Sm Saa6d125e-3 Sebm024208

SEBM024208

DIESEL ENGINE

© 2004 All Rights Reserved Printed in Japan 04-04 (01)

00-1 (8)

CONTENTS No. of page

01 GENERAL ............................................................................................................................

01-1

11 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD............................................

11-1

12 TESTING AND ADJUSTING ........................................................................

12-1

13 DISASSEMBLY AND ASSEMBLY ........................................................ 13-1 15 REPAIR AND REPLACEMENT OF PARTS .............................

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SAFETY

SAFETY NOTICE

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

GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • •

Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.

6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

00-3

SAFETY

PRECAUTIONS DURING WORK 11.When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.

00-4

SAFETY NOTICE

19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

FOREWORD

GENERAL

FOREWORD GENERAL

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: · volume to cover all models

REVISIONS

}

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.

FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5

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Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Symbol

Item

Remarks

k

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque

Places that require special attention for the tightening torque during assembly.

Coat

Places to be coated with adhesives and lubricants, etc.

5

Oil, water

Places where oil, water or fuel must be added, and the capacity.

6

Drain

Places where oil or water must be drained, and quantity to be drained.

a

4

3 2

FOREWORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4 •

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.

WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter

★

Allowable load

mm

kN

tons

10 11.5 12.5 14 16 18 20 22.4 30 40 50 60

9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

100%

88%

79%

71%

41% SAD00479

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150°.

The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.

2) Sling wire ropes from the middle portion of the hook.

00-7

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.

k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.

00-8

Type 1

FOREWORD

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 3

1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).

2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.

•

•

Disassembly

Type 2

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

Connection

Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.

00-9

FOREWORD

COATING MATERIALS

COATING MATERIALS ★ ★

The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list. Category

Komatsu code

Part No.

Q'ty

Container

Main applications, featuresr

LT-1A

790-129-9030

150 g

Tube

• Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.

LT-1B

790-129-9050

20 g (2 pcs.)

Polyethylene container

• Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal.

LT-2

09940-00030

50 g

Polyethylene container

• Features: Resistance to heat and chemicals • Used for anti-loosening and sealant purpose for bolts and plugs.

LT-3

790-129-9060 (Set of adhesive and hardening agent)

Adhesive: 1 kg Hardening agent: 500 g

Can

LT-4

790-129-9040

250 g

Polyethylene container

Holtz MH 705

790-126-9120

75 g

Tube

• Used as heat-resisting sealant for repairing engine.

50 g

Polyethylene container

• Quick hardening type adhesive • Cure time: within 5 sec. to 3 min. • Used mainly for adhesion of metals, rubbers, plastics and woods.

Adhesives

Three bond 1735

790-129-9140

• Used as adhesive or sealant for metal, glass and plastic.

Aron-alpha 201

790-129-9130

2g

Polyethylene container

• Quick hardening type adhesive • Quick cure type (max. strength after 30 minutes) • Used mainly for adhesion of rubbers, plastics and metals.

Loctite 648-50

79A-129-9110

50 cc

Polyethylene container

• Resistance to heat, chemicals • Used at joint portions subject to high temperatures.

LG-1

790-129-9010

200 g

Tube

• Used as adhesive or sealant for gaskets and packing of power train case, etc.

LG-5

790-129-9080

1 kg

Can

• Used as sealant for various threads, pipe joints, flanges. • Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.

Tube

• Features: Silicon based, resistance to heat, cold • Used as sealant for flange surface, tread. • Used as sealant for oil pan, final drive case, etc.

LG-6

790-129-9020

200 g

Gasket sealant LG-7

790-129-9070

1g

Tube

• Features: Silicon based, quick hardening type • Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.

Three bond 1211

790-129-9090

100 g

Tube

• Used as heat-resisting sealant for repairing engine.

Tube

• Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material • Used as sealing material for transfer case

Three bond 1207B

00-10

• Used as sealant for machined holes.

419-15-18131

100 g

FOREWORD

Molybdenum disulphide lubricant

Grease

Primer

Adhesive

Caulking material

Komatsu code

Part No.

Q'ty

Container

Main applications, featuresr

LM-G

09940-00051

60 g

Can

• Used as lubricant for sliding portion (to prevent from squeaking).

Tube

• Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. • Used as lubricant for linkage, bearings, etc.

LM-P

09940-00040

G2-LI

SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI

G2-CA

SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA

200 g

• General purpose type Various

Various

Various

Various

• Used for normal temperature, light load bearing at places in contact with water or steam.

• Used for heavy load portion

Molybdenum disulphide grease LM-G (G2-M)

SYG2-400M SYG2-400M-A SYGA-16CNM

Hyper White Grease G2-T G0-T (*) *: For use in cold district

SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*)

400 g 16 kg

• Seizure resistance and heat resistance higher than molybdenum diBellows type sulfide grease Can • Since this grease is white, it does not stand out against machine body.

Biogrease G2B G2-BT (*) *: For high temperature and large load

SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)

400 g 16 kg

Bellows type Can

SUNSTAR PAINT PRIMER 580 SUPER

20 ml

Glass container

SUNSTAR GLASS PRIMER 580 SUPER

20 ml

Glass container

400 g × 10 Bellows type 400 g × 20 Bellows type 16 kg Can

417-926-3910

SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W"

320 ml

Polyethylene container

Sika Japan, Sikaflex 256HV

20Y-54-39850

310 ml

Polyethylene container

SUNSTAR PENGUINE SEAL No. 2505

417-926-3920

320 ml

Polyethylene container

SEKISUI SILICONE SEALANT

20Y-54-55130

333 ml

Polyethylene container

• Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants. • Used as primer for cab side (Using limit: 4 months) • Used as primer for glass side (Using limit: 4 months) Adhesive for cab glass

Category

COATING MATERIALS

• "S" is used for high-temperature season (April - October) and "W" for low-temperature season (November - April) as adhesive for glass. (Using limit: 4 months) • Used as adhesive for glass. (Using limit: 6 months) • Used to seal joints of glass parts. (Using limit: 4 months) • Used to seal front window. (Using limit: 6 months)

00-11

FOREWORD

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Tightening torque Thread diameter of bolt

Width across flats

mm

mm

Nm

kgm

6 8 10 12 14

10 13 17 19 22

11.8 – 14.7 27 – 34 59 – 74 98 – 123 153 – 190

1.2 – 1.5 2.8 – 3.5 6 – 7.5 10 – 12.5 15.5 – 19.5

16 18 20 22 24

24 27 30 32 36

235 – 285 320 – 400 455 – 565 610 – 765 785 – 980

23.5 – 29.5 33 – 41 46.5 – 58 62.5 – 78 80 – 100

27 30 33 36 39

41 46 50 55 60

1150 – 1440 1520 – 1910 1960 – 2450 2450 – 3040 2890 – 3630

118 – 147 155 – 195 200 – 250 250 – 310 295 – 370

Thread diameter of bolt

Width across flats

mm

mm

Nm

kgm

6 8 10 12

10 13 14 27

5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2

0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2

Tightening torque

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.

SAD00483

Thread diameter

Width across flat

mm

mm

Nm

kgm

14 18 22 24 30 33 36 42

19 24 27 32 36 41 46 55

24.5 ± 4.9 49 ± 19.6 78.5 ± 19.6 137.3 ± 29.4 176.5 ± 29.4 196.1 ± 49 245.2 ± 49 294.2 ± 49

2.5 ± 0.5 5±2 8±2 14 ± 3 18 ± 3 20 ± 5 25 ± 5 30 ± 5

00-12

Tightening torque

FOREWORD

STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.

Thread diameter

Width across flat

Tightening torque

mm

mm

Nm

kgm

10 12 16

14 17 22

59 – 74 98 – 123 235 – 285

6 – 7.5 10 – 12.5 23.5 – 29.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter

Width across flat

mm

mm

14 20 24 33 42

Varies depending on type of connector.

Tightening torque (Nm {kgm})

Norminal No.

02 03, 04 05, 06 10, 12 14

Range 35 – 63 84 – 132 128 – 186 363 – 480 746 – 1010

{3.5 – 6.5} {8.5 – 13.5} {13.0 – 19.0} {37.0 – 49.0} {76.0 – 103}

Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter

Width across flat

mm

mm

08 10 12 14 16 18 20 24 30 33 36 42 52

14 17 19 22 24 27 30 32 32 — 36 — —

Tightening torque (Nm {kgm})

Norminal No.

08 10 12 14 16 18 20 24 30 33 36 42 52

Range 5.88 – 8.82 9.8 – 12.74 14.7 – 19.6 19.6 – 24.5 24.5 – 34.3 34.3 – 44.1 44.1 – 53.9 58.8 – 78.4 93.1 – 122.5 107.8 – 147.0 127.4 – 176.4 181.3 – 240.1 274.4 – 367.5

{0.6 – 0.9} {1.0 – 1.3} {1.5 – 2.0} {2.0 – 2.5} {2.5 – 3.5} {3.5 – 4.5} {4.5 – 5.5} {6.0 – 8.0} {9.5 – 12.5} {11.0 – 15.0} {13.0 – 18.0} {18.5 – 24.5} {28.0 – 37.5}

Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}

00-13

FOREWORD

STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

mm

Nm

kgm

10 0 2 24 0 4 43 0 6 77 0 12

6 8 10 12

1.02 0 0.20 2.45 0 0.41 4.38 0 0.61 7.85 0 1.22

2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine. Thread diameter

Tightening torque

mm

Nm

kgm

802 10 0 2 12 0 2 24 0 4 36 0 5

6 8 10 12 14

0.81 0 0.20 1.02 0 0.20 1.22 0 0.20 2.45 0 0.41 3.67 0 0.51

3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine. Thread diameter

Tightening torque

inch

Nm

kgm

301 802 12 0 2 15 0 2 24 0 4 36 0 5 60 0 9

1 / 16 1/8 1/4 3/8 1/2 3/4 1

0.31 0 0.10 0.81 0 0.20 1.22 0 0.20 1.53 0 0.41 2.45 0 0.41 3.67 0 0.51 6.12 0 0.92

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) ★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. ★ Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque (Nm {kgm}) Nominal size Width across of hose flats

Taper seal type

Face seal type

Nominal thread Thread size size Root diameter - Threads per (mm) inch, Thread series (mm) (Reference)

Range

Target

19

34 - 63 {3.5 - 6.5}

44 {4.5}

14

9 – - 18UNF 16

14.3

22

54 - 93 {5.5 - 9.5}

74 {4.5}

–

11 – - 16UN 16

17.5

24

59 - 98 {6.0 - 10.0}

78 {8.0}

18

–

–

04

27

84 - 132 {8.5 - 13.5}

103 {10.5}

22

13 – - 16UN 16

20.7

05

32

128 - 186 {13.0 - 19.0}

157 {16.0}

24

1 - 14UNS

25.4

06

36

177 - 245 {18.0 - 25.0}

216 {22.0}

30

3 1 – - 12UNF 16

30.3

(10)

41

177 - 245 {18.0 - 25.0}

216 {22.0}

33

–

–

(12)

46

197 - 294 {20.0 - 30.0}

245 {25.0}

36

–

–

(14)

55

246 - 343 {25.0 - 35.0}

294 {30.0}

42

–

–

02

03

00-14

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS Copper wire Cable O.D. (mm)

Current rating (A)

Applicable circuit

0.88

2.4

12

Starting, lighting, signal etc.

0.32

2.09

3.1

20

Lighting, signal etc.

65

0.32

5.23

4.6

37

Charging and signal

15

84

0.45

13.36

7.0

59

Starting (Glow plug)

40

85

0.80

42.73

11.4

135

Starting

60

127

0.80

63.84

13.6

178

Starting

100

217

0.80

109.1

17.6

230

Starting

Norminal number

Number of strands

Dia. of strands (mm2)

Cross section (mm2)

0.85

11

0.32

2

26

5

CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification

1

Primary

Charging

Ground

Starting

Lighting

Instrument

Signal

Other

Code

W

B

B

R

Y

G

L

Color

White

Black

Black

Red

Yellow

Green

Blue

Code

WR

—

BW

RW

YR

GW

LW

2 Color White & Red

—

Code

—

WB

White & Black Red & White Rellow & Red Green & White Blue & White BY

RB

YB

GR

LR

3

4

Auxiliary

Color White & Black

—

Code

—

WL

Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR

Color White & Blue

—

Code

—

—

Color White & Green

—

—

Code

—

—

—

Color

—

—

—

WG

RY

Black & Red Red & Yellow RG

YG

GY

LY

Yellow & Green

Green & Yellow

Blue & Yellow

YL

GB

LB

5 Red & Green Yellow & Blue Green & Black Blue & Black RL

YW

GL

6 Red & Blue Yellow & White Green & Blue

n n

00-15

FOREWORD

CONVERSION TABLE

CONVERSION TABLE METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.

EXAMPLE • Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line from A. (2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down from B. (3) Take the point where the two lines cross as C. This point C gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches. B Millimeters to inches 1 mm = 0.03937 in

A

00-16

0

1

2

3

4

0 10 20 30 40

0 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

5 0.197 0.591 0.984 1.378 1.772 C 2.165 2.559 2.953 3.346 3.740

6

7

8

9

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.536 1.929

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

FOREWORD

CONVERSION TABLE

Millimeters to Inches 1 mm = 0.03937 in

0

1

2

3

4

5

6

7

8

9

0

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

50

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.874

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

0

Kilogram to Pound 1 kg = 2.2046 lb

0 0

0

1

2

3

4

5

6

7

8

9

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

10

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

20

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

30

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

40

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

50

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

60

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

70

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

80

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

90

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

00-17

FOREWORD

CONVERSION TABLE

Liter to U.S. Gallon 1l = 0.2642 U.S. Gal

0

1

2

3

4

5

6

7

8

9

0

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

10

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

20

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

30

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

40

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

50

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

60

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

70

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

80

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

90

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

0

Liter to U.K. Gallon 1l = 0.21997 U.K. Gal

0

1

2

3

4

5

6

7

8

9

0

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

30

6.599

6.819

7.039

7.259

7.479

7.969

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

0

00-18

FOREWORD

CONVERSION TABLE

kgm to ft. lb 1 kgm = 7.233 ft. lb

0

1

2

3

4

5

6

7

8

9

0

0

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

00-19

FOREWORD

CONVERSION TABLE

kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2

0

1

2

3

4

5

6

7

8

9

0

0

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

10

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

70

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

80

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

90

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

00-20

FOREWORD

CONVERSION TABLE

Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right. 1°C = 33.8°F

°C

°F

°C

°F

°C

°F

°C

°F

–40.4 –37.2 –34.4 –31.7 –28.9

–40 –35 –30 –25 –20

–40.0 –31.0 –22.0 –13.0 –4.0

–11.7 –11.1 –10.6 –10.0 –9.4

11 12 13 14 15

51.8 53.6 55.4 57.2 59.0

7.8 8.3 8.9 9.4 10.0

46 47 48 49 50

114.8 116.6 118.4 120.2 122.0

27.2 27.8 28.3 28.9 29.4

81 82 83 84 85

117.8 179.6 181.4 183.2 185.0

–28.3 –27.8 –27.2 –26.7 –26.1

–19 –18 –17 –16 –15

–2.2 –0.4 1.4 3.2 5.0

–8.9 –8.3 –7.8 –7.2 –6.7

16 17 18 19 20

60.8 62.6 64.4 66.2 68.0

10.6 11.1 11.7 12.2 12.8

51 52 53 54 55

123.8 125.6 127.4 129.2 131.0

30.0 30.6 31.1 31.7 32.2

86 87 88 89 90

186.8 188.6 190.4 192.2 194.0

–25.6 –25.0 –24.4 –23.9 –23.3

–14 –13 –12 –11 –10

6.8 8.6 10.4 12.2 14.0

–6.1 –5.6 –5.0 –4.4 –3.9

21 22 23 24 25

69.8 71.6 73.4 75.2 77.0

13.3 13.9 14.4 15.0 15.6

56 57 58 59 0

132.8 134.6 136.4 138.2 140.0

32.8 33.3 33.9 34.4 35.0

91 92 93 94 95

195.8 197.6 199.4 201.2 203.0

–22.8 –22.2 –21.7 –21.1 –20.6

–9 –8 –7 –6 –5

15.8 17.6 19.4 21.2 23.0

–3.3 –2.8 –2.2 –1.7 –1.1

26 27 28 29 30

78.8 80.6 82.4 84.2 86.0

16.1 16.7 17.2 17.8 18.3

61 62 63 64 65

141.8 143.6 145.4 147.2 149.0

35.6 36.1 36.7 37.2 37.8

96 97 98 99 100

204.8 206.6 208.4 210.2 212.0

–20.0 –19.4 –18.9 –18.3 –17.8

–4 –3 –2 –1 0

24.8 26.6 28.4 30.2 32.0

–0.6 0 0.6 1.1 1.7

31 32 33 34 35

87.8 89.6 91.4 93.2 95.0

18.9 19.4 20.0 20.6 21.1

66 67 68 69 70

150.8 152.6 154.4 156.2 158.0

40.6 43.3 46.1 48.9 51.7

105 110 115 120 125

221.0 230.0 239.0 248.0 257.0

–17.2 –16.7 –16.1 –15.6 –15.0

1 2 3 4 5

33.8 35.6 37.4 39.2 41.0

2.2 2.8 3.3 3.9 4.4

36 37 38 39 40

96.8 98.6 100.4 102.2 104.0

21.7 22.2 22.8 23.3 23.9

71 72 73 74 75

159.8 161.6 163.4 165.2 167.0

54.4 57.2 60.0 62.7 65.6

130 135 140 145 150

266.0 275.0 284.0 293.0 302.0

–14.4 –13.9 –13.3 –12.8 –12.2

6 7 8 9 10

42.8 44.6 46.4 48.2 50.0

5.0 5.6 6.1 6.7 7.2

41 42 43 44 45

105.8 107.6 109.4 111.2 113.0

24.4 25.0 25.6 26.1 26.7

76 77 78 79 80

168.8 170.6 172.4 174.2 176.0

68.3 71.1 73.9 76.7 79.4

155 160 165 170 175

311.0 320.0 329.0 338.0 347.0

00-21

FOREWORD

UNITS

UNITS In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}

00-22

}.

01 GENERAL OUTLINE .....................................................................................................................................................01SPECIFICATIONS .......................................................................................................................................01GENERAL ASSEMBLY DRAWING .............................................................................................................01WEIGHT TABLE ..........................................................................................................................................01ENGINE PERFORMANCE CURVE ............................................................................................................01-

125-3 SERIES

2 12 22 31 42

01-1 (5)

GENERAL

OUTLINE

OUTLINE 1. Applicable machine In-line fuel injection pump specification Engine

Engine Serial No.

Applicable machine WA430-5

Wheel loader

SAA6D125E-3

Common rail specification Engine SA6D125E-3

SAA6D125E-3

01-2 (8)

Engine Serial No.

Applicable machine D65EX, PX-15 D85EX, PX-15

Bulldozer Bulldozer

WA470-5 WA480-5 HM300-1 PC400-7 PC450-7 HD255-5

Wheel loader Wheel loader Articulated dump truck Hydraulic excavator Hydraulic excavator Dump truck

125-3 SERIES

GENERAL

OUTLINE

2. Outline of engine •

The 125E-3 engine clears strict exhaust gas regulations (USA: EPA regulations for the year 2001, EU: regulations for the year 2002, Japan: construction equipment regulations for the year 2003). At the same time, it is a high performance, high efficiency engine which achieves low fuel consumption, low noise, improved exhaust gas color, and improved acceleration. This engine has been newly developed to meet various purposes of use as the power unit for construction equipment and industrial machinery.

•

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

125-3 SERIES

01-3

GENERAL

OUTLINE

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

01-4

125-3 SERIES

GENERAL

SPECIFICATIONS

SPECIFICATIONS IN-LINE FUEL INJECTION PUMP SPECIFICATION Engine

SAA6D125E-3

Machine model No. of cylinders - bore x stroke Piston displacement

Performance

Dimensions

Firing order Overall length Overall width Overall height (excl. exhaust pipe) Overall height (incl. exhaust pipe) Rated horsepower

Max. torque

High idling speed Low idling speed Min. fuel consumption ratio

Dry weight Fuel supply pump Governor Lubricating oil amount (replacement amount) Cooling water (engine only) Alternator Starting motor Battery Turbocharger Air compressor Others

01-12 (5)

WA430-5 mm

6 – 125 x 150 11.0 {11,040}

{cc} — mm mm mm

1,317 935 1,637

mm

—

kW/rpm {HP/rpm}

174/2,000 {237/2,000} (Net) 941/1,400 {96/1,400} (Net) 2,250±50 750 +500 — { } 1,200

Nm/rpm {kgm/rpm} rpm rpm g/kW·h {g/HP·h} kg — —

1–5–3–6–2–4

Bosch PE-P (PS3000) Boxch RSV, centrifugal, all speed type 47 (38)

— — — — — —

(21) 24V, 50A 24V, 7.5kW 12V 150Ah x 2 SCHWITZER S400 — With air-cooled aftercooler

125-3 SERIES

GENERAL

125-3 SERIES

SPECIFICATIONS

01-13 (5)

GENERAL

SPECIFICATIONS

COMMON RAIL SYSTEM SPECIFICATION Engine

SA6D125E-3

Machine model No. of cylinders - bore x stroke Piston displacement

Performance

Dimensions

Firing order Overall length Overall width Overall height (excl. exhaust pipe) Overall height (incl. exhaust pipe) Rated horsepower

Max. torque

High idling speed Low idling speed Min. fuel consumption ratio

Dry weight Fuel supply pump Governor Lubricating oil amount (replacement amount) Cooling water (engine only) Alternator Starting motor Battery Turbocharger Air compressor Others

01-14 (5)

D65EX, PX-15 mm

D85EX, PX-15 6 – 125 x 150 11.0 {11,040}

{cc} — mm mm mm

1,307 856 1,615

1–5–3–6–2–4 1,307 949 1,712

mm

—

—

kW/rpm {HP/rpm}

154/1,950 {206/1,950} (Gross) 1,012/1,400 {103.2/1,400} (Gross) 2,100 ± 50 825 ± 25 210 {157} 1,250

195/1,900 {261/1,900} (Gross) 1,265/1,400 {129/1,400} (Gross) 2,100±50 750 +500 214 {160} 1,250 Denso ECD-U2 Electronic control type 44 (38)

Nm/rpm {kgm/rpm} rpm rpm g/kW·h {g/HP·h} kg — —

44 (38)

— — — — — —

(21) (21) 24V, 50A 24V, 50A 24V, 7.5kW 24V, 7.5kW 12V 140Ah x 2 12V 150Ah x 2 SCHWITZER S400 SCHWITZER S400 — — With water-cooled With water-cooled aftercooler aftercooler

125-3 SERIES

GENERAL

SPECIFICATIONS

SAA6D125E-3 WA470-5

WA480-5

HM300-1

PC400, 450-7

HD255-5

1,442 935 1,637

1,442 935 1,637

6 – 125 x 150 11.0 {11,040} 1–5–3–6–2–4 1,665 1,045 1,217

1,718 995 —

1,550 958 1,207

—

—

—

1,645

—

195/2,000 {261/2,000} (Net) 1,245/1,400 {127/1,400} (Net) 2,170 +20 -80 750 +500 201 {150} 1,200

202/2,000 {271/2,000} (Net) 1,295/1,400 {132/1,400} (Net) 2,170 +20 -80 750 +500 201 {150} 1,200

259/1,850 {347/1,850} (Gross) 1,371/1,400 {139.8/1,400} (Gross) 1,930±50 1,000±25 199 {148} 1,200

241/2,100 {323/2,100} (Gross) 1,373/1,400 {140/1,400} (Gross) 2,420 +80 -20 750±50 208 {153} 1,200

47 (38)

47 (38)

250/2,000 {335/2,000} (Gross) 1,569/1,400 {160/1,400} (Gross) 2,200±50 725 +500 202 {150} 1,200 Denso ECD-U2 Electronic control type 47 (38)

43 (37)

44 (38)

(21) 24V, 50A 24V, 7.5kW 12V 150Ah x 2 SCHWITZER S400 —

(21) 24V, 50A 24V, 7.5kW 12V 150Ah x 2 SCHWITZER S400 —

(21) 24V, 75A 24V, 7.5kW 12V 150Ah x 4 SCHWITZER S400 —

(21) 24V, 35A 24V, 7.5kW 12V 150Ah x 4 SCHWITZER S400 —

With air-cooled aftercooler

With air-cooled aftercooler

With air-cooled aftercooler

With air-cooled aftercooler

(21) 24V, 35A 24V, 7.5kW 12V 150Ah x 4 SCHWITZER S400 SANWA SEIKI LTD. Recyprocating single cylinder type With air-cooled aftercooler

125-3 SERIES

01-15 (8)

GENERAL

GENERAL ASSEMBLY DRAWING

GENERAL ASSEMBLY DRAWING SAA6D125E-3 LEFT SIDE VIEW DRAWING (WA470-5, WA480-5)

01-22

+ Details may differ according to the machine model.

125-3 SERIES

GENERAL

SAA6D125E-3 RIGHT SIDE VIEW DRAWING (WA470-5, WA480-5)

125-3 SERIES

GENERAL ASSEMBLY DRAWING

★ Details may differ according to the machine model.

01-23

GENERAL

SAA6D125E-3 FRONT VIEW DRAWING (WA470-5, WA480-5)

01-24

GENERAL ASSEMBLY DRAWING

★ Details may differ according to the machine model.

125-3 SERIES

GENERAL

SAA6D125E-3 REAR VIEW DRAWING (WA470-5, WA480-5)

125-3 SERIES

GENERAL ASSEMBLY DRAWING

★ Details may differ according to the machine model.

01-25

GENERAL

SAA6D125E-3 LEFT SIDE VIEW DRAWING (WA430-5)

GENERAL ASSEMBLY DRAWING

★ Details may differ according to the machine model.

a. Crankshaft center b. Flywheel housing rear surface

01-26 2

125-3 SERIES

GENERAL

SAA6D125E-3 RIGHT SIDE VIEW DRAWING (WA430-5)

GENERAL ASSEMBLY DRAWING

★ Details may differ according to the machine model.

a. Crankshaft center b. Flywheel housing rear surface

125-3 SERIES

01-27

GENERAL

SAA6D125E-3 REAR VIEW DRAWING (WA430-5)

GENERAL ASSEMBLY DRAWING

★ Details may differ according to the machine model.

a. Crankshaft center b. Cylinder liner center

01-28 2

125-3 SERIES

GENERAL

SAA6D125E-3 FRONT VIEW DRAWING (WA430-5)

GENERAL ASSEMBLY DRAWING

★ Details may differ according to the machine model.

a. Crankshaft center b. Cylinder liner center

125-3 SERIES

01-29

GENERAL

SA6D125E-3 LEFT SIDE VIEW DRAWING (D65EX, PX-15)

GENERAL ASSEMBLY DRAWING

★ This drawing shows a typical model. ★ Details may differ according to the machine model.

a. Crankshaft center b. Flywheel housing rear surface

01-29-1 (5)

125-3 SERIES

GENERAL

SA6D125E-3 RIGHT SIDE VIEW DRAWING (D65EX, PX-15)

GENERAL ASSEMBLY DRAWING

★ This drawing shows a typical model. ★ Details may differ according to the machine model.

a. Crankshaft center b. Flywheel housing rear surface

125-3 SERIES

01-29-2 (5)

GENERAL

SA6D125E-3 FRONT VIEW DRAWING (D65EX, PX-15)

GENERAL ASSEMBLY DRAWING

★ This drawing shows a typical model. ★ Details may differ according to the machine model.

a. Crankshaft center b. Cylinder liner center

01-29-3 (5)

125-3 SERIES

GENERAL

SA6D125E-3 REAR VIEW DRAWING (D65EX, PX-15)

GENERAL ASSEMBLY DRAWING

+ This drawing shows a typical model. + Details may differ according to the machine model.

a. Crankshaft center b. Cylinder liner center

125-3 SERIES

01-29-4 (5)

GENERAL

GENERAL ASSEMBLY DRAWING

+ These dimensions are reference values for use when installing to a test bench.

DIMENSION TABLE IN-LINE FUEL INJECTION SPECIFICATION Engine SAA6D125E-3

Dimensions for each part (mm)

Machine model WA430-5

A

B

C

D

E

F

1,317

1,637

1,250

387

467.5

467.5

COMMON RAIL SYSTEM SPECIFICATION Engine SA6D125E-3

SAA6D125E-3

01-30 (8)

Machine model D65EX, PX-15 D85EX, PX-15 WA470-5, 480-5 PC400, 450-7 HD255-5

Dimensions for each part (mm) A

B

C

D

E

F

1,307 1,307 1,317 1,341 1,550

1,615 1,712 1,637 1,645 1,241

1,228 1,325 1,250 1,203 1,240

387 387 387 442 401

420 420 467.5 415 440

442 470 467.5 478 518

125-3 SERIES

GENERAL

WEIGHT TABLE

WEIGHT TABLE This weight table is guided for use when transporting or handling components. Unit:kg No.

Item

Components S400

SA6D125E-3

SAA6D125E-3

15

15

1

Turbocharger

SCHWITZER

2

Cylinder head assembly

Cylinder head, valve, rocker arm, valve spring

16 x 6

16 x 6

3

Cylinder block assembly

Cylinder block, main bearing cap, cylinder liner

370

370

4

Front cover

28

28

5

Engine oil pan

22.4

55.3 6

Flywheel assembly

26.7 (WA470/480-5) 34.2 (WA430-5)

Flywheel, ring gear

22.7 (HM300-1) 54

47

Crankshaft, crankshaft gear

104

104

Camshaft assembly

Camshaft, camshaft gear, thrust plate

16

16

10

Piston, connecting rod assembly

Piston, piston ring, piston pin, connecting rod

7.6 x 6 (FCD)

7.6 x 6 (FCD)

11

Oil pump

5

5

12

Fuel supply pump

13

13

13

Water pump

9.5

9.5

14

Water-cooled aftercooler

27

—

15

Air-cooled aftercooler assembly

—

24

7

Flywheel housing

8

Crankshaft assembly

9

16

17

24 V, 50 A

11

24V, 75A

13

13 (HM300-1)

24 V, 7.5 kW

15.5

15.5

24 V, 11 kW

18

18

Alternator

Starting motor

125-3 SERIES

11 (WA470/480-5) 10 (HM300-1 OPT)

01-31 (5)

GENERAL

ENGINE PERFORMANCE CURVE

ENGINE PERFORMANCE CURVE IN-LINE FUEL INJECTION PUMP SPECIFICATION Engine

Engine Serial No.

Machine model WA430-5

Page 01-64

SAA6D125E-3

COMMON RAIL SYSTEM SPECIFICATION Engine SA6D125E-3

SAA6D125E-3

01-42 (8)

Engine Serial No.

Machine model

Page

D65EX, PX-15 D85EX, PX-15

01-53 01-54

WA470-5 WA480-5 HM300-1 PC400, 450-7 HD255-5

01-65 01-66 01-67 01-68 01-69

125-3 SERIES

GENERAL

ENGINE PERFORMANCE CURVE

SA6D125E-3 (D65EX, PX-15) Flywheel horsepower: 154 kW {206 HP} / 1,950 rpm (Gross) Max. torque: 1,012 Nm {103.2 kgm} / 1,400 rpm (Gross)

125-3 SERIES

01-53 (5)

GENERAL

ENGINE PERFORMANCE CURVE

SA6D125E-3 (D85EX, PX-15) Flywheel horsepower: 195 kW {261 HP} / 1,900 rpm (Gross) Max. torque: 1,265 Nm {129 kgm} / 1,400 rpm (Gross)

01-54 (5)

125-3 SERIES

GENERAL

ENGINE PERFORMANCE CURVE

SAA6D125E-3 (WA430-5) Flywheel horsepower: 174 kW {233 HP} / 2,000 rpm (Gross) Max. torque: 941 Nm {96 kgm} / 1,400 rpm (Gross)

01-64 (5)

125-3 SERIES

GENERAL

ENGINE PERFORMANCE CURVE

SAA6D125E-3 (WA470-5) Flywheel horsepower: 204 kW {273 HP} / 2,000 rpm (Gross) Max. torque: 1,270 Nm {130 kgm} / 1,400 rpm (Gross)

125-3 SERIES

01-65 (5)

GENERAL

ENGINE PERFORMANCE CURVE

SAA6D125E-3 (WA480-5) Flywheel horsepower: 211 kW {283 HP} / 2,000 rpm (Gross) Max. torque: 1,320 Nm {134 kgm} / 1,400 rpm (Gross)

01-66 (5)

125-3 SERIES

GENERAL

ENGINE PERFORMANCE CURVE

SAA6D125E-3 (HM300-1) Flywheel horsepower: 250 kW {335 HP} / 2,000 rpm (Gross) Max. torque: 1,569 Nm {160 kgm} / 1,400 rpm (Gross)

125-3 SERIES

01-67 (5)

GENERAL

ENGINE PERFORMANCE CURVE

SAA6D125E-3 (PC400, 450-7) Flywheel horsepower: 259 kW {347 HP} / 1,850 rpm (Gross) Max. torque: 1,371 Nm {139.8 kgm} / 1,400 rpm (Gross)

01-68 (7)

125-3 SERIES

GENERAL

SAA6D125E-3 (HD255-5) Flywheel horsepower: 241 kW {323 HP} / 2,100 rpm (Gross) Max. torque: 1,373 Nm {140 kgm} / 1,400 rpm (Gross)

125-3 SERIES

01-69 (8)

11 STRUCTURE AND FUNCTION, MAINTENANCE STANDARD GENERAL STRUCTURE.............................. 11- 2 INTAKE, EXHAUST SYSTEM INTAKE, EXHAUST SYSTEM.................. 11- 12 AIR CLEANER ......................................... 11- 16 TURBOCHARGER................................... 11- 17 AFTERCOOLER ...................................... 11- 20 ENGINE BODY CYLINDER HEAD .................................... 11-202 CYLINDER BLOCK.................................. 11-206 CYLINDER LINER ................................... 11-210 MAIN CIRCULATION SYSTEM ............... 11-212 CRANKSHAFT......................................... 11-214 PISTON .................................................... 11-216 CONNECTING ROD ................................ 11-218 FLYWHEEL AND FLYWHEEL HOUSING 11-219 VIBRATION DAMPER.............................. 11-221 TIMING GEAR ......................................... 11-224 VALVE MECHANISM ............................... 11-228 CAMSHAFT ............................................. 11-230 CAM FOLLOWER AND PUSH ROD ....... 11-231 VALVE AND VALVE GUIDE ..................... 11-232 ROCKER ARM SHAFT ............................ 11-234 CROSSHEAD .......................................... 11-235

125-3 SERIES

LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ....... 11-302 OIL PUMP................................................ 11-303 OIL FILTER .............................................. 11-306 OIL COOLER........................................... 11-308 FUEL SYSTEM FUEL SYSTEM DIAGRAM ...................... 11-402 OUTLINE OF CRI SYSTEM .................... 11-403 FUEL PIPING .......................................... 11-416 FUEL COOLER ....................................... 11-418 FUEL FILTER........................................... 11-419 COOLING SYSTEM COOLING SYSTEM CHART ................... 11-501 WATER PUMP ......................................... 11-502 THERMOSTAT......................................... 11-505 CORROSION RESISTOR ....................... 11-507 ELECTRICAL SYSTEM ALTERNATOR MOUNTING..................... 11-902 ALTERNATOR ......................................... 11-903 STARTING MOTOR................................. 11-904 STARTING AID ........................................ 11-906

11-1 (7)

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

GENERAL STRUCTURE

GENERAL STRUCTURE GENERAL STRUCTURE (WITH IN-LINE FUEL INJECTION PUMP ENGINE) ★ Details may differ according to the machine model.

1. 2. 3. 4. 5. 6. 7. 8. 9.

Cylinder block Cylinder liner Piston Connecting rod Piston pin Intake valve Crosshead Exhaust valve Rocker arm shaft

11-2

10. 11. 12. 13. 14. 15. 16. 17. 18.

Fuel injection nozzle Cylinder head cover Camshaft Ring gear Flywheel Rear seal Flywheel housing Oil pan Crankshaft

19. 20. 21. 22. 23. 24. 25.

Main bearing cap Oil strainer Crankshaft gear Front cover Front seal Crankshaft pulley Vibration damper

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

26. 27. 28. 29. 30. 31. 32.

Cylinder head Thermostat Rocker arm Push rod Cam follower Connecting rod cap Oil pump

125-3 SERIES

GENERAL STRUCTURE

Engine: SA6D125E-3 (with turbocharger and aftercooler) SAA6D125E-3 (with turbocharger and air-cooled aftercooler) Type: In-line, 6-cylinders, water-cooled, direct fuel injection, 4-cycle diesel engine.

11-3

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

GENERAL STRUCTURE

(WITH COMMON RAIL FUEL INJECTION SYSTEM ENGINE) ★ Details may differ according to the machine model.

1. 2. 3. 4. 5. 6. 7. 8. 9.

Cylinder block Cylinder liner Piston Connecting rod Piston pin Intake valve Crosshead Exhaust valve Rocker arm shaft

11-4

10. 11. 12. 13. 14. 15. 16. 17. 18.

injector Cylinder head cover Camshaft Ring gear Flywheel Rear seal Flywheel housing Oil pan Crankshaft

19. 20. 21. 22. 23. 24. 25.

Main bearing cap Oil strainer Crankshaft gear Front cover Front seal Crankshaft pulley Vibration damper

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

26. 27. 28. 29. 30. 31. 32. 33. 34. 35.

