5} {1.8} {3.5 – 6.5} {1.8}
Min. 0.15 0.08 Min. 0.15 0.08 Min. 0.15 0.08 Min. 0.15 0.08
{1.5} {0.8} {1.5} {0.8} {1.5} {0.8} {1.5} {0.8}
Min. 0.10 0.07 Min. 0.10 0.07 Min. 0.10 0.07 Min. 0.10 0.07
{1.0} {0.7} {1.0} {0.7} {1.0} {0.7} {1.0} {0.7}
90 – 110 120 90 – 110 120 90 – 110 120 90 – 120 120
Max.0.5 1.0 Max.0.5 1.0 Max.0.5 1.0 Max.0.5 1.0

— — — — — — — —
— — — — — — — —
— — — — — — — —
— — — — — — — —
— — — — — — — —
125-3 SERIES 12-5-2

(7)
Engine model SAA6D125E-3

Machine model HD255-5
Standard Permissible
value value
High idling speed rpm 2,420 +80
–20 2,420 +80
–20
Performance
Engine speed
Low idling speed rpm 750±50 750±50
Necessary starting 0ºC(Without starting aid) rpm Min.100 Min.100

speed
–20ºC(With starting aid) rpm Min.85 Min.85
kPa Max.3.72 7.47
{mmH2O} {Max.380} {762}
kPa Min.107 87
{mmHg} {Min.800} {650}
Exhaust pressure kPa Min.120 107
At rated horsepower
(Turbine inlet press.) {mmHg} {Min.900} {800}
ºC Max.700 700
Max.4.0 6.0
Bosch
Exhaust gas color At rated horsepower Max.1.5 2.5
index
Bosch
High idling speed Max.1.0 2.0
index
Valve clearance Intake valve mm 0.33 —

(Whel engine is hot
or cold) Exhaust valve mm 0.71 —

Engine body
Compression pressure MPa Min. 2.9 2.0

(Engine speed:
(SAE30 or SAE15W-40) {kg/cm2} {Min. 30} {20}
150 – 200 rpm)
Blow-by pressure At rated horsepower kPa Max. 0.98 1.96
(SAE30 or SAE15W-40) (Water temp:Min.70ºC) {mmH2O} {Max. 100} {200}
At rated horsepower MPa 0.39 – 0.69 0.21
SAE30 or SAE15-40 oil {kg/cm2} {4.0 – 7.0} {2.1}
MPa 0.34 – 0.64 0.18
Lubrication system
{kg/cm2} {3.5 – 6.5} {1.8}

(Oil temperature:
At low idling MPa Min. 0.15 0.08
min.80ºC)
SAE30 or SAE15W-40 oil {kg/cm2} {Min. 1.5} {0.8}
MPa Min. 0.10 0.07
SAE10W oil
{kg/cm2} {Min. 1.0} {0.7}
All speed
Oil temperature ºC 90 – 120 120
(Oil in oil pan)
At continuous rated
Oil consumption ratio % Max.0.5 1.0
MPa
Fuel injection pressure Nozzle tester — —

{kg/cm2}
Fuel injection timing B.T.D.C. degree — —

Radiator pressure valve — —
Fan speed At rated engine speed rpm — —
Fan belt tension mm — —
12-5-3 125-3 SERIES

(8)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Connector Inspetion Measurement

Name of component Judgement table
No. method conditions
If the condition is as shown in the table below, it is normal 1) Insert T-adapter to AS1.
Potentiometer 2) Turn starting switch ON.
Between (3) and (1) 4.6 – 5.4V

Between (2) and (3) 0.3 – 4.5V
Acceleration pedal Measure Switch

AS1
(throttle sensor) voltage Potentiometer
Pin Voltage
voltage
Between (5) Max. 0.446V Max. 1V
and (4) Min. 0.446V 15 – 30V
Between (6) Max. 0.446V 20 – 30V
and (4) Min. 0.446V Max. 1V
If the condition is as shown in the table below, it is normal 1) Turn starging switch OFF.
Engine Ne rotation NE Measure 2) Disconnect NE.
Between (1) and (2) 85Ω – 210Ω
sensor (male) resistance
Between (1), (2) and ground Min. 1MΩ
If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF.
Engine G rotation G Measure 2) Disconnect G.
Between (1) and (2) 1.4kΩ – 3.5kΩ
2) Disconnect PSL.
Resistance
Position Engine
value
Engine oil PSL Measure
Engine
low-pressure switch (terminal) resistance Between switch Max. 1Ω
stopped
terminal and
600rpm
ground Min. 1MΩ
and above
2) Disconnect PSH.
Resistance
Position Engine
value
Engine oil PSH Measure
Engine
high-pressure switch (terminal) resistance Between switch Max. 1Ω
stopped
terminal and
1,300rpm
ground Min. 1MΩ
and above
Engine water
TWL Measure 2) Disconnect TWL.
low-temperature Between (1) and (2) 9kΩ – 0.3kΩ
(male) resistance
sensor Between (1), (2) and ground Min. 1MΩ
Engine water
TWH Measure 2) Disconnect TWH.
high-temperature Between (1) and (2) 90kΩ – 3.5kΩ
(male) resistance
sensor Between (1), (2) and ground Min. 1MΩ
Fuel temperature THL Measure 2) Disconnect THL.
Between (1) and (2) 9kΩ – 0.3kΩ
12-6 125-3 SERIES

3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Connector Inspetion Measurement

Name of component Judgement table
No. method conditions
2) Disconnect OF.
Resistance
Position Oil filter
Engine oil filter clog- OF Measure value
ging switch (terminal) resistance Between When normal Max. 1Ω
switch terminal
and ground When clogged Min. 1MΩ
2) Disconnect OL.
Resistance
Position Oil filter
Measure value
Engine oil level switch OL (male)
resistance When normal Max. 1Ω
Between (1)
and ground When low Min. 1MΩ
If the condition is as shown in the table below, it is normal 1) Insert T-adapter to PIM.
Boost pressure Measure 2) Turn starting switch ON.
PIM (male) Between (1) and (3) 4.6 – 5.4V
sensor voltage
Between (2) and (3) 0.3 – 4.7V
If the condition is as shown in the table below, it is normal 1) Insert T-adapter to

Common rail fuel PFUEL Measure PFUEL.
Between (1) and (3) 4.6 – 5.4V
pressure sensor (male) voltage 2) Turn starting switch ON.
Between (2) and (3) 0.3 – 4.7V
Fuel supply pump PCV1 Measure 2) Disconnect PCV1.
Between (1) and (2) 2.3 – 5.3Ω
PCV1 (male) resistance
Between (1), (2) and ground Min.1MΩ
Fuel supply pump PCV2 Measure 2) Disconnect PCV2.
Between (1) and (2) 2.3 – 5.3Ω
PCV2 (male) resistance
CN1 Measure 2) Disconnect CN1.
No.1 injector solenoid Between (1) and (2) 0.4 – 1.1Ω
(male) resistance
(male) resistance
(male) resistance
(male) resistance
(male) resistance
(male) resistance
125-3 SERIES 12-7

3
TESTING AND ADJUSTING TESTING AND ADJUSTING TOOL LIST
TESTING AND ADJUSTING TOOL LIST

Check or adjustment item Symbol Part Number Part Name Remarks
Digital display
Multi-tachome-
Engine speed A 799-203-8001 L:60 – 2,000 rpm
ter
H:60 – 19,999 rpm
Specific gravity of battery elec-
Battery, cool- 1.100 – 1.300
trolyte B 795-500-1001
ant tester
Coolant freezing temperature –5 to –50ºC
Water, oil, intake and exhaust
C 799-101-1502 Thermometer –99.9 – 1,299ºC
temperatures
Pressure
1 799-401-2320 1 MPa {10 kg/cm2}
gauge
Lubricant pressure D
799-101-5150 Hose Hydro tester kit
2
790-261-1150 Hose 799-101-5002
Air supply pressure (boost pres-
E 799-201-2201 Boost gauge kit –760 – 1500 mmHg
sure)
Blow-by
Blow-by pressure F 799-201-1504 0 – 1,000 mmAq
checker
Gauge assem- Kit Part No.795-502-1205
1 795-502-1590
bly 0 – 6.9MPa{0 – 70kg/cm2}
Compression pressure
In-line fuel injection pump
G 2 795-502-1360 Adapter
specification
Common rail system
3 795-471-1410 Adapter
specification
Commercially
Valve clearance H Feeler gauge 0.33, 0.71 mm
available
Handy smoke Discoloration 0 – 70%
1 792-201-9000
tester (With standard color)
Exhaust color I
Commercially (Discoloration x 1/4
2 Smoke meter Bosch index)
available
Engine oil Water content 0.1%,
Water, fuel in oil J 799-201-6000
checker 0.2% standard sample
Fuel injection pressure Commercially 0 – 39.2MPa
K Nozzle tester
Nozzle spray condition available {0 – 400kg/cm2}
PH, nitrous acid ion
Quality of coolant L 799-202-7002 Water tester
density
Pressure valve function Radiator cap 0 – 0.2MPa
M 799-202-9001
Leakage from cooling system tester {0 – 2kg/cm2}
Anemometer
Clogging of radiator N 799-202-2001 1 – 40m/s
(wind speed)
Engine with DC24V
Engine cranking O 795-610-1000 Cranking kit
starting motor
Gauge assem-
Adjusting injection timing P 795-471-1200
bly
Commercially
Electric circuit Q Tester
available
12-8 125-3 SERIES

2
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOT PRESSURE)
MEASURING INTAKE AIR PRESSURE

(BOOT PRESSURE)
IN-LINE FUEL INJECTION PUMP COMMON RAIL SYSTEM SPECIFICATION
SPECIFICATION 1. Switch to the monitoring function of Service
k When removing or installing the measuring Mode 1 and display the air supply pressure. For
equipment, be careful not to touch any high tem- details, see SPECIAL FUNCTIONS OF
perature parts. MACHINE MONITOR in the TROUBLESHOOT-
1. Remove intake air pressure measurement plug ING section.
(1)(PT 1/8) and install coupler (2) of oil pressure
★ Monitoring item: Boost pressure
gauge kit.
2. Start the engine.

2. Connect oil pressure measurement hose (3) to
3. Turn the transmission cut-off selector switch (1)
c oupler (2) and pres sure gauge E (1500
OFF and depress the left brake securely.
mmHg).
k When carrying out the measurement, be
4. Place the speed lever at F4 or R4.
careful not to touch any high temperature • Turn the transmission manual switch ON
parts or rotating parts. and place the speed lever at F4 or R4.
Note:
5. Release the parking brake.
Run the engine at a mid-range speed or above, and
use the self-seal portion of the gauge to bleed the oil 6. Depress the accelerator pedal gradually, and
from inside the hose. measure the air supply pressure at the rated
• Insert the gauge about half way, and repeat- speed when the torque converter stalls.
edly open the self-seal portion to bleed the
oil.
★ The gauge does not work if there is any oil in-
side the hose, so always be sure to bleed all
the oil.
3. Run the engine at the rated speed and measure

the pressure indicated by the gauge.
125-3 SERIES 12-9

2
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE
k Wait for the temperature of the exhaust pipe to

go down before installing or removing the meas-
uring equipment.
1. Remove the adiabatic cover, then remove

exhaust temperature measurement plug (1).
3. When measuring the exhaust temperature at

torque converter stall, do as follows.
• To prevent overheating of the torque con-
verter, stabilize the exhaust temperature at
full stall (torque converter stall + hydraulic
stall), then stall the torque converter only and
2. Install sensor (2) and connect to digital tempera- measure the temperature.
ture gauge C. 1) Start the engine and raise the cooling water
temperature to the operating range.
★ Be careful not to let the wiring harness of the
temperature gauge touch the high-temperature 2) Turn the transmission cut-off selector switch
portion. OFF and depress the left brake securely.
3) Place the directional lever at F4 or R4.
• Turn the transmission manual switch ON
and place the speed lever at F4 and R4.
4) Release the parking brake.
5) Depress the accelerator pedal gradually to
raise the engine speed to full throttle, stall
the torque converter, and extend boom cyl-
inder or bucket cylinder at the same time to
relieve the circuit.
★ Continue until the exhaust temperature
is around the standard value of 650 °C.
k Do not keep the stall condition for more

than 20 seconds. Make sure that the
torque converter oil temperature does
not exceed 120 °C.
12-10 125-3 SERIES

2
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
6) When the temperature becomes stable at

around the target temperature, cancel the
hydraulic relief, carry out only torque con-
verter stall, and measure the exhaust tem-
perature.
★ The exhaust temperature at full stall will
start to go down, so measure the tem-
perature when it becomes stable.
★ If the exhaust temperature does not go
down and continues to go up, make the
temperature setting at full stall higher.
4. When measuring maximum value for exhaust
gas temperature, carry out actual work and
measure the maximum value when operating.
★ Use the PEAK mode function (the maximum
value can be recorded) of the temperature
gauge.
★ The exhaust temperature differs greatly ac-
cording to the ambient temperature (engine
intake temperature), so if an abnormal value
is recorded, compensate for the tempera-
ture.
★ Compensation temperature value = meas-
ured value + 2 x (converted ambient temper-
ature – ambient temperature).
• The converted ambient temperature is
taken as 20 °C.
125-3 SERIES 12-11

2
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

1. Remove the cylinder head cover. ★ To adjust the valve clearance, loosen lock
nut (8) on adjustment screw (7), insert Feeler
2. Rotate the crankshaft in the normal direction, gauge H corresponding to the specified
and set the No. 1 cylinder to the compression top clearance between crosshead (6) and rocker
dead center. While doing this, watch the move- arm (5), and adjust the clearance with the
ment of the intake valves of No. 6 cylinder. Align adjustment screw until the thickness gauge
pointer (3) with the 1.6 TOP line on the vibration can slide lightly.
damper (2).
★ When the No. 1 cylinder comes near the top
dead center of the compression stroke, the
No. 6 intake valve will start to move (open).
3. Adjust the valve clearance for valves marked

in the valve arrangement chart.
4. Rotate the crankshaft in the normal direction by

one revolution and adjust the valve clearance for
the remaining valves marked .
5. After the clearance is properly adjusted, tighten

the lock nut to secure the adjustment screw.
3 Lock nut: 59 ± 6 Nm {6.0 ± 0.6 kgm}
★ The engine firing order is 1 - 5 - 3 - 6 - 2 - 4.

★ Intake and exhaust valve clearances may be ad-
justed for each cylinder in the firing order by ro-
tating the crankshaft 120° at a time in the normal
direction.
★ For details about valve clearance, see TESTING
AND ADJUSTING DATA.
12-12 125-3 SERIES

2
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
COMMON RAIL SYSTEM SPECIFICATION 4. To adjust the valve clearance, insert feeler
gauge H into clearance b between rocker arm
1. Disconnect 6 fuel high-pressure tubes (1). (4) and crosshead (5), and adjust the valve
• Remove the tube clamps also. clearance with adjustment screw (6).
★ Insert the feeler gauge and turn the adjust-
ment screw until the clearance is a sliding fit.
2. Remove cylinder head cover.

3 Head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm} 5. Hold adjustment screw (6) in position and
tighten locknut (7).
3 Locknut:
3. Rotate the crankshaft in the normal direction,
and align 1.6 line a on the damper with pointer 53.0 – 64.7 Nm {5.4 – 6.6 kgm}
(3) to set the No. 1 cylinder to compression top ★ After tightening the locknut, check the clear-
dead center. ance again.
★ At compression top dead center, the rocker
arm can be moved by hand by the amount of
the valve clearance. If the rocker arm does
not move, the crankshaft is not at compres-
sion top dead center, so rotate it one more
turn.
6. Rotate the crankshaft 120° each time in the nor-

mal direction and repeat the procedure in Steps
4 to 6 to adjust the clearance of the intake and
exhaust valves of each cylinder according to the
firing order.
★ Firing order: 1-5-3-6-2-4
7. After completing the measurement, return to the

original condition.
★ For details of the assembly of the fuel high-
pressure tube, see DISASSEMBLY AND
ASSEMBLY.
125-3 SERIES 12-13

2
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

k While measuring the compression pressure, 4. Install adapter G2 to the nozzle holder mounting
take care not burn yourself on the exhaust man- section of the cylinder to be measured, and tight-
ifold or muffler, and be careful not to get caught en the adapter to the specified torque.
in any revolving part of the engine.
★ Measure the compression pressure while the en- 3 Adapter: 21.6 ± 2.9 Nm {2.2 ± 0.3 kgm}
gine is warm.
(Engine oil temperature: 40 – 60ºC)
1. Adjust the valve clearance properly. For details,

see ADJUSTING VALVE CLEARANCE.
2. Remove spill tube (1) and disconnect fuel injec-
tion pipe (2).
5. Connect compression gauge G1 to the adapter.
3. Remove nozzle holder assembly (3) for each

cylinder.
★ Remove the nozzle holder assembly by pry-
ing it with two mounting bolts.
★ Take care not to let any dirt or foreign matter
get into the cylinder.
6. Place the fuel control lever in NO INJECTION

position, crank the engine with the starting motor,
and read the gauge when the pointer is stabi-
lized.
k If you do not put the fuel control lever in NO IN-

JECTION position, fuel will blow out.
★ Most compression leakage can be prevent-

ed by applying a small amount of oil to the
mounting section of the adapter.
★ For the reference values of the compression
pressure, see TESTING AND ADJUSTING
DATA.
12-14 125-3 SERIES

2
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
COMMON RAIL SYSYTEM SPECIFICATION

k When measuring the compression pressure, be 4. Fit adapter G3 and connect to compression
careful not to touch the exhaust manifold of muf- gauge G1.
fler and burn yourself, or to get caught in any ro-
★ Coat the connection of the adapter and
tating parts.
gauge with a small amount of engine oil to
make leakage more difficult.
★ Secure the adapter with the injector holder.
★ Measure the compression pressure with the en-
gine warmed up (engine oil temperature: 40 – 60 3 Mounting bolt:
°C). 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
1. Disconnect 6 fuel high-pressure tubes (1).
• Remove the tube clamps also.
5. Disconnect 2 engine centralized connectors (4) .

k If the connectors are not disconnected, there is
a danger that the engine may start during the
2. Remove cylinder head cover. measurement, so disconnect them without fail.
k Cover the connector at the controller end with
3 Head cover mounting bolt:
vinyl to prevent short circuits and leakages of
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
electricity.
3. Remove injector wiring harness and fuel injector
(3).
6. Crank the engine with the starting motor and

measure the compression pressure.
★ Measure the compression pressure at the
point where the compression gauge indica-
tor remains steady.
7. After completing the measurement, remove the
measuring equipment and return to the original
condition.
★ For details of the assembly of the fuel injec-
tor and fuel high-pressure tub, see DISAS-
SEMBLY and ASSEMBLY.
125-3 SERIES 12-15

2
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE
1. Install nozzle 1 and hose 2 to blow-by hose 6. Depress the accelerator pedal gradually to raise
(1), and connect to blow-by checker F. the engine speed to full throttle, and measure
the blow-by pressure when the torque converter
stalls.
k Do not keep the stall condition for more than
20 seconds. Make sure that the torque con-
verter oil temperature does not exceed 120
°C.
★ Precautions when measuring blow-by

Blow-by varies greatly according to the con-
dition of the engine. Therefore, if the blow-by
value is considered abnormal, check for
problems connected with defective blow-by,
such as excessive oil consumption, defec-
tive exhaust gas color, and prematurely dirty
2. Run the engine and raise the coolant tempera- or deteriorated oil.
ture to the operating range.
3. Turn the transmission cut-off selector switch
OFF and depress the left brake securely.
4. Place the speed lever at F4 and R4.
• Turn the transmission manual switch ON
and place the speed lever at F4 and R4.
5. Release the parking brake.
12-16 125-3 SERIES

2
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE
1. Remove engine oil pressure switch (1).or engine 3. Run the engine and raise the coolant tempera-
oil pressure measuring plug. ture to the operating range.
4. Measure the oil pressure with the engine at low
idling and high idling.
2. Install nipple 1 and hose D2, and connect oil

pressure gauge D1.
★ Use a 0.98 MPa {10 kg/cm2} oil pressure 5. After completing the measurement, remove the
gauge. measuring equipment and return to the original
condition.
125-3 SERIES 12-17

2
TESTING AND ADJUSTING MEASURING FUEL PRESSURE
MEASURING FUEL PRESSURE

★ When measuring the fuel pressure, measure 4. Run the engine and measure the fuel pressure
only the low pressure circuit between the feed at high idling.
pump - fuel filter - fuel supply pump.
★ For details of the standard value, see Trou-
k Extremely high pressure is generated in the
bleshooting of Engine Controller System.
high-pressure circuit between the fuel supply
pump - common rail - fuel injector, so it cannot
be measured.
1. Open the engine right side cover.

2. Remove the fuel pressure measurement plug
(1).
5. After completing the measurement, remove the

measuring equipment and return to the original
condition.
3. Install nipple 1 and hose D2, and connect oil

pressure gauge D1.
★ Use a 0.98 MPa {10 kg/cm2} oil pressure
gauge.
12-18 125-3 SERIES

2
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR
★ G speed sensor (CN-G) and Ne speed sensor

(CN-NE) for the engine controller of common rail
system specification cannot be adjusted.
★ Adjust the engine speed sensor (CN-EREV) as
follows.
1. Screw in until the tip of sensor (1) contacts the

tip of the tooth of flywheel ring gear (2).
★ Check that there are no scratches or metal
particles stuck to the tip of the sensor.
2 Thread portion: Hydraulic sealant
2. Turn sensor (1) back 1/2 - 2/3 turns from that

position.
★ Adjust clearance a between the tip of the
sensor and the tip of the gear tooth is 0.75 –
1.00 mm.
3. Secure sensor (1) with nut (3).
3 Nut:69 – 74 Nm {7.0 – 7.5 kgm}
125-3 SERIES 12-19

2
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING

There are the following methods for testing and 2) Align No. 1 cylinder with the compression
adjusting the fuel injection timing of the injection top dead center line (1 : 6).
pump. • When doing this, check that fuel injection
• When assembling to the same engine without timing line on the fuel injection pump
repairing the injection pump, adjust by aligning is near line on the fuel injection pump
the match marks. body.
• When replacing with a new injection pump, or
when installing a repaired injection pump, adjust
using the delivery valve method.
★ If the delivery valve method is used, the copper
gasket and O-ring for the delivery valve must be
replaced with new parts, so have new parts avail-
able when using this method.
★ Set the No. 1 cylinder to the compression top
dead center before testing and adjusting.
Testing and adjusting fuel injection timing

by aligning match marks
1. Testing fuel injection timing by aligning

match marks 3) Set dial gauge P to the nozzle holder hole
1) Disconnect spill tube (1) and delivery tube where the nozzle holder assembly has been
(2) of the No. 1 piston, then remove No. 1 removed.
nozzle holder assembly (3).
12-20 125-3 SERIES

2
4) Put the tip of dial gauge P in contact with the 7) Check that fuel injection timing line on
top center of the piston, then set the scale the fuel injection pump is aligned with line
on dial gauge P to 0 when the piston is at on the fuel injection pump body.
the top dead center.
★ Rotate the crankshaft in the normal di-
rection and in the reverse direction to
align the top dead center.
★ Record the value indicated by the short
indicator on dial gauge P.
5) Rotate the crankshaft approx. 45º in the
reverse direction from the No. 1 cylinder
TOP position.
6) Rotate the crankshaft again slowly in the
normal direction and set to the specified
dimension (piston displacement).
★ Always rotate the crankshaft in the nor-
mal direction to align the position.
★ For details of the specified dimension
(piston displacement), see the table be-
low.
★ For details of the fuel injection timing,
see TESTING AND ADJUSTING, Stan-
dard values for testing, adjusting, and
troubleshooting.
Piston displacement for each fuel injection

timing
Machine Injection Piston

Model timing displacement
WA430-5 BTDC8º ± 1º 0.96 ± 0.20 mm
125-3 SERIES 12-21

2
2. Adjusting fuel injection timing 4) Remove spring (3), delivery valve (4), and
If the lines are not aligned, loosen mounting bolt stopper (6) from delivery valve holder (2),
(4) and move coupling (5) to align lines and then assemble delivery valve holder (2)
, then tighten bolt (4). again.
3 Bolt (4): 88.3 ± 4.9 Nm {9 ± 0.5 kgm} 5) Set the fuel control lever at the FULL posi-
tion, then operate the priming pump and
rotate the crankshaft slowly in the normal
direction. Check the point where the fuel
stops flowing from the delivery valve holder.
Testing and adjusting fuel injection timing

with delivery valve method
★ If the delivery valve method is used, the copper
gasket and O-ring for the delivery valve must be
replaced with new parts, so have new parts avail-
able when using this method.
1. Testing fuel injection timing with delivery

valve method
1) Set with the No. 1 cylinder at the TOP posi-
tion, then rotate the crankshaft 30 – 40º in
the reverse direction.
2) Disconnect fuel injection tube (1) of No. 1
cylinder.
3) Remove delivery valve holder (2).
12-22 125-3 SERIES

