Komatsu 125E-5 series (SAA6D125E-5) engine
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ENGINE
SEN00177-15
125E
-5
SERIES
125E-5 Series 1
SEN00179-15
ENGINE
1SHOP MANUAL
125E-5 Series
00 Index and foreword 1
Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 3
SEN00179-15 00 Index and foreword
2 125E-5 Series
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs ............................................................ SEN00177-15
00 Index and foreword ......................................................................................................... SEN00178-15
Index ............................................................................................................................... SEN00179-15 q
Foreword and general information .................................................................................. SEN00180-06
01 Specification.................................................................................................................... SEN00181-06
Specification and technical data...................................................................................... SEN00182-06 q
10 Structure, function and maintenance standard ............................................................... SEN00183-07
Structure, function and maintenance standard, Part 1 .................................................... SEN00184-06 q
Structure, function and maintenance standard, Part 2 .................................................... SEN00185-06 q
20 Standard value table ....................................................................................................... SEN00186-09
Standard service value table ........................................................................................... SEN00546-09 q
30 Testing and adjusting ...................................................................................................... SEN00187-05
Testing and adjusting ...................................................................................................... SEN00547-05
40 Troubleshooting .............................................................................................................. SEN00188-04
General information on troubleshooting .......................................................................... SEN00548-03
Troubleshooting of electrical system (E-mode), Part 1 ................................................... SEN00550-01
Troubleshooting of electrical system (E-mode), Part 2 ................................................... SEN00551-01
Troubleshooting of mechanical system (S-mode) ........................................................... SEN00549-02
50 Disassembly and assembly ............................................................................................ SEN00189-04
General information on disassembly and assembly ....................................................... SEN00697-03
Disassembly and assembly, Part 1 (With EGR) .............................................................. SEN00698-02
Disassembly and assembly, Part 2 (EGR-less) .............................................................. SEN00699-03
Disassembly and assembly, Part 3 ................................................................................. SEN00700-00
90 Repair and replacement of parts..................................................................................... SEN05201-01
Information related to repair and replacement ................................................................ SEN05202-00
Parts related to cylinder head ......................................................................................... SEN05203-01
Parts related to cylinder block ......................................................................................... SEN05204-00
00 Index and foreword SEN00179-15
125E-5 Series 3
Table of contents 1
00 Index and foreword
Index ............................................................................................................................... SEN00179-15
Composition of shop manual ................................................................................................... 2
Table of contents ..................................................................................................................... 3
Foreword and general information .................................................................................. SEN00180-06
Safety notice ............................................................................................................................ 2
How to read the shop manual .................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
How to read electric wire code ................................................................................................ 23
Precautions when carrying out operation ................................................................................ 26
Method of disassembling and connecting push-pull type coupler ........................................... 29
Standard tightening torque table.............................................................................................. 32
Conversion table...................................................................................................................... 36
01 Specification
Specification and technical data ..................................................................................... SEN00182-06
Outline ..................................................................................................................................... 2
Specifications........................................................................................................................... 6
General view............................................................................................................................ 20
Weight table ............................................................................................................................. 48
Engine performance curves..................................................................................................... 51
10 Structure, function and maintenance standard
Structure, function and maintenance standard, Part 1.................................................... SEN00184-06
General structure ........................................................................................................................ 4
Air intake and exhaust unit .......................................................................................................... 6
Air cleaner ................................................................................................................................... 10
Turbocharger ............................................................................................................................... 12
Aftercooler ................................................................................................................................... 19
EGR system ................................................................................................................................ 20
Cylinder head .............................................................................................................................. 27
Cylinder block.............................................................................................................................. 30
