SEN00697-03

ENGINE 1SHOP MANUAL

125E-5 Series

50 Disassembly and assembly

General information on disassembly and
assembly
General information on disassembly and assembly ....................................................................................... 2
How to read this manual ...................................................................................................................... 2
Coating materials list............................................................................................................................ 4
Special tools list.................................................................................................................................... 7

125E-5 Series 1
SEN00697-03
General information on disassembly and assembly
How to read this manual
1. Removal and installation of assemblies
Special tools
q Special tools which are necessary for
re mo v a l o r i ns ta l l at io n o f p a rts a re
described as A1, ••• X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q Also the following information is de-
scribed in the special tool list.
1) Necessity
: Special tools that cannot be substi-
tuted and should always be used
: Special tools that will be useful if avail-
able and are substitutable with tools
available on the market
2) Distinction of new and existing special
tools
N: Tools newly developed for this
model. They have a new part num-
ber respectively.
R: Tools made available by redesign-
ing the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q The sketch of the special tool is pre-
sented in the section of “Sketches of
special tools”.
q Part No. of special tools starting with
79 T- - :
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
2 125E-5 Series
50 Disassembly and assembly
1
1
(Rev. 2009.01)
Removal
q In “Removal” section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q Common tools that are necessary for removal
are described as [1], [2]••• etc. and their part
numbers, part names and quantities are not
described.
q Various symbols used in “Removal” section are
explained and listed below.
k : Precautions related to work safety
a : Guidance or precautions for the work
[*1] : This mark shows that instructions or precau-
tions for parts installation work are given in
“Installation” section.
6 : Amount of oil or coolant to be drained
4:
Weight of part or component
Installation
q Unless otherwise instructed, installation of
parts is to be done in the reverse order to
removal.
q Instructions and precautions for parts installa-
tion is shown with the mark ([*1], [*2]...) which
corresponds to the mark in “Removal” section.
q Common tools that are necessary for installa-
tion are described as [1], [2]••• etc. and their
part numbers, part names and quantities are
not described.
q Marks shown in the “Installation” section stand
for the following.
k : Precautions related to work safety
a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
50 Disassembly and assembly
2. Disassembly and assembly of assemblies
Special tools
q Special tools which are necessary for dis-
assembly and assembly of parts are
described as A1, ••• X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q Also the following information is described
in the special tool list.
1) Necessity
: Special tools that cannot be substi-
tuted and should always be used.
: Special tools that will be useful if avail-
able and are substitutable with tools
available on the market.
2) Distinction of new and existing special
tools
N: Tools newly developed for this
model. They have a new part num-
ber respectively.
R: Tools made available by redesign-
ing the existing tools which were
developed for other models. Each
of them has a new part number
assigned by setting forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q The sketch of the special tool is pre-
sented in the section of “Sketches of
special tools”.
q Part No. of special tools starting with
79 T- - :
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
125E-5 Series
SEN00697-03
Disassembly
q In “Disassembly” section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q Common tools that are necessary for disas-
sembly are described as [1], [2]••• etc. and
their part numbers, part names and quantities
are not described.
q The meanings of the symbols used in “Disas-
sembly” section are as follows.
k : Precautions related to work safety
a : Guidance or precautions for the work
6 : Amount of oil or coolant drained
Assembly
q In “Assembly” section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be replenished
are described.
q Common tools that are necessary for assem-
bly are described as [1], [2]••• etc. and their
part numbers, part names and quantities are
not described.
q The meanings of the symbols used in “Assem-
bly” section are as follows.
k
: Precautions related to work safety
a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5
: Amount of oil or coolant to be replenished
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
3
SEN00697-03 50 Disassembly and assembly

Coating materials list 1

(Rev. 2009.02)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.

Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive

Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant

LG-6 790-129-9160 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9170 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.

4 125E-5 Series
50 Disassembly and assembly SEN00697-03

Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant

LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Used to prevent scuffing and seizure of press-fit-
ted portions, shrink-fitted portions, and threaded
LM-P 09940-00040 200 g Tube
portions.
Molybdenum

• Used to lubricate linkages, bearings, etc.

lubricant
disulfide

• Spray type
• Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuff-
— 09995-00250 190 g Can
ing each other.
• Applicable for the drive shaft splines, needle
bearings, pins and bolts of various links, etc.
• Feature: Seizure and scuffing prevention com-
prevention
compound

pound with metallic super-fine-grain, etc.

Seizure

LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
Grease

LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)

125E-5 Series 5
SEN00697-03 50 Disassembly and assembly

Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
Grease

• Used for oil seals of the transmission, etc.

• Feature: Urea (organic system) grease with heat
G2-U-S resistance and long life. Enclosed type.
427-12-11871 2 kg Can
ENS grease • Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)

Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer

PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive

• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass

facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material

SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)

6 125E-5 Series
50 Disassembly and assembly SEN00697-03

Special tools list 1

a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
“Sketches of special tools”).

New / Remodel
Necessity

Sketch
Sym-

Q'ty
Work item Part No. Part name Remarks
bol

Disassembly and assembly of 1 790-501-2001 Engine repair stand t 1

A
engine assembly 2 790-901-1240 Adapter t 1
Removal and installation of
C 795-102-2102 Spring pusher t 1
cylinder head valve spring
Removal and installation of piston
D 795-100-1191 Piston ring tool t 1
ring
Removal of cylinder liner E 795-220-1000 Liner puller t 1
Press fitting of cylinder liner F 795-225-1520 Liner driver t 1
Insertion of piston assembly G 795-921-1110 Piston holder t 1
Measuring projection of piston top
H 795-502-1121 Gauge holder t 1
surface
Adjusting valve clearance I 795-125-1360 Clearance gauge q 1
Angle tightening of bolt J 790-331-1110 Wrench q 1
Removal of rear oil seal L 795-931-1100 Seal puller assembly q
1 795-931-1210 Sleeve jig t 1
2 795-931-1220 Sleeve jig t 1
Press fitting of rear oil seal N
3 01050-31645 Bolt t 3
4 01050-31625 Bolt t 3
1 795-630-5500 Standard puller t 1
Removal of fuel supply pump P 2 01010-81090 Bolt t 2
3 01643-31032 Washer t 2

125E-5 Series 7
SEN00697-03

KOMATSU 125E-5 Series engine

Form No. SEN00697-03

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 05-09 (01)

8
 SEN00698-02

ENGINE 1SHOP MANUAL

125E-5 Series

50 Disassembly and assembly1

Disassembly and assembly, Part 1
(With EGR)
Disassembly and assembly, Part 1 (With EGR).............................................................................................. 2
General disassembly of engine ............................................................................................................ 2
General assembly of engine .............................................................................................................. 17

125E-5 Series 1
SEN00698-02 50 Disassembly and assembly

Disassembly and assembly, Part 1 (With EGR) 1

General disassembly of engine 1
a The shapes, quantity, locations, etc. of the
parts depend on each applicable machine.
Take care.

1. Preparation work
Before disassembling the engine, check its parts
for cracking, damage, etc. and clean it generally
and carefully for accurate inspection of its parts
and quick disassembly and assembly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.
6. Alternator
2. Setting engine assembly 1) Remove cover (1).
1) Set the engine assembly (1) on rigid and 2) Loosen alternator mounting bolt (2) and
stable stands [1]. lock bolt (3).
a The weight depends on the applica- 3) Loosen locknut (4) and then loosen the
ble machines.
4 Engine assembly: 1,300 kg
belt tension using the tension adjustment
nut and remove V-belt.
4) Remove mounting bolt (2) and lock bolt
(3) and then remove alternator (5).

2) Drain the engine coolant and engine oil.

a The quantity of the engine oil
depends on each applicable machine.
6 Engine oil: Approx. 40 7. Water pump suction tube
Remove tube (1).

3. Harness assembly
Disconnect the connector and clamp and
remove the harness assembly.

4. Heat shielding plate

Remove the heat shielding plate from EGR
and EGR piping.

5. Starting motor
Remove mounting bolt (1) and remove starting
motor (2).

2 125E-5 Series
50 Disassembly and assembly SEN00698-02

8. EGR cooler
1) Remove turbocharger drain tube (1).
2) Remove exhaust gas discharge tube (2).
3) Remove coolant tube (3).
4) Remove 2 air vent tubes (4).
5) Loosen rubber hose (5) clamp and then
remove the bolt on the water pump side
and remove tube (6).

10. Turbocharger and exhaust manifold assem-

bly
1) Remove bolt (1) used to mount the
assembly to bypass tube.
a The bypass tube is not used on some
machine models.
2) Disconnect turbocharger lubrication tube
(2).
6) Remove the bolt mounting it to EGR tube
(7).
7) Remove 4 mounting bolts and remove
EGR cooler (9).
a Remove bracket (8) at the same time.

3) Lift up the turbocharger side temporarily,

remove the exhaust manifold mounting
bolt and then remove the turbocharger
and exhaust manifold assembly.
4 Turbocharger and exhaust manifold
9. EGR tube assembly: 40 kg
1) Remove clamps (1) and (2).
2) Remove EGR gas pressure sensor tube (3).
3) Remove the bolt (4) mounting it to the
EGR valve and remove EGR tube (5).

125E-5 Series 3
SEN00698-02 50 Disassembly and assembly

11. Oil filter and oil tube assembly 13. Fuel tube
1) Remove the oil tube (1) block side mount- Remove clamp (3) and remove fuel tubes (1)
ing bolt. and (2).
2) Remove 4 mounting bolts on the oil filter
head side and remove oil filter and oil tube
assembly (2).

14. Lubrication tube and bracket

1) Remove brackets (1) and (2).
2) Remove turbocharger lubrication tube (3)
12. Fuel filter by removing 4 clamps on it.
1) Loosen clamp (3) to disconnect fuel tubes
(1) and (2).
2) Remove 4 mounting bolts on the head side
of the fuel filter and remove fuel filter (4).

15. High-pressure pipe

1) Remove bracket (1).
2) Remove splash prevention cover (2).

4 125E-5 Series
50 Disassembly and assembly
3) Remove 6 clamps (3) and 6 splash pre-
vention covers (4) on the injector side.
4) Remove clamps (5), (6), (7) and (8) and
then remove 6 high-pressure pipings (9).
16. Bypass tube
Remove bolt (2) on the bypass valve side and
then remove bypass tube (1).
125E-5 Series
SEN00698-02
17. Bypass valve
1) Remove clamp (1) and loosen clamp (2).
2) Remove oil drain tubes (4) and (5).
3) Remove the mounting bolt on oil inlet tube
(6).
4) Remove 2 mounting bolts (7) and then
remove bypass valve (8).
18. EGR valve
1) Remove oil inlet tube (1).
2) Remove 2 mounting bolts (2) and then
remove EGR valve (3).
19. Front hanger
Remove front hanger (1).
5
SEN00698-02 50 Disassembly and assembly

20. Diffuser and air housing assembly 21. Air intake manifold
1) Remove brackets (1) and (2) and then 1) Remove bracket (1).
remove oil filler (3).
2) Remove mounting bolt (4) at flanged por-
tion of the air housing. Remove the bolt
through the bottom.

2) Lift air intake manifold (2) temporarily,

remove its 24 mounting bolts and then
remove manifold.
4 Air intake manifold: 25 kg
3) Remove bracket (5) and then lift the dif-
fuser temporarily.
4) Remove the mounting bolt and then remove
diffuser and air housing assembly (6).
4 Diffuser and air housing assembly:
35 kg

22. Engine controller cooler

Disconnect fuel hose (1) and remove engine
controller cooler (2).
a Fuel hose (1) is not used on some
machine models.

6 125E-5 Series
50 Disassembly and assembly SEN00698-02

23. Fuel supply pump piping

1) Remove clamps (3), (4) and (5) and then
remove splash prevention cover (6).
2) Remove 2 high-pressure pipings (7).
3) Remove lubrication tube (8).
4) Remove fuel tube (1).

4) Remove pump mounting bolts (6) and

bracket (7).
a Leave bolts (6) tightened by 2 – 3
threads to prevent the pump from fall-
ing down.
5) Install tool P1 with P2 and P3 and then
24. Fuel supply pump assembly screw in the center bolt of P1 to remove
1) Remove cover (1). the gear from the shaft.
2) Rotate the crankshaft forward and set 6) Remove remaining bolts and then remove
intermediate point (a) between stamped fuel supply pump assembly (8).
“2/5 TOP” and “3/4 TOP” on damper (2) to a Leave tools P1, P2 and P3 in the
pointer (3) (stamped 1/6 TOP comes installed condition.
almost directly under).
a Make sure at this point that the forc-
ing tap of the drive gear is aligned to
the bolt hole at the top of cover (1).
(If not, rotate the crankshaft 1 more
turn.)
a At this point, the key of the shaft is
turned clockwise by 15° from the top.

3) Remove mounting nut (4) and then remove

washer (5).
a Use a magnet or the like in this opera-
tion so that washer (5) may not be
inadvertently dropped into the case.

125E-5 Series 7
SEN00698-02 50 Disassembly and assembly

25. Common rail and overflow tube 2) Remove the mounting bolt and then
1) Remove common rail (1). remove oil cooler assembly (4) using
2) Remove spill tube (2), overflow tube (3) guide bolt [1].
and block (4).

29. Engine repair stand adapter

26. Spill tube Install tool A2.
Remove spill tube (1).

27. Air vent tube

Remove air vent tube (2).

30. Head cover

Remove head cover (1).

28. Oil cooler assembly

1) Remove brackets (1) and (2) and drain
hose (3).

8 125E-5 Series
50 Disassembly and assembly
31. Injector harness
1) Fully loosen 2 harness terminal mounting
nuts (2) on the head of injector (1).
a Loosen nuts alternately.
2) Loosen bolt (3) of harness fixing holder.
32. Rocker arm and shaft assembly
1) Loosen locknut (3) and then loosen
adjustment screw (2).
2) Remove mounting bolt (4) and then
remove rocker arm and shaft assembly
(1).
33. Push rod
Remove 12 push rods (1).
125E-5 Series
SEN00698-02
34. Injector
Remove holder mounting bolt (3) of injector (1)
and then remove injector (1) along with holder
(2).
a Do not try to grip the solenoid valve at the
top of the injector using a pliers and the
like.
35. Crosshead
Remove 12 crossheads (1).
36. Injector wiring harness
1) Remove mounting bolt (2) of harness con-
nector (1).
2) Remove holder (3) from the harness.
9
SEN00698-02 50 Disassembly and assembly

3) Remove harness connector (1) by push- 39. Cam follower cover

ing outward from inside of rocker housing 1) Remove oil level gauge tube (1).
(4). 2) Remove oil tube (2) and bracket (3).
4) Remove O-ring (5) from the rocker housing. 3) Remove 3 cam follower covers (4).

37. Rocker arm housing 40. Cam follower

Remove rocker arm housing (1). Rem ove 12 mounting bolts (1) and the n
remove cam followers (2).
a Remove dowel pin (3).

38. Thermostat and water pump

1) Remove thermostat case (1) and tube (2).
2) Remove water pump (3).
41. Removal of cylinder head assembly
1) Remove each set of 7 mounting bolts (2)
of cylinder head assembly (1).
2) Using eyebolt [1], lift and remove cylinder
head assembly (1).
4 Cylinder head assembly: 20 kg
3) Remove each head gasket.

10 125E-5 Series
50 Disassembly and assembly SEN00698-02

42. Disassembly of cylinder head assembly 43. Setting to engine repair stand
1) Using tool C, compress valve spring (3) Lift the engine and then align currently installed
and remove valve cotter (4). tools A2 and A1 to set the engine.
2) Remove upper seat (5) and valve spring (3).