2
6) Check that fuel injection timing line on 2) Align No. 1 cylinder with the compression
the fuel injection pump is aligned with line top dead center line (1 : 6).
on the fuel injection pump body at the • When doing this, check that fuel injection
point where the fuel stops flowing. timing line on the fuel injection pump
★ BEYOND injection timing line: is near line on the fuel injection pump
Timing RETARDED body.
★ BEFORE injection timing line:
Timing ADVANCED
3) Set dial gauge P to the nozzle holder hole

where the nozzle holder assembly has been
removed. (See the diagram.)
2. Adjusting fuel injection timing with delivery
valve method
If the results of the test show that the fuel injec-
tion timing is incorrect, adjust the fuel injection
timing as follows.
1) Disconnect spill tube (1) and delivery tube
(2) of the No. 1 piston, then remove No. 1
nozzle holder assembly (3).
125-3 SERIES 12-23

2
4) Put the tip of dial gauge P in contact with the 7) Loosen mounting bolt (4), move coupling (5)
top center of the piston, then set the scale to align lines and , then tighten bolt
on dial gauge P to 0 when the piston is at (4).
the top dead center. 3 Bolt (4):
★ Rotate the crankshaft in the normal direction 88.3 ± 4.9 Nm {9 ± 0.5 kgm}
and in the reverse direction to align the top
dead center.
★ Record the value indicated by the short indi-
cator on dial gauge P.
8) Set with the No. 1 cylinder at the TOP posi-

tion, then rotate the crankshaft 30 – 40º in
the reverse direction. Set the fuel control
lever at the FULL position, then operate the
5) Rotate the crankshaft approx. 45º in the priming pump and rotate the crankshaft
reverse direction from the No. 1 cylinder slowly in the normal direction.
TOP position. Check the point where the fuel stops flowing
from the delivery valve holder.
6) Rotate the crankshaft again slowly in the
★ Check that fuel injection timing line on the
normal direction and set to the specified
fuel injection pump is aligned with line on
dimension (piston displacement).
the fuel injection pump body at the point
★ Always rotate the crankshaft in the nor-
where the fuel stops flowing.
mal direction to align the position.
★ For details of the specified dimension
(piston displacement), see the table be-
low.
★ For details of the fuel injection timing,
see TESTING AND ADJUSTING, Stan-
dard values for testing, adjusting, and
troubleshooting.
Piston displacement for each fuel injection

timing for 125E-3 engine
Injection timing Piston displacement

BTDC8º ± 1º 0.96 ± 0.20 mm
9) Repeat Steps 1) – 5) of "Adjusting fuel injec-
tion timing with delivery valve method" to
check that the fuel stops flowing from the
delivery valve holder.
12-24 125-3 SERIES

2
10) Remove delivery valve holder (2), assemble

delivery valve (4), spring (3), and stopper
(6), then assemble the delivery valve holder
to the fuel injection pump again.
3 Delivery valve holder:
98.0 ± 9.8 Nm {10.0 ± 1.0 kgm}
11) Fit nozzle holder assembly (3), then install

spill tube (1) and fuel injection tube (2).
3 Nozzle holder mounting bolt:
21.6 ± 2.9 Nm {2.2 ± 0.3 kgm}
3 Spill tube joint bolt:
12.3 ± 2.5 Nm {1.25 ± 0.25 kgm}
125-3 SERIES 12-25

2
TESTING AND ADJUSTING HANDLING EQUIPMENT IN FUEL SYSTEM
HANDLING EQUIPMENT IN RELEASING REMAINING

FUEL SYSTEM PRESSURE IN FUEL SYSTEM
COMMON RAIL SYSTEM SPECIFICATION COMMON RAIL SYSTEM SPECIFICATION
★ Precautions for inspection and maintenance of ★ When the engine is running, pressure is generat-
fuel system. ed in both the low-pressure circuit and the high-
The common rail type fuel injection system is pressure circuit of the fuel line.
constructed of more precise components than Low-pressure circuit: Feed pump - fuel filter -
the conventional fuel injection pump and nozzle, fuel supply pump
so problems may occur if dirt or dust get in. High-pressure circuit: Fuel supply pump - com-
When carrying out inspection and maintenance mon rail - fuel injector
of the fuel system, pay more attention than ★ For both the low-pressure circuit and high-pres-
usual to prevent dirt or dust from getting in. If sure circuit, the pressure automatically goes
there is any dirt stuck to any part, use clean fuel down to a safe level 30 seconds after the engine
to wash it off completely is stopped.
★ Precautions when replacing fuel filter cartridge. ★ The remaining pressure in the fuel system must
Always use a genuine Komatsu part for the fuel be completely released before carrying out in-
filter cartridge. spection of the fuel system or removal or instal-
The common rail type fuel injection system is lation of the equipment. Always follow the
constructed of more precise components than following precautions when carrying out the op-
the conventional fuel injection pump and nozzle, eration.
so a special filter with high efficiency filtering
ability is used to prevent dirt or dust from getting k When inspecting the fuel line or remov-
in. ing or installing equipment, wait for at
For this reason, if any filter is used as a substi- least 30 seconds after the engine is
tute for the genuine filter, there is danger that stopped, and release the remaining
problems will occur with the fuel system. To pre- pressure in the fuel system before
vent this, never use such filters. starting the operation. (There is still
pressure remaining in the circuit, so do
not start the operation immediately
after the engine is stopped.)
12-26 125-3 SERIES

2
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT

★ Bleeding the air as follows if the engine has run

out of fuel or the fuel circuit equipment has been
removed and installed.
1. Remove fuel filter (1), fill with fuel, then install

again.
★ When filling, use clean fuel and be careful
not to let dirt get in.
★ Add fuel through inlet port prtion a (8 places)
of the filter. Portion b is the outlet port (clean
side) after the fuel has been filtered, so never
add fuel from here.
★ If clean fuel is not available, do not remove
the filter. Operate the priming pump to fill the
filter with fuel.
125-3 SERIES 12-27

2
BLEEDING AIR FROM FUEL CIRCUIT
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN FUEL SYSTEM
2. Remove air bleed plug (2) of the fuel filter and Air bleeding steps
operate priming pump (4). i) Remove air bleeding plug (2) of fuel filter (1)
and operate priming pump (4).
★ Cotinue operating the priming pump until
• Continue to operate the priming pump
flow out from the plug hole. When fuel
until fuel is confirmed to flow out of the
comes out, install the plug.
3 Air bleed plug:
air bleeding plug hole and then tighten it.
3 Air bleeding plug:
7.8 – 9.8Nm{0.8 – 1.0kgm}
7.8 – 9.8Nm{0.8 – 1.0kgm}
3. There are the following two cases that the
ii) Remove fuel pressure measuring plug (3)
engine does not start up easily after bleeding air
for the fuel filter and operate priming pump
from CRI, (Common Rail Injection System), i.e.
(4).
even after carrying out the Items 1 and 2 above.
• Continue to operate the priming pump
★ If air has not been removed completely, leav- until fuel is confirmed to flow out of the
ing some in the system, cranking up the en- air bleeding plug hole and then tighten it.
gine with the engine starting motor cannot 3 Fuel pressure measuring plug:
get rid of the remaining air in a short span of 3.9 – 6.9Nm{0.4 – 0.7kgm}
time. Thus the engine start-up becomes dif-
iii) Loosen air bleeder (5) of the fuel supply
ficult.
pump (only after loosening the lock nut) and
1) In the cases that the fuel has run out, that
operate priming pump (4) 90 to 100 times.
the fuel filter has been replaced or that
• Continue to operate the primng pump
some fuel device has been removed and
until fuel is confirmed to flow out of air
installed.
bleeder (5) and then tighten it.
• Most of the fuel is left in the fuel circuit, 3 Air bleeder:
so the engine may be started after 4.9 – 6.9Nm{0.5 – 0.7kgm}
bleeding air with the air bleeding meth-
ods introduced in the Items 1 and 2 • Still continue to operate the priming
above. pump until it becomes harder to operate
2) In the case that a number of fuel devices and a relief sound of overflow valve (6) in
have been removed and installed in course the fuel supply pump is heard. (A high
of engine overhauling. pitch sound) It requires approx. 50 times
• Little fuel is left in the fuel circuit, so air of operation to reach that stage.
cannot be get rid of completely with the iv) Push in the knob of priming pump (4) to
air bleeding methods introduced in the tighten it.
Items 1 and 2 above (i.e. ordinary meth- v) Crank up the engine with the engine starting
od). In that case, bleed air in the follow- motor for start-up.
ing manner. ★ Do not keep the engine starting motor run-
ning idly for more than 20 seconds. Moreo-
ver try to start up the engine only after two
minute pause.
★ If the engine does not start up even after re-
peating to crank for 20 seconds 4 times, in-
sufficient air bleeding is suspected of. In that
case, start the air bleeding steps once again
from the beginning.
12-28 125-3 SERIES

2
TESTING AND ADJUSTING REDUCED CYLINDER MODE OPERATION FOR ENGINE
4. Loosen air bleeder (5) of the fuel supply pump

and operate priming pump (4) 90 to 100 times.
REDUCED CYLINDER MODE
OPERATION FOR ENGINE
★ Continue operating the priming pump until
fuel flows out from the bleeder. COMMON RAIL SYSTEM SPECIFICATION
When fuel comes out, tighten the bleeder, ★ Reduced cylinder mode operation for the engine
then operate several times until the priming means setting the fuel injectors of a single cylin-
pump becomes stiff.
3 Air bleeder:
der or multiple cylinders electronically to the NO
injection condition to run the engine on a reduced
4.9 – 6.9Nm{0.5 – 0.7kgm} number of cylinders. The reduced cylinder mode
operation is used when it is thought that one of
5. Crank the engine with the starting motor and the engine cylinders is not giving normal output
start the engine. (combustion). It is a method to determine which
★ When the engine is cranked, the air in the cylinder is not operating normally.
high-pressure circuit is automatically bled. ★ The reduced cylinder mode operation is carried
★ If the engine does not start, the air has prob- out by using the reduced cylinder mode opera-
ably been not properly bled from the low- tion setting function on the monitor panel.
pressure circuit, so repeat the procedure ★ For details of the method of operation, see the
from Step 2. TROUBLESHOOTING of chassis volume, Moni-
tor panel display and special functions.
125-3 SERIES 12-29

2
TESTING AND ADJUSTING CHECKING FOR LEAKAGE IN FUEL SYSTEM
CHECKING FOR LEAKAGE IN FUEL SYSTEM

k With the fuel system, the high-pressure circuit is 4. Start the engine and run it at high idling.
under extremely high pressure, so if fuel leaks 1) Check the fuel piping and equipment for fuel
when the engine is running, there is danger of leakage.
fire. ★ Check the high-pressure circuit for fuel leak-
age, particularly at the places sprayed with
Check for fuel leakage as follows when checking the color checker.
fuel circuit or when equipment has been removed ★ If there is fuel leakage, carry out repairs, then
and installed. repeat the check from Step 1.
k Never attempt to approach high-pressure piping 5. Start the engine, run it at high idling, then apply
connections until the check for fuel leakage is load to the engine.
completed. ★ Extend the boom cylinder and relieve the cir-
cuit.
★ To make it easier to check for fuel leakage, wipe 1) Check the fuel piping and equipment for fuel
the engine itself and the surrounding area clean leakage.
and remove all oil and grease before starting the ★ Check the high-pressure circuit for fuel leak-
inspection. age, particularly at the places sprayed with
color checker.
1. Thoroughly clean and remove all oil and grease, ★ If there is fuel leakage, carry out repairs, then
then spray the fuel supply pump, common rail, repeat the check from Step 1.
fuel injector, and high-pressure piping connec- ★ If no fuel leakage is found, the check is com-
tions with a color checker (developing solution). plete.
2. Start the engine, run it at under 1000 rpm, and
when the speed stabilizes, stop the engine.
1) Check the fuel piping and equipment for fuel
leakage.
★ Check the high-pressure circuit for fuel leak-
color checker.
★ If there is fuel leakage, carry out repairs, then
repeat the check from Step 1.
3. Start the engine and run it at low idling.
1) Check the fuel piping and equipment for fuel
leakage.
★ Check the high-pressure circuit for fuel leak-
color checker.
★ If there is fuel leakage, carry out repairs, then
repeat the check from Step 1.
12-30 125-3 SERIES

2
TESTING AND ADJUSTING ADJUSTING ENGINE STOP MOTOR LEVER
ADJUSTING ENGINE STOP MOTOR LEVER

1. Temporarily install ball joint (3) to cable (2) of en- 3. Adjust so that clearance a between stop lever (4)
gine stop motor (1) (tighten fully, then turn back of the fuel injection pump and STOP stopper (5)
approx. 1/2 turn), then install a ball joint to the is 1 – 2 mm.
stop lever of the fuel injection pump. Carry out the adjustment with nut (6) holding the
cable to the bracket, or make fine adjustments
by changing the amount that ball joint (3) is
screwed in.
2. Pull injection pump stop lever (4) by hand to the

ENGINE STOP (NO INJECTION) position, and
temporarily assemble the cable to the bracket.
When doing this, put stop lever (4) in contact with
ENGINE STOP stopper (5), and temporarily fit
the cable to the bracket using lock nut (6).
★ Engine stop motor (1) is delivered with cable

(2) pulled (ENGINE STOP position).
★ Stop lever (4) of the fuel injection pump is at
the RUN position when the lever is free. (It is
pulled to the RUN position by a spring.)
125-3 SERIES 12-31

2
TESTING AND ADJUSTING ADJUSTING ENGINE STOP MOTOR LEVER
4. Tighten all bolts and nuts. ★ Problems caused by defective adjustment of

the engine stop motor cable.
5. Turn the engine starting switch ON and OFF re-
peatedly, and check that engine stop motor (1) • When the clear- • Engine does not
and the cable move smoothly. Then check the ance between stop
following points again. the stop lever
1) When the engine is running, check visually and STOP stop-
that there is slack in the engine stop motor per is excessive
cable, and that the stop lever of the fuel with the engine
injection pump is fully returned to the RUN stop motor cable
position. pulled
2) Check again that the clearance between the • When the clear- • Fuel injection
stop lever and the STOP stopper is 1 – 2 ance between amount drops,
mm when the engine is stopped. the stop lever causing loss of
★ The engine stop motor has limit switches and the RUN engine output
built in at both ends of the cable stroke. stopper is exces-
★ Engine stop motor stroke: 35 mm sive at the free
Fuel injection pump stop lever stroke: 30 mm position
★ When the engine is running, there is slack in

the engine stop motor cable, and the RUN
position is maintained by the action of a
spring (this is frequently built into the fuel in-
jection pump).
★ There is a loose spring inside the engine
stop motor, and this absorbs the tolerance of
the stop motor when the engine is stopped.
However, if it is absorbed by the loose spring
of the engine stop motor, force is applied to
the injection pump, so depending on the
model, this may be impossible.
With such models, if the clearance between
the stop lever and the STOP stopper is made
0 when the engine is stopped, there is a risk
that problems may occur with the injection
pump.
12-32 125-3 SERIES

2
TESTING AND ADJUSTING CALIBRATION DATA
CALIBRATION DATA
injection pump part Engine serial

Engine Applicable machine Page
number number
WA430-5 6156-71-1210 12-51
SAA6D125E-3
12-50 125-3 SERIES

(7)
TESTING AND ADJUSTING CALIBRATION DATA
(CALIBRATION DATA)
Injection Pump Assembly Number
6156-71-1210 (106691-4110) Applicable Machine Applicable Engine
( ): Injection pump manufacturer’s part No. Model Serial No. Model Serial No.
WA430-5 SAA6D125E-3
Injection Injection pump
Pump Type manufacturer
PE-P (PS3) BOSCH
Injection pump specification Engine Specification

Rotating direction Counterclockwise Flywheel horsepower (kW {HP}) / rpm 174 {233}/2,000 (Gross)
Injection order 1–5–3–6–2–4 Maximum torque (Nm {kgm} / rpm) 941 {96}/1,400(Gross)
Injection interval 59°30’ – 60°30’ High idling speed (rpm) 2,250 ± 50
Plunger pre-storoke (mm) 3.0 – 4.5 Low idling speed (rpm) +50
770 0
Delivery valve Pump tester capacity for

(mm3/st) 90 Motor 7.5 kW
retraction volume Service standard
Calibration Standard ( ): Injection pump manufacturer’s part number

Service standard Manufacturer standard
Conditions Nozzle & nozzle holder part No. (105780-8140) 6156-11-3200 (105111-5090)
• Service standard Nozzle part No. (105780-0000) 6156-11-3220 (105025-4060)
indicates data using Nozzle holder part No. (105780-2080) 6152-12-3110 (105041-7130)
calibration test parts. Injection pipe
(mm) 8 X 3 X 600 6 X 2.2 X 790
• Manufacturer (Outside dia. x inside dia. x length)
standard is data for Test oil ASTM D975 No.2 diesel fuel or equivalent
factory test. Oil temperature (°C) 40 to 45
Nozzle opening pressure (MPa{kg/cm2}) 17.2{175} 27.5{280}
Transfer pump pressure (kPa{kg/cm2}) 255{2.6} 255{2.6}
Service standard (cc/1000 st.) Manufacturer standard (cc/ st)
Rack Pump
Injection volume Rack Maximum Maximum
position speed Injection Injection
• Rack positions point variance variance
(mm) (rpm) volume volume
B to E are the between cylinder between cylinder
reference volume A
12.3 1000 149 ± 2 ±3
when adjusting the (Basic point)
injection volume. B 12.3 700 165 ± 3 ±4
• Marks are C 7.2 400 21 ± 1.5 ± 15
average volumes. D — 100 150 ± 10 —
E
Governor performance curve Boost compensator performance curve
125-3 SERIES 12-51

(8)
TESTING AND ADJUSTING PERFORMANCE TEST
RUN-IN STANDARD
Machine Order
Engine Item
model 1 2 3 4 5 6
Running time min 2 8 2 3 5
Engine speed rpm 770 1,000 1,200 1,500 2,000
WA430-5 Dynamometer N{kg} 0{0} 304{31} 608{62} 961{98} 1,210{123}
load
Output kW{HP} 0{0} 23{31} 55{73} 108{145} 181{243}
Running time min
Engine speed rpm
Dynamometer N{kg}
load
Output kW{HP}
Running time min
Engine speed rpm
Dynamometer N{kg}
load
Output kW{HP}
SAA6D125E-3
Running time min
Engine speed rpm
Dynamometer N{kg}
load
Output kW{HP}
Running time min
Engine speed rpm
Dynamometer N{kg}
load
Output kW{HP}
Running time min
Engine speed rpm
Dynamometer N{kg}
load
Output kW{HP}
+ The table gives the standard values for machines without fan.
+ The loads for the dynamometer are at an arm’s length of 716 mm.
12-70 125-3 SERIES

(8)
Machine Order
Engine Item
model 1 2 3 4 5 6
Engine speed rpm 825 1,000 1,200 1,500 1,950
D65EX-15
Dynamomter N{kg} 0{0} 215{22} 529{54} 843{86} 1,058{108}
D65PX-15
load
Output kW{HP} 0{0} 16.2{22} 47.8{64} 94.9{127} 154{206}
SA6D125E-3
Engine speed rpm 750 950 1,140 1,425 1,900
D85EX-15
Dynamomter N{kg} 0{0} 275{28} 686{70} 1,098{112} 1,363{139}
D85PX-15
load
Output kW{HP} 0{0} 20{27} 59{79} 117{157} 195{261}
Engine speed rpm 750 1,000 1,200 1,500 2,000
WA470-5 Dynamomter N{kg} 0{0} 275{28} 677{69} 1,080{110} 1,350{138}
load
Output kW{HP} 0{0} 21{28} 61{82} 121{163} 203{272}
Engine speed rpm 750 1,000 1,200 1,500 2,000
WA480-5 Dynamomter N{kg} 0{0} 284{29} 706{72} 1,120{114} 1,400{143}
load
Output kW{HP} 0{0} 21{29} 63.3{85} 126{169} 210{282}
Engine speed rpm 725 1,000 1,200 1,500 2,000
SAA6D125E-3 HM300-1 Dynamomter N{kg} 0{0} 333{34} 834{85} 1,330{136} 1,670{170}
load
Output kW{HP} 0{0} 25{34} 75{101} 150{201} 250{335}
Engine speed rpm 1,000 1,000 1,200 1,500 1,850
PC400-7
Dynamomter N{kg} 0{0} 340{35} 860{88} 1,380{141} 1,860{190}
PC450-7
load
Output kW{HP} 0{0} 25.7{34} 78.0{105} 155{208} 259{347}
Engine speed rpm 750 1,000 1,200 1,500 2,100
HD255-5 Dynamomter N{kg} 0{0} 304{31} 765{78} 1,226{125} 1,530{156}
load
Output kW{HP} 0{0} 23{31} 69{93} 138{185} 241{323}
+ The table gives the standard values for machines without fan.
+ The loads for the dynamometer are at an arm’s length of 716 mm.
125-3 SERIES 12-71

(8)
PERFORMANCE TEST STANDARDS

Machine Speed Dynamometer

Engine Test item Specification value
model (rpm) load (N {kg})
Rated horsepower 174 kW/2,000 rpm 2,000 ± 5 1,130 – 1,200

{234 HP/2,000 rpm} {115 – 122}
Max. torque 941 Nm/1,400 rpm 1,400 ± 100 1,280 – 1,350
{96 kgm/1,400 rpm} {130 – 138}
WA430-5
High idling speed 2,250 ± 50 rpm 2,250 ± 50 rpm —
+50 +50
Low idling speed 770 0 rpm 770 0 rpm —
Rated horsepower
Max. torque
High idling speed
Low idling speed
Rated horsepower
Max. torque
High idling speed
Low idling speed

SAA6D125E-3
Rated horsepower
Max. torque
High idling speed
Low idling speed
Rated horsepower
Max. torque
High idling speed
Low idling speed
Rated horsepower
Max. torque
High idling speed
Low idling speed
★ This table shows the standard values using the JIS correction factor.
★ The output and torque values in the table are the standard values with the fan removed, so they are different
from the specification values.
★ The table shows the standard values with an air cleaner installed, muffler installed, alternator under no load,
and air compressor open (when installed).
★ The dynamometer load shows the value for an arm length of 716 mm.
12-74 125-3 SERIES

(5)
Fuel Cooling water Lubricating oil Lubricating oil Exhaust

Output Torque
consumption temperature temperature pressure temperature
(kW{HP}) Nm{kgm})
(sec/300cc) (ºC) (ºC) (kPa{kg/cm2}) (ºC)
169 – 179 (Gross) — 70 – 90 90 – 110 392 – 686 Max. 650
{227 – 241} (Gross) {4.0 – 7.0}
— 914 – 969 (Gross) 70 – 90 90 – 110 392 – 686 Max. 650
{93.2 – 98.8} (Gross) {4.0 – 7.0}
— — — 70 – 90 90 – 110 392 – 686 —
{4.0 – 7.0}
— — — 70 – 90 80 – 110 Min. 147 —
{Min. 1.5}
★ Use ASTMD975 diesel oil as the fuel.

