Komatsu Engine 125e 6 Series Workshop Manuals

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ENGINE 125E -6 SERIES

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SHOP MANUAL

ENGINE
125E-6 SERIES
Model Serial Number

125E-6
SERIES

00 Index and foreword

1 00 Index and foreword

125E-6 SERIES 00-1

00 Index and foreword
Index

Index
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ..................................................................................... 00-5
Important safety notice ......................................................................................................... 00-5
How to read the shop manual.............................................................................................. 00-10
Explanation of terms for maintenance standard .................................................................... 00-12
Handling of fuel system devices .......................................................................................... 00-14
Handling of intake system parts........................................................................................... 00-15
Handling of hydraulic equipment.......................................................................................... 00-16
Method of disconnecting and connecting push-pull type coupler............................................. 00-18
Handling of electrical equipment.......................................................................................... 00-21
How to read electric wire code............................................................................................. 00-29
Precautions when performing operation ............................................................................... 00-32
Standard tightening torque table.......................................................................................... 00-35
List of abbreviation ............................................................................................................. 00-39
Conversion table ................................................................................................................ 00-43
01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Exhaust gas regulation ......................................................................................................... 01-3
Applicable machines ............................................................................................................ 01-6
Specifications ...................................................................................................................... 01-7
General view ....................................................................................................................... 01-9
Weight table ...................................................................................................................... 01-18
Engine performance curve .................................................................................................. 01-19
10 Structure and function ................................................................................................................... 10-1
Table of contents ........................................................................................................................ 10-2
Components layout..................................................................................................................... 10-3
Components layout drawing.................................................................................................. 10-3
Intake and exhaust system parts .................................................................................................. 10-6
Intake and exhaust system layout drawing ............................................................................. 10-6
Intake and exhaust system circuit diagram ............................................................................. 10-7
Air cleaner ........................................................................................................................... 10-9
KVGT................................................................................................................................ 10-10
Aftercooler......................................................................................................................... 10-16
EGR system piping drawing ................................................................................................ 10-17
EGR system circuit diagram ................................................................................................ 10-19
EGR valve......................................................................................................................... 10-20
EGR cooler........................................................................................................................ 10-22
Mixing connector................................................................................................................ 10-24
KCCV layout drawing ......................................................................................................... 10-25
KCCV ventilator ................................................................................................................. 10-27
KDPF................................................................................................................................ 10-31
Engine main body parts............................................................................................................. 10-36
Cylinder head .................................................................................................................... 10-36
Cylinder block .................................................................................................................... 10-38
Main moving parts.............................................................................................................. 10-40
Vibration damper................................................................................................................ 10-43
Timing gear ....................................................................................................................... 10-44
Front cover ........................................................................................................................ 10-46
Valve system ..................................................................................................................... 10-47
Flywheel and flywheel housing ............................................................................................ 10-50
Lubrication system.................................................................................................................... 10-51
Lubrication system parts layout drawing ............................................................................... 10-51
Lubrication system diagram ................................................................................................ 10-52
Oil pump ........................................................................................................................... 10-53
Boost oil pump ................................................................................................................... 10-54
Oil filter.............................................................................................................................. 10-55

00-2 125E-6 SERIES

 00 Index and foreword
Index

Oil cooler........................................................................................................................... 10-56