44. Oil pan

3) Remove seal (7) and then remove lower
Remove oil pan (1) by reversing the engine.
seat (8).
4) Raise the cylinder head and remove valve
(6).
a Apply an marking and the like to the
valve so that it may be identifiable to
which head it should be combined.

45. Speed sensor

Remove speed sensors (1) and (2) by turning
over the engine.
a Speed sensor (2) is not used on some
machine models.

125E-5 Series 11
SEN00698-02 50 Disassembly and assembly

46. Flywheel
1) Using slings [1], lift up flywheel (1) tempo-
rarily.
2) Remove 6 mounting bolts to remove the
flywheel from the dowel pin and then lift off
the flywheel.
4 Flywheel: 25 kg

49. EGR oil pump

Remove EGR oil pump (1).

47. Flywheel housing

1) Apply slings [1] to both sides of housing
(1) to lift it up temporarily.
2) Remove 10 mounting bolts to remove the
housing from the dowel pin and then lift it off.
4 Flywheel housing: 80 kg

50. Front support and front cover

48. Damper and pulley assembly
Lift the damper and pulley assembly (1) tem-
porarily and then remove its 6 mounting bolts.
4 Damper and pulley assembly: 25 kg
1) Lift up front support (1) temporarily and
then remove it by removing the mounting
bolts.
a Its shape depends on the applicable
machines.
4 Front support: 30 kg
2) Remove adjustment rod (2).
3) Lift up front cover (3) temporarily and then
remove it by removing the mounting bolts.
4 Front cover: 30 kg
4) Remove tool P and then remove the sup-
ply pump drive gear.

12 125E-5 Series
50 Disassembly and assembly SEN00698-02

51. Camshaft 53. Idler gear

1) Remove 2 mounting bolts (1). 1) Remove mounting bolt (1) and then remove
2) Remove camshaft (2). plate (2) and oil pump idler gear (3).
a When pulling out the camshaft, turn it
gently so that damages may not be
left on the cam bushing.

2) Remove shaft (4).

3) Remove mounting bolt (5) and then
remove shaft (6), main idler gear (7) and
plate (8).
52. Oil pump
Remove 4 mounting bolts (1) and then remove
oil pump (2).

54. Oil suction pipe

Remove brackets (1) and then remove oil suc-
tion pipe (2).

125E-5 Series 13
SEN00698-02 50 Disassembly and assembly

55. Piston cooling nozzle

Remove mounting bolt (1) and each piston
cooling nozzle (2).

6) Push in and remove the piston and con-

56. Piston and connecting rod assembly
a Before removing the piston and connect-
ing rod assembly, measure its end play
with dial gauge [3], if necessary.
7)
necting rod assembly with a wood bar, etc.
from the oil pan side, while supporting pis-
ton (3) on the cylinder head side.
a Take care not to damage the inside of
the cylinder with a corner of the con-
necting rod.
Remove the other piston and connecting
rod assemblies according to the above
procedure.
a Take care not to damage the sliding
portions of the pistons and bearings.
a Assemble each connecting rod and
cap temporarily so that they will not
be assembled with other ones and
keep them and the bearing together.

1) Check the stamped No. of the connecting

rod cap.
q The cap No. and cylinder No. must be
the same.
q The cap No. must be stamped on the
cam side.
a If the No. is not stamped, stamp it
before removing the connecting rod.
2) Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
3) Scrub the carbon off the top wall of the cyl- 8) Disassemble the piston and connecting
inder liner with fine sandpaper. rod assembly according to the following
4) Remove connecting rod cap mounting procedure.
bolts (1). 1] Remove 2 snap rings (4).
5) Hit connecting rod cap (2) with a plastic 2] While supporting connecting rod (5),
hammer so lightly that the threads of the remove piston pin (6) to disconnect
connecting rod bolts will not be damaged piston (7) and connecting rod.
and remove connecting rod cap (2) and
connecting rod bearing as a unit.

14 125E-5 Series
50 Disassembly and assembly SEN00698-02

2) Insert the bolts in the bolt holes of the

main cap and remove the cap, while shak-
ing it.

3] Using tool D, remove piston ring (8).

a Keep the piston, connecting rod,
connecting rod bearing, piston
rings, and piston pin by each cyl-
inder. a Thrust bearing (3) is assembled to
No. 7 main cap. After removing the
cap, apply a marking to the re-assem-
bly position.

57. Crankshaft
a Before removing the crankshaft, measure its
end play with dial gauge [3], if necessary.
3) Lift off crankshaft (4).
a When removing the crankshaft, take
care so that its sliding surfaces may
not be damaged.
4 Crankshaft: 110 kg

1) Remove mounting bolts (2) of main cap (1).

125E-5 Series 15
SEN00698-02 50 Disassembly and assembly

4) Remove upper thrust bearing (5). 58. Cylinder liner

Using tool E, pull out cylinder (1).
a Before removing the cylinder liner, mea-
sure its projection with dial gauge [3], if
necessary.

5) Remove upper bearing (6).

a Apply a marking to the assembly
positions of the main cap, main bear-
ing, and thrust bearing. And store
them by the journal No.

16 125E-5 Series
50 Disassembly and assembly
General assembly of engine 1 2]
a The shapes, quantity, locations, etc. of the
parts depend on each applicable machine.
Take care.
a Clean each part carefully, and check it for
bruise, flaw, cavity, etc. Make sure each oil or
coolant path is through.
Tightening bolts by plastic-region turning angle
method
a Bolts tightened by plastic-region turning angle
method
q Cylinder head mounting bolt
q Main cap mounting bolt
q Connecting rod cap mounting bolt
a If the plastic-region turning angle method is
applied, the tightened bolts have permanent
strain. Accordingly, the allowable number of
using times of each bolt is limited. Observe the
following precautions.
q Before tightening each bolt, measure its
stem length and make sure that the length
is less than the using limit. If the stem is
longer than the using limit, it should not be
used but replaced.
q Check each mounting bolt head for punch
marks. If there are punch marks more than
the specified numbers, replace the bolt.
1. Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 320 kg
2) Before inserting the cylinder liners, pre-
pare the cylinder block according to the
following procedure.
1] Remove the rust and scales from faces
(A) and (B) with sandpaper, etc. until
the machined surfaces are exposed.
125E-5 Series
SEN00698-02
Polish part (R) with sandpaper of
about No. 240 until it becomes a
smooth rounded surface.
If part (R) is sharp or has burrs, finish
it with a scraper or sandpaper.
Finish this surface particularly smoothly
so that it will not damage the O-ring.
3] If face (B) is so pitted that it cannot be
repaired, replace the cylinder block.
4] If faces (A) and (R) are pitted, finish
them smoothly.
5] Check the counterbored part and
remove burrs. If chips or dust is
present on face (C), the liner may not
fit well, resulting in coolant leakage or
insufficient liner protrusion. Thus,
they must be eliminated.
a If the counterbored part is droop-
ing, corroded, or pitted, repair it.
2. Cylinder liner
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not roughened
because of rusting or pitting. If those parts
are roughened, replace the cylinder liner.
2) Install clevis seal (1), O-rings (2) and (3) to
the cylinder liner.
a Check that there is not a burr, dust,
etc. in the groove of the liner.
a Replace the O-ring and clevis seal
with new ones.
a Fit the clevis seal with the chamfered
side down. When fitting it, press it
against the seal groove all round so
that it will not be twisted.
a When installing O-rings (2) and (3),
refer to the following.
q O-ring (2): The whole ring is black.
q O-ring (3): The whole ring is red.
2 Clevis seal and O-ring:
Rubber lubricant (LH-50 from NOF
Corporation)
17
SEN00698-02
a If LH-50 is not available, apply clean
engine oil SAE No. 30.
a Since the clevis seal and O-ring are
swollen and deteriorated by oil, apply
a small amount of oil to them thinly
with a brush just before fitting them.
3) After fitting the O-ring, check it for twist. If
it is twisted, correct it with a flexible rod
(about 10 mm in diameter).
18
50 Disassembly and assembly
4) Apply gasket sealant to the parts of the
cylinder block and cylinder liner which will
fit to the counterboared parts.
a Wipe off dirt and oil with cloth from
the contact faces of the counter-
boared parts of the cylinder block and
liner flange.
2 Cylinder block: Gasket sealant (LG-6)
q Gasket sealant:
0.8 – 1.6 mm in diameter
q Overlap (a) of gasket sealant: 6 ± 6 mm
a If the applied gasket sealant is left for a
long time, its surface becomes hard.
Accordingly, install the cylinder block to
the cylinder head within 50 minutes.
5) Insert cylinder liner (1) to the cylinder block.
a Insert cylinder liner (1) in the cylinder
block slowly, taking care not to dam-
age the O-ring.
6) Push in cylinder liner (1) further by both
hands.
a If the liner does not enter the cylinder
smoothly, the O-ring may be dam-
aged. In this case, check the cylinder
block for burrs.
7) Using tool F, press fit cylinder liner (1) to
the cylinder block.
125E-5 Series
50 Disassembly and assembly
8) To prevent the gasket sealant from pro-
jecting through the clearance between the
block and liner after the cylinder head is
tightened, tighten the cylinder head tem-
po r ar i l y w it h th e us e d he a d g a s k et
inserted.
a At this time, observe the following tight-
ening torque and tightening order.
3 Temporary tightening torque:
127.5 – 147.1 Nm {13 – 15 kgm}
9) Remove the cylinder head and wipe off
the gasket sealant projected from the
counterbored part.
a Be sure to perform steps 8) and 9)
above since the projected gasket
sealant can deform the grommet of
the head gasket.
10) Using dial gauge [3], measure the projec-
tion of the cylinder liner.
a When measuring projection of the
liner, fix the liner using a plate so that
it may not be lifted by the O-ring.
a Projection of cylinder liner:
0.07 – 0.15 mm
a If the end play is out of the standard,
correct it. For details, see “Structure,
function and maintenance standard”.
125E-5 Series
SEN00698-02
3. Crankshaft
a Cylinder block and main bearing are
selective mating parts and the prepared
spare parts ensure the required clearance.
1) Install the upper main bearing (6) to the
notch of the cylinder block while aligning
the bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.
2 Bearing inner surface:
Engine oil (EO30)
2) Drive in the roll pin so that its projection
from the block end face may become 1.5 –
1.9 mm and then install upper side thrust
bearing (5).
a Install each thrust bearing with the
grooved surface on the crankshaft side.
3) Before assembling the crankshaft, check
the following.
q Troubles on the front side and rear
side threaded portions
(Bottom can be easily screwed in by
hand)
q Scratches or dents on pin and main
journal
q Presence or absence of dust inside
oil hole
19
SEN00698-02
4) Lift and set crankshaft (4) to the mounting
position.
a When installing the crankshaft, take
care not to damage its sliding sur-
fac es b y, f or i ns tanc e, b um pi ng
against the cylinder block.
a When replacing the crank gear, heat it
with a bearing heater set at 150°C
and then fit it immediately after the
heating.
4 Crankshaft: 110 kg
2 Cylinder block journal:
Engine oil (EO30)
5) Install lower main bearing (7) to the main
cap.
a Install lower main bearing (7) to the
notch of the main cap while aligning
the bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.
a Drive the roll pin of cap No. 7 so that it
will be projected by 1.5 – 1.9 mm from
the cap end and then install thrust
bearings (3) to both sides.
a Install each thrust bearing with the
grooved surface on the crankshaft side.
9) Tighten main cap mounting bolts (2)
2 Threaded portion of mounting bolt and washer:
20
50 Disassembly and assembly
6) Install main cap (1).
a When installing, make sure that the
stamped No. at center of the main
cap is aligned to the stamped journal
No. of the cylinder block.
a Install the main cap with the cast let-
ter (F) toward the front of the engine.
2 Crankshaft journal surface:
Engine oil (EO30)
7) Before tightening the main cap mounting
bolts, check the following items. If any of
the following conditions applies, do not
reuse that bolt but replace it.
q Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q Length (a) of bolt stem:
Min. 159.8 mm
8)
Screw in main cap mounting bolts (2)
alt ern ate ly unt il th e m ain ca p ( 1) is
securely fitted in its place.
according to the following procedure.
a Tighten the bolts from the center one
to the outer ones in order.
Engine oil (EO30)
125E-5 Series
50 Disassembly and assembly
3 Mounting bolt
1st time : 98.1 ± 9.8 Nm {10 ± 1 kgm}
2nd time : 196.1 ± 4.9 Nm {20 ± 0.5 kgm}
3rd time : Using tool J, tighten the bolt by
90° (+30°/0).
4.
a When not using tool J, apply mark (b)
to the main cap and bolt with paint,
then tighten the bolt by 90° (+30°/0).
10) Make punch mark (c) on the mounting bolt
head.
a When a new bolt is used, do not
make a punch mark on its head.
11) Check that the crankshaft turns smoothly.
12) Measure the end play of the crankshaft
with dial gauge [3].
a End play: 0.14 – 0.315 mm
a If the end play is out of the standard,
correct it. For details, see “Structure,
function and maintenance standard”.
125E-5 Series
SEN00698-02
Piston and connecting rod assembly
a Piston and cylinder liner are selective mat-
ing parts and the prepared spare parts
ensure the required clearance.
1) Using tool D, assemble piston ring (8) in
the order of oil ring, second ring and top
ring starting from the bottom.
a Fit the top ring and second ring to the
piston with the stamped mark side up.
q Stamp on top ring: 1R
q Stamp on second ring: 2R
a Take the expander out of the oil ring
and fit it to the piston first and then fit
the oil ring. At this time, make sure
that the expander is fitted to the ring
groove perfectly.
2) Set the abutment joint of each piston ring
as shown in the following figure.
a Adjust oil ring so that the joint of the
expander will be at 180° to the abut-
ment joint of the oil ring.
21
SEN00698-02
3) Install snap ring (4) to one side of piston (7).
4) Heat piston (7) at 100°C for 5 minutes
minimum in the heating furnace.
a When the furnace is not available,
heat it at 100°C for 5 minutes mini-
mum in hot water.
5) Set connecting rod (5) on piston (7).
a Set the connecting rod so that the ID
marking "6251" at the bottom of the
connecting rod comes to the left side
as the grade marking on the piston
top surface is faced toward the front
side of the engine. Then insert the
connecting rod to piston pin (6).
2 Piston boss: Engine oil (EO30)
6) Install snap ring (4) on the opposite side.
a Turn the snap ring on both sides to
make sure they are securely fitted to
the ring groove.
22
50 Disassembly and assembly
7) Install upper main bearing (8) to the notch
of the connecting rod while aligning the
bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.
a Make sure that the bearing hole and
connecting rod oil hole are aligned.
8) Install the connecting rod lower bearing
(9) to the notch of the connecting rod cap
while aligning the bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.
125E-5 Series
50 Disassembly and assembly
9) Set the cylinder crankshaft, to which the pis-
ton and connecting rod assembly is to be
assembled, to the bottom dead center.
10) Insert piston and connecting rod assembly
(3) in the cylinder block so that ID marking
"6251" of the connecting rod may be faced
toward the left side face of the engine.
a Make sure the abutment joint of the
piston ring is located in the position
indicated in the following figure.
2 Inner surface of connecting rod and
cylinder: Engine oil (EO30)
11) Using tool G, reduce the piston ring and
then push in the piston head with a wood
bar, etc.
125E-5 Series
SEN00698-02
12) Install connecting rod cap (2).
a Align match mark of connecting rod
(5 ) a nd co nn ec ti ng ro d ca p (2 ).
(Above aligns the match mark to ID
marking "6251" on the opposite side.)
2 Inner surface of connecting rod cap
bearing: Engine oil (EO30)
13) Before tightening the connecting rod cap
mounting bolts, check the following items.
If any of the following conditions applies,
do not reuse that bolt but replace it.
q Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q Length (a) of bolt stem: Min. 84.1 mm
23
SEN00698-02 50 Disassembly and assembly

14) Tighten connecting rod cap mounting bolts

alternately until the connecting rod cap is
closely contacted.
15) Tighten connecting rod cap mounting bolts
(1) according to the following procedure.
3 Mounting bolt
1st time : 98.1 ± 4.9 Nm {10 ± 0.5 kgm}
2nd time : Using tool J, tighten the
bolt by 90° (+30°/0).