★ Use SAE15W-40 or SAE30 as the lubricating oil.
125-3 SERIES 12-75

(5)

Rated horsepower 154 kW/1,900 rpm (Gross) 1,950 ± 5 1,030 – 1,090

{206 HP/1,900 rpm} (Gross) {104.7 – 110.7}
Max. torque 1,012 Nm/1,400 rpm (Gross) 1,400 ± 100 1,380 – 1,460
D65EX-15 {103.2 kgm/1,400 rpm} (Gross) {140 – 148.3}
D65PX-15 High idling speed 2,100 ± 50 rpm 2,100 ± 50 rpm —
Low idling speed 825 ± 25 rpm 825 ± 25 rpm —

SA6D125E-3
{261 HP/1,900 rpm} (Gross) {135 – 144}
D85EX-15 {129 kgm/1,400 rpm} (Gross) {175 – 186}
D85PX-15 High idling speed 2,100 ± 50 rpm 2,100 ± 50 rpm —
+50 +50

{261 HP/2,000 rpm} {135 – 143}
Max. torque 1,245 Nm/1,400 rpm 1,400 ± 100 1,730 – 1,830
{127 kgm/1,400 rpm} {176 – 187}
WA470-5
High idling speed 2,170 +50
-30 rpm 2,170 +50
-30 rpm —
+50 +50

{271 HP/2,000 rpm} {139 – 148}
Max. torque 1,295 Nm/1,400 rpm 1,400 ± 100 1,790 – 1,900
{132 kgm/1,400 rpm} {183 – 194}
WA480-5
High idling speed 2,170 +20
-30 rpm 2,170 +20
-30 rpm —
+50 +50
SAA6D125E-3
{335 HP/2,000 rpm} (Gross) {165 – 175}
{160 kgm/1,400 rpm} (Gross) {217 – 230}
HM300-1
High idling speed 2,200 ± 50 rpm — —
+50
Low idling speed 725 0 rpm — —

{347 HP/1,850 rpm} (Gross) {180 – 190}
PC400-7 {139.8 kgm/1,400 rpm} (Gross) {189 – 201}
PC450-7 High idling speed 1,930 ± 50 rpm 1,930 ± 50 rpm —
Low idling speed 1,000 ± 25 rpm 1,000 ± 25 rpm —
★ This table shows the standard values using the JIS correction factor.
★ The output and torque values in the table are the standard values with the fan removed, so they are different
★ The table shows the standard values with an air cleaner installed, muffler installed, alternator under no load,
★ The dynamometer load shows the value for an arm length of 716 mm.
12-76 125-3 SERIES

(7)

Output Torque
(kW{HP}) Nm{kgm})
150 – 159 (Gross) — 70 – 90 90 – 110 392 – 686 Max. 650
{201 – 213} (Gross) {4.0 – 7.0}
— 980 – 1,040 (Gross) 70 – 90 90 – 110 392 – 686 Max. 650
{100.2 – 106.2} (Gross) {4.0 – 7.0}
— — 70 – 90 90 – 110 392 – 686 —
{4.0 – 7.0}
— — 70 – 90 80 – 110 Min. 147 —
{Min. 1.5}
189 – 201 (Gross) — 70 – 90 90 – 110 392 – 686 Max. 680
{253 – 270} (Gross) {4.0 – 7.0}
— 1,230 – 1,310 (Gross) 70 – 90 90 – 110 392 – 686 Max. 680
{125 – 133} (Gross) {4.0 – 7.0}
— — 70 – 90 90 – 110 392 – 686 —
{4.0 – 7.0}
— — 70 – 90 80 – 110 Min. 147 —
{Min. 1.5}
198 – 210 — 70 – 90 90 – 110 392 – 686 Max. 650
{266 – 282} {4.0 – 7.0}
— 1,240 – 1,310 70 – 90 90 – 110 392 – 686 Max. 650
{126 – 134} {4.0 – 7.0}
— — 70 – 90 90 – 110 392 – 686 —
{4.0 – 7.0}
— — 70 – 90 80 – 110 Min. 147 —
{Min. 1.5}
205 – 218 — 70 – 90 90 – 110 392 – 686 Max. 650
{275 – 292} {4.0 – 7.0}
— 1,280 – 1,360 70 – 90 90 – 110 392 – 686 Max. 650
{131 – 139} {4.0 – 7.0}
— — 70 – 90 90 – 110 392 – 686 —
{4.0 – 7.0}
— — 70 – 90 80 – 110 Min. 147 —
{Min. 1.5}
243 – 257 (Gross) — 70 – 90 90 – 110 392 – 686 Max. 650
{325 – 345} (Gross) {4.0 – 7.0}
— 1,520 – 1,620 (Gross) 70 – 90 90 – 110 392 – 686 Max. 680
{155 – 165} (Gross) {4.0 – 7.0}
— — 70 – 90 90 – 110 392 – 686 —
{4.0 – 7.0}
— — 70 – 90 80 – 110 Min. 147 —
{Min. 1.5}
244 – 259 (Gross) — 70 – 90 90 – 110 392 – 686 Max. 680
{327 – 347} (Gross) {4.0 – 7.0}
— 1,330 – 1,410 (Gross) 70 – 90 90 – 110 392 – 686 Max. 680
{135.6 – 144} (Gross) {4.0 – 7.0}
— — 70 – 90 90 – 110 392 – 686 —
{4.0 – 7.0}
— — 70 – 90 80 – 110 Min. 147 —
{Min. 1.5}
★ Use ASTMD975 diesel oil as the fuel.
★ Use SAE15W-40 or SAE30 as the lubricating oil.
125-3 SERIES 12-77

(7)


{323 HP/2,100 rpm} (Gross) {155 – 164}
{140 kgm/1,400 rpm} (Gross) {190 – 201}
HD255-5 +80
High idling speed 2,420 –20 rpm 2,420 +80
–20 rpm —
Low idling speed 750 ± 50 rpm 750 ± 50 rpm —
Rated horsepower
Max. torque
High idling speed
Low idling speed
Rated horsepower
Max. torque
High idling speed
Low idling speed

SAA6D125E-3
Rated horsepower
Max. torque
High idling speed
Low idling speed
Rated horsepower
Max. torque
High idling speed
Low idling speed
Rated horsepower
Max. torque
High idling speed
Low idling speed
+ This table shows the standard values using the JIS correction factor.
+ The output and torque values in the table are the standard values with the fan removed, so they are different
+ The table shows the standard values with an air cleaner installed, muffler installed, alternator under no load,
+ The dynamometer load shows the value for an arm length of 716 mm.
12-78 125-3 SERIES

(8)

Output Torque
(kW{HP}) Nm{kgm})
239 – 253 (Gross) — — 70 – 90 90 – 110 392 – 686 Max. 700
{325 – 344} (Gross) {4.0 – 7.0}
— 1,334 – 1,416 (Gross) — 70 – 90 90 – 110 392 – 686 Max. 700
{136 – 144} (Gross) {4.0 – 7.0}
— — — 70 – 90 90 – 110 392 – 686 —
{4.0 – 7.0}
— — — 70 – 90 90 – 110 Min. 147 —
{Min. 1.5}
+ Use ASTMD975 diesel oil as the fuel.

+ Use SAE15W-40 or SAE30 as the lubricating oil.
125-3 SERIES 12-79

(8)
TROUBLESHOOTING OF
ENGINE SYSTEM (S MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING ..........................................................................12-102

METHOD OF USING TROUBLESHOOTING CHARTS..............................................................................12-103
S-1 Starting performance is poor (starting always takes time) ....................................................................12-107
S-2 Engine does not start ............................................................................................................................12-108
S-3 Engine does not pick up smoothly (follow-up is poor)...........................................................................12- 111
S-4 Engine stops during operations ............................................................................................................12- 112
S-5 Engine does not rotate smoothly (hunting) ...........................................................................................12- 113
S-6 Engine lacks output (or lacks power) ....................................................................................................12- 114
S-7 Exhaust smoke is black (incomplete combustion) ................................................................................12- 115
S-8 Oil consumption is excessive (or exhaust smoke is blue).....................................................................12- 116
S-9 Oil becomes contaminated quickly .......................................................................................................12- 117
S-10 Fuel consumption is excessive ...........................................................................................................12- 118
S-11 Oil is in cooling water (or water spurts back, or water level goes down).............................................12- 119
S-12 Oil pressure caution lamp lights up (drop in oil pressure)...................................................................12-120
S-13 Oil level rises (water, fuel in oil) ..........................................................................................................12-121
S-14 Water temperature becomes too high (overheating)...........................................................................12-122
S-15 Abnormal noise is made .....................................................................................................................12-123
S-16 Vibration is excessive .........................................................................................................................12-124
125-3 SERIES 12-101

TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the
parking brake is securely applied.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious
burns. Always wait for the water temperature to go down before removing the radiator cap.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
When removing a plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various
questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3. Checks before troubleshooting

hurry to disassemble the components 1) Is there any sign of abnormality in the
If components are disassembled immediately machine or engine?
any failure occurs: 2) Always carry out the Checks before starting.
• Parts that have no connection with the failure 3) Carry out other checks if necessary.
or other unnecessary parts will be 4) Other maintenance items can be checked
disassembled ex t e r n al l y, s o c h e c k an y i te m th a t i s
• It will become impossible to find the cause of considered to be necessary.
the failure. 5) Check for any error display on the controller.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose 4. Confirming failure
the confidence of the user or operator. Confirm the extent of the failure yourself, and
For this reason, when carrying out judge whether to handle it as a real failure or as
troubleshooting, it is necessary to carry out a problem with the method of operation, etc.
thorough prior investigation and to carry out ★ When operating the machine to re-enact the
troubleshooting in accordance with the fixed troubleshooting symptoms, do not carry out
procedure. any investigation or measurement that may
make the problem worse.
2. Points to ask user or operator
1) Have any other problems occurred apart 5. Troubleshooting
from the problem that has been reported? Us e th e r e s u l ts o f t he i nv e s ti g a ti o n a n d
2) Was there anything strange about the inspection in Items 2 – 4 to narrow down the
machine before the failure occurred? causes of failure, then use the troubleshooting
3) Did the failure occur suddenly, or were there matrix or flowchart to locate the position of the
problems with the machine condition before failure exactly.
this? ★ The basic procedure for troubleshooting is
4) Under what conditions did the failure occur? as follows.
5) Had any repairs been carried out before the 1) Start from the simple points.
failure? When were these repairs carried 2) Start from the most likely points.
out? 3) Investigate other related parts or information.
6) Has the same kind of failure occurred
before? 6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root cause.
12-102 125-3 SERIES

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]
Sections + in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in are
items that can be obtained from the user,
depending on the user's level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under in
the chart on the right correspond to this.
[Causes]
The serviceman narrows down the causes from
information that he has obtained from the
user and the results of that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with , and of these, causes that have a high prob-
ability are marked with .
Check each of the [Questions] and [Check items]
in turn, and marked the or in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
As a rule, do not use it when calculating the points
for locating the cause, but it can be included if nec-
essary to determine the order for troubleshooting.
Use the in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference.
125-3 SERIES 12-103

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example of troubleshooting> Exhaust smoke is black
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black

• Insufficient intake of air
• There is excessive fuel.
• Abnormal fuel injection condition
• Improper selection of fuel
• Engine overheating
★ See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited because
an error has occurred in the electrical system.)
12-104 125-3 SERIES

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) METHOD OF USING TROUBLESHOOTING
125-3 SERIES 12-105

2
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) S-1
S-1 Starting performance is poor (starting always takes time)
General causes why starting performance is poor

• Defective electrical system
• Insufficient supply of fuel
★ With the common rail fuel injection system, the

fuel injection timing is recognized electrically, so
even when the starting operation is carried out,
the engine may not start until the crankshaft has
completed two rotations. However, this does
not indicate any abnormality.
125-3 SERIES 12-107

2
S-2 Engine does not start
a) Engine does not turn

General causes why engine does not turn
• Internal parts of engine seized
★ See "Engine stops during operations".
• Defective electrical system
• Failure in power train
★ Carry out troubleshooting of the machine.
12-108 125-3 SERIES

b) Engine turns but no exhaust smoke comes out

General causes why engine turns but no exhaust
smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
125-3 SERIES 12-109

c) Exhaust smoke comes out but engine does not

start (Fuel is being injected)
General causes why exhaust smoke comes out
but engine does not start
• Lack of rotating force due to defective electrical
system
12-110 125-3 SERIES

S-3 Engine does not pick up smoothly (follow-up is poor)
General causes why engine does not pick up smoothly

125-3 SERIES 12-111

S-4 Engine stops during operations
General causes why engine stops

• Internal part of engine seized
• Failure in power train
★ Carry out troubleshooting of the machine.
12-112 125-3 SERIES

S-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate smoothly

• Air in fuel system
• Speed sensor is not normal
(abnormality not big enough to generate error display)
125-3 SERIES 12-113

S-6 Engine lacks output (or lacks power)
General causes why engine lacks output

12-114 125-3 SERIES

S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black

• There is excessive fuel.
125-3 SERIES 12-115

S-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive

• Abnormal combustion of oil
• The engine has been run at low or high idling for a
long time continuously (more than 20 minutes con-
tinuous operation is not allowed).
• External leakage of oil
• Wear of lubrication system
12-116 125-3 SERIES

S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly

• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Improper fuel used
• Improper oil used
• Operation under excessive load
125-3 SERIES 12-117

S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

• Leakage of fuel
• Improper condition of fuel injection (injection pressure,
injection timing)
• Excessive injection of fuel
12-118 125-3 SERIES

S-11 Oil is in cooling water (or water spurts back, or water level goes down)
General causes why oil is in cooling water

• Internal leakage in lubrication system
• Internal leakage in cooling system
125-3 SERIES 12-119

S-12 Oil pressure caution lamp lights up (drop in oil pressure)
General causes why oil pressure drops

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
12-120 125-3 SERIES

S-13 Oil level rises (water, fuel in oil)
General causes why oil level rises

• Water in oil (cloudy white)
• Fuel in oil (diluted, smells of diesel fuel)
★ If there is oil in the cooling water, carry out troubleshooting

for "Oil is in cooling water".
125-3 SERIES 12-121

S-14 Water temperature becomes too high (overheating)
General causes why water temperature becomes too high

• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in power train
★ Carry out troubleshooting for machine.
12-122 125-3 SERIES

S-15 Abnormal noise is made
General causes why abnormal noise is made

• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
★ Judge if the noise is an internal noise or an external noise.

★ If the engine is not thoroughly warmed up, the engine sound
becomes slightly louder because it is operated in the low
temperature mode, but this is not an abnormality.
★ When the engine is accelerated, it enters the acceleration
mode and the engine noise is higher for 3 seconds, but this
is not an abnormality.
125-3 SERIES 12-123

S-16 Vibration is excessive
General causes why vibration is excessive

• Defective parts (abnormal wear, breakage)
• Improper alignment with machine
• Abnormal combustion
★ If there is abnormal noise together with the vibration, carry

out troubleshooting also for "Abnormal noise is made".
12-124 125-3 SERIES

TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING...........................................................................12-203

METHOD OF USING TROUBLESHOOTING FLOWCHART ......................................................................12-204
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING ......................12-205
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE
WHEN ERROR CODE IS DISPLAYED ................................................................................................12-208
E-1 Error code [E-1b] [Abnormality in NE revolution sensor system] ..........................................................12-217
E-2 Error code [E-1C] [Abnormality in G revolution sensor system]............................................................12-218
E-3 Error code [E-20] [Abnormality in model selection system] ..................................................................12-219
E-4 Error code [E-22] [Overrun]...................................................................................................................12-220
E-5 Error code [E-23] [Overheat] .................................................................................................................12-220
E-6 Error code [E-24] [Drop in oil pressure] ................................................................................................12-221
E-7 Error code [E-30] [Abnormality in idling validation signal system] ........................................................12-222
E-8 Error code [E-31] [Abnormality in throttle sensor system].....................................................................12-224
E-9 Error code [E-34] [Abnormality in water temperature high-temperature sensor system] ......................12-227
E-10 Error code [E-36] [Abnormality in oil pressure switch system]............................................................12-228
E-11 Error code [E-3C] [Abnormality in boost pressure sensor system] .....................................................12-230
E-12 Error code [E-3d] [Abnormality in fuel temperature sensor system] ...................................................12-231
E-13 Error code [E-50] [Abnormality in preheating relay connecting point system] ....................................12-232
E-14 Error code [E-51] [Abnormality in preheat relay coil system] ..............................................................12-233
E-15 Error code [E-54] [Short circuit in starting switch C system]...............................................................12-234
E-16 Error code [E-56] [Power source system abnormality 1].....................................................................12-236
E-17 Error code [E-57] [Power source system abnormality 2].....................................................................12-238
E-18 Error code [E-5A] [Abnormality in fuel injection quantity control switch signal]...................................12-239
E-19 Error code [E-6A] [Abnormality in water temperature low-temperature sensor system] .....................12-240
E-20 Error code [E-70] [Excess current in fuel supply pump PCV1 system] ...............................................12-241
E-21 Error code [E-71] [Excess current in fuel supply pump PCV2 system] ...............................................12-242
E-22 Error code [E-74] [Disconnection in fuel supply pump PCV1 system] ................................................12-243
E-23 Error code [E-75] [Disconnection in fuel supply pump PCV2 system] ................................................12-244
E-24 Error code [E-77] [Abnormality in common rail fuel pressure sensor system] ....................................12-245
E-25 Error code [E-79] [Common rail fuel high pressure abnormality 1]
Error code [E-7A] [Common rail fuel high pressure abnormality 2].....................................................12-246
E-26 Error code [E-7b] [Fuel supply pump non-force feed 1]
Error code [E-7C] [Fuel supply pump non-force feed 2] ......................................................................12-248
★ This section gives the outline of the troubleshooting procedures for troubleshooting of the electrical system
related to the engine proper and the engine controller.
When carrying out troubleshooting of the electrical system with the engine mounted on the machine, see this
section and the shop manual for the machine.
125-3 SERIES 12-201

TROUBLESHOOTING
E-27 Error code [E-7d] [Abnormality in common rail fuel pressure] ............................................................ 12-250
E-28 Error code [E-80] [Defective controller]............................................................................................... 12-250
E-29 Error code [E-81] [Disconnection in No. 1 fuel injector system].......................................................... 12-251
E-35 Error code [E-8A] [Short circuit in No. 1, No. 2, No. 3 fuel injector system]........................................ 12-257
E-36 Error code [E-8b] [Short circuit in No. 4, No. 5, No. 6 fuel injector system] ........................................ 12-260
12-202 125-3 SERIES

TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the
parking brake is securely applied.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious
burns. Always wait for the water temperature to go down before removing the radiator cap.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
When removing a plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various ques-
tions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3. Checks before troubleshooting

hurry to disassemble the components 1) Is there any sign of abnormality in the
If components are disassembled immediately machine or engine?
any failure occurs: 2) Always carry out the Checks before starting.
• Parts that have no connection with the failure 3) Carry out other checks if necessary.
or other unnecessary parts will be 4) Other maintenance items can be checked
disassembled ex te r na l l y, s o c h e ck a ny i te m t h a t i s
• It will become impossible to find the cause of considered to be necessary.
the failure. 5) Check for any error display on the controller.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose 4. Confirming failure
the confidence of the user or operator. Confirm the extent of the failure yourself, and
Fo r t h i s r e a s o n , w h e n c a r r y i n g o u t judge whether to handle it as a real failure or as a
troubleshooting, it is necessary to carry out problem with the method of operation, etc.
thorough prior investigation and to carry out ★ When operating the machine to re-enact the
troubleshooting in accordance with the fixed troubleshooting symptoms, do not carry out
procedure. any investigation or measurement that may
make the problem worse.
2. Points to ask user or operator
1) Have any other problems occurred apart 5. Troubleshooting
from the problem that has been reported? U s e t h e r es ul t s o f t h e i nve s t i g at i o n a n d
2) Was there anything strange about the inspection in Items 2 – 4 to narrow down the
machine before the failure occurred? causes of failure, then use the troubleshooting
3) Did the failure occur suddenly, or were there matrix or flowchart to locate the position of the
problems with the machine condition before failure exactly.
this? ★ The basic procedure for troubleshooting is
4) Under what conditions did the failure occur? as follows.
5) Had any repairs been carried out before the 1) Start from the simple points.
failure? When were these repairs carried 2) Start from the most likely points.
out? 3) Investigate other related parts or information.
6) Has the same kind of failure occurred
before? 6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the
problem occurred. Then, remove the root cause.
125-3 SERIES 12-203

TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING FLOWCHART
METHOD OF USING TROUBLESHOOTING FLOWCHART

Troubleshooting code number and problem
The title at the top of the troubleshooting chart gives the troubleshooting code number and the problem with the
machine.
General precautions
When carrying out troubleshooting for the problem, precautions that apply to all items are given at the top of the
page under the title and marked with ★.
The common precautions marked ★ at the top of the page are not given in the (box formed by a broken line)
on the left, but must always be followed when carrying out the check given in the on the right.
Distinguishing conditions
Even with the same problem, the method of troubleshooting may differ according to the model, component, or
problem. In such cases, the failure mode is further divided into sections marked with small letters (for example,
a), b)), so go to the appropriate section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in the flow-
chart.
Method of following troubleshooting chart

NOTE: The number written at the top right corner of the is an index number; it does not indicate the order
to follow.)
• To the left of the there is (box formed by a broken line). This contains the procedure and con-
ditions needed for inspection and measurement of the item in the . Before starting inspection or mea-
surement, always read the instructions for the procedure carefully, and make sure that you understand
them.
• Check or measure the item inside , and judge if the result is YES or NO. If the judgement values in
the are correct or the answer to the question inside the is YES, follow the YES line; if the judge-
ment value is not correct, or the answer to the question is NO, follow the NO line. Continue the trou-
bleshooting for the next item in the same way.
Following the YES or NO lines according to the results of the inspection or measurement will lead finally
to the Cause and Remedy block. Check the cause and take the action given as the remedy.
Troubleshooting tools
Details of the tools needed for troubleshooting are given separately in the table of TOOLS FOR TESTING,
ADJUSTING, AND TROUBLESHOOTING.
<Example of troubleshooting>
E-20 Error code [E-70] [Excess current in fuel supply pump PCV1 system]
★ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Always connect any disconnected connectors before going on the next step.
Table 1 Table 2
PV1 (male) Resistance value CN7 (male) Resistance value
Between (1) and (2) 2.3 – 5.3 Ω Between (10) and (11) 2.3 – 5.3 Ω
Between (1)(2) and ground Min. 1 MΩ Between (10)(11) and ground Min. 1 MΩ
12-204 125-3 SERIES

ERROR CODE DISPLAYS AND POINTS TO REMEMBER
TROUBLESHOOTING WHEN TROUBLESHOOTING
ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN

TROUBLESHOOTING
1. Error code displays
• The engine controller displays the appropri-
ate error code for the abnormality in display
window (1) of the controller using seven seg-
ments with two alphanumeric digits.
• When the starting switch is turned ON, the
display check displays [88], then displays [E]
to show the occurrence of an error and a 2-
digit code repeatedly.
If there are multiple service codes in memo-
ry, the display returns to the first display after
completing all the displays.
• To prevent mistakes when reading, the nu-
merals and letters are displayed as follows.
Numerals: 0 1 2 3 4 5 6 7 8 9
Alphabet: A b C d E
• When re-enacting an abnormality or after
completion of repair of an abnormality, keep
the starting switch at the ON position and
connect the No. 4 pin circuit of connector (2)
CN4 to the ground.
125-3 SERIES 12-205

2. Table of error codes
Error code Nature of abnormality Operation for re-enaction

E-1b Abnormality in NE revolution sensor system Start engine.
E-1C Abnormality in G revolution sensor system Start engine.
E-20 Abnormality in model selection system Turn starting switch ON.
E-22 Overrun Start engine.
E-23 Overheat Start engine.
E-24 Drop in oil pressure Start engine.
E-30 Abnormality in idling validation signal system Turn starting switch ON.
E-31 Abnormality in throttle sensor system Turn starting switch ON.
E-34 Abnormality in water temperature high-temperature sensor system Turn starting switch ON.
E-36 Abnormality in oil pressure switch system Start engine.
E-3C Abnormality in boost pressure sensor system Turn starting switch ON.
E-3d Abnormality in fuel temperature sensor system Turn starting switch ON.
E-50 Abnormality in preheat relay contact system Turn starting switch ON.
E-51 Abnormality preheat relay coil system Turn starting switch ON.
E-54 Short circuit in starting switch signal C Turn starting switch OFF.
E-56 Abnormality 1 in power source system Turn starting switch ON.
E-57 Abnormality 2 in power source system Turn starting switch OFF.
E-5A Abnormality fuel injection quantity control switch signal Turn starting switch ON.
E-6A Abnormality in water temperature low-temperature sensor system Turn starting switch ON.
E-70 Excess current in fuel supply pump PCV1 system Turn starting switch ON.
E-71 Excess current in fuel supply pump PCV2 system Turn starting switch ON.
E-74 Disconnection in fuel supply pump PCV1 system Turn starting switch ON.
E-75 Disconnection in fuel supply pump PCV2 system Turn starting switch ON.
E-77 Abnormality in common rail fuel pressure sensor system Turn starting switch ON.
E-79 Abnormality 1 in common rail fuel high pressure Start engine.
E-7A Abnormality 2 in common rail fuel high pressure Start engine.
E-7b Fuel supply pump non-force feed 1 Start engine.
E-7C Fuel supply pump non-force feed 2 Start engine.
E-7d Abnormality in common rail fuel pressure Start engine.
E-80 Defective controller Turn starting switch ON.
E-81 Disconnection in No. 1 fuel injector system Turn starting switch ON.
E-8A Short circuit in No. 1, No. 2, No. 3 fuel injector system Turn starting switch ON.
E-8b Short circuit in No. 4, No. 5, No. 6 fuel injector system Turn starting switch ON.
12-206 125-3 SERIES

3. Points to remember when troubleshooting

1) Points to remember if abnormality returns to normal by itself:
If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the
connector is returned to its original position when carrying out troubleshooting of the failure, and the
error code is no longer displayed, or the [E] for the error code is no longer displayed, the abnormality
has probably returned to normal.
However, there is a high probability that the same problem will occur again, so it is desirable to follow up
this problem carefully.
2) Handling error code:
When carry out troubleshooting after displaying the error codes, save all the errors that have been dis-
played, then delete them. Following this, try to re-enact the problem and carry out troubleshooting for
the error codes that are displayed.
★ Among the error codes that are saved, there are some that were caused by mistaken operation or
when the connectors were disconnected, so re-enacting the failure prevents time from being wasted
on unnecessary checks.
After completing troubleshooting, erase all the error codes.
3) Handling connectors
★ Before starting troubleshooting, check that the connectors related to the error code are properly in-
serted.
★ Always connect any disconnected connectors before going on the next step or after completing trou-
bleshooting.
125-3 SERIES 12-207

ACTION TAKEN BY CONTROLLER AND CONDITION
TROUBLESHOOTING OF MACHINE WHEN ERROR CODE IS DISPLAYED
ACTION TAKEN BY CONTROLLER AND CONDITION OF

