Komatsu D475A-2 Shop Manual Serial No. 10201 and Up

D475A-2
MACHINE MODEL SERIAL No.
D475A-2 10201 and up
l This shop manual may contain attachments and optional equipment that are not
available in your area. Please consult your local Komatsu distributor for those items
you may require.
Materials and specifications are subject to change without notice.
l D475A-2 mount the SA12Vl40-1 engine.
For details of the engine, see the 12V140-1 Series Engine Shop Manual.
(Q1995KW*U
All Rights Reserved
09-95(01)01301 00&l

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02
01
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Fl
/
/
2
198FO2406
F2
/
ii 3 F56103203
F3
F56103204
F4
F56103205
30-23
0

REMOVAL OF TORQUE REMOVAL OF FUEL INJECTION
CONVERTER COOLER PUMP ASSEMBLY (LEFT,
ASSEMBLY RIGHT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Remove radiator top cover.
Remove underguard.
* Sling the underguard cover, remove the
mounting bolts, then lower slowly and
open.
Drain oil.
* Remove the drain plug and drain the oil
from the torque converter cooler.
Disconnect tube (1). (See Fl)
Disconnect hose (2). (See F2)
A Fix the fan with rope to prevent it from
turning, and take steps to make sure that
the engine cannot be started.
Disconnect bracket (3). (See F3)
* Disconnect the bracket at the cooler end.
Remove windbreak plate (4). (See F4)
Remove cap (5). (See F4)
Remove torque converter cooler assembly
(6). (See F5)
&Ikg Torque converter cooler assembly:
See Weight Table
t Remove the torque converter assembly
on the opposite side in the same way.
INSTALLATION OF TORQUE INSTALLATION OF FUEL
CONVERTER COOLER INJECTION PUMP ASSEMBLY
ASSEMBLY (LEFT, RIGHT)
. Carry out installation in the reverse order to
removal.
. Refill with oil
Add engine oil to the powertrain oil pan to the
specified level.
It
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Close the fuel supply valve.
Remove fuel strainer (I). (Left side fuel injec-
tion pump only) (See F6)
Ir Remove the mounting bolts of bracket (2),
andmovethefuelstrainerassemblytothe
side.
Remove injection pump coupling cover.
Remove fuel control rod.
Disconnect lubrication tube (3). (See F7)
Disconnect hose (4) for feed pump. (See F7)
Disconnect tubes (5) and (6). (See F7)
Disconnect fuel hose (7). (See F7)
Disconnect fuel injection tube (8). (See F7)m
Remove injection pump mounting bolts (9).
(See F7)
Remove coupling lock bolt (IO). (See F7) m
Remove injection pump assembly (I I). (See
F7) m
* Becareful nottolosethecoupling key,and
keep it in a safe place.
& kg Injection pump assembly:
See Weight Table
removal.
m m Sleeve nut:
See Tightening Torques and
Standard Values Table
m Qa Coupling lock bolt :
m. Adjust the injection timing.
For details, see TESTING AND
ADJUSTING.
30-24
0

Fl F2 F6
198FO2401~~ 198FO2402
F3
F4
F5
198F024OE
/
2
198FO2406
F7
I F56103207

REMOVAL OF WATER PUMP
ASSEMBLY
1.
2.
3.
4.
Drain cooling water.
:
w : See Lubricant and Coolant Table
Remove corrosion resistor (I). (See Fl)
Disconnect piping. (See Fl)
I) Disconnect bypass tube (2). (See Fl)
2) Disconnect aftercooler inlet tube (3). (See
Fl)
3) Disconnect brake cooler outlet tube (4).
(See Fl)
4) Disconnect engine inlet tube (5). (See Fl)
5) Disconnect bypass tube (6). (See Fl)
6) Disconnect water pump inlet tube (7). (See
Fl)
Remove water pump assembly (8). (See Fl)
INSTALLATION OF WATER
PUMP ASSEMBLY
removal.
. Refilling with water
* Add water to the specified level, and run
the engine to circulate the water through
the system. Then check the water level
again.
REMOVAL OF TURBOCHARGER
ASSEMBLY
1. Remove muffler assembly (I). (See F2)
2. Remove exhaust connector (2). (See F2)
3. Remove intake connector (3). (See F2)
4. Disconnect oil supply tube (4). (See F2)
5. Disconnect drain tube (5). (See F2)
6. Remove turbocharger assembly (6). (See F2)
* Disconnect hose, and remove the
turbocharger assembly.
* Remove the turbocharger assembly on
the opposite side in the same way.
INSTALLATION OF
TURBOCHARGER ASSEMBLY
removal.
m
m Turbocharger mounting nut :
2
See Tightening Torques and z
Standard Values Table Q)
z
30-26
0