19) Set the dial gauge on tool H and then

measure the projection of the piston top
surface from the top face of the cylinder
block.
a Piston projection: 0.984 – 1.335 mm
a Prior to the measurement, push the
piston top surface to eliminate the oil
clearance.

a When not using tool J, apply marking

(b) to the connecting rod, cap and
bolt with paint, then tighten the bolt by
90° (+30°/0).
16) After tightening the bolt, make a punch
mark (C) on its head.
a When a new bolt is used, do not
make a punch mark on its head.

5. Piston cooling nozzle

1) Rotate the crankshaft and set the No. 1 –
No. 3 pistons to the following positions for
installation of the piston cooling nozzles of
each piston.
q Set the No. 1 piston to top: Piston
cooling nozzles of the No. 1 and No. 6
pistons can be installed.
q Set the No. 2 piston to top: Piston
17) Turn the crankshaft to check that it rotates cooling nozzles of the No. 2 and No. 5
normally. pistons can be installed.
18) Measure the side clearance of the con- q Set the No. 3 piston to top: Piston
necting rod with dial gauge [3]. cooling nozzles of the No. 3 and No. 4
a Side clearance: 0.2 – 0.375 mm piston can be installed.
2) Set piston cooling nozzle (2) adjusting the
dowel pin position and then tighten mount-
ing bolt (1).
3 Mounting bolt:
27 – 34 Nm {2.8 – 3.5 kgm}

24 125E-5 Series
50 Disassembly and assembly SEN00698-02

a After the installation, make sure the

nozzle end is situated at center of the
cut of respective pistons.

6. Oil suction pipe

Install oil suction pipe (2) after attaching the O-
ring to it and then fix them using bracket (1).

8. Oil pump
1) Install oil pump (2) after attaching the O-
ring to it and then tighten 4 mounting bolts
(1).
2) Drive in the pin and then install shaft (4).

7. Idler gear
1) Install plate (8) to the engine block and then
install main idler gear (7) and shaft (6).
a When installing plate (8), set its
chamfered side to the front side of the
engine.
2) Matching “A” mark of the crankshaft gear
and “A” mark of main idler gear (7),
tighten mounting bolt (5).
3 Mounting bolt:
245 – 294 Nm {25 – 30 kgm}

125E-5 Series 25
SEN00698-02 50 Disassembly and assembly

9. Idler gear 11. Cam follower

Assemble oil pump idler gear (3), attach plate 1) Drive in dowel pin (3) to the cylinder block.
(2) to it and then tighten them using mounting 2) Tighten 6 cam followers (2) using mount-
bolt (1). ing bolt (1).
3 Mounting bolt: 3 Mounting bolt:
147 – 176.4 Nm {15 – 18 kgm} 44 – 59 Nm {4.5 – 6 kgm}

10. Camshaft 12. Cam follower cover

1) Assemble camshaft (2) to the cylinder 1) Install the O-ring and cam follower cover (4).
block. 3 Mounting bolt:

a Rotate the camshaft when assem- 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
bling so that the cam bushing may not 2) Install brackets (3), oil tube (2) and oil
be damaged. level gauge (1).
a When replacing the cam gear, heat it
at 200 – 240°C for 30 minutes mini-
mum in an electronic oven and then
shrink fit it.
2 Camshaft journal surface:
Engine oil (EO30)
2) Matching “B” mark of the crankshaft gear
and “B” mark of the main idler gear,
tighten mounting bolt (1).

13. Water pump assembly

Fit the O-ring to water pump assembly (3) and
install them.

26 125E-5 Series
50 Disassembly and assembly SEN00698-02

14. Thermostat and water tube

Fit the gasket and then install thermostat (1)
and tube (2).

16. Make sure that match marks (A to C) of drive

gears and idler gears are matched.

15. Fuel supply pump assembly

1) Set fuel supply pump assembly (3) and
then tighten it temporarily using 4 mount-
ing bolts (5).
a Tighten it permanently according to
Step 43 described below.
2 Mounting bolt: Adhesive (LT-2)
2) Set the assembly by aligning “C” mark to
“C” mark of camshaft gear (2) while align-
ing the key groove of supply pump drive
gear (1) to the woodruff key of the shaft.
3) Fit the washer and then tighten them
using gear mounting nut (4).
3 Gear mounting nut:
127 – 147 Nm {13 – 15 kgm} 17. Measuring backlash and end play
4) Install bracket (6). a Measure the backlash and end play of
3 Mounting bolt (supply pump side): each gear with dial gauge [3].
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
a Leave the cylinder block side mount- • Standard backlash of each gear
ing bolt in temporarily tightened state Position Range (mm)
(it is to be tightened permanently in
a 0.105 – 0.325
the following Step 43).
b 0.105 – 0.325
c 0.116 – 0.359
d 0.105 – 0.337
e 0.082 – 0.389
f 0.076 – 0.366

• Standard end play of each gear

Position Range (mm)
1 0.05 – 0.17
2 0.05 – 0.21

a If the end play is out of the standard, cor-

rect it. For details, see “Structure, function
and maintenance standard”.

125E-5 Series 27
SEN00698-02 50 Disassembly and assembly

3) Install cover (2).

4) Using dial gauge, measure the level differ-
ence between underside faces of the cyl-
inder block and front cover.
a Difference: 0 – 0.275 mm
a If the difference is out of the standard,
correct it. For details, see “Structure,
function and maintenance standard”.
5) Install adjustment rod (3).
6) Install front support (4).
a Its shape depends on the applicable
machines.
4 Front support: 30 kg

19. Flywheel housing

1) Apply a string of gasket sealant 1 mm in
18. Front cover
diameter as shown below.
1) Using the push tool (outside diameter 120
mm), press fit oil seal (5) to the cover.
a Oil seal press fit allowance (a):
16 (+1/0) mm
2 Oil seal lip (50 – 80% of void lip
space): Grease (G2-LI)

2) Sling flywheel housing (1) and then install

it to the cylinder block.
4 Flywheel housing: 80 kg
3) Tighten flywheel housing mounting bolts (2).

2) Lift front cover (1) and then install it using

the guide bolt.
a When installing, take care not to dam-
age the oil seal.
4 Front cover: 30 kg
2 Front cover mounting surface:
Gasket sealant (LG-7)

28 125E-5 Series
50 Disassembly and assembly SEN00698-02

imum on the flywheel housing includ-

a Tighten the flywheel housing mount-
ing bolts in the following order in 2
steps.
a The following indicates that mounting
bolts 1, 4 and 2, 9 are to be tightened
twice in 1st time.
2 Mounting bolt: Engine oil (EO30)
3 Mounting bolt:
1st time:
147 – 235 Nm {15 – 24 kgm}
2nd time:
245 – 309 Nm {25 – 31.5 kgm}
ing the periphery.
a Move the crankshaft either in the front
or rear side in order to prevent errors
due to the end play.
a Make sure after rotating the crank-
shaft by a turn that the gauge pointer
is returned to the position where it
had been situated when the crank-
shaft was started to turn.
a The gauge pointer deflects in both
sides – right and left. Thus, reason-
able care must be exercised to avoid
misreading of the pointer when the
gauge is provided in the top, bottom,
left and right side of the measured
end face.
a Facial runout: Max. 0.20 mm

Measurement of radial runout of flywheel

housing
Like in measurement of the facial runout, set
dial gauge [3] so that its probe may contact
against the flywheel housing centering location
at a right angle.
a In measurement of radial runout, errors
due to end play of the crankshaft do not
occur. As for other points, however, the
precautions noted for the facial runout
4) After installing the flywheel housing, mea- remain applicable to the radial runout
sure its facial runout and radial runout with as they are.
dial gauge [3]. a Radial runout: Max. 0.20 mm

Measurement of facial runout of flywheel

housing
1] Apply the magnet stand to the crank-
shaft end face.
2] Set dial gauge [3] so that its probe
may contact against the flywheel
housing end face at a right angle.
3] Rotate the crankshaft by a turn to
read the difference between the maxi-
mum and minimum values indicated
by the gauge pointer.
a Measurement shall be conducted at
eight equally distanced positions min-

125E-5 Series 29
SEN00698-02 50 Disassembly and assembly

5) Using dial gauge [3], measure the level
difference between underside faces of the
cylinder block and flywheel housing.
a Difference: 0 – 0.35 mm
a If the difference is out of the standard,
correct it. For details, see “Structure,
function and maintenance standard”.
a Never remove inside plastic cylinder
(3) of the standard spare seal before
installing the seal.
1) Set the large inside diameter side (b)
of plastic inside cylinder (3) to the end
of crankshaft (4).
a Take care not to mistake the direc-
tion of the plastic inside cylinder.

20. Rear oil seal

a Check the Teflon seal (Laydown lip seal)
by checking the wear of the crankshaft
and replace it with the “Standard seal” or
“Sleeved seal”.
a If the crankshaft is worn to the degree of
luster (If wear which you feel with your fin-
ger is less than 10 mm) and does not have
any flaw, install the standard seal. In other
cases, install the sleeved seal.
a The left one in the following figure is the
standard seal and the right one is the
sleeved seal.

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

hands and push it in firmly.
3) After pushing in the seal, remove
plastic inside cylinder (3).
a When removing the inside cylin-
der, take care not to damage the
seal lip.

Procedure for installing standard seal

a Before installing the seal, check that
the end corners and lip sliding sur-
faces of crankshaft (4) are free from
flaw, burr, and rust of the housing.
a When installing the seal, do not apply
oil or grease to the shaft and seal lip
(a). Wipe off the oil from the shaft.

30 125E-5 Series
50 Disassembly and assembly SEN00698-02

4) Tighten bolts (N3 and N4) evenly to press

fit seal (1) until the end of tool N1 reaches
the end of crankshaft (4).
a First tighten tool N1 until it is contacted
against bolt N3 (bolt stem 45 mm) and
then further tighten the tool with bolt N4
(bolt stem 25 mm).
a When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool set, etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.

2) Set the sleeve of the seal to the end

of the crankshaft, and then tighten
bolt N3 evenly to press fit sleeve and
seal assembly (2) until the end face of
tool N2 reaches the end of crankshaft
(4).

Procedure for installing sleeved seal

a Before installing the seal, make sure
that the end corners and lip sliding sur-
faces of crankshaft (4) are free from
flaws, burrs, and rusts of the housing.
a When installing the seal, do not apply
oil or grease to the shaft, sleeve (1),
and seal lip (a). Wipe off the oil from
the shaft.
a Handle the seal and sleeve as an
3) Remove tool N2 and then replace it
assembly and don't separate them
with tool N1.
from each other.
4) Tighten bolt N4 evenly to press fit
sleeve and seal assembly (2) until the
end face of tool N1 reaches the end
of crankshaft (4).
a After press fitting the seal, remove
the red sealant layer from its
periphery.

1) Set sleeve and seal assembly (2) to

tool N2.
2 Inside sleeve:
Gasket sealant (LG-7)

125E-5 Series 31
SEN00698-02 50 Disassembly and assembly

21. Flywheel
1) Using sling [1], lift up flywheel (1) and then
install it aligning to the dowel pin.
2) Tighten mounting bolts (2) in the following
order in 2 steps.
2 Mounting bolt: Engine oil (EO30)
3 Mounting bolt
1st time:
147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd time:
289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}

22. Speed sensor

a Before installing the sensor, make sure its
tip is free from steel chips or flaws.
1) Install speed sensor (1).
3 Mounting bolt:
4.9 – 7.9 Nm {0.5 – 0.8 kgm}
2) Install speed sensor (2).
1] Screw in speed sensor (2) until its tip
lightly touches the tooth tip of ring
gear (3).
2 Threads: Gasket sealant
3) Using dial gauge [3], measure the facial
(Hydraulic sealant
and radial runout.
from Loctite)
a Facial runout : Max. 0.20 mm
2] Rotate speed sensor (2) in the oppo-
a Radial runout: Max. 0.15 mm
site direction by 1/2 – 2/3 turns.
a Clearance (a) will become 0.75 –
1 mm.
3] Tighten nut (4) while fixing sensor (2).
3 Nut: 69 – 74 Nm {7 – 7.5 kgm}

32 125E-5 Series
50 Disassembly and assembly SEN00698-02

25. Oil pan

1) Reverse the engine.
2) Apply gasket sealant of 5 mm in diameter
along the entire inside periphery of oil pan
(1) mounting bolt hole and then tighten the
mounting bolt.
2 Mating face: Gasket sealant (LG-7)

23. EGR oil pump

Install the O-ring and EGR oil pump (1).

26. Removal from engine repair stand

1) Reverse the engine.
2) Lift the engine temporarily.
3) Disconnect tool A1 from tool A2.
4) Remove tool A2 from the engine.

24. Damper and pulley assembly

Lift and install damper and pulley assembly (1).
3 Mounting bolt (Width across flat 22 mm,
a single bolt):
157 – 196 Nm {16 – 20 kgm}
Mounting bolt (Width across flat 24 mm,
5 bolts):
245 – 309 Nm {25 – 31.5 kgm}

125E-5 Series 33
SEN00698-02 50 Disassembly and assembly

27. Setting the engine 29. Installation of cylinder head assembly

Set engine (1) on a rigid and stable stands [1].
1) Check that the cylinder head mounting
face and inside of the cylinder are free
from foreign matter and then set cylinder
head gasket (1).
a When fitting the gasket, check that
the grommets are fitted correctly.

28. Assembly of cylinder head assembly

1) Assemble valve (6).
2 Valve stem: Engine oil (EO30)
2) Raise the cylinder head and then install
lower seat (8) and seal (7).
2) Before tightening the cylinder head
mounting bolts, check the following items.
If any of the following conditions applies,
do not reuse that bolt but replace it.
q Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q Length (a) of bolt stem:
Min. 171.4 mm

3) Assemble valve spring (3) and upper

sheet (5).
4) Using tool C, compress the valve spring
and install valve cotter (4).
a Hit the valve stem lightly with a plastic
hammer to make sure that the valve
cotter is fitted to the groove of the
valve stem.

34 125E-5 Series
50 Disassembly and assembly SEN00698-02

3) Using sling [1], lift and set cylinder head

assembly (2) to the cylinder block.
4 Cylinder head assembly: 20 kg

a When not using tool J, apply

marking (b) to the cylinder head
and bolt with paint, then tighten
4) Tighten the cylinder head assembly the bolt by 90 – 120° (Target:
mounting bolts and auxiliary bolts. 120°).
1] Tighten the mounting bolts in the 2] Mark a punch mark (C) on its head to
order of 1 to 6 shown in the figure. show the number of tightening times.
2 Mounting bolt: a When a new bolt is used, do not
Molybdenum disulfide lubri- make a punch mark on its head.
cant (LM-P) or engine oil
(EO30)
3 Mounting bolt
1st time : 98.1 ± 9.8 Nm {10 ±
1 kgm}
2nd time: 166.6 – 176.4 Nm
{17 – 18 kgm}
(Target: 176.4 Nm
{18 kgm})
3rd time : Using tool J, tighten
the bolt by 90 – 120°
(Target: 120°).