MACHINE WHEN ERROR CODE IS DISPLAYED
Error System with
Nature of abnormality
code abnormality
6. Defective contact, disconnection, short circuit, or short circuit with ground in wiring harness inside NE rev-
olution sensor
Abnormality in 7. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1 (5)
E-1b NE revolution (+) and NE revolution sensor SNE (1)
sensor system 8. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1
(12) (–) and NE revolution sensor SNE (2)
9. Defective engine controller
1. Defective contact, disconnection, short circuit, or short circuit with ground in wiring harness inside G revo-
lution sensor
E-1C G revolution (+) and G revolution sensor SG (1)
sensor system 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2 (9)
(–) and G revolution sensor SG (2)
1. Defective model selection connector
2. Defective contact, or disconnection in wiring harness between controller CN4 (13) and model selection
Abnormality in connector MSC (1)
model 3. Short circuit with ground in wiring harness between controller CN4 (14) and model selection connector
E-20
selection MSC (2)
system 4. Defective contact, or disconnection in wiring harness between controller CN4 (15) and model selection
connector MSC (3)
1. Engine speed goes above operating range.
E-22 Overrun
1. Engine water temperature goes above operating range.
E-23 Overheat
1. Engine oil pressure goes below operating range.
2. Defective oil pressure low-pressure sensor
3. Defective oil pressure high-pressure sensor
Drop in oil 4. Short circuit with chassis ground in wiring harness between controller CN4 (5) and oil pressure low-pres-
E-24
pressure sure sensor POL
5. Short circuit with chassis ground in wiring harness between controller CN4 (6) and oil pressure low-pres-
sure sensor POH
1. Defective throttle sensor
2. Defective contact or disconnection in wiring harness between controller CN4 (female) (8) (GND) and throt-
Abnormality in tle sensor TS (female) (4)
idling 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN4
E-30
validation (female) (11) (signal 2) and throttle sensor TS (female) (5)
signal system 4. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN4
(female) (12) (signal 3) and throttle sensor TS (female) (6)
2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1 (4)
Abnormality in
(power source) and throttle sensor TS (3)
throttle sensor
system
(signal) and throttle sensor TS (2)
(accelerator
4. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1
pedal type)
(11) (GND) and throttle sensor TS (1)
E-31
Abnormality in
(power source) and throttle sensor TS (1)
throttle sensor
system
(signal) and throttle sensor TS (2)
(fuel control dial
type)
(11) (GND) and throttle sensor TS (3)
1. Defective water temperature high-temperature sensor
water temperature (signal) and water temperature high-temperature sensor TWH (1)
E-34
high-temperature 3. Defective contact or disconnection in wiring harness between controller CN2 (10) (GND) and water tem-
sensor system perature high-temperature sensor TWH (2)
12-208 125-3 SERIES

Condition when normal Action by controller Problem that appears on machine
• Sensor resistance value 1. Limits output for operation 1. Reduces output (when problem occurs
Between SNE (1) and (2): 85 – 210 Ω (when problem occurs independently) independently)
2. Control of the system becomes impossi- 2. Engine stops during operation
ble (when E-1C occurs at same time) (when E-1C occurs at same time)
3. Engine cannot be started
(when E-1C occurs at same time)
• Sensor resistance value 1. Limits output for operation 1. Output is reduced (when problem
Between SG (1) and (2): 1.4 k – 3.5 kΩ (when problem occurs independently) occurs independently)
2. Control of the system becomes impossi- 2. Engine stops during operation
ble (when E-1C occurs at same time) (when E-1b occurs at same time)
3. Engine cannot be started
(when E-1b occurs at same time)
• Resistance in ground connection circuit 1. Carries out operation under normal con- 1. Output is reduced
Between CN4 (female) and ground: trol.
Max. 1 Ω
• Resistance in ground cut-off circuit
Between CN4 (female) and ground:
Min. 1 MΩ
1. Stops fuel injection until engine speed 1. Engine speed varies abnormally.
goes down to operating range.
1. Limits fuel injection amount until temper- 1. Output is reduced
ature goes down to operating range.
• Low-pressure switch resistance value 1. Limits output for operation 1. Runs at low idling.
Between POL and ground
Engine stopped: Max. 1 Ω
Engine above 600 rpm: Min. 1 MΩ
• High-pressure switch resistance value
Between POH and ground
Engine above 1,300 rpm: Min. 1 MΩ
• Signal 2 voltage (between CN4 (11) 1. Carries out operation under normal con- 1. Operates normally.
and (8)) trol.
Throttle below 0.446 V: Max. 1 V
Throttle above 0.446 V: 15 – 30 V
• Signal 3 voltage (between CN4 (12)
and (8))
Throttle below 0.446 V: 15 – 30 V
Throttle above 0.446 V: Max. 1 V
• Sensor power source voltage 1. Actuated with throttle signal 100% 1. Fixed at high idling
Between CN1 (4) and (11): 4.6 – 5.4 V (when problem occurs independently (when problem occurs independently)
• Sensor signal voltage and simultaneously) 2. Fixed at low idling (when E-24 and E-36
Between CN1 (6) and (11): 0.3 – 4.5 V 2. Actuated with throttle signal 0% (when occur at same time)
E-24 and E-36 occur at same time)
• Sensor power source voltage 1. Actuated with throttle signal 100% 1. Fixed at high idling
Between CN1 (4) and (11): 4.6 – 5.4 V (when problem occurs independently (when problem occurs independently)
• Sensor signal voltage and simultaneously) 2. Fixed at low idling (when E-24 and E-36
Between CN1 (6) and (11): 0.3 – 4.7 V 2. Actuated with throttle signal 0% (when occur at same time)
E-24 and E-36 occur at same time)
• Sensor resistance value (water temper- 1. Carries out operation under normal 1. Fixes water temperature signal output to
ature: 10 – 100ºC) control. machine at 90ºC
Between TWH (1) and (2): 90 k – 3.5 kΩ
125-3 SERIES 12-209

Error System with

code abnormality
1. Defective oil pressure low-pressure sensor
2. Defective oil pressure high-pressure sensor
Abnormality in
and oil pressure low-pressure sensor POL
E-36 engine oil pressure
4. Defective contact or disconnection in wiring harness between controller CN4 (6) and oil pressure low-pres-
switch system
sure sensor POH
1. Defective boost pressure sensor

(power source) and boost pressure sensor PBA (3)
Abnormality in
E-3C boost pressure
(signal) and boost pressure sensor PBA (2)
sensor system
(10) (GND) and boost pressure sensor PBA (1)
1. Defective fuel temperature sensor
Abnormality in fuel
(11) (signal) and fuel temperature sensor TFL (A)
E-3d temperature
3. Defective contact or disconnection in wiring harness between controller CN2 (10) (GND) and fuel temper-
sensor system
ature sensor TFL (B)
1. Defective heater relay
Abnormality in
2. Defective contact, disconnection, short circuit with ground, or short circuit with power source in wiring har-
E-50 preheat relay
ness between controller CN4 (3) and heater relay HR3
contact system
1. Defective preheater relay
Abnormality in
E-51 preheat relay coil
and preheater relay RPH (2)
system
1. Defective starting switch
Short circuit in 2. Short circuit with power source in wiring harness between controller CN4 (2) and starting switch terminal
E-54 starting switch C
C signal system 3. Defective engine controller
1. Defective power source relay

2. Defective contact, disconnection, or short circuit with ground in wiring harness between starting switch ter-
minal ACC and power source relay RPW (1)
Power source 3. Defective contact or disconnection in wiring harness between power source relay RPW (2) and ground
E-56 system 4. Defective contact, disconnection, or short circuit with ground in wiring harness between power source fuse
abnormality 1 and power source relay RPW (3)
(6)(14) and power source relay RPW (5)
1. Defective power source relay
Power source
2. Short circuit with power source in wiring harness between controller CN7 (6)(14) and power source relay
E-57 system
(5)
abnormality 2
Abnormality in fuel 1. Defective setting of fuel injection quantity control switch
injection quantity 2. Defective engine controller
E-5A
control switch
signal
1. Defective water temperature low-temperature sensor
water temperature (signal) and water temperature low-temperature sensor TWL (A)
E-6A
low-temperature 3. Defective contact or disconnection in wiring harness between controller CN2 (10) (GND) and water tem-
sensor system perature low-temperature sensor TWL (B)
1. Defective fuel supply pump PCV1
Excess current in 2. Short circuit with chassis ground or short circuit with power source in wiring harness between controller
E-70 fuel supply pump CN7 (10) and PCV1 solenoid PV1 (1)
PCV1 system 3. Short circuit with power source in wiring harness between controller CN7 (11) and PCV1 solenoid PV1 (2)
Excess current in 2. Short circuit with chassis ground or short circuit with power source in wiring harness between controller
E-71 fuel supply pump CN7 (4) and PCV2 solenoid PV2 (1)
PCV2 system 3. Short circuit with power source in wiring harness between controller CN7 (12) and PCV2 solenoid PV2 (2)
12-210 125-3 SERIES

• Low-pressure switch resistance value 1. Carries out operation under normal con- 1. Operates normally.
Between POL and ground trol.
Engine above 600 rpm: Min. 1 MΩ
• High-pressure switch resistance value
Between POH and ground
Engine above 1,300 rpm: Min. 1 MΩ
• Sensor power source voltage 1. Operates normally.
Between PBA (3) and (1): 4.6 – 5.4 V
• Sensor signal voltage
Between PBA (2) and (1): 0.3 – 4.7 V
—
• Sensor resistance value 1. Carries out operation under normal con- 1. Operates normally.
(fuel temperature: 10 – 100°C) trol.
Between TFL (A) and (B): 9 k – 0.3 kΩ
• Preheating signal voltage 1. Carries out operation under normal con- 1. Starting ability in cold weather becomes
Between CN4 (3) and ground trol. worse.
Preheating not actuated: Max. 1 V
Preheating actuated: 20 – 30 V
• Preheating signal voltage 1. Carries out operation under normal con- 1. Starting ability in cold weather becomes
Between CN1 (5) and (6) trol. worse.
Preheating not actuated: 20 – 30 V
Preheating actuated: Max. 1 V
• Starting switch C signal voltage 1. Carries out operation under normal con- 1. Operates normally 10 seconds after
Between CN4 (2) and ground trol. engine starts.
Starting switch at ON: Max. 1 V
Starting switch at START: 20 – 30 V
• Power source voltage 1. Engine stops during operation.
Between CN7 (6)(14) and (5)(13) 2. Engine cannot be started.
Starting switch at ON: 20 – 30 V
• Power source voltage 1. Carries out operation under normal con- 1. Operates normally.
Between CN7 (6)(14) and (5)(13) trol.
Starting switch at OFF: Max. 8 V
• Either fuel injection quantity control 1. Carries out operation under normal con- 1. Fuel injection quantity control setting
switch 1 or 2 of controller is set to [F] trol. cannot be changed.
• Sensor resistance value (water temper- 1. Carries out operation under normal con- 1. Exhaust gas color at low temperatures is
ature: 10 – 100°C) trol. poor.
Between TWL (A) and (B): 9 k – 0.3 kΩ 2. Starting ability at low temperatures is
poor.
• Solenoid resistance value 1. Stops output to PCV1 (when problem 1. Operates normally (when problem
Between PV1 (1) and (2): 2.3 – 5.3 Ω occurs independently) occurs independently)
2. Stops output to PCV1 and PCV2 (when 2. Stops engine (when E-71 occurs at
E-71 occurs at same time) same time)
125-3 SERIES 12-211

Error System with

code abnormality
2. Defective contact or disconnection in wiring harness between controller CN7 (10) and PCV1 solenoid PV1
Disconnection in
(1)
E-74 fuel supply pump
PCV1 system
(11) and PCV1 solenoid PV1 (2)
2. Defective contact or disconnection in wiring harness between controller CN7 (4) and PCV2 solenoid PV2
Disconnection in
(1)
E-75 fuel supply pump
PCV2 system
(12) and PCV2 solenoid PV2 (2)
1. Defective common rail fuel pressure sensor
Abnormality in (power source) and fuel pressure sensor PFL (1)
common rail fuel 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1 (1)
E-77
pressure sensor (signal) and fuel pressure sensor PFL (2)
system 4. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2
(10) (GND) and fuel pressure sensor PFL (3)
1. Viscosity of fuel is too high (unsuitable fuel)
Common rail fuel 2. Defective overflow valve
E-79 high-pressure 3. Defective pressure limiter
abnormality 1 4. Defective common rail fuel pressure sensor
5. Clogged overflow piping
Common rail fuel ★ See E-79.
E-7A high-pressure
abnormality 2
1. Defective fuel low-pressure circuit (etc)
2. Defective fuel supply pump PSV
Supply pump
3. Defective pressure limiter
E-7b non-force
4. Defective common rail fuel pressure sensor
feed abnormality 1
5. Defective fuel injector
6. Leakage from fuel high-pressure piping
Supply pump ★ See E-7b.
E-7C non-force feed
abnormality 2
★ See E-79.
Abnormality in
E-7d common rail fuel
pressure
1. Defective contact or disconnection in wiring harness between controller CN7 (5)(13) and ground
Abnormality in
E-80
controller
1. Defective No. 1 fuel injector

2. Defective contact or disconnection in wiring harness between controller CN6 (7) (–) and No. 1 injector IJ1
Disconnection in
(1)
E-81 No. 1 fuel injector
3. Defective contact or disconnection in wiring harness between controller CN6 (8) (+) and No. 1 injector IJ1
system
(2)
Disconnection in
(1)
system
(2)
Disconnection in
(1)
system
(2)
12-212 125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)ACTION TAKEN BY CONTROLLER AND CON-
• Sensor power source voltage 1. Limits output with open control. 1. Output is reduced
Between PFL (1) and (3): 4.6 – 5.4 V
• Sensor signal voltage
Between PFL (2) and (3): 0.3 – 4.7 V
1. Operation carried out with limited output 1. Output is reduced
1. Stops output to fuel supply pump 1. Output is reduced

— 2. Limits output to fuel injector
1. Sets engine output to delayed 1. Output is reduced

2. Operation carried out with limited output
—
1. Stops output to fuel supply pump 1. Engine stops

— 2. Limits output to fuel injector
1. Carries out operation under normal con- 1. The engine does not run at high idling
trol. speed
—
2. The engine stops when a large load is
applied
1. Operation carried out with limited output 1. The engine does not run at high idling
speed
2. The engine stops when a large load is
—
applied
3. Engine stops during operation.
4. Engine cannot be started.
• No. 1 injector resistance value 1. Stops output to No. 1 injector (when 1. Output is reduced (when problem
Between IJ1 (1) and (2): 0.4 – 1.1 Ω problem occurs independently) occurs independently)
2. Stops output to fuel supply pump, all fuel 2. Engine stops (when E-82 to E-86 occur
injectors (when at same time in E-82 to at same time)
E-86)
injectors (when E-81 to E-86 occur at at same time)
same time)
same time)
125-3 SERIES 12-213

2
Error System with

code abnormality
Disconnection in
(1)
system
(2)
Disconnection in
(1)
system
(2)
Disconnection in
(1)
system
(2)
4. Short circuit with chassis ground or short circuit with power source in wiring harness between controller
CN6 (7) (+) and No. 1 injector IJ1 (1)
CN6 (8) (– ) and No. 1 injector IJ1 (2)
Short circuit in No. 6. Short circuit with chassis ground or short circuit with power source in wiring harness between controller
E-8A 1, No. 2, No. 3 fuel CN6 (4) (+) and No. 2 injector IJ2 (1)
injector system 7. Short circuit with chassis ground or short circuit with power source in wiring harness between controller
CN6 (10) (–) and No. 2 injector IJ2 (2)
Short circuit in No. 6. Short circuit with chassis ground or short circuit with power source in wiring harness between controller
E-8b 4, No. 5, No. 6 fuel CN7 (1) (+) and No. 5 injector IJ5 (1)
injector system 7. Short circuit with chassis ground or short circuit with power source in wiring harness between controller
12-214 125-3 SERIES

same time)
same time)
same time)
• No. 1 injector resistance value 1. Stops output to No. 1, No. 2, No. 3 fuel 1. Output is greatly reduced (when prob-
Between IJ1 (1) and (2): 0.4 – 1.1 Ω injectors (when problem occurs inde- lem occurs independently)
• No. 2 injector resistance value pendently) 2. Engine stops (when E-8b occurs at
Between IJ2 (1) and (2): 0.4 – 1.1 Ω 2. Stops output to fuel supply pump, all fuel same time)
• No. 3 injector resistance value injectors (when E-8b occurs at same
Between IJ3 (1) and (2): 0.4 – 1.1 Ω time)
• No. 4 injector resistance value 1. Stops output to No. 4, No. 5, No. 6 fuel 1. Output is greatly reduced (when prob-
Between IJ4 (1) and (2): 0.4 – 1.1 Ω injectors (when problem occurs inde- lem occurs independently)
• No. 5 injector resistance value pendently) 2. Engine stops (when E-8A occurs at
Between IJ5 (1) and (2): 0.4 – 1.1 Ω 2. Stops output to fuel supply pump, all fuel same time)
• No. 6 injector resistance value injectors (when E-8A occurs at same
Between IJ6 (1) and (2): 0.4 – 1.1 Ω time)
125-3 SERIES 12-215

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) E-1
E-1 Error code [E-1b] [Abnormality in NE revolution sensor system]
Table 1
SNE (male) Resistance value
Between (1) and (2) 85 – 210 Ω
Between (1)(2) and ground Min. 1 MΩ
E-1 Related electrical circuit diagram
125-3 SERIES 12-217

E-2 Error code [E-1C] [Abnormality in G revolution sensor system]
Table 1
SG (male) Resistance value
Between (1) and (2) 1.4 k – 3.5 kΩ
12-218 125-3 SERIES

E-3 Error code [E-20] [Abnormality in model selection system]
★ The troubleshooting given below takes a particular machine as an example, so the content of the trouble-
shooting and the electric wiring diagrams will differ according to the actual model of machine.
Table 1
MSC (female) Resistance value
Between (1) and (8) Max. 1 Ω
Between (2) and (8) Min. 1 MΩ
Between (3) and (8) Max. 1 Ω
125-3 SERIES 12-219

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) E-4, E-5
E-4 Error code [E-22] [Overrun]
E-5 Error code [E-23] [Overheat]
12-220 125-3 SERIES

E-6 Error code [E-24] [Drop in oil pressure]
125-3 SERIES 12-221

E-7 Error code [E-30] [Abnormality in idling validation signal system]
★ This troubleshooting applies only to machines with an accelerator pedal type throttle sensor.
Fig. 1
12-222 125-3 SERIES

125-3 SERIES 12-223

E-8 Error code [E-31] [Abnormality in throttle sensor system]
a) Accelerator pedal type throttle sensor
Table 1 Table 2
TS (male) Resistance value CN1 (male) Resistance value
Between (1) and (3) 4.0 k – 6.0 kΩ Between (4) and (11) 4.0 k – 6.0 kΩ
Between (2) and (1) 0.5 – 2.7 kΩ Between (6) and (11) 0.5 – 2.7 kΩ
12-224 125-3 SERIES

E-8 a) Related electrical circuit diagram
125-3 SERIES 12-225

b) Fuel control dial type throttle sensor
Table 1 Table 2
TS (male) Resistance value CN1 (male) Resistance value
Between (1) and (3) 4.0 k – 6.0 kΩ Between (4) and (11) 4.0 k – 6.0 kΩ
Between (2) and (3) 0.5 – 2.7 kΩ Between (6) and (11) 0.5 – 2.7 kΩ
E-8 b) Related electrical circuit diagram
12-226 125-3 SERIES

E-9 Error code [E-34] [Abnormality in water temperature high-temperature sensor system]
Table 1
TWH (male) Resistance value
Between (1) and (2) 90 k – 3.5 kΩ
Between (1) and ground Min. 1 MΩ
125-3 SERIES 12-227

E-10 Error code [E-36] [Abnormality in oil pressure switch system]
Table 1 Table 2
Resistance
CN4 Engine Voltage POL Engine
value
When
When stopped Max. 1 V Between POL Max. 1 Ω
Between (5) stopped
(switch) and
and ground At 600 rpm or At 600 rpm or
20 – 30 V ground Min. 1 MΩ
more more
Table 3 Table 4
CN4 Engine Resistance POH Engine Resistance
When
When stopped Max. 1 V Between POH Max. 1 Ω
Between (6) stopped
(switch) and
and ground At 1,300 rpm or At 1,300 rpm
20 – 30 V ground Min. 1 MΩ
more or more
12-228 125-3 SERIES

125-3 SERIES 12-229

E-11 Error code [E-3C] [Abnormality in boost pressure sensor system]
Table 1
CN1, PBA (female) Resistance value
Between CN1 (3) and PBA (2) Max. 1 Ω
Between CN1 (3) and ground Min. 1 MΩ
12-230 125-3 SERIES

E-12 Error code [E-3d] [Abnormality in fuel temperature sensor system]
Table 1
TFL (Male) Resistance value
Between (A) and (B) 9 k – 0.3 kΩ
Between (A) and ground Min. 1 MΩ
125-3 SERIES 12-231

E-13 Error code [E-50] [Abnormality in preheating relay connecting point system]
12-232 125-3 SERIES

E-14 Error code [E-51] [Abnormality in preheat relay coil system]
125-3 SERIES 12-233

E-15 Error code [E-54] [Short circuit in starting switch C system]
12-234 125-3 SERIES

E-16 Error code [E-56] [Power source system abnormality 1]
12-236 125-3 SERIES

125-3 SERIES 12-237

E-17 Error code [E-57] [Power source system abnormality 2]
12-238 125-3 SERIES

E-18 Error code [E-5A] [Abnormality in fuel injection quantity control switch signal]
125-3 SERIES 12-239

E-19 Error code [E-6A] [Abnormality in water temperature low-temperature sensor system]
Table 1
TWL (male) Resistance value
Between (A) and (B) 9 k – 0.3 kΩ
Between (A) and ground Min. 1 MΩ
12-240 125-3 SERIES

Table 1 Table 2
125-3 SERIES 12-241

Table 1 Table 2
12-242 125-3 SERIES

E-22 Error code [E-74] [Disconnection in fuel supply pump PCV1 system]
Table 1
CN7 (male) Resistance value
Between (10) and (11) 2.3 – 5.3 Ω
125-3 SERIES 12-243

E-23 Error code [E-75] [Disconnection in fuel supply pump PCV2 system]
Table 1
CN7 (male) Resistance value
Between (4) and (12) 2.3 – 5.3 Ω
Between (12) and ground Min. 1 MΩ
12-244 125-3 SERIES

E-24 Error code [E-77] [Abnormality in common rail fuel pressure sensor system]
Table 1
CN1, PFL (female) Resistance value
Between CN1 (1) and PFL (2) Max. 1 Ω
Between CN1 (1) and ground Min. 1 MΩ
125-3 SERIES 12-245

E-25 Error code [E-79] [Common rail fuel high pressure abnormality 1]
Error code [E-7A] [Common rail fuel high pressure abnormality 2]
12-246 125-3 SERIES

E-26 Error code [E-7b] [Fuel supply pump non-force feed 1]

Error code [E-7C] [Fuel supply pump non-force feed 2]
12-248 125-3 SERIES

Note 1: If the equipment in the low-pressure circuit is defective, inspect the following points.
1) Remaining amount of fuel
2) Stuck, worn feed pump, clogged filter
3) Leakage, clogged low-pressure fuel piping
4) Defective actuation of bypass valve, incorrect assembly with other parts (See Fig.1)
5) Clogged fuel filter
6) Fuel entering oil pan (fuel leakage inside head cover)
Fig. 1 Mounting positions of overflow valve (1), bypass valve (2), fuel inlet port joint (3)
Note 2: Method of measuring amount of fuel spill flow

The fuel in the spill line is at high temperature (up to 90°C), so be careful not to burn yourself during the
operation.
1) Disconnect the hose connected to the spill tube return collection portion (rear of engine).
2) Connect another hose to the tip of the spill tube, and collect the spill fuel in a container.
3) Start the engine, stall the engine at each speed, and measure the spill fuel amount for 1 minute.
Limits for fuel spill amount (total for 6 cylinders)

Stall speed (rpm) Spill limit (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
125-3 SERIES 12-249

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) E-27, E-28
E-27 Error code [E-7d] [Abnormality in common rail fuel pressure]
★ Go to Troubleshooting of error codes [E-79] and [E-7A].
E-28 Error code [E-80] [Defective controller]
12-250 125-3 SERIES

E-29 Error code [E-81] [Disconnection in No. 1 fuel injector system]
A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution
or electric leakage. For details, see TESTING AND ADJUSTING, Handling controller high voltage circuit.
125-3 SERIES 12-251

12-252 125-3 SERIES

125-3 SERIES 12-253

12-254 125-3 SERIES

125-3 SERIES 12-255

12-256 125-3 SERIES

E-35 Error code [E-8A] [Short circuit in No. 1, No. 2, No. 3 fuel injector system]
a) Determining location of problem
Table 1
CN6 (female) CN6 (female) CN6 (female) Resistance value
Between (7) and (8) Between (4) and (10) Between (3) and (9) 0.4 – 1.1 Ω
Between (7)(8) and ground Between (4)(10) and ground Between (3)(9) and ground Min. 1 MΩ
125-3 SERIES 12-257

b) Troubleshooting No. 1 fuel injector system
Table 2
IJ1 (female) Resistance value
Between (1) and (2) 0.4 – 1.1 Ω
c) Troubleshooting No. 2 fuel injector system
Table 3
Between (1) and (2) 0.4 – 1.1 Ω
d) Troubleshooting No. 3 fuel injector system
Table 4
Between (1) and (2) 0.4 – 1.1 Ω
12-258 125-3 SERIES

E-35 a), b) Related electrical circuit diagram
E-35 a), c) Related electrical circuit diagram
E-35 a), d) Related electrical circuit diagram
125-3 SERIES 12-259