Exhaust manifold Turbocharger Cylinder head Rocker arm Push rod Intake manifold Common rail Fuel supply pump Cam follower Connecting rod cap

125-3 SERIES

GENERAL STRUCTURE

Engine: SA6D125E-3 (with turbocharger and aftercooler) SAA6D125E-3 (with turbocharger and air-cooled aftercooler) Type: In-line, 6-cylinders, water-cooled, direct fuel injection, 4-cycle diesel engine.

11-5

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

INTAKE, EXHAUST SYSTEM

INTAKE, EXHAUST SYSTEM INTAKE, EXHAUST SYSTEM SA6D125E-3 (D65EX, PX-15) 1/2

1. 2. 3. 4. 5. 6.

Muffler Electrical intake air heater Air cleaner cover Air cleaner body Vacuator valve Intake manifold

11-12 (5)

★ This drawing shows a typical model. ★ Details may differ according to the machine model.

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

INTAKE, EXHAUST SYSTEM

SA6D125E-3 (D65EX, PX-15) 2/2

7. 8. 9. 10.

Turbocharger Exhaust manifold (front) Exhaust manifold (center) Exhaust manifold (rear)

125-3 SERIES

A. Intake inlet B. Exhaust outlet

11-13 (5)

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

SAA6D125E-3 (WA430-5, WA470-5, WA480-5) 1/4

INTAKE, EXHAUST SYSTEM

★ Details may differ according to the machine model.

1. Intake air connector 2. Electrical intake air heater 3. Intake manifold

11-13-1 (5)

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

INTAKE, EXHAUST SYSTEM

SAA6D125-3 (WA430-5, WA470-5, WA480-5) 2/4

4. 5. 6. 7. 8.

Turbocharger Intake air connector Exhaust manifold (front) Exhaust manifold (center) Exhaust manifold (rear)

125-3 SERIES

A. Intake inlet B. Exhaust outlet C. Air supply (between turbochager and air-cooled aftercooler)

11-13-2 (5)

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

INTAKE, EXHAUST SYSTEM

SAA6D125E-3 (WA430-5, WA470-5, WA480-5) 3/4

9. Muffler

11-14

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

SAA6D125E-3 (WA430-5, WA470-5, WA480-5) 4/4

INTAKE, EXHAUST SYSTEM

.

10. Vacuator valve 11. Air cleaner cover 12. Air cleaner body

125-3 SERIES

11-15

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

AIR CLEANER

INTAKE, EXHAUST SYSTEM

★ Details may differ according to the machine model.

FRG type (radial seal type)

1. Inlet 2. Guide vane (sleeve) 3. Guide vane Engine SA6D125E-3 SAA6D125E-3

4. Dust pan 5. Vacuator valve 6. Body

Machine model D65EX, PX-15 D85EX, PX-15 WA430-5, WA470-5, WA480-5, HM300-1, PC400, 450-7

Features • The element diameter is the same and the outside diameter of the body is small. The inlet is placed in the direction of connection, so no guide vane is used; a simple spiral guide vane can give ample centrifugal force. • The dust pan has no guide vane and its structure is simple.

11-16 (7)

7. Primary element 8. Safety element 9. Outlet Type

Vacuator valve

No. of elements

FRG

Automatic discharge

Inner cylinder 1, Outer cylinder 1

FRG

Automatic discharge

Inner cylinder 1, Outer cylinder 1

Structure • Air containing dust is sucked into the tangential from inlet (1). The dust is separated by the centrifugal separation effect of guide vane (3). More than 99.9% of the dust is then removed by primary element (7), and the clean air then passes through safety element (8) and outlet (9), and is sent to the engine. • The dust and water separated by guide vane (3) circulates around the inside wall of body (6), flies into vacuator valve (5), and is automatically discharged.

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

INTAKE, EXHAUST SYSTEM

TURBOCHARGER SCHWITZER S400

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Name Compressor cover Locknut Compressor wheel V-Clamp Lock nut Circlip Insert O-ring Piston ring Flinger sleeve Oil deflector Thrust sleeve Thrust bearing Snap ring Journal bearing

125-3 SERIES

No. 16 17 18 19 20 21 22 23 24 25 26

Name Snap ring Journal bearing Circlip O-ring Bearing housing Piston ring Turbine backplate V-Clamp Lock nut Shaft and turbine wheel assembly Shaft and turbine wheel Turbine housing

A. Air intake inlet B. Compressed air outlet C. Exhaust inlet D. Exhaust outlet

11-17

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

INTAKE, EXHAUST SYSTEM

AFTERCOOLER Water-cooled type SA6D125E-3 (D65EX, PX-15, D85EX, PX-15)

1. Aftercooler core 2. Aftercooler cover 3. Intake manifold

11-20 (5)

★ Details may differ according to the machine model.

A. B. C. D.

Intake air inlet Intake air outlet Water inlet (from cylinder head) Water outlet (to themostat)

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

Air-cooled type SAA6D125E-3 (WA430-5, WA470-5, WA480-5, HM300-1, PC400-7, PC450-7)

1. 2. 3. 4.

Tank Side support Tube Fin

125-3 SERIES

INTAKE, EXHAUST SYSTEM

★ Details may differ according to the machine model.

a. Air supply (Turbocharger↔intake manifold)

11-21 (7)

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

ENGINE BODY CYLINDER HEAD

1. 2. 3. 4. 5. 6. 7. 8. 9.

★ Details may differ according to the machine model.

Cooling water air tube Cylinder head bolt Injector Fuel spill tube Valve guide Cylinder head Cylinder head cover Valve seat insert Rocker arm housing

11-202

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

★ Details may differ according to the machine model.

CYLINDER HEAD • • • • •

Direct fuel injection 4-valve Injector assembled in cylinder head (With common rail fuel injection system engine) Injection nozzle assembled in cylinder head (With in-line fuel injection pump engine) Divided type (1 cylinder head for 1 cylinder)

VALVE SEAT • Press-fitted insert for intake and exhaust CYLINDER HEAD COVER • Floating type seal

125-3 SERIES

11-203

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

CYLINDER HEAD Tightening order of cylinder head mounting bolt

MAINTENANCE STANDARD No.

Unit: mm

Item.

1

Distortion of cylinder head mounting surface

2

Protrusion of nozzle

SA6D125E-3 SAA6D125E-3

Criteria Standard

Repair limit

0 – 0.06

0.09

Applicalbe model S.T.D. S.T.D.

Standard 3.25 – 3.95 3.25 – 3.95 Target Range Nm {kgm} Nm {kgm} 88 – 108 98 {10} {9 – 11} 127 – 147 137 {14} {13 – 15} Retighten with Retighten with 90º 90º + 030º

Bolt No.

3

Tightening torque of cylinder head mounting bolts (Coat the thread areas with molybdenum disulfide or engine oil)

Order 1st step

–

2nd step 3rd step

Target Nm {kgm} 66{6.75}

58 – 73 {6 – 7.5} Range Nm {kgm} 58.8 – 73.5 {6.0 – 7.5}

66{6.75}

58.8 – 73.5 {6.0 – 7.5}

— 4 5

Tightening torque of injector mounting bolt Tightening torque of rocker arm housing mounting bolt

11-204 1

Remedy Repair by grinding or replace Replace sleeve

Tihgten bolts in accordance with bolts No.

68 {7}

Retighten

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

CYLINDER BLOCK

1. 2. 3. 4. 5. 6.

Cylinder block Cylinder liner Crevice seal Liner seal (Ethylene propylene rubber) Liner seal (Silicon rubber) Front seal

11-206

7. 8. 9. 10. 11. 12.

Front cover Main bearing cap bolt Main bearing cap Main bearing Thrust bearing Piston cooling nozzle

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

CYLINDER BLOCK • Crankshaft: 7 bearings • Camshaft: 7 bearings FRONT SEAL • Single lip with dust seal PISTON COOLING • With piston cooling nozzle

125-3 SERIES

ENGINE BODY

CYLINDER LINER • Wet type • Treatment: Plateau honing finish Gas soft nitriding LINER SEAL • Top: • Middle: • Bottom:

Clevis seal O-ring (Ethylene propylene rubber) O-ring (Silicon rubber)

11-207

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

CYLINDER BLOCK

MAINTENANCE STANDARD No. Item 1

Distortion of cylinder head mounting surface Inside diameter of main bearing hole

2

Standard 0 – 0.080 Standard

3

Roundness of main bearing hole Inside diameter of main bearing

4

Inside diameter of cam bushing mounting hole

5

Inside diameter of cam bushing

11-208

Repair limit 0.12 Tolerance +0.015 –0.010 –0.005 –0.020

116

Thickness of main bearing

3

Unit: mm Remedy

Criteria

Repair limit: 0.005 Standard 110

Tolerance +0.040 +0.010

Standard 63 Standard 60

Tolerance +0.070 0

Repair limit 110.15 Tolerance +0.030 +0.000 Repair limit 60.30

Repair by grinding or replace Replace main bearing cap Replace main bearing Replace main bearing Repair or replace cylinder block Replace

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

MAINTENANCE STANDARD No. Item 6

Tihgtening torque of main bearing cap (Coat thread area with engine oil)

Order 1st step 2nd step 3rd step

Criteria Target Nm{kgm} 98{10} 196{20} Retighten with 90º

7

Tightening torque of oil pan mounting bolt

—

54{5.5}

8

Tightening torque of crankshaft pulley mounting bolt

M16 (5 bolts)

274{28}

M14 (1 bolt)

176{18}

9

10

Diffrence between lower face of cylinder block and flywheel housing Diffrence between lower face of cylinder block and front cover

125-3 SERIES

ENGINE BODY

Unit: mm Remedy Range Nm{kgm} 88 – 108{9 – 11} 186 – 206{19 – 21} 90º – 120º 34 – 73{3.5 – 7.5}

Tighten

245 – 309 {25 – 31.5} 157 – 196{16 – 20}

Repair limit : 0.35 Repair Repair limit : 0.28

11-209

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

CYLINDER LINER

MAINTENANCE STANDARD No. Item 1

Criteria

Protrusion of cylinder liner

Repair limit : 0.07 – 0.15 Rank

2

Inside diameter of cylinder liner Roundness of cylinder liner Cylindricity of cylinder liner

3

Outside diameter of cylinder liner (Counter bore)

5

*1

*1 *1

Standard

Interference between cylinder liner and block(Counter bore) *1 Outside diameter of cylinder liner (Counter bore bottom)

4

*1

Tolerance Repair limit +0.020 A 125 125.20 0 +0.040 B 125 125.20 +0.021 Repair limit : 0.08 Repair limit : 0.08 Standard Tolerance 153 ±0.025

Interference between cylinder liner and block (Counter bore bottom) Outside diameter of cylinder liner (O-ring)

Standard: 0 – 0.113 Standard

Standard

Tolerance +0.090 +0.040 Interference limit

0.01 – 0.12

0.01

Standard

Tolerance +0.386 +0.361

145

Clearance between cylinder liner and block (O-ring)

Unit: mm Remedy Replace liner or block

141

Standard : 0.014 – 0.079

Replace cylinder liner (only B rank is supplied)

Replace liner or block Replace liner Replace liner or block Replace liner Replace liner or block

*1 shows the dimension as an individual part

11-210

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

MAIN CIRCULATION SYSTEM

1. 2. 3. 4. 5. 6. 7.

Piston (FCD piston) Connecting rod bushing Piston pin Crankshaft Crankshaft gear (No. of teeth :33) Connecting rod cap Connecting rod bearing

11-212

8. 9. 10. 11. 12.

Connecting rod Connecting rod cap mounting bolt Top ring Second ring Oil ring

a. Re-entrant combustion chamber

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

CRANKSHAFT : Stamp forging : Induction hardening on journal portion and fillet portion PISTON Material

•

: FDC piston (Thin ductile cast iron structure, reentrant combustion chamber)

The FCD piston has the following features; (1) The FCD piston has high heat resistance. (2) Since the FCD piston has less thermal expansion coefficient, the clearance between it and liner can be reduced. (3) Since the FCD piston has high strength, the top ring can be installed to a higher place and the combustion chamber loss area can be reduced. Accordingly,an engine having the FCD piston has high combustion efficiency, produces lower noise and exhaust gas of better color, and can output higher power.

125-3 SERIES

ENGINE BODY

PISTON RING Top ring

Second ring

Oil ring

Both surface keystone, Barrel face, Hard chrome plating

Keystone, inner cut, taper face, hard chrome plating

Hard chrome plating with coil expander

CONNECTING ROD LUBE OIL HOLE :Provided PISTON COOLING FROM CONNECTING ROD TIP :Provided

11-213

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

CRANKSHAFT

MAINTENANCE STANDARD No. Item 1

Standard

Repair limit

0.140 – 0.315

0.50

End play

Outside diameter of main journal 2 Roundness of main journal Clearance of main journal

Outside diameter of crankpin journal 3 Roundness of crankpin journal Clearance of crankpin journal 4

Criteria

Standard STD 110 0.25 U.S. 109.75 0.50 U.S. 109.50 0.75 U.S. 109.25 1.00 U.S. 109.00 Standard 0 – 0.010 Standard 0.062 – 0.106 Standard STD 80 0.25 U.S. 79.75 0.50 U.S. 79.50 0.75 U.S. 79.25 1.00 U.S. 79.00 Standard 0 – 0.010 Standard 0.046 – 0.090

Repair limit 109.88 109.63 –0.050 109.38 –0.070 109.13 108.88 Repair limit 0.020 Clearance limit 0.27 Tolerance Repair limit 79.88 79.63 –0.050 79.38 –0.070 79.13 78.88 Repair limit 0.020 Clearance limit 0.24

Tolerance

Standard

Repair limit

0 – 0.09

0.20

Bend of crankshaft

11-214

Unit: mm Remedy Repair by using over size thrust bearing or replace

Repair by using over size bearing or replace

Replace main bearing

Repair by using undersize bearing or replace

Replace connecting rod Repair by using under size bearing or replace

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

PISTON

11-216

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

MAINTENANCE STANDARD No. Check item

1

Outside diameter of piston

Thickness of piston ring

2 3

Width of piston ring groove

4 Clearance between piston ring and ring groove

Piston ring gap

Outside diameter of piston pin 5

–

Inside diameter of piston pin hole Clearance between piston pin and piston Weight of piston

125-3 SERIES

ENGINE BODY

Criteria Tolerance –0.090 –0.105 –0.075 –0.090

Rank

Standard

A or S

125

B or L

125

No.

Measuring point

Standard

2

Top ring

2.42

3

Second ring

2.4

4

Oil ring

4.0

2 3

Top ring Second ring

4

Oil ring

2 3 4 2 3

Measuring point Top ring Second ring Oil ring Top ring Second ring

4

Oil ring

No.

Standard size

Unit: mm Remedy Repair limit 124.80 124.80 Tolerance –0.005 –0.025 –0.010 –0.030 –0.010 –0.030

Judge using groove wear gauge +0.040 +0.020 Clearance limit

4.0 Standard

Judge using groove wear gauge 0.030 – 0.070 0.37 – 0.47 0.50 – 0.60

0.15 2.0 1.5

0.28 – 0.40

1.0

Standard

Tolerance 0 –0.006 +0.045 +0.035 Clearance limit

0.035 – 0.051

0.063

48 48

3,000g

Replace piston (supplied only as rank A or S)

Permissible range: ± 60g

Replace piston ring

Replace piston

Replace piston or piston ring Replace piston ring or cylinder liner Replace piston pin Replace piston Replace piston or piston pin Replace piston

11-217

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

CONNECTING ROD

MAINTENANCE STANDARD No.

1

Inside diameter of bushing at connecting rod small end Clearance between bushing at connecting rod small end and piston pin

2

Inside diameter of bushing hole at connecting rod small end

3

Inside diameter of bearing at connecting rod big end (crankpin journal)

4

Inside diameter of bearing hole at connecting rod big end Thickness of connecting rod bearing

5

6

—

Unit: mm

Item Standard

Weight of connecting rod

11-218

Remedy Repair limit

+0.041 +0.025

48

48.08

Standard

Clearance limit

0.025 – 0.047

0.10

Standard 53 Standard 80 85

Tolerance +0.020 –0.010 +0.022 –0.004

2.5

Tolerance +0.030 +0.030 Repair limit 80.12 —

+0.005 –0.005

Replace connecting rod Replace bearing Replace connecting rod Replace bearing

— Standard

Repair limit

A : Bend

0 – 0.20

0.25

B : Twist

0 – 0.30

0.35

Order 1st step

Target Nm{kgm} 98{10}

Range Nm{kgm} 93 – 103(9.5 – 10.5)

2nd step

Retighten with 90º

90º – 120º

Permissible range: Variation between weights on the machine: max. 140g

Replace bushing Replace bushing or piston pin

Measure after tightening connecting rod cap with specified torque

Bend and twist of connecting rod

Tihgtening torque of connecting rod cap mounting bolt (Coat the bolt threads and nut seats with engine oil)

Criteria Tolerance

Replace connecting rod

Retighten

Replace

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

FLYWHEEL AND FLYWHEEL HOUSING WITHOUT PTO

1. 2. 3. 4.

Flywheel housing Ring gear Flywheel Rear seal

125-3 SERIES

★ Details may differ according to the machine model.

Machine model

No. of teeth on ring gear

No. of internal teeth on flywheel

WA470-5 WA480-5

137

72

11-219

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

FLYWHEEL AND FLYWHEEL HOUSING

MAINTENANCE STANDARD No. Item Face runout of flywheel 1 housing Radial runout of flywheel 2 housing

Criteria Repair limit: 0.35

Tightening torque of flywheel housing mounting bolts

Order

Target Nm{kgm}

1st step

142{14.5}

2nd step

279{28.5}

–

68{7}

M16

M10 4

Face runout of flywheel

Repair limit: 0.20

5

Radial runout of flywheel

Repair limit: 0.15

6

Tightening torque of flywheel mounting bolt (Coat the bolt threads with engine oil)

11-220

Repair by reassembling

Repair limit: 0.30 Bolt

3

Unit: mm Remedy

Tightening order

Order

Target Nm{kgm}

1st step

147{15}

2nd step

289{29.5}

Range Nm{kgm} 83 – 196 {8.5 – 20} 245 – 309 {25 – 31.5} 59 – 74 {6 – 7.5}

Retighten

Repair by reassembling Range Nm{kgm} 127 – 166 {13 – 17}

Retighten

270 – 309 {27.5 – 31.5}

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

VIBRATION DAMPER

1. 2. 3. 4. 5.

ENGINE BODY

★ Details may differ according to the machine model.

Vibration damper Pin Crankshaft pulley Crankshaft pulley mounting bolt Vibration damper mounting bolt

125-3 SERIES

11-221

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

VIBRATION DAMPER

MAINTENANCE STANDARD No. Item 1 Visual check Radial runout of vibration 2 damper Face runout of vibration 3 damper. Tightening torque 4 of vibration damper mounting bolt

11-222

Unit: mm Remedy Replace

Criteria Not appear any cracks on the rubber part. Repair limit :0.80

Replace

Repair limit :0.80

Replace

Bolt

Target Nm {kgm}

Range Nm{kgm}

M12

111{11.3}

98 – 123{10 – 12.5}

Retighten

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

TIMING GEAR

1. 2. 3. 4. 5. 6.

Cylinder block Water pump drive gear Main idler gear, large Main idler gear, small Oil pump drive gear Idler gear for oil pump

11-224

(No. of teeth: 22) (No. of teeth: 57) (No. of teeth: 38) (No. of teeth: 21) (No. of teeth: 25)

7. Fuel supply pump drive gear (No. of teeth: 44) 8. Timing gear cover 9. Camshaft gear (No. of teeth: 44) 10. Crankshaft gear (No. of teeth: 33) 11. Crankshaft A,B,C: Match marks for timing gears

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

125-3 SERIES

ENGINE BODY

11-225

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

TIMING GEAR

MAINTENANCE STANDARD No. Item Measuring point A B —

Backlash of each gears

C a b c

1

2 3 4

Clearance between main idler gear bushing and shaft Clearance between oil pump idler gear and shaft End play of main idler gear End play of oil pump idler gear

11-226

Standard size 47.5 35

Unit :mm Remedy

Criteria Gears Crankshaft gear and main idler gear (Large) Main idler gear (Small) and camshaft gear Camshaft gear and fuel supply pump drive gear Main idler gear (Large) and water pump drive gear Main idler gear (Large) and oil pump idler gear Oil pump idler gear and oil pump drive gear Tolerance Shaft Hole +0.165 +0.115 +0.140 +0.100 –0.025 –0.040

+0.065 0

Standard

Repair limit

0.116 – 0.359 0.105 – 0.325 0.105 – 0.325

Replace 0.6

0.076 – 0.366 0.105 – 0.337 0.082 – 0.389 Standard clearance

Clearance limit

0.025 – 0.060

0.20

0.025 – 0.105

0.20

Standard 0.05 – 0.17

Repair limit 0.4

0.05 – 0.21

0.4

Replace bushing

Replace thrust bearing

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

VALVE MECHANISM

1. 2. 3. 4.

Rocker arm shaft Cam roller Cam roller pin Engine speed output gear (No. of teegh: 14) 5. Camshaft 6. Camshaft gear (No. of teeth : 44) 7. Adjustment screw

11-228

8. 9. 10. 11. 12. 13.

Locknut Crosshead Upper valve spring seat Intake valve Valve spring Lower valve spring seat (Intake and exhaust)

14. 15. 16. 17. 18. 19. 20. 21.

Adjustment screw Locknut Rocker arm Push rod Cam follower Valve cotter Exhaust valve Valve stem seal (Intake and exhaust)

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

No. 1 cylinder intake side CAMSHAFT • Stamp forging • Journal portion, cam portion: Induction hardening

ENGINE BODY

No. 1 cylinder exhaust side VALVE TIMING

List of part (related to valve) to be set in place Parts set in Crosshead Valve Valve spring (Color code) Spring seat (Lower) Valve guide Stem seal

125-3 SERIES

IN 6150-42-5610 6150-42-4110 6150-41-4450 (White)

EX 6150-42-5610 6150-42-4210 6150-41-4450 (White)

6150-41-4430

6150-41-4430

6150-11-1370 6150-41-4570

6150-11-1370 6150-41-4570

11-229

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

CAMSHAFT

MAINTENANCE STANDARD No. Item 1

2

End play Outside diameter of camshaft journal Clearance of camshaft journal

3

Bend of camshaft

4

Cam height

11-230

Criteria Standard 0.15 – 0.35 Standard

Repair limit 0.50 Tolerance –0.080 60 –0.110 Standard Clearance limit 0.080 – 0.180 0.28 Repair limit: 0.03 (Total indicator reading) Standard Tolerance Repair limit +0.395 52 51.73 +0.195

Unit: mm Remedy Replace thrust plate Replace Replace cam bushing

Replace

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

CAM FOLLOWER AND PUSH ROD

MAINTENANCE STANDARD No. Item Standard Outside diameter of cam follower shaft 1 Inside diameter of cam follower shaft hole 2

19.8 19.8

Outside diameter of cam roller

32

Inside diameter of cam roller

13

Outside diameter of cam roller pin

13

3

Criteria Tolerance –0.040 –0.050 +0.020 0 –0.250 –0.280 –0.262 –0.287 –0.364 –0.376

Unit: mm Remedy Repair limit 19.73

31.70 12.78

Replace

12.62

Standard

4

Radius of push rod ball end

5

Radius of push rod socket end

6

Bend of push rod Tightening torque of cam follower housing mounting bolt

7

125-3 SERIES

Tolerance 0 12.7 –0.20 0 12.7 –0.20 Repair limit: 0.50 (Total indicator reading) 51±7.4Nm{5.25±0.75kgm}

Retighten

11-231

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

VALVE AND VALVE GUIDE

11-232

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

MAINTENANCE STANDARD No.

Unit: mm

Item

1

Amount of valve sinking

2

Thickness of valve lip

3

Valve seat angle

Outside diameter of valve stem

Criteria Valve Intake Exhaust Valve Intake Exhaust Valve Intake Exhaust Valve Intake Exhaust

4

Inside diameter of valve guide Clearance between valve guide and valve stem Bend of valve stem

5

Protrusion of valve guide Free lengh of valve spring

6

Installed load of valve spring

Squarence of valve spring

125-3 SERIES

Before inserting After inserting Valve Intake Exhaust

Remedy

Standard 1.88 1.20

Tolerance Repair limit ±0.10 2.51 ±0.10 1.90 Standard Repair limit 2.10 1.7 1.50 1.2 Standard Tolerance 30º ±0º15' 45º ±0º15' Standard Tolerance –0.045 9 –0.065 –0.050 9 –0.070 +0.015 9 –0.003 +0.009 9 –0.011 Standard Clearance limit 0.034 – 0.074 0.22 0.039 – 0.079

0.24

Repair limit: 0.01 (Total indicated runout for 100 mm) Standard size Tolerance 20 ±0.2 Valve Color code Free length Repair limit Intake White 75.2 — Exhaust White 75.2 — Color Installed Installed load Repair limit Valve code length 520±25 N 468 N Intake White 56.0 {53.0±2.6 kg} {47.7 kg} 520±25 N 468 N Exhaust White 56.0 {53.0±2.6 kg} {47.7 kg}

Replace valve or valve seat Replace

Repair or replace

Replace

Replace

Replace valve guide on valve stem Replace Repair

Replace

Repair limit: 2º (for both end)

11-233

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

ROCKER ARM SHAFT

MAINTENANCE STANDARD No.

Item Outside diameter of rocker arm shaft

1

Inside diameter of rocker arm shaft hole Clearance between rocker arm shaft and rocker arm Bend of rocker arm shaft

2

Tightening torque of rocker arm adjustment nut

3

Valve clearance (at hot or cold)

11-234

Criteria Standard

Remedy

Standard

Tolerance –0.053 –0.066 +0.033 –0.027 Clearance limit

0.026 – 0.099

0.130

28.6 28.6

Repair limit :0.20 (Total indicated runout) 53 – 65Nm (5.4 – 6.6kgm) Valve Intake Exhaust

Standard 0.33 0.71

Tolerance ±0.02 ±0.02

Replace rocker arm shaft Replace rocker arm Replace rocker arm or rocker arm shaft Replace rocker arm shaft Retighten Adjust

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ENGINE BODY

CROSSHEAD

MAINTENANCE STANDARD No. Item Standard Inside diameter of crosshead 1 Outside diameter of crosshead guide 2 3

Protrusion of crosshead guide Tightening torque of crosshead lock nut

125-3 SERIES

11 11 45.5

Criteria Tolerance +0.075 +0.025 +0.011 0 ±0.25

Unit: mm Remedy Repair limit

66±7.4 Nm{6.7±0.75 kgm}

11.18

Replace

10.95 —

Repair Retighten

11-235

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

LUBRICATION SYSTEM

LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ★ Details may differ according to the machine model.

1. 2. 3. 4. 5. 6. 7.

Oil pan Oil strainer Oil pump Relief valve Oil cooler Thermo valve Oil filter

11-302

8. 9. 10. 11. 12. 13. 14.

Safety valve Crankshaft Piston cooling nozzle Piston Camshaft Cam follower Rocker arm

15. 16. 17. 18.

Intake, exhaust valve Timing gear Turbocharger Fuel supply pump assembly

W. Cooling water

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

LUBRICATION SYSTEM

OIL PUMP

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Pump drive gear (No.of teeth :21) Bushing Pump cover Drive gear Pump body Drive shaft Main relief valve Valve spring Retainer Driven shaft Bushing Driven gear

125-3 SERIES

OIL PUMP • Type: • Pump speed: MAIN RELIEFE VALVE • Set pressure:

Gear pump Engine speed x 1.571 +0.1

0.7 0 MPa {7 +10 kg/cm2}

11-303

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

LUBRICATION SYSTEM

OIL PUMP

MAINTENANCE STANDARD No.

1

Unit: mm

Item

Axial clearance of pump gear

Criteria Standard size 47

2

3

4

5

6 7 8 9

Radial clearance of pump gear

Interference between pump drive gear and drive shaft Clearance between drive shaft and cover bushing Interference between pump gear and drive shaft Clearance between drive shaft and body bushing Clearance between driven shaft and body Clearance between driven shaft and gear bushing Interference between driven shaft and cover

11-304

Standard size

Tolerance Gear Body thickness depth 0 +0.065 –0.025 +0.040 Tolerance Gear O.D. Gear I.D. –0.15 +0.060 –0.21 +0.600 Tolerance

Remedy Standard clearance

Clearance limit

0.03 – 0.09

0.10

Standard clearance

Clearance limit

Shaft

Hole

18

+0.106 +0.088

+0.065 +0.047

0.03 – 0.10 Standard interference or clearance 0.023 – 0.059

18

+0.106 +0.088

+0.173 +0.146

0.040 – 0.085

18

+0.106 +0.088

+0.063 +0.028

0.025 – 0.078

18

–0.006 –0.024

+0.061 +0.034

0.040 – 0.085

18

+0.090 +0.070

+0.129 +0.102

0.012 – 0.059

18

+0.090 +0.070

+0.147 +0.122

0.032 – 0.077

18

+0.090 +0.070

+0.040 +0.020

0.030 – 0.068

51.4 Standard size

Replace gear

0.13 Clearance limit

Replace

— Replace bushing —

Replace Replace bushing

—

Replace Replace bushing

—

Replace

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

LUBRICATION SYSTEM

MAIN RELIFE VALVE

MAINTENANCE STANDARD No. Item 1

Relief valve set pressure

2

Clearance between valve and body

3

Relief valve spring

125-3 SERIES

Criteria +0.1

Unit: mm Remedy

+1

0.7 0 MPa {7 0 kg/cm2} Standard Tolerance Standard Clearance Shaft Hole size clearance limit –0.040 +0.043 0.040– 16 –0.060 0 0.103 Standard size Repair limit Installed Installed Installed Free length Free length length load length 120 N 110 N 48.8 38.8 {12.2 kg} {11.2 kg}

Replace

11-305

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

OIL FILTER Remote mounting type

1. Safety valve 2. Filter head 3. Cartridge A. Oil inlet B. Oil outlet

11-306

LUBRICATION SYSTEM

★ Details may differ according to the machine model.

Oil filter • Filtration area: 0.42 m2 (Full-flow) Safety valve • Set pressure:

245 ± 20 kPa {2.5 ± 0.2 kg/cm2}

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

LUBRICATION SYSTEM

SAFETY VALVE

1. 2. 3. 4.

Safety valve Filter head Spring Cap

MAINTENANCE STANDARD No. Item 1 Safety valve set pressure

125-3 SERIES

Criteria 245 ± 20 kPa {2.5 ± 0.2 kg/cm2}

Unit :mm Remedy Replace

11-307

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

LUBRICATION SYSTEM

OIL COOLER

1. 2. 3. 4. 5.

Thermostat housing Thermostat Cooler cover Cooler element Strainer

THERMOSTAT FUNCTION • Valve cracking temperature: 85 ± 1.5ºC • Full opening temperature: 100ºC • Full opening left: Min.8 mm

a. b. c. d.

Water drain port Oil inlet To engine each part Water inlet

Oil cooler • Effective area:

11-308

0.575m2

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

LUBRICATION SYSTEM

OIL COOLER

MAINTENANCE STANDARD No.

1

Item Lift of thermostat valve Opening and closing of valve in thermostat

125-3 SERIES

Unit: mm Criteria Min.11 (Check after immersion in a hot oil bath of 100ºC for 4 or 5 minutes.) Valve must be close fully when immersed in a hot oil bath (85ºC) for 4 or 5 minutes after being immersed in a hot oil bath (100ºC) to fully open the valve.

Remedy

Replace

11-309

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

FUEL SYSTEM FUEL SYSTEM DIAGRAM CRI SYSTEM

1. Fuel tank 2. Fuel supply pump assembly 2A. PCV 2B. High-pressure pump 2C. Priming pump 2D. Feed pump 2E. Bypass valve 2F. G revolution sensor

11-402

★ CRI is short for Common Rail Injection. Hereinafter called CRI.

3. 4. 5. 6. 7. 8. 9. 10. 11.

Fuel filter Overflow valve Common rail Pressure limiter Flow damper Injector assembly Fuel cooler ECU (Engine Control Unit) NE revolution sensor

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

OUTLINE OF CRI SYSTEM OUTLINE The CRI system detects the condition of the engine (engine speed, accelerator angle, cooling water temperature, etc.) from various sensors, and uses a microcomputer to carry out overall control of the fuel injection amount, fuel injection timing, and fuel injection pressure to operate the engine under the optimum conditions. The computer also carries out self-diagnosis of the main components, and if any abnormality is found, it carries out diagnosis and sends an alarm to inform the operator. It also has a fail-safe function to stop the engine according to the location of the abnormality and a backup function to switch the control method to make it possible to continue operation.

STRUCTURE The CRI system can be divided in terms of function into the fuel system and control system. 1. Fuel system The high-pressure fuel generated by the fuel supply pump goes from the common rail and is distributed to each cylinder. The start and finish of injection is controlled by opening or closing the nozzle needle valve by using an electromagnetic valve inside the injector.

2. Control system The ECU (Engine Control Unit) carries out control by calculating the length of time and the timing of sending current to the injector by using the signals from the sensors installed to the engine and various parts of the machine so that it injects a suitable amount at the suitable injection timing. The control system and electrical components can be broadly divided into the sensors, computer, and actuators.

125-3 SERIES

11-403

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

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

11-404

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

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

1. 2. 3. 4. 5.

3-protrusion type cam Overflow valve Drive gear No.1 high-pressure pump PCV (discharge control valve)

125-3 SERIES

6. 7. 8. 9.

No.2 high-pressure pump Priming pump Feed pump G revolution sensor gear

11-405

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

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

11-406

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

4) PCV (discharge control valve) The PCV acts to adjust the fuel discharge amount from the fuel supply pump to adjust the common rail fuel pressure. The discharge amount sent to the common rail from the fuel supply pump is determined by the timing of the electric current sent to the PCV.

5) Feed pump The feed pump is built into the fuel supply pump assembly. It sucks up the fuel from the fuel tank, sends it through the fuel filter, and into the high-pressure pump chamber. The feed pump rotor is driven by the camshaft, and when the outer/inner rotors start to turn respectively, fuel is sucked in at the suction side and sent out at the discharge size according to the change in the size of space created by the outer/inner rotors.

2. Common rail 1) Structure The common rail acts to distribute the high-pressure fuel generated by the high-pressure pump and send it to the injector of each cylinder. The common rail is equipped with a common rail fuel pressure sensor, flow damper, and pressure limiter. The flow damper is equipped with a fuel injection pipe and sends high-pressure fuel to the injector. The piping of the pressure limiter is arranged to return to the fuel tank.

125-3 SERIES

11-407

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

2) Flow damper The flow damper reduces the pressure pulses inside the high-pressure piping and acts to supply fuel at a stable pressure to the injector. If any excess fuel flow out, it acts to shut off the fuel passage and prevent any abnormal outflow of fuel. If any abnormal outflow is generated, high pressure bears on the piston, so the piston and ball move to the right as shown in the diagram and come into contact with the seat. As a result, the fuel passage is shut off.

3) Pressure limiter The pressure limiter opens if any abnormal high pressure is generated, and acts to allow the pressure to escape. It is actuated (opens) if the fuel pressure in the common rail reaches approx. 140 MPa {1,430 kg/cm2}, and when the pressure goes down to approx. 30 MPa {310 kg/cm2}, it is restored (closes) and acts to maintain the pressure.

11-408

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

4) Common rail fuel pressure sensor The common rail fuel pressure sensor is installed to the common rail and detects the fuel pressure. The sensor is a semi-conductor pressure sensor. This uses the characteristic of silicon, which changes the electrical resistance if pressure is applied to it.

3. Injector 1) Outline The function of the injectors is to inject high-pressure fuel from the common rail according to the signal from the ECU into the injection chamber of the engine at the optimum fuel injection timing, fuel injection amount, fuel injection ratio and spray condition. The TWV (Two-Way electromagnetic Valve) controls the pressure in the control chamber in order to control the start and finish of the fuel injection. The orifice controls the angle of opening of the nozzle to control the fuel injection ratio. The hydraulic piston transmits force to the needle valve of the nozzle according to the pressure in the control chamber. The nozzle acts to spray out the fuel. When fuel injection starts (TWV ON)

125-3 SERIES

When fuel injection finishes (TWV OFF)

11-409

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

2) Structure The injector consists of a conventional nozzle, 2-way electromagnetic valve, hydraulic piston, and orifice which controls the fuel injection ratio.

1. 2. 3. 4.

Inlet connector Terminal Upper body Solenoid

11-410

5. 6. 7. 8. 9.

Outer body Inner valve Valve body OUT orifice IN orifice

Valve assembly

10. 11. 12. 13. 14.

Control chamber Command piston Spring Pressure pin Nozzle assembly

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

3) Operation The TWV of the injector is a 2-way valve and consists of inner valve (fixed) (4) and outer valve (variable) (3). It is precisely joined to the same shaft. It forms both the inner and outer seats, and when the TWV is switched ON/OFF, one of the two seats is selected to open. i) No injection of fuel When no electric current is being sent to the solenoid, outer valve (3) is pushed down by the valve spring and the fuel pressure, and outer seat (5) is closed. High pressure from the common rail is applied to control chamber (7), so nozzle (8) is closed and there is no fuel injection. ii) Start of fuel injection When electric current starts to flow to the TWV, outer valve (3) is pulled up by the electromagnetic force and outer seat (5) opens. As a result, fuel flows out from the control chamber through orifices (2) and (6), the nozzle needle goes up, and fuel injection starts. Because of the action of orifices (2) and (6), the fuel injection ratio is gradually raised. If electric current continues to be sent, the maximum fuel injection ratio is reached. iii) Completion of fuel injection When the flow of electric current to the TWV is stopped, outer valve (3) goes down under the force of the valve spring and the fuel pressure, and outer seat (5) closes. When this happens, the high-pressure fuel in the common rail is suddenly applied to the control chamber, so the nozzle is suddenly closed and a sharp completion of the fuel injection is obtained.