Oil cooler thermo-valve....................................................................................................... 10-57
Oil pan .............................................................................................................................. 10-58
Fuel system ............................................................................................................................. 10-59
Fuel system parts layout drawing......................................................................................... 10-59
Fuel system circuit diagram................................................................................................. 10-61
Outline of CRI system......................................................................................................... 10-64
Fuel dozing........................................................................................................................ 10-77
Pre-filter ............................................................................................................................ 10-80
Main filter .......................................................................................................................... 10-81
Cooling system......................................................................................................................... 10-82
Cooling system parts layout drawing.................................................................................... 10-82
Cooling system circuit diagram............................................................................................ 10-83
Water pump....................................................................................................................... 10-84
Thermostat ........................................................................................................................ 10-85
Electrical equipment.................................................................................................................. 10-87
Alternator .......................................................................................................................... 10-87
Alternator mounting ............................................................................................................ 10-91
With built-in safety relay (7.5 kW)......................................................................................... 10-92
With built-in safety relay (11 kW).......................................................................................... 10-94
Fuel feed pump.................................................................................................................. 10-96
Fuel feed pump switch........................................................................................................ 10-97
Engine wiring harness ........................................................................................................ 10-98
Engine controller .............................................................................................................. 10-100
Sensors .......................................................................................................................... 10-106
20 Standard value table ..................................................................................................................... 20-1
Table of contents ........................................................................................................................ 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Running-in standard and performance test standard ............................................................... 20-7
50 Disassembly and assembly ........................................................................................................... 50-1
Table of contents ........................................................................................................................ 50-2
General information on disassembly and assembly........................................................................ 50-3
How to read this manual ....................................................................................................... 50-3
Coating materials list ............................................................................................................ 50-5
Special tool list..................................................................................................................... 50-9
Sketch of special tool.......................................................................................................... 50-11
Disassembly and assembly ....................................................................................................... 50-14
General disassembly of engine ........................................................................................... 50-14
General assembly of engine................................................................................................ 50-35
Removal and installation procedure of supply pump as single component............................... 50-79
Engine front oil seal replacement procedure ......................................................................... 50-84
Engine rear oil seal replacement procedure.......................................................................... 50-87
60 Maintenance standard................................................................................................................... 60-1
Table of contents ........................................................................................................................ 60-2
Intake and exhaust system parts .................................................................................................. 60-3
KVGT.................................................................................................................................. 60-3
Engine main body parts............................................................................................................... 60-4
Cylinder head ...................................................................................................................... 60-4
Cylinder block ...................................................................................................................... 60-5
Cylinder liner ....................................................................................................................... 60-7
Crankshaft........................................................................................................................... 60-8
Cam follower and push rod ................................................................................................... 60-9
Piston ............................................................................................................................... 60-11
Connecting rod .................................................................................................................. 60-13
Vibration damper................................................................................................................ 60-15
Timing gear ....................................................................................................................... 60-16
Camshaft .......................................................................................................................... 60-17
Valve and valve guide......................................................................................................... 60-18

125E-6 SERIES 00-3

00 Index and foreword
Index

Rocker arm........................................................................................................................ 60-20

Crosshead and guide ......................................................................................................... 60-21
Flywheel............................................................................................................................ 60-22
Lubrication system.................................................................................................................... 60-24
Main relief valve ................................................................................................................. 60-24
Safety valve....................................................................................................................... 60-25
Cooling system......................................................................................................................... 60-26
Oil cooler........................................................................................................................... 60-26
Water pump....................................................................................................................... 60-27
Thermostat ........................................................................................................................ 60-28
Index.................................................................................................................................................................... 1

00-4 125E-6 SERIES

 00 Index and foreword
Foreword, safety and general information

Foreword, safety and general information

Important safety notice
(Rev. 2011/02)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
Shop Manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special precautions during the work. The work
indicated with the warning mark should be performed according to the instructions with special attention to
the precautions. Should a hazardous situation occur or be anticipated during such work, be sure to keep
safe first and take every necessary measure.

General precautions wear welding gloves, apron, shielding goggles,

cap and other clothes suited for welding work.
k Inappropriate handling creates an extreme • Before starting work, warm up your body
danger. Read and understand what is thoroughly to start work under good condition.
described in the Operation and Maintenance • Avoid continuing work for long hours and take
Manual before operating the machine. In rests at proper intervals to keep your body in
addition read this manual carefully and good condition. Take rests in specified safe
understand its contents before starting work. places.
• Before performing any greasing or repairs, read Safety points
all the safety labels stuck to the machine. For 1 Good arrangement
the locations of the safety labels and detailed 2 Correct work clothes
explanation of precautions, see the Operation Following work standard
3
and Maintenance Manual.
4 Making and checking signals
• Locate a place in the repair workshop to keep
Prohibition of operation and handling by
tools and removed parts. Always keep the tools 5
unlicensed workers
and parts in their correct places. Always keep
6 Safety check before starting work
the work area clean and make sure that there is
Wearing protective goggles (for cleaning or
no dirt, water, or oil on the floor. Smoke only in 7 grinding work)
the areas provided for smoking. Never smoke
Wearing shielding goggles and protectors (for
while working. 8 welding work)
• When performing any work, always wear safety
shoes and helmet. Do not wear loose work 9 Good physical condition and preparation
clothes, or clothes with buttons missing. Precautions against work which you are not
10 used to or you are used to too much
1. Always wear the protective eyeglasses when
hitting parts with a hammer. Preparation work
2. Always wear the protective eyeglasses when • Before adding oil or making any repairs, park the
grinding parts with a grinder, etc. machine on a hard and level ground, and apply
• When performing any work with two or more the parking brake and chock the wheels or
workers, always agree on the operating tracks to prevent the machine from moving.
procedure before starting. Always inform your • Before starting work, lower the work equipment
fellow workers before starting any step of the (blade, ripper, bucket, etc.) to the ground. If this
work. During the work, hang UNDER REPAIR is not possible, insert the lock pin or use blocks
warning tag in the operator's compartment. to prevent the work equipment from falling. In
• Only qualified workers must perform the work addition, be sure to lock all the control levers
and operation which require license or and hang warning tag on them.
qualification. • When disassembling or assembling, support the
• Keep all tools in good condition. Learn the machine with blocks, jacks, or stands before
correct way to use them, and use the proper starting the work.
ones of them. Before starting work, thoroughly • Remove all mud and oil from the steps or other
check the tools, machine, forklift truck, service places used to get on and off the machine.
car, etc. Always use the handrails, ladders or steps when
• If welding repairs are needed, always have a getting on or off the machine. Never jump on or
trained and experienced welder perform the off the machine. When a scaffolding is not
work. When performing welding work, always