3] Tighten the auxiliary cylinder head

bolt (following figure 7).
3 Auxiliary bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

125E-5 Series 35
SEN00698-02
30. Rocker arm housing
1) Install gasket (1) and then install rocker
arm housing (2).
2) Tighten mounting bolts (3).
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
31. Injector harness connector
1) Install O-ring (4) to harness connector (1).
2 O-ring: Engine oil (EO30)
2) Insert harness connector (1) to rocker
housing (3) and then tighten them with
mounting bolt (2).
3) Fit in harness to holder (3).
36
50 Disassembly and assembly
32. Crosshead
1) Set crosshead (1) and then loosen locknut
(2) to return adjustment screw (3) to its
original position.
2) Using your finger, lightly hold down the
crosshead (1) face contacting the rocker
arm to maintain contact between the push
rod side valve stem and crosshead (1).
3) Screw in adjustment screw (3) until cross-
head (1) comes in contact with another
valve stem.
4) As they are contacted, further screw in the
adjustment screw by 20° and then tighten
locknut (2) from that state.
2 Crosshead guide and crosshead
top face: Engine oil (EO30)
3 Locknut:
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
125E-5 Series
50 Disassembly and assembly SEN00698-02

33. Injector 4) Fit the ball washer to bolt (3) and tighten
a Check that the inside of the injector sleeve holder (2) temporarily.
is free from dirt. 2 Spherical part of washer:
1) Install common rail (9) temporarily. Engine oil (EO30)
5) Locate high-pressure sleeve (4) to inlet
connector (5) and then tighten them tem-
porarily.
a Tighten the common rail side sleeve
nut temporarily, too.
6) Tighten holder (2) with bolt (3) perma-
nently.
a Tighten bolt (3) while pulling the tube
of the high-pressure pipe in the oppo-
site direction of the injector.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
7) After tightening the holder, remove the
high-pressure sleeve (4) from the inlet
connector (5) and then install the other
2) Install gasket (6) and O-rings (7) and (8) to injectors in order according to the above
injector (1).
2 O-ring: Engine oil (EO30)
procedure.
8) Remove the temporarily installed common
rail.

3) Insert holder (2) to injector (1). Continue

from that state, insert inlet connector (5) to 34. Push rod
the high-pressure pipe insertion hole Install push rod (1).
through the rocker housing. a Check that the push rod end is placed in
the cam follower socket.

125E-5 Series 37
SEN00698-02
35. Rocker arm and shaft assembly
1) Set rocker arm and shaft assembly (1).
a When installing the rocker arm shaft,
be sure to set its side with a larger
mounting hole diameter to the bottom
and to direct ball plug (6) side toward
the front side of the engine.
2) Before tightening mounting bolts (4),
check that the ball of adjustment screw (2)
is fitted to socket (5) of the push rod.
a Install the mounting bolt after cleaning
its oil hole.
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
36. Injector wiring harness
1) Tighten mounting bolts (3) of the harness
fixing holder.
3 Mounting bolt:
27.0 – 34.0 Nm {2.8 – 3.5 kgm}
2) Tighten 2 harness terminal mounting nuts
(2) to injector (1).
a Tighten the nuts alternately.
3 Mounting nut:
2.0 – 2.4 Nm {0.2 – 0.24 kgm}
38
50 Disassembly and assembly
37. Adjusting valve clearance
a Adjust the clearance between the cross-
head and rocker arm to the following
value.
a Valve clearance (in cold state)
Unit: mm
Intake valve Exhaust valve
0.33 0.71
a Rotate the engine and adjust the valve
clearance of each cylinder in the firing
order of 1 – 5 – 3 – 6 – 2 – 4.
1) Rotate the crankshaft forward and match
stamped line of “1.6 TOP” on vibration
damper (1) to pointer (2), watching the
movement of the valve.
2) Insert clearance gauge l between rocker
arm (3) and crosshead (4) and screw in
adjustment screw (5) until the gauge
becomes movable. Then tighten the lock-
nut.
3 Locknut:
58.8 – 73.5 Nm {6 – 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.
125E-5 Series
50 Disassembly and assembly SEN00698-02

38. Head cover 41. Oil cooler assembly

Fit the O-ring and install head cover (1). 1) Fit the gasket to oil cooler assembly (4)
a Take care so that O-ring may not be twisted. and then install them using guide bolt [1].
3 Mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}

2) Install drain hose (3) and brackets (2) and

(1).
39. Air vent tube
Fit a gasket on both sides and then install air
vent tube (2).
3 Joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

40. Spill tube

Fit a gasket on both sides and then install spill
tube (1).
3 Joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

42. Common rail and overflow tube

1) Install block (4) and then install overflow
tube (3) and spill tube (2).
2) Install common rail (1).
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}

125E-5 Series 39
SEN00698-02 50 Disassembly and assembly

43. Installation of high-pressure pipe between

fuel supply pump and common rail
1) Tighten high-pressure pipes (3) and (4) by
hand first, and then tighten them perma-
nently.
3 Sleeve nut
(Pump side):
39.2 – 49 Nm {4 – 5 kgm}
(Common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
2) Tighten supply pump mounting bolts (2)
permanently.
3) Tighten the cylinder block side mounting
bolt of bracket (1) permanently.
4) Install the splash prevention cover on both
ends of the high-pressure pipe.
a Face the common rail side slit down-
ward and the supply side slit toward
the cylinder block.
5) Tighten lubrication tube (12) by hand.
6) Tighten and install clamp (10) by hand
first, and then tighten it permanently.
7) Tighten and install brackets (6) and (5) by
hand first, and then tighten them perma-
nently.
8) Tighten and install bracket (8) and clamp
(9) by hand first, and then tighten them
permanently.
3 Clamp (9) mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
9) Tighten and install clamp (11) by hand
first, and then tighten it permanently.
3 Clamp (11) mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
10) Tighten lubrication tube (12) permanently.
3 Joint bolt:
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
11) Tighten and install clamp (7) by hand first,
and then tighten it permanently.
3 Clamp (7) mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}

40 125E-5 Series
50 Disassembly and assembly SEN00698-02

44. Engine controller cooler 3) Install bracket (1).

1) Install engine controller cooler (1).
3 Joint bolt:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
2) Install fuel hose (2).
3 Fuel hose:
84 – 132 Nm {8.5 – 13.5 kgm}

46. Diffuser and air housing assembly

1) Fit the gasket and then install diffuser (2)
and air housing assembly (4) temporarily.
2) Fit the gasket and then install front hanger
(3) temporarily.
3) After fixing the front hanger, move air
45. Air intake manifold housing assembly (4) in order to eliminate
1) Fit the gasket and then install air intake clearance in (b) (between front hanger
manifold (2) temporarily. and air housing) and part (a) (between air
4 Air intake manifold: 25 kg housing and diffuser). Then tighten every
bolt.

2) Tighten the mounting bolts in the order of

4) Install brackets (5), (6), (7) and (8).
given below.
3 Mounting bolt:
5) Install oil filler port (9).
59 – 74 Nm {6 – 7.5 kgm}

125E-5 Series 41
SEN00698-02 50 Disassembly and assembly

47. EGR valve 4) Install clamps (2) and (1).

1) Install tube (5) with clamp (4) temporarily.
2) Fit the gasket and then install EGR valve
(3) with bolts (2) temporarily.
a Tighten it permanently according to
Step 56. described below.
3) Install oil inlet tube (1).
a Make sure when installing the tube
that it is free from twist or interfer-
ence.
3 Sleeve nut:
24 – 27 Nm {2.4 – 2.7 kgm}
4) Tighten clamp (4).

49. Bypass tube

1) Fit the gasket and then install bypass tube
(1) temporarily.
2) Adjust the angle between the bypass
valve and bypass tube and then tighten
their mounting bolt permanently.
3 Bypass valve mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}

48. Bypass valve

1) Fit the gasket and then install bypass
valve (8) with bolt (7) temporarily.
a Tighten it permanently according to
Step 49. described below.
2) Install oil inlet tube (6).
a Make sure when installing the tube
that it is free from twist or interfer-
ence.
3 Sleeve nut:
24 – 27 Nm {2.4 – 2.7 kgm}
50. High-pressure pipe
3) Install drain tubes (5) and (4).
a Before installing the high-pressure pipe,
a Make sure when installing the tubes
check it for the following defects. If there is
that they are free from twist or inter-
any of these defects, it can cause fuel
ference.
3 Joint bolt:
leakage. Accordingly, replace the high-
pressure pipe.
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
q Check the taper seal of the connecting
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q Check part (d) (end of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.

42 125E-5 Series
50 Disassembly and assembly SEN00698-02

1) Install high-pressure pipes (3), (4), (5), (6), 5) Install bracket (17).
(7) and (8). 3 Clamp tightening torque:
a Mounting angle of the high-pressure 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
injection pipe is adjusted before the 6) Tighten clamps (11), (12), (13), and (14)
installation of the injector. permanently.
3 Sleeve nut (on both sides): 3 Mounting bolt:
39.2 – 49 Nm {4 – 5 kgm} 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
2) Tighten bracket (9) and clamp (10) by
hand first, and then tighten them perma-
nently.
3 Mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3) Install clamps (11), (12), (13) and (14) by
tightening them by hand.
4) Install 6 each of the splash prevention
covers (15) and (16).
Direct the slit on the injector side down-
ward and that on the common rail side
toward the cylinder block.

51. Lubrication tube and bracket

1) Install lubrication tube (3).
3 Sleeve nut:
24 – 27 Nm {2.4 – 2.7 kgm}
2) Install brackets (1) and (2).

125E-5 Series 43
SEN00698-02
52. Fuel tube
Install fuel tubes (1) and (2) and clamp (3) tem-
porarily.
a Tighten them permanently after installing
the fuel filter.
53. Fuel filter
1) Install fuel filter (4) with the 4 bolts.
2) Tighten permanently above fuel tubes (1)
and (2) and clamp (3) that are currently
temporarily installed.
3 Joint bolt (for both tubes (1) and (2)):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
44
50 Disassembly and assembly
54. Oil filter and oil tube
1) Install oil filter (2) temporarily with the 4
bolts.
2) Install the O-ring and then install oil tube
(1) temporarily.
3) Tighten the bottom flange of oil tube (1)
permanently and then tighten the top
flange permanently.
4) Tighten 4 oil filter (2) mounting bolts per-
manently.
55. Turbocharger and exhaust manifold assem-
bly
1) Lift turbocharger and exhaust manifold
assembly (1), fit the gasket to the assem-
bly and then install them temporarily.
4 Turbocharger and manifold assem-
bly: 40 kg
2) After tightening bolts (2), (3) and (4), and
then tighten remaining bolts.
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
125E-5 Series
50 Disassembly and assembly SEN00698-02

3) Fit the gasket and then connect lubrication

tube (2).
4) Fit the gasket and then connect EGR
bypass tube (1).

4) Install air vent tube (4).

5) Fit the gasket and O-ring, and then install
coolant tube (3).
6) Fit the gasket and install exhaust gas dis-
56. EGR tube charge tube (2).
1) Fit the gasket, adjust its angle to the EGR 3 Mounting bolt:
valve and then install EGR tube (5) tem- 59 – 74 Nm {6.0 – 7.5 kgm}
porarily. 7) Fit the gasket and install drain tube (1).
2) Tighten EGR tube mounting bolt (4) and
EGR valve mounting bolt.
3 EGR valve mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
3) Fit the gasket and then install EGR gas
pressure sensor tube (3).
4) Install clamps (2) and (1).

58. Water pump suction tube

Fit the gasket and install tube (1).

57. EGR cooler

1) Install EGR cooler (9) with the 4 bolts.
2) Fit the gasket and then connect EGR tube
(7).
a Clamp (8) is to be tightened together.
3) Fit the O-ring, install coolant tube (6) and
then tighten the clamp of rubber hose (5).

125E-5 Series 45
SEN00698-02 50 Disassembly and assembly

59. Alternator 63. Tightening torque for sensor

1) Hang V-belt on the pulley of alternator (5) Use the following tightening torque when
and tighten mounting bolt (2) and lock bolt removal and installation or replacement of the
(3) temporarily. sensor.
2) Adjust the belt tension with V-belt tension
Sensor name Tightening torque
adjustment nut and tighten mounting bolt
(2) and lock bolt (3). Fuel
23 ± 3 Nm {2.35 ± 0.3 kgm}
3) Check the belt tension and then tighten temperature
locknut (4). Boost pressure 5.5 ± 0.5 Nm {0.56 ± 0.05 kgm}
4) Install cover (1). Intake air
23 ± 3 Nm {2.35 ± 0.3 kgm}
temperature
Coolant
23 ± 3 Nm {2.35 ± 0.3 kgm}
temperature
EGR gas
23 ± 3 Nm {2.35 ± 0.3 kgm}
pressure
Engine oil
23 ± 3 Nm {2.35 ± 0.3 kgm}
pressure
4.5 ± 0.5 Nm {0.46 ± 0.05 kgm}
Atmospheric
(Hexagonal head bolt and hexago-
pressure
nal socket head bolt)
Fuel pressure Never disassemble.

64. Checking for fuel leakage

60. Starting motor a If fuel supply pump (2), common rail (1), or
Set starting motor (2) and then tighten 3 hi gh - pr e ss u re pi pe is re m ov e d a nd
mounting bolts (1). installed, after assembling the engine,
check for fuel leakage according to the fol-
lowing procedure.

61. Heat shielding plate

Install the heat shielding plate to EGR and
EGR pipe.
62. Harness assembly
Locate the harness in the specified position,
connect the harness connectors to the speci-
fied counterparts and then fix them using the
clamp.
a Clean and degrease the engine and the
parts around it in advance so that you can
test it easily for fuel leakage.
1) Spray color checker (developer) over the
fuel supply pump, common rail, fuel injec-
tor, and joints of the high-pressure piping.
2) Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.

46 125E-5 Series
50 Disassembly and assembly SEN00698-02

3) Check the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pres-
sure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
4) Run the engine at low idle.
5) Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pres-
sure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
6) Run the engine at high idle.
7) Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pres-
sure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
8) Run the engine at high idle and load it.
a When checking while the components
to be checked are mounted on the
machine, stall the torque converter or
relieve the hydraulic pump.
9) Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pres-
sure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
a If no fuel leakage is detected, check
is completed.

125E-5 Series 47
SEN00698-02

KOMATSU 125E-5 Series engine

Form No. SEN00698-02

© 2008 KOMATSU
All Rights Reserved
Printed in Japan 12-08 (01)

48
 SEN00699-03

ENGINE 1SHOP MANUAL

125E-5 Series

50 Disassembly and assembly1

Disassembly and assembly, Part 2
(EGR-less)
Disassembly and assembly, Part 2 (EGR-less) .............................................................................................. 2
General disassembly of engine ............................................................................................................ 2
General assembly of engine .............................................................................................................. 16

125E-5 Series 1
SEN00699-03 50 Disassembly and assembly

Disassembly and assembly, Part 2 (EGR-less) 1

General disassembly of engine 1
a The shapes, quantity, locations, etc. of the
parts depend on each applicable machine.
Take care.
4. Wiring harness assembly
Disconnect the connectors and clamps and
remove wiring harness assembly (1).

1. Preparation work
Before disassembling the engine, check its
parts for cracking, damage, etc. and clean it
generally and carefully for accurate inspection
of its parts and quick disassembly and assem-
bly.
a Before cleaning the engine, carefully seal
or remove the openings, electric parts,
and wiring connectors so that water will
not enter them.