Cylinder liner ............................................................................................................................... 34
Main moving parts ....................................................................................................................... 35
Crankshaft ................................................................................................................................... 37
Camshaft ..................................................................................................................................... 38
Cam follower and push rod ......................................................................................................... 39
Piston, piston ring and piston pin ................................................................................................ 40
Connecting rod ............................................................................................................................ 42
Flywheel and flywheel housing ................................................................................................... 43
Vibration damper ......................................................................................................................... 48
Timing gear ................................................................................................................................. 50
Valve system ............................................................................................................................... 58
Valve and valve guide ................................................................................................................. 62
Rocker arm and shaft .................................................................................................................. 64
Crosshead and guide .................................................................................................................. 65
Structure, function and maintenance standard, Part 2.................................................... SEN00185-06
Lubrication system ...................................................................................................................... 4
Lubrication system diagram..................................................................................................... 4
SEN00179-15 00 Index and foreword
4 125E-5 Series
Oil pump .................................................................................................................................. 8
Main relief valve ....................................................................................................................... 9
EGR oil pump .......................................................................................................................... 10
Oil filter..................................................................................................................................... 11
Safety valve ............................................................................................................................. 13
Oil cooler.................................................................................................................................. 14
Fuel system ................................................................................................................................. 16
CRI system diagram ................................................................................................................ 16
Outline of CRI system.............................................................................................................. 18
Fuel piping ............................................................................................................................... 40
Fuel filter .................................................................................................................................. 42
Electric priming pump .............................................................................................................. 44
Engine controller cooler ........................................................................................................... 45
Cooling system............................................................................................................................ 46
Cooling system diagram .......................................................................................................... 46
Water pump ............................................................................................................................. 48
Thermostat ............................................................................................................................... 50
Electrical equipment .................................................................................................................... 52
Alternator ................................................................................................................................. 52
Starting motor .......................................................................................................................... 60
Electrical intake air heater ....................................................................................................... 64
Engine controller ...................................................................................................................... 65
20 Standard value table
Standard service value table ........................................................................................... SEN00546-09
Standard service value table ....................................................................................................... 2
Standard service value table for testing, adjusting, and troubleshooting ................................. 2
Running-in standard and performance test standard .............................................................. 16
30 Testing and adjusting
Testing and adjusting ...................................................................................................... SEN00547-05
Testing and adjusting (With EGR) ............................................................................................... 3
Testing and adjusting tools list ................................................................................................. 3
Sketches of special tools ......................................................................................................... 5
Testing air boost pressure........................................................................................................ 6
Testing exhaust temperature ................................................................................................... 7
Adjusting valve clearance ........................................................................................................ 8
Testing compression pressure ................................................................................................. 9
Testing blow-by pressure ......................................................................................................... 11
Testing engine oil pressure ...................................................................................................... 12
