Komatsu d475 a 2 dozer bulldozer service repair manual (sn 10201 and up)
- 1. 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
- 4. 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 . Carry out installation in the reverse order to removal. m m Sleeve nut: See Tightening Torques and Standard Values Table m Qa Coupling lock bolt : See Tightening Torques and Standard Values Table m. Adjust the injection timing. For details, see TESTING AND ADJUSTING. 30-24 0
- 5. Fl F2 F6 198FO2401~~ 198FO2402 F3 F4 F5 198F024OE / 2 198FO2406 F7 I F56103207
- 6. 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 . Carry out installation in the reverse order to 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 . Carry out installation in the reverse order to removal. m m Turbocharger mounting nut : 2See Tightening Torques and z Standard Values Table Q) z 30-26 0
- 8. REMOVAL OF AFTERCOOLER REMOVAL OF NOZZLE HOLDER CORE ASSEMBLY ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. IO. Drain cooling water. 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 . Carry out installation in the reverse order to 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. 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 . Carry out installation in the reverse order to removal. m m Sleeve nut : See Tightening Torques and Standard Values Table m W Connection : See Tightening Torques and Standard Values Table W Locknut: See Tightening Torques and Standard Values Table m Ir Fit the spherical washer to the bolt and install. m Holder mounting bolt : See Tightening Torques and Standard Values Table m Ir Clean the nozzle holder assembly mount before installing. 30-28 a
- 10. 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. Drain cooling water. 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 : See Tightening Torques and Standard Values Table 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 Standard Values Table 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 : See Tightening Torques and Standard Values Table m * Adjust the valve clearance. For details, see TESTING AND ADJUST- ING, Adjusting valve clearance. m Rocker arm, screw, locknut : See Tightening Torques and Standard Values Table m m Cylinder head mounting bolt : See Tightening Torques and Standard Values Table 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
- 11. Fl F5 F2 F56103226 F3 F56103227 F4 F56103228 F56103229 F8 F9 -1 +----- F56103232 F56103233 30-3 1 0
- 12. 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
- 13. Fl 3 F2 I 4 I j 198FO241' IwfilIIIll 198FO2412 30-33 0
- 14. 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. &?Ikg Radiator assembly : See Weight Table 8. Disconnect tube (II). (See F4) 9. Disconnect hose (12). (See F4) INSTALLATION OF RADIATOR ASSEMBLY . Carry out installation in the reverse order to 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. 30-34 a
- 15. Fl G 311 r--T---y198FO2413 F2 198FO2414 F3 F4 198FO2417 F7 I II lCiEiFO2419 F8
- 16. 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 . Carry out installation in the reverse order to removal. m Standard shim thickness : 4 mm . 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. 30-36 0
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- 18. Fl F5 F6 F2 F3 4’ 198FO242i F4 ISSF I407 F7 / F9 I 97F38 I 30-37 0
- 19. 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 . Carry out installation in the reverse order to 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. &?Ikg 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) . Carry out installation in the reverse order to 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
- 20. Fl F6 4. F2 F7 198FO2430 198FO2431/ 5 5 9’ 198FO243: F8 30-39 0