2. Setting engine assembly

1) Place engine assembly (1) on stable block 5. Starting motor assembly
[1] so that it will not tip over. Remove 3 mounting bolts (1) and starting
a The weight depends on each applica- motor assembly (2).
ble machine.
4 Engine assembly: 1,250 kg

2) Drain the engine coolant and engine oil.

a The quantity of the engine oil
depends on each applicable machine.
6 Engine oil: Approx. 40

3. Muffler, air cleaner and related parts

a These parts depend on each applicable
machine.

Remove the muffler, air cleaner and related

parts.

2 125E-5 Series
50 Disassembly and assembly SEN00699-03

6. Alternator assembly
1) Remove cover (1).
2) Loosen alternator mounting bolt (2) and
fixing bolt (3).
3) Remove nut (4), loosen the locknut, lower
the belt tension with the tension adjust-
ment nut, and remove V-belt (5).
4) Remove mounting bolt (2), fixing bolt (3)
and alternator assembly (6).
5) Remove plate (7) and bracket (8).
a These parts depend on each applicable
machine.

9. Exhaust manifold assembly

Sling exhaust manifold assembly (1), remove
18 mounting bolts (2), and remove the exhaust
manifold assembly.
4 Exhaust manifold assembly: 35 kg

7. Water pump suction tube

Remove tube (1).

10. Thermostat housing assembly

1) Remove connector (1).
2) Remove thermostat housing assembly (2).

8. Turbocharger assembly
1) Remove bracket (1).
2) Remove the 5 clamps and turbocharger
lubricating oil inlet tube (2).
3) Remove the tube bracket and turbo-
charger outlet tube (3).
4) Remove 4 mounting bolts (4) and turbo-
charger assembly (5).

125E-5 Series 3
SEN00699-03 50 Disassembly and assembly

11. Water pump assembly 14. Fuel filters

1) Remove connector (1). 1) Remove cover (1).
2) Remove 3 mounting bolts (2) and water 2) Remove the joint bolt and tubes (2) and
pump assembly (3). (3).
3) Remove the joint bolt and hose (4).
4) Remove the 2 clamps, joint bolt and tube
(5).
5) Remove clamp (6), joint bolt and tubes (7)
and (8).
6) Remove fuel filters (9) and (10).

12. Oil cooler assembly

Remove the mounting bolts and then remove
oil cooler assembly (1), using guide bolts.

15. Brackets
Remove brackets (1), (2), (3), (4), (5), (6) and
(7).

13. Oil filter

1) Disconnect clamp (1).
2) Remove oil tubes (2) and (3).
3) Remove oil filter (4).

4 125E-5 Series
50 Disassembly and assembly SEN00699-03

16. Engine controller cooler assembly and 18. Bracket

block 1) Remove wiring harness (1).
1) Remove the 5 mounting bolts and engine 2) Remove brackets (2) and (3).
controller cooler assembly (1).
2) Remove the joint bolt and tubes (2) and
(3).
3) Remove block (4).

19. Air connector, electrical intake air heater

and front hanger
1) Remove the 6 mounting bolts, air connec-
tor (1) and electrical intake air heater (2).
17. Electric priming pump and block 2) Remove plates (3) and (4).
a Electric priming pump is not set for some 3) Remove front hanger (5).
models.
1) Disconnect wiring harness connector (1).
2) Remove the joint bolt and hoses (2) and
(3).
3) Remove the joint bolt and tube (4).
4) Remove the joint bolt, loosen the sleeve
nut, and remove tube (5).
5) Remove Electric priming pump (6).
6) Remove block (7).

20. Diffuser air housing assembly

Remove the 8 mounting bolts and lift off dif-
fuser and air housing assembly (1).
4 Diffuser and air housing assembly: 40 kg

125E-5 Series 5
SEN00699-03 50 Disassembly and assembly

21. Bracket 23. High-pressure pipe

1) Remove the 2 mounting bolts and bracket 1) Remove high-pressure pipe clamp mount-
(1). ing bolt (1).
2) Remove the 4 mounting bolts and bracket 2) Remove the 2 mounting bolts and bracket
(2). (2).

22. Spill pipe 3) Remove high-pressure pipe clamp (3).

Remove 6 joint bolts (1) and spill pipe (2). 4) Remove 10 high-pressure pipe clamps
(4).
5) Remove 6 brackets (5).
6) Remove the pin, 6 splash prevention cov-
ers (6) on the injector side and 6 splash
prevention covers (7) on the common rail
side.
7) Remove 6 high-pressure pipes (8).

6 125E-5 Series
50 Disassembly and assembly SEN00699-03

24. Air intake manifold 26. Fuel supply pump assembly

Sling air intake manifold (1), remove the 24 1) Remove cover (1).
mounting bolts, and remove the air intake man- 2) Rotate the crankshaft forward and set
ifold. intermediate point (a) between stamped
4
“2/5 TOP” and “3/4 TOP” on damper (2) to
Air intake manifold: 40 kg
pointer (3) (stamped 1/6 TOP comes
almost directly under).
a Make sure at this point that the forc-
ing tap of the drive gear is aligned to
the bolt hole at the top of cover (1).
(If not, rotate the crankshaft 1 more
turn.)
a At this point, the key of the shaft is
turned clockwise by 15° from the top.

25. Common rail

1) Remove the pin, 2 splash prevention cov-
ers (1) on the common rail side and 2
splash prevention covers (2) on the fuel
supply pump side.
2) Remove high-pressure pipe clamps (3),
(4), (5) and (6) and high-pressure pipes
(7) and (8).
3) Remove the joint bolt and tube (9). 3) Remove mounting nut (4) and then remove
4) Remove common rail (10). washer (5).
5) Remove the 4 mounting bolts and bracket a Use a magnet or the like in this opera-
(11). tion so that washer (5) may not be
inadvertently dropped into the case.

125E-5 Series 7
SEN00699-03 50 Disassembly and assembly

4) Remove pump mounting bolts (6) and 28. Injector wiring harness
bracket (7). 1) Fully loosen 2 wiring harness terminal
a Leave bolts (6) tightened by 2 – 3 mounting nuts (2) on the head of injector
threads to prevent the pump from fall- (1).
ing down. a Loosen nuts alternately.
5) Install tool P1 with P2 and P3 and then 2) Loosen bolt (3) of harness fixing holder.
screw in the center bolt of P1 to remove
the gear from the shaft.
6) Remove remaining bolts and then remove
fuel supply pump assembly (8).
a Leave tools P1, P2 and P3 in the
installed condition.

29. Rocker arm and shaft assembly

1) Loosen locknut (3) and adjustment screw
(2).
2) Remove mounting bolts (4) and rocker
arm and shaft assembly (1).

30. Push rods

27. Tube and head cover
Remove 12 push rods (1).
1) Remove 6 joint bolts (1) and tube (2).
2) Remove the mounting bolts and head cov-
ers (3).

8 125E-5 Series
50 Disassembly and assembly SEN00699-03

31. Injector 3) Press out wiring harness connector (1)

Remove holder mounting bolts (3) of injector from insid e of rock er h ousin g (4) to
(1) and then remove injector (1) and holder (2) remove it.
together. 4) Remove O-ring (5) from the rocker hous-
a Never hold the solenoid valve at the top of ing.
the injector with pliers, etc.

34. Rocker arm housing

32. Crosshead Remove rocker arm housing (1).
Remove 12 crossheads (1).

35. Cam follower cover

33. Injector wiring harness 1) Remove 3 cam follower covers (1).
1) Remove mounting bolt (2) of wiring har- 2) Remove oil level gauge tube (2).
ness connector (1).
2) Remove holder (3) from the wiring har-
ness.

125E-5 Series 9
SEN00699-03 50 Disassembly and assembly

36. Cam follower 38. Disassembly of cylinder head assembly

Remove 12 mounting bolts (1) and 6 cam fol- 1) Using tool C, compress valve spring (3)
lowers (2). and remove valve cotter (4).
a Remove dowel pin (3). 2) Remove upper seat (5) and valve spring
(3).

37. Removal of cylinder head assembly

1) Remove 7 mounting bolts (2) each from 3) Remove seal (7) and lower seat (8).
cylinder head assembly (1). 4) Raise the cylinder head and remove valve
2) Using eyebolts [1], lift off cylinder head (6).
assembly (1). a Make marks for combinations of the
4 Cylinder head assembly: 20 kg valves and heads.
3) Remove each head gasket.

39. Setting to engine repair stand

Sling the engine, install tool A2, and set the
engine while matching tool A2 to tool A1.

10 125E-5 Series
50 Disassembly and assembly SEN00699-03

40. Oil pan 43. Flywheel housing

Reverse the engine and remove oil pan (1).
1) Install slings [1] to the right and left of
housing (1) and sling the housing.
2) Remove the 10 mounting bolts, remove
the housing from the dowel pins, and lift it
off.
4 Flywheel housing: 80 kg

41. Speed sensors

Reverse the engine and remove speed sen-
sors (1) and (2).
a Speed sensor (2) may not be installed,
depending on each applicable machine.
44. Damper and pulley assembly
Sling damper and pulley assembly (1), remove
the 6 mounting bolts, and lift off the assembly.
4 Damper and pulley assembly: 25 kg

42. Flywheel
1) Install sling [1] to flywheel (1) and lift it up.
2) Remove the 6 mounting bolts, remove the
flywheel from the dowel pins, and lift it off.
4 Flywheel: 25 kg

125E-5 Series 11
SEN00699-03 50 Disassembly and assembly

45. Front support and front cover 47. Oil pump

1) Sling front support (1), remove the mount- Remove 4 mounting bolts (1) and then remove
ing bolts, and lift off the front support. oil pump (2).
a The shape depends on the applicable
machine.
3 Front support: 30 kg
2) Sling front cover (2), remove the mounting
bolts, and lift off the front cover.
3 Front cover: 30 kg
3) Remove tool P and supply pump drive
gear.

48. Idler gear

1) Remove mounting bolt (1) and then remove
plate (2) and oil pump idler gear (3).
2) Remove shaft (4).
3) Remove mounting bolt (5) and then
remove shaft (6), main idler gear (7) and
plate (8).

46. Camshaft
1) Remove 2 mounting bolts (1).
2) Remove camshaft (2).
a When pulling out the camshaft, turn it
gently so that damages may not be
left on the cam bushing.

12 125E-5 Series
50 Disassembly and assembly SEN00699-03

49. Oil suction pipe 51. Piston and connecting rod assembly
Remove brackets (1) and then remove oil suc- a Before removing the piston and connect-
tion pipe (2). ing rod assembly, measure its end play
with dial gauge [3], if necessary.

50. Piston cooling nozzle

Remove mounting bolt (1) and each piston
cooling nozzle (2).
1) Check the stamped No. of the connecting
rod cap.
q The cap No. and cylinder No. must be
the same.
q The cap No. must be stamped on the
cam side.
a If the No. is not stamped, stamp it
before removing the connecting rod.
2) Rotate the crankshaft and bring the piston
to be removed to the bottom dead center.
3) Scrub the carbon off the top wall of the cyl-
inder liner with fine sandpaper.
4) Remove connecting rod cap mounting
bolts (1).
5) Hit connecting rod cap (2) with a plastic
hammer so lightly that the threads of the
connecting rod bolts will not be damaged
and remove connecting rod cap (2) and
connecting rod bearing as a unit.

125E-5 Series 13
SEN00699-03 50 Disassembly and assembly

6) Push in and remove the piston and con- 3] Using tool D, remove piston ring (8).
necting rod assembly with a wood bar, etc. a Keep the piston, connecting rod,
from the oil pan side, while supporting pis- connecting rod bearing, piston
ton (3) on the cylinder head side. rings, and piston pin by each cyl-
a Take care not to damage the inside of inder.
the cylinder with a corner of the con-
necting rod.
7) Remove the other piston and connecting
rod assemblies according to the above
procedure.
a Take care not to damage the sliding
portions of the pistons and bearings.
a Assemble each connecting rod and
cap temporarily so that they will not
be assembled with other ones and
keep them and the bearing together.

52. Crankshaft
a Before removing the crankshaft, measure its
end play with dial gauge [3], if necessary.

8) Disassemble the piston and connecting

rod assembly according to the following
procedure.
1] Remove 2 snap rings (4).
2] While supporting connecting rod (5),
remove piston pin (6) to disconnect
1) Remove mounting bolts (2) of main cap (1).
piston (7) and connecting rod.
2) Insert the bolts in the bolt holes of the
main cap and remove the cap, while shak-
ing it.

14 125E-5 Series
50 Disassembly and assembly SEN00699-03

a Thrust bearing (3) is assembled to 5) Remove upper bearing (6).

No. 7 main cap. After removing the a Apply a marking to the assembly
cap, apply a marking to the re-assem- positions of the main cap, main bear-
bly position. ing, and thrust bearing. And store
them by the journal No.

3) Lift off crankshaft (4).

a When removing the crankshaft, take
53. Cylinder liner
care so that its sliding surfaces may
Using tool E, pull out cylinder (1).
not be damaged.
a Before removing the cylinder liner, mea-
4 Crankshaft: 110 kg
sure its projection with dial gauge [3], if
necessary.

4) Remove upper thrust bearing (5).

