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Komatsu D475A-5 Shop Manual

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MACHINE MODEL
D475A-5
•
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.
•
D475A-5 mount the SDA12V140E-1 engine.
For details of the engine, see the 12V140-1 Series Engine Shop Manual.
© 2016
All Rights Reserved
Printed in Japan 10-16 (01)
SERIAL No.
20001 and up
SEBM033710
00-1
(10)

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Summary of Contents for Komatsu D475A-5

  • Page 1 20001 and up • 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. •...
  • Page 2 GENERAL CONTENTS No. of page 01 GENERAL ..........................01-1 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ..........10-1 20 TESTING AND ADJUSTING ................ 20-1 30 DISASSEMBLY AND ASSEMBLY ............. 30-1 90 OTHERS ..........................90-1 00-2 D475A-5 Find manuals at https://best-manuals.com...
  • Page 3 10-31 10-61 10-93 00-16 10-1 10-32 10-63 10-94 00-17 10-2 10-33 10-64 10-94-1 00-18 10-4 10-34 10-65 10-94-2 00-19 10-5 10-35 10-66 10-96 00-20 10-6 10-36 10-68 10-97 00-21 10-7 10-38 10-69 10-98 00-2-1 D475A-5 (10) Find manuals at https://best-manuals.com...
  • Page 4 10-172 10-214 10-259 10-134 10-173 10-215 10-260 20-101 10-135 10-174 10-216 10-261 20-102 10-136 10-175 10-217 10-262 20-103 10-137 10-176 10-218 10-263 20-104 10-138 10-177 10-219 10-264 20-105 10-139 10-178 10-220 10-265 20-106 00-2-2 D475A-5 (10) Find manuals at https://best-manuals.com...
  • Page 5 20-140 20-181 20-221 20-261 20-337 20-141 20-182 20-222 20-262 20-338 20-142 20-183 20-223 20-263 20-340 20-143 20-184 20-224 20-264 20-341 20-144 20-185 20-225 20-342 20-145 20-186 20-226 20-301 20-343 20-146 20-187 20-227 20-302 20-344 00-2-3 D475A-5 Find manuals at https://best-manuals.com...
  • Page 6 20-442 20-484 20-525 20-567 20-403 20-443 20-485 20-526 20-568 20-404 20-444 20-486 20-527 20-569 20-405 20-445 20-487 20-528 20-570 20-406 20-446 20-488 20-529 20-572 20-407 20-447 20-489 20-530 20-573 20-408 20-448 20-490 20-531 20-574 00-2-4 D475A-5 Find manuals at https://best-manuals.com...
  • Page 7 20-648 20-712 20-752 20-916 20-609 20-649 20-713 20-753 20-917 20-610 20-650 20-714 20-754 20-918 20-611 20-651 20-715 20-755 20-919 20-612 20-652 20-716 20-756 20-920 20-613 20-653 20-717 20-757 20-921 20-614 20-654 20-718 20-758 20-922 00-2-5 D475A-5 Find manuals at https://best-manuals.com...
  • Page 8 30-101 30-141 30-180 30-25 30-66 30-102 30-142 30-181 30-26 30-67 30-103 30-143 30-182 30-27 30-68 30-104 30-144 30-183 30-28 30-69 30-105 30-145 30-184 30-29 30-70 30-106 30-146 30-185 30-30 30-71 30-107 30-147 30-186 00-2-6 D475A-5 (10) Find manuals at https://best-manuals.com...
  • Page 9 90-23 30-194 90-25 30-195 90-27 30-196 30-197 30-198 30-199 30-200 30-201 30-202 30-203 30-204 30-205 30-206 30-207 30-208 30-209 30-210 30-211 30-212 30-213 30-214 30-215 30-216 30-217 30-218 30-219 90-1 90-3 90-5 90-7 90-9 00-2-7 D475A-5 Find manuals at https://best-manuals.com...
  • Page 10 Find manuals at https://best-manuals.com...

  • Page 11: 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.

  • Page 12: Safety Notice

    SAFETY SAFETY NOTICE PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi- nal places. 11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts. hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure them slowly to prevent the oil from spurting out.
  • Page 13 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 judge- ments.
  • Page 14 DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be Symbol Item Remarks sent to KOMATSU distributors. Get the most up-to- date information before you start any work. Special safety precautions Safety are necessary when per- forming the work.