125E-6 SERIES 00-5

00 Index and foreword
Foreword, safety and general information

provided, use steps or a step ladder to secure When installing hoses and wires, be sure that
your footing. they will not be damaged by contact with other
parts when the machine is operated.
Precautions during work • When installing high pressure hoses and tubes,
• For the machine equipped with a battery make sure that they are not twisted. Damaged
disconnect switch, before starting the work, hoses and tubes are dangerous, so be
check that the system operating lamp is turned extremely careful when installing hoses and
OFF, and then turn the battery disconnect switch tubes for high-pressure circuits. In addition,
to the OFF (Q) position and pull the switch key check that connections of them are correct.
out. For machines without a battery disconnect • When assembling or installing parts, always
switch, before starting the work, remove the tighten them to the specified torques. When
cables from the battery. Always remove the installing protective parts such as guards, or
cable from the negative (–) terminal first. parts which vibrate violently or rotate at high
• Before disconnecting or removing components speeds, be particularly careful to check that they
of the oil, water, or air circuits, first release the are installed correctly.
remaining pressure completely from the circuit. • When aligning two holes, never insert your
When removing the oil filter cap, a drain plug, or fingers or hand. Be careful not to get your
an oil pressure pickup plug, loosen it slowly to fingers caught in a hole.
prevent the oil from spurting out. • When measuring hydraulic pressure, check that
• The coolant and oil in the circuits are hot when the measuring tools are correctly installed.
the engine is shut down. Be careful not to get • Take care when removing or installing the tracks
scalded. Wait for the oil and coolant to cool of track-type machines. When removing the
before performing any work on the oil or water track, the track separates suddenly, so never let
circuits. anyone stand at either end of the track.
• Before starting work, shut down the engine. • If the engine is operated for a long time in a
When working on or around a rotating part, in place which is not ventilated well, you may suffer
particular, shut down the engine. When checking from gas poisoning. Accordingly, open the
the machine without stopping the engine windows and doors to ventilate well.
(measuring oil pressure, revolving speed,
temperature, etc.), take extreme care not to get Precautions for slinging work and making
rolled or caught in rotating parts or moving parts. signals
• When raising a heavy component (heavier than • Only one appointed worker must make signals
25 kg), use a hoist or crane. Before starting work, and co-workers must communicate with each
check that the slings (wire ropes, chains, and other frequently. The appointed signaler must
hooks) are free from damage. Always use slings make specified signals clearly at a place where
which have ample capacity and install them to he (she) is well seen from the operator's seat
proper places. Operate the hoist or crane slowly and where he (she) can see the working
to prevent the component from hitting any other condition easily. The signaler must always stand
part. Do not work with any part still raised by the in front of the load and guide the operator safely.
hoist or crane. 1. Do not stand under the load.
• When removing a cover which is under internal 2. Do not step on the load.
pressure or under reaction force of a spring, • Check the slings before starting sling work.
always leave two bolts in diagonal positions. • Keep putting on gloves during sling work. (Put
Loosen those two bolts gradually and alternately on leather gloves, if available.)
to release the pressure, and then remove the • Measure the weight of the load by the eye and
cover. check its center of gravity.
• When removing components, be careful not to • Use proper sling according to the weight of the
break or damage the electrical wiring. Damaged load and method of slinging. If too thick wire
wiring may cause electrical fires. ropes are used to sling a light load, the load may
• When removing piping, stop the fuel or oil from slip and fall.
spilling out. If any fuel or oil drips onto the floor, • Do not sling a load with one wire rope alone. If it
wipe it off immediately. Fuel or oil on the floor is slung by one wire rope, It may rotate and slip
can cause you to slip and can even cause fires. out of the rope. Install two or more wire ropes
• As a general rule, do not use gasoline to wash symmetrically.
parts. Do not use it to clean electrical parts, in
particular. k Slinging with one rope may cause turning of
• Be sure to assemble all parts again in their the load during hoisting, untwisting of the
original places. Replace any damaged parts and rope, or slipping of the rope from its original
parts which must not be reused with new parts.

