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SEN00182-00

ENGINE 1SHOP MANUAL

125E-5 Series

01 Specification 1
Specification and technical data
Outline.................................................................................................................................................. 2
Specifications ....................................................................................................................................... 5
General view ........................................................................................................................................ 8
Weight table ....................................................................................................................................... 17
Engine performance curves ............................................................................................................... 18

125E-5 Series 1
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Outline 1
1. Applicable machine

Engine Engine serial No. Applicable machine


PC400-7, PC400LC-7
Hydraulic excavator
PC450-7, PC450LC-7
SAA6D125E-5
D85EX-15, D85PX-15 Bulldozer
HM300-2 Articulated dump truck

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01 Specification SEN00182-00

2. Outline of engine

q The 125E-5 engine is a high-performance and 5) The common rail high-pressure fuel injection
high-efficiency engine, which passed strict system controlled electronically is employed
emission regulations (USA: EPA Regulations for the 125E-3 and after models. This system
for 2006, EU: Regulations for 2006, Japan: can inject the fuel at high pressure of 120 MPa
Construction machinery regulations for 2006) {1,200 kg/cm2} from the low-speed range to the
and attained low fuel consumption, low noise, high-speed range. In addition, this system can
better exhaust gas color, and high acceleration control the form of injection most properly by
performance. Accordingly, this newly devel- electronic control according to the speed and
oped engine is suitable as a power source of load. The injection system of 125E-5 is further
construction machinery and industrial machin- improved to employ multiple injection and
ery used for various purposes. increase the injection pressure up to 140 MPa
{1,400 kg/cm2}. As a result, exhaust gas of the
q The 125E-5 engine is the successor to the cleanest level in the world, good exhaust gas
125E-3 engine. While it is an in-line 6-cylinder, color, low fuel consumption, and low noise are
water-cooled, common rail direct injection, 4- realized simultaneously.
stroke diesel engine, it is equipped with the
cooled EGR system which is a new technol- 6) As the injection pressure of the common rail
ogy. injection system employed for the 125E-3
engine and after models is increased (from
1) The main components of the cooled EGR sys- 120 to 140 MPa {from 1,200 to 1,400 kg/cm2}),
tem are the EGR cooler of corrugated tube the pressure resistance of the common rail,
type made of newly developed special stain- injector, and supply pump is improved for
less steel and the EGR valve driven hydrauli- higher reliability.
cally and controlled electronically which
KOMATSU developed by itself. The cooled 7) The main fuel filter of high efficiency and the
EGR system secures the optimum EGR rate pre-fuel filter are installed as standard so that
from the low-speed range to the high-speed the low grade fuel in the market (equivalent to
range to attain both clean exhaust gas and low Class NAS13) can be used. In addition, the
fuel consumption with the bypass assist circuit delivery of the priming pump used to replace
consisting of the venturi system and bypass the filters is increased for higher serviceability.
valve which has the same function and struc-
ture as those of the EGR valve. 8) The high-quality piston made of cast iron which
has been employed for the 125E-2 engine and
2) The special EGR oil pump is employed to gen- after models is employed. This piston has a
erate high oil pressure (1.47 MPa {15 kg/cm2}) less coefficient of thermal expansion, a reen-
as the drive power source of the EGR valve trant combustion chamber, and a shaker cool-
driven hydraulically and controlled electroni- ing gallery. As a result, clean exhaust gas,
cally. good exhaust gas color, and low fuel consump-
tion are attained simultaneously, and high
3) The 125E-5 engine is equipped with the com- durability and reliability are also obtained.
bination filter system of high performance and
efficiency, which has been employed for the 9) By using the above-mentioned high-pressure
125E-3 engine, to meet the requirements of fuel injection system controlled electronically,
the EGR system and high-dispersion oil and the multiple injection and injection characteris-
capture large and small particles. In addition, tics are set most properly to improve the start-
the recommended sub-materials for operation ability and reduce the white exhaust smoke
(oil and fuel) are changed to improve the reli- when the temperature is low.
ability and durability of the engine.
10) Since the engine controller is mounted on the
4) Since the high-pressure fuel injection system engine and equipped with the automatic high-
controlled electronically is employed, less soot altitude compensation function, the engine can
is produced and the draining interval of the oil be operated at high altitude without replacing
is lengthened. (While the capacity of the oil the controller. As a result, the serviceability is
pan is not changed, the oil replacement inter- improved.
val of 500 hours is secured.)

125E-5 Series 3
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11) The KTR90 turbocharger newly developed and


manufactured by KOMATSU for higher reliabil-
ity and higher performance is mounted. The
efficiency of the blower impeller is improved
and special manufacturing methods for higher
strength of the material are employed to obtain
higher efficiency and higher pressure ratio. As
a result, high performance is maintained from
the low-speed range to the high-speed range.