No injection of fuel 1. 2. 3. 4. 5. 6.

Hydraulic piston Orifice 1 Outer valve Inner valve Outer seat Orifice 2

125-3 SERIES

Start of fuel injection

Completion of fuel injection

7. Control chamber 8. Nozzle A. Common rail (always at high pressure) (18 to 130 MPa{180 to 1,330 kg/cm2}) B. Leak

11-411

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

4) Electric circuit diagram

High voltage (118V) is applied to the wiring harnesses connected to the ECU and EDU COMMON1, COMMON2, and TWV #1 to #6, so be careful to avoid electrocution.

11-412

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

4. Sensors and relays NE revolution sensor (crank angle) 1) NE revolution sensor (crank angle sensor) When the signal hole in the flywheel passes the sensor, the line of magnetic force passing through the coil changes and an AC voltage is generated in the coil. Signal holes are provided in the flywheel every 7.5o, but there are 3 places where there is no hole, so there is a total of 45 signal holes. Therefore, for every 2 turns of the engine, 90 pulses are output. From this signal, the engine speed and the crank angle for every 7.5o is detected. 2) G revolution sensor (cylinder judgement sensor) In the same way as the NE revolution sensor, the change in the line of magnetic force passing through the coil is used to generate an AC voltage. The disc-shaped gear provided in the center of the camshaft of the high-pressure pump has teeth cut (a notch is made) every 120o, and in addition, there is an extra tooth at one point. Therefore, for every 2 turns of the engine, 7 pulses are output. The combination of the NE revolution sensor pulse and G revolution sensor pulse is recognized as the No. 1 cylinder standard pulse.

125-3 SERIES

G revolution sensor (cylinder judgement)

11-413

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

3) Water temperature sensor The water temperature sensor detects the temperature of the engine cooling water and sends it to the ECU. The sensor uses a thermistor which changes the resistance value according to the temperature. It applies voltage to the thermistor and detects with the voltage divided into the resistance value inside the computer and the resistance value of the thermistor.

4) Fuel temperature sensor The fuel temperature sensor detects the temperature of the fuel and sends it to the ECU. The sensor uses a thermistor which changes the resistance value according to the temperature. It applies voltage to the thermistor and detects with the voltage divided into the resistance value inside the computer and the resistance value of the thermistor.

11-414

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL SYSTEM

Controls The CRI system control of the fuel injection amount and fuel injection timing is carried out more suitably than on the mechanical governor and timer used in conventional fuel injection pumps. The system control carries out the necessary calculation in the ECU from the signal from the sensors installed to the engine and machine, and controls the timing and length of time that electricity is sent to the injector so that it can carry out the optimum fuel injection at the optimum fuel injection timing. 1. Control function for fuel injection amount The function to control the fuel injection amount replaces the conventional function of the governor. It functions to control the fuel injection so that the optimum fuel injection amount is injected, based on the signal from the engine speed and accelerator angle. 2. Control function for fuel injection timing The function to control the fuel injection timing replaces the conventional function of the timer. It functions to control the fuel injection so that the optimum fuel injection timing is carried out, based on the signal from the engine speed and fuel injection amount. 3. Control function for fuel injection pressure (common rail fuel pressure control function) The function to control the fuel injection pressure (common rail fuel pressure control function) measures the fuel pressure with the common rail fuel pressure sensor. This function feeds back to the ECU and controls the amount of fuel discharged from the fuel supply pump. It controls the pressure feedback so that it matches the optimum value (command value) set according to the engine speed and fuel injection amount.

125-3 SERIES

11-415

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL PIPING

1. 2. 3. 4. 5. 6. 7. 8.

Fuel injection pipe (No. 1 cylinder) Fuel injection pipe (No. 2 cylinder) Fuel injection pipe (No. 3 cylinder) Fuel injection pipe (No. 4 cylinder) Fuel injection pipe (No. 5 cylinder) Fuel injection pipe (No. 6 cylinder) Fuel return pipe Common rail

11-416

FUEL SYSTEM

★ Details may differ according to the machine model.

9. 10. 11. 12. 13. 14. 15.

Priming pump Feed pump Oil inlet pipe (for pump lubrication oil) High-pressure pump Fuel supply pump drive gear (No. of teeth: 44) Overflow valve PCV

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

A. B. C. D. E. F. G.

Fuel inlet To fuel filter From fuel filter To injector Fuel return (between overflow valve and fuel tank) Fuel return (between injector and fuel tank) Engine oil (to fuel supply pump)

125-3 SERIES

FUEL SYSTEM

Fuel supply pump • Maker: Nihon Denso • Type: Denso ECD-U2 • Lubrication method: Forced lubrication using engine oil

11-417

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL COOLER

1. Mount bracket 2. Core A. From fuel tank B. To fuel supply pump

11-418

FUEL SYSTEM

★ Details may differ according to the machine model.

Specifications • • •

Cooling method: Air cooled Core type: AL-CFT-1 Heat dissipation surface: 3.31m2

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

FUEL FILTER

1. Air bleed plug 2. Filter head 3. Cartridge

FUEL SYSTEM

★ Details may differ according to the machine model.

Specifications •

Filtering area: 1.0 m2

A. Fuel inlet B. Fuel outlet

125-3 SERIES

11-419

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

COOLING SYSTEM

COOLING SYSTEM COOLING SYSTEM CHART ★ Details may differ according to the machine model.

1. 2. 3. 4. 5. 6.

Radiator Thermostat Water pump Water temperature gauge Water manifold (Integrated with cylinder block) Corrosion resistor

7. 8. 9. 10. 11. 12.

Cylinder head Cylinder liner Piston Cylinder block Oil cooler Air compressor

A. Lubrication oil B. Cooling water (water manifold to cylinder block)

125-3 SERIES

11-501

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

COOLING SYSTEM

WATER PUMP MOUNTING

1. 2. 3. 4. 5.

Thermostat Housing cover Thermostat housing Water pump Oil cooler

★ Details may differ according to the machine model.

A. B. C. D. E. F.

To radiator (coolant) From engine each part (coolant) To engine each part thru oil cooler (coolant) From radiator (coolant) From oil pump (oil) To engine each part (oil)

a. Outlet for car heater b. Water temperature gauge pick-up c. Coolant drain plug

11-502

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

COOLING SYSTEM

WATER PUMP

1. Water pump drive gear (No. of teeth: 22) 2. Pump shaft 3. Ball bearing 4. Pump body 5. Water seal 6. Impeller 7. Pump cover

WATER PUMP Type: Pump speed:

Centrifugal gear drive. Engine speed x 1.5

a. From thermostat b. From radiator c. To engine each part

125-3 SERIES

11-503

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

COOLING SYSTEM

WATER PUMP

MAINTENANCE STANDARD No.

1

2

3

4

Unit: mm

Item Interference between impeller and shaft Interference between drive gear and shaft Clearance between impeller and body

Abrasion of seal ring in water seal

11-504

Criteria Standard size 15.9 20.0

Remedy

Tolerance Shaft +0.018 +0.005

Hole –0.020 –0.050

+0.015 +0.002

–0.023 –0.053

Standard interference 0.025 – 0.068 0.025 – 0.068

Replace impeller Replace gear

Standard : 0.30 – 1.10 (Including end play)

Repair limit A: 1.5

Replace

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

THERMOSTAT MOUNTING

COOLING SYSTEM

★ Details may differ according to the machine model.

1. Thermostat 2. Thermostat housing a. To radiator b. To water pump

125-3 SERIES

11-505

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

COOLING SYSTEM

THERMOSTAT

Cool (full close)

1. 2. 3. 4. 5. 6.

Thermostat Seal Valve Body Piston Sensor

7. 8. 9. a. b. c.

Expander Sleeve Flang To water pump (bypass) To radiator From engine

Warm (full open)

Function • Opening temperature: 71ºC • Full opening temperature: 90ºC • Valve lift: Min. 10 mm

MAINTENANCE STANDARD No.

Check item Lift of thermostat to fully open position

1

Opening/closing of thermostat

11-506

Unit: mm Criteria

Remedy

Min. 10 mm (soak the valve in oil bath at 90ºC for 4 to 5 minutes to check) Check that the valve closes fully when the water temperature has gone down to 71°C from 90°C when the valve was fully open. (Soak the valve in a water bath for 4 to 5 minutes to check)

Replace

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

COOLING SYSTEM

CORROSION RESISTOR

1. 2. 3. 4. 5.

Head Cartridge Element (Paper) Element (Chemicals) Spring

CORROSION RESISTOR • Filtration area: 0.5 m2

A. Water inlet B. Water outlet

125-3 SERIES

11-507

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM ALTERNATOR MOUNTING SA6D125E-3 SAA6D125E-3 (WA430-5, WA470-5, WA480-5)

1. 2. 3. 4.

Alternator pulley Alternator drive belt Clankshaft pulley Adjusting bolt

11-902 (7)

★ Details may differ according to the machine model.

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

SAA6D125E-3 (HM300-1, PC400-7, PC450-7)

1. 2. 3. 4. 5.

ELECTRICAL SYSTEM

★ Details may differ according to the machine model.

Alternator pulley Alternator drive belt Crankshaft pulley Adjusting bolt Fan pulley

125-3 SERIES

11-902-1 (7)

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ELECTRICAL SYSTEM

ALTERNATOR WITH BUILT-IN REGULATOR (OPEN TYPE, 35A)

1. 2. 3. 4. 5.

Alternator Alternator pulley Terminal B Terminal R Terminal E

6. Internal electric circuit diagram 6A. Primary energized resistance 6B. Regulator 6C. Field coil Pulley

Engine

Machine model

Type

Specification

SAA6D125E-3

PC400-7, PC450-7

Nikko Denki Open type (brushless)

24V, 35A

125-3 SERIES

No . of steps

Outside diameter (mm)

Weight (kg)

2

93

8

11-903 (7)

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ELECTRICAL SYSTEM

WITH BUILT-IN REGULATOR (OPEN TYPE, 50A)

1. 2. 3. 4. 5.

Alternator Alternator pulley Terminal B Terminal R Terminal E

6. Internal electric circuit diagram 6A. Primary energized resistance 6B. Regulator 6C. Field coil Pulley

Engine

SA6D125E-3 SAA6D125E-3

11-903-1 (8)

Machine model

Type

D65EX, PX-15, D85EX, PX-15 WA430-5, WA470-5, WA480-5, HD255-5

Nikko Denki Open type (brushless)

Specification

No . of steps

Outside diameter (mm)

Weight (kg)

24V, 50A

2

75

11

24V, 50A

2

75

11

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ELECTRICAL SYSTEM

WITH BUILT-IN REGULATOR (OPEN TYPE, 75A)

1. 2. 3. 4. 5.

Alternator Alternator pulley Terminal R Terminal E Terminal B

6. Internal electric circuit diagram 6A. Alternator 6B. Regulator a. Load Pulley

Engine

Machine model

D65EX, PX-15, D85EX, PX-15 WA430-5 SAA6D125E-3 HM300-1 SA6D125E-3

125-3 SERIES

Type

Specification

Sawafuji Denki, Open type

Weight (kg)

No. of steps

Outside diameter (mm)

24V, 75A

2

95

13

24V, 75A 24V, 75A

2 2

95 95

13 13

11-903-2 (5)

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ELECTRICAL SYSTEM

WITH BUILT-IN REGULATOR (OPEN TYPE, 75A)

1. 2. 3. 4. 5.

Alternator Alternator pulley Terminal R Terminal E Terminal B

6. Internal electric circuit diagram 6A. Alternator 6B. Regulator a. Load Pulley

Engine

Machine model

D65EX, PX-15, D85EX, PX-15 WA430-5 SAA6D125E-3 HM300-1 SA6D125E-3

11-903-3 (7)

Type

Specification

Sawafuji Denki, Open type

Weight (kg)

No. of steps

Outside diameter (mm)

24V, 75A

2

95

13

24V, 75A 24V, 75A

2 2

95 95

13 13

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

STARTING MOTOR BUILT-IN SAFETY RELAY TYPE (7.5kW)

1. 2. 3. 4.

Pinion gear Starting motor (body) Magnetic switch External wiring diagram [2-pin connector type) (male)] 4A. Safety relay portion 4B. Starting motor portion

Engine

11-904 (5)

★ Details may differ according to the machine model.

5. External wiring diagram [3-pin connector type (male)] 5A. Safety relay portion 5B. Starting motor portion 6. Connector specitication A Type : 2-pin connector (male) B Type : 2-pin drip-proof connector (male) C Type : 3-pin drip-proof connector (male) D Type : 2-pin connector

B.C.R.S.E : Terminal

Machine model

Type

Specification

No. of pinion teeth

Weight (kg)

Connector type

Nikko Denki Waterproof, oilproof type

24V, 7.5kW

12

18

D

All machine

24V, 7.5kW

12

20

D

SA6D125E-3 SAA6D125E-3

ELECTRICAL SYSTEM

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

BUILT-IN SAFETY RELAY TYPE (11kW)

1. 2. 3. 4.

Pinion gear Starting motor (body) Magnetic switch External wiring diagram 4A. Safety relay portion 4B. Starting motor portion Engine

SA6D125E-3 SAA6D125E-3

125-3 SERIES

ELECTRICAL SYSTEM

★ Details may differ according to the machine model.

5. Connector specification A Type : 2-pin connector (male) B Type : 2-pin drip-proof connector (male)

B.C.R.S.E : Terminal

Machine model

Type

Specification

No. of pinion teeth

Weight (kg)

Connector type

All machine (option) All machine (option)

Nikko Denki Waterproof, oilproof type

24V, 11kW

12

18

—

24V, 11kW

12

18

A

11-905 (5)

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ELECTRICAL SYSTEM

STARTING AID ELECTRICAL INTAKE AIR HEATER For SA6D140E-3

1. Body 2. Heater coil 3. Connection circuit diagram (using 6 heaters) ELECTRICAL INTAKE AIR HEATER • Rated voltage: DC22 V • Rated current: 27.3 A (total: 164A with 6)

11-906 (5)

125-3 SERIES

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD

ELECTRICAL SYSTEM

ELECTRICAL INTAKE AIR HEATER SAA6D125E-3

1. 2. 3. 4.

Terminal Body Heater coil Wiring diagram

ELECTRICAL INTAKE AIR HEATER • Rated voltage: DC22 V • Rated current: 111 A

125-3 SERIES

11-907 (6)

12 TESTING AND ADJUSTING, TROUBLESHOOTING TESTING AND ADJUSTING DATA .............................................................................................................12- 4 STANDARD VALUE TABLE FOR ELECTRICAL PARTS ............................................................................12- 6 TESTING AND ADJUSTING TOOL LIST....................................................................................................12- 8 TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOT PRESSURE) ........................................................12- 9 MEASURING EXHAUST TEMPERATURE......................................................................................12- 10 ADJUSTING VALVE CLEARANCE ..................................................................................................12- 12 MEASURING COMPRESSION PRESSURE ...................................................................................12- 14 MEASURING BLOW-BY PRESSURE..............................................................................................12- 16 MEASURING ENGINE OIL PRESSURE..........................................................................................12- 17 MEASURING FUEL PRESSURE .....................................................................................................12- 18 ADJUSTING ENGINE SPEED SENSOR .........................................................................................12- 19 TESTING AND ADJUSTING FUEL INJECTION TIMING ................................................................12- 20 HANDLING EQUIPMENT IN FUEL SYSTEM ..................................................................................12- 26 RELEASING REMAINING PRESSURE IN FUEL SYSTEM ............................................................12- 26 BLEEDING AIR FROM FUEL CIRCUIT ...........................................................................................12- 27 REDUCED CYLINDER MODE OPERATION FOR ENGINE............................................................12- 29 CHECKING FOR LEAKAGE IN FUEL SYSTEM..............................................................................12- 30 ADJUSTING ENGINE STOP MOTOR LEVER.................................................................................12- 31 CALIBRATION DATA.............................................................................................................................12- 50 PERFORMANCE TEST RUN-IN STANDARD.........................................................................................................................12- 70 PERFORMANCE TEST STANDARDS.............................................................................................12- 74 TROUBLESHOOTING TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).....................................................................12-101 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) ............................................................12-201

125-3 SERIES

12-1 (5)

TESTING AND ADJUSTING k When carrying out testing and adjusting, or troubleshooting, stop the machine on level ground, fit safety pins, block the wheels, and apply the parking brake. k When carrying out operations with two or more workers, always use signals, and do not allow any unauthorized person near the machine.

k When-checking the water level, if the radiator cap is removed when the engine is hot, boiling water will spurt out and may cause burns, so always wait for the engine to cool down before checking the water level. k Be extremely careful not to touch any hot parts.

k Be extremely careful not to get caught in the fan or any other rotating parts.

k When removing the plugs or caps from places under hydraulic pressure, water pressure, or air pressure, release the internal pressure first. Fit the measuring tools securely before carrying out any testing, adjusting, or troubleshooting. a When using the standard values table for judgement in testing, adjusting or troubleshooting, it is necessary to be careful of the following points. 1. The standard values for the new machines in the standard values table are values given as reference from the standards for machines shipped from the factory. They should be used as values for estimating wear during operation or as target values when carrying out repairs. 2. The failure judgement standard values in the standard values table are values using estimated values based on the results of various tests and standard values for machines shipped from the factory. Use these values for reference together with the repair and operation history of the machine when judging failures. 3. Do not use this standard values table as a standard for judging claims.

12-2

125-3 SERIES

TESTING AND ADJUSTING

TESTING AND ADJUSTING DATA

TESTING AND ADJUSTING DATA IN-LINE FUEL INJECTION PUMP SPECIFICATION Engine model

SAA6D125E-3

Machine model

High idling speed Low idling speed

rpm rpm

Necessary starting speed

0ºC(Without starting aid)

rpm

Min.100

—

–20ºC(With starting aid)

rpm

Min.85

—

Intake resistance

At all speed

Boost pressure

At rated horsepower

kPa {mmH2O} kPa {mmHg} kPa {mmHg}

Max.2.94 {300} Min.80 {600} Min.80 {600}

7.47 {762} 60 {450} 73 {550}

ºC

Max.650

700

Max.4.5

6.5

Max.1.0

2.0

Max.1.0

2.0

Intake and exhaust system

Performance

Item Engine speed

Exhaust pressure (Turbine inlet press.) Exhaust temperature (Turbine inlet temp.)

Exhaust gas color

Engine body Lubrication system

At rated horsepower All speed (At 20ºC) Quick acceleration (Low idle → high idle) At rated horsepower

Oil pressure (Oil temperature: min.80ºC)

Oil temperature

Fuel injection pressure Fuel injection timing Radiator pressure valve Fan speed Fan belt tension

12-4

Unit

Bosch index Bosch index Bosch index

Permissible value 2,250 +500 770 +500

Intake valve

mm

0.33

—

Exhaust valve

mm

0.71

—

MPa {kg/cm2}

Min. 2.9 {30}

2.0 {20}

Oil temperature:40 – 60ºC Compression pressure (Engine speed: (SAE30 or SAE15W-40) 150 – 200 rpm) Blow-by pressure At rated horsepower (SAE30 or SAE15W-40) (Water temp:Min.70ºC) At rated horsepower SAE30 or SAE15-40 oil

Oil consumption ratio Cooling system Fuel system

Condition, etc

High idling speed Valve clearance (Whel engine is hot or cold)

(7)

WA430-5 Standard value 2,250 +500 770 +500

Max. 0.98 kPa {100} {mmH2O} 0.39 – 0.69 MPa {kg/cm2} {4.0 – 7.0} 0.34 – 0.64 MPa SAE10W oil {kg/cm2} {3.5 – 6.5} Min. 0.15 At low idling MPa {1.5} SAE30 or SAE15W-40 oil {kg/cm2} Min. 0.10 MPa SAE10W oil {1.0} {kg/cm2} All speed ºC 90 – 110 (Oil in oil pan) At continuous rated % Max.0.5 (Ratio to fuel consumption) MPa Nozzle tester — {kg/cm2}

B.T.D.C.

degree

Opening pressure (Differential pressure) At rated engine speed

kPa {kg/cm2} rpm

Deflects when pushed with a force of 59 N {6 kg}

mm

1.96 {200} 0.21 {2.1} 0.18 {1.8} 0.08 {0.8} 0.07 {0.7} 120 1.0 —

8±1

—

—

—

—

—

—

—

125-3 SERIES

TESTING AND ADJUSTING

Permissible value

Standard value

Permissible value

Standard value

Permissible value

Standard value

Permissible value

Cooling system Fuel system

Lubrication system

Engine body

Intake and exhaust system

Performance

Standard value

TESTING AND ADJUSTING DATA

125-3 SERIES

12-5

TESTING AND ADJUSTING

TESTING AND ADJUSTING DATA

COMMON RAIL SYSTEM SPECIFICATION Engine model

SA6D125E-3

Machine model

rpm rpm

Necessary starting speed

0ºC(Without starting aid)

rpm

Min.100

—

Min.100

—

–20ºC(With starting aid)

rpm

Min.85

—

Min.85

—

Intake resistance

At all speed

Boost pressure

At rated horsepower

kPa {mmH2O} kPa {mmHg} kPa {mmHg}

Max.3.72 {380} Min.80 {600} Min.80 {600}

7.47 {762} 60 {450} 73 {550}

Max.3.72 {380} Min.80 {600} Min.80 {600}

7.47 {762} 60 {450} 73 {550}

ºC

Max.650

700

Max.650

700

Max.4.5

6.5

Max.4.5

6.5

Max.1.5

2.5

Max.1.5

2.5

Max.1.0

2.0

Max.1.0

2.0

Performance Intake and exhaust system

Engine speed

Exhaust pressure (Turbine inlet press.) Exhaust temperature (Turbine inlet temp.)

Exhaust gas color

Engine body Lubrication system

Condition, etc

At rated horsepower All speed (At 20ºC) Quick acceleration (Low idle → high idle) At rated horsepower High idling speed

Valve clearance (Whel engine is hot or cold)

Oil pressure (Oil temperature: min.80ºC)

Oil temperature

Fuel injection pressure Fuel injection timing Radiator pressure valve Fan speed Fan belt tension

12-5-1

Unit

Bosch index Bosch index Bosch index

Permissible value 2,100±50 825±25

Standard value 2,100±50 750 +500

Permissible value 2,100±50 750 +500

Intake valve

mm

0.33

—

0.33

—

Exhaust valve

mm

0.71

—

0.71

—

MPa {kg/cm2}

Min. 2.9 {30}

2.0 {20}

Min. 2.9 {30}

2.0 {20}

1.96 {200} 0.21 {2.1} 0.18 {1.8} 0.08 {0.8} 0.07 {0.7}

Max. 0.98 {100} 0.39 – 0.69 {4.0 – 7.0} 0.34 – 0.64 {3.5 – 6.5} Min. 0.15 {1.5} Min. 0.10 {1.0}

1.96 {200} 0.21 {2.1} 0.18 {1.8} 0.08 {0.8} 0.07 {0.7}

120

90 – 110

120

1.0

Max.0.5

1.0

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

Oil temperature:40 – 60ºC Compression pressure (Engine speed: (SAE30 or SAE15W-40) 150 – 200 rpm) Blow-by pressure At rated horsepower (SAE30 or SAE15W-40) (Water temp:Min.70ºC) At rated horsepower SAE30 or SAE15-40 oil

Oil consumption ratio Cooling system Fuel system

D85EX, PX-15

High idling speed Low idling speed

Item

(5)

D65EX, PX-15 Standard value 2,100±50 825±25

Max. 0.98 kPa {100} {mmH2O} 0.39 – 0.69 MPa {kg/cm2} {4.0 – 7.0} 0.34 – 0.64 MPa SAE10W oil {kg/cm2} {3.5 – 6.5} Min. 0.15 At low idling MPa {1.5} SAE30 or SAE15W-40 oil {kg/cm2} Min. 0.10 MPa SAE10W oil {1.0} {kg/cm2} All speed ºC 90 – 110 (Oil in oil pan) At continuous rated % Max.0.5 (Ratio to fuel consumption) MPa Nozzle tester — {kg/cm2}

B.T.D.C.

degree

Opening pressure (Differential pressure) At rated engine speed

kPa {kg/cm2} rpm

Deflects when pushed with a force of 59 N {6 kg}

mm

125-3 SERIES

TESTING AND ADJUSTING

TESTING AND ADJUSTING DATA

SAA6D125E-3 Permissible value 2,170 +20 –80 750 +500

Standard value 1,930±50 1,000±25

Permissible value 1,930±50 1,000±25

Min.100

—

Min.100

—

Min.100

—

Min.100

—

Min.85 Max.2.94 {300} Min.80 {600} Min.80 {600}

— 7.47 {762} 60 {450} 73 {550}

Min.85 Max.2.94 {300} Min.80 {600} Min.80 {600}

— 7.47 {762} 60 {450} 73 {550}

Min.85 Max.2.94 {300} Min.80 {600} Min.80 {600}

— 7.47 {762} 60 {450} 73 {550}

Min.85 Max.2.94 {300} Min.107 {800} Min.93 {700}

— 7.47 {762} 87 {650} 80 {600}

Max.650

700

Max.650

700

Max.650

700

Max.700

700

Max.4.5

6.5

Max.4.5

6.5

Max.4.5

6.5

Max.4.0

6.0

Max.1.5

2.5

Max.1.5

2.5

Max.1.5

2.5

Max.1.5

2.5

Max.1.0

2.0

Max.1.0

2.0

Max.1.0

2.0

Max.1.0

2.0

0.33

—

0.33

—

0.33

—

0.33

—

0.71

—

0.71

—

0.71

—

0.71

—

Min. 2.9 {30}

2.0 {20}

Min. 2.9 {30}

2.0 {20}

Min. 2.9 {30}

2.0 {20}

Min. 2.9 {30}

2.0 {20}

Max. 0.98 {100} 0.39 – 0.69 {4.0 – 7.0} 0.34 – 0.64 {3.5 – 6.5} Min. 0.15 {1.5} Min. 0.10 {1.0}

1.96 {200} 0.21 {2.1} 0.18 {1.8} 0.08 {0.8} 0.07 {0.7}

Max. 0.98 {100} 0.39 – 0.69 {4.0 – 7.0} 0.34 – 0.64 {3.5 – 6.5} Min. 0.15 {1.5} Min. 0.10 {1.0}

1.96 {200} 0.21 {2.1} 0.18 {1.8} 0.08 {0.8} 0.07 {0.7}

Max. 0.98 {100} 0.39 – 0.69 {4.0 – 7.0} 0.34 – 0.64 {3.5 – 6.5} Min. 0.15 {1.5} Min. 0.10 {1.0}

1.96 {200} 0.21 {2.1} 0.18 {1.8} 0.08 {0.8} 0.07 {0.7}

Max. 1.18 {120} 0.39 – 0.69 {4.0 – 7.0} 0.34 – 0.64 {3.5 – 6.5} Min. 0.15 {1.5} Min. 0.10 {1.0}

1.96 {200} 0.21 {2.1} 0.18 {1.8} 0.08 {0.8} 0.07 {0.7}

90 – 110

120

90 – 110

120

90 – 110

120

90 – 120

120

Max.0.5

1.0

Max.0.5

1.0

Max.0.5

1.0

Max.0.5

1.0

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

125-3 SERIES

Intake and exhaust system

Standard value 2,170 +20 –80 750 +500

Performance

PC400, 450-7

Permissible value 2,170 +20 –80 750 +500

Engine body

HM300-1

Standard value 2,170 +20 –80 750 +500

Lubrication system

WA480-5

Permissible value 2,170 +20 –80 750 +500

Cooling system Fuel system

WA470-5 Standard value 2,170 +20 –80 750 +500

12-5-2 (7)

TESTING AND ADJUSTING

TESTING AND ADJUSTING DATA

COMMON RAIL SYSTEM SPECIFICATION Engine model

SAA6D125E-3

Machine model

High idling speed Low idling speed

rpm rpm

Necessary starting speed

0ºC(Without starting aid)

rpm

Min.100

Min.100

–20ºC(With starting aid)

rpm

Min.85

Min.85

Intake resistance

At all speed

Boost pressure

At rated horsepower

kPa {mmH2O} kPa {mmHg} kPa {mmHg}

Max.3.72 {Max.380} Min.107 {Min.800} Min.120 {Min.900}

7.47 {762} 87 {650} 107 {800}

ºC

Max.700

700

Max.4.0

6.0

Max.1.5

2.5

Max.1.0

2.0

Intake and exhaust system

Performance

Item Engine speed

Exhaust pressure (Turbine inlet press.) Exhaust temperature (Turbine inlet temp.)

Exhaust gas color

Engine body Lubrication system

At rated horsepower All speed (At 20ºC) Quick acceleration (Low idle → high idle) At rated horsepower

Oil pressure (Oil temperature: min.80ºC)

Oil temperature

Fuel injection pressure Fuel injection timing Radiator pressure valve Fan speed Fan belt tension

12-5-3

Unit

Bosch index Bosch index Bosch index

Permissible value 2,420 +80 –20 750±50

Intake valve

mm

0.33

—

Exhaust valve

mm

0.71

—

MPa {kg/cm2}

Min. 2.9 {Min. 30}

2.0 {20}

Oil temperature:40 – 60ºC Compression pressure (Engine speed: (SAE30 or SAE15W-40) 150 – 200 rpm) Blow-by pressure At rated horsepower (SAE30 or SAE15W-40) (Water temp:Min.70ºC) At rated horsepower SAE30 or SAE15-40 oil

Oil consumption ratio Cooling system Fuel system

Condition, etc

High idling speed Valve clearance (Whel engine is hot or cold)

(8)

HD255-5 Standard value 2,420 +80 –20 750±50

Max. 0.98 kPa {mmH2O} {Max. 100} 0.39 – 0.69 MPa {kg/cm2} {4.0 – 7.0} 0.34 – 0.64 MPa SAE10W oil {kg/cm2} {3.5 – 6.5} Min. 0.15 At low idling MPa SAE30 or SAE15W-40 oil {kg/cm2} {Min. 1.5} Min. 0.10 MPa SAE10W oil {kg/cm2} {Min. 1.0} All speed ºC 90 – 120 (Oil in oil pan) At continuous rated % Max.0.5 (Ratio to fuel consumption) MPa Nozzle tester — {kg/cm2}

B.T.D.C.

degree

Opening pressure (Differential pressure) At rated engine speed

kPa {kg/cm2} rpm

Deflects when pushed with a force of 59 N {6 kg}

mm

1.96 {200} 0.21 {2.1} 0.18 {1.8} 0.08 {0.8} 0.07 {0.7} 120 1.0 —

—

—

—

—

—

—

—

—

125-3 SERIES

TESTING AND ADJUSTING

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

STANDARD VALUE TABLE FOR ELECTRICAL PARTS COMMON RAIL SYSTEM SPECIFICATION Name of component

Connector No.

Inspetion method

Measurement conditions

Judgement table

If the condition is as shown in the table below, it is normal 1) Insert T-adapter to AS1. 2) Turn starting switch ON. Potentiometer Between (3) and (1) Between (2) and (3) Acceleration pedal (throttle sensor)

AS1

Measure voltage

4.6 – 5.4V 0.3 – 4.5V

Switch Pin Between (5) and (4) Between (6) and (4)

Potentiometer voltage Max. 0.446V Min. 0.446V Max. 0.446V Min. 0.446V

Voltage Max. 1V 15 – 30V 20 – 30V Max. 1V

Engine Ne rotation sensor

NE (male)

Measure resistance

If the condition is as shown in the table below, it is normal 1) Turn starging switch OFF. 2) Disconnect NE. Between (1) and (2) 85Ω – 210Ω Between (1), (2) and ground Min. 1MΩ

Engine G rotation sensor

G (male)

Measure resistance

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect G. Between (1) and (2) 1.4kΩ – 3.5kΩ Between (1), (2) and ground Min. 1MΩ

Engine oil low-pressure switch

Engine oil high-pressure switch

PSL (terminal)

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect PSL. Resistance Position Engine value Measure Engine Max. 1Ω Between switch resistance stopped terminal and 600rpm ground Min. 1MΩ and above

PSH (terminal)

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect PSH. Resistance Position Engine value Measure Engine Max. 1Ω Between switch resistance stopped terminal and 1,300rpm ground Min. 1MΩ and above

Engine water low-temperature sensor

TWL (male)

Measure resistance

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect TWL. Between (1) and (2) 9kΩ – 0.3kΩ Between (1), (2) and ground Min. 1MΩ

Engine water high-temperature sensor

TWH (male)

Measure resistance

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect TWH. Between (1) and (2) 90kΩ – 3.5kΩ Between (1), (2) and ground Min. 1MΩ

Fuel temperature sensor

THL (male)

Measure resistance

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect THL. Between (1) and (2) 9kΩ – 0.3kΩ Between (1), (2) and ground Min. 1MΩ

12-6 3

125-3 SERIES

TESTING AND ADJUSTING

Name of component

Engine oil filter clogging switch

Engine oil level switch

STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Connector No.

Inspetion method

OF (terminal)

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect OF. Resistance Position Oil filter value Measure Between resistance When normal Max. 1Ω switch terminal and ground When clogged Min. 1MΩ

OL (male)

Measure resistance

Measurement conditions

Judgement table

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect OL. Resistance Position Oil filter value Between (1) and ground

When normal

Max. 1Ω

When low

Min. 1MΩ

PIM (male)

Measure voltage

If the condition is as shown in the table below, it is normal 1) Insert T-adapter to PIM. 2) Turn starting switch ON. Between (1) and (3) 4.6 – 5.4V Between (2) and (3) 0.3 – 4.7V

Common rail fuel pressure sensor

PFUEL (male)

Measure voltage

If the condition is as shown in the table below, it is normal 1) Insert T-adapter to PFUEL. Between (1) and (3) 4.6 – 5.4V 2) Turn starting switch ON. Between (2) and (3) 0.3 – 4.7V

Fuel supply pump PCV1

PCV1 (male)

Measure resistance

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect PCV1. Between (1) and (2) 2.3 – 5.3Ω Between (1), (2) and ground Min.1MΩ

Fuel supply pump PCV2

PCV2 (male)

Measure resistance

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect PCV2. Between (1) and (2) 2.3 – 5.3Ω Between (1), (2) and ground Min.1MΩ

No.1 injector solenoid

CN1 (male)

Measure resistance

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect CN1. Between (1) and (2) 0.4 – 1.1Ω Between (1), (2) and ground Min.1MΩ

No.2 injector solenoid

CN2 (male)

Measure resistance

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect CN2. Between (1) and (2) 0.4 – 1.1Ω Between (1), (2) and ground Min.1MΩ

No.3 injector solenoid

CN3 (male)

Measure resistance

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect CN3. Between (1) and (2) 0.4 – 1.1Ω Between (1), (2) and ground Min.1MΩ

No.4 injector solenoid

CN4 (male)

Measure resistance

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect CN4. Between (1) and (2) 0.4 – 1.1Ω Between (1), (2) and ground Min.1MΩ

No.5 injector solenoid

CN5 (male)

Measure resistance

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect CN5. Between (1) and (2) 0.4 – 1.1Ω Between (1), (2) and ground Min.1MΩ

No.6 injector solenoid

CN6 (male)

Measure resistance

If the condition is as shown in the table below, it is normal 1) Turn starting switch OFF. 2) Disconnect CN6. Between (1) and (2) 0.4 – 1.1Ω Between (1), (2) and ground Min.1MΩ

Boost pressure sensor

125-3 SERIES

12-7 3

TESTING AND ADJUSTING

TESTING AND ADJUSTING TOOL LIST

TESTING AND ADJUSTING TOOL LIST Check or adjustment item

Symbol

Part Number

Part Name

Remarks Digital display L:60 – 2,000 rpm H:60 – 19,999 rpm

Engine speed

A

799-203-8001

Multi-tachometer

Specific gravity of battery electrolyte

B

795-500-1001

Battery, coolant tester

1.100 – 1.300

799-101-1502

Thermometer

–99.9 – 1,299ºC

799-401-2320

Pressure gauge

1 MPa {10 kg/cm2}

799-101-5150

Hose

790-261-1150

Hose

Hydro tester kit 799-101-5002

Coolant freezing temperature Water, oil, intake and exhaust temperatures

C 1

Lubricant pressure

D 2

–5 to –50ºC

Air supply pressure (boost pressure)

E

799-201-2201

Boost gauge kit

–760 – 1500 mmHg

Blow-by pressure

F

799-201-1504

Blow-by checker

0 – 1,000 mmAq

1

795-502-1590

Gauge assembly

Kit Part No.795-502-1205 0 – 6.9MPa{0 – 70kg/cm2}

2

795-502-1360

Adapter

In-line fuel injection pump specification

3

795-471-1410

Adapter

Common rail system specification

Commercially available

Feeler gauge

0.33, 0.71 mm

1

792-201-9000

Handy smoke tester

2

Commercially available

Smoke meter

Discoloration 0 – 70% (With standard color) (Discoloration x 1/4 Bosch index)

J

799-201-6000

Engine oil checker

Water content 0.1%, 0.2% standard sample

K

Commercially available

Nozzle tester

0 – 39.2MPa {0 – 400kg/cm2}

L

799-202-7002

Water tester

PH, nitrous acid ion density

M

799-202-9001

Radiator cap tester

0 – 0.2MPa {0 – 2kg/cm2}

Clogging of radiator

N

799-202-2001

Anemometer (wind speed)

1 – 40m/s

Engine cranking

O

795-610-1000

Cranking kit

Engine with DC24V starting motor

Adjusting injection timing

P

795-471-1200

Gauge assembly

Electric circuit

Q

Commercially available

Compression pressure G

Valve clearance

Exhaust color

Water, fuel in oil Fuel injection pressure Nozzle spray condition Quality of coolant Pressure valve function Leakage from cooling system

12-8 2

H

I

Tester

125-3 SERIES

TESTING AND ADJUSTING

MEASURING INTAKE AIR PRESSURE (BOOT PRESSURE)

MEASURING INTAKE AIR PRESSURE (BOOT PRESSURE) IN-LINE FUEL INJECTION PUMP SPECIFICATION

k When removing or installing the measuring

equipment, be careful not to touch any high temperature parts. 1. Remove intake air pressure measurement plug (1)(PT 1/8) and install coupler (2) of oil pressure gauge kit.