REMOVAL OF AFTERCOOLER REMOVAL OF NOZZLE HOLDER
CORE ASSEMBLY ASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
9.
IO.
Remove exhaust pipe and engine hood.
For details, see REMOVAL OF ENGINE
ASSEMBLY.
Remove muffler assembly (1). (See Fl)
Sr Remove the muffler bracket.
Remove air cleaner assembly (2). (See Fl)
* Remove the air cleaner bracket.
Remove intake connector (3). (See F2)
Disconnect electrical intake air heater wiring
(4). (See F2)
Disconnect cooling water piping (51, (61, (7),
and (8). (See F3, F4, F5)
Remove connector (9). (See F5)
Remove cover (IO). (See F5)
Remove aftercooler core assembly (II). (See
F5)
INSTALLATION OF
AFTERCOOLER CORE
ASSEMBLY
removal.
Add water to the specified level, and run the
engine to circulate the water through the
system. Then check the water level again.
1.
2.
3.
4.
5.
Remove cover (I ). (See F6)
Disconnect fuel injection piping (2). (See F6)
/33tl/
Remove connection (3). (See F7) m
Remove holder (4). (See F7) m
Remove nozzle holder assembly (5). (See F8)
m
* Screw in the bolts, and using a lever, pull
out.
* Check that there is a gasket fitted to the tip
of the nozzle holder.
* Mark the nozzle holder assemblies with
the cylinder number, and keep them in a
safe place to prevent damage to the tips.
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
removal.
m
m Sleeve nut :
m
W Connection :
W Locknut:
m
Ir Fit the spherical washer to the bolt and
install.
m Holder mounting bolt :
m
Ir Clean the nozzle holder assembly mount
before installing.
30-28
a

