Komatsu WA475-10 WA475-10E0 Wheel Loader Workshop Repair Service Manual PDF - MKMTSWA475E0.zip
Full service and repair documentation, complete with Electrical Wiring Diagrams, covering the Komatsu WHEEL LOADER WA475-10 and WA475-10E0 — everything you need to service, troubleshoot, fix, and rebuild these machines just like a trained technician.
Inside the Komatsu WHEEL LOADER WA475-10, WA475-10E0 workshop service repair manual, you'll find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEN06773-04 - Komatsu WHEEL LOADER WA475-10, WA475-10E0 (SERIAL NUMBERS 120001 and up) Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 4,353 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
COVER...1
00 INDEX AND FOREWORD...1
INDEX...2
FOREWORD, SAFETY, BASIC INFORMATION...27
HOW TO READ THE SHOP MANUAL...27
SAFETY NOTICE FOR OPERATION...29
PRECAUTIONS TO PREVENT FIRE...37
ACTIONS IF FIRE OCCURS...39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS...40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...41
PRECAUTIONS FOR DEF...42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING...42
PRECAUTIONS FOR ADDING...42
PRECAUTIONS FOR STORING...42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE...42
THE OTHER PRECAUTIONS...42
STORE AdBlue/DEF...43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT...44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS...47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT...54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT...56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...57
PRACTICAL USE OF KOMTRAX...58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER...59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR...68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL...70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH...71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE...73
HOW TO READ ELECTRICAL WIRE CODE...74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...78
STANDARD TIGHTENING TORQUE TABLE...81
CONVERSION TABLE...88
ABBREVIATION LIST...93
01 SPECIFICATIONS...1
CONTENTS...2
SPECIFICATIONS...3
SPECIFICATION DRAWING...3
SPECIFICATION DRAWING: WA475-10...3
SPECIFICATION DRAWING: WA475-10E0...5
SPECIFICATIONS...7
SPECIFICATIONS: WA475-10...7
SPECIFICATIONS: WA475-10E0...12
WEIGHT TABLE...17
WEIGHT TABLE: WA475-10...17
WEIGHT TABLE: WA475-10E0...19
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA)...21
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...21
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION)...23
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...23
10 STRUCTURE AND FUNCTION...1
CONTENTS...2
UREA SCR SYSTEM...7
LAYOUT DRAWING OF UREA SCR SYSTEM...7
UREA SCR SYSTEM DIAGRAM...9
FUNCTION OF UREA SCR SYSTEM...10
FUNCTION OF AdBlue/DEF SYSTEM...10
INDUCEMENT STRATEGY...12
COMPONENT PARTS OF UREA SCR SYSTEM...26
AdBlue/DEF MIXING TUBE...26
SCR ASSEMBLY...27
AdBlue/DEF TANK...29
AdBlue/DEF PUMP...31
AdBlue/DEF INJECTOR...32
AdBlue/DEF HOSE...33
AdBlue/DEF TANK HEATING VALVE...34
BOOT-UP SYSTEM...35
LAYOUT DRAWING OF BOOT-UP SYSTEM...35
SYSTEM OPERATING LAMP SYSTEM...37
SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP SYSTEM...37
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM...37
BATTERY DISCONNECT SWITCH...39
FUNCTION OF BATTERY DISCONNECT SWITCH...39
OPERATION OF BATTERY DISCONNECT SWITCH...39
PREHEATING SYSTEM...40
PREHEATING SYSTEM DIAGRAM...40
FUNCTION OF AUTOMATIC PREHEATING SYSTEM...40