E-36 Error code [E-8b] [Short circuit in No. 4, No. 5, No. 6 fuel injector system]
a) Determining location of problem
Table 1
CN6 (female) CN6 (female) CN6 (female) Resistance value
Between (3) and (9) Between (1) and (7) Between (2) and (8) 0.4 – 1.1 Ω
Between (3)(9) and ground Between (1)(7) and ground Between (2)(8) and ground Min. 1 MΩ
12-260 125-3 SERIES

b) Troubleshooting No. 4 fuel injector system
Table 2
Between (1) and (2) 0.4 – 1.1 Ω
c) Troubleshooting No. 5 fuel injector system
Table 3
Between (1) and (2) 0.4 – 1.1 Ω
d) Troubleshooting No. 6 fuel injector system
Table 4
Between (1) and (2) 0.4 – 1.1 Ω
125-3 SERIES 12-261

E-36 a), b) Related electrical circuit diagram
E-36 a), c) Related electrical circuit diagram
E-36 a), d) Related electrical circuit diagram
12-262 125-3 SERIES

13 DISASSEMBLY AND
ASSEMBLY
METHOD OF USING MANUAL.......................... 13- 3 24. Rocker arm ............................................. 13- 12

PRECAUTIONS WHEN CARRYING OUT 25. Push rod ................................................. 13- 12
OPERATION..................................................... 13- 4 26. Injector.................................................... 13- 12
SPECIAL TOOL LIST .......................................... 13- 6 27. Nozzle tip................................................ 13- 13
SKETCHES OF SPECIAL TOOLS ..................... 13- 7 28. Crosshead .............................................. 13- 13
GENERAL DISASSEMBLY................................. 13- 8 29. Rocker arm housing ............................... 13- 14
1. Preparation work.....................................13- 8 30. Injector harness connector ..................... 13- 14
2. Starting motor .........................................13- 8 31. Thermostat ............................................. 13- 14
3. Turbocharger lubricant return tube .........13- 8 32. Cam follower cover................................. 13- 14
4. Radiator lower hose ................................13- 8 33. Cam follower........................................... 13- 14
5. Engine oil cooler .....................................13- 8 34. Cylinder head ......................................... 13- 14
6. Adapter for engine overhauling...............13- 9 35. Setting engine on engine overhaul
7. Radiator upper hose ...............................13- 9 stand....................................................... 13- 15
8. Exhaust muffler .......................................13- 9 36. Oil pan .................................................... 13- 15
9. Fan securing bracket ..............................13- 9 37. Flywheel ................................................. 13- 15
10. Turbocharger lubrication tube .................13- 9 38. Flywheel housing.................................... 13- 15
11. Turbocharger and exhaust manifold .......13- 9 39. Damper................................................... 13- 16
12. Fuel filter assembly .................................13- 9 40. Front support .......................................... 13- 16
13. Oil filter....................................................13- 10 41. Front cover ............................................. 13- 16
14. Wiring harness ........................................13- 10 42. Water pump ............................................ 13- 16
15. Air cleaner securing bracket ...................13- 10 43. Camshaft ................................................ 13- 16
16. Exhaust muffler securing bracket............13- 10 44. Oil pump ................................................. 13- 16
17. High pressure tube clamp .......................13- 10 45. Idler gear ................................................ 13- 16
18. Suction manifold assembly .....................13- 10 46. Oil suction pipe ....................................... 13- 17
19. Supply pump ...........................................13- 10 47. Piston cooling nozzle.............................. 13- 17
20. Common rail............................................13- 11 48. Piston and connecting rod assembly...... 13- 17
21. Spill pipe .................................................13- 12 49. Crankshaft .............................................. 13- 18
22. Head cover..............................................13- 12 50. Cylinder liner........................................... 13- 19
23. Injector harness ......................................13- 12
125-3 SERIES 13-1

1
DISASSEMBLY AND ASSEMBLY
GENERAL ASSEMBLY....................................... 13- 52 24. Installing injector harness connector to

Preparation work .......................................... 13- 52 rocker arm housing .................................13- 70
1. Cylinder liner .......................................... 13- 53 25. Crosshead...............................................13- 70
2. Crankshaft .............................................. 13- 54 26. Push rod..................................................13- 71
3. Piston and connecting rod assembly...... 13- 57 27. Rocker arm .............................................13- 71
4. Piston cooling nozzle ............................. 13- 60 28. Adjusting valve clearance .......................13- 71
5. Oil suction pipe....................................... 13- 61 29. Nozzle tip ................................................13- 71
6. Idler gear ................................................ 13- 61 30. Injector ....................................................13- 73
7. Oil pump ................................................. 13- 61 31. Head cover..............................................13- 73
8. Camshaft ................................................ 13- 62 32. Spill pipe .................................................13- 73
9. Cam follower .......................................... 13- 62 33. Thermostat..............................................13- 74
10. Cam follower cover................................. 13- 62 34. Engine oil cooler .....................................13- 74
11. Water pump............................................ 13- 62 35. Engine cooling water temperature
12. Supply pump driving gear....................... 13- 62 sensor .....................................................13- 74
13. Front cover ............................................. 13- 63 36. Engine oil supply tube.............................13- 74
14. Flywheel housing ................................... 13- 64 37. Common rail and high pressure tube......13- 74
15. Rear seal ................................................ 13- 65 38. Suction manifold .....................................13- 75
16. Flywheel ................................................. 13- 67 39. Engine oil filter ........................................13- 76
17. Damper .................................................. 13- 67 40. Fuel filter .................................................13- 76
18. Oil pan .................................................... 13- 68 41. Turbocharger and suction manifold
19. Removing engine from engine assemblies ..............................................13- 76
overhaul stand........................................ 13- 68 42. Starting motor .........................................13- 76
20. Setting engine on engine stand.............. 13- 68 43. Fan bracket lifting hook...........................13- 77
21. Cylinder head ......................................... 13- 68 44. Wiring harness ........................................13- 77
22. Cylinder head assembly ......................... 13- 68 45. Air cleaner...............................................13- 77
23. Rocker arm housing ............................... 13- 70 46. Exhaust muffler .......................................13- 77
13-2 125-3 SERIES

1
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
1) When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
2) Any special techniques applying only to the installation procedure are marked , and the same mark
is placed after the relevant step in the removal procedure to indicate which step in the installation proce-
dure it applies to.
(Example)
REMOVAL OF ASSEMBLY.........................Title of operation
k ................................................................................Precautions related to safety when carrying out the
operation
1. X X X X (1) ..............................................................Step in operation
★ .............................................................................Technique or important point to remember when
removing XXXX (1).
2. (2):.......................................................... Indicates that a technique is listed for use dur-
ing installation
3. assembly (3)
6 ......................................................................Quantity of oil or water drained
INSTALLATION OF ASSEMBLY .................Title of operation

• Carry out installation in the reverse order to removal.
..........................................................................Technique used during installation
★ .............................................................................Technique or important point to remember when
installing (2)
• Adding water, oil ...............................................Step in operation
★.......................................................................Point to remember when adding water or oil
5 ..................................................................Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools

1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the opera-
tion procedure, see the SPECIAL TOOLS LIST given in this manual.
125-3 SERIES 13-3

1
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general pre-
cautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
★ Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal number Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
13-4 125-3 SERIES

1
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hy-
draulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
★ When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed, always bleed the air from the system after reas-
sembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
125-3 SERIES 13-5

1
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

★ Tools with part number 79 T- - cannot be supplied (they must be locally manufactured).
★ Tools marked in the Sketch column are tools introduced in the sketches of the special tools (See SKETCH-
ES OF SPECIAL TOOLS).
Symbol Part No. Part Name Q'ty Sketch

A 790-901-1240 Adapter 1
B 790-501-2001 Engine repair stand 1
C 795-102-2102 Spring pusher 1
1 795-931-1220 Push tool 1
C2
2 01050-31645 Bolt 3
1 795-931-1210 Push tool 1
C3
2 01050-31625 Bolt 3
D 795-100-1191 Piston ring tool 1
E 795-220-1000 Liner puller 1
F 795-225-1520 Liner driver 1
G 795-102-3900 Piston holder 1
H 795-502-1121 Gauge 1
I 795-125-1360 Feeler gauge 1
J 790-331-1110 Angle wrench 1
K 795-471-1500 Fuel supply pump remover 1
L 795T-471-1550 Injector wrench 1
13-6 125-3 SERIES

1
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

NOTE: Komatsu shall not be liable for any trouble or accident resulting from using the tool fabricated to this
drawing.
L. Injector wrench
125-3 SERIES 13-7

1
DISASSEMBLY AND ASSEMBLY GENERAL DISASSEMBLY
GENERAL DISASSEMBLY
1. Preparation work 3. Turbocharger lubricant return tube
Before starting to disassemble the engine, 1) Remove the bolts two each on the turbo-
check each component part of the engine for charger side and on the block side that
crack or damage, and clean it thoroughly to secure turbocharger lubricant return tube
assure correct inspection of parts and disas- and take off the tube.
sembling and reassembling work. 2) Remove the four securing bolts to take off
★ Before cleaning the engine, seal off each open- engine oil filler port (2).
ing, electrical parts and wiring connectors com-
pletely so that water will not enter them, or
remove them beforehand.
★ Prepare stable and sturdy engine stand and
secure engine assembly (1) on the stand to pre-
vent it from falling over.
4 Engine assembly: Approx. 1,170 kg

(The weight differs according to the
machine model.)
• When raising the engine assembly, the air
cleaner has to be detached. To detach it, loosen
the suction hose clamp and the air cleaner fixing
band.
4. Radiator lower hose
Remove the four securing bolts on the water
pump side to take off hose securing tube (1).
2. Starting motor
Remove the three securing bolts and detach
starting motor (1).
5. Engine oil cooler
Fit two guide bolts to oil cooler (1), and then
remove the oil cooler securing bolts (17 pieces
in total), taking care not to let it fall, to dismantle
the engine oil cooler.
13-8 125-3 SERIES

1
6. Adapter for engine overhauling

Attach adapter A to the oil cooler installation
portion.
11. Turbocharger and exhaust manifold

1) Lift off turbocharger (1) with a sling tempo-
rarily.
2) Remove the bolts on the right and left sides
7. Radiator upper hose
of exhaust manifold (2), and install two
Loosen the two clamps to take off radiator upper
guide bolts .
hose (1).
3) Remove the exhaust manifold securing bolts
(18 bolts in total), and dismantle the turbo-
8. Exhaust muffler
charger manifold assembly by lifting it off.
Remove exhaust muffler (2) together with the
bracket on the right side.
9. Fan securing bracket

Loosen the six bolts to take off bracket (3).
12. Fuel filter assembly

1) Take off two tubes (3) between fuel filter
head (1) and fuel supply pump (2).
2) Remove the bolts securing fuel filter head to
detach the fuel filter assembly.
10. Turbocharger lubrication tube
3) Take off harness connectors (4) and (5) for
1) Remove the bolts that secure lubrication
fuel supply pump.
tube (1) on the turbocharger side and the
engine block side.
2) Take off two clamps (2) on the head and
another one at the head side to remove the
lubrication tube.
125-3 SERIES 13-9

1
13. Oil filter 18. Suction manifold assembly

1) Take off two tubes (2) between oil filter head 1) Remove the right and left bolts of suction
(1) and the cylinder block. manifold (1), then fit guide bolts , and
2) Remove filter head (1) securing bolts to remove the securing bolts (24 bolts in total).
detach the oil filter assembly. 2) Lift off the manifold assembly for disman-
tling.
★ Fix slings to the right and left sides of the
suction manifold and lift it off temporarily to
remove each bolt.
14. Wiring harness

1) Take off each clamp holding wiring harness
(1) leading to the injector from gate type
frame (2) above the suction manifold.
2) Take off each connector (3) connected to 19. Supply pump
the injectors to detach wiring harness 1) Take off lubrication tube (2) of supply pump
assembly (1). (1).
17 2) Take off each clamp (4) between the supply
pump and common rail (3) to detach boot
(5).
3) Loosen four sleeve nuts (6) to take off the
two tubes.
4) Take off cover (8) for the pump driving gear
that is attached to the front of engine front
cover (7).
15. Take off air cleaner securing bracket (1).
16. Take off exhaust muffler securing bracket (2).
17. Take off each high-pressure tube clamp (3).
5) Confirm that punching mark C (12) on sup-

ply pump driving gear (11) is matched with
the C mark on the camshaft gear, when
matching pointer (9) on the front cover with
punching mark 1.6 TOP (10) on the damper.
6) Remove the nuts and washers that secure
pump driving gear (11).
★ At that time, take care not to let fall the nuts
and washers inside the front case.
13-10 125-3 SERIES

1
9) Dismantle pump assembly (1).
7) Detach gear (11) off the pump shaft, using

special tool K. (Leave the detached gear
20. Common rail
inside the case)
1) Take off three clamps (3) for high-pressure
★ At that time, know that a woodruff key is fitted
tubes (2) connecting common rail (1) and
to the pump shaft. Hence take care not to let
the injectors.
fall it.
2) Take off protector (4) located where high-
pressure tubes (2) connected to common
rail (1) is installed.
8) Remove the bolts that secure pump (1) to

the front case and bracket (13).
3) Loosen each sleeve nut (5) for six high-
pressure tubes (2) between common rail (1)
and the injectors, and take off the high-pres-
sure tubes one by one in proper sequence.
4) Detach common rail (1) together with the
brackets.
125-3 SERIES 13-11

1
21. Spill pipe 24. Rocker arm

Take off fuel spill pipe (1) and water spill pipe 1) Loosen lock nut (3) for locker arm adjusting
(2). screw (2) to loosen the screw.
2) Remove locker arm securing bolts (4) to
take off the locker arm.
22. Head cover

Take off head cover (1). (There are 12 bolts fix-
ing it) 25. Push rod
1) Remove 12 push rods (1).
23. Injector harness

1) Remove two nuts (2) that secure the har- 26. Injector
ness plate to the head of injectors (1). 1) Remove bolt (3) for holder (2) that secures
2) Loosen bolt (3) for the harness fixing holder. injector assembly (1) so as to detach the
assembly.
★ Never attempt to hold the solenoid valve on
top of the injector with a plier or the like.
13-12 125-3 SERIES

1
27. Nozzle tip 4) Remove retaining nut (4) from injector (3).
★ [EPA regulations] 5) Pull up nozzle assembly (5) vertically to
In countries where the EPA regulations are en- detach it. At that time, do not remove tip
forced, the nozzles in the common rail engines guide (6).
must be replaced as an assembly. On the other
hand, in countries where the EPA regulations are
not in place yet, the nozzle tips may be replaced
in the following manner.
1) Fix injector securing jig L to vice .
★ It is forbidden to hold an injector direct with a
vice. Be sure to use the jig L.
6) There is no need to disassemble tip guide

(6) any further than shown below.
★ Take care not to allow dust or any other for-
eign objects to enter the inside.
2) Set injector assembly (3) on the injector fix-

ing jig.
28. Crosshead
Remove 12 crossheads (1).
3) Apply 19 mm deep socket wrench to

retaining nut (4) and turn it counterclockwise
to loosen it.
125-3 SERIES 13-13

1
29. Rocker arm housing 32. Cam follower cover

Remove seven bolts (2) that secures housing Take off three cam follower covers (1).
(1) to detach it.
33. Cam follower

30. Injector harness connector Remover 12 securing bolts (1) to take off cam
★ How to remove injector harness connector follower (2).
(2) from rocker housing (1) ★ Remove dowel ring (3).
1) Remove bolt (4) of lock plate (3) for connec-
tor (2) to take off the lock plate.
2) Push connector (2) outward.
3) Remove O-ring (5) attached to connector
(2), then push the connector in and take it
off together with harness holder (6).
34. Cylinder head assembly

1) Remove each of the seven bolts that secure
cylinder head (1).
2) Fix sling to the cylinder head to lift it off.
3) Remove each of gaskets (2).
31. Thermostat
Take off thermostat case (1) and tube (2).
13-14 125-3 SERIES

1
• Disassemble the cylinder head assembly in the 36. Oil pan

following sequence. Turn the engine assembly 180 degrees and
1) Compress valve spring (3) with spring detach oil pan (1).
pusher C and take off valve cotter (4).
2) Remove upper seat (5) and valve spring (3).
37. Flywheel
1) Turn the engine assembly 180 degrees,
3) Remove seal (7) and then lower seat (8). then fix sling to the flywheel (1) and sling
4) Raise the cylinder head and take off valve the engine.
(6). 2) Remove the six securing bolts, then take the
★ Take note that seals are used only on flywheel off the knock pins and lift it off.
the exhaust side.
★ Assign a number to each valve to show
the right combination with the cylinder
head.
38. Flywheel housing

1) Fix slings to the right and left sides of fly-
wheel housing (1) to sling it.
2) Remove the ten securing bolts, then take
35. Setting to engine overhaul stand the housing off the knock pins and lift it off.
1) Lift off the engine and match previously fit-
ted adapter A with engine overhaul stand B
to set the engine assembly to the stand.
125-3 SERIES 13-15

1
39. Damper 43. Camshaft

Sling damper (1), then remove the six securing 1) Remove two securing bolts (1).
bolts and lift it off. 2) Detach camshaft (2).
★ When removing the camshaft, rotate it and
put it out gently so that the cam bushing may
not damaged.
40. Front support

Remove the securing bolts of front support (1),
then take off support.
44. Oil pump
41. Front cover Remove four mounting bolts (1) and dismantle
Remove the bolts of front cover (2), then lift it oil pump (2).
off.
45. Idler gear

42. Water pump 1) Remove mounting bolt (1), then plate (2)
Detach water pump (1) and tube (2). and take off oil pump idler gear (3).
2) Take off shaft (4).
3) Remove mounting bolt (5), then take off
shaft (6) and main idler gear (7).
13-16 125-3 SERIES

1
2) Rotate the crankshaft so that piston to be

removed is placed in bottom dead center.
3) Remove the carbon from the liner wall using
a fine sand paper.
★ If necessary, measure the end play of
the connecting rod using dial gauge
before removing the piston and connect-
ing rod assembly.
46. Oil suction pipe

Take off bracket (1) and then oil suction pipe (2).
4) Remove bolt (1) from the connecting rod

cap.
5) Remove connecting rod cap (2) and the
connecting rod lower bearing as a unit by
tapping the connecting rod bolt with a plastic
hammer.
★ Take care not to damage the thread of
the connecting rod bolts.
47. Piston cooling nozzle
Remove mounting bolts (1) and each piston
cooling nozzle (2).
6) Push the piston and connecting rod assem-

bly from the oil pan side with a wooden
stick. Hold piston (3) in your hand and
48. Piston and connecting rod assembly
remove it from the cylinder head side.
1) Check stamp numbers on connecting rod
★ Take care not to damage the piston cool-
caps.
ing nozzle.
(Make sure the cap number coincides with
★ During removal, take care not to damage
the cylinder number and also that the num-
the inner surface of the liner with the
ber is stamped on the cam side)
connecting rod.
★ If there is no stamp number, stamp the
number before the cap is removed.
125-3 SERIES 13-17

1
7) Remove the remaining piston and connect- 4) Remove piston rings (8) using piston ring
ing rod assembles in the same manner. tool D.
★ When storing the pistons and connect- ★ Store the piston, connecting rod, con-
ing rods, take care not to damage sliding necting rod bearings, piston rings, and
portions of the piston and the connecting piston pin for every cylinder.
rod bearings.
★ Assemble the connecting rods and the
caps temporarily, and keep them togeth-
er with the bearings to avoid confusion
during the reassembling work.
49. Crankshaft
★ If necessary, measure the crankshaft end
play using dial gauge before removing the
crankshaft.
• Disassemble the piston and connecting rod

assembly as follows.
1) Remove snap ring (4).
2) Pull out piston pin (6) while holding connect-
ing rod (5) in your hand, and separate con-
necting rod from piston (7).
3) Remove the snap ring on the opposite side.
1) Remove mounting bolts (2) for main cap (1).

2) Insert a bolt into the hole on the main cap,
and remove the main cap by shaking it.
13-18 125-3 SERIES

1
3) Since lower thrust bearing (3) is installed to 6) Remove upper bearings (6).
main cap No. 7, mark the installation posi- ★ Put identification tags on the main caps,
tion after removing the cap. main bearings, and thrust bearings or mark
their installation positions with a felt-tip pen,
segregate them for each cap, and store them
properly to protect them from damage.
4) Using nylon slings, lift off crankshaft (4).

★ When lifting the crankshaft, take care not
to let it hit against the cylinder block.
★ Store the crankshaft in an appropriate 50. Cylinder liner
place so that its sliding portions do not Pull out cylinder liners (1) using liner puller E.
get damaged. ★ If necessary, measure the cylinder liner pro-
trusion using dial gauge before removing
the cylinder liners.
5) Remove upper thrust bearing (5).
125-3 SERIES 13-19

1
DISASSEMBLY AND ASSEMBLY GENERAL ASSEMBLY
GENERAL ASSEMBLY
TIGHTENING BOLTS BY THE POLASTIC RANGE 3) Punch a mark after tightening the bolt. Do not
TURNING ANGLE METHOD use the bolt again if there are already five
• Important bolts in the 125-3 Series engines are marks punched, but replace it with new one.
tightened by the plastic range turning angle 4) If the bolt is tightened in excess of the speci-
method. In this method, special bolts are used. fied angle, once loosen it completely and
By being tightened to the load (plastic range) at tighten it again. (Punch two marks at that time)
which they begin to be permanently deformed, 5) The tightening angle should be targeted at
accurate and high tightening force can be the standard value plus or minus tolerance.
obtained. ★ Clean every part thoroughly and check the part
★ The most common method for tightening bolts is for dents, flaws, and blowholes. When assem-
the torque control method. In this method, how- bling the parts, make sure that none of the oil and
ever, it is difficult to accurately control the tight- water passages are blocked.
ening force because of the coefficient of friction.
• The plastic range turning angle method is based Preparation work
on the initial tightening torque and the turning • Install adapter to the cylinder block, then raise it
angle. and place it on engine overhaul stand.
• Bolts to be tightened by the plastic range turning • Repair the cylinder block as follows before
angle method in the 125-3 Series engines. inserting the cylinder liners.
1) Cylinder head mounting bolts 1) Remove rust and scale from surfaces
2) Main cap mounting bolts and with sandpaper until the machined
3) Connecting rod cap mounting bolts surface is exposed.
2) Polish portion with No. 240 sandpaper to
make surface smooth.
(P la st ic ra ng e)
3) Polish portions and with No. 240 sand-
paper to make them smooth.
If portion is edgy or burred, polish it with
sandpaper or a scraper.
Axial force
Plastic range turning angle

ange
method Finish this portion to an especially smooth

surface to protect the O-ring from damage.
tic r
4) If the pitting in surface is so rough that it

(Elas
Torque method cannot be repaired, replace the cylinder block.