Fl
F2 F7
F3
F5
’
F5610321 E
F56103216
F8
3
F56103222
F56103223
30-29
0

REMOVAL OF CYLINDER HEAD
ASSEMBLY
A.Disconnect the cable from the negative (-1
1.
2.
3.
4.
5.
6.
7.
a.
9.
10.
11.
12.
13.
14.
15.
terminal of the battery.
18. Remove cylinder head assembly (24). (See F9)
n
Remove exhaust pipe and engine hood.
For details, see REMOVAL OF ENGINE
ASSEMBLY.
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
Remove muffler assembly (I ). (See Fl)
* Remove the muffler bracket.
Remove air cleaner assembly (2). (See Fl)
j, Remove the air cleaner bracket.
Remove turbocharger assembly (3). (See F2)
For details, see REMOVAL OF TURBO-
CHARGER ASSEMBLY.
l Carry out installation in the reverse order to
removal.
m
m Sleeve nut :
m
Ir Checkthatthe balloftheadiustmentscrew
Remove exhaust manifold assembly (4). (See is fixed securely in the socket of the
F2) rod.
Remove intake manifold assembly (for left
bank). (See F3)
I) Disconnect tubes (5) and (6) for air
m Rocker arm mountino bolt :
m
*
m
*
i)
ii)
iii)
iv)
See Tightening Torques
compressor.
2) Disconnect tube (7) for aftercooler.
3) Disconnect 2 heater relay wires (8).
4) Remove intake manifold assembly (9).
5) Remove electrical intake air heater (IO).
Remove intake manifold assembly (for right
bank). (See F4)
1) Disconnectelectrical intakeairheaterwire
Checkthatthe push rod isfixed securely in
the cam follower.
(II).
2) Disconnect tubes (12) and (13) for
aftercooler.
3) Remove intake manifold assembly (14).
4) Remove electrical intake air heater (15).
Disconnect fuel injection piping (16). (See F5)
m
Adjust the crosshead as follows.
Loosen the locknut, and turn back the
adjustment screw.
Hold the top surface of the crosshead
lightly, and screw in the adjustment screw.
After the adjustment screw contacts the
valve stem, tighten it a further 20”.
Tighten the locknut to hold the screw in
position.
Disconnect spill tube (17). (See F5)
Disconnect air vent tube (18). (See F5)
Remove head cover (191. (See F5)
Remove rocker arm (20). (See F6) m
Remove push rod (21). (See F7) m
Remove crosshead (22). (See F7) m
m Locknut :
m
* Adjust the valve clearance.
For details, see TESTING AND ADJUST-
ING, Adjusting valve clearance.
m Rocker arm, screw, locknut :
m
m Cylinder head mounting bolt :
16. Remove nozzle holder assembly.
* For details, see REMOVAL OF NOZZLE
HOLDER ASSEMBLY.
17. Remove rocker housing (23). (See F8) m
push
and
30-30
0

Fl F5
F2
F56103226
F3
F56103227
F4
F56103228
F56103229
F8 F9
-1 +----- F56103232 F56103233
30-3 1
0

REMOVAL OF FUEL TANK
ASSEMBLY
1. Disconnect hose (1). (See Fl)
* Before disconnecting the hose, close the
fuel valve.
INSTALLATION OF FUEL TANK
ASSEMBLY
l Carry out installation in the reverse order to
removal.
2. Remove bracket (2). (See Fl)
3. Remove wiring connector (3). (See Fl)
4. Remove clamp of drain hose (4). (See Fl)
5. Disconnect hoses (5) and (6). (See F2)
6. Remove fuel tank assembly (7). (See F3)
& kg Fuel tank assembly:
See Weight Table
30-32
a

Fl
3
F2
I 4 I j 198FO241'
IwfilIIIll 198FO2412
30-33
0

REMOVAL OF RADIATOR
ASSEMBLY
1. Drain cooling water.
10. Remove left and right isolators (13). (See F5)
2. Remove cover (I), engine hood (2), and left
and right side covers (3). (See Fl)
+ Liftofftheenginehoodandthesidecovers.
& kg Engine hood : See Weight Table
& kg Side cover : See Weight Table
3. Remove underguard (4). (See F2)
* Settransmissionjack 0 underthecenter
of the underguard, and lower the
transmission jack slowly to remove the
underguard.
11. Remove left and right brackets (14). (See F6)
PIkg Underguard : See Weight Table
4. Remove underguard (5). (See F2)
* Fit a sling around the underguard, lower
slowly, and open the underguard.
5. Disconnect wiring connector (6). (See F3) 12. Remove left and right caps (15). (See F7)
6. Disconnect hose (7) and tube (8). (See F3)
7. Remove condenser assembly (9). (See F3)
* Disconnect the hose of receiver tank (IO),
and remove the condenser assembly.
13. Remove radiator assembly (16). (See F8)
Sr Raise the radiator assembly carefully, and
be careful not to damage the core.
&?I
kg Radiator assembly :
See Weight Table
8. Disconnect tube (II). (See F4)
9. Disconnect hose (12). (See F4) INSTALLATION OF RADIATOR
ASSEMBLY
removal.
30-34
a