  • Page 15: Hoisting Instructions

    FOREWORD HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS HOISTING k Heavy parts (25 kg or more) must be lifted 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 max- with a hoist, etc.
  • Page 16 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 Type 1 the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.
  • Page 17 FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER Type 2 Type 3 1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre- vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of the hexagonal portion at the male end.

  • Page 18: 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, features •...
  • Page 19 FOREWORD COATING MATERIALS Category Komatsu code Part No. Q’ty Container Main applications, features • Used as lubricant for sliding portion (to LM-G 09940-00051 60 g prevent from squeaking). Molybdenum • Used to prevent seizure or scuffling of the disulphide thread when press fitting or shrink fitting.

  • Page 20: Standard Tightening Torque

    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 Width across...
  • Page 21 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 59 –...
  • Page 22 FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine. Thread diameter Tightening torque 10 0 2 1.02 0 0.20 24 0 4 2.45 0 0.41 43 0 6 4.38 0 0.61...
  • Page 23 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 Current...

  • Page 24: Conversion Table

    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 •...
  • Page 25 FOREWORD CONVERSION TABLE Millimeters to Inches 1 mm = 0.03937 in 0.236 0.276 0.315 0.354 0.039 0.079 0.118 0.157 0.197 0.630 0.669 0.709 0.748 0.394 0.433 0.472 0.512 0.551 0.591 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260...
  • Page 26 FOREWORD CONVERSION TABLE Liter to U.S. Gallon 1l = 0.2642 U.S. Gal 1.585 1.849 2.113 2.378 0.264 0.528 0.793 1.057 1.321 4.227 4.491 4.755 5.019 2.642 2.906 3.170 3.434 3.698 3.963 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661 7.925 8.189...
  • Page 27 FOREWORD CONVERSION TABLE kgm to ft. lb 1 kgm = 7.233 ft. lb 28.9 36.2 43.4 50.6 57.9 65.1 14.5 21.7 137.4 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 209.8 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 217.0 224.2...
  • Page 28 FOREWORD CONVERSION TABLE kg/cm to lb/in 1kg/cm = 14.2233 lb/in 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 14.2 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 142.2 156.5 369.8 384.0 398.3 412.5 284.5 298.7 312.9 327.1 341.4 355.6 512.0 526.3 540.5 554.7...
  • Page 29 FOREWORD CONVERSION TABLE Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen- tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col- umn of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
  • Page 30 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/cm kPa {mmH kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}...
  • Page 31 01 GENERAL SPECIFICATION DRAWINGS ........................01- 2 SPECIFICATIONS ............................01- 3 WEIGHT TABLE............................01- 12 FUEL, COOLANT AND LUBRICANTS ......................01- 16 01-1 D475A-5...

  • Page 32: Specification Drawings

    SPECIFICATION DRAWINGS SPECIFICATION DRAWINGS DIMENSIONS Semi-U tiltdozer Full-U tiltdozer Superdozer + Symbol Item Unit + giant ripper + giant ripper counterweight Overall length 11,565 12,065 10,525 Overall height (including ROPS) 4,590 4,590 4,590 Overall width 5,265 6,205 6,465 01-2 D475A-5...