00-6 125E-6 SERIES

 00 Index and foreword
Foreword, safety and general information

winding position on the load, which can result

in a dangerous accident.
• Limit the hanging angle to 60 degrees, as a rule.
• Do not sling a heavy load (25 kg or more) with
ropes forming a wide hanging angle from the
hook.
a When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angle. The figure below
shows the variation of allowable load in kN
{kg} when hoisting is made with two ropes,
each of which is allowed to sling up to 9.8 kN
• Do not use twisted or kinked wire ropes.
{1,000 kg} vertically, at various hanging
• When lifting up a load, observe the following.
angles. When the two ropes sling a load
vertically, up to 19.6 kN {2,000 kg} of total 1. Wind in the crane slowly until wire ropes are
weight can be suspended. This weight is stretched. When settling the wire ropes with
reduced to 9.8 kN {1,000 kg} when the two the hand, do not grasp them but press them
ropes make a hanging angle of 120 degrees. from above. If you grasp them, your fingers
If the two ropes sling a 19.6 kN {2,000 kg} may be caught.
load at a lifting angle of 150 degrees, each 2. After the wire ropes are stretched, stop the
rope is subjected to a force as large as 39.2 crane and check the condition of the slung
kN {4,000 kg}. load, wire ropes, and pads.
3. If the load is unstable or the wire rope or
chains are twisted, lower the load and lift it
up again.
4. Do not lift up the load at an angle.
• When lowering a load, observe the following.
1. When lifting down a load, stop it temporarily
at 30 cm above the floor, and then lower it
slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
• When installing wire ropes to an angular load,
apply pads to protect the wire ropes. If the load Precautions for using mobile crane
is slippery, apply proper material to prevent the a Read the Operation and Maintenance Manual of
wire rope from slipping. the crane carefully in advance and operate the
• Use the specified eyebolts and fix wire ropes, crane safely.
chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle portion of the Precautions for using overhead traveling crane
hook.
k When raising a heavy part (heavier than 25
a Slinging near the tip of the hook may cause kg), use a hoist, etc. . In disassembly and
the rope to slip off the hook during hoisting. assembly, the weight of a part heavier than
The hook has the maximum strength at the
middle part. 25 kg is indicated after the mark of 4 .

• Before starting work, inspect the wire ropes,

brake, clutch, controller, rails, over wind stop
device, ground fault circuit interrupter, crane
collision prevention device, and power
application warning lamp, and check safety.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Check the direction indicator plates (north, south,
east, and west) and the directions of the control
buttons without fail.