125E-5 Series 15
SEN00699-03
General assembly of engine 1 2]
a The shapes, quantity, locations, etc. of the
parts depend on each applicable machine.
Take care.
a Clean each part carefully, and check it for
bruise, flaw, cavity, etc. Make sure each oil or
coolant path is through.
Tightening bolts by plastic-region turning angle
method
a Bolts tightened by plastic-region turning angle
method
q Cylinder head mounting bolt
q Main cap mounting bolt
q Connecting rod cap mounting bolt
a If the plastic-region turning angle method is
applied, the tightened bolts have permanent
strain. Accordingly, the allowable number of
using times of each bolt is limited. Observe the
following precautions.
q Before tightening each bolt, measure its
stem length and make sure that the length
is less than the using limit. If the stem is
longer than the using limit, it should not be
used but replaced.
q Check each mounting bolt head for punch
marks. If there are punch marks more than
the specified numbers, replace the bolt.
1. Cylinder block
1) Install tool A2 to the cylinder block, and
then sling the cylinder block and set it to
tool A1.
4 Cylinder block: 320 kg
2) Before inserting the cylinder liners, pre-
pare the cylinder block according to the
following procedure.
1] Remove the rust and scales from faces
(A) and (B) with sandpaper, etc. until
the machined surfaces are exposed.
16
50 Disassembly and assembly
Polish part (R) with sandpaper of
about No. 240 until it becomes a
smooth rounded surface.
If part (R) is sharp or has burrs, finish
it with a scraper or sandpaper.
Finish this surface particularly smoothly
so that it will not damage the O-ring.
3] If face (B) is so pitted that it cannot be
repaired, replace the cylinder block.
4] If faces (A) and (R) are pitted, finish
them smoothly.
5] Check the counterbored part and
remove burrs. If chips or d ust is
present on face (C), the liner may not
fit well, resulting in coolant leakage or
insufficient liner protrusion. Thus,
they must be eliminated.
a If the counterbored part is droop-
ing, corroded, or pitted, repair it.
2. Cylinder liner
1) Check that the cylinder liner O-ring groove
and periphery of the liner are not roughened
because of rusting or pitting. If those parts
are roughened, replace the cylinder liner.
2) Install clevis seal (1), O-rings (2) and (3) to
the cylinder liner.
a Check that there is not a burr, dust,
etc. in the groove of the liner.
a Replace the O-ring and clevis seal
with new ones.
a Fit the clevis seal with the chamfered
side down. When fitting it, press it
against the seal groove all round so
that it will not be twisted.
a When installing O-rings (2) and (3),
refer to the following.
q O-ring (2): The whole ring is black.
q O-ring (3): The whole ring is red.
2 Clevis seal and O-ring:
Rubber lubricant (LH-50 from NOF
Corporation)
125E-5 Series
50 Disassembly and assembly
a If LH-50 is not available, apply clean
engine oil SAE No. 30.
a Since the clevis seal and O-ring are
swollen and deteriorated by oil, apply
a small amount of oil to them thinly
with a brush just before fitting them.
3) After fitting the O-ring, check it for twist. If
it is twisted, correct it with a flexible rod
(about 10 mm in diameter).
125E-5 Series
SEN00699-03
4) Apply gasket sealant to the parts of the
cylinder block and cylinder liner which will
fit to the counterboared parts.
a Wipe off dirt and oil with cloth from
the contact faces of the counter-
boared parts of the cylinder block and
liner flange.
2 Cylinder block: Gasket sealant (LG-6)
q Gasket sealant:
0.8 – 1.6 mm in diameter
q Overlap (a) of gasket sealant: 6 ± 6 mm
a If the applied gasket sealant is left for a
long time, its surface becomes hard.
Accordingly, install the cylinder block to
the cylinder head within 50 minutes.
5) Insert cylinder liner (1) to the cylinder block.
a Insert cylinder liner (1) in the cylinder
block slowly, taking care not to dam-
age the O-ring.
6) Push in cylinder liner (1) further by both
hands.
a If the liner does not enter the cylinder
smoothly, the O-ring may be dam-
aged. In this case, check the cylinder
block for burrs.
7) Using tool F, press fit cylinder liner (1) to
the cylinder block.
17
SEN00699-03
8) To prevent the gasket sealant from pro-
jecting through the clearance between the
block and liner after the cylinder head is
tightened, tighten the cylinder head tem-
po r ar i l y w it h th e us e d he a d g a s k et
inserted.
a At this time, observe the following tight-
ening torque and tightening order.
3 Temporary tightening torque:
127.5 – 147.1 Nm {13 – 15 kgm}
9) Remove the cylinder head and wipe off
the gasket sealant projected from the
counterbored part.
a Be sure to perform steps 8) and 9)
above since the projected gasket
sealant can deform the grommet of
the head gasket.
10) Using dial gauge [3], measure the projec-
tion of the cylinder liner.
a When measuring projection of the
liner, fix the liner using a plate so that
it may not be lifted by the O-ring.
a Projection of cylinder liner:
0.07 – 0.15 mm
a If the end play is out of the standard,
correct it. For details, see “Structure,
function and maintenance standard”.
18
50 Disassembly and assembly
3. Crankshaft
a Cylinder block and main bearing are
selective mating parts and the prepared
spare parts ensure the required clearance.
1) Install the upper main bearing (6) to the
notch of the cylinder block while aligning
the bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.
2 Bearing inner surface:
Engine oil (EO30-DH)
2) Drive in the roll pin so that its projection
from the block end face may become 1.5 –
1.9 mm and then install upper side thrust
bearing (5).
a Install each thrust bearing with the
grooved surface on the crankshaft side.
3) Before assembling the crankshaft, check
the following.
q Troubles on the front side and rear
side threaded portions
(Bottom can be easily screwed in by
hand)
q Scratches or dents on pin and main
journal
q Presence or absence of dust inside
oil hole
125E-5 Series
50 Disassembly and assembly
4) Lift and set crankshaft (4) to the mounting
position.
a When installing the crankshaft, take
care not to damage its sliding sur-
fac es b y, fo r i ns tan ce, b um pi ng
against the cylinder block.
a When replacing the crank gear, heat it
with a bearing heater set at 150°C
and then fit it immediately after the
heating.
4 Crankshaft: 110 kg
2 Cylinder block journal:
Engine oil (EO30-DH)
5) Install lower main bearing (7) to the main
cap.
a Install lower main bearing (7) to the
notch of the main cap while aligning
the bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.
a Drive the roll pin of cap No. 7 so that it
will be projected by 1.5 – 1.9 mm from
the cap end and then install thrust
bearings (3) to both sides.
a Install each thrust bearing with the
grooved surface on the crankshaft side.
9) Tighten main cap mounting bolts (2)
2 Threaded portion of mounting bolt and washer:
125E-5 Series
SEN00699-03
6) Install main cap (1).
a When installing, make sure that the
stamped No. at center of the main
cap is aligned to the stamped journal
No. of the cylinder block.
a Install the main cap with the cast let-
ter (F) toward the front of the engine.
2 Crankshaft journal surface:
Engine oil (EO30-DH)
7) Before tightening the main cap mounting
bolts, check the following items. If any of
the following conditions applies, do not
reuse that bolt but replace it.
q Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q Length (a) of bolt stem:
Min. 159.8 mm
8)
Screw in main cap mounting bolts (2)
alt ern ate ly unt il th e m ain ca p ( 1) is
securely fitted in its place.
according to the following procedure.
a Tighten the bolts from the center one
to the outer ones in order.
Engine oil (EO30-DH)
19
SEN00699-03
3 Mounting bolt
1st time : 98.1 ± 9.8 Nm {10 ± 1 kgm}
2nd time : 196.1 ± 4.9 Nm {20 ± 0.5 kgm}
3rd time : Using tool J, tighten the bolt by
90° (+30°/0).
4.
a When not using tool J, apply mark (b)
to the main cap and bolt with paint,
then tighten the bolt by 90° (+30°/0).
10) Make punch mark (c) on the mounting bolt
head.
a When a new bolt is used, do not
make a punch mark on its head.
11) Check that the crankshaft turns smoothly.
12) Measure the end play of the crankshaft
with dial gauge [3].
a End play: 0.14 – 0.315 mm
a If the end play is out of the standard,
correct it. For details, see “Structure,
function and maintenance standard”.
20
50 Disassembly and assembly
Piston and connecting rod assembly
a Piston and cylinder liner are selective mat-
ing parts and the prepared spare parts
ensure the required clearance.
1) Using tool D, assemble piston ring (8) in
the order of oil ring, second ring and top
ring starting from the bottom.
a Fit the top ring and second ring to the
piston with the stamped mark side up.
q Stamp on top ring: 1R
q Stamp on second ring: 2R
a Take the expander out of the oil ring
and fit it to the piston first and then fit
the oil ring. At this time, make sure
that the expander is fitted to the ring
groove perfectly.
2) Set the abutment joint of each piston ring
as shown in the following figure.
a Adjust oil ring so that the joint of the
expander will be at 180° to the abut-
ment joint of the oil ring.
125E-5 Series
50 Disassembly and assembly
3) Install snap ring (4) to one side of piston (7).
4) Heat piston (7) at 100°C for 5 minutes
minimum in the heating furnace.
a When the furnace is not available,
heat it at 100°C for 5 minutes mini-
mum in hot water.
5) Set connecting rod (5) on piston (7).
a Set the connecting rod so that the ID
marking "6251" at the bottom of the
connecting rod comes to the left side
as the grade marking on the piston
top surface is faced toward the front
side of the engine. Then insert the
connecting rod to piston pin (6).
2 Piston boss: Engine oil (EO30-DH)
6) Install snap ring (4) on the opposite side.
a Turn the snap ring on both sides to
make sure they are securely fitted to
the ring groove.
125E-5 Series
SEN00699-03
7) Install upper main bearing (8) to the notch
of the connecting rod while aligning the
bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.
a Make sure that the bearing hole and
connecting rod oil hole are aligned.
8) Install the connecting rod lower bearing
(9) to the notch of the connecting rod cap
while aligning the bearing projection to it.
a Before fitting the bearing, check that its
back side is free from foreign matter.
21
SEN00699-03
9) Set the cylinder crankshaft, to which the pis-
ton and connecting rod assembly is to be
assembled, to the bottom dead center.
10) Insert piston and connecting rod assembly
(3) in the cylinder block so that ID marking
"6251" of the connecting rod may be faced
toward the left side face of the engine.
a Make sure the abutment joint of the
piston ring is located in the position
indicated in the following figure.
2 Inner surface of connecting rod and
cylinder: Engine oil (EO30-DH)
11) Using tool G, reduce the piston ring and
then push in the piston head with a wood
bar, etc.
22
50 Disassembly and assembly
12) Install connecting rod cap (2).
a Align match mark of connecting rod
(5 ) a nd co nn ec ti ng ro d c a p (2 ).
(Above aligns the match mark to ID
marking "6251" on the opposite side.)
2 Inner surface of connecting rod cap
bearing: Engine oil (EO30-DH)
13) Before tightening the connecting rod cap
mounting bolts, check the following items.
If any of the following conditions applies,
do not reuse that bolt but replace it.
q Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q Length (a) of bolt stem: Min. 84.1 mm
125E-5 Series
50 Disassembly and assembly SEN00699-03

14) Tighten connecting rod cap mounting bolts

alternately until the connecting rod cap is
closely contacted.
15) Tighten connecting rod cap mounting bolts
(1) according to the following procedure.
3 Mounting bolt
1st time : 98.1 ± 4.9 Nm {10 ± 0.5 kgm}
2nd time : Using tool J, tighten the
bolt by 90° (+30°/0).

19) Set the dial gauge on tool H and then

measure the projection of the piston top
surface from the top face of the cylinder
block.
a Piston projection: 0.984 – 1.335 mm
a Prior to the measurement, push the
piston top surface to eliminate the oil
clearance.

a When not using tool J, apply marking

(b) to the connecting rod, cap and
bolt with paint, then tighten the bolt by
90° (+30°/0).
16) After tightening the bolt, make a punch
mark (C) on its head.
a When a new bolt is used, do not
make a punch mark on its head.

5. Piston cooling nozzle

1) Rotate the crankshaft and set the No. 1 –
No. 3 pistons to the following positions for
installation of the piston cooling nozzles of
each piston.
q Set the No. 1 piston to top: Piston
cooling nozzles of the No. 1 and No. 6
pistons can be installed.
q Set the No. 2 piston to top: Piston
17) Turn the crankshaft to check that it rotates cooling nozzles of the No. 2 and No. 5
normally. pistons can be installed.
18) Measure the side clearance of the con- q Set the No. 3 piston to top: Piston
necting rod with dial gauge [3]. cooling nozzles of the No. 3 and No. 4
a Side clearance: 0.2 – 0.375 mm piston can be installed.
2) Set piston cooling nozzle (2) adjusting the
dowel pin position and then tighten mount-
ing bolt (1).
3 Mounting bolt:
27 – 34 Nm {2.8 – 3.5 kgm}

125E-5 Series 23
SEN00699-03 50 Disassembly and assembly

a After the installation, make sure the

nozzle end is situated at center of the
cut of respective pistons.

6. Oil suction pipe

Install oil suction pipe (2) after attaching the O-
ring to it and then fix them using bracket (1).

8. Oil pump
1) Install oil pump (2) after attaching the O-
ring to it and then tighten 4 mounting bolts
(1).
2) Drive in the pin and then install shaft (4).

7. Idler gear
1) Install plate (8) to the engine block and then
install main idler gear (7) and shaft (6).
a When installing plate (8), set its
chamfered side to the front side of the
engine.
2) Matching “A” mark of the crankshaft gear
and “A” mark of main idler gear (7),
tighten mounting bolt (5).
3 Mounting bolt:
245 – 294 Nm {25 – 30 kgm}

24 125E-5 Series
50 Disassembly and assembly SEN00699-03

9. Idler gear 11. Cam follower

Assemble oil pump idler gear (3), attach plate 1) Drive in dowel ring (3) to the cylinder block.
(2) to it and then tighten them using mounting 2) Tighten 6 cam followers (2) using mount-
bolt (1). ing bolt (1).
3 Mounting bolt: 3 Mounting bolt:
147 – 176.4 Nm {15 – 18 kgm} 44 – 59 Nm {4.5 – 6 kgm}

10. Camshaft 12. Cam follower cover

1) Assemble camshaft (2) to the cylinder Install the O-ring and cam follower cover (1).
block. 3 Mounting bolt:

a Rotate the camshaft when assem- 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
bling so that the cam bushing may not
be damaged.
a When replacing the cam gear, heat it
at 200 – 240°C for 30 minutes mini-
mum in an electronic oven and then
shrink fit it.
2 Camshaft journal surface:
Engine oil (EO30-DH)
2) Matching “B” mark of the crankshaft gear
and “B” mark of the main idler gear,
tighten mounting bolt (1).

13. Water pump assembly

Fit the O-ring to water pump assembly (3) and
install them temporarily.

125E-5 Series 25
SEN00699-03 50 Disassembly and assembly

14. Fuel supply pump assembly 15. Make sure that match marks (A to C) of drive
1) Set fuel supply pump assembly (3) and gears and idler gears are matched.
then tighten it temporarily using 4 mount-
ing bolts (5).
a Tighten it permanently according to
Step 39. described below.
2 Mounting bolt: Adhesive (LT-2)
2) Set the assembly by aligning “C” mark to
“C” mark of camshaft gear (2) while align-
ing the key groove of supply pump drive
gear (1) to the woodruff key of the shaft.
3) Fit the washer and then tighten them
using gear mounting nut (4).
3 Gear mounting nut:
127 – 147 Nm {13 – 15 kgm}
4) Install bracket (6).
3 Mounting bolt (supply pump side):
19.6 – 29.4 Nm {2.0 – 3.0 kgm} 16. Measuring backlash and end play
a Leave the cylinder block side mount- a Measure the backlash and end play of
ing bolt in temporarily tightened state each gear with dial gauge [3].
(it is to be tightened permanently in
the following Step 39.). • Standard backlash of each gear
Position Range (mm)
a 0.105 – 0.325
b 0.105 – 0.325
c 0.116 – 0.359
d 0.105 – 0.337
e 0.082 – 0.389
f 0.076 – 0.366

• Standard end play of each gear

Position Range (mm)
1 0.05 – 0.17
2 0.05 – 0.21

a If the end play is out of the standard, cor-

rect it. For details, see “Structure, function
and maintenance standard”.

26 125E-5 Series
50 Disassembly and assembly SEN00699-03

2) Lift front cover (2) and then install it using

the guide bolt.
a When installing, take care not to dam-
age the oil seal.
4 Front cover: 30 kg
2 Front cover mounting surface:
Gasket sealant (LG-7)
3) Install cover (3).
4) Using dial gauge, measure the level differ-
ence between underside faces of the cyl-
inder block and front cover.
a Difference: 0 – 0.275 mm
a If the difference is out of the standard,
correct it. For details, see “Structure,
function and maintenance standard”.
5) Install front support (1).
a Its shape depends on the applicable
machines.
4 Front support: 30 kg

17. Front cover

1) Using the push tool (outside diameter 120
mm), press fit oil seal (5) to the cover.
a Oil seal press fit allowance (a):
16 (+1/0) mm
2 Oil seal lip (50 – 80% of void lip
18. Flywheel housing
space): Grease (G2-LI)
1) Apply a string of gasket sealant 1 mm in
diameter as shown below.

2) Sling flywheel housing (1) and then install

it to the cylinder block.
4 Flywheel housing: 80 kg
3) Tighten flywheel housing mounting bolts (2).

