Komatsu wa270 3 wheel loader service repair manual sn wa270 h20051 and up
- 1. Shop Manual VEBM340200 Wheel Loader Serial-no. WA270-3 WA270H20051 and up WA270PT-3 WA270H30051 and up WA270-3 WA270PT-3 © 2001 All Rights Reserved Printed in Europe 09-01
- 2. 00-2 CONTENTS 00 SAFETY ............................................................................. 00-3 01 GENERAL ......................................................................... 01-1 10 STRUCTURE AND FUNCTION....................................... 10-1 20 TESTING AND ADJUSTING............................................ 20-1 30 DISASSEMBLY AND ASSEMBLY................................... 30-1 90 OTHERS ........................................................................... 90-1 No. of page
- 3. SAFETY Safety Notice 00-3 00 SAFETY Safety Notice = Important Safety Notice Proper service and repair is extremely important for safe machine operation. Some of the described service and repair techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol = is used to mark safety precautions in this manual. The cautions accompanying these symbols must always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. = General Precautions Mistakes in operation are extremely dangerous. Read the OPERATION AND MAINTENANCE MANUAL ca- refully before operating the machine! Always follow the safety rules valid in your country carefully! 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. l Always wear safety glasses when hitting parts with a hammer. l Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Never smoke while working. Smoke only in the areas provided for smoking. Preparations for Work 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground and install the safety bar on the frame. If this is not possible, insert the safety pin or use blocks to prevent the work equip- ment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
- 4. Safety Notice SAFETY 00-4 Precautions during Work 11. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 12. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure com- pletely from the circuit. 13. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 14. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) ter- minal first. 15. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 16. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 17. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 18. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 19. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. Do not smoke! 20. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. l When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 21. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Al- so, check that connecting parts are correctly installed. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly.
- 5. 30-9 DISASSEMBLY AND ASSEMBLY ENGINE HOOD ASSEMBLY REMOVAL OF ENGINE HOOD ASSEMBLY Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Disconnect the cable from the negative (–) terminal of the battery. 1. Upper side of cover 1) Loosen clips (2) and (4), then disconnect air filter (1) and exhaust piping (3) from engine. 2) Remove hose (5) from cooler to tank at the cooler side.
- 6. 30-10 DISASSEMBLY AND ASSEMBLY ENGINE HOOD ASSEMBLY « If there is an air condition installed: DANGER! Refer to the air conditiner manual for details of releasing refrigerent and oil return operations. 2. Air conditioner: « Fit tags to distinguish the hoses. 1) Disconnect hose (7) from condenser. 2) Disconnect hose (6) from dry receiver. « After disconnecting the hoses, fit a cover to prevent dirt or water from entering. 3. Front side of cover « Fit tags to distinguish the connectors. 1) Disconnect four wiring connectors. 2) Disconnect two hoses (8) for windscreen washer. 4. Loosen the bolt with the grip (9).
- 7. 30-11 DISASSEMBLY AND ASSEMBLY ENGINE HOOD ASSEMBLY 5. Lift off engine hood « Make sure that all necessary connectors, hoses and clamps are removed from hood. 1) Open radiator guard, and remove two nuts at the back side of cover 2) Remove eight mounting bolts. 3) Fit four eye-bolts and lift off engine hood. « The space inside the hood is confined, so lift off slowly and be careful not to hit any internal parts. Engine hood: 89 kg
- 8. 30-12 DISASSEMBLY AND ASSEMBLY ENGINE HOOD ASSEMBLY INSTALLATION OF ENGINE HOOD ASSEMBLY • Carry out installation in the reverse order to re- moval. Refill the air conditioner with coolant. « Refer to the air conditiner manual, how to refill coolant to the air conditioner. « To prevent the hose from twisting, hold the hose securely with two wrenches when tightening. « The space inside the hood is confined, so lower slowly and be careful not to hit any internal parts. « Connect the wiring connectors securely. Mounting bolts: 115 Nm
- 9. 30-13 DISASSEMBLY AND ASSEMBLY ENGINE REMOVAL OF ENGINE ASSEMBLY Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Disconnect the cable from the negative (–) terminal of the battery. Loosen the pressure relief screw slowly to release the pressure inside the hydraulic tank. Then oper- ate the steering wheel and control levers several times to release the remaining pressure in the hy- draulic piping. • Remove the engine hood. For details, see RE- MOVAL OF ENGINE HOOD. 1. Draining coolant Loosen drain valve (1) and drain coolant. Coolant: 56 l « If the coolant contains antifreeze, dispose of it correctly. 2. Hoses Remove hoses (2), (3) from radiator. 3. Fan guard At first remove plates (5), then mounting bolts (4) and pull the fan guard back over the fan.
- 10. 30-14 DISASSEMBLY AND ASSEMBLY ENGINE 6. Hydraulic pump Remove all hoses, tubes from hydraulic pump. 4. Transmission Remove all hoses, tubes and checkpoint-piping from transmission end. 5. Emergency steering pump Remove two hoses from steering pump. 7. Electric wiring Disconnect the following electric wiring: - Sensor fuel level (7). - Engine ground connection (6).