COMMON RAIL SYSTEM SPECIFICATION 1. Switch to the monitoring function of Service Mode 1 and display the air supply pressure. For details, see SPECIAL FUNCTIONS OF MACHINE MONITOR in the TROUBLESHOOTING section. ★ Monitoring item: Boost pressure

2. Start the engine. 2. Connect oil pressure measurement hose (3) to c oupler (2) and pres sure gauge E (1500 mmHg). k When carrying out the measurement, be

careful not to touch any high temperature parts or rotating parts.

Note: Run the engine at a mid-range speed or above, and use the self-seal portion of the gauge to bleed the oil from inside the hose. • Insert the gauge about half way, and repeatedly open the self-seal portion to bleed the oil.

3. Turn the transmission cut-off selector switch (1) OFF and depress the left brake securely. 4. Place the speed lever at F4 or R4. •

Turn the transmission manual switch ON and place the speed lever at F4 or R4.

5. Release the parking brake. 6. Depress the accelerator pedal gradually, and measure the air supply pressure at the rated speed when the torque converter stalls.

★ The gauge does not work if there is any oil inside the hose, so always be sure to bleed all the oil.

3. Run the engine at the rated speed and measure the pressure indicated by the gauge.

125-3 SERIES

12-9 2

TESTING AND ADJUSTING

MEASURING EXHAUST TEMPERATURE

MEASURING EXHAUST TEMPERATURE k Wait for the temperature of the exhaust pipe to

go down before installing or removing the measuring equipment.

1. Remove the adiabatic cover, then remove exhaust temperature measurement plug (1).

3. When measuring the exhaust temperature at torque converter stall, do as follows. •

2. Install sensor (2) and connect to digital temperature gauge C. ★ Be careful not to let the wiring harness of the temperature gauge touch the high-temperature portion.

1) 2) 3)

4) 5)

To prevent overheating of the torque converter, stabilize the exhaust temperature at full stall (torque converter stall + hydraulic stall), then stall the torque converter only and measure the temperature. Start the engine and raise the cooling water temperature to the operating range. Turn the transmission cut-off selector switch OFF and depress the left brake securely. Place the directional lever at F4 or R4. • Turn the transmission manual switch ON and place the speed lever at F4 and R4. Release the parking brake. Depress the accelerator pedal gradually to raise the engine speed to full throttle, stall the torque converter, and extend boom cylinder or bucket cylinder at the same time to relieve the circuit. ★ Continue until the exhaust temperature is around the standard value of 650 °C. k Do not keep the stall condition for more

than 20 seconds. Make sure that the torque converter oil temperature does not exceed 120 °C.

12-10 2

125-3 SERIES

TESTING AND ADJUSTING

MEASURING EXHAUST TEMPERATURE

6) When the temperature becomes stable at around the target temperature, cancel the hydraulic relief, carry out only torque converter stall, and measure the exhaust temperature. ★ The exhaust temperature at full stall will start to go down, so measure the temperature when it becomes stable. ★ If the exhaust temperature does not go down and continues to go up, make the temperature setting at full stall higher. 4. When measuring maximum value for exhaust gas temperature, carry out actual work and measure the maximum value when operating. ★ Use the PEAK mode function (the maximum value can be recorded) of the temperature gauge. ★ The exhaust temperature differs greatly according to the ambient temperature (engine intake temperature), so if an abnormal value is recorded, compensate for the temperature. ★ Compensation temperature value = measured value + 2 x (converted ambient temperature – ambient temperature). • The converted ambient temperature is taken as 20 °C.

125-3 SERIES

12-11 2

TESTING AND ADJUSTING

ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE IN-LINE FUEL INJECTION PUMP SPECIFICATION 1. Remove the cylinder head cover. 2. Rotate the crankshaft in the normal direction, and set the No. 1 cylinder to the compression top dead center. While doing this, watch the movement of the intake valves of No. 6 cylinder. Align pointer (3) with the 1.6 TOP line on the vibration damper (2). ★ When the No. 1 cylinder comes near the top dead center of the compression stroke, the No. 6 intake valve will start to move (open).

★ To adjust the valve clearance, loosen lock nut (8) on adjustment screw (7), insert Feeler gauge H corresponding to the specified clearance between crosshead (6) and rocker arm (5), and adjust the clearance with the adjustment screw until the thickness gauge can slide lightly.

3. Adjust the valve clearance for valves marked in the valve arrangement chart. 4. Rotate the crankshaft in the normal direction by one revolution and adjust the valve clearance for the remaining valves marked .

5. After the clearance is properly adjusted, tighten the lock nut to secure the adjustment screw. 3 Lock nut: 59 ± 6 Nm {6.0 ± 0.6 kgm}

★ The engine firing order is 1 - 5 - 3 - 6 - 2 - 4. ★ Intake and exhaust valve clearances may be adjusted for each cylinder in the firing order by rotating the crankshaft 120° at a time in the normal direction. ★ For details about valve clearance, see TESTING AND ADJUSTING DATA.

12-12 2

125-3 SERIES

TESTING AND ADJUSTING

COMMON RAIL SYSTEM SPECIFICATION 1. Disconnect 6 fuel high-pressure tubes (1). •

Remove the tube clamps also.

ADJUSTING VALVE CLEARANCE

4. To adjust the valve clearance, insert feeler gauge H into clearance b between rocker arm (4) and crosshead (5), and adjust the valve clearance with adjustment screw (6). ★ Insert the feeler gauge and turn the adjustment screw until the clearance is a sliding fit.

2. Remove cylinder head cover.

3 Head cover mounting bolt:

9.8 ± 1 Nm {1.0 ± 0.1 kgm}

3. Rotate the crankshaft in the normal direction, and align 1.6 line a on the damper with pointer (3) to set the No. 1 cylinder to compression top dead center.

5. Hold adjustment screw (6) in position and tighten locknut (7). 3 Locknut:

53.0 – 64.7 Nm {5.4 – 6.6 kgm} ★ After tightening the locknut, check the clearance again.

★ At compression top dead center, the rocker arm can be moved by hand by the amount of the valve clearance. If the rocker arm does not move, the crankshaft is not at compression top dead center, so rotate it one more turn.

6. Rotate the crankshaft 120° each time in the normal direction and repeat the procedure in Steps 4 to 6 to adjust the clearance of the intake and exhaust valves of each cylinder according to the firing order. ★ Firing order: 1-5-3-6-2-4 7. After completing the measurement, return to the original condition. ★ For details of the assembly of the fuel highpressure tube, see DISASSEMBLY AND ASSEMBLY.

125-3 SERIES

12-13 2

TESTING AND ADJUSTING

MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE IN-LINE FUEL INJECTION PUMP SPECIFICATION k While measuring the compression pressure,

take care not burn yourself on the exhaust manifold or muffler, and be careful not to get caught in any revolving part of the engine. ★ Measure the compression pressure while the engine is warm. (Engine oil temperature: 40 – 60ºC)

4. Install adapter G2 to the nozzle holder mounting section of the cylinder to be measured, and tighten the adapter to the specified torque. 3 Adapter: 21.6 ± 2.9 Nm {2.2 ± 0.3 kgm}

1. Adjust the valve clearance properly. For details, see ADJUSTING VALVE CLEARANCE. 2. Remove spill tube (1) and disconnect fuel injection pipe (2).

5. Connect compression gauge G1 to the adapter.

3. Remove nozzle holder assembly (3) for each cylinder. ★ Remove the nozzle holder assembly by prying it with two mounting bolts. ★ Take care not to let any dirt or foreign matter get into the cylinder. 6. Place the fuel control lever in NO INJECTION position, crank the engine with the starting motor, and read the gauge when the pointer is stabilized. k If you do not put the fuel control lever in NO IN-

JECTION position, fuel will blow out.

★ Most compression leakage can be prevented by applying a small amount of oil to the mounting section of the adapter. ★ For the reference values of the compression pressure, see TESTING AND ADJUSTING DATA.

12-14 2

125-3 SERIES

TESTING AND ADJUSTING

MEASURING COMPRESSION PRESSURE

COMMON RAIL SYSYTEM SPECIFICATION

k When measuring the compression pressure, be

careful not to touch the exhaust manifold of muffler and burn yourself, or to get caught in any rotating parts.

★ Measure the compression pressure with the engine warmed up (engine oil temperature: 40 – 60 °C). 1. Disconnect 6 fuel high-pressure tubes (1). •

4. Fit adapter G3 and connect to compression gauge G1. ★ Coat the connection of the adapter and gauge with a small amount of engine oil to make leakage more difficult. ★ Secure the adapter with the injector holder. 3 Mounting bolt:

58.8 – 73.5 Nm {6.0 – 7.5 kgm}

Remove the tube clamps also.

5. Disconnect 2 engine centralized connectors (4) .

k If the connectors are not disconnected, there is

2. Remove cylinder head cover.

3 Head cover mounting bolt:

9.8 ± 1 Nm {1.0 ± 0.1 kgm}

a danger that the engine may start during the measurement, so disconnect them without fail. k Cover the connector at the controller end with vinyl to prevent short circuits and leakages of electricity.

3. Remove injector wiring harness and fuel injector (3).

6. Crank the engine with the starting motor and measure the compression pressure. ★ Measure the compression pressure at the point where the compression gauge indicator remains steady. 7. After completing the measurement, remove the measuring equipment and return to the original condition. ★ For details of the assembly of the fuel injector and fuel high-pressure tub, see DISASSEMBLY and ASSEMBLY. 125-3 SERIES

12-15 2

TESTING AND ADJUSTING

MEASURING BLOW-BY PRESSURE

MEASURING BLOW-BY PRESSURE 1. Install nozzle 1 and hose 2 to blow-by hose (1), and connect to blow-by checker F.

6. Depress the accelerator pedal gradually to raise the engine speed to full throttle, and measure the blow-by pressure when the torque converter stalls.

k Do not keep the stall condition for more than

20 seconds. Make sure that the torque converter oil temperature does not exceed 120 °C.

2. Run the engine and raise the coolant temperature to the operating range.

★ Precautions when measuring blow-by Blow-by varies greatly according to the condition of the engine. Therefore, if the blow-by value is considered abnormal, check for problems connected with defective blow-by, such as excessive oil consumption, defective exhaust gas color, and prematurely dirty or deteriorated oil.

3. Turn the transmission cut-off selector switch OFF and depress the left brake securely. 4. Place the speed lever at F4 and R4. •

Turn the transmission manual switch ON and place the speed lever at F4 and R4.

5. Release the parking brake.

12-16 2

125-3 SERIES

TESTING AND ADJUSTING

MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL PRESSURE 1. Remove engine oil pressure switch (1).or engine oil pressure measuring plug.

3. Run the engine and raise the coolant temperature to the operating range. 4. Measure the oil pressure with the engine at low idling and high idling.

2. Install nipple 1 and hose D2, and connect oil pressure gauge D1. ★ Use a 0.98 MPa {10 kg/cm2} oil pressure gauge.

125-3 SERIES

5. After completing the measurement, remove the measuring equipment and return to the original condition.

12-17 2

TESTING AND ADJUSTING

MEASURING FUEL PRESSURE

MEASURING FUEL PRESSURE COMMON RAIL SYSTEM SPECIFICATION ★ When measuring the fuel pressure, measure only the low pressure circuit between the feed pump - fuel filter - fuel supply pump. k Extremely high pressure is generated in the

4. Run the engine and measure the fuel pressure at high idling. ★ For details of the standard value, see Troubleshooting of Engine Controller System.

high-pressure circuit between the fuel supply pump - common rail - fuel injector, so it cannot be measured.

1. Open the engine right side cover. 2. Remove the fuel pressure measurement plug (1).

5. After completing the measurement, remove the measuring equipment and return to the original condition.

3. Install nipple 1 and hose D2, and connect oil pressure gauge D1. ★ Use a 0.98 MPa {10 kg/cm2} oil pressure gauge.

12-18 2

125-3 SERIES

TESTING AND ADJUSTING

ADJUSTING ENGINE SPEED SENSOR

ADJUSTING ENGINE SPEED SENSOR ★ G speed sensor (CN-G) and Ne speed sensor (CN-NE) for the engine controller of common rail system specification cannot be adjusted. ★ Adjust the engine speed sensor (CN-EREV) as follows.

1. Screw in until the tip of sensor (1) contacts the tip of the tooth of flywheel ring gear (2). ★ Check that there are no scratches or metal particles stuck to the tip of the sensor. 2 Thread portion: Hydraulic sealant

2. Turn sensor (1) back 1/2 - 2/3 turns from that position. ★ Adjust clearance a between the tip of the sensor and the tip of the gear tooth is 0.75 – 1.00 mm. 3. Secure sensor (1) with nut (3). 3 Nut:69 – 74 Nm {7.0 – 7.5 kgm}

125-3 SERIES

12-19 2

TESTING AND ADJUSTING

TESTING AND ADJUSTING FUEL INJECTION TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING IN-LINE FUEL INJECTION PUMP SPECIFICATION There are the following methods for testing and adjusting the fuel injection timing of the injection pump. • When assembling to the same engine without repairing the injection pump, adjust by aligning the match marks. • When replacing with a new injection pump, or when installing a repaired injection pump, adjust using the delivery valve method. ★ If the delivery valve method is used, the copper gasket and O-ring for the delivery valve must be replaced with new parts, so have new parts available when using this method. ★ Set the No. 1 cylinder to the compression top dead center before testing and adjusting.

2) Align No. 1 cylinder with the compression top dead center line (1 : 6). • When doing this, check that fuel injection timing line on the fuel injection pump is near line on the fuel injection pump body.

Testing and adjusting fuel injection timing by aligning match marks 1. Testing fuel injection timing by aligning match marks 1) Disconnect spill tube (1) and delivery tube (2) of the No. 1 piston, then remove No. 1 nozzle holder assembly (3).

12-20 2

3) Set dial gauge P to the nozzle holder hole where the nozzle holder assembly has been removed.

125-3 SERIES

TESTING AND ADJUSTING

4) Put the tip of dial gauge P in contact with the top center of the piston, then set the scale on dial gauge P to 0 when the piston is at the top dead center. ★ Rotate the crankshaft in the normal direction and in the reverse direction to align the top dead center. ★ Record the value indicated by the short indicator on dial gauge P.

TESTING AND ADJUSTING FUEL INJECTION TIMING

7) Check that fuel injection timing line on the fuel injection pump is aligned with line on the fuel injection pump body.

5) Rotate the crankshaft approx. 45º in the reverse direction from the No. 1 cylinder TOP position. 6) Rotate the crankshaft again slowly in the normal direction and set to the specified dimension (piston displacement). ★ Always rotate the crankshaft in the normal direction to align the position. ★ For details of the specified dimension (piston displacement), see the table below. ★ For details of the fuel injection timing, see TESTING AND ADJUSTING, Standard values for testing, adjusting, and troubleshooting. Piston displacement for each fuel injection timing Machine Model WA430-5

125-3 SERIES

Injection Piston timing displacement BTDC8º ± 1º 0.96 ± 0.20 mm

12-21 2

TESTING AND ADJUSTING

2. Adjusting fuel injection timing If the lines are not aligned, loosen mounting bolt (4) and move coupling (5) to align lines and , then tighten bolt (4). 3 Bolt (4): 88.3 ± 4.9 Nm {9 ± 0.5 kgm}

TESTING AND ADJUSTING FUEL INJECTION TIMING

4) Remove spring (3), delivery valve (4), and stopper (6) from delivery valve holder (2), then assemble delivery valve holder (2) again. 5) Set the fuel control lever at the FULL position, then operate the priming pump and rotate the crankshaft slowly in the normal direction. Check the point where the fuel stops flowing from the delivery valve holder.

Testing and adjusting fuel injection timing with delivery valve method ★ If the delivery valve method is used, the copper gasket and O-ring for the delivery valve must be replaced with new parts, so have new parts available when using this method. 1. Testing fuel injection timing with delivery valve method 1) Set with the No. 1 cylinder at the TOP position, then rotate the crankshaft 30 – 40º in the reverse direction. 2) Disconnect fuel injection tube (1) of No. 1 cylinder. 3) Remove delivery valve holder (2).

12-22 2

125-3 SERIES

TESTING AND ADJUSTING

6) Check that fuel injection timing line on the fuel injection pump is aligned with line on the fuel injection pump body at the point where the fuel stops flowing. ★ BEYOND injection timing line: Timing RETARDED ★ BEFORE injection timing line: Timing ADVANCED

TESTING AND ADJUSTING FUEL INJECTION TIMING

2) Align No. 1 cylinder with the compression top dead center line (1 : 6). • When doing this, check that fuel injection timing line on the fuel injection pump is near line on the fuel injection pump body.

3) Set dial gauge P to the nozzle holder hole where the nozzle holder assembly has been removed. (See the diagram.) 2. Adjusting fuel injection timing with delivery valve method If the results of the test show that the fuel injection timing is incorrect, adjust the fuel injection timing as follows. 1) Disconnect spill tube (1) and delivery tube (2) of the No. 1 piston, then remove No. 1 nozzle holder assembly (3).

125-3 SERIES

12-23 2

TESTING AND ADJUSTING

TESTING AND ADJUSTING FUEL INJECTION TIMING

4) Put the tip of dial gauge P in contact with the top center of the piston, then set the scale on dial gauge P to 0 when the piston is at the top dead center. ★ Rotate the crankshaft in the normal direction and in the reverse direction to align the top dead center. ★ Record the value indicated by the short indicator on dial gauge P.

5) Rotate the crankshaft approx. 45º in the reverse direction from the No. 1 cylinder TOP position. 6) Rotate the crankshaft again slowly in the normal direction and set to the specified dimension (piston displacement). ★ Always rotate the crankshaft in the normal direction to align the position. ★ For details of the specified dimension (piston displacement), see the table below. ★ For details of the fuel injection timing, see TESTING AND ADJUSTING, Standard values for testing, adjusting, and troubleshooting.

7) Loosen mounting bolt (4), move coupling (5) to align lines and , then tighten bolt (4). 3 Bolt (4): 88.3 ± 4.9 Nm {9 ± 0.5 kgm}

8) Set with the No. 1 cylinder at the TOP position, then rotate the crankshaft 30 – 40º in the reverse direction. Set the fuel control lever at the FULL position, then operate the priming pump and rotate the crankshaft slowly in the normal direction. Check the point where the fuel stops flowing from the delivery valve holder. ★ Check that fuel injection timing line on the fuel injection pump is aligned with line on the fuel injection pump body at the point where the fuel stops flowing.

Piston displacement for each fuel injection timing for 125E-3 engine Injection timing BTDC8º ± 1º

Piston displacement 0.96 ± 0.20 mm 9) Repeat Steps 1) – 5) of "Adjusting fuel injection timing with delivery valve method" to check that the fuel stops flowing from the delivery valve holder.

12-24 2

125-3 SERIES

TESTING AND ADJUSTING

TESTING AND ADJUSTING FUEL INJECTION TIMING

10) Remove delivery valve holder (2), assemble delivery valve (4), spring (3), and stopper (6), then assemble the delivery valve holder to the fuel injection pump again. 3 Delivery valve holder: 98.0 ± 9.8 Nm {10.0 ± 1.0 kgm}

11) Fit nozzle holder assembly (3), then install spill tube (1) and fuel injection tube (2). 3 Nozzle holder mounting bolt: 21.6 ± 2.9 Nm {2.2 ± 0.3 kgm} 3 Spill tube joint bolt: 12.3 ± 2.5 Nm {1.25 ± 0.25 kgm}

125-3 SERIES

12-25 2

TESTING AND ADJUSTING

HANDLING EQUIPMENT IN FUEL SYSTEM

HANDLING EQUIPMENT IN FUEL SYSTEM

RELEASING REMAINING PRESSURE IN FUEL SYSTEM

COMMON RAIL SYSTEM SPECIFICATION

COMMON RAIL SYSTEM SPECIFICATION

★ Precautions for inspection and maintenance of fuel system. The common rail type fuel injection system is constructed of more precise components than the conventional fuel injection pump and nozzle, so problems may occur if dirt or dust get in. When carrying out inspection and maintenance of the fuel system, pay more attention than usual to prevent dirt or dust from getting in. If there is any dirt stuck to any part, use clean fuel to wash it off completely ★ Precautions when replacing fuel filter cartridge. Always use a genuine Komatsu part for the fuel filter cartridge. The common rail type fuel injection system is constructed of more precise components than the conventional fuel injection pump and nozzle, so a special filter with high efficiency filtering ability is used to prevent dirt or dust from getting in. For this reason, if any filter is used as a substitute for the genuine filter, there is danger that problems will occur with the fuel system. To prevent this, never use such filters.

★ When the engine is running, pressure is generated in both the low-pressure circuit and the highpressure circuit of the fuel line. Low-pressure circuit: Feed pump - fuel filter fuel supply pump High-pressure circuit: Fuel supply pump - common rail - fuel injector ★ For both the low-pressure circuit and high-pressure circuit, the pressure automatically goes down to a safe level 30 seconds after the engine is stopped. ★ The remaining pressure in the fuel system must be completely released before carrying out inspection of the fuel system or removal or installation of the equipment. Always follow the following precautions when carrying out the operation.

12-26 2

k

When inspecting the fuel line or removing or installing equipment, wait for at least 30 seconds after the engine is stopped, and release the remaining pressure in the fuel system before starting the operation. (There is still pressure remaining in the circuit, so do not start the operation immediately after the engine is stopped.)

125-3 SERIES

TESTING AND ADJUSTING

BLEEDING AIR FROM FUEL CIRCUIT

BLEEDING AIR FROM FUEL CIRCUIT COMMON RAIL SYSTEM SPECIFICATION

★ Bleeding the air as follows if the engine has run out of fuel or the fuel circuit equipment has been removed and installed. 1. Remove fuel filter (1), fill with fuel, then install again. ★ When filling, use clean fuel and be careful not to let dirt get in. ★ Add fuel through inlet port prtion a (8 places) of the filter. Portion b is the outlet port (clean side) after the fuel has been filtered, so never add fuel from here. ★ If clean fuel is not available, do not remove the filter. Operate the priming pump to fill the filter with fuel.

125-3 SERIES

12-27 2

TESTING AND ADJUSTING

BLEEDING AIR FROM FUEL CIRCUIT RELEASING REMAINING PRESSURE IN FUEL SYSTEM

2. Remove air bleed plug (2) of the fuel filter and operate priming pump (4). ★ Cotinue operating the priming pump until flow out from the plug hole. When fuel comes out, install the plug. 3 Air bleed plug: 7.8 – 9.8Nm{0.8 – 1.0kgm} 3. There are the following two cases that the engine does not start up easily after bleeding air from CRI, (Common Rail Injection System), i.e. even after carrying out the Items 1 and 2 above. ★ If air has not been removed completely, leaving some in the system, cranking up the engine with the engine starting motor cannot get rid of the remaining air in a short span of time. Thus the engine start-up becomes difficult. 1) In the cases that the fuel has run out, that the fuel filter has been replaced or that some fuel device has been removed and installed. • Most of the fuel is left in the fuel circuit, so the engine may be started after bleeding air with the air bleeding methods introduced in the Items 1 and 2 above. 2) In the case that a number of fuel devices have been removed and installed in course of engine overhauling. • Little fuel is left in the fuel circuit, so air cannot be get rid of completely with the air bleeding methods introduced in the Items 1 and 2 above (i.e. ordinary method). In that case, bleed air in the following manner.

Air bleeding steps i) Remove air bleeding plug (2) of fuel filter (1) and operate priming pump (4). • Continue to operate the priming pump until fuel is confirmed to flow out of the air bleeding plug hole and then tighten it. 3 Air bleeding plug: 7.8 – 9.8Nm{0.8 – 1.0kgm} ii)

iii) Loosen air bleeder (5) of the fuel supply pump (only after loosening the lock nut) and operate priming pump (4) 90 to 100 times. • Continue to operate the primng pump until fuel is confirmed to flow out of air bleeder (5) and then tighten it. 3 Air bleeder: 4.9 – 6.9Nm{0.5 – 0.7kgm} •

iv) v) ★

★

12-28 2

Remove fuel pressure measuring plug (3) for the fuel filter and operate priming pump (4). • Continue to operate the priming pump until fuel is confirmed to flow out of the air bleeding plug hole and then tighten it. 3 Fuel pressure measuring plug: 3.9 – 6.9Nm{0.4 – 0.7kgm}

Still continue to operate the priming pump until it becomes harder to operate and a relief sound of overflow valve (6) in the fuel supply pump is heard. (A high pitch sound) It requires approx. 50 times of operation to reach that stage. Push in the knob of priming pump (4) to tighten it. Crank up the engine with the engine starting motor for start-up. Do not keep the engine starting motor running idly for more than 20 seconds. Moreover try to start up the engine only after two minute pause. If the engine does not start up even after repeating to crank for 20 seconds 4 times, insufficient air bleeding is suspected of. In that case, start the air bleeding steps once again from the beginning.

125-3 SERIES

TESTING AND ADJUSTING

REDUCED CYLINDER MODE OPERATION FOR ENGINE

4. Loosen air bleeder (5) of the fuel supply pump and operate priming pump (4) 90 to 100 times. ★ Continue operating the priming pump until fuel flows out from the bleeder. When fuel comes out, tighten the bleeder, then operate several times until the priming pump becomes stiff. 3 Air bleeder: 4.9 – 6.9Nm{0.5 – 0.7kgm} 5. Crank the engine with the starting motor and start the engine. ★ When the engine is cranked, the air in the high-pressure circuit is automatically bled. ★ If the engine does not start, the air has probably been not properly bled from the lowpressure circuit, so repeat the procedure from Step 2.

125-3 SERIES

REDUCED CYLINDER MODE OPERATION FOR ENGINE COMMON RAIL SYSTEM SPECIFICATION ★ Reduced cylinder mode operation for the engine means setting the fuel injectors of a single cylinder or multiple cylinders electronically to the NO injection condition to run the engine on a reduced number of cylinders. The reduced cylinder mode operation is used when it is thought that one of the engine cylinders is not giving normal output (combustion). It is a method to determine which cylinder is not operating normally. ★ The reduced cylinder mode operation is carried out by using the reduced cylinder mode operation setting function on the monitor panel. ★ For details of the method of operation, see the TROUBLESHOOTING of chassis volume, Monitor panel display and special functions.

12-29 2

TESTING AND ADJUSTING

CHECKING FOR LEAKAGE IN FUEL SYSTEM

CHECKING FOR LEAKAGE IN FUEL SYSTEM COMMON RAIL SYSTEM SPECIFICATION k With the fuel system, the high-pressure circuit is

under extremely high pressure, so if fuel leaks when the engine is running, there is danger of fire.

Check for fuel leakage as follows when checking the fuel circuit or when equipment has been removed and installed. k Never attempt to approach high-pressure piping

connections until the check for fuel leakage is completed.

★ To make it easier to check for fuel leakage, wipe the engine itself and the surrounding area clean and remove all oil and grease before starting the inspection. 1. Thoroughly clean and remove all oil and grease, then spray the fuel supply pump, common rail, fuel injector, and high-pressure piping connections with a color checker (developing solution).

4. Start the engine and run it at high idling. 1) Check the fuel piping and equipment for fuel leakage. ★ Check the high-pressure circuit for fuel leakage, particularly at the places sprayed with color checker. ★ If there is fuel leakage, carry out repairs, then repeat the check from Step 1. 5. Start the engine, run it at high idling, then apply load to the engine. ★ Extend the boom cylinder and relieve the circuit. 1) Check the fuel piping and equipment for fuel leakage. ★ Check the high-pressure circuit for fuel leakage, particularly at the places sprayed with color checker. ★ If there is fuel leakage, carry out repairs, then repeat the check from Step 1. ★ If no fuel leakage is found, the check is complete.

2. Start the engine, run it at under 1000 rpm, and when the speed stabilizes, stop the engine. 1) Check the fuel piping and equipment for fuel leakage. ★ Check the high-pressure circuit for fuel leakage, particularly at the places sprayed with color checker. ★ If there is fuel leakage, carry out repairs, then repeat the check from Step 1. 3. Start the engine and run it at low idling. 1) Check the fuel piping and equipment for fuel leakage. ★ Check the high-pressure circuit for fuel leakage, particularly at the places sprayed with color checker. ★ If there is fuel leakage, carry out repairs, then repeat the check from Step 1.

12-30 2

125-3 SERIES

TESTING AND ADJUSTING

ADJUSTING ENGINE STOP MOTOR LEVER

ADJUSTING ENGINE STOP MOTOR LEVER IN-LINE FUEL INJECTION PUMP SPECIFICATION 1. Temporarily install ball joint (3) to cable (2) of engine stop motor (1) (tighten fully, then turn back approx. 1/2 turn), then install a ball joint to the stop lever of the fuel injection pump.

3. Adjust so that clearance a between stop lever (4) of the fuel injection pump and STOP stopper (5) is 1 – 2 mm. Carry out the adjustment with nut (6) holding the cable to the bracket, or make fine adjustments by changing the amount that ball joint (3) is screwed in.

2. Pull injection pump stop lever (4) by hand to the ENGINE STOP (NO INJECTION) position, and temporarily assemble the cable to the bracket. When doing this, put stop lever (4) in contact with ENGINE STOP stopper (5), and temporarily fit the cable to the bracket using lock nut (6). ★ Engine stop motor (1) is delivered with cable (2) pulled (ENGINE STOP position). ★ Stop lever (4) of the fuel injection pump is at the RUN position when the lever is free. (It is pulled to the RUN position by a spring.)

125-3 SERIES

12-31 2

TESTING AND ADJUSTING

4. Tighten all bolts and nuts. 5. Turn the engine starting switch ON and OFF repeatedly, and check that engine stop motor (1) and the cable move smoothly. Then check the following points again. 1) When the engine is running, check visually that there is slack in the engine stop motor cable, and that the stop lever of the fuel injection pump is fully returned to the RUN position. 2) Check again that the clearance between the stop lever and the STOP stopper is 1 – 2 mm when the engine is stopped. ★ The engine stop motor has limit switches built in at both ends of the cable stroke. ★ Engine stop motor stroke: 35 mm Fuel injection pump stop lever stroke: 30 mm

ADJUSTING ENGINE STOP MOTOR LEVER

★ Problems caused by defective adjustment of the engine stop motor cable. •

When the clearance between the stop lever and STOP stopper is excessive with the engine stop motor cable pulled

•

Engine does not stop

•

When the clearance between the stop lever and the RUN stopper is excessive at the free position

•

Fuel injection amount drops, causing loss of engine output

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

12-32 2

125-3 SERIES

TESTING AND ADJUSTING

CALIBRATION DATA

CALIBRATION DATA IN-LINE FUEL INJECTION PUMP SPECIFICATION Engine

Applicable machine WA430-5

injection pump part number 6156-71-1210

Engine serial number

Page 12-51

SAA6D125E-3

12-50 (7)

125-3 SERIES

TESTING AND ADJUSTING

CALIBRATION DATA

(CALIBRATION DATA) Injection Pump Assembly Number 6156-71-1210 (106691-4110)

Applicable Machine Model

( ): Injection pump manufacturer’s part No. Injection Pump Type

Injection pump manufacturer

PE-P (PS3)

BOSCH

Counterclockwise

Flywheel horsepower

• Rack positions B to E are the reference volume when adjusting the injection volume. • Marks
are average volumes.

59°30’ – 60°30’

High idling speed

(rpm)

3.0 – 4.5

Low idling speed

(rpm)

(mm) (mm3/st)

2,250 ± 50 770

Pump tester capacity for Service standard

90

+50 0

Motor 7.5 kW

( ): Injection pump manufacturer’s part number

Nozzle & nozzle holder part No.

(mm) (°C)

Nozzle opening pressure

(MPa{kg/cm2})

Transfer pump pressure

(kPa{kg/cm2})

Rack point

Service standard

Manufacturer standard

(105780-8140)

6156-11-3200 (105111-5090)

(105780-0000) (105780-2080)

6156-11-3220 (105025-4060) 6152-12-3110 (105041-7130)

8 X 3 X 600

6 X 2.2 X 790

ASTM D975 No.2 diesel fuel or equivalent 40 to 45 17.2{175} 27.5{280} 255{2.6} Service standard (cc/1000 st.) Maximum Injection variance volume between cylinder

255{2.6} Manufacturer standard (cc/ st) Maximum Injection variance volume between cylinder

Rack position (mm)

Pump speed (rpm)

12.3

1000


149 ± 2

±3

12.3 7.2 —

700 400 100


165 ± 3
21 ± 1.5
150 ± 10

±4 ± 15 —

A (Basic point) B C D E

Governor performance curve

125-3 SERIES

941 {96}/1,400(Gross)

(Nm {kgm} / rpm)

• Service standard Nozzle part No. indicates data using Nozzle holder part No. calibration test parts. Injection pipe (Outside dia. x inside dia. x length) • Manufacturer standard is data for Test oil factory test. Oil temperature

Injection volume

174 {233}/2,000 (Gross)

Maximum torque

Calibration Standard Conditions

Serial No.

(kW {HP}) / rpm

1–5–3–6–2–4

Injection interval

Delivery valve retraction volume

Model SAA6D125E-3

Engine Specification

Rotating direction

Plunger pre-storoke

Serial No.

WA430-5

Injection pump specification

Injection order

Applicable Engine

Boost compensator performance curve

12-51 (8)

TESTING AND ADJUSTING

PERFORMANCE TEST

RUN-IN STANDARD IN-LINE FUEL INJECTION PUMP SPECIFICATION Engine

Machine model

Item

Running time min Engine speed rpm WA430-5 Dynamometer N{kg} load Output kW{HP}

Order 1

2

3

4

5

2 770 0{0}

8 1,000 304{31}

2 1,200 608{62}

3 1,500 961{98}

5 2,000 1,210{123}

0{0}

23{31}

55{73}

108{145}

181{243}

6

min Running time Engine speed rpm Dynamometer N{kg} load Output kW{HP}

SAA6D125E-3

Running time min Engine speed rpm Dynamometer N{kg} load Output kW{HP} Running time min Engine speed rpm Dynamometer N{kg} load Output kW{HP} Running time min Engine speed rpm Dynamometer N{kg} load Output kW{HP} Running time min Engine speed rpm Dynamometer N{kg} load Output kW{HP}

+ The table gives the standard values for machines without fan. + The loads for the dynamometer are at an arm’s length of 716 mm.

12-70 (8)

125-3 SERIES

TESTING AND ADJUSTING

PERFORMANCE TEST

COMMON RAIL SYSTEM SPECIFICATION Engine

SA6D125E-3

Machine model

Order

Item

1

2

3

4

5

Running time min Engine speed rpm D65EX-15 Dynamomter N{kg} D65PX-15 load Output kW{HP}

2 825 0{0}

8 1,000 215{22}

2 1,200 529{54}

3 1,500 843{86}

5 1,950 1,058{108}

0{0}

16.2{22}

47.8{64}

94.9{127}

154{206}

Running time min Engine speed rpm D85EX-15 Dynamomter N{kg} D85PX-15 load Output kW{HP}

2 750 0{0}

8 950 275{28}

2 1,140 686{70}

3 5 1,425 1,900 1,098{112} 1,363{139}

0{0}

20{27}

59{79}

Running time min Engine speed rpm WA470-5 Dynamomter N{kg} load kW{HP} Output

2 750 0{0}

8 1,000 275{28}

2 1,200 677{69}

0{0}

21{28}

61{82}

Running time Engine speed Dynamomter load Output Running time Engine speed Dynamomter load Output Running time Engine speed Dynamomter load Output Running time Engine speed Dynamomter load Output

min rpm N{kg}

2 750 0{0}

8 1,000 284{29}

2 1,200 706{72}

3 5 1,500 2,000 1,120{114} 1,400{143}

kW{HP} min rpm N{kg}

0{0} 2 725 0{0}

21{29} 8 1,000 333{34}

63.3{85} 2 1,200 834{85}

126{169} 210{282} 3 5 1,500 2,000 1,330{136} 1,670{170}

kW{HP} min rpm N{kg}

0{0} 2 1,000 0{0}

25{34} 8 1,000 340{35}

75{101} 2 1,200 860{88}

150{201} 250{335} 3 5 1,500 1,850 1,380{141} 1,860{190}

kW{HP} min rpm N{kg}

0{0} 2 750 0{0}

25.7{34} 8 1,000 304{31}

kW{HP}

0{0}

23{31}

WA480-5

SAA6D125E-3 HM300-1

PC400-7 PC450-7

HD255-5

117{157}

6

195{261}

5 3 1,500 2,000 1,080{110} 1,350{138} 121{163}

203{272}

78.0{105} 155{208} 259{347} 2 3 5 1,200 1,500 2,100 765{78} 1,226{125} 1,530{156} 69{93}

138{185}

241{323}

+ The table gives the standard values for machines without fan. + The loads for the dynamometer are at an arm’s length of 716 mm.