(conventional method)
5) If surface and portion are roughened
with pitting, finish them smooth.
6) Inspect the counterbore section and remove
any burrs. Chips and dirt on surface will
Elongation of bolt
DEE00088 cause poor contact of the liner, which will lead
to water leakage or improper liner projection.
★ In the plastic range turning angle method, the ★ Repair the counterbore section if there is
permanent strain remains in bolts after they are any drooping, corrosion, or pitting.
tightened. Therefore, the number of times that
each bolt can be reused is limited. Observe the
following precautions.
1) Before tightening, measure the stem length
of bolt and check that bolt length exceeds
tolerance limit or not. Do not reuse any bolt
which has exceeded the tolerance limit.
Before tightening, measure the free length
of bolt and check that bolt length exceeds
tolerance limit or not.
2) If a bolt has been tightened in excess of the
specified turning angle, loosen the bolt and
measure the free length of bolt again.
13-52 125-3 SERIES

1
1. Cylinder liner 5) Install the liner O-ring and clevis seal as

★ Replace the liner O-ring and clevis seal with shown in the diagram.
new parts just before assembling the liner. ★ Install the clevis seal with the cham-
• Method of installing liner O-rings and cle- fered side down.
vis seal
1) Confirm that the cylinder liner O-ring
grooves and the circumference of the
liner are free from rust and pitting.
★ If these surfaces are roughened
Cylinder liner
with pitting, replace the liner to re-
Clevis seal
move the cause of water leakage. Black (Ethylene propylene rubber)
2) Coat liner O-rings and clevis seals with
O-ring
clean SAE No. 30 engine oil. Black (Ethylene propylene rubber)
★ The clevis seal and black O-ring will
O-ring
become swollen and degraded be- Orange (Silicon rubber)
cause of oil. To prevent this, do not
leave these parts immersed in oil. DEE00090
Apply a little oil with a brush just be-

fore assembling the parts. • Method of inserting cylinder liners
3) After fitting the O-ring on the cylinder 1) Coat the counterbore with gasket sealant
liner, check that it is not twisted. If it is (LG-6).
twisted, use a smooth bar (approx. 10 ★ Diameter of line of sealant:
mm O.D.) to remove the twist from the Ø1.5 – 2.0 mm
O-ring. 2) Coat the liner O-ring and cylinder block O-
ring groove with RF-1 rubber lubricant. As
equivalent to RF-1, DS-50, the product of
Daido Chemical Industry, is available in the
commercial markets. If RF-1 is not readily
available, use clean engine oil (SAE #30)
instead.
★ Coat by hand uniformly around the
whole circumference.
3) Set the "A or B" mark on the top surface of
the liner facing the front, then insert the liner
into the cylinder block, taking care not to
damage the O-ring.
4) Insert the liner by pushing with both hands
and using all your weight.
4) To prevent the clevis seal from twisting, ★ If the liner does not go in smoothly when
continue to press the whole circumfer- you push with your weight, there is dan-
ence until it is installed properly in the ger that the O-ring may by damaged, so
groove. check for any burrs or flashes on the cyl-
inder block.
Press it to the grove
Chamfered side
DEE00089
125-3 SERIES 13-53

1
5) Using liner driver F, press fit cylinder liner (1) 2. Crankshaft

to the cylinder block. ★ The cylinder block and main bearing are se-
lective fitting parts, but spare parts are avail-
able for supply to maintain the clearance.
1) Align the protrusion of upper main bearings
(6) with the groove in the cylinder block, and
assemble to the cylinder block.
★ Check that there is no dirt or dust stuck
to the rear face of the bearing before in-
stalling. Coat the inside surface of the
bearing with SAE 30 engine oil. Do not
coat the rear surface with oil.
★ Use the following procedure to squeeze

out the gasket sealant coated on the
counterbore.
i) Use an old head gasket and tighten the
cylinder head temporarily.
3 Mounting bolt:
127.5 – 147.1 Nm{13 – 15 kgm}
ii) Remove the cylinder head, then wipe off
all the gasket sealant that was squeezed
out between the cylinder liner and cylin-
der block. 2) Drive in the roll pin so that the protrusion
• If the gasket sealant gets on the grommet in from the end face of the block is 1.5 to 1.9
the head gasket, it will deform the grommet mm, and install upper thrust bearing (5).
and this will cause water leakage, so be ★ Assemble the thrust bearing so that the
careful to wipe off all the gasket sealant. side with the groove is on the crankshaft
6) After press fitting the cylinder liner, use dial side.
gauge and measure the protrusion of the
cylinder liner.
★ When measuring the protrusion of the
liner, press the liner with a plate to re-
move any rise of the liner caused by the
O-ring.
★ Cylinder liner protrusion:
0.07 – 0.15 mm
★ If the measurement is not within the
specified value, take the action given in
STRUCTURE AND FUNCTION, MAIN-
TENANCE STANDARD.
3) Before assembling the crankshaft, check

the following points.
i) Check for abnormality in the front or
rear side thread.
(The bolt can be screwed in smoothly by
hand)
ii) Check for any scratches or dents in the
pin or main journal portion.
iii) Check for any dirt stuck inside the oil
hole.
4) Using a nylon sling, raise crankshaft (4) and
set it in the mounting position.
13-54 125-3 SERIES

1
★ When doing this, be careful not to let it 7) Coat the crankshaft journal with SAE30
hit the cylinder block and be damaged. engine oil, confirm that stamp No. on main
★ When replacing the crankshaft gear, cap (1) coincides with the number on the
heat the new gear in an electric furnace cylinder block, and install the main cap.
at 200°C for at least 30 minutes, and ★ Install the main cap with the embossed
shrink fit it. number facing the engine front.
8) Before tightening main cap mounting bolt
(2), make sure as follows.
i) Measure the stem length a of all bolts
and check that bolt length exceeds tol-
erance limit or not.
ii) Tolerance limit of bolt stem length:
Max. 159.8 mm
★ If the bolt length a exceeds tolerance
limit, do not reuse.
★ Coat the main cap mounting bolt thread
portion and main cap seat washer with
engine oil (SAE30).
5) Install lower main bearing (7) with the pro-

jected part of the bearing aligned with the
groove on the main cap.
★ Before installing the bearing, make sure
that no foreign matter is stuck on the
back of the bearing. Do not coat oil on
the bearing backside then.
6) Drive the roll pin into the No. 7 cap until its
protrusion reaches 1.5 to 1.9 mm from the
end of the cap, and install thrust bearings
(3) to both sides.
★ Install the thrust bearings with the
grooved side facing the crankshaft. 9) Tighten mounting bolts (2) of main cap (1) in
turn to fit main cap fully.
10) Tighten main cap mounting bolts (2) as fol-

lows.
★ When tightening the bolts, start from the
center and work to the outside. Tighten
the bolts to the specified tightening
torque in the following steps.
125-3 SERIES 13-55

1
•When using tool G to tighten the main cap

mounting bolts
3 Main cap mounting bolt
1st step: Tighten to
98.1 ± 9.8 Nm {10.0 ± 1.0 kgm}
2nd step:Tighten again to
196.1 ± 4.9 Nm {20.0 ± 0.5 kgm}
3rd step: 90° +30°
0
i) Tighten mounting bolts to second stage
with torque wrench or tool G.
ii) With tool G set to mounting bolt, install
tube and clip to tool G, then set clip to
engine block.
iii) Set scale angle of tool G to 90°, then
tighten until scale reads 0°.
• When not using tool G

3 Main cap mounting bolt
98.1 ± 9.8 Nm {10.0 ± 1.0 kgm}
2nd step:Tighten again to
196.1 ± 4.9 Nm {20.0 ± 0.5 kgm}
3rd step: Mark bolt and cap with felt-tip pen,
then tighten bolt 90° +30°
0
• With the above procedure, use a torque

wrench to tighten the mounting bolts.
11) After tightening the bolts, rotate the crank-
shaft and check that it rotates smoothly.
12) Measure end play of the crankshaft with dial
gauge . If it is outside the standard value,
take actions according to the maintenance
standard.
★ End play: 0.14 – 0.315 mm
13-56 125-3 SERIES

1
3. Piston and connecting rod assembly

★ The piston and cylinder liner are selective fit-
ting parts, and parts which ensure the nar-
row clearance are provided as spare parts.
Reassemble the piston and connecting rod
assembly as follows.
1) Remove expander from oil ring, fit in oil ring
groove of piston, then assemble oil ring.
2) Using tool D, assemble piston rings (8) in
the order of oil ring, 2nd ring, and top ring.
★ When doing this, check that the expand-
er is fitted completely in the ring groove.
★ Set the protruding part of the expander
coil at 180° to the end gap of the oil ring. 5) Coat the piston boss with engine oil
★ Assemble each piston ring as shown in (SAE30), match the number stamped on the
the diagram. connecting rod with the cylinder number on
★ Install each ring to the piston with the the piston head, set the numbers facing in
stamped mark facing up. the same direction, then insert piston pin
(6), and assemble piston (7) to connecting
rod (5).
6) Install snap ring (4) on opposite side.
★ Turn the snap rings to check that the left
and right snap rings are completely fitted
in the ring groove.
7) Align the protruding part of connecting rod

upper bearing (8) with a notch in connecting
rod (10), and install.
on the backside of the bearing, then in-
stall. When doing this, the backside sur-
face must not be coated with oil.
3) Install snap ring (4) on one side. ★ Check that the bearing hole and con-
4) Heat up piston (7) in a heating furnace at necting rod oil hole are aligned.
100°C for more than 5 minutes.
★ If no heating furnace is available, heat in
hot water at 100°C for more than 5 min-
utes.
★ If the piston is heated up in hot water,
clean it completely after setting it.
125-3 SERIES 13-57

1
10) Turn the embossed letters on the connect-

ing rod to face the engine front side (the
punching number is then on the camshaft
side), then position the piston ring end gap
as illustrated and insert piston and connect-
ing rod assembly (3).
★ When inserting the piston and connect-
ing rod assembly, be careful not to dam-
age the piston cooling nozzle.
8) Align the protruding part of connecting rod

lower bearing (9) with the notch in connect-
ing rod cap, and install.
on the backside of the bearing, then in-
stall. When doing this, the backside sur-
face must not be coated with oil.
9) Set the crankshaft for the cylinder to be

assembled to the bottom dead center, and
coat the inside surface of the connecting rod 11) Using tool G, compress the piston ring and
bearing and inside surface of cylinder liner push in the piston head with a wooden bar.
with engine oil (SAE30). ★ When inserting the piston, be careful not
to damage the piston cooling nozzle.
Check also that the nozzle is positioned
at the center of the notched portion of
the piston.
★ When assembling the piston and con-
necting rod assembly, assemble it when
the crankshaft is at the bottom dead cen-
ter.
13-58 125-3 SERIES

1
13) Before tightening the connecting rod bolts,

check the following points.
i) Measure the stem length a of all bolts
and check that bolt length exceeds tol-
erance limit or not.
ii) Tolerance limit of bolt free length:
Max. 84.1 mm
★ If the bolt length a exceeds tolerance
limit, do not reuse.
12) Coat connecting rod lower bearing (9) with

engine oil (SAE30), check the cap number,
align with the dowel pin, and install connect-
ing rod cap (2).
★ When coating engine oil, spread the oil
on the whole surface with a finger.
14) Coat the washer and thread of the connect-

ing rod bolt with engine oil (SAE30).
★ When assembling a new connecting rod,

mark the cylinder number with an elec-
tric pen (do not use a stamping tool).
15) Tighten connecting rod bolts (1) in turn until

the connecting rod cap is tightly fitted.
125-3 SERIES 13-59

1
★ If an impact wrench or other tool is used

to tighten the bolts at high speed, the
thread may be damaged, so tighten with
a hand tool.
19) Using gauge H, measure protrusion from

top surface of the cylinder block to top of the
piston.
★ Piston protrusion: 0.984 – 1.335 mm
(Push top surface of the piston, and
16) Tightening connecting rod bolts
3 Connecting rod cap bolt
check that oil clearance is 0 and that
there is no rocking)
98.1 ± 4.9 Nm {10.0 ± 0.5 kgm}
2nd step:Mark bolt and cap with felt-tip pen,
then tighten bolt 90° +30°
0
★ For tightening the connecting rod, see 2-
10) and tighten to the specified value
above.
4. Piston cooling nozzle

Install piston cooling nozzle (2) to each piston
and mounting bolt (1).
★ It is critical that the piston cooling nozzle
holds the right injection direction. Follow the
installation steps below strictly and take
good care in handling the nozzle.
17) After installing the piston and connecting rod 1) Install the nozzle after assembling the piston
assembly, rotate the crankshaft and check and connecting rod assembly.
that there is no catching or abnormality in 2) Position the nozzle at the notch center of
the rotation. each piston.
18) Using dial gauge , measure side clear- 3) Put all the nozzles in array and check them
ance of the connecting rod. for any abnormality like bending before
★ Standard value for side clearance: installation.
0.2 – 0.375 mm 4) In disassembling, be sure to take off the
nozzle first and then the piston and connec-
tion rod assembly.
3 Mounting bolt:
27.4 – 34.3 Nm {2.8 – 3.5 kgm}
13-60 125-3 SERIES

1
★ Precautions when assembling idler gear

Align the "A" mark on the crankshaft gear
with the "A" mark on main idler gear (7),
then tighten mounting bolt (5).
5. Oil suction pipe

Fit O-ring, install oil suction pipe (2), then fit
bracket (1) and secure the pipe in position.
7. Oil pump
1) Fit O-ring, install oil pump (2), then tighten 4
mounting bolts (1).
3 Mounting bolt:
68.6 ± 4.9 Nm {7.0 ± 0.5 kgm}
2) Knock in the pin and install shaft (4).
6. Idler gear
1) Assemble plate (8) to the engine block, then
install gear (7) and shaft (6), and tighten
mounting bolt (5).
★ Assemble plate (8) with the chamfered
end facing the front of the engine.
3 Mounting bolt:
245 – 294 Nm {25 – 30 kgm}
3) Assemble oil pump idler gear (3), then
install plate (2) and tighten mounting bolt
(1).
3 Mounting bolt:
147.0 – 176.4 Nm {15 – 18 kgm}
125-3 SERIES 13-61

1
10. Cam follower covers

Fit O-rings and install cam follower covers (1).
3 Mounting bolt:
11.3 ± 1.5 Nm {1.15 ± 0.15 kgm}
8. Camshaft
Coat the camshaft journal surface with engine
oil (SAE30). Align "B" mark of the camshaft gear
with "B" mark of the main idler gear, install cam-
shaft (2), then tighten mounting bolts (1).
3 Mounting bolt of plate:
11. Water pump
Install an O-ring to water pump assembly (1)
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
and install the assembly to the engine.
★ When installing the camshaft, rotate the cam-
shaft to prevent damage to the cam bushing.
★ If the cam gear has been replaced, heat the new
cam gear in an electric furnace at 200 to 240°C
for more than 30 minutes, then shrink fir the gear.
12. Fuel supply pump driving gear

1) Align the C mark on fuel supply pump driv-
ing gear (1) with the C mark on camshaft
gear (2) and set the pump.
2) Align the woodruff key in the driving shaft of
9. Cam followers
fuel supply pump (3) with the key slot in driv-
1) Knock dowel ring (3) into the cylinder block.
ing gear (1), and then engage the pump and
2) Tighten 6 cam follower assemblies (2) with
the gear.
bolts (1).
3 Mounting bolt:
3) Install the fuel supply pump, then fit a
washer to driving gear (1) and tighten nut (4)
51.5 ± 7.4 Nm {5.25 ± 0.75 kgm}
to the specified torque.
3 Gear mounting nut:
127 – 147 Nm {13 – 15 kgm}
★ Coat four mounting bolts (5) of fuel supply
pump (3) with LT-2 liquid adhesive com-
pound.
13-62 125-3 SERIES

1
2) Standard end play for each gear
Position Range (mm)

1 0.09 – 0.48
2 0.10 – 0.25
3 0.05 – 0.17
4 0.05 – 0.21
5 0.03 – 0.09
★ Check that each counter mark matches with

each other between the driving gear and the
idler gear.
13. Front cover

1) Using a push tool (120 mm O.D.), press fit
oil seal (3) into the cover.
★ Oil seal press-fitting tolerance a: 11 +10 mm
2 Fill oil seal lip (50 to 80% of space
★ Measure backlash and end play of each gear at lip) with grease (G2-LI).
using a dial gauge .
1) Standard backlash for each gear
Position Range (mm)

a 0.127 – 0.393
b 0.127 – 0.393
c 0.139 – 0.427
d 0.128 – 0.405
e 0.082 – 0.389
125-3 SERIES 13-63

1
2) Coat front cover (1) with gasket sealant and

install it by lifting it up. (Use a guide bolt)
★ When installing the cover, be careful not 11 12 9 10
to damage the oil seal.
2 Mating surface:
Gasket sealant (LG-7) 6 7 4 5
3) Fit tachometer drive assembly (2). 5 8 3 6
4) Install cover (3) for the fuel supply pump
drive gear. 1,4 2,9 2 7
5) Using a dial gauge, measure the stepped 3 10 1 8
difference between the cylinder block and 1st step 2nd step
front cover. DEE00102
★ Stepped difference: 0 – 0.275 mm
6) Install front support (4).
1) After installing the flywheel housing, mea-
sure the face runout and radial runout with
dial gauge .
★ Radial runout: Max. 0.20 mm
★ Face runout: Max. 0.20 mm
• Measuring face runout of flywheel housing
Measure as follows.
i) Put magnet stand (1) in contact with the
end face of the crankshaft.
ii) Set dial indicator (2) so that its probe is
in contact with the end face of the fly-
wheel housing at the right angle.
iii) Rotate the crankshaft one turn, and
read out difference between the maxi-
14. Flywheel housing mum value and the minimum value of
Raise flywheel housing (1), coat the mounting the indicator.
surface with gasket sealant, then install on the ★ When measuring, measure at least
cylinder block and tighten bolts (2). 8 places evenly spaced around the
2 Contact surface: Gasket sealant (LG-7) circumference of the end face of the
2 Coat the bolt thread and seat face with flywheel housing.
engine oil (SAE30) before tightening. ★ When measuring, move the crank-
shaft either to the front or rear to
pr e v e nt a ny er r o r fr o m be i n g
caused by the end play.
★ Check that the indicator returns to
the original position when the
crankshaft is rotated one full turn.
★ The indicator will fluctuate either to
the left or right, so be careful not to
misread the direction of fluctuation
when the indicator is at the top or
bottom, or left or right of the end
face being measured.
★ Tighten the mounting bolts of the flywheel

housing in the order shown in the diagram
and to the following torques.
3 Flywheel housing mounting bolt
Unit: Nm {kgm}
Order Target Range
1st step 186.3 {19} 147.1 – 235.3 {15 – 24}
2nd step 274.6 {28} 245.2 – 308.9 {25 – 31.5}
13-64 125-3 SERIES

1
• Measuring radial runout of flywheel housing

Measure as follows.
Make sure that the probe of dial indicator (2)
is in contact with the spigot joint portion of
the flywheel housing at the right angle, i.e. in
the same way as when measuring face
runout.
★ When measuring the radial runout, there
is no error caused by the end play of the
crankshaft, but the other precautions are
the same as the precautions followed
when measuring the face runout.
• Procedure for assembling standard seal

★ Before assembling the seal, check tat
there is no damage, burrs, flashes, or rust
on the housing, sliding surface of the lip
and the corner of the end face of the
crankshaft.
★ When assembling the seal, do not coat
the shaft or seal lip with oil or grease. If
there is any oil or grease on the shaft,
wipe it off completely.
★ Do not remove the plastic tube inside the
standard seal provided as a spare part un-
til immediately before assembling the seal.
2) Using dial gauge , measure the stepped
difference between the cylinder block and
flywheel housing.
★ Stepped difference: 0 – 0.35 mm
Lip at engine end Lip at PTO end
Assembly guide
(plastic tube)
Large inside Small inside

diameter end diameter end
DEE00105
1) Put large inside diameter end of plastic

inner tube (3) in contact with the end of
crankshaft (4).
★ Be particularly careful not to mistake
15. Rear seal the direction when assembling.
Check the condition of wear of the shaft, then
select the standard seal or a seal with sleeve for
Teflon seal (lay-down lip seal) and assemble the
seal.
The condition of wear of the shaft can be judged
from the degree of luster (touch with the flat of
your finger to check that the depth of wear is
less than 10 µm). If there are no scratches,
assemble a standard seal. In all other cases,
assemble a seal with sleeve.
125-3 SERIES 13-65

1
2) Hold the metal ring of seal (2) with both

hands, and push it in evenly and giving
sudden pushing force.
3) After pushing in seal, remove plastic
inner tube (3).
★ Be particularly careful not to dam-
age the seal lip when removing the
inner tube.
1) Set sleeve/seal (2) to tool C2.

2 Surface of sleeve inner tube:
Gasket sealant (LG-7)
4) Tighten bolts (C2-2, C3-1) uniformly until

the end face of tool C3 contacts the end
face of crankshaft (4) to press fit seal (2).
★ When press fitting the seal, be ex-
tremely careful not to damage the lip
at the PTO end when setting the tool.
★ After press fitting the seal, remove
the red sealant layer from the out-
side circumference.
2) Put the sleeve of the seal in contact with
the end face of the crankshaft, tighten
bolt (C2-2) of tool C2 uniformly until the
end face of tool C2 contacts the end
face of crankshaft (2) to press fit sleeve/
seal (2).
• Procedure for assembling seal with sleeve

★ Before assembling the seal, check that
there is no damage, burrs, flashes, or
rust on the housing, sliding surface of
the lip and the corner of the end face of
the crankshaft.
3) Remove tool C2 and replace with tool
★ When assembling the seal, do not coat
C3.
the shaft, and the space between the
4) Tighten bolt (C3-2) of tool C3 uniformly
sleeve and seal lip with oil or grease. If
until the end face of tool C3 contacts the
there is any oil or grease on the shaft,
end face of crankshaft (4) to press fit
wipe it off completely.
sleeve/seal (2).
★ Handle the seal and sleeve as an as-
sembly. Never separate them.
13-66 125-3 SERIES

1
★ After press fitting the seal, remove 3) Using dial gauge , measure the face
the red sealant layer from the out- runout and radial runout of the flywheel.
side circumference. ★ Face runout: below 0.20 mm
★ Radial runout: below 0.15 mm
16. Flywheel
1) Fix sling to flywheel (1), lift it off and
install, aligning with the knock pin.
★ Thoroughly coat the thread of mounting bolts
(2), seat face and the washer with clean lu-
brication oil (EO30-CD).
3 Mounting bolt:
1st step: 147.0 ± 19.6 Nm {15.0 ± 2.0 kgm}
2nd step: 289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
17. Damper
Lift off damper (1) and install it.
3 Damper mounting bolt:
Width across flats 22 mm, 1 bolt
156.8 – 196.0 Nm {16 – 20 kgm}
Damper mounting bolt:
Width across flats 24 mm, 5 bolts
245.0 – 308.7 Nm {25.0 – 31.5 kgm}
2) Tighten the flywheel mounting bolts in the

sequence shown in the diagram below.
125-3 SERIES 13-67

1
18. Oil pan 21. Cylinder head

1) Turn the engine assembly 180°. • Assemble the cylinder head assembly as fol-
2) Coat gasket sealant on the whole mating lows.
surface of the circumference (line diameter 1) Coat the valve stem and the inside surface
Ø 1 mm) of oil pan (1), then install it and of the valve guide with engine oil (SAE30),
tighten the mounting bolts to the specified then assemble valve (6).
tightening torque. 2) Raise the cylinder head, then fit lower seat
2 Mating surface: (8) and install seal (7).
Gasket sealant (LG-7)
3) Assemble valve spring (3) and upper seat

19. Removing engine assembly from engine (5).
overhaul stand 4) Using spring pusher C, compress the valve
1) Turn the engine assembly 180° and sling it. spring and install valve cotters (4).
2) Separate engine overhaul stand B and ★ Tap the valve stem with a plastic hammer to
adapter A. check that the cotters are fitted securely in
3) Remove adapter A from the engine assembly. the valve stem groove.
20. Setting engine assembly on blocks 22. Cylinder head assembly

Prepare for sturdy and steady blocks and ★ Thoroughly clean the cylinder head lower
place the engine assembly (1) on them. surface, cylinder block top surface and cylin-
der liners with a dry cloth or cloth with sol-
vent.
★ Coat threads of the mounting bolts and bolt
stem with LM-P or SAE30 engine oil.
★ Tighten the mounting bolts by hand for the
first two turns or more.
★ Before tightening the cylinder head bolts,
measure the stem length a of all the bolts
and check that bolt length does not exceed
tolerance limit or not. Do not reuse any bolt
which has exceeded the tolerance limit.
• Tolerance limit of bolt stem length:
Max. 171.4 mm
13-68 125-3 SERIES

1
★ Tighten the mounting bolts to the specified

torque as follows.
3 Cylinder head mounting bolts
98.1 ± 9.8 Nm {10 ± 1 kgm}
2nd step: Tighten to
156.9 – 166.7 Nm {16 – 17 kgm}
3rd step: Mark the bolt and bolt head with a
felt-tip pen and turn the bolt 90° +30°
0
★ Tighten bolt to
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}.
★ If any bolt is tightened exceeding the speci-

fied angle, remove the bolt and measure the
bolt stem length again.
1) Set each cylinder head gasket (1) on top of
the cylinder head.
★ After tightening, punch a mark on each bolt

head. Do not use a bolt which already has
five punching marks, but replace it with new
one.
2) Lift off cylinder head (2) with sling and set

it on the cylinder block.
3) Tighten each cylinder head mounting bolt

(3) to the specified torque for each cylinder
head (2).
125-3 SERIES 13-69

1
4) For the 3rd step tightening, use following 3) Insert lock plate (3) into the groove of con-
tool J (angle tightening wrench), and tighten nector (1).
the bolts to 90° +30°
0 in the sequence of – 4) Secure the lock plate to the housing with
as shown in the diagram above. mounting bolts (4) to fix the connector.
5) Secure harness holder (5) to the housing
with mounting bolts.
3 Harness holder mounting bolt:
19.6 – 25.5 Nm {2.0 – 2.6 kgm}
23. Rocker arm housing

1) Fit gasket (1) and then assemble rocker arm
housing (2).
2) Tighten mounting bolts (3) to the specified
torque. 25. Crosshead
3 Mounting bolt: 1) Set each crosshead (1), then loosen lock
58.8 – 73.5 Nm {6 – 7.5 kgm} nut (2) and unscrew adjusting screw (3).
2) Lightly hold down the contact surface of the
crosshead and rocker arm with a finger.
Hold the crosshead in contact with the valve
stem on the pushrod side.
3) Turn the adjusting screw until it comes to
contact the valve stem at hand.
4) After the adjusting screw contacts the valve
stems, tighten it a further 20°, and then
tighten the lock nut.
★ Coat the crosshead guide and cross-
head top with SAE30 oil thoroughly and
assemble them.
3 Locknut:
58.8 – 73.5 Nm {6 – 7 kgm}
24. Assembling injector harness connector to
rocker arm housing
1) Take out injector harness connector (1) from
within the housing without O-ring.
2) Fit O-ring (2) to the connector and push it
inside the housing.
13-70 125-3 SERIES

1
26. Pushrod ★ Crank the engine and adjust the valve clear-
Install pushrod (1). ance of each cylinder in the firing order 1-5-
★ Check that pushrods are inserted securely 3-6-2-4.
into the holes in the cam follower socket. 1) Rotate the crankshaft in the normal direction
to align pointer (2) with the 1.6 TOP mark on
vibration damper (1). When rotating, check
the movement of the valves.
27. Rocker arm

1) Set each rocker arm in the designated posi-
tion.
2) Check that the ball of the adjusting screw is 2) To adjust, insert feeler gauge between
properly fitted into socket (2) of the pushrod, rocker arm (3) and crosshead (4) and turn
and tighten 12 mounting bolts (3). adjustment screw (5) until clearance is a
★ Clean the oil hole in the bolts before installa- sliding fit. Then tighten lock nut (6).
tion. 3 Locknut:
3 Mounting bolts: 58.8 – 73.5 Nm {6 – 7.5 kgm}
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} ★ After tightening the lock nut, check the clear-
★ Set the large hole (Ø13 mm) at the bottom ance again.
and assemble the rocker arm shaft so that
the blind ball plug is at the front.
29. Nozzle tip

★ [EPA regulations]
28. Adjusting valve clearance In the countries where EPA regulations are
Adjust the valve clearance as follows. enforced, nozzles in the common rail engines
★ Adjust the valve clearance so that the clear- must be replaced with a nozzle assembly. On
ance between the crosshead and rocker arm the other hand, in the countries where EPA reg-
is the following value. ulations are not in place, nozzle tips are replace-
★ Valve clearance (both when hot and when able as a single part.
cold) 1) Set injector fixing jig L to vice .
Unit: mm ★ It is forbidden to hold the injectors direct with
Intake valve Exhaust valve a vice. Be sure to use the specified jig.
0.33 0.71
125-3 SERIES 13-71

1
5) After setting nozzle assembly (3), set retain-

ing nut (2) and turn it by hand clockwise to
screw it in.
2) Set injector (1) to fixing jig L.