Measuring EGR valve and bypass valve drive pressure ......................................................... 13
Handling fuel system parts ...................................................................................................... 14
Releasing residual pressure in fuel system ............................................................................. 14
Testing fuel pressure................................................................................................................ 15
Reduced cylinder mode operation ........................................................................................... 16
No-injection cranking ............................................................................................................... 16
Testing leakage from pressure limiter and return rate from injector ......................................... 17
Bleeding air from fuel circuit .................................................................................................... 20
Testing fuel system for leakage ............................................................................................... 22
Adjusting speed sensor ........................................................................................................... 23
Testing and adjusting alternator belt tension ........................................................................... 24
Handling controller voltage circuit ............................................................................................ 25
Testing and adjusting (EGR-less) ................................................................................................ 26
Testing and adjusting tools list ................................................................................................. 26
Sketches of special tools ......................................................................................................... 28
Testing air boost pressure........................................................................................................ 29
00 Index and foreword SEN00179-15
125E-5 Series 5
Testing exhaust temperature ................................................................................................... 30
Adjusting valve clearance ........................................................................................................ 31
Testing compression pressure ................................................................................................. 32
Testing blow-by pressure ......................................................................................................... 34
Testing engine oil pressure ...................................................................................................... 35
Handling fuel system parts ...................................................................................................... 36
Releasing residual pressure in fuel system ............................................................................. 36
Testing fuel pressure ............................................................................................................... 37
Reduced cylinder mode operation ........................................................................................... 38
No-injection cranking ............................................................................................................... 38
Testing leakage from pressure limiter and return rate from injector ........................................ 39
Bleeding air from fuel circuit .................................................................................................... 41
Testing fuel system for leakage ............................................................................................... 43
Adjusting speed sensor ........................................................................................................... 44
Testing and adjusting alternator belt tension ........................................................................... 45
Handling controller voltage circuit ............................................................................................ 46
40 Troubleshooting
General information on troubleshooting.......................................................................... SEN00548-03
General information on troubleshooting ...................................................................................... 2
Points on troubleshooting ........................................................................................................ 2
Error code and failure code table ............................................................................................ 4
Information in troubleshooting table ........................................................................................ 8
Troubleshooting of electrical system (E-mode), Part 1 ................................................... SEN00550-01
Troubleshooting of electrical system (E-mode), Part 1 ............................................................... 4
E-1 Code [111/CA111] ECM Critical Internal Failure................................................................ 4
E-2 Code [115/CA115] Eng. Ne and Bkup Speed Sensor Error .............................................. 6
E-3 Code [122/CA122] Charge Air Press Sensor High Error .................................................. 8
E-4 Code [123/CA123] Charge Air Press Sensor Low Error ................................................... 10
E-5 Code [131/CA131] Throttle Sensor High Error ................................................................. 12
E-6 Code [132/CA132] Throttle Sensor Low Error .................................................................. 16
E-7 Code [135/CA135] Oil press. Sensor High Error .............................................................. 18
E-8 Code [141/CA141] Oil press. Sensor Low Error ............................................................... 20
E-9 Code [144/CA144] Coolant Temp. Sensor High Error ...................................................... 22
E-10 Code [145/CA145] Coolant Temp. Sensor Low Error ..................................................... 24
E-11 Code [153/CA153] Charge Air Temp. Sensor High Error ................................................ 26
E-12 Code [154/CA154] Charge Air Temp. Sensor Low Error ................................................ 28
E-13 Code [187/CA187] Sensor Sup. 2 Volt. Low Error .......................................................... 29
E-14 Code [221/CA221] Ambient Air Press. Sensor High Error .............................................. 30
E-15 Code [222/CA222] Ambient Air Press. Sensor Low Error ............................................... 32
E-16 Code [227/CA227] Sensor Sup. 2 Volt. High Error ......................................................... 34
E-17 Code [234/CA234] Eng. Overspeed ............................................................................... 36
E-18 Code [238/CA238] Ne Speed Sensor Sup. Volt. Error .................................................... 38
E-19 Code [263/CA263] Fuel Temp. Sensor High Error .......................................................... 40
E-20 Code [265/CA265] Fuel Temp. Sensor Low Error ........................................................... 42