125E-5 Series 27
SEN00699-03 50 Disassembly and assembly

imum on the flywheel housing includ-

a Tighten the flywheel housing mount-
ing bolts in the following order in 2
steps.
a The following indicates that mounting
bolts 1, 4 and 2, 9 are to be tightened
twice in 1st time.
2 Mounting bolt: Engine oil (EO30-
DH)
3 Mounting bolt:
1st time:
147 – 235 Nm {15 – 24 kgm}
2nd time:
245 – 309 Nm {25 – 31.5 kgm}
ing the periphery.
a Move the crankshaft either in the front
or rear side in order to prevent errors
due to the end play.
a Make sure after rotating the crank-
shaft by a turn that the gauge pointer
is returned to the position where it
had been situated when the crank-
shaft was started to turn.
a The gauge pointer deflects in both
sides – right and left. Thus, reason-
able care must be exercised to avoid
misreading of the pointer when the
gauge is provided in the top, bottom,
left and right side of the measured
end face.
a Facial runout: Max. 0.20 mm

Measurement of radial runout of flywheel

housing
Like in measurement of the facial runout, set
dial gauge [3] so that its probe may contact
against the flywheel housing centering location
at a right angle.
a In measurement of radial runout, errors
due to end play of the crankshaft do not
occur. As for other points, however, the
4) After installing the flywheel housing, mea- precautions noted for the facial runout
sure its facial runout and radial runout with remain applicable to the radial runout
dial gauge [3]. as they are.
a Radial runout: Max. 0.20 mm
Measurement of facial runout of flywheel
housing
1] Apply the magnet stand to the crank-
shaft end face.
2] Set dial gauge [3] so that its probe
may contact against the flywheel
housing end face at a right angle.
3] Rotate the crankshaft by a turn to
read the difference between the maxi-
mum and minimum values indicated
by the gauge pointer.
a Measurement shall be conducted at
eight equally distanced positions min-

28 125E-5 Series
50 Disassembly and assembly SEN00699-03

5) Using dial gauge [3], measure the level
difference between underside faces of the
cylinder block and flywheel housing.
a Difference: 0 – 0.35 mm
a If the difference is out of the standard,
correct it. For details, see “Structure,
function and maintenance standard”.
a Never remove inside plastic cylinder
(3) of the standard spare seal before
installing the seal.
1) Set the large inside diameter side (b)
of plastic inside cylinder (3) to the end
of crankshaft (4).
a Take care not to mistake the direc-
tion of the plastic inside cylinder.

19. Rear oil seal

a Check the Teflon seal (Laydown lip seal)
by checking the wear of the crankshaft
and replace it with the “Standard seal” or
“Sleeved seal”.
a If the crankshaft is worn to the degree of
luster (If wear which you feel with your fin-
ger is less than 10 mm) and does not have
any flaw, install the standard seal. In other
cases, install the sleeved seal.
a The left one in the following figure is the
standard seal and the right one is the
sleeved seal.

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

hands and push it in firmly.
3) After pushing in the seal, remove
plastic inside cylinder (3).
a When removing the inside cylin-
der, take care not to damage the
seal lip.

Procedure for installing standard seal

a Before installing the seal, check that
the end corners and lip sliding sur-
faces of crankshaft (4) are free from
flaw, burr, and rust of the housing.
a When installing the seal, do not apply
oil or grease to the shaft and seal lip
(a). Wipe off the oil from the shaft.

125E-5 Series 29
SEN00699-03 50 Disassembly and assembly

4) Tighten bolts (N3 and N4) evenly to press

fit seal (1) until the end of tool N1 reaches
the end of crankshaft (4).
a First tighten tool N1 until it is contacted
against bolt N3 (bolt stem 45 mm) and
then further tighten the tool with bolt N4
(bolt stem 25 mm).
a When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool set, etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.

2) Set the sleeve of the seal to the end

of the crankshaft, and then tighten
bolt N3 evenly to press fit sleeve and
seal assembly (2) until the end face of
tool N2 reaches the end of crankshaft
(4).

Procedure for installing sleeved seal

a Before installing the seal, make sure
that the end corners and lip sliding sur-
faces of crankshaft (4) are free from
flaws, burrs, and rusts of the housing.
a When installing the seal, do not apply
oil or grease to the shaft, sleeve (1),
and seal lip (a). Wipe off the oil from
the shaft.
3) Remove tool N2 and then replace it
a Handle the seal and sleeve as an
with tool N1.
assembly and don't separate them
4) Tighten bolt N4 evenly to press fit
from each other.
sleeve and seal assembly (2) until the
end face of tool N1 reaches the end
of crankshaft (4).
a After press fitting the seal, remove
the red sealant layer from its
periphery.

1) Set sleeve and seal assembly (2) to

tool N2.
2 Inside sleeve:
Gasket sealant (LG-7)

30 125E-5 Series
50 Disassembly and assembly SEN00699-03

20. Flywheel
1) Using sling [1], lift up flywheel (1) and then
install it aligning to the dowel pin.
2) Tighten mounting bolts (2) in the following
order in 2 steps.
2 Mounting bolt: Engine oil (EO30-
DH)
3 Mounting bolt
1st time:
147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd time:
289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}

21. Speed sensor

a Before installing the sensor, make sure its
tip is free from steel chips or flaws.
1) Install speed sensor (1).
3 Mounting bolt:
4.9 – 7.9 Nm {0.5 – 0.8 kgm}
2) Install speed sensor (2).
1] Screw in speed sensor (2) until its tip
lightly touches the tooth tip of ring
gear (3).
2 Threads: Gasket sealant
3) Using dial gauge [3], measure the facial (Hydraulic sealant
and radial runout. from Loctite)
a Facial runout : Max. 0.20 mm 2] Rotate speed sensor (2) in the oppo-
a Radial runout: Max. 0.15 mm site direction by 1/2 – 2/3 turns.
a Clearance (a) will become 0.75 –
1 mm.
3] Tighten nut (4) while fixing sensor (2).
3 Nut: 69 – 74 Nm {7 – 7.5 kgm}

125E-5 Series 31
SEN00699-03 50 Disassembly and assembly

23. Oil pan

1) Reverse the engine.
2) Apply gasket sealant of 5 mm in diameter
along the entire inside periphery of oil pan
(1) mounting bolt hole and then tighten the
mounting bolt.
2 Mating face: Gasket sealant (LG-7)

24. Removal from engine repair stand

1) Reverse the engine.
2) Disconnect tool A1 from tool A2.
3) Remove tool A2 from the engine.

22. Damper and pulley assembly

Lift and install damper and pulley assembly (1).
3 Mounting bolt (Width across flat 22 mm,
a single bolt):
157 – 196 Nm {16 – 20 kgm}
Mounting bolt (Width across flat 24 mm,
5 bolts):
245 – 309 Nm {25 – 31.5 kgm}

25. Setting the engine

Set engine (1) on a rigid and stable stands [1].

32 125E-5 Series
50 Disassembly and assembly
26. Assembly of cylinder head assembly
1) Assemble valve (6).
2 Valve stem: Engine oil (EO30-DH)
2) Raise the cylinder head and then install
lower seat (8) and seal (7).
3) Assemble valve spring (3) and upper
sheet (5).
4) Using tool C, compress the valve spring
and install valve cotter (4).
a Hit the valve stem lightly with a plastic
hammer to make sure that the valve
cotter is fitted to the groove of the
valve stem.
125E-5 Series
SEN00699-03
27. Installation of cylinder head assembly
1) Check that the cylinder head mounting
face and inside of the cylinder are free
from foreign matter and then set cylinder
head gasket (1).
a When fitting the gasket, check that
the grommets are fitted correctly.
2) Before tightening the cylinder head
mounting bolts, check the following items.
If any of the following conditions applies,
do not reuse that bolt but replace it.
q Number of tightening time of bolt: 6
(Number of punch marks on bolt head
is 5.)
q Length (a) of bolt stem:
Min. 171.4 mm
33
SEN00699-03 50 Disassembly and assembly

3) Using sling [1], lift and set cylinder head

assembly (2) to the cylinder block.
4 Cylinder head assembly: 20 kg

a When not using tool J, apply

marking (b) to the cylinder head
and bolt with paint, then tighten
4) Tighten the cylinder head assembly the bolt by 90 – 120° (Target:
mounting bolts and auxiliary bolts. 120°).
1] Tighten the mounting bolts in the 2] Mark a punch mark (C) on its head to
order of 1 to 6 shown in the figure. show the number of tightening times.
2 Mounting bolt: a When a new bolt is used, do not
Molybdenum disulfide lubri- make a punch mark on its head.
cant (LM-P) or engine oil
(EO30-DH)
3 Mounting bolt
1st time : 98.1 ± 9.8 Nm {10 ±
1 kgm}
2nd time: 166.6 – 176.4 Nm
{17 – 18 kgm}
(Target: 176.4 Nm
{18 kgm})
3rd time : Using tool J, tighten
the bolt by 90 – 120°
(Target: 120°).

3] Tighten the auxiliary cylinder head

bolt (following figure 7).
3 Auxiliary bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

34 125E-5 Series
50 Disassembly and assembly
28. Rocker arm housing
1) Install gasket (1) and then install rocker
arm housing (2).
2) Tighten mounting bolts (3).
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
29. Injector harness connector
1) Install O-ring (4) to harness connector (1).
2 O-ring: Engine oil (EO30-DH)
2) Insert harness connector (1) to rocker
housing (3) and then tighten them with
mounting bolt (2).
3) Fit in harness to holder (3).
125E-5 Series
SEN00699-03
30. Crosshead
1) Set crosshead (1) and then loosen locknut
(2) to return adjustment screw (3) to its
original position.
2) Using your finger, lightly hold down the
crosshead (1) face contacting the rocker
arm to maintain contact between the push
rod side valve stem and crosshead (1).
3) Screw in adjustment screw (3) until cross-
head (1) comes in contact with another
valve stem.
4) As they are contacted, further screw in the
adjustment screw by 20° and then tighten
locknut (2) from that state.
2 Crosshead guide and crosshead
top face: Engine oil (EO30-DH)
3 Locknut:
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
35
SEN00699-03 50 Disassembly and assembly

31. Injector 4) Fit the ball washer to bolt (3) and tighten
a Check that the inside of the injector sleeve holder (2) temporarily.
is free from dirt. 2 Spherical part of washer:
1) Fit bracket (5) and install common rail (6) Engine oil (EO30-DH)
temporarily. 5) Locate high-pressure sleeve (4) to inlet
connector (5) and then tighten them tem-
porarily.
a Tighten the common rail side sleeve
nut temporarily, too.
6) Tighten holder (2) with bolt (3) perma-
nently.
a Tighten bolt (3) while pulling the tube
of the high-pressure pipe in the oppo-
site direction of the injector.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
7) After tightening the holder, remove the
high-pressure sleeve (4) from the inlet
connector (5) and then install the other
2) Install gasket (6) and O-rings (7) and (8) to injectors in order according to the above
injector (1). procedure.
2 O-ring: Engine oil (EO30-DH) 8) Remove the temporarily installed common
rail.

3) Insert holder (2) to injector (1). Continue

from that state, insert inlet connector (5) to 32. Push rod
the high-pressure pipe insertion hole Install push rod (1).
through the rocker housing. a Check that the push rod end is placed in
the cam follower socket.

36 125E-5 Series
50 Disassembly and assembly
33. Rocker arm and shaft assembly
1) Set rocker arm and shaft assembly (1).
a When installing the rocker arm shaft,
be sure to set its side with a larger
mounting hole diameter to the bottom
and to direct ball plug (6) side toward
the front side of the engine.
2) Before tightening mounting bolts (4),
check that the ball of adjustment screw (2)
is fitted to socket (5) of the push rod.
a Install the mounting bolt after cleaning
its oil hole.
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
34. Injector harness
1) Tighten mounting bolts (3) of the harness
fixing holder.
3 Mounting bolt:
27.0 – 34.0 Nm {2.8 – 3.5 kgm}
2) Tighten 2 harness capture nuts (2) to
injector (1).
a Tighten the nuts alternately.
3 Mounting nut:
2.0 – 2.4 Nm {0.2 – 0.24 kgm}
125E-5 Series
SEN00699-03
35. Adjusting valve clearance
a Adjust the clearance between the cross-
head and rocker arm to the following
value.
a Valve clearance (in cold state)
Unit: mm
Intake valve Exhaust valve
0.33 0.71
a Rotate the engine and adjust the valve
clearance of each cylinder in the firing
order of 1 – 5 – 3 – 6 – 2 – 4.
1) Rotate the crankshaft forward and match
stamped line of “1.6 TOP” on vibration
damper (1) to pointer (2), watching the
movement of the valve.
2) Insert clearance gauge l between rocker
arm (3) and crosshead (4) and screw in
adjustment screw (5) until the gauge
becomes movable. Then tighten the lock-
nut.
3 Locknut:
58.8 – 73.5 Nm {6 – 7.5 kgm}
a After tightening the locknut, check the
valve clearance again.
37
SEN00699-03 50 Disassembly and assembly

36. Head cover and tube 38. Common rail

1) Fit the O-ring and install head cover (3). Install common rail (5).
a Install the O-ring without twisting it. 3 Mounting bolt:
3 Mounting bolt: 59 – 74 Nm {6 – 7.5 kgm}
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
2) Fit the gaskets on both sides, install tube
(2), and tighten joint bolt (1).
3 Joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}

37. Oil level gauge tube

Install oil level gauge tube (2).
3 Sleeve nut:
44.1 – 58.8 Nm {4.5 – 6.0 kgm}

38 125E-5 Series
50 Disassembly and assembly SEN00699-03

39. Installation of high-pressure pipes between

fuel supply pump and common rail
1) Tighten high-pressure pipes (3) and (4) by
hand first, and then tighten them perma-
nently.
3 Sleeve nut
(Pump side):
39.2 – 49 Nm {4 – 5 kgm}
(Common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
2) Tighten supply pump mounting bolts (2)
permanently.
3) Tighten the cylinder block side mounting
bolt of bracket (1) permanently.
4) Install the splash prevention cover on both
ends of the high-pressure pipe.
a Face the common rail side slit down-
ward and the supply side slit toward
the cylinder block.
5) Tighten lubrication tube (12) by hand.
6) Tighten and install clamp (10) by hand
first, and then tighten it permanently.
7) Tighten and install brackets (6) and (5) by
hand first, and then tighten them perma-
nently.
8) Tighten and install bracket (8) and clamp
(9) by hand first, and then tighten them
permanently.
3 Clamp (9) mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
9) Tighten and install clamp (11) by hand
first, and then tighten it permanently.
3 Clamp (11) mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
10) Tighten lubrication tube (12) permanently.
3 Joint bolt:
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
11) Tighten and install clamp (7) by hand first,
and then tighten it permanently.
3 Clamp (7) mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}

125E-5 Series 39
SEN00699-03 50 Disassembly and assembly

40. Air intake manifold 41. High-pressure pipes

1) Fit the gasket and install air intake mani-
fold (1) temporarily.
4 Air intake manifold: 40 kg
a Before installing each high-pressure pipe,
check it for the following defects. If there is
any of these defects, it can cause fuel leakage.
Accordingly, replace the high-pressure pipe.
q Check the taper seal of the connecting part
(Part “a”: Part of 2 mm from the end) for visible
lengthwise slit “b” and dent “c”.
q Check part “d” (end of the taper seal: Part at 2
mm from the end) for stepped-type wear
(fatigue) which your nail can feel.

2) Tighten the mounting bolts in the numeric

order shown below.
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}

1) Install 6 high-pressure pipes (8).

a The installed angle of the high-pres-
sure pipes was set when the injectors
were installed.
3 Sleeve nut (for both sides):
39.2 – 49 Nm {4 – 5 kgm}
2) Tighten 6 brackets (5) and 10 high-pres-
sure pipe clamps (4) with your fingers and
then tighten them permanently.
3 Clamp mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3) Install 6 each of scatter prevention covers
(6) and (7).
a Direct the slit on the injector side
down and that on the common rail
side toward the cylinder block.
4) Set high-pressure pipe clamp (3) to the
high-pressure pipes.