3) Thoroughly clean the threads of the lower
body and retaining nut (2) with a spray type
parts cleaner, and blow them with com-
pressed air. 6) Set a 19 mm deep socket to a torque
wrench and tighten the retaining nut clock-
wise to the specified torque.
3 Retaining nut: 88.3 Nm {9.0 kgm}
4) Set new nozzle assembly (3), aligning it with

the knock pin of nozzle tip guide (4).
★ When setting the nozzle assembly, be care-
ful not to let fall the nozzle tip. 7) After tightening to the specified torque,
implement angle-tightening.
★ Put a marker (6) on retaining nut (2) and low-
er body (5) and tighten it to a further 45°.
★ Coat the nozzle body with rust inhibitor oil.
13-72 125-3 SERIES

1
30. Fuel injector 4) Tighten two injector harness capture nuts

1) Insert gasket (2) and O-ring (3) into fuel (9) to injector (1).
injector (1). ★ Tighten the two nuts by hand at the same
2) Put injector (1) through injector holder (4) time and then tighten to the specified torque.
and insert it into the rocker housing to fix it 3 Mounting nut:
temporarily. 2.0 – 2.4 Nm {0.2 – 0.24 kgm}
★ Insert injector (1) deeply enough until its seal
surface comes to contact the cylinder head
seal surface. Then check that injector key (5)
is securely fitted in key slot (6) of the rocker
housing.
31. Head cover

Fit an O-ring to cylinder head cover (1), then set
it on the cylinder head and secure it by tighten-
ing 12 bolts to the specified torque.
3 Mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
★ Fit the O-ring so that it may not be twisted.
3) Coat with engine oil spherical portion (7) of

the spherical washer which is fitted to the
top of a bolt hole in injector holder (4). Then
tighten injector holder bolt (8). 32. Spill pipe
3 Mounting bolt: Fit a gasket to both faces of the cooling water
spill pipe and the fuel spill pipe and install them.
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
125-3 SERIES 13-73

1
33. Thermostat 5) Fit each oil seal (3) to head cover (7).
Fit a gasket to thermostat case (1) and tube (2)
and install them.
34. Engine oil cooler

Fit a gasket to engine oil cooler (3) and secure it
with 16 bolts, using a guide bolt at the right and
left on the upper side.
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
6) Tighten the two sleeve nuts for high-pres-

sure tube (9) between fuel supply pump (8)
and common rail (2) all by hand to tempo-
rarily secure the tube.
7) Firmly tighten the sleeve nut of high-pres-
sure tube to the specified torque.
3 Sleeve nut on supply pump side:
39.2 – 49 Nm {4 – 5 kgm}
3 Sleeve nut on common rail side:
35. Engine cooling water temperature sensor 39.2 – 58.8 Nm {4 – 6 kgm}
Install engine cooling water temperature sensor 8) Tighten each bolt of clamp (10) for the high-
(1). pressure tube all by hand to temporarily
secure it, and tighten firmly to the specified
36. Engine oil supply tube torque thereafter.
Fit a gasket to engine oil supply tube (2) and 3 Clamp bolt:
install it. 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
9) Install lubrication tube (11) to fuel supply
pump (8).
3 Mounting bolt on engine block side:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
Mounting bolt on supply pump:
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
37. High-pressure tube for common rail

1) Fix mounting bracket (1) to common rail (2)
and mount it with two bolts.
3 Common rail mounting bracket:
59 – 74 Nm {6.02 – 7.55 kgm}
2) Coat the internal surface of each oil seal with
engine oil and fit it to high-pressure tube (4). 10) Fix three bolts of clamp (12) to six high-
3) Screw sleeve nut (5) in the injector connec- pressure tubes (4) all by hand and tighten
tion and sleeve nut (6) in the common rail all them to the specified torque firmly.
by hand temporarily. 3 Clamp bolt:
4) Install each high-pressure tube (6) one by 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
one and tighten each sleeve nut to the spec-
ified torque firmly.
3 Sleeve nut: 39.2 – 49 Nm {4 – 5 kgm}
13-74 125-3 SERIES

1
11) Tighten clamps (13) for the high-pressure 38. Suction manifold
tube and mounting bolts (16) for gate type 1) Lift off suction manifold (1) with sling . Fit
frame (14) and cover (15) all by hand for each mounting bolt and gasket (2).
temporary securing, and tighten them firmly 2) Fix guide bolt (3) to the front and rear cylin-
thereafter. der heads, then set suction manifold (1) on
3 Clamp bolt: the cylinder head and tighten the mounting
11.8 – 14.7 Nm {1.2 – 1.5 kgm} bolts temporarily.
★ A total of 10 clamps in use for the high-pres- 3) Firmly tighten the mounting bolts to the
sure tube are very critical parts. Should the specified torque in the sequence of – .
engine be kept running with any of them 3 Mounting bolts:
loosened or slipped off, or with the rubber 59 – 74 Nm {6 – 7.5 kgm}
hardened, there is the danger that the rup-
ture of the high-pressure tube is caused due
to friction and vibration at the connection of
the high-pressure tube.
Hence make sure that the high-pressure
tube is assembled with a regular clamp
which is tightened to the specified torque.
★ It is dangerous to have the high-pressure
tube contact any of the nearby wiring har-
nesses for electronic control.
A deformed wiring harness is sometimes
found (like being trampled on) while the ma-
chine is in operation. When replacing a wir-
ing harness close to the high-pressure tube,
the whole replacement work is deemed com- 4) Fit three clamps (5) to six high-pressure
pleted only after it is confirmed that the wiring tubes (4) that are installed on top of suction
harness and the high-pressure tube are sep- manifold (1). Fit clamps (5) to three gate
arated more than 10 mm apart. type brackets (6) all by hand for temporary
If this separation falls short of 10 mm, move securing.
the wiring harness securing position to allow 5) Tighten each clamp bolt for the high-pres-
10 mm distance. sure tubes firmly.
(A contact between the high-pressure tube 3 Clamp bolt:
and a wiring harness poses a danger in that 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
it causes the shield of a wiring harness to
break, which in turn leads to short-circuiting
or wear and damage to the tube)
★ If a high-pressure tube is reused by bending
it, or used for other applications, the tube will
likely be broken, inviting a great danger.
Thus it is forbidden to use a bent high-pres-
sure tube again.
★ Install the fuel supply pump with the slit in the
sleeve boot facing the cylinder block.
125-3 SERIES 13-75

1
6) Secure each gate type bracket by tightening i) Screw in each mounting bolt by hand for
the mounting bolts firmly. 2 - 3 threads.
ii) After tightening to mounting bolts,
tighten the other bolts, too.
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
39. Engine oil filter

1) Secure engine oil filter head (1) temporarily
with four bolts.
2) Assemble filter inlet and outlet tubes (2) and
tighten each mounting bolt temporarily. 3) Install lubrication tube (4) to turbocharger
3) Install the engine oil filter by firmly tightening (3), then tighten the mounting bolts tempo-
bolts in the sequence of the tube upper side rarily and also tighten two bolts for clamp (5)
bolt, tube lower side bolt and head bolt. above the rocker housing.
4) Tighten the lubrication tube mounting bolts
40. Fuel filter to the specified torque and the clamp bolts.
1) Secure fuel filter head (3) temporarily by 3 Tube mounting bolt:
tightening four bolts. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
2) Assemble tube (4) between the fuel filter 5) Install drain tube (6) to turbocharger (3).
and the fuel supply pump and tighten the
mounting bolts temporarily.
3) Tighten the tube to the specified torque.
3 Mounting bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
4) Install fuel filter head (3) by tightening the
mounting bolts firmly.
42. Starting motor

Install starting motor (1) with three mounting
bolts.
41. Turbocharger and exhaust manifold assem-

bly
1) Lift off turbocharger and exhaust manifold
assembly (1) and fit a gasket and 18 mount-
ing bolts (2).
★ Fit the gasket with a mark facing out-
ward.
2) Tighten the mounting bolts to the specified
torque in the following order.
13-76 125-3 SERIES

1
43. Fan bracket lifting hook

1) Fix cooling fan mounting brackets and lifting
hooks (1) to the engine block after fitting a
spacer to the rocker housing.
2) Fix a rear lifting hook (2) to the flywheel
housing.
46. Exhaust muffler

1) Fit bracket (1) on top of the suction manifold
and exhaust manifold.
2) Lift off exhaust muffler (2), then insert
exhaust pipe joint into turbocharger (4), and
set the exhaust muffler on the bracket.
44. Wiring harness
1) Fix wiring harness (1) with clamps to gate
type bracket (2) at three points that is fitted
to the suction manifold.
2) Position the wiring harness in the desig-
nated place and fix it by matching its con-
nectors with other given connectors in
various components (e.g. fuel injectors, fuel
supply pump, common rail, rotary sensor,
cooling water temperature sensor, etc.).
3) Tighten the bolt for bracket (5) and install

the exhaust muffler by tightening the nut for
U bolt (6) to the specified torque.
3 U bolt nut:
9.8 – 14.7 Nm {1.0 – 1.5 kgm}
45. Air cleaner

1) Fit bracket (1) to the suction manifold.
2) Fasten air cleaner (2) with band (3). Then fit
a suction hose to turbocharger (4) and
tighten clamp bolt (5).
3 Band mounting bolt:
9.8 – 11.76 Nm {1.0 – 1.2 kgm}
Hose clamp bolt:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
125-3 SERIES 13-77

1
15 REPAIR AND REPLACEMENT
OF PARTS
CYLINDER HEAD
REPLACING VALVE SEAT INSERT ......................................................................................................15- 3
REPLACING NOZZLE HOLDER SLEEVE ............................................................................................15- 8
REPLACING VALUE GUIDE .................................................................................................................15- 11
REPLACING CROSS HEAD GUIDE .....................................................................................................15- 12
GRINDING THE VALVE .........................................................................................................................15- 13
GRINDING THE FITTING FACE OF CYLINDER HEAD .......................................................................15- 13
PRESSURE TEST .................................................................................................................................15- 14
CYLINDER BLOCK
REPLACING CAM BUSHING ................................................................................................................15- 22
REPLACING CAM GEAR ......................................................................................................................15- 25
REPLACING FLYWHEEL RING GEAR .................................................................................................15- 25
REPLACING ENGINE REAR SEAL ......................................................................................................15- 26
REPLACING CONNECTING ROD SMALL END BUSHING .................................................................15- 31
REPLACING MAIN BEARING CAP.......................................................................................................15- 32
GRINDING CRANKSHAFT....................................................................................................................15- 51
REPLACING WEAR SLEEVE (When equipped with sleeve) ................................................................15- 60
125-3 SERIES 15-1

(6)
REPAIR AND REPLACEMENT OF PARTS CYLINDER HEAD
REPLACING VALVE SEAT INSERT

Special tools
No. Part No. Part Name Q'ty

A 795-100-4801 Puller (valve seat) 1
Push tool
790-901-1260 1
(for intake valve)
B
Push tool
790-901-1250 1
(for exhaust valve)
795-100-3005 Seat cutter( KIT) 1
795-100-3100 Body ass'y 1
795-100-3200 Micrometer 1
1
795-100-3300 Gauge 1
795-100-3401 Tool head 1
795-100-3601 Head support 1
2 795-100-3710 Cutter 1
C 3 795-100-3720 Cutter (for 30º) 1
4 795-100-3730 Cutter (for 45º) 1
795-100-4111 Pilot (9.00 mm) 1
795-100-4121 Pilot (9.01 mm) 1
795-100-4131 Pilot (9.02 mm) 1
5
795-100-4141 Pilot (9.03 mm) 1
795-100-4171 Pilot (8.98 mm) 1
795-100-4181 Pilot (8.99 mm) 1
1. Removal of valve seat insert
When using a grinder to carry out this work, car-

ry out a test run for one minute before starting
the operation to check that there is no abnor-
mality.
• If the grindstone has been replaced, carry
out the test run 3 minutes.
Check that there is no damage to the grind-

stone, fit it to the grinder spindle so that there is
play, and wear safety glasses when using the
grinder.
• When removing with a valve seat puller

1) Install grindstone to grinder .
2) Align the groove of sleeve with holder ,
and insert.
★ Adjust the position of the grinder with set
screw .
125-3 SERIES 15-3

3) Adjust the position of the grinder so that the

center of grindstone is at the center of
seat insert (1), then tighten the set screw to
fix the grinder in place.
4) Rotate the grindstone and move it slowly
until it contacts insert (1).
5) Press the grindstone lightly against the
inside face of the insert and make a groove
around the whole circumference of the
inside face of the insert.
★ Depth of groove: Approx. 1 mm
6) Push the three claws (a) of puller head of

tool A inwards by hand, and fit into insert (1).
7) Tighten screw to push the three claws
into the groove on the inside face of the
insert.
★ When the claws are completely in con-
tact with the groove, stop tightening.
8) Insert bridge on the outside of the puller
head, set plates and on top of the
bridge, and tighten nut to pull out the
insert.
• When welding a bar to the insert to remove

1) Weld bar (1) (diameter: approx. 10 Ø) of a
diameter 0.1 – 0.5 mm smaller than the
inside diameter of the insert to insert (2).
★ Be careful not to deposit any of the weld-
ing metal on the head itself.
2) When the temperature of the weld has
dropped to around room temperature, insert
a used valve (3) in the opposite direction,
and hit the face of the valve with a small
hammer to remove the insert.
★ Be careful not to hit too hard, as any ex-
cessive shock may cause the weld to
break off.
15-4 125-3 SERIES

2. Press fitting the valve seat insert

• When not grinding and correcting the press
fitting surface for the valve seat insert
1) Using tool B, press fit standard valve seat
insert (2).
★ Donot use a hammer to press fit.
★ Press-fitting force for valve seat
Intake side : Approx. 9.8 kN {Approx 1 ton}
Exhaust side : Approx. 9.8 kN {Approx 1 ton}
2) Check the depth of the insert from the bottom

surface (b) of the cylinder head.
★ Depth of the insert h
Intake side : 3.78 – 4.08 mm
Exhaust side : 3.10 – 3.40 mm
125-3 SERIES 15-5

3. Machining valve seat insert mounting hole to

oversize
1) Using tools C1 and C2, grind the hole to a
one size larger over size.
★ Machine within a range of 1.0 mm over-
size. If it is more than 1.0 mm, replace
the cylinder head.
• Dimensions of insert and mounting hole
Unit:mm
Insert Insert mounting hole
Insert Valve
d h D1 D2 H
Intake 47.50+0.100
+0.090 7.5 -0.1
0
47.55 +0.020
+0.010
50.30±0.2 11.38±0.1
STD +0.080
Exhaust 46.5 +0.070 7.5 -0.10 46.55 +0.020
+0.010
49.30±0.2 10.7 ±0.1
Intake 47.75+0.100
+0.090 7.5 -0.10 47.75 +0.020
+0.010
50.55±0.2 11.38±0.1
0.25 O.S.
Exhaust 46.75+0.080
+0.070 7.5 -0.10 46.75 +0.020
+0.010
49.55±0.2 10.7 ±0.1
Intake 48.0 +0.100
+0.090 7.62 -0.10 48.05 +0.020
+0.010
50.80±0.2 11.5 ±0.1
0.50 O.S.
Exhaust 47.0 +0.100
+0.090 7.62 -0.10 47.05 +0.020
+0.010
49.80±0.2 10.82±0.1
Intake 48.25+0.100
+0.090 7.75 -0.10 48.25 +0.020
+0.010
51.05±0.2 11.63±0.1
0.75 O.S.
Exhaust 47.25+0.080
+0.070 7.75 -0.10 47.25 +0.020
+0.010
50.05±0.2 10.95±0.1
Intake 48.5 +0.100
+0.090 7.88 -0.10 48.55 +0.020
+0.010
51.30±0.2 11.76±0.1
1.00 O.S.
Exhaust 47.5 +0.080
+0.070 7.88 -0.10 47.55 +0.020
+0.010
50.30±0.2 11.08±0.1
Insert Inset mounting hole
j : Cylinder head bottom surface

★ Inside surface roughness: 12.5S max.
★ Mounting hole bottom roughness: 12.5S max.
★ Concentricity of valve guide hole and insert:
0.07 mm(T.I.R)max.
15-6 125-3 SERIES

4. Finishing insert seat surface

1) Using tools C1, C3, and C4, finish the surface
of the insert seat to the dimensions shown in
the diagram below.
★ When selecting a pilot C5 to insert into
the valve guide, choose one that gives
no clearance.
• Intake valve
• Exhaust valve
2) Rub the seat surface with compound.
5. Finish inspection
• Coat the seat surface of the new valve thinly
with red lead(minimum), insert it in the valve
guide, push lightly against the valve insert
surface, and rotate 10º. Check the valve in-
sert contact surface, and confirm that the
contact is uniform without any breaks.
• Or
Make marks with a pencil on the seat surface
of the new valve as shown in the diagram be-
low, insert it in the valve guide, push lightly
against the valve insert surface, and rotate
10º. Check that the pencil marks have been
erased uniformly around the whole circum-
ference.
125-3 SERIES 15-7

REPLACING NOZZLE HOLDER SLEEVE
Special tools
Part No. Part Name Q'ty

A 795-600-1191 Push bar 1
B 795-600-1220 Push bar 1
C 795-600-1540 Sleeve driver 1
D 795-600-1410 Rolling tool 1
E 795-901-1210 Sleeve holder 1
F 795-600-1420 Sleeve expander 1
G 795-901-1230 Guide bushing 1
H 795-600-1430 Sleeve cutter 1
1. Removing the sleeve

1) Insert push bar A inside the sleeve.
2) Using sleeve extraction tap , cut tap to
about 25 mm depth from top face of sleeve.
Add oil while cutting.
★ Sleeve extraction tap: M2.5, P=1.5
3) Insert push bar B from the bottom of the
head and tap with the hammer to remove
the sleeve.
4) Remove the sleeve material cleanly from

portion P of the cylinder head.
2. Press-fitting the sleeve

Insert sleeve (1) into the cylinder head, then
using sleeve driver C, tap lightly until the sleeve
is completely in close contact with the seat sur-
face.
★ Before installing the sleeve, clean the sleeve
and seat.
★ Apply adhesive to the seat around the sleeve.
2 Adhesive: LT-2
15-8 125-3 SERIES

3. Roll-fitting the taper section of sleeve

Using rolling tool D, roll-fit the taper section of
the sleeve.
★ Set the roll-fitting amount with stopper of
the expander.
★ Install the expander to a radial drilling ma-
chine or upright drilling machine to roll-fit
with its own weight.
★ Rotating speed: 200 to 300 rpm.
4. Roll-fitting press-fitting portion at top of sleeve

1) Using sleeve holder E, tighten sleeve (a)
from the bottom surface of the cylinder.
3Sleeve holder: 20 Nm {2 kgm}
2) Using sleeve expander F, carry out rolling to
caulk the press-fitting portion.
★ Rotating speed: 450 rpm
★ Inside diameter: 23.9±0.1 mm
★ Amount of insertion of roller (h): 31 mm
★ Adjust the inside diameter with stopper
, and fix the position.
3) After rolling, turn in the reverse direction and
remove the sleeve expander.
4) Remove the sleeve holder.
5) Roll the sleeve taper portion again.
5. Spot-facing the inside seat of the sleeve

1) Using guide bushing G as the guide, spot-
face the seat with sleeve cutter H.
★ When grinding the seat surface, insert
the nozzle holder, check that the protru-
sion is within the standard value, and cut
a little more each time.
★ Rotating speed: 500 to 600 rpm
★ Protrusion of nozzle (S.T.D.):
3.35 – 4.25 mm
2) Remove all the metal chips and dust from
the machined surface.
125-3 SERIES 15-9

6. Checking the leakage from the seat

Carry out a water pressure or air pressure test to
check that there is no leakage from the sleeve
seat surface or upper press-fitting portion.
★ When checking for leakage from the seat
surface, install a used nozzle holder.
15-10 125-3 SERIES

REPLACING VALUE GUIDE
Special tools

A 795-100-1531 Valve guide remover 1
Valve guide driver
B 795-100-1661 1
(for intake)
Valve guide driver
C 795-100-1670 1
(for exhaust)
1. Removing the valve guide

Remove the valve guide with valve guide
remover A.
2. Press-fitting the valve guide

1) Press-fit the valve guide until the tip of valve
guide driver B or C contacts the cylinder
head.
2) Confirm that the protrusion of the valve
guide is within specification.
★ Protrusion of valve guide: 20.0 ± 0.2 mm
125-3 SERIES 15-11

REPLACING CROSS HEAD GUIDE
Special tools

Cross head guide
A 795-130-3300 1
puller
Cross head guide
B 790-471-1120 1
driver
1. Removing the cross head guide

• Using cross head guide puller A, pull out the
cross head guide.
1) As shown in the figure, hold the cross head
guide with collet of the puller.
2) Tighten the collet with bolt to lock sleeve
.
3) Rotate nut and pull out the cross head
guide.
4) Remove burns, fins, etc. from the mounting
place of the cross head guide and clean it.
a: Cylinder head
2. Press-fitting the cross head guide

• Using cross head guide driver B, press fit the
cross head guide.
★ Protrusion of cross head guide:
45.5 ± 0.25 mm
15-12 125-3 SERIES

GRINDING THE VALVE
Special tools

A – (Purchase) Valve refacer 1
1. Grinding the seat surface

• Grind the seat surface with valve refacer A.
★ Angle of valve seat (α):
Intake valve: 30º
Exhaust valve: 45º
2. Checking after grinding

• Confirm that the thickness of the valve head,
protrusion of the valve, and the contact sur-
face of the valve seat are within specifica-
tion.
★ Allowable thickness of valve head (h)
Intake valve: 1.7 mm
Exhaust valve: 1.2 mm
★ Sinking distance of valve
Intake valve: 1.88 ± 0.1 mm
Exhaust valve: 1.20 ± 0.1 mm
GRINDING THE FITTING FACE

OF CYLINDER HEAD
1. Grinding
1) Removing the valve seat insert. See the
section of replacement of valve seat insert.
2) Remove the distortion and corrosion of the
cylinder head by grinding within the allow-
able limit of height H, then stamp the letter
"R" on the left side of the cylinder head.
★ Cylinder head height H
Basic height: 105 ± 0.05 mm
★ Flatness: max. 0.05 mm
★ Height difference among cylinder heads:
max. 0.15
★ Limit after grinding: 104.65 mm
★ Permissible limit for one grinding repair
work: 0.10 – 0.15 mm
★ Roughness of surface: Within. 6 S
3) Fit an oversize insert one rank larger. See
the section of replacing valve seat insert.
2. Check after grinding

Confirm that the sinking distance of the valve is
within the standard range. Grind for adjustment,
if necessary.
125-3 SERIES 15-13

PRESSURE TEST
• If the area round the cylinder head has been
corrected, test as follows.
Special tools

A 790-553-1500 Coolant tester kit 1
B 79A-471-1050 Pump ass'y 1
1. Water pressure test

1) Tighten the nozzle holder assembly to the
specified torque.
2) Assemble tool A and tool B, and connect a
hose to flange (1).
3) Apply water pressure (0.35 – 0.4 MPa {3.5 –
4.0 kg/cm 2 }) for approx. 10 minutes, and
check for any leakage from around the cylin-
der head.
★ It is preferable to warm the whole cylinder
head and carry out the test with hot water
(80 – 95 ºC).
2. Air pressure test

1) Tighten the nozzle holder assembly to the
specified torque.
2) Connect the pump hose to flange (1).
3) Place the cylinder head in a water bath,
apply air pressure (0.3 – 0.35 MPa {3.0 –
3.5 kg/cm 2 }) for approx. 30 seconds, and
check for any air leakage in the water.
★ If the above teat shows that there are cracks
around the nozzle holder and plugs, replace
the cylinder head.
15-14 125-3 SERIES