125E-6 SERIES 00-7

00 Index and foreword
Foreword, safety and general information

• Do not sling a load at an angle. Do not move the Precautions for disconnecting and connecting
crane while the slung load is swinging. hoses and tubes in air conditioner circuit
• Do not raise or lower a load while the crane is
Disconnection
moving longitudinally or laterally.
• Do not drag a sling. k Disconnection although the refrigerant
• When lifting up a load, stop it just after it leaves (refrigerant gas: R134a) used on the
the ground and check safety, and then lift it up. machine's air conditioner is less destructive
• Consider the travel route in advance and lift up a to the ozone layer for environmentally
load to a safe height. friendliness, it is not allowed to be released
• Place the control switch in a position where it will into the atmosphere as is. Whenever
not be an obstacle to work and passage. disconnecting the air conditioner gas circuit,
• After operating the hoist, do not swing the be sure to recover the refrigerant gas to
control switch. reuse it.
• Remember the position of the main switch so
that you can turn off the power immediately in an a Ask a qualified person for collection, and charge
emergency. of the refrigerant (R134a).
• If the hoist stops because of a power failure, turn a Never release the refrigerant (R134a) to the
the power switch OFF. When turning on a switch atmosphere.
which was turned OFF by the ground fault circuit
interrupter, check that the devices related to that k If refrigerant gas (R134a) gets in your eyes,
switch are not in operating condition. you may lose your sight. And if it touches
• If you find an obstacle around the hoist, stop the your skins, you may suffer from frostbite.
operation. Accordingly, put on protective eyeglasses,
• After finishing the work, stop the hoist at the gloves and working suits with long sleeves
specified position and raise the hook to at least while you are collecting or filling the
two meters above the floor. Do not leave the refrigerant (R134a).
sling attached to the hook.
• When loosening the nuts fixing air conditioner
Selecting wire ropes hoses and tubes, be sure to use two wrenches;
• Select adequate ropes depending on the weight use one wrench to fix and use the other one to
of parts to be hoisted, referring to the table loosen the nut.
below
Connection
Wire ropes (standard "Z" twist ropes without
• When installing the air conditioner hoses and
galvanizing) (JIS G3525, No. 6, Type 6x37-A)
tubes, take care to prevent any dirt, dust or
Nominal water from entering.
diameter of rope Allowable load
• When installing the air conditioner hoses and
mm kN ton tubes, check that O-rings are fitted to their joints.
10 8.8 0.9 • Once an O-ring is used, it is deformed and
12 12.7 1.3 deteriorated. Accordingly, do not reuse it.
14 17.3 1.7 • When removing O-rings, use a soft tool so that
16 22.6 2.3 the piping will not be damaged.
18 28.6 2.9 • Check that there is no defect or deterioration on
20 35.3 3.6 the O-ring.
• Apply compressor oil for refrigerant (R134a) to
25 55.3 5.6
the O-ring.
30 79.6 8.1
40 141.6 14.4 a However, do not apply oil to the threads
50 221.6 22.6 portion of a bolt, nut or union.
60 318.3 32.4 Manufacturer Part name
DENSO ND–OIL8
a The allowable load is one-sixth of the breaking
VALEO
strength of the rope to be used (Safety THERMAL ZXL100PG (equivalent to PAG46)
coefficient: 6). SYSTEMS
SANDEN SP–10
• When tightening nuts of the air conditioner
hoses and tubes, be sure to use two wrenches.
Use one wrench to fix and tighten the nut with

00-8 125E-6 SERIES

 00 Index and foreword
Foreword, safety and general information

the other wrench to the specified torque (Use a

torque wrench for tightening).
a Example of fitting of O-ring
• An O-ring is fitted to every joint of hoses and
tubes in the air conditioner circuit.

a For tightening torques, see "Others",

"Precautions for disconnection and connection
of air conditioner piping".

125E-6 SERIES 00-9

00 Index and foreword
Foreword, safety and general information

How to read the shop manual

(Rev. 2011/02)
• Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of
them is required, consult KOMATSU distributors.
• Materials and specifications are subject to change without notice.
• Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the
engine volume of the engine model mounted on the machine.

Composition of shop manual

• This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. Index and foreword
• This section contains the index, foreword, safety and basic information. If any revision is made, the LIST
OF REVISED PAGES will be added.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of each component. It serves not only to give an
understanding for the structure of each component, but also serves as reference material for
troubleshooting.
20. Standard value table
• This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and
adjusting and to judge parts in troubleshooting.
50. Disassembly and assembly
• This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque, and quantity
and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard
• This section gives maintenance standard values of each component. The maintenance standard sub-
section explains the criteria and remedies for disassembly and service.

Revision and distribution

• Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual will be
used practically.
Symbol Item Description
Safety Special safety precautions which are necessary when performing work are
k described.
Special technical precautions or other precautions for preserving
a Caution standards which are necessary when performing work are described.
Weight of parts of component or parts are indicated. Caution necessary
4 Weight when selecting hoisting wire, or when working posture is important, etc.
are described.
Tightening
3 Tightening torque of the places that requires special attention.
torque
2 Coat Places to be coated with adhesives, etc. during assembly are indicated.