OPERATION OF AUTOMATIC PREHEATING SYSTEM...40
FUNCTION OF MANUAL PREHEATING SYSTEM...41
OPERATION OF MANUAL PREHEATING SYSTEM...41
ENGINE SYSTEM...42
LAYOUT DRAWING OF ENGINE SYSTEM...42
FUNCTION OF ENGINE SYSTEM...43
ENGINE CONTROL SYSTEM...44
SYSTEM DIAGRAM OF ENGINE CONTROL...44
FUNCTION OF ENGINE CONTROL SYSTEM...45
OPERATION OF ENGINE CONTROL SYSTEM...46
AUTOMATIC IDLE STOP SYSTEM...48
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...48
COMPONENT PARTS OF ENGINE SYSTEM...49
VGT...49
EGR SYSTEM...53
EGR VALVE...55
EGR COOLER...57
KCCV SYSTEM...58
KCCV VENTILATOR...60
KDPF...62
COOLING SYSTEM...66
LAYOUT DRAWING OF COOLING SYSTEM...66
SPECIFICATIONS OF COOLING SYSTEM...67
COOLING FAN CONTROL SYSTEM...68
SYSTEM DIAGRAM OF COOLING FAN CONTROL SYSTEM...68
FUNCTION OF COOLING FAN CONTROL SYSTEM...69
COMPONENT PARTS OF COOLING SYSTEM...73
BRAKE AND COOLING FAN PUMP...73
COOLING FAN MOTOR...81
CONTROL SYSTEM...88
LAYOUT DRAWING OF CONTROL SYSTEM PARTS...88
MACHINE MONITOR SYSTEM...90
SYSTEM DIAGRAM OF MACHINE MONITOR SYSTEM...90
FUNCTION OF MACHINE MONITOR SYSTEM...90
REARVIEW MONITOR SYSTEM...92
SYSTEM DIAGRAM OF REARVIEW MONITOR SYSTEM...92
FUNCTION OF REARVIEW MONITOR SYSTEM...92
KOMTRAX SYSTEM...93
SYSTEM DIAGRAM OF KOMTRAX SYSTEM...93
FUNCTION OF KOMTRAX SYSTEM...93
LOAD METER SYSTEM...94
SYSTEM DIAGRAM OF LOAD METER...94
FUNCTION OF LOAD METER SYSTEM...94
COMPONENT PARTS OF CONTROL SYSTEM...99
MACHINE MONITOR...99
MONITOR SWITCH...119
KEYPAD...120
REARVIEW MONITOR...121
REARVIEW CAMERA...123
Gateway Controller...124
COMMUNICATION TERMINAL...127
TRANSMISSION CONTROLLER...128
WORK EQUIPMENT CONTROLLER...132
MONITOR CONTROLLER...136
CAN TERMINATING RESISTOR...141
ENGINE CONTROLLER...142
ACCELERATOR PEDAL...149
SPEED CONTROL DIAL...151
HYDRAULIC SYSTEM...152
LAYOUT DRAWING OF HYDRAULIC SYSTEM...152
CLSS...153
STRUCTURE OF CLSS...153
FUNCTION OF CLSS...154
WORK EQUIPMENT PUMP AND STEERING PUMP CONTROL SYSTEM...157
SWASH PLATE CONTROL FUNCTION OF WORK EQUIPMENT PUMP AND STEERING PUMP...157
PICKUP ASSISTANCE CONTROL FUNCTION WHEN ENGINE SPEED IS LOW...157
OVERHEAT PREVENTION FUNCTION OF WORK EQUIPMENT CIRCUIT...157
COMPONENT PARTS OF HYDRAULIC SYSTEM...158
HYDRAULIC TANK...158
WORK EQUIPMENT PUMP...161
STEERING PUMP...179
POWER TRAIN CHARGE PUMP AND POWER TRAIN LUBRICATION PUMP...192
CONTROL VALVE...193
TOTAL CONTROL SYSTEM...233
SYSTEM DIAGRAM OF TOTAL CONTROL SYSTEM...233
INDEPENDENT WORK EQUIPMENT CONTROL FUNCTION...234
POWER MODE SELECTOR FUNCTION...236
OVERHEAT PREVENTION FUNCTION...237
OUTPUT LIMITATION FUNCTION FOR LOW TEMPERATURE...238
WORK EQUIPMENT SPEED LEVEL...239
POWER TRAIN SYSTEM...240
LAYOUT DRAWING OF POWER TRAIN SYSTEM...240
OPERATION OF POWER TRAIN SYSTEM...242
HST CHARGE SYSTEM...243
SYSTEM DIAGRAM OF HST CHARGE SYSTEM...243
FUNCTION OF HST CHARGE SYSTEM...243
PUMP MOTOR CONTROL SYSTEM...244
SYSTEM DIAGRAM OF PUMP MOTOR CONTROL SYSTEM...244
STEPLESS GEAR SHIFT ADJUSTMENT FUNCTION...244
INCHING CONTROL FUNCTION...245
TRANSMISSION GEAR SHIFT CONTROL SYSTEM...246
SYSTEM DIAGRAM OF TRANSMISSION GEAR SHIFT CONTROL SYSTEM...246
AUTOMATIC GEAR SHIFT FUNCTION...246
GEAR SHIFT DISPLAY FUNCTION...247
HUNTING PREVENTION FUNCTION...247
TRANSMISSION PROTECTION FUNCTION...248
SPEED LIMITATION FUNCTION...248
NEUTRALIZER FUNCTION...248
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION...249
TRACTION CONTROL SYSTEM...251
SYSTEM DIAGRAM OF TRACTION CONTROL SYSTEM...251