E-21 Code [271/CA271] PCV1 Short Error ............................................................................. 44
E-22 Code [272/CA272] PCV1 Open Error ............................................................................. 46
E-23 Code [273/CA273] PCV2 Short Error ............................................................................. 48
E-24 Code [274/CA274] PCV2 Open Error ............................................................................. 50
E-25 Code [322/CA322] Injector #1 (L/B #1) System Open/Short Error ................................. 52
E-26 Code [323/CA323] Injector #5 (L/B #5) System Open/Short Error ................................. 54
E-27 Code [324/CA324] Injector #3 (L/B #3) System Open/Short Error ................................. 56
E-28 Code [325/CA325] Injector #6 (L/B #6) System Open/Short Error ................................. 58
E-29 Code [331/CA331] Injector #2 (L/B #2) System Open/Short Error ................................. 60
E-30 Code [332/CA332] Injector #4 (L/B #4) System Open/Short Error ................................. 62
E-31 Code [342/CA342] Calibration Code Incompatibility ....................................................... 64
E-32 Code [351/CA351] INJ. Drive Circuit Error ..................................................................... 66
SEN00179-15 00 Index and foreword
6 125E-5 Series
E-33 Code [352/CA352] Sensor Sup. 1 Volt. Low Error .......................................................... 68
E-34 Code [386/CA386] Sensor Sup. 1 Volt. High Error ......................................................... 70
E-35 Code [431/CA431] Idle Validation SW Low error ............................................................ 72
E-36 Code [432/CA432] Idle Validation Process error ............................................................. 74
E-37 Code [441/CA441] Battery voltage low error ................................................................... 74
E-38 Code [442/CA442] Battery voltage high error ................................................................. 75
Troubleshooting of electrical system (E-mode), Part 2 ................................................... SEN00551-01
Troubleshooting of electrical system (E-mode), Part 2................................................................ 3
E-39 Code [449/CA449] Rail Press. Very High Error............................................................... 3
E-40 Code [451/CA451] Rail Press. Sensor High Error .......................................................... 4
E-41 Code [452/CA452] Rail Press. Sensor Low Error ........................................................... 6
E-42 Code [553/CA553] Rail Press. High Error ....................................................................... 6
E-43 Code [554/CA554] Rail Press Sensor In Range Error .................................................... 7
E-44 Code [559/CA559] Rail Press. Low Error........................................................................ 8
E-45 Code [689/CA689] Eng. Ne Speed Sensor Error ............................................................ 12
E-46 Code [731/CA731] Eng. Bkup Speed Sensor Phase Error ............................................. 14
E-47 Code [757/CA757] All Persistent Data Lost Error ........................................................... 15
E-48 Code [778/CA778] Eng. Bkup Speed Sensor Error ........................................................ 16
E-49 Code [1228/CA1228] EGR Valve Servo Error 1.............................................................. 18
E-50 Code [1625/CA1625] EGR Valve Servo Error 2.............................................................. 19
E-51 Code [1626/CA1626] Bypass Valve Solenoid Current High Error ................................... 20
E-52 Code [1627/CA1627] Bypass Valve Solenoid Current Low Error.................................... 22
E-53 Code [1628/CA1628] Bypass Valve Servo Error 1 .......................................................... 23
E-54 Code [1629/CA1629] Bypass Valve Servo Error 2 .......................................................... 24
E-55 Code [1631/CA1631] BP valve Lift Position Sensor High Error ...................................... 26
E-56 Code [1632/CA1632] BP valve Lift Position Sensor Low Error ....................................... 28
E-57 Code [1633/CA1633] KOMNET Datalink Timeout Error ................................................. 28
E-58 Code [1642/CA1642] EGR Inlet Press Sensor Low Error ............................................... 29
E-59 Code [1653/CA1653] EGR Inlet Press Sensor High Error .............................................. 30
E-60 Code [2185/CA2185] Throttle Sens. Sup. Volt. High Error ............................................. 32
E-61 Code [2186/CA2186] Throttle Sens. Sup. Volt. Low Error .............................................. 36
E-62 Code [2249/CA2249] Rail Press. Very Low Error ........................................................... 37
E-63 Code [2271/CA2271] EGR Valve Lift Position Sensor High Error ................................... 38
E-64 Code [2272/CA2272] EGR Valve Lift Position Sensor Low Error.................................... 40
E-65 Code [2351/CA2351] EGR Valve Solenoid Current High Error ....................................... 42
E-66 Code [2352/CA2352] EGR Valve Solenoid Current Low Error ....................................... 44
E-67 Code [2555/CA2555] Grid Heater Relay Volt. Low Error ................................................ 45
E-68 Code [2556/CA2556] Grid Heater Relay Volt. High Error ............................................... 46
E-69 Code [(143)/B@BAZG] Eng. Oil press. Torque Derate ................................................... 48
E-70 Code [(146)/B@BCNS] Eng. Overheat ........................................................................... 48
E-71 Code [(415)/B@BAZG] Eng. Oil press. Low Speed Derate ............................................ 49
Troubleshooting of mechanical system (S-mode) ........................................................... SEN00549-02
Troubleshooting of mechanical system (S-mode) ....................................................................... 4
Method of using troubleshooting charts ................................................................................... 4
S-1 Starting performance is poor ............................................................................................. 8
S-2 Engine does not start ........................................................................................................ 10
S-3 Engine does not pick up smoothly .................................................................................... 14
S-4 Engine stops during operations......................................................................................... 15
S-5 Engine does not rotate smoothly....................................................................................... 16
S-6 Engine lacks output (or lacks power) ................................................................................ 17
S-7 Exhaust smoke is black (incomplete combustion) ............................................................ 18
S-8 Oil consumption is excessive (or exhaust smoke is blue) ................................................. 20
S-9 Oil becomes contaminated quickly.................................................................................... 21