125-3 SERIES

12-71 (8)

TESTING AND ADJUSTING

PERFORMANCE TEST

PERFORMANCE TEST STANDARDS IN-LINE FUEL INJECTION PUMP SPECIFICATION Engine

Machine model

Test item Rated horsepower Max. torque

WA430-5

High idling speed Low idling speed

Specification value 174 kW/2,000 rpm {234 HP/2,000 rpm} 941 Nm/1,400 rpm {96 kgm/1,400 rpm} 2,250 ± 50 rpm 770

+50 0

rpm

Speed (rpm)

Dynamometer load (N {kg})

2,000 ± 5

2,250 ± 50 rpm

1,130 – 1,200 {115 – 122} 1,280 – 1,350 {130 – 138} —

+50 0

—

1,400 ± 100

770

rpm

Rated horsepower Max. torque High idling speed Low idling speed Rated horsepower Max. torque High idling speed Low idling speed SAA6D125E-3

Rated horsepower Max. torque High idling speed Low idling speed Rated horsepower Max. torque High idling speed Low idling speed Rated horsepower Max. torque High idling speed Low idling speed

★ This table shows the standard values using the JIS correction factor. ★ The output and torque values in the table are the standard values with the fan removed, so they are different from the specification values. ★ The table shows the standard values with an air cleaner installed, muffler installed, alternator under no load, and air compressor open (when installed). ★ The dynamometer load shows the value for an arm length of 716 mm.

12-74 (5)

125-3 SERIES

TESTING AND ADJUSTING

PERFORMANCE TEST

Fuel consumption (sec/300cc)

Cooling water Lubricating oil Lubricating oil pressure temperature temperature (ºC) (ºC) (kPa{kg/cm2})

Output (kW{HP})

Torque Nm{kgm})

169 – 179 (Gross) {227 – 241} (Gross) —

—

70 – 90

90 – 110

70 – 90

90 – 110

—

914 – 969 (Gross) {93.2 – 98.8} (Gross) —

—

70 – 90

90 – 110

—

—

—

70 – 90

80 – 110

392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} Min. 147 {Min. 1.5}

Exhaust temperature (ºC) Max. 650 Max. 650 — —

★ Use ASTMD975 diesel oil as the fuel. ★ Use SAE15W-40 or SAE30 as the lubricating oil.

125-3 SERIES

12-75 (5)

TESTING AND ADJUSTING

PERFORMANCE TEST

COMMON RAIL SYSTEM SPECIFICATION Engine

Machine model

Test item Rated horsepower

Max. torque D65EX-15 D65PX-15 High idling speed Low idling speed SA6D125E-3

Rated horsepower Max. torque D85EX-15 D85PX-15 High idling speed Low idling speed Rated horsepower Max. torque WA470-5

High idling speed Low idling speed Rated horsepower Max. torque

WA480-5

High idling speed Low idling speed

SAA6D125E-3

Rated horsepower

Specification value

Speed (rpm)

Dynamometer load (N {kg})

154 kW/1,900 rpm (Gross)

1,950 ± 5

{206 HP/1,900 rpm} (Gross) 1,012 Nm/1,400 rpm (Gross)

1,400 ± 100

2,100 ± 50 rpm

2,100 ± 50 rpm

1,030 – 1,090 {104.7 – 110.7} 1,380 – 1,460 {140 – 148.3} —

825 ± 25 rpm

825 ± 25 rpm

—

195 kW/1,900 rpm (Gross) {261 HP/1,900 rpm} (Gross) 1,265 Nm/1,400 rpm (Gross) {129 kgm/1,400 rpm} (Gross)

1,900 ± 5

2,100 ± 50 rpm

1,327 – 1,409 {135 – 144} 1,713 – 1,820 {175 – 186} —

+50 0

—

{103.2 kgm/1,400 rpm} (Gross)

2,100 ± 50 rpm 750

+50 0

rpm

1,400 ± 100

750

195 kW/2,000 rpm {261 HP/2,000 rpm} 1,245 Nm/1,400 rpm {127 kgm/1,400 rpm} 2,170 +50 -30 rpm

2,170

+50 0

750

750

rpm

2,000 ± 5 1,400 ± 100

2,170

+50 0

750

rpm

+50 -30

+50 0

202 kW/2,000 rpm {271 HP/2,000 rpm} 1,295 Nm/1,400 rpm {132 kgm/1,400 rpm} 2,170 +20 -30 rpm 750

rpm

rpm

rpm

2,000 ± 5 1,400 ± 100 +20 -30

+50 0

rpm

rpm

HM300-1

Low idling speed Rated horsepower

+50 0

—

—

1,850 ± 5

1,400 ± 100

725

rpm

1,930 ± 50 rpm

1,930 ± 50 rpm

1,770 – 1,860 {180 – 190} 1,850 – 1,970 {189 – 201} —

1,000 ± 25 rpm

1,000 ± 25 rpm

—

259 kW/1,850 rpm (Gross) {347 HP/1,850 rpm} (Gross)

Max. torque PC400-7 PC450-7 High idling speed Low idling speed

—

—

1,569 Nm/1,400 rpm (Gross) {160 kgm/1,400 rpm} (Gross)

High idling speed

1,360 – 1,450 {139 – 148} 1,790 – 1,900 {183 – 194} —

2,200 ± 50 rpm

{335 HP/2,000 rpm} (Gross)

Max. torque

—

1,620 – 1,720 {165 – 175} 2,130 – 2,260 {217 – 230} —

250 kW/2,000 rpm (Gross)

2,000 ± 5

1,320 – 1,400 {135 – 143} 1,730 – 1,830 {176 – 187} —

1,371 Nm/1,400 rpm (Gross)

1,400 ± 100

{139.8 kgm/1,400 rpm} (Gross)

★ This table shows the standard values using the JIS correction factor. ★ The output and torque values in the table are the standard values with the fan removed, so they are different from the specification values. ★ The table shows the standard values with an air cleaner installed, muffler installed, alternator under no load, and air compressor open (when installed). ★ The dynamometer load shows the value for an arm length of 716 mm.

12-76 (7)

125-3 SERIES

TESTING AND ADJUSTING

PERFORMANCE TEST

Fuel consumption (sec/300cc)

Cooling water Lubricating oil Lubricating oil pressure temperature temperature (ºC) (ºC) (kPa{kg/cm2})

Output (kW{HP})

Torque Nm{kgm})

150 – 159 (Gross) {201 – 213} (Gross) —

—

70 – 90

90 – 110

980 – 1,040 (Gross)

70 – 90

90 – 110

{100.2 – 106.2} (Gross)

—

—

70 – 90

90 – 110

—

—

70 – 90

80 – 110

70 – 90

90 – 110

70 – 90

90 – 110

70 – 90

90 – 110

189 – 201 (Gross) — {253 – 270} (Gross) — 1,230 – 1,310 (Gross) {125 – 133} (Gross) — — —

—

70 – 90

80 – 110

198 – 210 {266 – 282} —

—

70 – 90

90 – 110

70 – 90

90 – 110

—

1,240 – 1,310 {126 – 134} —

70 – 90

90 – 110

—

—

70 – 90

80 – 110

205 – 218 {275 – 292} —

—

70 – 90

90 – 110

70 – 90

90 – 110

—

1,280 – 1,360 {131 – 139} —

70 – 90

90 – 110

—

—

70 – 90

80 – 110

243 – 257 (Gross) {325 – 345} (Gross) —

—

70 – 90

90 – 110

1,520 – 1,620 (Gross)

70 – 90

90 – 110

—

{155 – 165} (Gross) —

70 – 90

90 – 110

—

—

70 – 90

80 – 110

244 – 259 (Gross) {327 – 347} (Gross) —

—

70 – 90

90 – 110

1,330 – 1,410 (Gross)

70 – 90

90 – 110

—

{135.6 – 144} (Gross) —

70 – 90

90 – 110

—

—

70 – 90

80 – 110

Exhaust temperature (ºC)

392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} Min. 147 {Min. 1.5} 392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} Min. 147 {Min. 1.5} 392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} Min. 147 {Min. 1.5} 392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} Min. 147 {Min. 1.5}

Max. 650

392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} Min. 147 {Min. 1.5}

Max. 650

392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} Min. 147 {Min. 1.5}

Max. 680

Max. 650 — — Max. 680 Max. 680 — — Max. 650 Max. 650 — — Max. 650 Max. 650 — —

Max. 680 — —

Max. 680 — —

★ Use ASTMD975 diesel oil as the fuel. ★ Use SAE15W-40 or SAE30 as the lubricating oil.

125-3 SERIES

12-77 (7)

TESTING AND ADJUSTING

PERFORMANCE TEST

COMMON RAIL SYSTEM SPECIFICATION Engine

Machine model

HD255-5

Specification value

Speed (rpm)

Dynamometer load (N {kg})

Rated horsepower

241 kW/2,100 rpm (Gross)

2,100 ± 5

Max. torque

{323 HP/2,100 rpm} (Gross) 1,373 Nm/1,400 rpm (Gross) {140 kgm/1,400 rpm} (Gross)

1,400 ± 5

Test item

High idling speed

2,420

rpm

2,420 +80 –20 rpm

1,520 – 1,610 {155 – 164} 1,860 – 1,970 {190 – 201} —

Low idling speed

750 ± 50 rpm

750 ± 50 rpm

—

+80 –20

Rated horsepower Max. torque High idling speed Low idling speed Rated horsepower Max. torque High idling speed Low idling speed SAA6D125E-3

Rated horsepower Max. torque High idling speed Low idling speed Rated horsepower Max. torque High idling speed Low idling speed Rated horsepower Max. torque High idling speed Low idling speed

+ This table shows the standard values using the JIS correction factor. + The output and torque values in the table are the standard values with the fan removed, so they are different from the specification values. + The table shows the standard values with an air cleaner installed, muffler installed, alternator under no load, and air compressor open (when installed). + The dynamometer load shows the value for an arm length of 716 mm.

12-78 (8)

125-3 SERIES

TESTING AND ADJUSTING

Output (kW{HP})

PERFORMANCE TEST

Torque Nm{kgm})

239 – 253 (Gross) — {325 – 344} (Gross) — 1,334 – 1,416 (Gross)

Fuel consumption (sec/300cc)

Cooling water Lubricating oil Lubricating oil pressure temperature temperature (ºC) (ºC) (kPa{kg/cm2})

—

70 – 90

90 – 110

—

70 – 90

90 – 110

{136 – 144} (Gross)

—

—

—

70 – 90

90 – 110

—

—

—

70 – 90

90 – 110

392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} 392 – 686 {4.0 – 7.0} Min. 147 {Min. 1.5}

Exhaust temperature (ºC) Max. 700 Max. 700 — —

+ Use ASTMD975 diesel oil as the fuel. + Use SAE15W-40 or SAE30 as the lubricating oil.

125-3 SERIES

12-79 (8)

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) POINTS TO REMEMBER WHEN TROUBLESHOOTING ..........................................................................12-102 METHOD OF USING TROUBLESHOOTING CHARTS..............................................................................12-103 S-1 Starting performance is poor (starting always takes time) ....................................................................12-107 S-2 Engine does not start ............................................................................................................................12-108 S-3 Engine does not pick up smoothly (follow-up is poor)...........................................................................12- 111 S-4 Engine stops during operations ............................................................................................................12- 112 S-5 Engine does not rotate smoothly (hunting) ...........................................................................................12- 113 S-6 Engine lacks output (or lacks power) ....................................................................................................12- 114 S-7 Exhaust smoke is black (incomplete combustion) ................................................................................12- 115 S-8 Oil consumption is excessive (or exhaust smoke is blue).....................................................................12- 116 S-9 Oil becomes contaminated quickly .......................................................................................................12- 117 S-10 Fuel consumption is excessive ...........................................................................................................12- 118 S-11 Oil is in cooling water (or water spurts back, or water level goes down).............................................12- 119 S-12 Oil pressure caution lamp lights up (drop in oil pressure)...................................................................12-120 S-13 Oil level rises (water, fuel in oil) ..........................................................................................................12-121 S-14 Water temperature becomes too high (overheating)...........................................................................12-122 S-15 Abnormal noise is made .....................................................................................................................12-123 S-16 Vibration is excessive .........................................................................................................................12-124

125-3 SERIES

12-101

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the parking brake is securely applied. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious burns. Always wait for the water temperature to go down before removing the radiator cap. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. When removing a plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled • It will become impossible to find the cause of the failure. It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?

12-102

3. Checks before troubleshooting 1) Is there any sign of abnormality in the machine or engine? 2) Always carry out the Checks before starting. 3) Carry out other checks if necessary. 4) Other maintenance items can be checked ex t e r n al l y, s o c h e c k an y i te m th a t i s considered to be necessary. 5) Check for any error display on the controller. 4. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. ★ When operating the machine to re-enact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting Us e th e r e s u l ts o f t he i nv e s ti g a ti o n a n d inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting matrix or flowchart to locate the position of the failure exactly. ★ The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

125-3 SERIES

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation.

[Questions] Sections + in the chart on the right corresponds to the items where answers can be obtained from the user. The items in are items that can be obtained from the user, depending on the user's level.

[Check items] The serviceman carries out simple inspection to narrow down the causes. The items under in the chart on the right correspond to this.

[Causes] The serviceman narrows down the causes from information that he has obtained from the user and the results of that he has obtained from his own inspection.

[Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items]. The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with , and of these, causes that have a high probability are marked with . Check each of the [Questions] and [Check items] in turn, and marked the or in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting. Use the in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference.

125-3 SERIES

12-103

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING CHARTS

<Example of troubleshooting> Exhaust smoke is black S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black • Insufficient intake of air • There is excessive fuel. • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating ★ See troubleshooting for [Overheat]. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)

12-104

125-3 SERIES

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

125-3 SERIES

METHOD OF USING TROUBLESHOOTING

12-105 2

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-1

S-1 Starting performance is poor (starting always takes time) General causes why starting performance is poor • Defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel ★ With the common rail fuel injection system, the fuel injection timing is recognized electrically, so even when the starting operation is carried out, the engine may not start until the crankshaft has completed two rotations. However, this does not indicate any abnormality.

125-3 SERIES

12-107 2

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-2

S-2 Engine does not start a) Engine does not turn General causes why engine does not turn • Internal parts of engine seized ★ See "Engine stops during operations". • Defective electrical system • Failure in power train ★ Carry out troubleshooting of the machine.

12-108

125-3 SERIES

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-2

b) Engine turns but no exhaust smoke comes out General causes why engine turns but no exhaust smoke comes out • Fuel is not being supplied • Supply of fuel is extremely small • Improper selection of fuel (particularly in winter)

125-3 SERIES

12-109

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-2

c) Exhaust smoke comes out but engine does not start (Fuel is being injected) General causes why exhaust smoke comes out but engine does not start • Lack of rotating force due to defective electrical system • Insufficient supply of fuel • Insufficient intake of air • Improper selection of fuel

12-110

125-3 SERIES

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-3

S-3 Engine does not pick up smoothly (follow-up is poor) General causes why engine does not pick up smoothly • Insufficient intake of air • Insufficient supply of fuel • Abnormal fuel injection condition • Improper selection of fuel • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)

125-3 SERIES

12-111

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-4

S-4 Engine stops during operations General causes why engine stops • Internal part of engine seized • Insufficient supply of fuel • Engine overheating ★ See troubleshooting for [Overheat]. • Failure in power train ★ Carry out troubleshooting of the machine.

12-112

125-3 SERIES

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-5

S-5 Engine does not rotate smoothly (hunting) General causes why engine does not rotate smoothly • Air in fuel system • Speed sensor is not normal (abnormality not big enough to generate error display)

125-3 SERIES

12-113

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-6

S-6 Engine lacks output (or lacks power) General causes why engine lacks output • Insufficient intake of air • Insufficient supply of fuel • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating ★ See troubleshooting for [Overheat]. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)

12-114

125-3 SERIES

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-7

S-7 Exhaust smoke is black (incomplete combustion) General causes why exhaust smoke is black • Insufficient intake of air • There is excessive fuel. • Abnormal fuel injection condition • Improper selection of fuel • Engine overheating ★ See troubleshooting for [Overheat]. • Controller controlled by delayed mode (The injection amount (output) is limited because an error has occurred in the electrical system.)

125-3 SERIES

12-115

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-8

S-8 Oil consumption is excessive (or exhaust smoke is blue) General causes why oil consumption is excessive • Abnormal combustion of oil • The engine has been run at low or high idling for a long time continuously (more than 20 minutes continuous operation is not allowed). • External leakage of oil • Wear of lubrication system

12-116

125-3 SERIES

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-9

S-9 Oil becomes contaminated quickly General causes why oil becomes contaminated quickly • Entry of exhaust gas into oil due to internal wear • Clogging of lubrication passage • Improper fuel used • Improper oil used • Operation under excessive load

125-3 SERIES

12-117

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-10

S-10 Fuel consumption is excessive General causes why fuel consumption is excessive • Leakage of fuel • Improper condition of fuel injection (injection pressure, injection timing) • Excessive injection of fuel

12-118

125-3 SERIES

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-11

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

125-3 SERIES

12-119

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-12

S-12 Oil pressure caution lamp lights up (drop in oil pressure) General causes why oil pressure drops • Leakage, clogging, wear of lubricating system • Defective oil pressure control • Improper oil used (improper viscosity) • Deterioration of oil due to overheating

12-120

125-3 SERIES

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-13

S-13 Oil level rises (water, fuel in oil) General causes why oil level rises • Water in oil (cloudy white) • Fuel in oil (diluted, smells of diesel fuel) ★ If there is oil in the cooling water, carry out troubleshooting for "Oil is in cooling water".

125-3 SERIES

12-121

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-14

S-14 Water temperature becomes too high (overheating) General causes why water temperature becomes too high • Lack of cooling air (deformation, damage of fan) • Drop in heat dissipation efficiency • Defective cooling circulation system • Rise in oil temperature in power train ★ Carry out troubleshooting for machine.

12-122

125-3 SERIES

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-15

S-15 Abnormal noise is made General causes why abnormal noise is made • Abnormality due to defective parts • Abnormal combustion • Air sucked in from intake system ★ Judge if the noise is an internal noise or an external noise. ★ If the engine is not thoroughly warmed up, the engine sound becomes slightly louder because it is operated in the low temperature mode, but this is not an abnormality. ★ When the engine is accelerated, it enters the acceleration mode and the engine noise is higher for 3 seconds, but this is not an abnormality.

125-3 SERIES

12-123

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

S-16

S-16 Vibration is excessive General causes why vibration is excessive • Defective parts (abnormal wear, breakage) • Improper alignment with machine • Abnormal combustion ★ If there is abnormal noise together with the vibration, carry out troubleshooting also for "Abnormal noise is made".

12-124

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) POINTS TO REMEMBER WHEN TROUBLESHOOTING...........................................................................12-203 METHOD OF USING TROUBLESHOOTING FLOWCHART ......................................................................12-204 ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING ......................12-205 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED ................................................................................................12-208 E-1 Error code [E-1b] [Abnormality in NE revolution sensor system] ..........................................................12-217 E-2 Error code [E-1C] [Abnormality in G revolution sensor system]............................................................12-218 E-3 Error code [E-20] [Abnormality in model selection system] ..................................................................12-219 E-4 Error code [E-22] [Overrun]...................................................................................................................12-220 E-5 Error code [E-23] [Overheat] .................................................................................................................12-220 E-6 Error code [E-24] [Drop in oil pressure] ................................................................................................12-221 E-7 Error code [E-30] [Abnormality in idling validation signal system] ........................................................12-222 E-8 Error code [E-31] [Abnormality in throttle sensor system].....................................................................12-224 E-9 Error code [E-34] [Abnormality in water temperature high-temperature sensor system] ......................12-227 E-10 Error code [E-36] [Abnormality in oil pressure switch system]............................................................12-228 E-11 Error code [E-3C] [Abnormality in boost pressure sensor system] .....................................................12-230 E-12 Error code [E-3d] [Abnormality in fuel temperature sensor system] ...................................................12-231 E-13 Error code [E-50] [Abnormality in preheating relay connecting point system] ....................................12-232 E-14 Error code [E-51] [Abnormality in preheat relay coil system] ..............................................................12-233 E-15 Error code [E-54] [Short circuit in starting switch C system]...............................................................12-234 E-16 Error code [E-56] [Power source system abnormality 1].....................................................................12-236 E-17 Error code [E-57] [Power source system abnormality 2].....................................................................12-238 E-18 Error code [E-5A] [Abnormality in fuel injection quantity control switch signal]...................................12-239 E-19 Error code [E-6A] [Abnormality in water temperature low-temperature sensor system] .....................12-240 E-20 Error code [E-70] [Excess current in fuel supply pump PCV1 system] ...............................................12-241 E-21 Error code [E-71] [Excess current in fuel supply pump PCV2 system] ...............................................12-242 E-22 Error code [E-74] [Disconnection in fuel supply pump PCV1 system] ................................................12-243 E-23 Error code [E-75] [Disconnection in fuel supply pump PCV2 system] ................................................12-244 E-24 Error code [E-77] [Abnormality in common rail fuel pressure sensor system] ....................................12-245 E-25 Error code [E-79] [Common rail fuel high pressure abnormality 1] Error code [E-7A] [Common rail fuel high pressure abnormality 2].....................................................12-246 E-26 Error code [E-7b] [Fuel supply pump non-force feed 1] Error code [E-7C] [Fuel supply pump non-force feed 2] ......................................................................12-248

★ This section gives the outline of the troubleshooting procedures for troubleshooting of the electrical system related to the engine proper and the engine controller. When carrying out troubleshooting of the electrical system with the engine mounted on the machine, see this section and the shop manual for the machine. 125-3 SERIES

12-201

TROUBLESHOOTING

E-27 Error code [E-7d] [Abnormality in common rail fuel pressure] ............................................................ 12-250 E-28 Error code [E-80] [Defective controller]............................................................................................... 12-250 E-29 Error code [E-81] [Disconnection in No. 1 fuel injector system].......................................................... 12-251 E-30 Error code [E-82] [Disconnection in No. 2 fuel injector system].......................................................... 12-252 E-31 Error code [E-83] [Disconnection in No. 3 fuel injector system].......................................................... 12-253 E-32 Error code [E-84] [Disconnection in No. 4 fuel injector system].......................................................... 12-254 E-33 Error code [E-85] [Disconnection in No. 5 fuel injector system].......................................................... 12-255 E-34 Error code [E-86] [Disconnection in No. 6 fuel injector system].......................................................... 12-256 E-35 Error code [E-8A] [Short circuit in No. 1, No. 2, No. 3 fuel injector system]........................................ 12-257 E-36 Error code [E-8b] [Short circuit in No. 4, No. 5, No. 6 fuel injector system] ........................................ 12-260

12-202

125-3 SERIES

TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the parking brake is securely applied. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious burns. Always wait for the water temperature to go down before removing the radiator cap. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (–) terminal of the battery first. When removing a plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly. The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components If components are disassembled immediately any failure occurs: • Parts that have no connection with the failure or other unnecessary parts will be disassembled • It will become impossible to find the cause of the failure. It will also cause a waste of man-hours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. Fo r t h i s r e a s o n , w h e n c a r r y i n g o u t troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before?

125-3 SERIES

3. Checks before troubleshooting 1) Is there any sign of abnormality in the machine or engine? 2) Always carry out the Checks before starting. 3) Carry out other checks if necessary. 4) Other maintenance items can be checked ex te r na l l y, s o c h e ck a ny i te m t h a t i s considered to be necessary. 5) Check for any error display on the controller. 4. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. ★ When operating the machine to re-enact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting U s e t h e r es ul t s o f t h e i nve s t i g at i o n a n d inspection in Items 2 – 4 to narrow down the causes of failure, then use the troubleshooting matrix or flowchart to locate the position of the failure exactly. ★ The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause.

12-203

TROUBLESHOOTING

METHOD OF USING TROUBLESHOOTING FLOWCHART

METHOD OF USING TROUBLESHOOTING FLOWCHART Troubleshooting code number and problem The title at the top of the troubleshooting chart gives the troubleshooting code number and the problem with the machine. General precautions When carrying out troubleshooting for the problem, precautions that apply to all items are given at the top of the page under the title and marked with ★. The common precautions marked ★ at the top of the page are not given in the (box formed by a broken line) on the left, but must always be followed when carrying out the check given in the on the right. Distinguishing conditions Even with the same problem, the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode is further divided into sections marked with small letters (for example, a), b)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in the flowchart. Method of following troubleshooting chart NOTE: The number written at the top right corner of the is an index number; it does not indicate the order to follow.) • To the left of the there is (box formed by a broken line). This contains the procedure and conditions needed for inspection and measurement of the item in the . Before starting inspection or measurement, always read the instructions for the procedure carefully, and make sure that you understand them. • Check or measure the item inside , and judge if the result is YES or NO. If the judgement values in the are correct or the answer to the question inside the is YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line. Continue the troubleshooting for the next item in the same way. Following the YES or NO lines according to the results of the inspection or measurement will lead finally to the Cause and Remedy block. Check the cause and take the action given as the remedy. Troubleshooting tools Details of the tools needed for troubleshooting are given separately in the table of TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING. <Example of troubleshooting> E-20 Error code [E-70] [Excess current in fuel supply pump PCV1 system] ★ Before carrying out troubleshooting, check that all the related connectors are properly inserted. ★ Always connect any disconnected connectors before going on the next step.

Table 1 PV1 (male) Between (1) and (2) Between (1)(2) and ground

12-204

Table 2 Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

CN7 (male) Between (10) and (11) Between (10)(11) and ground

Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

125-3 SERIES

TROUBLESHOOTING

ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING

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

125-3 SERIES

12-205

TROUBLESHOOTING

ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING

2. Table of error codes Error code E-1b E-1C E-20 E-22 E-23 E-24 E-30 E-31 E-34 E-36 E-3C E-3d E-50 E-51 E-54 E-56 E-57 E-5A E-6A E-70 E-71 E-74 E-75 E-77 E-79 E-7A E-7b E-7C E-7d E-80 E-81 E-82 E-83 E-84 E-85 E-86 E-8A E-8b

12-206

Nature of abnormality Abnormality in NE revolution sensor system Abnormality in G revolution sensor system Abnormality in model selection system Overrun Overheat Drop in oil pressure Abnormality in idling validation signal system Abnormality in throttle sensor system Abnormality in water temperature high-temperature sensor system Abnormality in oil pressure switch system Abnormality in boost pressure sensor system Abnormality in fuel temperature sensor system Abnormality in preheat relay contact system Abnormality preheat relay coil system Short circuit in starting switch signal C Abnormality 1 in power source system Abnormality 2 in power source system Abnormality fuel injection quantity control switch signal Abnormality in water temperature low-temperature sensor system Excess current in fuel supply pump PCV1 system Excess current in fuel supply pump PCV2 system Disconnection in fuel supply pump PCV1 system Disconnection in fuel supply pump PCV2 system Abnormality in common rail fuel pressure sensor system Abnormality 1 in common rail fuel high pressure Abnormality 2 in common rail fuel high pressure Fuel supply pump non-force feed 1 Fuel supply pump non-force feed 2 Abnormality in common rail fuel pressure Defective controller Disconnection in No. 1 fuel injector system Disconnection in No. 2 fuel injector system Disconnection in No. 3 fuel injector system Disconnection in No. 4 fuel injector system Disconnection in No. 5 fuel injector system Disconnection in No. 6 fuel injector system Short circuit in No. 1, No. 2, No. 3 fuel injector system Short circuit in No. 4, No. 5, No. 6 fuel injector system

Operation for re-enaction Start engine. Start engine. Turn starting switch ON. Start engine. Start engine. Start engine. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Start engine. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Turn starting switch OFF. Turn starting switch ON. Turn starting switch OFF. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Start engine. Start engine. Start engine. Start engine. Start engine. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON. Turn starting switch ON.

125-3 SERIES

TROUBLESHOOTING

ERROR CODE DISPLAYS AND POINTS TO REMEMBER WHEN TROUBLESHOOTING

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

125-3 SERIES

12-207

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

TROUBLESHOOTING

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

System with abnormality

Nature of abnormality

Abnormality in E-1b NE revolution sensor system

6. Defective contact, disconnection, short circuit, or short circuit with ground in wiring harness inside NE revolution sensor 7. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1 (5) (+) and NE revolution sensor SNE (1) 8. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1 (12) (–) and NE revolution sensor SNE (2) 9. Defective engine controller

Abnormality in E-1C G revolution sensor system

1. Defective contact, disconnection, short circuit, or short circuit with ground in wiring harness inside G revolution sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2 (1) (+) and G revolution sensor SG (1) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2 (9) (–) and G revolution sensor SG (2) 4. Defective engine controller

E-20

Abnormality in model selection system

1. Defective model selection connector 2. Defective contact, or disconnection in wiring harness between controller CN4 (13) and model selection connector MSC (1) 3. Short circuit with ground in wiring harness between controller CN4 (14) and model selection connector MSC (2) 4. Defective contact, or disconnection in wiring harness between controller CN4 (15) and model selection connector MSC (3) 5. Defective engine controller

E-22 Overrun

1. Engine speed goes above operating range. 2. Defective engine controller

E-23 Overheat

1. Engine water temperature goes above operating range. 2. Defective engine controller

E-24

E-30

Drop in oil pressure

1. 2. 3. 4.

Engine oil pressure goes below operating range. Defective oil pressure low-pressure sensor Defective oil pressure high-pressure sensor Short circuit with chassis ground in wiring harness between controller CN4 (5) and oil pressure low-pressure sensor POL 5. Short circuit with chassis ground in wiring harness between controller CN4 (6) and oil pressure low-pressure sensor POH 6. Defective engine controller

Abnormality in idling validation signal system

1. Defective throttle sensor 2. Defective contact or disconnection in wiring harness between controller CN4 (female) (8) (GND) and throttle sensor TS (female) (4) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN4 (female) (11) (signal 2) and throttle sensor TS (female) (5) 4. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN4 (female) (12) (signal 3) and throttle sensor TS (female) (6) 5. Defective engine controller

Abnormality in throttle sensor system (accelerator pedal type)

1. Defective throttle sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1 (4) (power source) and throttle sensor TS (3) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1 (6) (signal) and throttle sensor TS (2) 4. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1 (11) (GND) and throttle sensor TS (1) 5. Defective engine controller

Abnormality in throttle sensor system (fuel control dial type)

1. Defective throttle sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1 (4) (power source) and throttle sensor TS (1) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1 (6) (signal) and throttle sensor TS (2) 4. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1 (11) (GND) and throttle sensor TS (3) 5. Defective engine controller

E-31

Abnormality in water temperature E-34 high-temperature sensor system

12-208

1. Defective water temperature high-temperature sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2 (4) (signal) and water temperature high-temperature sensor TWH (1) 3. Defective contact or disconnection in wiring harness between controller CN2 (10) (GND) and water temperature high-temperature sensor TWH (2) 4. Defective engine controller

125-3 SERIES

TROUBLESHOOTING

Condition when normal

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

Action by controller

Problem that appears on machine

•

Sensor resistance value Between SNE (1) and (2): 85 – 210 Ω

1. Limits output for operation (when problem occurs independently) 2. Control of the system becomes impossible (when E-1C occurs at same time)

1. Reduces output (when problem occurs independently) 2. Engine stops during operation (when E-1C occurs at same time) 3. Engine cannot be started (when E-1C occurs at same time)

•

Sensor resistance value Between SG (1) and (2): 1.4 k – 3.5 kΩ

1. Limits output for operation (when problem occurs independently) 2. Control of the system becomes impossible (when E-1C occurs at same time)

1. Output is reduced (when problem occurs independently) 2. Engine stops during operation (when E-1b occurs at same time) 3. Engine cannot be started (when E-1b occurs at same time)

•

Resistance in ground connection circuit Between CN4 (female) and ground: Max. 1 Ω Resistance in ground cut-off circuit Between CN4 (female) and ground: Min. 1 MΩ

1. Carries out operation under normal control.

1. Output is reduced

1. Stops fuel injection until engine speed goes down to operating range.

1. Engine speed varies abnormally.

1. Limits fuel injection amount until temperature goes down to operating range.

1. Output is reduced

Low-pressure switch resistance value Between POL and ground Engine stopped: Max. 1 Ω Engine above 600 rpm: Min. 1 MΩ High-pressure switch resistance value Between POH and ground Engine stopped: Max. 1 Ω Engine above 1,300 rpm: Min. 1 MΩ

1. Limits output for operation

1. Runs at low idling.

Signal 2 voltage (between CN4 (11) and (8)) Throttle below 0.446 V: Max. 1 V Throttle above 0.446 V: 15 – 30 V Signal 3 voltage (between CN4 (12) and (8)) Throttle below 0.446 V: 15 – 30 V Throttle above 0.446 V: Max. 1 V

1. Carries out operation under normal control.

1. Operates normally.

Sensor power source voltage Between CN1 (4) and (11): 4.6 – 5.4 V Sensor signal voltage Between CN1 (6) and (11): 0.3 – 4.5 V

1. Actuated with throttle signal 100% (when problem occurs independently and simultaneously) 2. Actuated with throttle signal 0% (when E-24 and E-36 occur at same time)

1. Fixed at high idling (when problem occurs independently) 2. Fixed at low idling (when E-24 and E-36 occur at same time)

Sensor power source voltage Between CN1 (4) and (11): 4.6 – 5.4 V Sensor signal voltage Between CN1 (6) and (11): 0.3 – 4.7 V

1. Actuated with throttle signal 100% (when problem occurs independently and simultaneously) 2. Actuated with throttle signal 0% (when E-24 and E-36 occur at same time)

1. Fixed at high idling (when problem occurs independently) 2. Fixed at low idling (when E-24 and E-36 occur at same time)

Sensor resistance value (water temperature: 10 – 100ºC) Between TWH (1) and (2): 90 k – 3.5 kΩ

1. Carries out operation under normal control.

1. Fixes water temperature signal output to machine at 90ºC

•

•

•

•

•

• •

• •

•

125-3 SERIES

12-209

TROUBLESHOOTING

Error code

System with abnormality

Abnormality in E-36 engine oil pressure switch system

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

Nature of abnormality 1. Defective oil pressure low-pressure sensor 2. Defective oil pressure high-pressure sensor 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN4 (5) and oil pressure low-pressure sensor POL 4. Defective contact or disconnection in wiring harness between controller CN4 (6) and oil pressure low-pressure sensor POH 5. Defective engine controller

Abnormality in E-3C boost pressure sensor system

1. Defective boost pressure sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2 (2) (power source) and boost pressure sensor PBA (3) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1 (3) (signal) and boost pressure sensor PBA (2) 4. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2 (10) (GND) and boost pressure sensor PBA (1) 5. Defective engine controller

Abnormality in fuel E-3d temperature sensor system

1. Defective fuel temperature sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2 (11) (signal) and fuel temperature sensor TFL (A) 3. Defective contact or disconnection in wiring harness between controller CN2 (10) (GND) and fuel temperature sensor TFL (B) 4. Defective engine controller

Abnormality in E-50 preheat relay contact system

1. Defective heater relay 2. Defective contact, disconnection, short circuit with ground, or short circuit with power source in wiring harness between controller CN4 (3) and heater relay HR3 3. Defective engine controller

Abnormality in E-51 preheat relay coil system

1. Defective preheater relay 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2 (5) and preheater relay RPH (2) 3. Defective engine controller

Short circuit in E-54 starting switch C signal system

1. Defective starting switch 2. Short circuit with power source in wiring harness between controller CN4 (2) and starting switch terminal C 3. Defective engine controller

Power source E-56 system abnormality 1

1. Defective power source relay 2. Defective contact, disconnection, or short circuit with ground in wiring harness between starting switch terminal ACC and power source relay RPW (1) 3. Defective contact or disconnection in wiring harness between power source relay RPW (2) and ground 4. Defective contact, disconnection, or short circuit with ground in wiring harness between power source fuse and power source relay RPW (3) 5. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN7 (6)(14) and power source relay RPW (5) 6. Defective engine controller

Power source E-57 system abnormality 2

1. Defective power source relay 2. Short circuit with power source in wiring harness between controller CN7 (6)(14) and power source relay (5) 3. Defective engine controller

Abnormality in fuel injection quantity E-5A control switch signal

1. Defective setting of fuel injection quantity control switch 2. Defective engine controller

Abnormality in water temperature E-6A low-temperature sensor system

1. Defective water temperature low-temperature sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2 (3) (signal) and water temperature low-temperature sensor TWL (A) 3. Defective contact or disconnection in wiring harness between controller CN2 (10) (GND) and water temperature low-temperature sensor TWL (B) 4. Defective engine controller

Excess current in E-70 fuel supply pump PCV1 system

1. Defective fuel supply pump PCV1 2. Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN7 (10) and PCV1 solenoid PV1 (1) 3. Short circuit with power source in wiring harness between controller CN7 (11) and PCV1 solenoid PV1 (2) 4. Defective engine controller

Excess current in E-71 fuel supply pump PCV2 system

1. Defective fuel supply pump PCV2 2. Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN7 (4) and PCV2 solenoid PV2 (1) 3. Short circuit with power source in wiring harness between controller CN7 (12) and PCV2 solenoid PV2 (2) 4. Defective engine controller

12-210

125-3 SERIES

TROUBLESHOOTING

Condition when normal •

•

• •

Low-pressure switch resistance value Between POL and ground Engine stopped: Max. 1 Ω Engine above 600 rpm: Min. 1 MΩ High-pressure switch resistance value Between POH and ground Engine stopped: Max. 1 Ω Engine above 1,300 rpm: Min. 1 MΩ Sensor power source voltage Between PBA (3) and (1): 4.6 – 5.4 V Sensor signal voltage Between PBA (2) and (1): 0.3 – 4.7 V

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

Action by controller 1. Carries out operation under normal control.