12) The copper sleeve at the injector mounting


hole of the cylinder head is eliminated.
Instead, the dry sleeve structure is employed
and the top and bottom faces of the cylinder
head are connected by casting to meet the
requirements of the high output and attain
higher reliability.

13) The cylinder block is changed partly to add the


cooled EGR system. Since its overall length,
overall width, and overall height are the same
as before, however, its compactness is main-
tained.

14) If only fuel containing sulfur more than 5,000


PPM (0.5%) is obtained in a district where the
emission regulations are not applied, the high
sulfur-content fuel specification without EGR
system is prepared.

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Specifications 1

Engine name SAA6D125E-5


PC400-7, PC400LC-7
Applicable machine
PC450-7, PC450LC-7
Number of cylinders – Bore × Stroke mm 6 – 125 × 150
Total displacement l {cc} 11.0 {11,040}
Firing order — 1–5–3–6–2–4
Overall length mm 1,713
Dimensions

Overall width mm 1,001


Overall height (excluding exhaust pipe) mm —
Overall height (including exhaust pipe) mm 1,741
262.5 / 1,900
kW/rpm
Rated output {353 / 1,900}
{HP/rpm}
(Gross)
1,422 / 1,400
Nm/rpm
Performance

Max. torque {145 / 1,400}


{kgm/rpm}
(Gross)
No-load max. speed
rpm 1,930 ± 25
(High idle speed)
No-load min. speed
rpm 1,000 ± 25
(Low idle speed)
g/kW·h 211
Fuel consumption ratio at rated output
{g/HP·h} {157}
Dry weight kg 1,310
Fuel injection pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil 46
l
(Refill capacity) (37)
Quantity of coolant
l
(for only engine) (21)
Alternator — 24V, 35A
Starting motor — 24V, 7.5kW
Battery — 12V, 150Ah×2
Turbocharger — KOMATSU KTR90
Air compressor — —
Others — With air-cooled aftercooler

125E-5 Series 5
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Engine name SAA6D125E-5


Applicable machine D85EX-15, D85PX-15
Number of cylinders – Bore × Stroke mm 6 – 125 × 150
Total displacement l {cc} 11.0 {11,040}
Firing order — 1–5–3–6–2–4
Overall length mm 1,307
Dimensions

Overall width mm 1,004


Overall height (excluding exhaust pipe) mm 1,711
Overall height (including exhaust pipe) mm —
199 / 1,900
kW/rpm
Rated output {267 / 1,900}
{HP/rpm}
(Gross)
1,272 / 1,400
Nm/rpm
Performance

Max. torque {130 / 1,400}


{kgm/rpm}
(Gross)
No-load max. speed
rpm 2,100 ± 50
(High idle speed)
No-load min. speed
rpm 750 (+50/0)
(Low idle speed)
g/kW·h 215
Fuel consumption ratio at rated output
{g/HP·h} {160}
Dry weight kg 1,330
Fuel injection pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil 44
l
(Refill capacity) (38)
Quantity of coolant
l
(for only engine) (21)
Alternator — 24V, 50A
Starting motor — 24V, 7.5kW
Battery — 12V, 150Ah×2
Turbocharger — KOMATSU KTR90
Air compressor — —
Others — With air-cooled aftercooler

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01 Specification SEN00182-00

Engine name SAA6D125E-5


Applicable machine HM300-2
Number of cylinders – Bore × Stroke mm 6–125 × 150
Total displacement l {cc} 11.0 {11,040}
Firing order — 1–5–3–6–2–4
Overall length mm 1,681
Dimensions

Overall width mm 1,010


Overall height (excluding exhaust pipe) mm 1,268
Overall height (including exhaust pipe) mm —
254 / 2,000
kW/rpm
Rated output {341 / 2,000}
{HP/rpm}
(Gross)
1,706 / 1,400
Nm/rpm
Performance

Max. torque {174 / 1,400}


{kgm/rpm}
(Gross)
No-load max. speed
rpm 2,220 ± 50
(High idle speed)
No-load min. speed
rpm 725 (+50/0)
(Low idle speed)
g/kW·h 215
Fuel consumption ratio at rated output
{g/HP·h} {161}
Dry weight kg 1,285
Fuel injection pump — DENSO ECD-U2
Governor — Electronic control type
Quantity of lubricating oil 44
l
(Refill capacity) (35)
Quantity of coolant
l
(for only engine) (21)
Alternator — 24V, 50A
Starting motor — 24V, 7.5kW
Battery — 12V, 300Ah×2
Turbocharger — KOMATSU KTR90
Air compressor — —
Others — With air-cooled aftercooler

125E-5 Series 7
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General view 1
SAA6D125E-5 (Left side of engine)
Applicable machines: PC400-7, PC400LC-7, PC450-7, PC450LC-7

a The shape is subject to machine models.


a For the dimensions of each part, see the last page of the general view.