Fl
G 311 r--T---y
198FO2413
F2
198FO2414
F3
F4
198FO2417
F7
I II lCiEiFO2419
F8

REMOVAL OF RADIATOR
GUARD ASSEMBLY
5. Disconnect wiring connector (6). (See F5)
. See REMOVAL OF RADIATOR ASSEMBLY, and
carry out Steps 1 - 9.
1. Disconnect hose (I). (See Fl)
2. Disconnect hose (2). (See F2)
3. Remove cap (3) and shim (4). (See F3) m
* Check the number and thickness of the
shims, and keep in a safe place.
* Sling the blade cylinder, and run the
engine, retract the piston rod, then secure
the blade cylinder to the holder pin on the
chassis.
+ Remove the cap and shim on the opposite
side, and secure the blade cylinder to the
holder pin on the chassis.
4. Disconnect hose (5). (See F4)
A Stop the engine, and operate the control
levers several times to release the
remaining pressure in the hydraulic piping.
Then loosen the oil filler cap slowly to
release the pressure inside the hydraulic
tank.
6. Remove pin (7). (See F6)
* Sling the radiator guard assembly, and
remove the lock bolt, then using tool A,
push out the pin.
* Push out the pin on the opposite side in
the same way. ,
7. Remove pin (8). (See F7)
* Using tool A, pull out the pin.
8. Remove radiator guard assembly (9). (See F8)
* Check that all the wiring and piping has
been removed before removing the
radiator guard assembly.
& kg Radiator guard assembly :
See Weight Table
INSTALLATION OF RADIATOR
GUARD ASSEMBLY
removal.
m
Standard shim thickness : 4 mm
30-36
0

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Fl F5 F6
F2
F3
4’ 198FO242i
F4
ISSF I407
F7 /
F9
I 97F38 I
30-37
0

REMOVAL OF FAN DRIVE
PUMP ASSEMBLY
1. Turn over ROPS cab assembly.
* For details, see TURNING OVER ROPS
CAB ASSEMBLY.
2. Remove wiring connector (1). (See Fl)
3. Disconnect hose (2). (See Fl)
4. Remove pump assembly (3). (See Fl)
* Move coupling (41, then remove the pump
assemblytogetherwith suction pipe. (See
Fl)
& kg Pump assembly :
See Weight Table
INSTALLATION OF FAN DRIVE
ASSEMBLY
removal.
REMOVAL OF FAN MOTOR
ASSEMBLY
1.
2.
3.
4.
5.
Drain hydraulic oil from tank.
:
_ : See Lubricant and Coolant Table
Remove fan (I). (See F2)
Ir Sling the fan, then using guide bolt @
(Thread dia.=12mm, Pitch=l.75mm),
remove the fan.
&?I
kg Fan : See Weight Table
Disconnect hose (2). (See F3)
Disconnect drain hose (3). (See F4)
* Sling the bracket, tilt the top towards the
front, and disconnect the hose.
Remove fan motor assembly (4). (See F5)
&Ikg Fan motor assembly (including
bracket) : See Weight Table
*
I)
2)
3)
4)
Remove the fan motor assembly from the
bracket as follows.
Remove hose (5) and bracket (6). (See F6)
Remove nut (7). (See F7)
Using puller@, remove pulley (8). (See F8)
Remove fan motor assembly (9) from
bracket. (See F6)
INSTALLATION OF FAN MOTOR
ASSEMBLY
Ir Install the fan motor assembly to the bracket
as follows.
1) Set fan motor assembly (9) to the bracket.
(See F6)
2) Fitthe keytothe motorshaft, install pulley
(8), tighten nut (7), then secure with the
lock plate. (See F7, F8)
+ Tighten the nut to 80- 100 kgm, and if
the lock plate position is not aligned,
turninthetighteningdirectiontoalign.
3) Install bracket (6) and hose (5). (See F6)
removal.
. Refilling with oil z
Addengineoilthroughoilfillertothespecified 2
level, and run the engine to circulate the oil %
through the system. Then check the oil level
again.
Hydraulic tank :
See Lubricant and Coolant Table
30-38
0

Fl F6
4.
F2 F7
198FO2430 198FO2431/
5 5
9’ 198FO243:
F8
30-39
0

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