Problem that appears on machine 1. Operates normally.

1. Operates normally.

—

•

Sensor resistance value (fuel temperature: 10 – 100°C) Between TFL (A) and (B): 9 k – 0.3 kΩ

1. Carries out operation under normal control.

1. Operates normally.

•

Preheating signal voltage Between CN4 (3) and ground Preheating not actuated: Max. 1 V Preheating actuated: 20 – 30 V

1. Carries out operation under normal control.

1. Starting ability in cold weather becomes worse.

•

Preheating signal voltage Between CN1 (5) and (6) Preheating not actuated: 20 – 30 V Preheating actuated: Max. 1 V

1. Carries out operation under normal control.

1. Starting ability in cold weather becomes worse.

•

Starting switch C signal voltage Between CN4 (2) and ground Starting switch at ON: Max. 1 V Starting switch at START: 20 – 30 V

1. Carries out operation under normal control.

1. Operates normally 10 seconds after engine starts.

•

Power source voltage Between CN7 (6)(14) and (5)(13) Starting switch at ON: 20 – 30 V

1. Engine stops during operation. 2. Engine cannot be started. —

•

Power source voltage Between CN7 (6)(14) and (5)(13) Starting switch at OFF: Max. 8 V

1. Carries out operation under normal control.

1. Operates normally.

•

Either fuel injection quantity control switch 1 or 2 of controller is set to [F]

1. Carries out operation under normal control.

1. Fuel injection quantity control setting cannot be changed.

•

Sensor resistance value (water temperature: 10 – 100°C) Between TWL (A) and (B): 9 k – 0.3 kΩ

1. Carries out operation under normal control.

1. Exhaust gas color at low temperatures is poor. 2. Starting ability at low temperatures is poor.

•

Solenoid resistance value Between PV1 (1) and (2): 2.3 – 5.3 Ω

1. Stops output to PCV1 (when problem occurs independently) 2. Stops output to PCV1 and PCV2 (when E-71 occurs at same time)

1. Operates normally (when problem occurs independently) 2. Stops engine (when E-71 occurs at same time)

•

Solenoid resistance value Between PV2 (1) and (2): 2.3 – 5.3 Ω

1. Stops output to PCV2 (when problem occurs independently) 2. Stops output to PCV1 and PCV2 (when E-70 occurs at same time)

1. Operates normally (when problem occurs independently) 2. Stops engine (when E-70 occurs at same time)

125-3 SERIES

12-211

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

TROUBLESHOOTING

Error code

System with abnormality

Nature of abnormality

Disconnection in E-74 fuel supply pump PCV1 system

1. Defective fuel supply pump PCV1 2. Defective contact or disconnection in wiring harness between controller CN7 (10) and PCV1 solenoid PV1 (1) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN7 (11) and PCV1 solenoid PV1 (2) 4. Defective engine controller

Disconnection in E-75 fuel supply pump PCV2 system

1. Defective fuel supply pump PCV2 2. Defective contact or disconnection in wiring harness between controller CN7 (4) and PCV2 solenoid PV2 (1) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN7 (12) and PCV2 solenoid PV2 (2) 4. Defective engine controller

Abnormality in common rail fuel pressure sensor system

1. Defective common rail fuel pressure sensor 2. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2 (2) (power source) and fuel pressure sensor PFL (1) 3. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN1 (1) (signal) and fuel pressure sensor PFL (2) 4. Defective contact, disconnection, or short circuit with ground in wiring harness between controller CN2 (10) (GND) and fuel pressure sensor PFL (3) 5. Defective engine controller

E-77

1. 2. 3. 4. 5.

Common rail fuel E-79 high-pressure abnormality 1 Common rail fuel E-7A high-pressure abnormality 2

★

Supply pump E-7C non-force feed abnormality 2 Abnormality in E-7d common rail fuel pressure

See E-79.

1. 2. 3. 4. 5. 6.

Supply pump E-7b non-force feed abnormality 1

Viscosity of fuel is too high (unsuitable fuel) Defective overflow valve Defective pressure limiter Defective common rail fuel pressure sensor Clogged overflow piping

Defective fuel low-pressure circuit (etc) Defective fuel supply pump PSV Defective pressure limiter Defective common rail fuel pressure sensor Defective fuel injector Leakage from fuel high-pressure piping

★

See E-7b.

★

See E-79.

1. Defective contact or disconnection in wiring harness between controller CN7 (5)(13) and ground 2. Defective engine controller E-80

Abnormality in controller

Disconnection in E-81 No. 1 fuel injector system

1. Defective No. 1 fuel injector 2. Defective contact or disconnection in wiring harness between controller CN6 (7) (–) and No. 1 injector IJ1 (1) 3. Defective contact or disconnection in wiring harness between controller CN6 (8) (+) and No. 1 injector IJ1 (2) 4. Defective engine controller

Disconnection in E-82 No. 2 fuel injector system

1. Defective No. 2 fuel injector 2. Defective contact or disconnection in wiring harness between controller CN6 (4) (–) and No. 2 injector IJ2 (1) 3. Defective contact or disconnection in wiring harness between controller CN6 (10) (+) and No. 2 injector IJ2 (2) 4. Defective engine controller

Disconnection in E-83 No. 3 fuel injector system

1. Defective No. 3 fuel injector 2. Defective contact or disconnection in wiring harness between controller CN6 (3) (–) and No. 3 injector IJ3 (1) 3. Defective contact or disconnection in wiring harness between controller CN6 (9) (+) and No. 3 injector IJ3 (2) 4. Defective engine controller

12-212

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)ACTION TAKEN BY CONTROLLER AND CON-

Condition when normal

Action by controller

Problem that appears on machine

•

Solenoid resistance value Between PV1 (1) and (2): 2.3 – 5.3 Ω

1. Stops output to PCV1 (when problem occurs independently) 2. Stops output to PCV1 and PCV2 (when E-71 occurs at same time)

1. Operates normally (when problem occurs independently) 2. Stops engine (when E-71 occurs at same time)

•

Solenoid resistance value Between PV2 (1) and (2): 2.3 – 5.3 Ω

1. Stops output to PCV2 (when problem occurs independently) 2. Stops output to PCV1 and PCV2 (when E-70 occurs at same time)

1. Operates normally (when problem occurs independently) 2. Stops engine (when E-70 occurs at same time)

•

Sensor power source voltage Between PFL (1) and (3): 4.6 – 5.4 V Sensor signal voltage Between PFL (2) and (3): 0.3 – 4.7 V

1. Limits output with open control.

1. Output is reduced

1. Operation carried out with limited output

1. Output is reduced

1. Stops output to fuel supply pump 2. Limits output to fuel injector

1. Output is reduced

1. Sets engine output to delayed 2. Operation carried out with limited output

1. Output is reduced

1. Stops output to fuel supply pump 2. Limits output to fuel injector

1. Engine stops

1. Carries out operation under normal control.

1. The engine does not run at high idling speed 2. The engine stops when a large load is applied

1. Operation carried out with limited output

1. The engine does not run at high idling speed 2. The engine stops when a large load is applied 3. Engine stops during operation. 4. Engine cannot be started.

•

—

—

—

—

—

—

•

No. 1 injector resistance value Between IJ1 (1) and (2): 0.4 – 1.1 Ω

1. Stops output to No. 1 injector (when problem occurs independently) 2. Stops output to fuel supply pump, all fuel injectors (when at same time in E-82 to E-86)

1. Output is reduced (when problem occurs independently) 2. Engine stops (when E-82 to E-86 occur at same time)

•

No. 2 injector resistance value Between IJ2 (1) and (2): 0.4 – 1.1 Ω

1. Stops output to No. 2 injector (when problem occurs independently) 2. Stops output to fuel supply pump, all fuel injectors (when E-81 to E-86 occur at same time)

1. Output is reduced (when problem occurs independently) 2. Engine stops (when E-81 to E-86 occur at same time)

•

No. 3 injector resistance value Between IJ3 (1) and (2): 0.4 – 1.1 Ω

1. Stops output to No. 3 injector (when problem occurs independently) 2. Stops output to fuel supply pump, all fuel injectors (when E-81 to E-86 occur at same time)

1. Output is reduced (when problem occurs independently) 2. Engine stops (when E-81 to E-86 occur at same time)

125-3 SERIES

12-213 2

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

TROUBLESHOOTING

Error code

System with abnormality

Nature of abnormality

Disconnection in E-84 No. 4 fuel injector system

1. Defective No. 4 fuel injector 1. Defective contact or disconnection in wiring harness between controller CN7 (3) (–) and No. 4 injector IJ4 (1) 1. Defective contact or disconnection in wiring harness between controller CN7 (9) (+) and No. 4 injector IJ4 (2) 1. Defective engine controller

Disconnection in E-85 No. 5 fuel injector system

1. Defective No. 5 fuel injector 2. Defective contact or disconnection in wiring harness between controller CN7 (1) (–) and No. 5 injector IJ5 (1) 3. Defective contact or disconnection in wiring harness between controller CN7 (7) (+) and No. 5 injector IJ5 (2) 4. Defective engine controller

Disconnection in E-86 No. 6 fuel injector system

1. Defective No. 6 fuel injector 1. Defective contact or disconnection in wiring harness between controller CN7 (2) (–) and No. 6 injector IJ6 (1) 1. Defective contact or disconnection in wiring harness between controller CN7 (8) (+) and No. 6 injector IJ6 (2) 1. Defective engine controller 1. 2. 3. 4. 5.

Short circuit in No. E-8A 1, No. 2, No. 3 fuel injector system

6. 7. 8. 9. 10. 11. 1. 2. 3. 4. 5.

Short circuit in No. E-8b 4, No. 5, No. 6 fuel injector system

6. 7. 8. 9. 10. 11.

12-214

Defective No. 1 fuel injector Defective No. 2 fuel injector Defective No. 3 fuel injector Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN6 (7) (+) and No. 1 injector IJ1 (1) Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN6 (8) (– ) and No. 1 injector IJ1 (2) Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN6 (4) (+) and No. 2 injector IJ2 (1) Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN6 (10) (–) and No. 2 injector IJ2 (2) Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN6 (3) (+) and No. 3 injector IJ3 (1) Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN6 (9) (– ) and No. 3 injector IJ3 (2) Defective contact or disconnection in wiring harness between controller CN7 (5)(13) and ground Defective engine controller Defective No. 4 fuel injector Defective No. 5 fuel injector Defective No. 6 fuel injector Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN7 (3) (+) and No. 4 injector IJ4 (1) Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN7 (9) (– ) and No. 4 injector IJ4 (2) Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN7 (1) (+) and No. 5 injector IJ5 (1) Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN7 (7) (– ) and No. 5 injector IJ5 (2) Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN7 (2) (+) and No. 6 injector IJ6 (1) Short circuit with chassis ground or short circuit with power source in wiring harness between controller CN7 (8) (– ) and No. 6 injector IJ6 (2) Defective contact or disconnection in wiring harness between controller CN7 (5)(13) and ground Defective engine controller

125-3 SERIES

TROUBLESHOOTING

Condition when normal

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

Action by controller

Problem that appears on machine

•

No. 4 injector resistance value Between IJ4 (1) and (2): 0.4 – 1.1 Ω

1. Stops output to No. 4 injector (when problem occurs independently) 2. Stops output to fuel supply pump, all fuel injectors (when E-81 to E-86 occur at same time)

1. Output is reduced (when problem occurs independently) 2. Engine stops (when E-81 to E-86 occur at same time)

•

No. 5 injector resistance value Between IJ5 (1) and (2): 0.4 – 1.1 Ω

1. Stops output to No. 5 injector (when problem occurs independently) 2. Stops output to fuel supply pump, all fuel injectors (when E-81 to E-86 occur at same time)

1. Output is reduced (when problem occurs independently) 2. Engine stops (when E-81 to E-86 occur at same time)

•

No. 6 injector resistance value Between IJ6 (1) and (2): 0.4 – 1.1 Ω

1. Stops output to No. 6 injector (when problem occurs independently) 2. Stops output to fuel supply pump, all fuel injectors (when E-81 to E-85 occur at same time)

1. Output is reduced (when problem occurs independently) 2. Engine stops (when E-81 to E-85 occur at same time)

•

No. 1 injector resistance value Between IJ1 (1) and (2): 0.4 – 1.1 Ω No. 2 injector resistance value Between IJ2 (1) and (2): 0.4 – 1.1 Ω No. 3 injector resistance value Between IJ3 (1) and (2): 0.4 – 1.1 Ω

1. Stops output to No. 1, No. 2, No. 3 fuel injectors (when problem occurs independently) 2. Stops output to fuel supply pump, all fuel injectors (when E-8b occurs at same time)

1. Output is greatly reduced (when problem occurs independently) 2. Engine stops (when E-8b occurs at same time)

No. 4 injector resistance value Between IJ4 (1) and (2): 0.4 – 1.1 Ω No. 5 injector resistance value Between IJ5 (1) and (2): 0.4 – 1.1 Ω No. 6 injector resistance value Between IJ6 (1) and (2): 0.4 – 1.1 Ω

1. Stops output to No. 4, No. 5, No. 6 fuel injectors (when problem occurs independently) 2. Stops output to fuel supply pump, all fuel injectors (when E-8A occurs at same time)

1. Output is greatly reduced (when problem occurs independently) 2. Engine stops (when E-8A occurs at same time)

• •

• • •

125-3 SERIES

12-215

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-1

E-1 Error code [E-1b] [Abnormality in NE revolution sensor system]

Table 1 SNE (male) Between (1) and (2) Between (1)(2) and ground

Resistance value 85 – 210 Ω Min. 1 MΩ

E-1 Related electrical circuit diagram

125-3 SERIES

12-217

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-2

E-2 Error code [E-1C] [Abnormality in G revolution sensor system]

Table 1 SG (male) Between (1) and (2) Between (1)(2) and ground

Resistance value 1.4 k – 3.5 kΩ Min. 1 MΩ

E-2 Related electrical circuit diagram

12-218

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-3

E-3 Error code [E-20] [Abnormality in model selection system] ★ The troubleshooting given below takes a particular machine as an example, so the content of the troubleshooting and the electric wiring diagrams will differ according to the actual model of machine.

Table 1 MSC (female) Between (1) and (8) Between (2) and (8) Between (3) and (8)

Resistance value Max. 1 Ω Min. 1 MΩ Max. 1 Ω

E-3 Related electrical circuit diagram

125-3 SERIES

12-219

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-4, E-5

E-4 Error code [E-22] [Overrun]

E-5 Error code [E-23] [Overheat]

12-220

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-6

E-6 Error code [E-24] [Drop in oil pressure]

E-6 Related electrical circuit diagram

125-3 SERIES

12-221

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-7

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

Fig. 1

12-222

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-7

E-7 Related electrical circuit diagram

125-3 SERIES

12-223

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-8

E-8 Error code [E-31] [Abnormality in throttle sensor system] a) Accelerator pedal type throttle sensor

Table 1 TS (male) Between (1) and (3) Between (2) and (1) Between (2)(3) and ground

12-224

Table 2 Resistance value 4.0 k – 6.0 kΩ 0.5 – 2.7 kΩ Min. 1 MΩ

CN1 (male) Between (4) and (11) Between (6) and (11) Between (4)(6) and ground

Resistance value 4.0 k – 6.0 kΩ 0.5 – 2.7 kΩ Min. 1 MΩ

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-8

E-8 a) Related electrical circuit diagram

125-3 SERIES

12-225

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-8

b) Fuel control dial type throttle sensor

Table 1 TS (male) Between (1) and (3) Between (2) and (3) Between (1)(2) and ground

Table 2 Resistance value 4.0 k – 6.0 kΩ 0.5 – 2.7 kΩ Min. 1 MΩ

CN1 (male) Between (4) and (11) Between (6) and (11) Between (4)(6) and ground

Resistance value 4.0 k – 6.0 kΩ 0.5 – 2.7 kΩ Min. 1 MΩ

E-8 b) Related electrical circuit diagram

12-226

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-9

E-9 Error code [E-34] [Abnormality in water temperature high-temperature sensor system]

Table 1 TWH (male) Between (1) and (2) Between (1) and ground

Resistance value 90 k – 3.5 kΩ Min. 1 MΩ

E-9 Related electrical circuit diagram

125-3 SERIES

12-227

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-10

E-10 Error code [E-36] [Abnormality in oil pressure switch system]

Table 1 CN4 Between (5) and ground

Table 3 CN4 Between (6) and ground

12-228

Table 2 Engine

Voltage

POL

Engine

When stopped

Max. 1 V

At 600 rpm or more

20 – 30 V

Between POL (switch) and ground

When stopped At 600 rpm or more

Engine

Resistance

When stopped

Max. 1 V

At 1,300 rpm or more

20 – 30 V

Table 4 POH Between POH (switch) and ground

Engine When stopped At 1,300 rpm or more

Resistance value Max. 1 Ω Min. 1 MΩ

Resistance Max. 1 Ω Min. 1 MΩ

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-10

E-10 Related electrical circuit diagram

125-3 SERIES

12-229

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-11

E-11 Error code [E-3C] [Abnormality in boost pressure sensor system]

Table 1 CN1, PBA (female) Between CN1 (3) and PBA (2) Between CN1 (3) and ground

Resistance value Max. 1 Ω Min. 1 MΩ

E-11 Related electrical circuit diagram

12-230

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-12

E-12 Error code [E-3d] [Abnormality in fuel temperature sensor system]

Table 1 TFL (Male) Between (A) and (B) Between (A) and ground

Resistance value 9 k – 0.3 kΩ Min. 1 MΩ

E-12 Related electrical circuit diagram

125-3 SERIES

12-231

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-13

E-13 Error code [E-50] [Abnormality in preheating relay connecting point system]

E-13 Related electrical circuit diagram

12-232

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-14

E-14 Error code [E-51] [Abnormality in preheat relay coil system]

E-14 Related electrical circuit diagram

125-3 SERIES

12-233

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-15

E-15 Error code [E-54] [Short circuit in starting switch C system]

E-15 Related electrical circuit diagram

12-234

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-16

E-16 Error code [E-56] [Power source system abnormality 1]

12-236

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-16

E-16 Related electrical circuit diagram

125-3 SERIES

12-237

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-17

E-17 Error code [E-57] [Power source system abnormality 2]

E-17 Related electrical circuit diagram

12-238

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-18

E-18 Error code [E-5A] [Abnormality in fuel injection quantity control switch signal]

125-3 SERIES

12-239

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-19

E-19 Error code [E-6A] [Abnormality in water temperature low-temperature sensor system]

Table 1 TWL (male) Between (A) and (B) Between (A) and ground

Resistance value 9 k – 0.3 kΩ Min. 1 MΩ

E-19 Related electrical circuit diagram

12-240

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-20

E-20 Error code [E-70] [Excess current in fuel supply pump PCV1 system]

Table 1 PV1 (male) Between (1) and (2) Between (1)(2) and ground

Table 2 Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

CN7 (male) Between (10) and (11) Between (10)(11) and ground

Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

E-20 Related electrical circuit diagram

125-3 SERIES

12-241

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-21

E-21 Error code [E-71] [Excess current in fuel supply pump PCV2 system]

Table 1 PV2 (male) Between (1) and (2) Between (1)(2) and ground

Table 2 Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

CN7 (male) Between (4) and (12) Between (4)(12) and ground

Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

E-21 Related electrical circuit diagram

12-242

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-22

E-22 Error code [E-74] [Disconnection in fuel supply pump PCV1 system]

Table 1 CN7 (male) Between (10) and (11) Between (1)(2) and ground

Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

E-22 Related electrical circuit diagram

125-3 SERIES

12-243

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-23

E-23 Error code [E-75] [Disconnection in fuel supply pump PCV2 system]

Table 1 CN7 (male) Between (4) and (12) Between (12) and ground

Resistance value 2.3 – 5.3 Ω Min. 1 MΩ

E-23 Related electrical circuit diagram

12-244

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-24

E-24 Error code [E-77] [Abnormality in common rail fuel pressure sensor system]

Table 1 CN1, PFL (female) Between CN1 (1) and PFL (2) Between CN1 (1) and ground

Resistance value Max. 1 Ω Min. 1 MΩ

E-24 Related electrical circuit diagram

125-3 SERIES

12-245

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-25

E-25 Error code [E-79] [Common rail fuel high pressure abnormality 1] Error code [E-7A] [Common rail fuel high pressure abnormality 2]

12-246

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-26

E-26 Error code [E-7b] [Fuel supply pump non-force feed 1] Error code [E-7C] [Fuel supply pump non-force feed 2]

12-248

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-26

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

Note 2: Method of measuring amount of fuel spill flow The fuel in the spill line is at high temperature (up to 90°C), so be careful not to burn yourself during the operation. 1) Disconnect the hose connected to the spill tube return collection portion (rear of engine). 2) Connect another hose to the tip of the spill tube, and collect the spill fuel in a container. 3) Start the engine, stall the engine at each speed, and measure the spill fuel amount for 1 minute. Limits for fuel spill amount (total for 6 cylinders) Stall speed (rpm) 1,600 1,700 1,800 1,900 2,000

125-3 SERIES

Spill limit (cc/min) 960 1,020 1,080 1,140 1,200

12-249

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-27, E-28

E-27 Error code [E-7d] [Abnormality in common rail fuel pressure] ★ Go to Troubleshooting of error codes [E-79] and [E-7A].

E-28 Error code [E-80] [Defective controller]

E-28 Related electrical circuit diagram

12-250

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-29

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

E-29 Related electrical circuit diagram

125-3 SERIES

12-251

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-30

E-30 Error code [E-82] [Disconnection in No. 2 fuel injector system] A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling controller high voltage circuit.

E-30 Related electrical circuit diagram

12-252

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-31

E-31 Error code [E-83] [Disconnection in No. 3 fuel injector system] A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling controller high voltage circuit.

E-31 Related electrical circuit diagram

125-3 SERIES

12-253

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-32

E-32 Error code [E-84] [Disconnection in No. 4 fuel injector system] A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling controller high voltage circuit.

E-32 Related electrical circuit diagram

12-254

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-33

E-33 Error code [E-85] [Disconnection in No. 5 fuel injector system] A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling controller high voltage circuit.

E-33 Related electrical circuit diagram

125-3 SERIES

12-255

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-34

E-34 Error code [E-86] [Disconnection in No. 6 fuel injector system] A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling controller high voltage circuit.

E-34 Related electrical circuit diagram

12-256

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-35

E-35 Error code [E-8A] [Short circuit in No. 1, No. 2, No. 3 fuel injector system] A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling controller high voltage circuit. a) Determining location of problem

Table 1 CN6 (female) Between (7) and (8) Between (7)(8) and ground

125-3 SERIES

CN6 (female) Between (4) and (10) Between (4)(10) and ground

CN6 (female) Between (3) and (9) Between (3)(9) and ground

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

12-257

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-35

b) Troubleshooting No. 1 fuel injector system

Table 2 IJ1 (female) Between (1) and (2) Between (1)(2) and ground

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

c) Troubleshooting No. 2 fuel injector system

Table 3 IJ2 (female) Between (1) and (2) Between (1)(2) and ground

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

d) Troubleshooting No. 3 fuel injector system

Table 4 IJ3 (female) Between (1) and (2) Between (1)(2) and ground

12-258

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-35

E-35 a), b) Related electrical circuit diagram

E-35 a), c) Related electrical circuit diagram

E-35 a), d) Related electrical circuit diagram

125-3 SERIES

12-259

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-36

E-36 Error code [E-8b] [Short circuit in No. 4, No. 5, No. 6 fuel injector system] A high voltage (110 – 130 V) is used in the electrical circuit for the fuel injector, so be careful of electrocution or electric leakage. For details, see TESTING AND ADJUSTING, Handling controller high voltage circuit. a) Determining location of problem

Table 1 CN6 (female) Between (3) and (9) Between (3)(9) and ground

12-260

CN6 (female) Between (1) and (7) Between (1)(7) and ground

CN6 (female) Between (2) and (8) Between (2)(8) and ground

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

125-3 SERIES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-36

b) Troubleshooting No. 4 fuel injector system

Table 2 IJ4 (female) Between (1) and (2) Between (1)(2) and ground

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

c) Troubleshooting No. 5 fuel injector system

Table 3 IJ5 (female) Between (1) and (2) Between (1)(2) and ground

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

d) Troubleshooting No. 6 fuel injector system

Table 4 IJ6 (female) Between (1) and (2) Between (1)(2) and ground

125-3 SERIES

Resistance value 0.4 – 1.1 Ω Min. 1 MΩ

12-261

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

E-36

E-36 a), b) Related electrical circuit diagram

E-36 a), c) Related electrical circuit diagram

E-36 a), d) Related electrical circuit diagram

12-262

125-3 SERIES

13 DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL.......................... 13- 3 PRECAUTIONS WHEN CARRYING OUT OPERATION..................................................... 13- 4 SPECIAL TOOL LIST .......................................... 13- 6 SKETCHES OF SPECIAL TOOLS ..................... 13- 7 GENERAL DISASSEMBLY................................. 13- 8 1. Preparation work.....................................13- 8 2. Starting motor .........................................13- 8 3. Turbocharger lubricant return tube .........13- 8 4. Radiator lower hose ................................13- 8 5. Engine oil cooler .....................................13- 8 6. Adapter for engine overhauling...............13- 9 7. Radiator upper hose ...............................13- 9 8. Exhaust muffler .......................................13- 9 9. Fan securing bracket ..............................13- 9 10. Turbocharger lubrication tube .................13- 9 11. Turbocharger and exhaust manifold .......13- 9 12. Fuel filter assembly .................................13- 9 13. Oil filter....................................................13- 10 14. Wiring harness ........................................13- 10 15. Air cleaner securing bracket ...................13- 10 16. Exhaust muffler securing bracket............13- 10 17. High pressure tube clamp .......................13- 10 18. Suction manifold assembly .....................13- 10 19. Supply pump ...........................................13- 10 20. Common rail............................................13- 11 21. Spill pipe .................................................13- 12 22. Head cover..............................................13- 12 23. Injector harness ......................................13- 12

125-3 SERIES

24. Rocker arm ............................................. 13- 12 25. Push rod ................................................. 13- 12 26. Injector.................................................... 13- 12 27. Nozzle tip................................................ 13- 13 28. Crosshead .............................................. 13- 13 29. Rocker arm housing ............................... 13- 14 30. Injector harness connector ..................... 13- 14 31. Thermostat ............................................. 13- 14 32. Cam follower cover................................. 13- 14 33. Cam follower........................................... 13- 14 34. Cylinder head ......................................... 13- 14 35. Setting engine on engine overhaul stand....................................................... 13- 15 36. Oil pan .................................................... 13- 15 37. Flywheel ................................................. 13- 15 38. Flywheel housing.................................... 13- 15 39. Damper................................................... 13- 16 40. Front support .......................................... 13- 16 41. Front cover ............................................. 13- 16 42. Water pump ............................................ 13- 16 43. Camshaft ................................................ 13- 16 44. Oil pump ................................................. 13- 16 45. Idler gear ................................................ 13- 16 46. Oil suction pipe ....................................... 13- 17 47. Piston cooling nozzle.............................. 13- 17 48. Piston and connecting rod assembly...... 13- 17 49. Crankshaft .............................................. 13- 18 50. Cylinder liner........................................... 13- 19

13-1 1

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY....................................... 13- 52 Preparation work .......................................... 13- 52 1. Cylinder liner .......................................... 13- 53 2. Crankshaft .............................................. 13- 54 3. Piston and connecting rod assembly...... 13- 57 4. Piston cooling nozzle ............................. 13- 60 5. Oil suction pipe....................................... 13- 61 6. Idler gear ................................................ 13- 61 7. Oil pump ................................................. 13- 61 8. Camshaft ................................................ 13- 62 9. Cam follower .......................................... 13- 62 10. Cam follower cover................................. 13- 62 11. Water pump............................................ 13- 62 12. Supply pump driving gear....................... 13- 62 13. Front cover ............................................. 13- 63 14. Flywheel housing ................................... 13- 64 15. Rear seal ................................................ 13- 65 16. Flywheel ................................................. 13- 67 17. Damper .................................................. 13- 67 18. Oil pan .................................................... 13- 68 19. Removing engine from engine overhaul stand........................................ 13- 68 20. Setting engine on engine stand.............. 13- 68 21. Cylinder head ......................................... 13- 68 22. Cylinder head assembly ......................... 13- 68 23. Rocker arm housing ............................... 13- 70

13-2 1

24. Installing injector harness connector to rocker arm housing .................................13- 70 25. Crosshead...............................................13- 70 26. Push rod..................................................13- 71 27. Rocker arm .............................................13- 71 28. Adjusting valve clearance .......................13- 71 29. Nozzle tip ................................................13- 71 30. Injector ....................................................13- 73 31. Head cover..............................................13- 73 32. Spill pipe .................................................13- 73 33. Thermostat..............................................13- 74 34. Engine oil cooler .....................................13- 74 35. Engine cooling water temperature sensor .....................................................13- 74 36. Engine oil supply tube.............................13- 74 37. Common rail and high pressure tube......13- 74 38. Suction manifold .....................................13- 75 39. Engine oil filter ........................................13- 76 40. Fuel filter .................................................13- 76 41. Turbocharger and suction manifold assemblies ..............................................13- 76 42. Starting motor .........................................13- 76 43. Fan bracket lifting hook...........................13- 77 44. Wiring harness ........................................13- 77 45. Air cleaner...............................................13- 77 46. Exhaust muffler .......................................13- 77

125-3 SERIES

DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL

METHOD OF USING MANUAL 1. When removing or installing unit assemblies 1) When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. 2) Any special techniques applying only to the installation procedure are marked , and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF

ASSEMBLY.........................Title of operation

k ................................................................................Precautions related to safety when carrying out the

operation 1. X X X X (1) ..............................................................Step in operation ★ .............................................................................Technique or important point to remember when removing XXXX (1). 2. (2):.......................................................... Indicates that a technique is listed for use during installation 3. assembly (3) 6 ......................................................................Quantity of oil or water drained

INSTALLATION OF ASSEMBLY .................Title of operation • Carry out installation in the reverse order to removal. ..........................................................................Technique used during installation ★ .............................................................................Technique or important point to remember when installing (2) • Adding water, oil ...............................................Step in operation ★.......................................................................Point to remember when adding water or oil 5 ..................................................................Quantity when filling with oil and water

2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 3. Listing of special tools 1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.

125-3 SERIES

13-3 1

DISASSEMBLY AND ASSEMBLY

PRECAUTIONS WHEN CARRYING OUT OPERATION

PRECAUTIONS WHEN CARRYING OUT OPERATION [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work • If the coolant contains antifreeze, dispose of it correctly. • After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. • When draining oil, prepare a container of adequate size to catch the oil. • Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. • To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. • Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. • Check the number and thickness of the shims, and keep in a safe place. • When raising components, be sure to use lifting equipment of ample strength. • When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. • Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. ★ Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts Nominal number

Plug (nut end)

Sleeve nut (elbow end) Use the two items below as a set

02

07376-50210

07221-20210 (Nut), 07222-00210 (Plug)

03

07376-50315

07221-20315 (Nut), 07222-00312 (Plug)

04

07376-50422

07221-20422 (Nut), 07222-00414 (Plug)

05

07376-50522

07221-20522 (Nut), 07222-00515 (Plug)

06

07376-50628

07221-20628 (Nut), 07222-00616 (Plug)

10

07376-51034

07221-21034 (Nut), 07222-01018 (Plug)

12

07376-51234

07221-21234 (Nut), 07222-01219 (Plug)

2) Split flange type hoses and tubes Nominal number

Flange (hose end)

Sleeve head (tube end)

Split flange

04

07379-00400

07378-10400

07371-30400

05

07379-00500

07378-10500

07371-30500

3) If the part is not under hydraulic pressure, the following corks can be used. Nominal number

Part Number

06

13-4 1

Dimensions D

d

L

07049-00608

6

5

8

08

07049-00811

8

6.5

11

10

07049-01012

10

8.5

12

12

07049-01215

12

10

15

14

07049-01418

14 11.5 18

16

07049-01620

16 13.5 20

18

07049-01822

18

15

22

20

07049-02025

20

17

25

22

07049-02228

22 18.5 28

24

07049-02430

24

27

07049-02734

27 22.5 34

20

30

125-3 SERIES

DISASSEMBLY AND ASSEMBLY

2. • • • • • • • • • • • • •

PRECAUTIONS WHEN CARRYING OUT OPERATION

Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

★ When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1) Start the engine and run at low idling. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. ★ When using the machine for the first time after repair or long storage, follow the same procedure. 3. Precautions when completing the operation • If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. • If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. • If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. ★ For details, see TESTING AND ADJUSTING, Bleeding air. • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

125-3 SERIES

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DISASSEMBLY AND ASSEMBLY

SPECIAL TOOL LIST

SPECIAL TOOL LIST ★ Tools with part number 79 Tcannot be supplied (they must be locally manufactured). ★ Tools marked in the Sketch column are tools introduced in the sketches of the special tools (See SKETCHES OF SPECIAL TOOLS). Symbol

Part No.

A

790-901-1240

Adapter

1

B

790-501-2001

Engine repair stand

1

C

795-102-2102

Spring pusher

1

1

795-931-1220

Push tool

1

2

01050-31645

Bolt

3

1

795-931-1210

Push tool

1

2

01050-31625

Bolt

3

D

795-100-1191

Piston ring tool

1

E

795-220-1000

Liner puller

1

F

795-225-1520

Liner driver

1

G

795-102-3900

Piston holder

1

H

795-502-1121

Gauge

1

I

795-125-1360

Feeler gauge

1

J

790-331-1110

Angle wrench

1

K

795-471-1500

Fuel supply pump remover

1

L

795T-471-1550

Injector wrench

1

C2 C3

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Part Name

Q'ty

Sketch

125-3 SERIES

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS NOTE: Komatsu shall not be liable for any trouble or accident resulting from using the tool fabricated to this drawing. L. Injector wrench

125-3 SERIES

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DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

GENERAL DISASSEMBLY 1. Preparation work Before starting to disassemble the engine, check each component part of the engine for crack or damage, and clean it thoroughly to assure correct inspection of parts and disassembling and reassembling work. ★ Before cleaning the engine, seal off each opening, electrical parts and wiring connectors completely so that water will not enter them, or remove them beforehand. ★ Prepare stable and sturdy engine stand and secure engine assembly (1) on the stand to prevent it from falling over.

3. Turbocharger lubricant return tube 1) Remove the bolts two each on the turbocharger side and on the block side that secure turbocharger lubricant return tube and take off the tube. 2) Remove the four securing bolts to take off engine oil filler port (2).

4

•

Engine assembly: Approx. 1,170 kg (The weight differs according to the machine model.) When raising the engine assembly, the air cleaner has to be detached. To detach it, loosen the suction hose clamp and the air cleaner fixing band. 4. Radiator lower hose Remove the four securing bolts on the water pump side to take off hose securing tube (1).

2. Starting motor Remove the three securing bolts and detach starting motor (1). 5. Engine oil cooler Fit two guide bolts to oil cooler (1), and then remove the oil cooler securing bolts (17 pieces in total), taking care not to let it fall, to dismantle the engine oil cooler.

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DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

6. Adapter for engine overhauling Attach adapter A to the oil cooler installation portion.

7. Radiator upper hose Loosen the two clamps to take off radiator upper hose (1). 8. Exhaust muffler Remove exhaust muffler (2) together with the bracket on the right side.

11. Turbocharger and exhaust manifold 1) Lift off turbocharger (1) with a sling temporarily. 2) Remove the bolts on the right and left sides of exhaust manifold (2), and install two guide bolts . 3) Remove the exhaust manifold securing bolts (18 bolts in total), and dismantle the turbocharger manifold assembly by lifting it off.

9. Fan securing bracket Loosen the six bolts to take off bracket (3).

10. Turbocharger lubrication tube 1) Remove the bolts that secure lubrication tube (1) on the turbocharger side and the engine block side. 2) Take off two clamps (2) on the head and another one at the head side to remove the lubrication tube.

125-3 SERIES

12. Fuel filter assembly 1) Take off two tubes (3) between fuel filter head (1) and fuel supply pump (2). 2) Remove the bolts securing fuel filter head to detach the fuel filter assembly. 3) Take off harness connectors (4) and (5) for fuel supply pump.

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DISASSEMBLY AND ASSEMBLY

13. Oil filter 1) Take off two tubes (2) between oil filter head (1) and the cylinder block. 2) Remove filter head (1) securing bolts to detach the oil filter assembly.