REPAIR AND REPLACEMENT OF PARTS CYLINDER BLOCK
REPLACING CAM BUSHING
Special tools

A 795-225-1200 Push tool 1
1 795-225-1310 Push bar 1
2 795-225-1210 Push tool 1
A 3 795-225-1220 Collar 1
4 795-225-1230 Guide 1
5 792-103-0400 Grip 1
★ When replacing the cam bushing, first remove

the blind plug at the rear of the cylinder block.
1. Removal of No. 1, 7 bushings

As shown in the diagram, assemble push tool
A2, collar A3, and push bar A1 of push tools A,
then hit the push bar to knock bushing (2) out
from cylinder block (1).
2. Removal of No. 2, 6 bushings

Assemble push bar A1, push tool A2, collar A3,
and guide A4 of push tool A, then hit the push
bar to knock bushing (3) out from cylinder block
(1).
3. Removal of No. 3, 4, 5 bushings

• Assemble push bar A1, push tool A2, collar A3,
and guide A4 of push tool A, then hit the push
bar to knock bushing (4) out from cylinder block
(1).
15-22 125-3 SERIES

• After removing the bushing, remove any burrs or

dirt, and clean the mounting hole of the bushing.
★ Cam bushing assembly drawing
1: Cylinder block
a: Oil hole
b: Notch
c: Bushing
d: Oil return hole
1. Press fitting No. 3, 4, 5 bushings

Assemble bushing (4) to tool A, and press fit the
bushing until the oil hole of cylinder clock (1)
matches the oil hole of the bushing.
2. Press fitting No. 2, 6 bushings

3. Press fitting No. 1, 7 bushings

125-3 SERIES 15-23

• Using inside gauge , measure the inside

diameter of the bushing (c).
• Check the clearance between the bushing and
shaft, and if the clearance is not within the spec-
ified range, or the shaft does not move
smoothly, correct the inside diameter of the
bushing with a reamer.
• When the inside diameter of the bushing has
been corrected with a reamer, clean all the
metal particles from the oil hole and oil
groove.
1: Cylinder block
★ Inside diameter of cam bushing: ø60+0.070
-0 mm
★ Clearance of camshaft journal: 0.080 – 0.180
mm
15-24 125-3 SERIES

REPLACING CAM GEAR

★ Heating temperature for cam gear:
220 to 240 ºC
Heating time: More than 30 minutes
REPLACING FLYWHEEL RING GEAR

Take care not to let the flywheel fall.
1. Removing the ring gear

• Make a groove on the tooth bottom surface of
the ring gear with a grinder, then crack the gear
with a chisel.
Take care in handling the grinder and chisel.
2. Press-fitting the ring gear

1) Check the fitting surface of the ring gear. If
any flaw is found, repair it with an oilstone.
2) Heat the ring gear at the specified tempera-
ture for the specified time for shrinkage fit-
ting.
★ Heating temperature for ring gear:
max. 200ºC
Heating time: More than 30 minutes
3) With the chamferred side of ring gear facing
the flywheel, fit it until its side contacts the
flywheel.
125-3 SERIES 15-25

REPLACING ENGINE REAR SEAL
Special tools Single lip seal Double lip seal

(for dry type) (for wet type)
Type
Part No. Part Name Q'ty Flywheel end is Flywheel end is
A 795-931-1100 Seal puller assembly 1 dry specification wet specification
B 795-931-1210 Sleeve jig (for assembly) 1 Standard
(when shipped
C 795-931-1220 Sleeve jig (for assembly) 1
from factory)
With sleeve
(for repair when
shaft wear is
large)
★ The types of engine rear seal (Teflon seal) are
shown on the right.
• For details of disassembly and assembly of fly-
wheel and flywheel housing (1), see DISAS-
SEMBLY AND ASSEMBLY.
1. Removing seal
1) Hook tip of tool A under the metal ring of
seal (2), then remove it with the impact force
of slide hammer .
★ Before removing seal (2), knock seal (2)
in to free it from flywheel housing (1) and
make it easy to remove.
★ Be careful not to scratch or damage
crankshaft (3).
★ Do not use a drill. If a drill is used, metal
particles will get inside the engine.
2. Removing sleeve
(when equipped with sleeve)
1) For details of the method of removing the
sleeve, see REPLACING WEAR SLEEVE,
REMOVING SLEEVE.
3. Checking wear of shaft

1) If the wear is only seen as luster (when
touched with the flat of the finger, the wear
cannot be detected; wear depth: approx. 10
µm or less) and there are no scratches or
other damage, the part can be used again.
2) In any case other than the above, install a
seal with sleeve.
15-26 125-3 SERIES

4. Install seal with sleeve

(when equipped with sleeve)
• The shape of the spare seal when shipping
is as shown in the right.
★ Handle seal (4) and sleeve (5) as an as-
sembly. Do not separate them.
1) Coat inside surface of sleeve (5) with

gasket sealant, then set on tool C.
★ Before assembling seal (4), remove all
scratches, burrs, flashes, and rust from
the end face corner and sliding face
of lip of crankshaft (3) and flywheel
housing (1).
★ Do not coat the area between sleeve (5)
and seal lip with oil.
2 Gasket sealant: LG-7
2) Put sleeve (5) in contact with the end face of
crankshaft (3), tighten uniformly with bolts
(6), and assemble sleeve (5) and seal (4) as
one unit.
★ Tightening bolt (6): 01050-31645 (x 3)
3) Press fit sleeve (5) and seal (4) until tool C

contacts end face of crankshaft (3).
★ Remove tool C when it contacts end face
of crankshaft (3).
125-3 SERIES 15-27

4) Replace with tool B, tighten again uniformly

with bolts (7), and start to press fit sleeve (5)
and seal (4).
★ Tightening bolt (7): 01050-31625 (x 3)
5) Press fit until tool B contacts end face of

crankshaft (3).
★ Wipe off all the gasket sealant that is
squeezed out to the outside circumfer-
ence.
5. Installing standard seal

• The shape of the spare seal when shipping
is as shown in the right.
★ Do not separate seal (8) and plastic in-
ner tube/assembly guide until seal (8)
is assembled. (The guide also acts to
protect the seal lip.)
1) Put large inside diameter of plastic inner

tube in contact with end face of crank-
shaft (3).
★ Be careful not to mistake the direction.
★ Before assembling seal (8), remove all
scratches, burrs, flashes, and rust from
the end face corner and sliding face
of lip of clutch shaft (3) and flywheel
housing (1).
★ Wipe off all the oil from the sliding sur-
face.
15-28 125-3 SERIES

2) Push in the metal ring of seal (8) uniformly

with both hands until it feels that it has
passed inside diameter large end of plas-
tic tube .
3) Remove plastic tube , taking care not to
damage the lip.
4) Put tool B in contact as shown in the dia-

gram on the right, then tighten uniformly
with the bolts.
★ Tightening bolt (6) : 01050-31645 (x 3)
Tightening bolt (7) : 01050-31625 (x 3)
★ Be careful not to damage the tip of lip .
5) Press fit until tool B contacts end face of

crankshaft (3).
★ Wipe off all the gasket sealant that is
squeezed out to the outside circumfer-
ence.
125-3 SERIES 15-29

TOOL B (795-931-1210)
Unit: mm
TOOL C (795-931-1220)
Unit: mm
15-30 125-3 SERIES

REPLACING CONNECTING ROD SMALL END BUSHING
Special tools

A 795-903-1201 Push tool assembly 1
1 795-903-1211 Push tool 1
2 795-903-1220 Push tool 1
B
3 795-903-1230 Block 1
4 795-903-1240 Nut 1
1. Removal of connecting rod bushing

1) 1) Set connecting rod (2) on tool B3.
2) 2) Using tools B1 and B3, remove connect-
ing rod bushing (1) with a press.
★ After removing the bushing, remove any
burrs or dirt, and clean the mounting hole of
the bushing.
2. Press fitting connecting rod bushing

1) Set connecting rod (2) on tool B3.
2) Assemble connecting rod bushing (1) to tool
B1, then set tool B2 and secure with tool B4
so that it does not move.
★ Align the connecting rod bushing oil hole and
the connecting rod oil hole.
3) Push tool B1 with a press and press fit con-
necting rod bushing (1).
• The bushing is supplied as a semi-finished prod-
uct, so the inside diameter is too small and the
piston pin will not go in.
• After press fitting the bushing, machine the
inside diameter of the bushing with a reamer or
honing machine in accordance with the MAIN-
TENANCE STANDARD.
★ After machining, remove all the metal parti-
cles from the oil hole and oil groove.
125-3 SERIES 15-31

REPLACING MAIN BEARING CAP

• When replacing the main bearing cap, machine
the semi-finish product to the following dimen-
sions, then install.
Correction parts
Part No. Part Name

Main bearing caps other than
6150-29-1210
No.7
6150-29-1250 No.7 main bearing cap
1. Machining inside diameter of main bearing

cap
1) Remove the cylinder liner.
2) Install the replacement main bearing cap to
the cylinder block, and tighten to the speci-
fied torque.
2 Main bearing cap mounting bolt:
Coat seat face of threaded por-
tion with engine oil.
3 Main bearing cap mounting bolt:
Unit: Nm {kgm}
Order Target Range
88 – 108
1st step 98 {10}
{9 – 11}
191 – 201
2nd step 196 {20}
{19.5 – 20.5}
3rd step Tighten a further 90º 90º +30º

+0
★ Align the cylinder block and main bear-

ing cap notch.
3) Set a cylinder block mounting jig on the
table of a horizontal boring machine, fit the
cylinder liner mounting hole of the cylinder
block to the standard line on the jig, and
install the cylinder block.
4) Of the main bearing caps to be used again,
take the one with the longest pitch and put a
dial gauge in contact with the inside diame-
ter at two places to align the center of the
boring machine arbor.
15-32 125-3 SERIES

(6)
5) Check the machined inside diameter of

bearing cap (1) and grind a little at a time.
★ Grind until the bit touches the inside sur-
face of cylinder block (2).
★ Inside diameter of main bearing cap
Machining dimension
Tolerance: 116 +0.015
+0 mm
Inside diameter of cap when main
bearing cap is tightened to specified
torque after machining
Tolerance: 116 +0.013
–0.009 mm
(Up-down range of 10º at mating
surface of main bearing cap)
★ Finishing roughness: Within 10 S
★ Do not grind the inside face of the cylin-
der block.
2. Machining width of main bearing cap

(Only when machining No.7 main bearing
cap)
1) Insert cast iron bushing , then pass arbor
through.
2) Install facing bit to the arbor.
3) Grind A portion of cap (1) until the bit
touches the cylinder block (2) face.
4) Grind the B portion of opposite side in the
same way.
★ Roughness of thrust bearing mounting
surface: Within 12.5 S
★ Do not grind the cylinder block.
★ Width of main bearing cap
Tolerance: 38 –0
–0.025 mm
125-3 SERIES 15-33

(6)
GRINDING CRANKSHAFT
★ When grinding the crankshaft to correct wear,
light seizure or damage, grind to an undersize.
★ If there is curvature of the crankshaft, it is prefer-

able to replace the crankshaft and not to grind it
to an undersize. (There are problems with bal-
ancing.)
★ Do not try to correct a bent crankshaft with a
press. When the engine is run, the crank-
shaft will gradually return to its bent shape.
★ The journal portion has been given induction
hardening, so do not try to repair it by bead
welding or plating.
★ Unevenly worn crankshafts will bend or be unbal-

anced even if repaired, so always replace une-
venly worn crankshafts.
★ Measure the part for grinding to decide the un-

dersize dimension.
★ Judge from the measured dimension, and if the

undersize dimension will exceed the repair limit,
replace the crankshaft.
★ When repairing the plating of the damaged sur-

face, repair only the following places.
1) Rear seal journal portion
2) Crankshaft gear mount
★ When correcting damage to the crankshaft, pay

particular attention when finishing the R portion
of the fillet and shoulder r (see the diagram on
the right) and the R at the inlet port of the oil hole.
125-3 SERIES 15-51

★ Necessary equipment and jigs for grinding

1) Magnetic flaw detector
2) Shore hardness gauge
3) Etching kit (quantity for one check of traces
of seizure)
i) 4% nitric acid solution: 250 g
ii) 2% hydrochloric + acetone solution:
250 g
iii) Acetone: 250 g
iv) Cotton wool: 1 packet
v) Stainless steel pincette: 1
4) Crankshaft milling machine
i) Milling machine
ii) V gauge, set of attachments for other
grinding
iii) Dresser (for oil stone)
iv) Oil stone (reference)
• 19A54M, 19A46M or 19A54L
• Material: WA or A
• Grain size: Medium, No. 46, or No. 54
• Grade: Medium, M, L, N, or O
5) Crankshaft polisher
6) Roughness gauge
7) Fillet R measurement ball gauge
1. Inspecting before grinding

1) Visual inspection
• If any heat cracks can be seen, the hardened
layer is damaged, so replace the crankshaft.
• If there is discoloration up to the unmachined
shoulder near the journal face or thrust face,
it shows that the crankshaft has been heated
to an excessive temperature, so replace the
crankshaft.
• If the wear or damage to the journal means
that it cannot be corrected to an undersize,
replace the crankshaft. (Skill is needed.)
• Replace the crankshaft if there is damage to
any part which will affect the strength of the
R portion.
• If only one of the crankshaft pin journals is
worn, it will affect the balancing, so replace
the crankshaft.
2) Inspecting hardness of journal surface

• Measure the hardness of the journal surface
with a Shore hardness gauge. If it is not with-
in the standard value, it shows that there has
been excessive heat damage, so replace the
crankshaft.
15-52 125-3 SERIES

2. Inspection during grinding and after grinding

1) Inspecting R portion of fillet
• Check that the R portion of the fillet is con-
nected smoothly to the shoulder of the jour-
nal. (See diagram.)
• Check that there are no scratches or seizure
which will cause concentration of stress
around the R portion of the fillet.
• Check that the R dimension of the fillet is
within the specified dimension.
R dimension: Between minimum radius
ball gauge and maximum
radius ball gauge.
• To check the R dimension and the start of

the fillet, use a pencil light and ball gauge for
measuring the fillet, and check as follows.
i) Move the minimum radius ball gauge
gradually away from the journal surface
towards the fillet and shine the light from
behind the ball to check the contact
point (a).
• If the fillet is correct, the ball will roll and
always be in contact with one point (a1).
• If the ball is in contact with two points at
the same time, part of the diameter of
the fillet is smaller than the minimum val-
ue, so correct it again.
ii) Move the maximum radius ball gauge

gradually away from the journal surface
towards the fillet and check the contact
point in the same way as for Check i).
• If the fillet is correct, the ball will always
be in contact with two points (a2) at R.
• If the ball is in contact with only one
point, the diameter of the fillet is larger
than the maximum value, so correct it
again.
• Radius R can be adjusted by correcting the
grindstone.
125-3 SERIES 15-53

2) Checking for traces of seizure using vii) After the inspection, polish off the dis-
etching coloration caused by the etching, then
• After grinding the crankshaft, carry out an clean and dry the surface.
etching test to confirm that there are no trac- To neutralize the surface, wipe with a
es of grinding seizure. weak solution of slaked lime or with any
• If bearing failure has caused any damage, similar weak alkali solution.
seizure, or streaks in the journal portion, car- viii) After drying, coat with rust-prevention
ry out an etching inspection to check for trac- oil.
es of seizure. This helps to judge if there has Pay particular attention to the inspection
been any drop in hardness, and to decide the surface and oil holes.
undersize dimension. If the crankshaft is installed immediately
• Etching inspection is used to find out if there in the engine, it can be coated with
are any traces of seizure which cannot be engine oil.
found by visual check or hardness check. It • If any seizure is found, grind off approx. 0.02
is also used to find traces of grinding seizure mm and correct to the next undersize.
caused by heating of the surface during
grinding.
• Grinding seizure and traces of seizure in the
journal or fillet portion destroy the structure
of the metal because heat is applied. This
normally occurs near to the surface, but it
may cause concentration of stress which in
turn will lead to breakage of the crankshaft.
• Procedure for etching inspection
i) Wipe the inspection surface clean.
ii) Wipe the inspection surface with a 4%
nitric acid solution. Roll a piece of cotton
wool into a diameter of 2 to 3 cm. Soak
it in the nitric acid solution, then hold it
with the pincette and wipe for 1 to 2 min-
utes.
iii) Wash off the nitric acid solution with
water, then dry the surface.
Soak some cotton wool in acetone, wipe
again, then dry the surface.
iv) Soak some cotton wool with dilute
hydrochloric acid (2% hydrochloric acid
mixed in acetone) and apply for 30 sec.
to 1 min. to etch the inspection surface.
v) Wash off the dilute hydrochloric acid
with water, wipe with acetone, then dry
with compressed air.
vi) Check the inspection surface.
• If there is no seizure, the whole etched
surface will be a uniform bright color.
• If there are any streaks or dark patches
on a bright grey surface, this shows the
existence of grinding seizure.
• If there are stripes brighter than the grey
surface, this shows the existence of ex-
cessive grinding seizure.
• If there is any suspicious pattern, polish
the etched surface, and etch again.
• If there is any seizure, the same pattern
will appear when the etching is repeated.
15-54 125-3 SERIES

3) Magnetic flaw detection

• The stress on the crankshaft is greatest at
this point, so there must not be even the
slightest crack.
• Carry out a magnetic flaw detection test be-
fore using the corrected crankshaft.
• Be particularly careful to check the journal fil-
let portion entering the danger zone of each
web of the crankshaft.
4) Measuring curvature
(measuring alignment)
• Measure the curvature of the crankshaft af-
ter grinding and check that it is within the
standard value.
• Check the curvature (alignment) at the fol-
lowing four places.
Before measuring the curvature of the
crankshaft, check that the cylindricity
and out-of-roundness are within the
repair limit.
i) Measuring alignment of total length of
crankshaft
Support the front and rear ends of the
crankshaft. Rotate the crankshaft and
measure the radial runout at the center
main journal with a dial gauge.
ii) Measuring alignment of adjacent jour-

nals
Support the rear journal and the journal
next to the journal to be measured.
Measure the runout of the journal with a
dial gauge.
iii) Measuring alignment of front end of
crankshaft
Support the journals at the front and
rear ends of the crankshaft. Measure
the runout at a point within 6 mm from
the front end of the crankshaft.
iv) Measuring alignment of rear end of
crankshaft
Support the journals at the front and
rear ends of the crankshaft. Measure
the runout at a point within 6 mm from
the rear end of the crankshaft.
125-3 SERIES 15-55

3. Grinding main journal

★ Grind each main journal to the same under-
size dimension.
★ Mark the undersize dimension on the ground
crankshaft as shown in the diagram to pre-
vent any mistake in the size when assem-
bling the bearing.
★ After grinding, check that the difference be-
tween the dimensions of the journals is with-
in the permitted range.
4. Grinding thrust surface

★ There is no particular need to grind the front
and rear thrust surface to the same under-
size dimension.
★ Mark the undersize dimension on the ground
crankshaft as shown in the diagram to pre-
vent any mistake in the size when assem-
bling the thrust bearing.
tween the thrust widths of the journals is
within the permitted range.
★ If the thrust surface width has been ground,
check that the end play of the crankshaft is
within the permitted range.
• Conditions for grinding (reference)

Grinding speed: 1800 – 2200 rpm
Feeding speed: 0.2 – 0.4 mm/min.
15-56 125-3 SERIES

5. Grinding pin journal

★ Grind each pin journal to the same undersize
dimension.
★ Mark the crankshaft pin undersize dimension
on the ground shaft in the same way as with
the undersize mark on the main journal.
tween the dimensions of the journals is with-
in the permitted range.
6. Grinding main journal width and pin journal

width
★ When correcting the wear surface on both
sides of the main journal and pin journal, if
there are streaks, scratches, or dents, cor-
rect using the minimum amount of grinding.
★ Leave a thickness of at least 0.25 mm on the
friction surface of the main journal.
★ If the width of the pin journal is too large, the

connecting rod will move up and down or
from side to side on the crankshaft when the
engine is running. This will cause uneven
wear. To avoid this, remove the minimum
possible amount when grinding, and always
keep strictly to the repair limit.
• Conditions for grinding (reference)

Grinding speed: 1800 – 2200 rpm
Feeding speed: 0.2 – 0.4 mm/min.
125-3 SERIES 15-57

7. Correcting grindstone
• Apply dressing to the grindstone for each jour-
nal.
• The start and the R dimension of the journal fillet
have a big effect on the strength of the crank-
shaft, so adjust with the following grinding
method.
1) Grindstone dresser
Angle of tip (b): 75º ± 1º
Radius of tip: See Shop Manual for each
series
Use a conical type with inset industrial
diamonds.
When using the dresser, adjust so that
the tip of the cone is at the center of the
shank.
2) Adjust the diamond of the grindstone cor-

recting device, and modified the edge of the
grindstone to match the arc of the fillet.
3) First, correct the surface of the grindstone
and record the reading of the feed dial
gauge.
Next, put the radius of one of the edge arcs
in contact with the surface of the grindstone.
• The final feed of the corrected surface
should be finished within 0.013 mm.
4) Hold a small coarse grindstone in your hand
and put it in contact with the front face of the
grindstone. Grind lightly so that the arc at
the edge contacts smoothly with the front
face of the grindstone.
When doing this, slightly change the angle
of the grindstone in your hand and put it
lightly in contact with the grindstone.
5) When testing the start or the R dimension of
the fillet, first grind a piece of wood as a test.
Check with a ball gauge, and correct to a
perfect fillet shape.
6) Correct the edge on the other side of the
grindstone in the same way.
7) Make a test grinding of the crankshaft, then
finally check the shape of the fillet.
15-58 125-3 SERIES

8. Prevention of grinding seizure 9. Finishing surface

• To prevent seizure when grinding, follow the • Finish the journal surface smoothly because this
precautions below strictly. affects the fatigue strength of the crankshaft and
1) Always put the grindstone at right angles to the wear of the bearing.
the crankshaft (plunge grind method) when • Standard surface roughness after grinding
grinding. If the grindstone is put in contact Journal face, thrust surface, fillet portion:
with the crankshaft and then moves to the Within 0.8 S
side (bump method), there is a high risk of Pin and main boss portion: Within 3.2 S
seizure. Tip nose portion, rear flange face: Within 2.0 S
2) Even when using the whole width of the • When using a belt-type lapping machine, pull
grindstone, avoid grinding the boss surface the emery cloth in the same direction as the
as far as possible. rotation of the crankshaft.
Finish the boss surface by polishing. This is to avoid fine particles flying in the direc-
If the grindstone contacts the boss surface, tion of rotation. These fine particles may cause
the feeding speed should be below 0.025 scratches if they are caught in the crankshaft.
mm/sec. • Finish the area around the oil holes to the same
3) The cooling oil sent to the side face copy surface roughness as the journal portion.
grinding device and the main jet should fully • Allowance for polish finishing: 0.007 – 0.008 mm
contact the grinding area. Start the flow of • Rust or corrosion causes wear of the bearing, so
oil before starting to grind. remove all rust and corrosion completely, and
4) When the crankshaft speed is approx. 50 coat with high-quality rust-prevention oil.
rpm, make the standard grinding speed at • Finishing conditions (reference)
the circumference of the grindstone 2000 m/ Paper to use: AA#120
min. Shaft rotating speed: 100 rpm
Grinding speed: 36 m/min.
10. Action after grinding

• Check again that each dimension is as speci-
fied.
• Wash each part thoroughly (particularly the oil
holes) and coat the whole crankshaft with rust-
prevention oil.
• Be extremely careful to avoid causing scratches
or damage when handling.
• When storing for a long period, support at three
points or fit a lifting tool and stand upright to pre-
vent curvature.
125-3 SERIES 15-59

REPLACING WEAR SLEEVE (When equipped with sleeve)

★ If the wear sleeve is worn or damaged, replace
as follows.
1. Removing sleeve
1) Make a groove in the sleeve (1) with a
grinder.
2) Put a chisel in contact with the groove in the
sleeve and hit with a hammer to remove.
★ The interference is tight, so remove as fol-
lows.
Make a V cut in the sleeve with a
grinder.
Split the wear sleeve at the V cut with a
chisel, then remove the sleeve.
Be extremely careful not to let the chisel fly.
★ When removing the wear sleeve, be careful
not to damage the shaft.
2. Press fitting sleeve

1) Check the interference between the sleeve
and shaft, and confirm that it is within the
standard value.
2) Using a sleeve driver, shrink fit the sleeve.
★ When using oil to heat the sleeve, use oil
with a high flash point and be extremely
careful not to cause any fire.
15-60 125-3 SERIES

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11 STRUCTURE AND FUNCTION,

12 TESTING AND ADJUSTING ........................................................................ 12-1

13 DISASSEMBLY AND ASSEMBLY ........................................................ 13-1

15 REPAIR AND REPLACEMENT OF PARTS ............................. 15-1

00-2 125-3 SERIES

The affected pages are indicated by the use of the

Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

125-3 SERIES 00-2-1

Time of Time of Time of Time of Time of

00-2-2 125-3 SERIES

Time of Time of Time of Time of Time of

125-3 SERIES 00-2-3

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

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

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rub-

Holtz • Used as heat-resisting sealant for re-

• Used as lubricant for sliding portion

SYG2-400CA • Used for normal temperature, light

Molybdenum • Used for heavy load portion

SUNSTAR • Used as primer for cab side

• "S" is used for high-tempera-

SUNSTAR • Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 ENGINE SERIES

ELECTRIC WIRE CODE