5 Oil, coolant Places where oil, etc. must be added, and capacity are indicated.
Places where oil, etc. must be drained, and quantity to be drained are
6 Drain
indicated.

Unit
• In this shop manual, the units are indicated with International System of units (SI).

00-10 125E-6 SERIES

 00 Index and foreword
Foreword, safety and general information

• For reference, conventionally used Gravitational System of units is indicated in parentheses { }.

125E-6 SERIES 00-11

00 Index and foreword
Foreword, safety and general information

Explanation of terms for maintenance standard

(Rev. 2011/02)
• The maintenance standard chapter describes the criteria for replacing or reusing products or parts in the
machine disassembly and maintenance work. The following terms are used to describe the criteria.

Standard dimension and tolerance

• To be accurate, the finished dimension of parts
is slightly different from one to another.
• To specify the finished dimension of a part, a
certain dimension is set for the part and an
allowable difference from that dimension is
indicated.
• The above dimension set is called the "standard
dimension" and the range of difference from the
standard dimension is called the "tolerance".
• The tolerance with the symbols of + or is
indicated on the right side of the standard
dimension.
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a
table as "standard dimension (upper limit of
tolerance/lower limit of tolerance)."
Example) 120 (–0.022/–0.126)
• Usually, the dimension of a hole and the
dimension of the shaft to be inserted into that
hole are indicated by the same standard
dimension and different tolerances of the hole
and shaft. The tightness of fit is decided by the
tolerance. Standard interference
• Indication of dimension of rotating shaft and hole • When the diameter of a hole of a part shown in
and their related drawing. the given standard dimension and tolerance
Example: table is smaller than that of the shaft to be
Standard Tolerance inserted, the difference between those
dimension Shaft Hole diameters is called the "interference".
-0.030 +0.046 • Subtract the maximum dimension of the hole
60 from the minimum dimension of the shaft and
-0.076 0
call it (A). Subtract the minimum dimension of
Standard clearance and standard value the hole from the maximum dimension of the
• The clearance made when new parts are shaft and call it (B). The range between (A) and
assembled is called the standard clearance, (B) is the "standard interference".
which is indicated by the range from the • After repairing or replacing some parts, measure
minimum clearance to the maximum clearance. the dimension of their hole and shaft and check
• When some parts are repaired, the clearance is that the interference is in the standard range.
generally adjusted to the standard clearance.
Repair limit and allowable value or allowable
• The values indicating performance and function dimension
of new products or equivalent are called the • The dimension of parts changes due to the wear
"standard value", which is indicated by a range or deformation while they are used. When the
or a target value. dimension charges exceeding certain valve,
• When some parts are repaired, the value of parts can not be used any longer. This value is
performance/function is set to the standard called the "repair limit".
value. • If a part is worn to the repair limit, it must be
replaced or repaired.

00-12 125E-6 SERIES

 00 Index and foreword
Foreword, safety and general information

• The performance and function of products

lowers while they are used. When alternative
charactaristic value of the performance and
function towers exceeding certain limit, it fluence
operation etc. This value is called the allowable
value or allowable dimension
• If a product deviates from the allowable value, it
must be checked or repaired. However, since
the allowable values are generally estimated
from various tests or experiences in most cases,
it must be judged after considering the operating
condition and customer's requirement.

Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.

Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
• The allowable interference shows the repair limit
of the part of smaller tolerance.
• If the interference between the parts exceeds
the allowable interference, they must be
replaced or repaired.

125E-6 SERIES 00-13

00 Index and foreword
Foreword, safety and general information

Handling of fuel system devices

(Rev. 2011/02)
• The common rail fuel injection system (CRI)
consists of more precise parts than the
conventional fuel injection pump and nozzles. If
foreign matter enters this system, it can cause a
problem. Use special care to prevent entry of
foreign matter when performing inspection and
maintenance of the fuel system.

Be careful of the work environment

• Avoid replacing filters or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
• After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by
leaking oil so never do this. Do not simply drain
oil out onto the ground, but collect it and ask the
customer to dispose of it, or take it back with you
for disposal.

Cleaning off dusts

• Wash the system carefully with clean fuel if
dusts enter the system.