14. Wiring harness 1) Take off each clamp holding wiring harness (1) leading to the injector from gate type frame (2) above the suction manifold. 2) Take off each connector (3) connected to the injectors to detach wiring harness assembly (1). 17

GENERAL DISASSEMBLY

18. Suction manifold assembly 1) Remove the right and left bolts of suction manifold (1), then fit guide bolts , and remove the securing bolts (24 bolts in total). 2) Lift off the manifold assembly for dismantling. ★ Fix slings to the right and left sides of the suction manifold and lift it off temporarily to remove each bolt.

19. Supply pump 1) Take off lubrication tube (2) of supply pump (1). 2) Take off each clamp (4) between the supply pump and common rail (3) to detach boot (5). 3) Loosen four sleeve nuts (6) to take off the two tubes. 4) Take off cover (8) for the pump driving gear that is attached to the front of engine front cover (7).

15. Take off air cleaner securing bracket (1). 16. Take off exhaust muffler securing bracket (2). 17. Take off each high-pressure tube clamp (3). 5) Confirm that punching mark C (12) on supply pump driving gear (11) is matched with the C mark on the camshaft gear, when matching pointer (9) on the front cover with punching mark 1.6 TOP (10) on the damper. 6) Remove the nuts and washers that secure pump driving gear (11). ★ At that time, take care not to let fall the nuts and washers inside the front case.

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DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

9) Dismantle pump assembly (1).

7) Detach gear (11) off the pump shaft, using special tool K. (Leave the detached gear inside the case) ★ At that time, know that a woodruff key is fitted to the pump shaft. Hence take care not to let fall it.

20. Common rail 1) Take off three clamps (3) for high-pressure tubes (2) connecting common rail (1) and the injectors. 2) Take off protector (4) located where highpressure tubes (2) connected to common rail (1) is installed.

8) Remove the bolts that secure pump (1) to the front case and bracket (13). 3) Loosen each sleeve nut (5) for six highpressure tubes (2) between common rail (1) and the injectors, and take off the high-pressure tubes one by one in proper sequence. 4) Detach common rail (1) together with the brackets.

125-3 SERIES

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DISASSEMBLY AND ASSEMBLY

21. Spill pipe Take off fuel spill pipe (1) and water spill pipe (2).

22. Head cover Take off head cover (1). (There are 12 bolts fixing it)

23. Injector harness 1) Remove two nuts (2) that secure the harness plate to the head of injectors (1). 2) Loosen bolt (3) for the harness fixing holder.

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GENERAL DISASSEMBLY

24. Rocker arm 1) Loosen lock nut (3) for locker arm adjusting screw (2) to loosen the screw. 2) Remove locker arm securing bolts (4) to take off the locker arm.

25. Push rod 1) Remove 12 push rods (1).

26. Injector 1) Remove bolt (3) for holder (2) that secures injector assembly (1) so as to detach the assembly. ★ Never attempt to hold the solenoid valve on top of the injector with a plier or the like.

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DISASSEMBLY AND ASSEMBLY

27. Nozzle tip ★ [EPA regulations] In countries where the EPA regulations are enforced, the nozzles in the common rail engines must be replaced as an assembly. On the other hand, in countries where the EPA regulations are not in place yet, the nozzle tips may be replaced in the following manner. 1) Fix injector securing jig L to vice . ★ It is forbidden to hold an injector direct with a vice. Be sure to use the jig L.

GENERAL DISASSEMBLY

4) Remove retaining nut (4) from injector (3). 5) Pull up nozzle assembly (5) vertically to detach it. At that time, do not remove tip guide (6).

6) There is no need to disassemble tip guide (6) any further than shown below. ★ Take care not to allow dust or any other foreign objects to enter the inside.

2) Set injector assembly (3) on the injector fixing jig.

28. Crosshead Remove 12 crossheads (1).

3) Apply 19 mm deep socket wrench to retaining nut (4) and turn it counterclockwise to loosen it.

125-3 SERIES

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DISASSEMBLY AND ASSEMBLY

29. Rocker arm housing Remove seven bolts (2) that secures housing (1) to detach it.

30. Injector harness connector ★ How to remove injector harness connector (2) from rocker housing (1) 1) Remove bolt (4) of lock plate (3) for connector (2) to take off the lock plate. 2) Push connector (2) outward. 3) Remove O-ring (5) attached to connector (2), then push the connector in and take it off together with harness holder (6).

GENERAL DISASSEMBLY

32. Cam follower cover Take off three cam follower covers (1).

33. Cam follower Remover 12 securing bolts (1) to take off cam follower (2). ★ Remove dowel ring (3).

34. Cylinder head assembly 1) Remove each of the seven bolts that secure cylinder head (1). 2) Fix sling to the cylinder head to lift it off. 3) Remove each of gaskets (2). 31. Thermostat Take off thermostat case (1) and tube (2).

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125-3 SERIES

DISASSEMBLY AND ASSEMBLY

•

Disassemble the cylinder head assembly in the following sequence. 1) Compress valve spring (3) with spring pusher C and take off valve cotter (4). 2) Remove upper seat (5) and valve spring (3).

3) Remove seal (7) and then lower seat (8). 4) Raise the cylinder head and take off valve (6). ★ Take note that seals are used only on the exhaust side. ★ Assign a number to each valve to show the right combination with the cylinder head.

35. Setting to engine overhaul stand 1) Lift off the engine and match previously fitted adapter A with engine overhaul stand B to set the engine assembly to the stand.

125-3 SERIES

GENERAL DISASSEMBLY

36. Oil pan Turn the engine assembly 180 degrees and detach oil pan (1).

37. Flywheel 1) Turn the engine assembly 180 degrees, then fix sling to the flywheel (1) and sling the engine. 2) Remove the six securing bolts, then take the flywheel off the knock pins and lift it off.

38. Flywheel housing 1) Fix slings to the right and left sides of flywheel housing (1) to sling it. 2) Remove the ten securing bolts, then take the housing off the knock pins and lift it off.

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DISASSEMBLY AND ASSEMBLY

39. Damper Sling damper (1), then remove the six securing bolts and lift it off.

GENERAL DISASSEMBLY

43. Camshaft 1) Remove two securing bolts (1). 2) Detach camshaft (2). ★ When removing the camshaft, rotate it and put it out gently so that the cam bushing may not damaged.

40. Front support Remove the securing bolts of front support (1), then take off support. 41. Front cover Remove the bolts of front cover (2), then lift it off.

42. Water pump Detach water pump (1) and tube (2).

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44. Oil pump Remove four mounting bolts (1) and dismantle oil pump (2).

45. Idler gear 1) Remove mounting bolt (1), then plate (2) and take off oil pump idler gear (3). 2) Take off shaft (4). 3) Remove mounting bolt (5), then take off shaft (6) and main idler gear (7).

125-3 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL DISASSEMBLY

2) Rotate the crankshaft so that piston to be removed is placed in bottom dead center. 3) Remove the carbon from the liner wall using a fine sand paper. ★ If necessary, measure the end play of the connecting rod using dial gauge before removing the piston and connecting rod assembly.

46. Oil suction pipe Take off bracket (1) and then oil suction pipe (2).

47. Piston cooling nozzle Remove mounting bolts (1) and each piston cooling nozzle (2).

48. Piston and connecting rod assembly 1) Check stamp numbers on connecting rod caps. (Make sure the cap number coincides with the cylinder number and also that the number is stamped on the cam side) ★ If there is no stamp number, stamp the number before the cap is removed.

125-3 SERIES

4) Remove bolt (1) from the connecting rod cap. 5) Remove connecting rod cap (2) and the connecting rod lower bearing as a unit by tapping the connecting rod bolt with a plastic hammer. ★ Take care not to damage the thread of the connecting rod bolts.

6) Push the piston and connecting rod assembly from the oil pan side with a wooden stick. Hold piston (3) in your hand and remove it from the cylinder head side. ★ Take care not to damage the piston cooling nozzle. ★ During removal, take care not to damage the inner surface of the liner with the connecting rod.

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DISASSEMBLY AND ASSEMBLY

7) Remove the remaining piston and connecting rod assembles in the same manner. ★ When storing the pistons and connecting rods, take care not to damage sliding portions of the piston and the connecting rod bearings. ★ Assemble the connecting rods and the caps temporarily, and keep them together with the bearings to avoid confusion during the reassembling work.

GENERAL DISASSEMBLY

4) Remove piston rings (8) using piston ring tool D. ★ Store the piston, connecting rod, connecting rod bearings, piston rings, and piston pin for every cylinder.

49. Crankshaft ★ If necessary, measure the crankshaft end play using dial gauge before removing the crankshaft. •

Disassemble the piston and connecting rod assembly as follows. 1) Remove snap ring (4). 2) Pull out piston pin (6) while holding connecting rod (5) in your hand, and separate connecting rod from piston (7). 3) Remove the snap ring on the opposite side.

1) Remove mounting bolts (2) for main cap (1). 2) Insert a bolt into the hole on the main cap, and remove the main cap by shaking it.

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125-3 SERIES

DISASSEMBLY AND ASSEMBLY

3) Since lower thrust bearing (3) is installed to main cap No. 7, mark the installation position after removing the cap.

4) Using nylon slings, lift off crankshaft (4). ★ When lifting the crankshaft, take care not to let it hit against the cylinder block. ★ Store the crankshaft in an appropriate place so that its sliding portions do not get damaged.

GENERAL DISASSEMBLY

6) Remove upper bearings (6). ★ Put identification tags on the main caps, main bearings, and thrust bearings or mark their installation positions with a felt-tip pen, segregate them for each cap, and store them properly to protect them from damage.

50. Cylinder liner Pull out cylinder liners (1) using liner puller E. ★ If necessary, measure the cylinder liner protrusion using dial gauge before removing the cylinder liners.

5) Remove upper thrust bearing (5).

125-3 SERIES

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DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

GENERAL ASSEMBLY TIGHTENING BOLTS BY THE POLASTIC RANGE TURNING ANGLE METHOD • Important bolts in the 125-3 Series engines are tightened by the plastic range turning angle method. In this method, special bolts are used. By being tightened to the load (plastic range) at which they begin to be permanently deformed, accurate and high tightening force can be obtained. ★ The most common method for tightening bolts is the torque control method. In this method, however, it is difficult to accurately control the tightening force because of the coefficient of friction. • The plastic range turning angle method is based on the initial tightening torque and the turning angle. • Bolts to be tightened by the plastic range turning angle method in the 125-3 Series engines. 1) Cylinder head mounting bolts 2) Main cap mounting bolts 3) Connecting rod cap mounting bolts

tic r ange ) (Elas

Axial force

(P la st ic ra ng e)

Plastic range turning angle method

Torque method (conventional method)

Elongation of bolt DEE00088

★ In the plastic range turning angle method, the permanent strain remains in bolts after they are tightened. Therefore, the number of times that each bolt can be reused is limited. Observe the following precautions. 1) Before tightening, measure the stem length of bolt and check that bolt length exceeds tolerance limit or not. Do not reuse any bolt which has exceeded the tolerance limit. Before tightening, measure the free length of bolt and check that bolt length exceeds tolerance limit or not. 2) If a bolt has been tightened in excess of the specified turning angle, loosen the bolt and measure the free length of bolt again.

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3) Punch a mark after tightening the bolt. Do not use the bolt again if there are already five marks punched, but replace it with new one. 4) If the bolt is tightened in excess of the specified angle, once loosen it completely and tighten it again. (Punch two marks at that time) 5) The tightening angle should be targeted at the standard value plus or minus tolerance. ★ Clean every part thoroughly and check the part for dents, flaws, and blowholes. When assembling the parts, make sure that none of the oil and water passages are blocked. Preparation work • Install adapter to the cylinder block, then raise it and place it on engine overhaul stand. • Repair the cylinder block as follows before inserting the cylinder liners. 1) Remove rust and scale from surfaces and with sandpaper until the machined surface is exposed. 2) Polish portion with No. 240 sandpaper to make surface smooth. 3) Polish portions and with No. 240 sandpaper to make them smooth. If portion is edgy or burred, polish it with sandpaper or a scraper. Finish this portion to an especially smooth surface to protect the O-ring from damage. 4) If the pitting in surface is so rough that it cannot be repaired, replace the cylinder block. 5) If surface and portion are roughened with pitting, finish them smooth. 6) Inspect the counterbore section and remove any burrs. Chips and dirt on surface will cause poor contact of the liner, which will lead to water leakage or improper liner projection. ★ Repair the counterbore section if there is any drooping, corrosion, or pitting.

125-3 SERIES

DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

1. Cylinder liner ★ Replace the liner O-ring and clevis seal with new parts just before assembling the liner. • Method of installing liner O-rings and clevis seal 1) Confirm that the cylinder liner O-ring grooves and the circumference of the liner are free from rust and pitting. ★ If these surfaces are roughened with pitting, replace the liner to remove the cause of water leakage. 2) Coat liner O-rings and clevis seals with clean SAE No. 30 engine oil. ★ The clevis seal and black O-ring will become swollen and degraded because of oil. To prevent this, do not leave these parts immersed in oil. Apply a little oil with a brush just before assembling the parts. 3) After fitting the O-ring on the cylinder liner, check that it is not twisted. If it is twisted, use a smooth bar (approx. 10 mm O.D.) to remove the twist from the O-ring.

4) To prevent the clevis seal from twisting, continue to press the whole circumference until it is installed properly in the groove.

5) Install the liner O-ring and clevis seal as shown in the diagram. ★ Install the clevis seal with the chamfered side down.

Cylinder liner Clevis seal Black (Ethylene propylene rubber) O-ring Black (Ethylene propylene rubber) O-ring Orange (Silicon rubber) DEE00090

•

Method of inserting cylinder liners 1) Coat the counterbore with gasket sealant (LG-6). ★ Diameter of line of sealant: Ø1.5 – 2.0 mm 2) Coat the liner O-ring and cylinder block Oring groove with RF-1 rubber lubricant. As equivalent to RF-1, DS-50, the product of Daido Chemical Industry, is available in the commercial markets. If RF-1 is not readily available, use clean engine oil (SAE #30) instead. ★ Coat by hand uniformly around the whole circumference. 3) Set the "A or B" mark on the top surface of the liner facing the front, then insert the liner into the cylinder block, taking care not to damage the O-ring. 4) Insert the liner by pushing with both hands and using all your weight. ★ If the liner does not go in smoothly when you push with your weight, there is danger that the O-ring may by damaged, so check for any burrs or flashes on the cylinder block.

Press it to the grove

Chamfered side

DEE00089

125-3 SERIES

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DISASSEMBLY AND ASSEMBLY

5) Using liner driver F, press fit cylinder liner (1) to the cylinder block.

★ Use the following procedure to squeeze out the gasket sealant coated on the counterbore. i) Use an old head gasket and tighten the cylinder head temporarily. 3 Mounting bolt: 127.5 – 147.1 Nm{13 – 15 kgm} ii) Remove the cylinder head, then wipe off all the gasket sealant that was squeezed out between the cylinder liner and cylinder block. • If the gasket sealant gets on the grommet in the head gasket, it will deform the grommet and this will cause water leakage, so be careful to wipe off all the gasket sealant. 6) After press fitting the cylinder liner, use dial gauge and measure the protrusion of the cylinder liner. ★ When measuring the protrusion of the liner, press the liner with a plate to remove any rise of the liner caused by the O-ring. ★ Cylinder liner protrusion: 0.07 – 0.15 mm ★ If the measurement is not within the specified value, take the action given in STRUCTURE AND FUNCTION, MAINTENANCE STANDARD.

GENERAL ASSEMBLY

2. Crankshaft ★ The cylinder block and main bearing are selective fitting parts, but spare parts are available for supply to maintain the clearance. 1) Align the protrusion of upper main bearings (6) with the groove in the cylinder block, and assemble to the cylinder block. ★ Check that there is no dirt or dust stuck to the rear face of the bearing before installing. Coat the inside surface of the bearing with SAE 30 engine oil. Do not coat the rear surface with oil.

2) Drive in the roll pin so that the protrusion from the end face of the block is 1.5 to 1.9 mm, and install upper thrust bearing (5). ★ Assemble the thrust bearing so that the side with the groove is on the crankshaft side.

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

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125-3 SERIES

DISASSEMBLY AND ASSEMBLY

★ When doing this, be careful not to let it hit the cylinder block and be damaged. ★ When replacing the crankshaft gear, heat the new gear in an electric furnace at 200°C for at least 30 minutes, and shrink fit it.

5) Install lower main bearing (7) with the projected part of the bearing aligned with the groove on the main cap. ★ Before installing the bearing, make sure that no foreign matter is stuck on the back of the bearing. Do not coat oil on the bearing backside then. 6) Drive the roll pin into the No. 7 cap until its protrusion reaches 1.5 to 1.9 mm from the end of the cap, and install thrust bearings (3) to both sides. ★ Install the thrust bearings with the grooved side facing the crankshaft.

GENERAL ASSEMBLY

7) Coat the crankshaft journal with SAE30 engine oil, confirm that stamp No. on main cap (1) coincides with the number on the cylinder block, and install the main cap. ★ Install the main cap with the embossed number facing the engine front. 8) Before tightening main cap mounting bolt (2), make sure as follows. i) Measure the stem length a of all bolts and check that bolt length exceeds tolerance limit or not. ii) Tolerance limit of bolt stem length: Max. 159.8 mm ★ If the bolt length a exceeds tolerance limit, do not reuse. ★ Coat the main cap mounting bolt thread portion and main cap seat washer with engine oil (SAE30).

9) Tighten mounting bolts (2) of main cap (1) in turn to fit main cap fully.

10) Tighten main cap mounting bolts (2) as follows. ★ When tightening the bolts, start from the center and work to the outside. Tighten the bolts to the specified tightening torque in the following steps.

125-3 SERIES

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DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

•

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

•

With the above procedure, use a torque wrench to tighten the mounting bolts. 11) After tightening the bolts, rotate the crankshaft and check that it rotates smoothly. 12) Measure end play of the crankshaft with dial gauge . If it is outside the standard value, take actions according to the maintenance standard. ★ End play: 0.14 – 0.315 mm

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125-3 SERIES

DISASSEMBLY AND ASSEMBLY

3. Piston and connecting rod assembly ★ The piston and cylinder liner are selective fitting parts, and parts which ensure the narrow clearance are provided as spare parts. Reassemble the piston and connecting rod assembly as follows. 1) Remove expander from oil ring, fit in oil ring groove of piston, then assemble oil ring. 2) Using tool D, assemble piston rings (8) in the order of oil ring, 2nd ring, and top ring. ★ When doing this, check that the expander is fitted completely in the ring groove. ★ Set the protruding part of the expander coil at 180° to the end gap of the oil ring. ★ Assemble each piston ring as shown in the diagram. ★ Install each ring to the piston with the stamped mark facing up.

3) Install snap ring (4) on one side. 4) Heat up piston (7) in a heating furnace at 100°C for more than 5 minutes. ★ If no heating furnace is available, heat in hot water at 100°C for more than 5 minutes. ★ If the piston is heated up in hot water, clean it completely after setting it.

125-3 SERIES

GENERAL ASSEMBLY

5) Coat the piston boss with engine oil (SAE30), match the number stamped on the connecting rod with the cylinder number on the piston head, set the numbers facing in the same direction, then insert piston pin (6), and assemble piston (7) to connecting rod (5). 6) Install snap ring (4) on opposite side. ★ Turn the snap rings to check that the left and right snap rings are completely fitted in the ring groove.

7) Align the protruding part of connecting rod upper bearing (8) with a notch in connecting rod (10), and install. ★ Check that there is no dirt or dust stuck on the backside of the bearing, then install. When doing this, the backside surface must not be coated with oil. ★ Check that the bearing hole and connecting rod oil hole are aligned.

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DISASSEMBLY AND ASSEMBLY

GENERAL ASSEMBLY

10) Turn the embossed letters on the connecting rod to face the engine front side (the punching number is then on the camshaft side), then position the piston ring end gap as illustrated and insert piston and connecting rod assembly (3). ★ When inserting the piston and connecting rod assembly, be careful not to damage the piston cooling nozzle.

8) Align the protruding part of connecting rod lower bearing (9) with the notch in connecting rod cap, and install. ★ Check that there is no dirt or dust stuck on the backside of the bearing, then install. When doing this, the backside surface must not be coated with oil.

9) Set the crankshaft for the cylinder to be assembled to the bottom dead center, and coat the inside surface of the connecting rod bearing and inside surface of cylinder liner with engine oil (SAE30).

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11) Using tool G, compress the piston ring and push in the piston head with a wooden bar. ★ When inserting the piston, be careful not to damage the piston cooling nozzle. Check also that the nozzle is positioned at the center of the notched portion of the piston. ★ When assembling the piston and connecting rod assembly, assemble it when the crankshaft is at the bottom dead center.

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13) Before tightening the connecting rod bolts, check the following points. i) Measure the stem length a of all bolts and check that bolt length exceeds tolerance limit or not. ii) Tolerance limit of bolt free length: Max. 84.1 mm ★ If the bolt length a exceeds tolerance limit, do not reuse.

12) Coat connecting rod lower bearing (9) with engine oil (SAE30), check the cap number, align with the dowel pin, and install connecting rod cap (2). ★ When coating engine oil, spread the oil on the whole surface with a finger.

14) Coat the washer and thread of the connecting rod bolt with engine oil (SAE30).

★ When assembling a new connecting rod, mark the cylinder number with an electric pen (do not use a stamping tool).

15) Tighten connecting rod bolts (1) in turn until the connecting rod cap is tightly fitted.

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★ If an impact wrench or other tool is used to tighten the bolts at high speed, the thread may be damaged, so tighten with a hand tool.

16) Tightening connecting rod bolts 3 Connecting rod cap bolt 1st step: Tighten to 98.1 ± 4.9 Nm {10.0 ± 0.5 kgm} 2nd step:Mark bolt and cap with felt-tip pen, then tighten bolt 90° +30° 0 ★ For tightening the connecting rod, see 210) and tighten to the specified value above.

17) After installing the piston and connecting rod assembly, rotate the crankshaft and check that there is no catching or abnormality in the rotation. 18) Using dial gauge , measure side clearance of the connecting rod. ★ Standard value for side clearance: 0.2 – 0.375 mm

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19) Using gauge H, measure protrusion from top surface of the cylinder block to top of the piston. ★ Piston protrusion: 0.984 – 1.335 mm (Push top surface of the piston, and check that oil clearance is 0 and that there is no rocking)

4. Piston cooling nozzle Install piston cooling nozzle (2) to each piston and mounting bolt (1). ★ It is critical that the piston cooling nozzle holds the right injection direction. Follow the installation steps below strictly and take good care in handling the nozzle. 1) Install the nozzle after assembling the piston and connecting rod assembly. 2) Position the nozzle at the notch center of each piston. 3) Put all the nozzles in array and check them for any abnormality like bending before installation. 4) In disassembling, be sure to take off the nozzle first and then the piston and connection rod assembly. 3 Mounting bolt: 27.4 – 34.3 Nm {2.8 – 3.5 kgm}

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★ Precautions when assembling idler gear Align the "A" mark on the crankshaft gear with the "A" mark on main idler gear (7), then tighten mounting bolt (5).

5. Oil suction pipe Fit O-ring, install oil suction pipe (2), then fit bracket (1) and secure the pipe in position. 7. Oil pump 1) Fit O-ring, install oil pump (2), then tighten 4 mounting bolts (1). 3 Mounting bolt: 68.6 ± 4.9 Nm {7.0 ± 0.5 kgm} 2) Knock in the pin and install shaft (4).

6. Idler gear 1) Assemble plate (8) to the engine block, then install gear (7) and shaft (6), and tighten mounting bolt (5). ★ Assemble plate (8) with the chamfered end facing the front of the engine. 3 Mounting bolt: 245 – 294 Nm {25 – 30 kgm}

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3) Assemble oil pump idler gear (3), then install plate (2) and tighten mounting bolt (1). 3 Mounting bolt: 147.0 – 176.4 Nm {15 – 18 kgm}

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10. Cam follower covers Fit O-rings and install cam follower covers (1). 3 Mounting bolt: 11.3 ± 1.5 Nm {1.15 ± 0.15 kgm}

8. Camshaft Coat the camshaft journal surface with engine oil (SAE30). Align "B" mark of the camshaft gear with "B" mark of the main idler gear, install camshaft (2), then tighten mounting bolts (1). 3 Mounting bolt of plate: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} ★ When installing the camshaft, rotate the camshaft to prevent damage to the cam bushing. ★ If the cam gear has been replaced, heat the new cam gear in an electric furnace at 200 to 240°C for more than 30 minutes, then shrink fir the gear.

9. Cam followers 1) Knock dowel ring (3) into the cylinder block. 2) Tighten 6 cam follower assemblies (2) with bolts (1). 3 Mounting bolt: 51.5 ± 7.4 Nm {5.25 ± 0.75 kgm}

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11. Water pump Install an O-ring to water pump assembly (1) and install the assembly to the engine.

12. Fuel supply pump driving gear 1) Align the C mark on fuel supply pump driving gear (1) with the C mark on camshaft gear (2) and set the pump. 2) Align the woodruff key in the driving shaft of fuel supply pump (3) with the key slot in driving gear (1), and then engage the pump and the gear. 3) Install the fuel supply pump, then fit a washer to driving gear (1) and tighten nut (4) to the specified torque. 3 Gear mounting nut: 127 – 147 Nm {13 – 15 kgm} ★ Coat four mounting bolts (5) of fuel supply pump (3) with LT-2 liquid adhesive compound.

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2) Standard end play for each gear Position

Range (mm)

1

0.09 – 0.48

2

0.10 – 0.25

3

0.05 – 0.17

4

0.05 – 0.21

5

0.03 – 0.09

★ Check that each counter mark matches with each other between the driving gear and the idler gear.

★ Measure backlash and end play of each gear using a dial gauge . 1) Standard backlash for each gear Position

Range (mm)

a

0.127 – 0.393

b

0.127 – 0.393

c

0.139 – 0.427

d

0.128 – 0.405

e

0.082 – 0.389

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13. Front cover 1) Using a push tool (120 mm O.D.), press fit oil seal (3) into the cover. ★ Oil seal press-fitting tolerance a: 11 +10 mm 2 Fill oil seal lip (50 to 80% of space at lip) with grease (G2-LI).

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2) Coat front cover (1) with gasket sealant and install it by lifting it up. (Use a guide bolt) ★ When installing the cover, be careful not to damage the oil seal. 2 Mating surface: Gasket sealant (LG-7) 3) Fit tachometer drive assembly (2). 4) Install cover (3) for the fuel supply pump drive gear. 5) Using a dial gauge, measure the stepped difference between the cylinder block and front cover. ★ Stepped difference: 0 – 0.275 mm 6) Install front support (4).

14. Flywheel housing Raise flywheel housing (1), coat the mounting surface with gasket sealant, then install on the cylinder block and tighten bolts (2). 2 Contact surface: Gasket sealant (LG-7) 2 Coat the bolt thread and seat face with engine oil (SAE30) before tightening.

11

12

6

4

7

5

8

1,4 3 1st step

10

9

5

3

2,9

2

10

1

6 7 8 2nd step DEE00102

1) After installing the flywheel housing, measure the face runout and radial runout with dial gauge . ★ Radial runout: Max. 0.20 mm ★ Face runout: Max. 0.20 mm • Measuring face runout of flywheel housing Measure as follows. i) Put magnet stand (1) in contact with the end face of the crankshaft. ii) Set dial indicator (2) so that its probe is in contact with the end face of the flywheel housing at the right angle. iii) Rotate the crankshaft one turn, and read out difference between the maximum value and the minimum value of the indicator. ★ When measuring, measure at least 8 places evenly spaced around the circumference of the end face of the flywheel housing. ★ When measuring, move the crankshaft either to the front or rear to pr e v e nt a ny er r o r fr o m be i n g caused by the end play. ★ Check that the indicator returns to the original position when the crankshaft is rotated one full turn. ★ The indicator will fluctuate either to the left or right, so be careful not to misread the direction of fluctuation when the indicator is at the top or bottom, or left or right of the end face being measured.

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

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•

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

2) Using dial gauge , measure the stepped difference between the cylinder block and flywheel housing. ★ Stepped difference: 0 – 0.35 mm

Procedure for assembling standard seal ★ Before assembling the seal, check tat there is no damage, burrs, flashes, or rust on the housing, sliding surface of the lip and the corner of the end face of the crankshaft. ★ When assembling the seal, do not coat the shaft or seal lip with oil or grease. If there is any oil or grease on the shaft, wipe it off completely. ★ Do not remove the plastic tube inside the standard seal provided as a spare part until immediately before assembling the seal.

Lip at engine end

Lip at PTO end Assembly guide (plastic tube)

Large inside diameter end

Small inside diameter end DEE00105

15. Rear seal Check the condition of wear of the shaft, then select the standard seal or a seal with sleeve for Teflon seal (lay-down lip seal) and assemble the seal. The condition of wear of the shaft can be judged from the degree of luster (touch with the flat of your finger to check that the depth of wear is less than 10 µm). If there are no scratches, assemble a standard seal. In all other cases, assemble a seal with sleeve.

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1) Put large inside diameter end of plastic inner tube (3) in contact with the end of crankshaft (4). ★ Be particularly careful not to mistake the direction when assembling.

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2) Hold the metal ring of seal (2) with both hands, and push it in evenly and giving sudden pushing force. 3) After pushing in seal, remove plastic inner tube (3). ★ Be particularly careful not to damage the seal lip when removing the inner tube.

1) Set sleeve/seal (2) to tool C2. 2 Surface of sleeve inner tube: Gasket sealant (LG-7)

4) Tighten bolts (C2-2, C3-1) uniformly until the end face of tool C3 contacts the end face of crankshaft (4) to press fit seal (2). ★ When press fitting the seal, be extremely careful not to damage the lip at the PTO end when setting the tool. ★ After press fitting the seal, remove the red sealant layer from the outside circumference.

•

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Procedure for assembling seal with sleeve ★ Before assembling the seal, check that there is no damage, burrs, flashes, or rust on the housing, sliding surface of the lip and the corner of the end face of the crankshaft. ★ When assembling the seal, do not coat the shaft, and the space between the sleeve and seal lip with oil or grease. If there is any oil or grease on the shaft, wipe it off completely. ★ Handle the seal and sleeve as an assembly. Never separate them.

2) Put the sleeve of the seal in contact with the end face of the crankshaft, tighten bolt (C2-2) of tool C2 uniformly until the end face of tool C2 contacts the end face of crankshaft (2) to press fit sleeve/ seal (2).

3) Remove tool C2 and replace with tool C3. 4) Tighten bolt (C3-2) of tool C3 uniformly until the end face of tool C3 contacts the end face of crankshaft (4) to press fit sleeve/seal (2).

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★

After press fitting the seal, remove the red sealant layer from the outside circumference.

GENERAL ASSEMBLY

3) Using dial gauge , measure the face runout and radial runout of the flywheel. ★ Face runout: below 0.20 mm ★ Radial runout: below 0.15 mm

16. Flywheel 1) Fix sling to flywheel (1), lift it off and install, aligning with the knock pin. ★ Thoroughly coat the thread of mounting bolts (2), seat face and the washer with clean lubrication oil (EO30-CD). 3 Mounting bolt: 1st step: 147.0 ± 19.6 Nm {15.0 ± 2.0 kgm} 2nd step: 289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}

17. Damper Lift off damper (1) and install it. 3 Damper mounting bolt: Width across flats 22 mm, 1 bolt 156.8 – 196.0 Nm {16 – 20 kgm} Damper mounting bolt: Width across flats 24 mm, 5 bolts 245.0 – 308.7 Nm {25.0 – 31.5 kgm} 2) Tighten the flywheel mounting bolts in the sequence shown in the diagram below.

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18. Oil pan 1) Turn the engine assembly 180°. 2) Coat gasket sealant on the whole mating surface of the circumference (line diameter Ø 1 mm) of oil pan (1), then install it and tighten the mounting bolts to the specified tightening torque. 2 Mating surface: Gasket sealant (LG-7)

19. Removing engine assembly from engine overhaul stand 1) Turn the engine assembly 180° and sling it. 2) Separate engine overhaul stand B and adapter A. 3) Remove adapter A from the engine assembly.

20. Setting engine assembly on blocks Prepare for sturdy and steady blocks place the engine assembly (1) on them.

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and

21. Cylinder head • Assemble the cylinder head assembly as follows. 1) Coat the valve stem and the inside surface of the valve guide with engine oil (SAE30), then assemble valve (6). 2) Raise the cylinder head, then fit lower seat (8) and install seal (7).

3) Assemble valve spring (3) and upper seat (5). 4) Using spring pusher C, compress the valve spring and install valve cotters (4). ★ Tap the valve stem with a plastic hammer to check that the cotters are fitted securely in the valve stem groove.

22. Cylinder head assembly ★ Thoroughly clean the cylinder head lower surface, cylinder block top surface and cylinder liners with a dry cloth or cloth with solvent. ★ Coat threads of the mounting bolts and bolt stem with LM-P or SAE30 engine oil. ★ Tighten the mounting bolts by hand for the first two turns or more. ★ Before tightening the cylinder head bolts, measure the stem length a of all the bolts and check that bolt length does not exceed tolerance limit or not. Do not reuse any bolt which has exceeded the tolerance limit. • Tolerance limit of bolt stem length: Max. 171.4 mm 125-3 SERIES

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

★ If any bolt is tightened exceeding the specified angle, remove the bolt and measure the bolt stem length again. 1) Set each cylinder head gasket (1) on top of the cylinder head.

★ After tightening, punch a mark on each bolt head. Do not use a bolt which already has five punching marks, but replace it with new one.

2) Lift off cylinder head (2) with sling it on the cylinder block.

and set

3) Tighten each cylinder head mounting bolt (3) to the specified torque for each cylinder head (2).

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4) For the 3rd step tightening, use following tool J (angle tightening wrench), and tighten the bolts to 90° +30° in the sequence of – 0 as shown in the diagram above.

23. Rocker arm housing 1) Fit gasket (1) and then assemble rocker arm housing (2). 2) Tighten mounting bolts (3) to the specified torque. 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

GENERAL ASSEMBLY

3) Insert lock plate (3) into the groove of connector (1). 4) Secure the lock plate to the housing with mounting bolts (4) to fix the connector. 5) Secure harness holder (5) to the housing with mounting bolts. 3 Harness holder mounting bolt: 19.6 – 25.5 Nm {2.0 – 2.6 kgm}

25. Crosshead 1) Set each crosshead (1), then loosen lock nut (2) and unscrew adjusting screw (3). 2) Lightly hold down the contact surface of the crosshead and rocker arm with a finger. Hold the crosshead in contact with the valve stem on the pushrod side. 3) Turn the adjusting screw until it comes to contact the valve stem at hand. 4) After the adjusting screw contacts the valve stems, tighten it a further 20°, and then tighten the lock nut. ★ Coat the crosshead guide and crosshead top with SAE30 oil thoroughly and assemble them. 3 Locknut: 58.8 – 73.5 Nm {6 – 7 kgm}

24. Assembling injector harness connector to rocker arm housing 1) Take out injector harness connector (1) from within the housing without O-ring. 2) Fit O-ring (2) to the connector and push it inside the housing.

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26. Pushrod Install pushrod (1). ★ Check that pushrods are inserted securely into the holes in the cam follower socket.

27. Rocker arm 1) Set each rocker arm in the designated position. 2) Check that the ball of the adjusting screw is properly fitted into socket (2) of the pushrod, and tighten 12 mounting bolts (3). ★ Clean the oil hole in the bolts before installation. 3 Mounting bolts: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm} ★ Set the large hole (Ø13 mm) at the bottom and assemble the rocker arm shaft so that the blind ball plug is at the front.

28. Adjusting valve clearance Adjust the valve clearance as follows. ★ Adjust the valve clearance so that the clearance between the crosshead and rocker arm is the following value. ★ Valve clearance (both when hot and when cold) Unit: mm Intake valve 0.33

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Exhaust valve 0.71

★ Crank the engine and adjust the valve clearance of each cylinder in the firing order 1-53-6-2-4. 1) Rotate the crankshaft in the normal direction to align pointer (2) with the 1.6 TOP mark on vibration damper (1). When rotating, check the movement of the valves.

2) To adjust, insert feeler gauge between rocker arm (3) and crosshead (4) and turn adjustment screw (5) until clearance is a sliding fit. Then tighten lock nut (6). 3 Locknut: 58.8 – 73.5 Nm {6 – 7.5 kgm} ★ After tightening the lock nut, check the clearance again.

29. Nozzle tip ★ [EPA regulations] In the countries where EPA regulations are enforced, nozzles in the common rail engines must be replaced with a nozzle assembly. On the other hand, in the countries where EPA regulations are not in place, nozzle tips are replaceable as a single part. 1) Set injector fixing jig L to vice . ★ It is forbidden to hold the injectors direct with a vice. Be sure to use the specified jig.

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5) After setting nozzle assembly (3), set retaining nut (2) and turn it by hand clockwise to screw it in.

2) Set injector (1) to fixing jig L. 3) Thoroughly clean the threads of the lower body and retaining nut (2) with a spray type parts cleaner, and blow them with compressed air.

4) Set new nozzle assembly (3), aligning it with the knock pin of nozzle tip guide (4). ★ When setting the nozzle assembly, be careful not to let fall the nozzle tip.

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6) Set a 19 mm deep socket to a torque wrench and tighten the retaining nut clockwise to the specified torque. 3 Retaining nut: 88.3 Nm {9.0 kgm}

7) After tightening to the specified torque, implement angle-tightening. ★ Put a marker (6) on retaining nut (2) and lower body (5) and tighten it to a further 45°. ★ Coat the nozzle body with rust inhibitor oil.