  • Page 33: Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS Semi-U tiltdozer and full-U tiltdozer specifications Machine model D475A-5 Serial Number 20001 and up Machine weight • Tractor 77,310 • Above + Semi-U tiltdozer 93,810 • Above + Variable giant ripper 101,110 • Above + ROPS cab + Air conditioner 102,500 Min.
  • Page 34 GENERAL SPECIFICATIONS Machine model D475A-5 Serial Number 20001 and up Model name Komatsu SDA12V140E-1 Type 4-cycle, water-cooled, V-type, direct-injection engine with turbocharger and aftercooler Number of cylinder–Bore x Stroke 12–140 x 165 l {cc} Total displacement 30.48 {30,480} Rated output...
  • Page 35 GENERAL SPECIFICATIONS Machine model D475A-5 Serial Number 20001 and up Max. pressure MPa {kg/cm 27.5 {280} Type Variable swash plate type: 2 pcs. (HPV 125 + 125) l/min Capacity (at engine speed of 2,000 rpm) Variable swash plate type: 2 pcs. (LPV 90 + 30)
  • Page 36 GENERAL SPECIFICATIONS Machine model D475A-5 Serial Number 20001 and up Bore of cylinder (Both of right and left) Outside diameter of piston rod (Both of right and left) Stroke of piston (Both of right and left) Max. distance between pins...
  • Page 37 GENERAL SPECIFICATIONS Machine model D475A-5 Serial Number 20001 and up Hydraulic semi-U tiltdozer Type Hydraulic full-U tiltdozer Blade supporting method Brace type (Right tilt cylinder) Max. lift above ground 1,620 Max. drop below ground 1,010 Max. tilting distance Changing range of blade deg.
  • Page 38 GENERAL SPECIFICATIONS Superdozer specification Machine model D475A-5 Serial Number 20001 and up Machine weight • Tractor 78,510 • Superdozer + ROPS cab + Air conditioner 108,000 + Counterweight Min. turning radius Gradeability deg. Stability (Front, Rear, Left, Right) deg. 0 – 3.5 km/h 0 –...
  • Page 39 GENERAL SPECIFICATIONS Machine model D475A-5 Serial Number 20001 and up Model name Komatsu SDA12V140E-1 Type 4-stroke, water-cooled, V-type, direct-injection engine with turbocharger and aftercooler Number of cylinder–Bore x Stroke 12–140 x 165 l {cc} Total displacement 30.48 {30,480} Rated output...
  • Page 40 GENERAL SPECIFICATIONS Machine model D475A-5 Serial Number 20001 and up Max. pressure MPa {kg/cm 27.5 {280} Type Variable swash plate type: 2 pcs. (HPV 125 + 125) l/min Capacity (at engine speed of 2,000 rpm) Variable swash plate type: 2 pcs. (LPV 90 + 30)
  • Page 41 GENERAL SPECIFICATIONS Machine model D475A-5 Serial Number 20001 and up Type Hydraulic superdozer (Pitchdozer) Blade supporting method Cylinder type Max. lift above ground 1,960 Max. drop below ground Max. tilting distance 900 (at cutting edge angle of 52 deg.) Max. pitch dump angle deg.
  • Page 42 WEIGHT TABLE WEIGHT TABLE This weight table is a reference for handling and transportation of components. Semi-U tiltdozer and full-U tiltdozer specifications Unit: kg Machine model D475A-5 Serial Number 20001 and up Engine and damper assembly 4,250 • Engine assembly 4,035 •...
  • Page 43 GENERAL WEIGHT TABLE Unit: kg Machine model D475A-5 Serial Number 20001 and up Radiator guard assembly 4,640 • Radiator guard 2,530 • Blade lift cylinder assembly (Each side) • Fan motor Radiator mask (Including grille) (Each side) Engine underguard (Front)
  • Page 44 GENERAL WEIGHT TABLE Superdozer specification Unit: kg Machine model D475A-5 Serial Number 20001 and up Engine and damper assembly 4,250 • Engine assembly 4,035 • Damper assembly Main radiator assembly Sub radiator assembly Oil cooler assembly Fuel tank assembly [When full]...
  • Page 45 GENERAL WEIGHT TABLE Unit: kg Machine model D475A-5 Serial Number 20001 and up Radiator mask (Including grille) (Each side) Engine underguard (Front) Engine underguard (Rear) Power train underguard (Front) Power train underguard (Rear) Hood Fender (Left) Fender (Right) ROPS mount assembly (Left)

  • Page 46: Fuel, Coolant And Lubricants

    GENERAL FUEL, COOLANT AND LUBRICANTS FUEL, COOLANT AND LUBRICANTS 01-16 D475A-5...
  • Page 47 ASTM: American Society of Testing and Material (5) We recommend Komatsu genuine oil which has SAE: Society of Automotive Engineers been specifically formulated and approved for...
  • Page 49 FUEL INJECTION PUMP WITH WORK EQUIPMENT HYDRAULIC ELECTRONIC GOVERNOR....10-254 EQUIPMENT ARRANGEMENT MONITOR SYSTEM.........10-255 DIAGRAM .......... 10- 114 MONITOR PANEL ........10-257 PPC CONTROL PIPING DIAGRAM..10- 118 SENSORS..........10-261 WORK EQUIPMENT CONTROL .... 10-120 WORK EQUIPMENT PUMP....10-122 COOLING FAN PUMP ......10-139 10-1 D475A-5...
  • Page 50 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MODE SELECTION SYSTEM....10-265 ELECTRICAL EQUIPMENT ....10-271 STEERING ELECTRONIC CONTROL SYSTEM..........10-274 VHMS CONTROLLER......10-276 SENSORS ..........10-279 COMMUNICATION (ORB: ORBCOMM) CONTROLLER/ANTENNA....10-282 10-2 D475A-5...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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20001

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