Precautions for replacing fuel filter cartridge

• Be sure to use the Komatsu genuine fuel filter
cartridge.
• Since the common rail fuel injection system
(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzles, it
employs a high-efficiency special filter to prevent
foreign matter from entering it. If a filter other
than the genuine one is used, the fuel system
may have a trouble. Accordingly, never use such
a filter.

00-14 125E-6 SERIES

 00 Index and foreword
Foreword, safety and general information

Handling of intake system parts

(Rev. 2011/02)
• The Komatsu Variable Geometry Turbocharger
(KVGT) consists of more precise parts (variable
mechanism) than the conventional turbocharger.
If foreign matter enters this system, it can cause
a problem. Use special care to prevent entry of
foreign matter when servicing the air intake
system.

Be careful of the work environment

• Avoid repairing the machine in rain or high winds,
or at places where there is a lot of dust.

Sealing openings
• Install a cap, tape, plastic bag, etc. to the open
ends of disconnected piping to prevent entry of
foreign matter. Never leave the openings
uncovered nor plug the openings with rags.
Foreign matter will enter the system.

125E-6 SERIES 00-15

00 Index and foreword
Foreword, safety and general information

Handling of hydraulic equipment

(Rev. 2011/02)
• With the increase in pressure and precision of hydraulic components, the most common cause of failure is
dirt (foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding
hydraulic oil, or when disassembling or assembling hydraulic components.

Be careful of the work environment

• Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.

Disassembly and maintenance work in the field

• When disassembly or maintenance work is
performed on hydraulic components in the field,
there is danger of dust entering the components.
It is also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
components should be performed in a specially
prepared dustproof workshop, and the Preventing intrusion of foreign materials during
performance should be checked with special refilling operations.
test equipment. • Be careful not to let any foreign materials get in
when refilling with hydraulic oil. Always keep the
oil filler and the area around it clean, and also
use clean pumps and oil containers. If an oil
cleaning device is used, it is possible to filter out
the dirt that has been collected during storage,
so this is an even more effective method.

Sealing openings
• After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any foreign materials from
entering. If the opening is exposed or is blocked
with a rag, there is a danger of foreign materials
entering or of the surrounding area being Replacing hydraulic oil while its temperature is
contaminated by leaking oil, so never do this. Do high
not simply drain oil out onto the ground, but • When hydraulic oil or other oil is warm, it flows
collect it and ask the customer to dispose of it, or easily. In addition, the sludge can also be
take it back with you for disposal. drained out easily from the circuit together with
the oil, so it is better to change the oil when it is
still warm. When changing the oil, the old
hydraulic oil must be drained out as much as
possible. (Drain the oil not only from the
hydraulic tank, but also from the filter and the
drain plug hole in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.

00-16 125E-6 SERIES

 00 Index and foreword
Foreword, safety and general information

Flushing operations
• After disassembling and assembling the
equipment, or changing the oil with new one,
use flushing oil to remove the contaminants,
sludge, and old oil from the hydraulic circuit.
Normally, flushing is performed twice. Primary
flushing is performed by use of flushing oil and
secondary flushing is performed by use of the
specified hydraulic oil.

Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
perform oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit. The oil
cleaning equipment can remove the ultra fine
(about 3 m) particles that the filter built in the
hydraulic equipment cannot remove, so it is an
extremely effective device.

125E-6 SERIES 00-17

Komatsu Engine 125e 6 Series Workshop Manuals
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00 Index and foreword
Foreword, safety and general information

Method of disconnecting and connecting push-pull type coupler

(Rev. 2011/02)

k Before performing the following work, loosen the oil filler cap of the hydraulic tank slowly to
release the remaining pressure in the hydraulic tank.

k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.

Type 1

Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3). (Fig. 1) mating adapter (3), aligning them with each
other. (Fig. 4)
a The adapter can be pushed in approximately
3.5 mm. a Do not hold rubber cap portion (4).
2. After inserting the hose fitting in the adapter on
a Do not hold rubber cap portion (4).
the other side perfectly, pull it back to check the
2. While hose joint (2) is pushed into adapter (3),
connecting condition (Fig. 5)
press rubber cap portion (4) against adapter (3)
until it "clicks". (Fig.2) a When the hose is pulled back, the rubber cap
3. Hold hose adapter (1) or hose (5) and pull it out. portion moves toward the hose
(Fig. 3) approximately 3.5 mm. This does not
indicate abnormality, however.
a Since some hydraulic oil flows out, prepare
an oil container.

00-18 125E-6 SERIES

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