1. Center of crankshaft
2. Rear face of flywheel housing

8 125E-5 Series
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SAA6D125E-5 (Front side of engine)


Applicable machines: PC400-7, PC400LC-7, PC450-7, PC450LC-7

a The shape is subject to machine models.


a For the dimensions of each part, see the last page of the general view.

1. Center of crankshaft
2. Center of cylinder liner

125E-5 Series 9
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SAA6D125E-5 (Left side of engine)


Applicable machines: D85EX-15, D85PX-5

a The shape is subject to machine models.


a For the dimensions of each part, see the last page of the general view.

1. Center of crankshaft
2. Rear face of flywheel housing

10 125E-5 Series
01 Specification SEN00182-00

SAA6D125E-5 (Front side of engine)


Applicable machines: D85EX-15, D85PX-5

a The shape is subject to machine models.


a For the dimensions of each part, see the last page of the general view.

1. Center of crankshaft
2. Center of cylinder liner

125E-5 Series 11
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SAA6D125E-5 (Left side of engine)


Applicable machine: HM300-2

a The shape is subject to machine models.


a For the dimensions of each part, see the last page of the general view.

1. Center of crankshaft
2. Rear face of flywheel housing

12 125E-5 Series
01 Specification SEN00182-00

SAA6D125E-5 (Front side of engine)


Applicable machine: HM300-2

a The shape is subject to machine models.


a For the dimensions of each part, see the last page of the general view.

1. Center of crankshaft
2. Center of cylinder liner

125E-5 Series 13
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SAA6D125E-5 (Top of engine)


Applicable machine: HM300-2

a The shape is subject to machine models.


a For the dimensions of each part, see the last page of the general view.

1. Center of crankshaft

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125E-5 Series 15
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Dimensions table
Unit: mm
Dimension of each part
Engine Machine
A B C D E F G H J
PC400-7, PC400LC-7
1,713 1,741 438 — — — — 1,001 —
PC450-7, PC450LC-7
SAA6D125E-5
D85EX-15, D85PX-15 1,307 1,711 387 15 15 777 949 1,004 —
HM300-2 1,681 1,268 401 178 — 530 760 1,010 718
a These dimensions are given for reference when the engine is set on a test bench.

16 125E-5 Series
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Weight table 1
Unit: kg
No. Item Main parts SAA6D125E-5
1 Turbocharger KOMATSU KTR90 17
Cylinder head, valve,
2 Cylinder head assembly 15
valve spring
Cylinder block, bearing,
3 Cylinder block assembly 305
cap, cylinder liner
4 Front cover 29
PC400-7, PC400LC-7
18
PC450-7, PC450LC-7
5 Oil pan D85EX-15
21
D85PX-15
HM300-2 22
PC400-7, PC400LC-7
49
PC450-7, PC450LC-7
6 Flywheel assembly Flywheel ring gear D85EX-15
55
D85PX-15
HM300-2 23
7 Flywheel housing assembly 54
8 Crankshaft assembly Crankshaft, crank gear 106
Camshaft, cam gear,
9 Camshaft assembly 16
thrust plate
Piston and connecting rod Piston, piston ring,
10 8
assembly piston pin, connecting rod
11 Oil pump 5
12 Fuel supply pump 10
13 Water pump 10
24V, 35A 8
14 Alternator 24V, 50A 10
24V, 75A 13
24V, 7.5kW 16
15 Starting motor
24V, 11kW 18
16 EGR oil pump 6
17 EGR valve 16
18 Bypass valve 16
19 EGR cooler 9

125E-5 Series 17
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Engine performance curves 1

Engine Engine serial No. Applicable machine Page


PC400-7, PC400LC-7
19
PC450-7, PC450LC-7
SAA6D125E-5
D85EX-15, D85PX-15 20
HM300-2 21

18 125E-5 Series
01 Specification SEN00182-00

SAA6D125E-5 (Applicable machine: PC400-7, PC400LC-7, PC450-7, PC450LC-7)

Rated output: 262.5 kW {353 HP}/1,900 rpm (Gross)


Max. torque: 1,423 Nm {145 kgm}/1,400 rpm (Gross)

125E-5 Series 19
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SAA6D125E-5 (Applicable machine: D85EX-15, D85PX-15)

Rated output: 199 kW {267 HP}/1,900 rpm (Gross)


Max. torque: 1,272 Nm {130 kgm}/1,400 rpm (Gross)

20 125E-5 Series
01 Specification SEN00182-00

SAA6D125E-5 (Applicable machine: HM300-2)

Rated output: 254 kW {341 HP}/2,000 rpm (Gross)


Max. torque: 1,706 Nm {174 kgm}/1,400 rpm (Gross)

125E-5 Series 21
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KOMATSU 125E-5 Series engine

Form No. SEN00182-00

© 2005 KOMATSU
All Rights Reserved
Printed in Japan 09-05 (01)

22 125E-5 Series