FUNCTION OF TRACTION CONTROL SYSTEM...251
COMPONENT PARTS OF POWER TRAIN SYSTEM...254
DRIVE SHAFT...254
TRANSMISSION...256
TRANSMISSION CONTROL VALVE...258
ECMV...260
VALVE ASSEMBLY (MAIN RELIEF, POWER TRAIN OIL COOLER RELIEF)...262
SOLENOID VALVE (TRANSMISSION CHARGE PUMP BYPASS)...265
HST PUMP MOTOR...267
HST VALVE...274
HST CHARGE PUMP...280
PILOT SEQUENSE VALVE...281
MANIFOLD VALVE...284
SOLENOID VALVE (HST CHARGE PUMP BYPASS)...287
AXLE...289
CONVENTIONAL DIFFERENTIAL...291
LIMITED SLIP DIFFERENTIAL...294
FINAL DRIVE...299
AJSS KNOB...301
COMBINATION SWITCH...302
WORK EQUIPMENT SYSTEM...306
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM...306
WORK EQUIPMENT CONTROL SYSTEM...308
WORK EQUIPMENT SPEED PATTERN CONTROL FUNCTION BY WORK EQUIPMENT LEVER STROKE...308
WORK EQUIPMENT LEVER DETENT POSITION AND WORK EQUIPMENT STARTUP CURRENT CONTROL FUNCTION...308
WORK EQUIPMENT LEVER OPERATING FUNCTION SYSTEM DIAGRAM...309
WORK EQUIPMENT LEVER OPERATION FUNCTION...310
BOOM STOP MODULATION FUNCTION...310
WORK EQUIPMENT SHOCK REDUCTION FUNCTION...311
WORK EQUIPMENT NEUTRAL LOCK SYSTEM...314
WORK EQUIPMENT NEUTRAL LOCK SYSTEM DIAGRAM...314
FUNCTION OF WORK EQUIPMENT NEUTRAL LOCK SYSTEM...314
REMOTE POSITIONER SYSTEM...316
REMOTE BUCKET POSITIONER SYSTEM DIAGRAM...316
FUNCTION OF REMOTE BUCKET POSITIONER SYSTEM...316
REMOTE BOOM POSITIONER SYSTEM DIAGRAM...318
FUNCTION OF REMOTE BOOM POSITIONER SYSTEM...318
AUTOMATIC BUCKET SHAKE SYSTEM...321
SYSTEM DIAGRAM OF AUTOMATIC BUCKET SHAKE SYSTEM...321
FUNCTION OF AUTOMATIC BUCKET SHAKE SYSTEM...321
BUCKET POSITIONER AND BOOM POSITIONER...322
STRUCTURE OF BUCKET POSITIONER AND BOOM POSITIONER...322
AUTO-DIGGING SYSTEM...323
AUTO-DIGGING SYSTEM DIAGRAM...323
FUNCTION OF AUTO-DIGGING SYSTEM...324
ECSS...326
ECSS DIAGRAM...326
FUNCTION OF ECSS...326
OPERATION OF ECSS...326
WORK EQUIPMENT SYSTEM...328
WORK EQUIPMENT LOCK SOLENOID VALVE...328
PILOT CIRCUIT ACCUMULATOR...329
ECSS CIRCUIT ACCUMULATOR...330
WORK EQUIPMENT ELECTRIC LEVER...332
BUCKET CONTROL SWITCH...335
MULTIFUNCTION MONO-LEVER...336
STEERING SYSTEM...338
LAYOUT DRAWING OF STEERING SYSTEM...338
SECONDARY STEERING SYSTEM...341
SECONDARY STEERING SYSTEM DIAGRAM...341
FUNCTION OF SECONDARY STEERING SYSTEM...341
AJSS...343
LAYOUT DRAWING OF AJSS...343
AJSS SYSTEM DIAGRAM...344
FUNCTION OF AJSS...345
NEUTRALIZER FUNCTION OF AJSS...345
NEUTRAL INTERLOCK FUNCTION OF AJSS...346
SPEED SENSING STEERING FUNCTION OF AJSS...347
TURN SIGNAL PILOT LAMP CONTROL FUNCTION OF AJSS...348
STEERING COLUMN...349
STRUCTURE OF STEERING COLUMN...349
STEERING SYSTEM...350
AJSS EPC VALVE...350
STEERING LOCK VALVE...351
ROTARY VALVE...352
ORBITROL VALVE...355
STOP VALVE...359
STEERING VALVE...360
SECONDARY STEERING PUMP...372
SECONDARY STEERING MOTOR...373
BRAKE SYSTEM...374
LAYOUT DRAWING OF BRAKE SYSTEM...374
LAYOUT DRAWING OF BRAKE COOLING SYSTEM...376
PARKING BRAKE CONTROL SYSTEM...378
PARKING BRAKE CONTROL SYSTEM DIAGRAM...378
OPERATION OF PARKING BRAKE CONTROL SYSTEM...378
BRAKE COOLING CONTROL SYSTEM...380
BRAKE COOLING CONTROL SYSTEM DIAGRAM...380
FUNCTION OF BRAKE COOLING CONTROL SYSTEM...380
COMPONENT PARTS OF BRAKE SYSTEM...381
CHARGE VALVE...381
PARKING BRAKE SOLENOID VALVE...386
PARKING BRAKE EMERGENCY RELEASE VALVE...388
BRAKE CIRCUIT ACCUMULATOR...389
BRAKE VALVE...391
SLACK ADJUSTER...395
BRAKE...397
PARKING BRAKE...400
BRAKE COOLING PUMP...402
BRAKE COOLING OIL COOLER...403
AUTO-GREASING SYSTEM...404
LAYOUT DRAWING OF AUTOMATIC GREASE SYSTEM...404