40 125E-5 Series
50 Disassembly and assembly SEN00699-03

5) Install bracket (2) and tighten the 2 mount- 44. Diffuser and air housing assembly
ing bolts. Fit the gasket and install diffuser and air hous-
6) Tighten 7 high-pressure pipe clamp ing assembly temporarily.
mounting bolts (1). 4 Diffuser and air housing assembly: 40 kg
3 Clamp mounting bolt:
a Fix the front hanger first and then tighten
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
the mounting bolts permanently.

42. Spill pipe

45. Front hanger, electrical intake air heater
Fit the gasket to both ends of spill pipe (2),
and air connector
install them, and tighten joint bolt (1).
3 Joint bolt:
1) Fit the gasket and install front hanger (5).
2) Install plates (4) and (3) and tighten 6 dif-
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
fuser and air housing assembly mounting
bolts and 4 plate mounting bolts.
3) Fit the gasket, install electrical intake air
heater (2) and air connector (1), and
tighten the 6 mounting bolts.

43. Bracket
1) Install bracket (2).
2) Install bracket (1).

125E-5 Series 41
SEN00699-03 50 Disassembly and assembly

46. Brackets
1) Install brackets (3) and (2).
2) Install wiring harness (1).

48. Overflow tube, spill tube and engine con-

troller cooler assembly
1) Install block (4).
47. Electric priming pump and block 2) Install tube (3).
a Electric priming pump is not set for some 3 Joint bolts:
models. (Block side):
1) Install block (7). 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
2) Install electric priming pump (6) and (Cylinder head side):
bracket together. 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3) Install the tube and hose according to the 3) Install tube (2) temporarily.
following procedure. 4) Install engine controller cooler assembly
1] Install hose (3) and tube (4) tempo- (1).
rarily.
2] Install tube (5) temporarily.
3] Tighten the joint bolts of tube (4) and
hose (3).
3 Joint bolt
(Block side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
(Supply pump side):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
4] Tighten the joint bolt and sleeve nut of
tube (5).
3 Joint bolt:
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
3 Sleeve nut:
43 – 47 Nm {4.4 – 4.8 kgm}
5] Install hose (2) and tighten the joint 49. Brackets
bolts. Install brackets (1), (2), (3), (4), (5), (6) and (7).
3 Joint bolt
(Block side):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
(Electric priming pump):
17.6 – 22.6 Nm {1.8 – 2.3 kgm}
a When tightening the joint bolt on
the electric priming pump side,
fix the hexagonal part of the
priming pump.
6] Connect connector (1).

42 125E-5 Series
50 Disassembly and assembly SEN00699-03

50. Fuel filters 52. Oil cooler assembly

1) Install fuel filters (9) and (10). Fit the gasket to oil cooler assembly (1) and
2) Install tubes (7) and (8) and clamp (6). install them by using the guide bolts.
3 Joint bolts (for both tubes (7) (8)):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3 Clamp (6) mounting bolt:
27 – 34 Nm {2.8 – 3.5 kgm}
3) Install tube (5) and connect the 2 clamps.
3 Joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
4) Install hose (4).
3 Joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
5) Install tubes (3) and (2).
3 Joint bolt (for both tubes (9) and
(10)): 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
6) Install cover (1).
53. Water pump assembly
1) Fit the O-ring, install water pump assem-
bly (3), and tighten mounting bolts (2).
2) Fit the gasket and install connector (1).

51. Oil filter

1) Install oil filter (4) with the 4 bolts tempo-
rarily.
2) Fit the O-ring and install oil tubes (2) and
(3).
54. Thermostat housing assembly
3) Tighten the lower flanges of oil tubes (2)
1) Fit the gasket and install thermostat hous-
and (3) permanently and then tighten the
ing assembly (2).
upper flanges permanently.
2) Fit the gasket and install connector (1).
4) Tighten the 4 mounting bolts of oil filter (4)
permanently.
5) Install clamp (1).

125E-5 Series 43
SEN00699-03 50 Disassembly and assembly

55. Exhaust manifold assembly 56. Turbocharger assembly

1) Sling exhaust manifold assembly (1), fit 1) Fit the gasket, install turbocharger assem-
the gasket, and tighten mounting bolts (2) bly (6), and tighten mounting bolts (5).
temporarily 3 Mounting bolt:

4
44.1 – 49 Nm {4.5 – 5.0 kgm}
Exhaust manifold assembly: 35 kg
2) Fit the gasket and install turbocharger out-
let tube (4) and tube bracket.
3) Fit the gasket and install turbocharger
lubricating oil inlet tube (3) and 5 clamps.
3 Sleeve nut (Cylinder block side):
40 – 44 Nm {4.1 – 4.5 kgm}
4) Install brackets (2) and (1).

2) Tighten bolts (3), (4) and (5) first and then

tighten the other bolts.
3 Mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}

57. Water pump suction tube

Fit the gasket and install suction tube (1).

44 125E-5 Series
50 Disassembly and assembly SEN00699-03

58. Alternator assembly 60. Wiring harness assembly

1) Install bracket (8) and plate (7). Install wiring harness assembly (1), connect
2) Install V-belt (5) to the pulley of alternator each connector, and install each clamp.
assembly (6) and secure the alternator
assembly with mounting bolt (2) and fixing
bolt (3).
3) Adjust the belt tension with the V-belt ten-
sion adjustment nut and tighten mounting
bolt (2) and fixing bolt (3).
a Adjust the V-belt tension so that the
belt will be deflected by 13 – 16 mm
when it is pressed with a force of
about 6 kg by the center between the
crankshaft pulley and alternator pul-
ley.
3 Mounting bolt (2):
107.8 – 147 Nm {11 – 15 kgm}
3 Mounting bolt (3):
61. Air cleaner, muffler and heat insulation
28.4 – 38.2 Nm {2.9 – 3.9 kgm}
plate
4) Check the belt tension and tighten the
1) Install the air cleaner.
locknut.
2) Install the muffler and the drain tube.
5) Tighten nut (4).
3) Install the heat insulation plate.
6) Install cover (1).

59. Starting motor assembly

Fit the gasket, install starting motor assembly
(2), and tighten mounting bolts (1).

125E-5 Series 45
SEN00699-03 50 Disassembly and assembly

62. Tightening torque for sensor 5) Check the fuel piping and devices for fuel
Use the following tightening torque when leakage.
removal and installation or replacement of the a Check mainly around the high-pres-
sensor. sure circuit parts coated with the color
checker for fuel leakage.
Sensor name Tightening torque
a If any fuel leakage is detected, repair
Fuel it and check again from step 2).
23 ± 3 Nm {2.35 ± 0.3 kgm}
temperature 6) Run the engine at high idle.
Boost pressure 5.5 ± 0.5 Nm {0.56 ± 0.05 kgm} 7) Check the fuel piping and devices for fuel
Intake air leakage.
23 ± 3 Nm {2.35 ± 0.3 kgm} a Check mainly around the high-pres-
temperature
Coolant sure circuit parts coated with the color
23 ± 3 Nm {2.35 ± 0.3 kgm} checker for fuel leakage.
temperature
a If any fuel leakage is detected, repair
Engine oil
23 ± 3 Nm {2.35 ± 0.3 kgm} it and check again from step 2).
pressure
8) Run the engine at high idle and load it.
4.5 ± 0.5 Nm {0.46 ± 0.05 kgm} a When checking while the components
Atmospheric
(Hexagonal head bolt and hexago-
pressure to be checked are mounted on the
nal socket head bolt)
machine, stall the torque converter or
Fuel pressure Never disassemble. relieve the hydraulic pump.
9) Check the fuel piping and devices for fuel
leakage.
63. Checking for fuel leakage a Check mainly around the high-pres-
a If fuel supply pump (2), common rail (1), or sure circuit parts coated with the color
hi g h- p re ss u re pi p e i s re m ov e d a nd checker for fuel leakage.
installed, after assembling the engine, a If any fuel leakage is detected, repair
check for fuel leakage according to the fol- it and check again from step 2).
lowing procedure. a If no fuel leakage is detected, check
is completed.

a Clean and degrease the engine and the

parts around it in advance so that you can
test it easily for fuel leakage.
1) Spray color checker (developer) over the
fuel supply pump, common rail, fuel injec-
tor, and joints of the high-pressure piping.
2) Run the engine at speed below 1,000 rpm
and stop it after its speed is stabilized.
3) Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pres-
sure circuit parts coated with the color
checker for fuel leakage.
a If any fuel leakage is detected, repair
it and check again from step 2).
4) Run the engine at low idle.

46 125E-5 Series
50 Disassembly and assembly SEN00699-03

125E-5 Series 47
SEN00699-03

KOMATSU 125E-5 Series engine

Form No. SEN00699-03

© 2010 KOMATSU
All Rights Reserved
Printed in Japan 04-10

48
 SEN00700-00

ENGINE 1SHOP MANUAL

125E-5 Series

50 Disassembly and assembly1

Disassembly and assembly, Part 3
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

125E-5 Series 1
SEN00700-00 50 Disassembly and assembly

Disassembly and assembly, Part 3 1

Removal and installation of fuel 7. Remove cover (16).
supply pump unit 1
8. Rotate the crankshaft forward and set interme-
diate point (a) between stamped “2/5 TOP” and
Removal “3/4 TOP” on damper (17) to pointer (18).
1. Disconnect sensor connectors (1), (2) and (3). (Stamped “1/6 TOP” comes almost directly bot-
tom)
2. Remove clamps (4) and (5) and then remove a At this time, check that the forcing tap of
fuel tube (6). [*1] the drive gear is aligned to the mounting
bolt hole of cover (16).
3. Remove clamps (7), (8) and (9) and then (If not, rotate the crankshaft one more
remove splash prevention covers (10) and turn.)
(11). [*2] a At this point, the key of the shaft is turned
clockwise by 15° from the top.
4. Remove high-pressure pipes (12) and (13).
[*3]

5. Remove lubrication tube (14).

6. Remove fuel tube (15). [*4]

9. Remove mounting nut (19) and then remove

washer (20). [*5]
a Use a magnet or the like in this operation
so that washer (20) may not be inadvert-
ently dropped into the case.

2 125E-5 Series
50 Disassembly and assembly SEN00700-00

10. Loosen mounting bolts (21) and then remove Installation

the mounting bolt on the cylinder block side of a Carry out installation in the reverse order to
bracket (22). [*6] removal.
a Leave bolts (21) tightened by 2 – 3 [*1]
threads to prevent the pump from falling 3 Joint bolt of tube (6):
down. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}

11. Install tool P1 with P2 and P3 and then screw [*2]

in the center bolt of P1 to remove the gear from
the shaft.
12. Remove bolts (21) and then remove fuel sup-
ply pump assembly (23).
a If tool P is removed, the gear falls down.
Accordingly, keep it installed until the
pump is installed.
1) Tighten clamps (7), (8), and (9) by hand first,
and then tighten them permanently.
3 Clamp mounting bolt:
11.8 – 4.7 Nm {1.2 – 1.5 kgm}
2) Face the pump side slit of the splash preven-
tion cover to the cylinder block side and the
common rail side slit downward.
[*3]
a Tighten high-pressure pipes (12) and (13) by
hand first, and then tighten them permanently.
3 Sleeve nut of high-pressure tubes (12) and
(13)
Common rail side:
39.2 – 58.8 Nm {4 – 6 kgm}
Pump side:
39.2 – 49 Nm {4 – 5 kgm}

[*4]
3 Joint bolt of pump side:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}

[*5]
3 Gear mounting nut:
127 – 147 Nm {13 – 15 kgm}

[*6]
2 Mounting bolt: Gasket sealant (LT-2)

125E-5 Series 3
SEN00700-00
Replacement of oil seal of engine
mounted on machine 1 a Check the Teflon seal (Laydown lip seal) by
Rear oil seal
a For the work up to removal of the flywheel, see
the Shop manual for the applicable machine.
Removal of standard seal
Hitch the end of tool L to the metal ring of seal (1)
and pull out the seal with impacts of slide hammer
[1].
a Before pulling out the seal, drive in it a little to
separate it from housing (2) for the ease of
removal.
a Do not use a drill, etc. since chips may enter
the engine.
Removal of sleeved seal
1) Hitch the end of tool L to the metal ring of
seal (1) and pull out the seal with impacts
of slide hammer [1].
a Before pulling out the seal, drive in it
a little to separate it from housing (2)
for the ease of removal.
2) Cut and remove sleeve (3) with a chisel
and a hammer.
a Take care not to damage crankshaft
(4).
a Remove all the chips.
4 125E-5 Series
50 Disassembly and assembly
Installation
checking the wear of the shaft and replace it
with the “Standard seal” or “Sleeved seal”.
a If the shaft is worn to the degree of luster (If
wear which you feel with your finger is less
than 10 mm) and does not have any flaw, install
the standard seal. In other cases, install the
sleeved seal.
a The left one in the following figure is the stan-
dard seal and the right one is the sleeved seal.
Procedure for installing standard seal
a Before installing the seal, check that the end
corners and lip sliding surfaces of crankshaft
(4) are free from flaw, burr, and rust of the
housing.
a When installing the seal, do not apply oil or
grease to the shaft and seal lip (a). Wipe off oil
from the shaft.
a Never remove inside plastic cylinder (3) of the
standard spare seal before installing the seal.
1) Set the large diameter side (b) of plastic
inside cylinder (3) to the end of crankshaft
(4).
a Take care not to mistake the direction
of the plastic inside cylinder.
50 Disassembly and assembly
2) Hold the metal ring of seal (1) by both
hands and push it in firmly.
3) After pushing in the seal, remove plastic
inside cylinder (3).
a When removing the inside cylinder,
take care not to damage the seal lip.
4) Tighten bolts (N3 and N4) evenly to press
fit seal (1) until the end face of tool N1
reaches the end face crankshaft (4).
a First tighten tool N1 until it is con-
tacted against bolt N3 (stem length 45
mm) and then further tighten the tool
with bolt N4 (stem length 25 mm).
a When press fitting the seal, take care
not to damage the lip on the PTO side
with the tool set, etc.
a After press fitting the seal, remove the
red sealant layer from its periphery.
125E-5 Series
SEN00700-00
Procedure for installing sleeved seal
a Before installing the seal, make sure that the
end corners and lip sliding surfaces of crank-
shaft (4) are free from flaws, burrs, and rusts of
the housing.
a When installing the seal, do not apply oil or
grease to the shaft, sleeve (1), and seal lip (a).
Wipe off oil from the shaft.
a Handle the seal and sleeve as an assembly
and don't separate them from each other.
1) Set sleeve and seal assembly (2) to tool
N2.
2 Inside sleeve: Gasket sealant (LG-7)
5
SEN00700-00
2) Set the sleeve of the seal to the end of the
crankshaft, and then tighten bolt N3
evenly to press fit sleeve and seal assem-
bl y (2) unt il the en d fa ce of tool N2
reaches the end of crankshaft (4).
3) Remove tool N2 and then replace it with
tool N1.
4) Tighten bolt N4 evenly to press fit sleeve
and seal assembly (2) until the end face of
tool N1 reaches the end of crankshaft (4).
a After press fitting the seal, remove the
red sealant layer from its periphery.
6 125E-5 Series
50 Disassembly and assembly
Front oil seal
Removal
Remove front oil seal (1).
a For the work up to removal of the clamp pulley
(damper), see the Shop manual for the appli-
cable machine.
Installation
Using the push tool (outside diameter 120 mm),
press fit front oil seal (1) to the cover.
a Oil seal press fit allowance (a): 16 (+1/0) mm
2 Oil seal lip (50 – 80% of void lip space):
Grease (G2-LI)
50 Disassembly and assembly SEN00700-00

125E-5 Series 7
SEN00700-00

KOMATSU 125E-5 Series engine

Form No. SEN00700-00

© 2006 KOMATSU
All Rights Reserved
Printed in Japan 01-06 (01)