S-10 Fuel consumption is excessive ....................................................................................... 22
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) .............................. 23
S-12 Oil pressure drops ........................................................................................................... 24
S-13 Oil level rises (Entry of coolant or fuel) ........................................................................... 25
00 Index and foreword SEN00179-15
125E-5 Series 7
S-14 Coolant temperature becomes too high (overheating) .................................................... 27
S-15 Abnormal noise is made ................................................................................................. 28
S-16 Vibration is excessive ..................................................................................................... 29
50 Disassembly and assembly
General information on disassembly and assembly ....................................................... SEN00697-03
General information on disassembly and assembly.................................................................... 2
How to read this manual .......................................................................................................... 2
Coating materials list ............................................................................................................... 4
Special tools list ....................................................................................................................... 7
Disassembly and assembly, Part 1 (With EGR).............................................................. SEN00698-02
Disassembly and assembly, Part 1 (With EGR) .......................................................................... 2
General disassembly of engine ............................................................................................... 2
General assembly of engine .................................................................................................... 17
Disassembly and assembly, Part 2 (EGR-less) .............................................................. SEN00699-03
Disassembly and assembly, Part 2 (EGR-less)........................................................................... 2
General disassembly of engine ............................................................................................... 2
General assembly of engine .................................................................................................... 16
Disassembly and assembly, Part 3 ................................................................................. SEN00700-00
Disassembly and assembly, Part 3 ............................................................................................. 2
Removal and installation of fuel supply pump unit .................................................................. 2
Replacement of oil seal of engine mounted on machine ......................................................... 4
90 Repair and replacement of parts
Information related to repair and replacement ................................................................ SEN05202-00
Flowchart ................................................................................................................................. 2
Special tool table ..................................................................................................................... 4
Special tool sketch ................................................................................................................... 6
Parts related to cylinder head ......................................................................................... SEN05203-01
Part names related to cylinder head ........................................................................................ 2
Testing and inspection of cylinder head................................................................................... 3
Pressure test of cylinder head ................................................................................................. 5
Replacement of valve guide .................................................................................................... 5
Replacement of valve seat insert ............................................................................................ 6
Replacement of crosshead guide ............................................................................................ 13
Repair of valve by grinding ...................................................................................................... 14
Parts related to cylinder block ......................................................................................... SEN05204-00
Part names related to cylinder block ....................................................................................... 2
Testing and inspection of cylinder block .................................................................................. 3
Part names related to crankshaft ............................................................................................. 6
Testing and inspection of crankshaft ....................................................................................... 7
Part names related to connecting rod...................................................................................... 8
Testing and inspection of connecting rod ................................................................................ 9
Replacement of flywheel ring gear .......................................................................................... 11
Replacement of camshaft gear ................................................................................................ 11
Replacement of main bearing metal cap ................................................................................. 12
Replacement of connecting rod small end bushing ................................................................. 14
Replacement of cam bushing .................................................................................................. 15
Replacement of engine rear seal ............................................................................................. 17
Replacement of wear sleeve (when sleeve is installed) .......................................................... 21
Repair of crankshaft by grinding .............................................................................................. 22
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This comprehensive workshop manual is 589 pages long and covers the Komatsu 125E-5 series (SAA6D125E-5) engine. It is a valuable resource for both professional mechanics and DIY enthusiasts.
The manual provides detailed information on the maintenance, repair, and troubleshooting of the Komatsu 125E-5 series engine, which is used in the following Komatsu machines:
- PC400-7E0, PC400LC-7E0
- PC450-7E0, PC450LC-7E0
- PC400-8, PC400LC-8, PC400-8R, PC400LC-8R
- PC450-8, PC450LC-8, PC450-8R, PC450LC-8R
- D85EX-15E0, D85EX-15R
- D85PX-15E0, D85PX-15R Bulldozer
- WA450-6, WA470-6, WA470-6R Wheel loader
- WA480-6, WA480-6R Wheel loader
- HM250-2, HM300-2, HM300-2R Articulated dump truck
- BR580JG-1 Mobile crusher
- DCA-300SSK4
For a preview of the manual, click the preview button located underneath the add to cart button.