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30. Fuel injector 1) Insert gasket (2) and O-ring (3) into fuel injector (1). 2) Put injector (1) through injector holder (4) and insert it into the rocker housing to fix it temporarily. ★ Insert injector (1) deeply enough until its seal surface comes to contact the cylinder head seal surface. Then check that injector key (5) is securely fitted in key slot (6) of the rocker housing.

GENERAL ASSEMBLY

4) Tighten two injector harness capture nuts (9) to injector (1). ★ Tighten the two nuts by hand at the same time and then tighten to the specified torque. 3 Mounting nut: 2.0 – 2.4 Nm {0.2 – 0.24 kgm}

31. Head cover Fit an O-ring to cylinder head cover (1), then set it on the cylinder head and secure it by tightening 12 bolts to the specified torque. 3 Mounting bolt: 9.8 ± 1 Nm {1.0 ± 0.1 kgm} ★ Fit the O-ring so that it may not be twisted.

3) Coat with engine oil spherical portion (7) of the spherical washer which is fitted to the top of a bolt hole in injector holder (4). Then tighten injector holder bolt (8). 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

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32. Spill pipe Fit a gasket to both faces of the cooling water spill pipe and the fuel spill pipe and install them. 3 Mounting bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}

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33. Thermostat Fit a gasket to thermostat case (1) and tube (2) and install them.

GENERAL ASSEMBLY

5) Fit each oil seal (3) to head cover (7).

34. Engine oil cooler Fit a gasket to engine oil cooler (3) and secure it with 16 bolts, using a guide bolt at the right and left on the upper side. 3 Mounting bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}

35. Engine cooling water temperature sensor Install engine cooling water temperature sensor (1). 36. Engine oil supply tube Fit a gasket to engine oil supply tube (2) and install it.

37. High-pressure tube for common rail 1) Fix mounting bracket (1) to common rail (2) and mount it with two bolts. 3 Common rail mounting bracket: 59 – 74 Nm {6.02 – 7.55 kgm} 2) Coat the internal surface of each oil seal with engine oil and fit it to high-pressure tube (4). 3) Screw sleeve nut (5) in the injector connection and sleeve nut (6) in the common rail all by hand temporarily. 4) Install each high-pressure tube (6) one by one and tighten each sleeve nut to the specified torque firmly. 3 Sleeve nut: 39.2 – 49 Nm {4 – 5 kgm}

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6) Tighten the two sleeve nuts for high-pressure tube (9) between fuel supply pump (8) and common rail (2) all by hand to temporarily secure the tube. 7) Firmly tighten the sleeve nut of high-pressure tube to the specified torque. 3 Sleeve nut on supply pump side: 39.2 – 49 Nm {4 – 5 kgm} 3 Sleeve nut on common rail side: 39.2 – 58.8 Nm {4 – 6 kgm} 8) Tighten each bolt of clamp (10) for the highpressure tube all by hand to temporarily secure it, and tighten firmly to the specified torque thereafter. 3 Clamp bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm} 9) Install lubrication tube (11) to fuel supply pump (8). 3 Mounting bolt on engine block side: 9.8 – 12.7 Nm {1.0 – 1.3 kgm} Mounting bolt on supply pump: 7.9 – 12.7 Nm {0.8 – 1.3 kgm}

10) Fix three bolts of clamp (12) to six highpressure tubes (4) all by hand and tighten them to the specified torque firmly. 3 Clamp bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm}

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11) Tighten clamps (13) for the high-pressure tube and mounting bolts (16) for gate type frame (14) and cover (15) all by hand for temporary securing, and tighten them firmly thereafter. 3 Clamp bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm}

38. Suction manifold 1) Lift off suction manifold (1) with sling . Fit each mounting bolt and gasket (2). 2) Fix guide bolt (3) to the front and rear cylinder heads, then set suction manifold (1) on the cylinder head and tighten the mounting bolts temporarily.

★ A total of 10 clamps in use for the high-pressure tube are very critical parts. Should the engine be kept running with any of them loosened or slipped off, or with the rubber hardened, there is the danger that the rupture of the high-pressure tube is caused due to friction and vibration at the connection of the high-pressure tube. Hence make sure that the high-pressure tube is assembled with a regular clamp which is tightened to the specified torque. ★ It is dangerous to have the high-pressure tube contact any of the nearby wiring harnesses for electronic control. A deformed wiring harness is sometimes found (like being trampled on) while the machine is in operation. When replacing a wiring harness close to the high-pressure tube, the whole replacement work is deemed completed only after it is confirmed that the wiring harness and the high-pressure tube are separated more than 10 mm apart. If this separation falls short of 10 mm, move the wiring harness securing position to allow 10 mm distance. (A contact between the high-pressure tube and a wiring harness poses a danger in that it causes the shield of a wiring harness to break, which in turn leads to short-circuiting or wear and damage to the tube) ★ If a high-pressure tube is reused by bending it, or used for other applications, the tube will likely be broken, inviting a great danger. Thus it is forbidden to use a bent high-pressure tube again. ★ Install the fuel supply pump with the slit in the sleeve boot facing the cylinder block.

3) Firmly tighten the mounting bolts to the specified torque in the sequence of – . 3 Mounting bolts: 59 – 74 Nm {6 – 7.5 kgm}

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4) Fit three clamps (5) to six high-pressure tubes (4) that are installed on top of suction manifold (1). Fit clamps (5) to three gate type brackets (6) all by hand for temporary securing. 5) Tighten each clamp bolt for the high-pressure tubes firmly. 3 Clamp bolt: 11.8 – 14.7 Nm {1.2 – 1.5 kgm}

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6) Secure each gate type bracket by tightening the mounting bolts firmly.

GENERAL ASSEMBLY

i) ii)

39. Engine oil filter 1) Secure engine oil filter head (1) temporarily with four bolts. 2) Assemble filter inlet and outlet tubes (2) and tighten each mounting bolt temporarily. 3) Install the engine oil filter by firmly tightening bolts in the sequence of the tube upper side bolt, tube lower side bolt and head bolt. 40. Fuel filter 1) Secure fuel filter head (3) temporarily by tightening four bolts. 2) Assemble tube (4) between the fuel filter and the fuel supply pump and tighten the mounting bolts temporarily. 3) Tighten the tube to the specified torque. 3 Mounting bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} 4) Install fuel filter head (3) by tightening the mounting bolts firmly.

Screw in each mounting bolt by hand for 2 - 3 threads. After tightening to mounting bolts, tighten the other bolts, too. 3 Mounting bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}

3) Install lubrication tube (4) to turbocharger (3), then tighten the mounting bolts temporarily and also tighten two bolts for clamp (5) above the rocker housing. 4) Tighten the lubrication tube mounting bolts to the specified torque and the clamp bolts. 3 Tube mounting bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} 5) Install drain tube (6) to turbocharger (3).

42. Starting motor Install starting motor (1) with three mounting bolts.

41. Turbocharger and exhaust manifold assembly 1) Lift off turbocharger and exhaust manifold assembly (1) and fit a gasket and 18 mounting bolts (2). ★ Fit the gasket with a mark facing outward. 2) Tighten the mounting bolts to the specified torque in the following order.

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

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

3) Tighten the bolt for bracket (5) and install the exhaust muffler by tightening the nut for U bolt (6) to the specified torque. 3 U bolt nut: 9.8 – 14.7 Nm {1.0 – 1.5 kgm}

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

125-3 SERIES

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15 REPAIR AND REPLACEMENT OF PARTS CYLINDER HEAD REPLACING VALVE SEAT INSERT ......................................................................................................15REPLACING NOZZLE HOLDER SLEEVE ............................................................................................15REPLACING VALUE GUIDE .................................................................................................................15REPLACING CROSS HEAD GUIDE .....................................................................................................15GRINDING THE VALVE .........................................................................................................................15GRINDING THE FITTING FACE OF CYLINDER HEAD .......................................................................15PRESSURE TEST .................................................................................................................................15CYLINDER BLOCK REPLACING CAM BUSHING ................................................................................................................15REPLACING CAM GEAR ......................................................................................................................15REPLACING FLYWHEEL RING GEAR .................................................................................................15REPLACING ENGINE REAR SEAL ......................................................................................................15REPLACING CONNECTING ROD SMALL END BUSHING .................................................................15REPLACING MAIN BEARING CAP.......................................................................................................15GRINDING CRANKSHAFT....................................................................................................................15REPLACING WEAR SLEEVE (When equipped with sleeve) ................................................................15-

125-3 SERIES

3 8 11 12 13 13 14 22 25 25 26 31 32 51 60

15-1 (6)

REPAIR AND REPLACEMENT OF PARTS

CYLINDER HEAD

REPLACING VALVE SEAT INSERT Special tools No.

Part No.

Part Name

Q'ty

A

795-100-4801

Puller (valve seat)

1

790-901-1260

Push tool (for intake valve)

1

790-901-1250

Push tool (for exhaust valve)

1

795-100-3005

Seat cutter( KIT)

1

795-100-3100

Body ass'y

1

795-100-3200

Micrometer

1

795-100-3300

Gauge

1

795-100-3401

Tool head

1

795-100-3601

Head support

1

Cutter

1

C 3 795-100-3720

Cutter (for 30º)

1

4 795-100-3730

Cutter (for 45º)

1

795-100-4111

Pilot (9.00 mm)

1

795-100-4121

Pilot (9.01 mm)

1

795-100-4131

Pilot (9.02 mm)

1

795-100-4141

Pilot (9.03 mm)

1

795-100-4171

Pilot (8.98 mm)

1

795-100-4181

Pilot (8.99 mm)

1

B

1

2 795-100-3710

5

1. Removal of valve seat insert When using a grinder to carry out this work, carry out a test run for one minute before starting the operation to check that there is no abnormality. • If the grindstone has been replaced, carry out the test run 3 minutes. Check that there is no damage to the grindstone, fit it to the grinder spindle so that there is play, and wear safety glasses when using the grinder. •

When removing with a valve seat puller 1) Install grindstone to grinder . 2) Align the groove of sleeve with holder , and insert. ★ Adjust the position of the grinder with set screw .

125-3 SERIES

15-3

REPAIR AND REPLACEMENT OF PARTS

CYLINDER HEAD

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

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

•

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

15-4

125-3 SERIES

REPAIR AND REPLACEMENT OF PARTS

CYLINDER HEAD

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

2) Check the depth of the insert from the bottom surface (b) of the cylinder head. ★ Depth of the insert h Intake side : 3.78 – 4.08 mm Exhaust side : 3.10 – 3.40 mm

125-3 SERIES

15-5

REPAIR AND REPLACEMENT OF PARTS

CYLINDER HEAD

3. Machining valve seat insert mounting hole to oversize 1) Using tools C1 and C2, grind the hole to a one size larger over size. ★ Machine within a range of 1.0 mm oversize. If it is more than 1.0 mm, replace the cylinder head.

•

Dimensions of insert and mounting hole

Insert STD 0.25 O.S. 0.50 O.S. 0.75 O.S. 1.00 O.S.

Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust

Insert d 47.50+0.100 +0.090 +0.080 +0.070 47.75+0.100 +0.090 46.75+0.080 +0.070 48.0 +0.100 +0.090 47.0 +0.100 +0.090 48.25+0.100 +0.090 47.25+0.080 +0.070 48.5 +0.100 +0.090 47.5 +0.080 +0.070

46.5

h 0 -0.1 7.5 -0.10 7.5 -0.10 7.5 -0.10 7.62 -0.10 7.62 -0.10 7.75 -0.10 7.75 -0.10 7.88 -0.10 7.88 -0.10

7.5

Insert

D1 47.55 +0.020 +0.010

Unit:mm Insert mounting hole D2 H 50.30±0.2 11.38±0.1

46.55 +0.020 +0.010

49.30±0.2

10.7 ±0.1

47.75 +0.020 +0.010 46.75 +0.020 +0.010 48.05 +0.020 +0.010 47.05 +0.020 +0.010 48.25 +0.020 +0.010 47.25 +0.020 +0.010 48.55 +0.020 +0.010 47.55 +0.020 +0.010

50.55±0.2

11.38±0.1

49.55±0.2

10.7 ±0.1

50.80±0.2

11.5 ±0.1

49.80±0.2

10.82±0.1

51.05±0.2

11.63±0.1

50.05±0.2

10.95±0.1

51.30±0.2

11.76±0.1

50.30±0.2

11.08±0.1

Inset mounting hole

j : Cylinder head bottom surface ★ Inside surface roughness: 12.5S max. ★ Mounting hole bottom roughness: 12.5S max. ★ Concentricity of valve guide hole and insert: 0.07 mm(T.I.R)max.

15-6

125-3 SERIES

REPAIR AND REPLACEMENT OF PARTS

CYLINDER HEAD

4. Finishing insert seat surface 1) Using tools C1, C3, and C4, finish the surface of the insert seat to the dimensions shown in the diagram below. ★ When selecting a pilot C5 to insert into the valve guide, choose one that gives no clearance. • Intake valve

•

Exhaust valve

2) Rub the seat surface with compound.

5. Finish inspection • Coat the seat surface of the new valve thinly with red lead(minimum), insert it in the valve guide, push lightly against the valve insert surface, and rotate 10º. Check the valve insert contact surface, and confirm that the contact is uniform without any breaks. • Or Make marks with a pencil on the seat surface of the new valve as shown in the diagram below, insert it in the valve guide, push lightly against the valve insert surface, and rotate 10º. Check that the pencil marks have been erased uniformly around the whole circumference. 125-3 SERIES

15-7

REPAIR AND REPLACEMENT OF PARTS

CYLINDER HEAD

REPLACING NOZZLE HOLDER SLEEVE Special tools Part No.

Part Name

Q'ty

A

795-600-1191

Push bar

1

B

795-600-1220

Push bar

1

C

795-600-1540

Sleeve driver

1

D

795-600-1410

Rolling tool

1

E

795-901-1210

Sleeve holder

1

F

795-600-1420

Sleeve expander

1

G

795-901-1230

Guide bushing

1

H

795-600-1430

Sleeve cutter

1

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

4) Remove the sleeve material cleanly from portion P of the cylinder head.

2. Press-fitting the sleeve Insert sleeve (1) into the cylinder head, then using sleeve driver C, tap lightly until the sleeve is completely in close contact with the seat surface. ★ Before installing the sleeve, clean the sleeve and seat. ★ Apply adhesive to the seat around the sleeve. 2 Adhesive: LT-2

15-8

125-3 SERIES

REPAIR AND REPLACEMENT OF PARTS

CYLINDER HEAD

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

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

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

125-3 SERIES

15-9

REPAIR AND REPLACEMENT OF PARTS

CYLINDER HEAD

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

15-10

125-3 SERIES

REPAIR AND REPLACEMENT OF PARTS

CYLINDER HEAD

REPLACING VALUE GUIDE Special tools Part No.

Part Name

Q'ty

A

795-100-1531

1

B

795-100-1661

C

795-100-1670

Valve guide remover Valve guide driver (for intake) Valve guide driver (for exhaust)

1 1

1. Removing the valve guide Remove the valve guide with valve guide remover A.

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

125-3 SERIES

15-11

REPAIR AND REPLACEMENT OF PARTS

CYLINDER HEAD

REPLACING CROSS HEAD GUIDE Special tools Part No. A

795-130-3300

B

790-471-1120

Part Name Cross head guide puller Cross head guide driver

Q'ty 1 1

1. Removing the cross head guide • Using cross head guide puller A, pull out the cross head guide. 1) As shown in the figure, hold the cross head guide with collet of the puller. 2) Tighten the collet with bolt to lock sleeve . 3) Rotate nut and pull out the cross head guide. 4) Remove burns, fins, etc. from the mounting place of the cross head guide and clean it. a: Cylinder head 2. Press-fitting the cross head guide • Using cross head guide driver B, press fit the cross head guide. ★ Protrusion of cross head guide: 45.5 ± 0.25 mm

15-12

125-3 SERIES

REPAIR AND REPLACEMENT OF PARTS

CYLINDER HEAD

GRINDING THE VALVE Special tools Part No. A

– (Purchase)

Part Name Valve refacer

Q'ty 1

1. Grinding the seat surface • Grind the seat surface with valve refacer A. ★ Angle of valve seat (α): Intake valve: 30º Exhaust valve: 45º 2. Checking after grinding • Confirm that the thickness of the valve head, protrusion of the valve, and the contact surface of the valve seat are within specification. ★ Allowable thickness of valve head (h) Intake valve: 1.7 mm Exhaust valve: 1.2 mm ★ Sinking distance of valve Intake valve: 1.88 ± 0.1 mm Exhaust valve: 1.20 ± 0.1 mm

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

125-3 SERIES

15-13

REPAIR AND REPLACEMENT OF PARTS

CYLINDER HEAD

PRESSURE TEST •

If the area round the cylinder head has been corrected, test as follows.

Special tools Part No.

Part Name

Q'ty

A

790-553-1500

Coolant tester kit

1

B

79A-471-1050

Pump ass'y

1

1. Water pressure test 1) Tighten the nozzle holder assembly to the specified torque. 2) Assemble tool A and tool B, and connect a hose to flange (1). 3) Apply water pressure (0.35 – 0.4 MPa {3.5 – 4.0 kg/cm 2 }) for approx. 10 minutes, and check for any leakage from around the cylinder head. ★ It is preferable to warm the whole cylinder head and carry out the test with hot water (80 – 95 ºC). 2. Air pressure test 1) Tighten the nozzle holder assembly to the specified torque. 2) Connect the pump hose to flange (1). 3) Place the cylinder head in a water bath, apply air pressure (0.3 – 0.35 MPa {3.0 – 3.5 kg/cm 2 }) for approx. 30 seconds, and check for any air leakage in the water. ★ If the above teat shows that there are cracks around the nozzle holder and plugs, replace the cylinder head.

15-14

125-3 SERIES

REPAIR AND REPLACEMENT OF PARTS

CYLINDER BLOCK

REPLACING CAM BUSHING Special tools No. A

Part No.

Part Name

Q'ty

795-225-1200

Push tool

1

1 795-225-1310

Push bar

1

2 795-225-1210

Push tool

1

A 3 795-225-1220

Collar

1

4 795-225-1230

Guide

1

5 792-103-0400

Grip

1

★ When replacing the cam bushing, first remove the blind plug at the rear of the cylinder block. 1. Removal of No. 1, 7 bushings As shown in the diagram, assemble push tool A2, collar A3, and push bar A1 of push tools A, then hit the push bar to knock bushing (2) out from cylinder block (1).

2. Removal of No. 2, 6 bushings Assemble push bar A1, push tool A2, collar A3, and guide A4 of push tool A, then hit the push bar to knock bushing (3) out from cylinder block (1).

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

15-22

125-3 SERIES

REPAIR AND REPLACEMENT OF PARTS

CYLINDER BLOCK

•

After removing the bushing, remove any burrs or dirt, and clean the mounting hole of the bushing. ★ Cam bushing assembly drawing 1: Cylinder block a: Oil hole b: Notch c: Bushing d: Oil return hole

1. Press fitting No. 3, 4, 5 bushings Assemble bushing (4) to tool A, and press fit the bushing until the oil hole of cylinder clock (1) matches the oil hole of the bushing.

2. Press fitting No. 2, 6 bushings Assemble bushing (3) to tool A, and press fit the bushing until the oil hole of cylinder clock (1) matches the oil hole of the bushing.

3. Press fitting No. 1, 7 bushings Assemble bushing (2) to tool A, and press fit the bushing until the oil hole of cylinder clock (1) matches the oil hole of the bushing.

125-3 SERIES

15-23

REPAIR AND REPLACEMENT OF PARTS

CYLINDER BLOCK

•

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

15-24

125-3 SERIES

REPAIR AND REPLACEMENT OF PARTS

CYLINDER BLOCK

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

REPLACING FLYWHEEL RING GEAR Take care not to let the flywheel fall. 1. Removing the ring gear • Make a groove on the tooth bottom surface of the ring gear with a grinder, then crack the gear with a chisel. Take care in handling the grinder and chisel. 2. Press-fitting the ring gear 1) Check the fitting surface of the ring gear. If any flaw is found, repair it with an oilstone. 2) Heat the ring gear at the specified temperature for the specified time for shrinkage fitting. ★ Heating temperature for ring gear: max. 200ºC Heating time: More than 30 minutes 3) With the chamferred side of ring gear facing the flywheel, fit it until its side contacts the flywheel.

125-3 SERIES

15-25

REPAIR AND REPLACEMENT OF PARTS

CYLINDER BLOCK

REPLACING ENGINE REAR SEAL Special tools Part No.

Part Name

Q'ty

A 795-931-1100

Seal puller assembly

1

B 795-931-1210

Sleeve jig (for assembly)

1

C 795-931-1220

Sleeve jig (for assembly)

1

Type

Single lip seal (for dry type)

Double lip seal (for wet type)

Flywheel end is Flywheel end is dry specification wet specification

Standard (when shipped from factory) With sleeve (for repair when shaft wear is large)

★ The types of engine rear seal (Teflon seal) are shown on the right. • For details of disassembly and assembly of flywheel and flywheel housing (1), see DISASSEMBLY AND ASSEMBLY. 1. Removing seal 1) Hook tip of tool A under the metal ring of seal (2), then remove it with the impact force of slide hammer . ★ Before removing seal (2), knock seal (2) in to free it from flywheel housing (1) and make it easy to remove. ★ Be careful not to scratch or damage crankshaft (3). ★ Do not use a drill. If a drill is used, metal particles will get inside the engine. 2. Removing sleeve (when equipped with sleeve) 1) For details of the method of removing the sleeve, see REPLACING WEAR SLEEVE, REMOVING SLEEVE. 3. Checking wear of shaft 1) If the wear is only seen as luster (when touched with the flat of the finger, the wear cannot be detected; wear depth: approx. 10 µm or less) and there are no scratches or other damage, the part can be used again. 2) In any case other than the above, install a seal with sleeve.

15-26

125-3 SERIES

REPAIR AND REPLACEMENT OF PARTS

CYLINDER BLOCK

4. Install seal with sleeve (when equipped with sleeve) • The shape of the spare seal when shipping is as shown in the right. ★ Handle seal (4) and sleeve (5) as an assembly. Do not separate them.

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

3) Press fit sleeve (5) and seal (4) until tool C contacts end face of crankshaft (3). ★ Remove tool C when it contacts end face of crankshaft (3).

125-3 SERIES

15-27

REPAIR AND REPLACEMENT OF PARTS

CYLINDER BLOCK

4) Replace with tool B, tighten again uniformly with bolts (7), and start to press fit sleeve (5) and seal (4). ★ Tightening bolt (7): 01050-31625 (x 3)

5) Press fit until tool B contacts end face of crankshaft (3). ★ Wipe off all the gasket sealant that is squeezed out to the outside circumference.

5. Installing standard seal • The shape of the spare seal when shipping is as shown in the right. ★ Do not separate seal (8) and plastic inner tube/assembly guide until seal (8) is assembled. (The guide also acts to protect the seal lip.)

1) Put large inside diameter of plastic inner tube in contact with end face of crankshaft (3). ★ Be careful not to mistake the direction. ★ Before assembling seal (8), remove all scratches, burrs, flashes, and rust from the end face corner and sliding face of lip of clutch shaft (3) and flywheel housing (1). ★ Wipe off all the oil from the sliding surface.

15-28

125-3 SERIES

REPAIR AND REPLACEMENT OF PARTS

CYLINDER BLOCK

2) Push in the metal ring of seal (8) uniformly with both hands until it feels that it has passed inside diameter large end of plastic tube . 3) Remove plastic tube , taking care not to damage the lip.

4) Put tool B in contact as shown in the diagram on the right, then tighten uniformly with the bolts. ★ Tightening bolt (6) : 01050-31645 (x 3) Tightening bolt (7) : 01050-31625 (x 3) ★ Be careful not to damage the tip of lip .

5) Press fit until tool B contacts end face of crankshaft (3). ★ Wipe off all the gasket sealant that is squeezed out to the outside circumference.

125-3 SERIES

15-29

REPAIR AND REPLACEMENT OF PARTS

CYLINDER BLOCK

TOOL B (795-931-1210) Unit: mm

TOOL C (795-931-1220) Unit: mm

15-30

125-3 SERIES

REPAIR AND REPLACEMENT OF PARTS

CYLINDER BLOCK

REPLACING CONNECTING ROD SMALL END BUSHING Special tools No. A

B

Part No. 795-903-1201

Part Name

Q'ty

Push tool assembly

1

1 795-903-1211

Push tool

1

2 795-903-1220

Push tool

1

3 795-903-1230

Block

1

4 795-903-1240

Nut

1

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

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

125-3 SERIES

15-31

REPAIR AND REPLACEMENT OF PARTS

CYLINDER BLOCK

REPLACING MAIN BEARING CAP •

When replacing the main bearing cap, machine the semi-finish product to the following dimensions, then install.

Correction parts Part No.

Part Name

6150-29-1210

Main bearing caps other than No.7

6150-29-1250

No.7 main bearing cap

1. Machining inside diameter of main bearing cap 1) Remove the cylinder liner. 2) Install the replacement main bearing cap to the cylinder block, and tighten to the specified torque. 2 Main bearing cap mounting bolt: Coat seat face of threaded portion with engine oil. 3 Main bearing cap mounting bolt: Unit: Nm {kgm} Order

Target

Range

1st step

98 {10}

88 – 108 {9 – 11}

2nd step

196 {20}

191 – 201 {19.5 – 20.5}

3rd step

Tighten a further 90º

90º +30º +0

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

15-32 (6)

125-3 SERIES

REPAIR AND REPLACEMENT OF PARTS

CYLINDER BLOCK

5) Check the machined inside diameter of bearing cap (1) and grind a little at a time. ★ Grind until the bit touches the inside surface of cylinder block (2). ★ Inside diameter of main bearing cap Machining dimension Tolerance: 116 +0.015 mm +0 Inside diameter of cap when main bearing cap is tightened to specified torque after machining Tolerance: 116 +0.013 –0.009 mm (Up-down range of 10º at mating surface of main bearing cap) ★ Finishing roughness: Within 10 S ★ Do not grind the inside face of the cylinder block. 2. Machining width of main bearing cap (Only when machining No.7 main bearing cap) 1) Insert cast iron bushing , then pass arbor through. 2) Install facing bit to the arbor. 3) Grind A portion of cap (1) until the bit touches the cylinder block (2) face. 4) Grind the B portion of opposite side in the same way. ★ Roughness of thrust bearing mounting surface: Within 12.5 S ★ Do not grind the cylinder block. ★ Width of main bearing cap Tolerance: 38 –0 –0.025 mm

125-3 SERIES

15-33 (6)

REPAIR AND REPLACEMENT OF PARTS

CYLINDER BLOCK

GRINDING CRANKSHAFT ★ When grinding the crankshaft to correct wear, light seizure or damage, grind to an undersize. ★ If there is curvature of the crankshaft, it is preferable to replace the crankshaft and not to grind it to an undersize. (There are problems with balancing.) ★ Do not try to correct a bent crankshaft with a press. When the engine is run, the crankshaft will gradually return to its bent shape. ★ The journal portion has been given induction hardening, so do not try to repair it by bead welding or plating. ★ Unevenly worn crankshafts will bend or be unbalanced even if repaired, so always replace unevenly worn crankshafts. ★ Measure the part for grinding to decide the undersize dimension. ★ Judge from the measured dimension, and if the undersize dimension will exceed the repair limit, replace the crankshaft. ★ When repairing the plating of the damaged surface, repair only the following places. 1) Rear seal journal portion 2) Crankshaft gear mount ★ When correcting damage to the crankshaft, pay particular attention when finishing the R portion of the fillet and shoulder r (see the diagram on the right) and the R at the inlet port of the oil hole.

125-3 SERIES

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★ Necessary equipment and jigs for grinding 1) Magnetic flaw detector 2) Shore hardness gauge 3) Etching kit (quantity for one check of traces of seizure) i) 4% nitric acid solution: 250 g ii) 2% hydrochloric + acetone solution: 250 g iii) Acetone: 250 g iv) Cotton wool: 1 packet v) Stainless steel pincette: 1 4) Crankshaft milling machine i) Milling machine ii) V gauge, set of attachments for other grinding iii) Dresser (for oil stone) iv) Oil stone (reference) • 19A54M, 19A46M or 19A54L • Material: WA or A • Grain size: Medium, No. 46, or No. 54 • Grade: Medium, M, L, N, or O 5) Crankshaft polisher 6) Roughness gauge 7) Fillet R measurement ball gauge 1. Inspecting before grinding 1) Visual inspection • If any heat cracks can be seen, the hardened layer is damaged, so replace the crankshaft. • If there is discoloration up to the unmachined shoulder near the journal face or thrust face, it shows that the crankshaft has been heated to an excessive temperature, so replace the crankshaft. • If the wear or damage to the journal means that it cannot be corrected to an undersize, replace the crankshaft. (Skill is needed.) • Replace the crankshaft if there is damage to any part which will affect the strength of the R portion. • If only one of the crankshaft pin journals is worn, it will affect the balancing, so replace the crankshaft. 2) Inspecting hardness of journal surface • Measure the hardness of the journal surface with a Shore hardness gauge. If it is not within the standard value, it shows that there has been excessive heat damage, so replace the crankshaft.

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2. Inspection during grinding and after grinding 1) Inspecting R portion of fillet • Check that the R portion of the fillet is connected smoothly to the shoulder of the journal. (See diagram.) • Check that there are no scratches or seizure which will cause concentration of stress around the R portion of the fillet. • Check that the R dimension of the fillet is within the specified dimension. R dimension: Between minimum radius ball gauge and maximum radius ball gauge.

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

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

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2) Checking for traces of seizure using etching • After grinding the crankshaft, carry out an etching test to confirm that there are no traces of grinding seizure. • If bearing failure has caused any damage, seizure, or streaks in the journal portion, carry out an etching inspection to check for traces of seizure. This helps to judge if there has been any drop in hardness, and to decide the undersize dimension. • Etching inspection is used to find out if there are any traces of seizure which cannot be found by visual check or hardness check. It is also used to find traces of grinding seizure caused by heating of the surface during grinding. • Grinding seizure and traces of seizure in the journal or fillet portion destroy the structure of the metal because heat is applied. This normally occurs near to the surface, but it may cause concentration of stress which in turn will lead to breakage of the crankshaft. • Procedure for etching inspection i) Wipe the inspection surface clean. ii) Wipe the inspection surface with a 4% nitric acid solution. Roll a piece of cotton wool into a diameter of 2 to 3 cm. Soak it in the nitric acid solution, then hold it with the pincette and wipe for 1 to 2 minutes. iii) Wash off the nitric acid solution with water, then dry the surface. Soak some cotton wool in acetone, wipe again, then dry the surface. iv) Soak some cotton wool with dilute hydrochloric acid (2% hydrochloric acid mixed in acetone) and apply for 30 sec. to 1 min. to etch the inspection surface. v) Wash off the dilute hydrochloric acid with water, wipe with acetone, then dry with compressed air. vi) Check the inspection surface. • If there is no seizure, the whole etched surface will be a uniform bright color. • If there are any streaks or dark patches on a bright grey surface, this shows the existence of grinding seizure. • If there are stripes brighter than the grey surface, this shows the existence of excessive grinding seizure. • If there is any suspicious pattern, polish the etched surface, and etch again. • If there is any seizure, the same pattern will appear when the etching is repeated.

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vii) After the inspection, polish off the discoloration caused by the etching, then clean and dry the surface. To neutralize the surface, wipe with a weak solution of slaked lime or with any similar weak alkali solution. viii) After drying, coat with rust-prevention oil. Pay particular attention to the inspection surface and oil holes. If the crankshaft is installed immediately in the engine, it can be coated with engine oil. If any seizure is found, grind off approx. 0.02 mm and correct to the next undersize.

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

ii)

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

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3. Grinding main journal ★ Grind each main journal to the same undersize dimension. ★ Mark the undersize dimension on the ground crankshaft as shown in the diagram to prevent any mistake in the size when assembling the bearing. ★ After grinding, check that the difference between the dimensions of the journals is within the permitted range. 4. Grinding thrust surface ★ There is no particular need to grind the front and rear thrust surface to the same undersize dimension. ★ Mark the undersize dimension on the ground crankshaft as shown in the diagram to prevent any mistake in the size when assembling the thrust bearing. ★ After grinding, check that the difference between the thrust widths of the journals is within the permitted range. ★ If the thrust surface width has been ground, check that the end play of the crankshaft is within the permitted range. •

Conditions for grinding (reference) Grinding speed: 1800 – 2200 rpm Feeding speed: 0.2 – 0.4 mm/min.

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5. Grinding pin journal ★ Grind each pin journal to the same undersize dimension. ★ Mark the crankshaft pin undersize dimension on the ground shaft in the same way as with the undersize mark on the main journal. ★ After grinding, check that the difference between the dimensions of the journals is within the permitted range.

6. Grinding main journal width and pin journal width ★ When correcting the wear surface on both sides of the main journal and pin journal, if there are streaks, scratches, or dents, correct using the minimum amount of grinding. ★ Leave a thickness of at least 0.25 mm on the friction surface of the main journal. ★ If the width of the pin journal is too large, the connecting rod will move up and down or from side to side on the crankshaft when the engine is running. This will cause uneven wear. To avoid this, remove the minimum possible amount when grinding, and always keep strictly to the repair limit. •

Conditions for grinding (reference) Grinding speed: 1800 – 2200 rpm Feeding speed: 0.2 – 0.4 mm/min.

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7. Correcting grindstone • Apply dressing to the grindstone for each journal. • The start and the R dimension of the journal fillet have a big effect on the strength of the crankshaft, so adjust with the following grinding method. 1) Grindstone dresser Angle of tip (b): 75º ± 1º Radius of tip: See Shop Manual for each series Use a conical type with inset industrial diamonds. When using the dresser, adjust so that the tip of the cone is at the center of the shank. 2) Adjust the diamond of the grindstone correcting device, and modified the edge of the grindstone to match the arc of the fillet. 3) First, correct the surface of the grindstone and record the reading of the feed dial gauge. Next, put the radius of one of the edge arcs in contact with the surface of the grindstone. • The final feed of the corrected surface should be finished within 0.013 mm. 4) Hold a small coarse grindstone in your hand and put it in contact with the front face of the grindstone. Grind lightly so that the arc at the edge contacts smoothly with the front face of the grindstone. When doing this, slightly change the angle of the grindstone in your hand and put it lightly in contact with the grindstone. 5) When testing the start or the R dimension of the fillet, first grind a piece of wood as a test. Check with a ball gauge, and correct to a perfect fillet shape. 6) Correct the edge on the other side of the grindstone in the same way. 7) Make a test grinding of the crankshaft, then finally check the shape of the fillet.

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8. Prevention of grinding seizure • To prevent seizure when grinding, follow the precautions below strictly. 1) Always put the grindstone at right angles to the crankshaft (plunge grind method) when grinding. If the grindstone is put in contact with the crankshaft and then moves to the side (bump method), there is a high risk of seizure. 2) Even when using the whole width of the grindstone, avoid grinding the boss surface as far as possible. Finish the boss surface by polishing. If the grindstone contacts the boss surface, the feeding speed should be below 0.025 mm/sec. 3) The cooling oil sent to the side face copy grinding device and the main jet should fully contact the grinding area. Start the flow of oil before starting to grind. 4) When the crankshaft speed is approx. 50 rpm, make the standard grinding speed at the circumference of the grindstone 2000 m/ min.

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9. Finishing surface • Finish the journal surface smoothly because this affects the fatigue strength of the crankshaft and the wear of the bearing. • Standard surface roughness after grinding Journal face, thrust surface, fillet portion: Within 0.8 S Pin and main boss portion: Within 3.2 S Tip nose portion, rear flange face: Within 2.0 S • When using a belt-type lapping machine, pull the emery cloth in the same direction as the rotation of the crankshaft. This is to avoid fine particles flying in the direction of rotation. These fine particles may cause scratches if they are caught in the crankshaft. • Finish the area around the oil holes to the same surface roughness as the journal portion. • Allowance for polish finishing: 0.007 – 0.008 mm • Rust or corrosion causes wear of the bearing, so remove all rust and corrosion completely, and coat with high-quality rust-prevention oil. • Finishing conditions (reference) Paper to use: AA#120 Shaft rotating speed: 100 rpm Grinding speed: 36 m/min. 10. Action after grinding • Check again that each dimension is as specified. • Wash each part thoroughly (particularly the oil holes) and coat the whole crankshaft with rustprevention oil. • Be extremely careful to avoid causing scratches or damage when handling. • When storing for a long period, support at three points or fit a lifting tool and stand upright to prevent curvature.

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REPLACING WEAR SLEEVE (When equipped with sleeve) ★ If the wear sleeve is worn or damaged, replace as follows. 1. Removing sleeve 1) Make a groove in the sleeve (1) with a grinder. 2) Put a chisel in contact with the groove in the sleeve and hit with a hammer to remove. ★ The interference is tight, so remove as follows. Make a V cut in the sleeve with a grinder. Split the wear sleeve at the V cut with a chisel, then remove the sleeve. Be extremely careful not to let the chisel fly. ★ When removing the wear sleeve, be careful not to damage the shaft. 2. Press fitting sleeve 1) Check the interference between the sleeve and shaft, and confirm that it is within the standard value. 2) Using a sleeve driver, shrink fit the sleeve. ★ When using oil to heat the sleeve, use oil with a high flash point and be extremely careful not to cause any fire.

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