- 11. 30-15 DISASSEMBLY AND ASSEMBLY ENGINE 10. Rear drive shaft Remove rear drive shaft. « Make match marks on the coupling and use as a guideline when assembling. Rear drive shaft: 8,5 kg 8. Fuel hoses Disconnect fuel hoses (9) from fuel tank. « Fit tags to distinguish the hoses. 9. Fuel filler Remove fuel filler (8) from fuel tank. « Close openings on tank to prevent dirt from getting into the fuel tank. 11. Fuel control cable « Make match marks before removing the locknut, and use as a guideline when assembling. 1) Remove locknut (11) and knuckle (10) of fuel control cable. 2) Remove clamp (12) from bracket. 12. Engine assembly 1) Sling engine at three points, and remove mount- ing bolts (13) from engine and (14) from trans- mission. « Before raising the engine, make sure that all connections are disconnected. « When raising the engine, move horizontally and be careful of the pilot bore mating sur- face. Be careful to maintain the balance when the pilot comes out completely. 2) Lift up the engine slowly. Engine: 453 kg Transmission: 285 kg
- 12. 30-16 DISASSEMBLY AND ASSEMBLY ENGINE INSTALLATION OF ENGINE ASSEMBLY • Carry out installation in the reverse order to re- moval. « Connect the wiring connectors securely. « Adjust the length of the cable. « Align the match mark and assemble. Mounting bolts: 70-75 Nm « To prevent dirt or water from entering, do not remove the cover from the hose until immedi- ately before installing. « Position the engine correctly. Mounting bolts: 280 Nm « Transmission mounting bolts. Mounting bolts: 280 Nm • Refilling with coolant: Add coolant through water filler to the specified level. « Run the engine to circulate the coolant through the system. Then check the water level again. Coolant: 56 l • Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. « Run the engine to circulate the oil through the system. Then check the oil level again.
- 13. 30-17 Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Disconnect the cable from the negative (–) terminal of the battery. • Remove the engine hood. For details, see RE- MOVAL OF ENGINE HOOD . 1. Draining coolant Loosen drain valve (1) and drain coolant. Coolant: 56 l « If the coolant contains antifreeze, dispose of it correctly. DISASSEMBLY AND ASSEMBLY RADIATOR REMOVAL OF RADIATOR ASSEMBLY 2. Electric wiring Remove engine coolant level sensor (2). 3. Hoses 1) Remove hoses (3), (4) and (5) from radiator.
- 14. 30-18 DISASSEMBLY AND ASSEMBLY RADIATOR 2) Remove hoses (6) and (7) from oil cooler. 5. Fan guard At first remove plates (8), then mounting bolts (9) and pull the fan guard back over the fan. 6. Radiator Sling radiator, then remove mounting bolts (10) and (11) on both sides and lift off radiator. « When removing, move towards the counter- weight to prevent the radiator core from touch- ing the fan. Radiator: 127,5 kg
- 15. 30-19 DISASSEMBLY AND ASSEMBLY RADIATOR INSTALLATION OF RADIATOR ASSEMBLY • Carry out installation in the reverse order to re- moval. « Connect the wiring connectors securely. « Adjust the alternator fan belt. For details, see TESTING AND ADJUSTING FAN BELT. « The space inside the hood is confined, so lower slowly and be careful not to hit any internal parts. « Install the fan guard so that the clearance from the fan is uniform. « Install the hoses without twisting or interference. « Make sure that the clearance from the fan is uniform when installing. « Be careful not to damage the radiator core. « Insert the radiator carefully from the counter- weight end. Mounting bolts: 70 Nm • Refilling with coolant: Add coolant through water filler to the specified level. « Run the engine to circulate the coolant through the system. Then check the water level again. Coolant: 56 l
- 16. 30-20 DISASSEMBLY AND ASSEMBLY FUEL TANK REMOVAL OF FUEL TANK ASSEMBLY 4. Fuel tank Disconnect fuel hoses (6) from fuel tank. « Fit tags to distinguish the hoses. 5. Fuel filler Remove fuel filler (4) from fuel tank. « Close all openings on tank to prevent dirt from getting into the fuel tank. 6. Clamps Remove clamps (5) of oil cooler hose from fuel tank. 7. Fuel tank 1) Set a pallet under the tank and support the tank securely. 2) Remove mounting bolts (7) and lift up. Fuel tank: 180 kg Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. 1. Draining fuel Loosen drain screw (2) and drain fuel. Fuel: 185 l 2. Electric wiring Disconnect fuel sensor (3) from the tank. 3. Breather hose Remove breather hose (1) from tank.
- 17. 30-21 DISASSEMBLY AND ASSEMBLY FUEL TANK INSTALLATION OF FUEL TANK ASSEMBLY • Carry out installation in the reverse order to re- moval. « Connect the wiring connector securely. « When raising, keep horizontal and set in the mounting position. « Tighten the fuel tank mounting bolts. Mounting bolts: 280 Nm • Refilling with fuel Tighten the drain valve and add fuel through the fuel filler. Fuel: 185 l
- 18. 30-22 DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT REMOVAL OF COUNTERWEIGHT Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. 1. Connectors 1) Disconnect wiring connector (1) for the number plate light. 2. Counterweight 1) Install two eye bolts M30 at left and right side of the counterweight. 2) Sling counterweight (2), then remove the four mounting bolts (3) and lift off. « When removing the counterweight, be care- ful to maintain the balance. Counterweight: 1238 kg
- 19. 30-23 DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT INSTALLATION OF COUNTERWEIGHT • Carry out installation in the reverse order to re- moval. « Connect the wiring connector securely. Mounting bolts: 560 Nm
- 20. 30-24 DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK REMOVAL OF HYDRAULIC TANK ASSEMBLY 2. Hydraulic piping 1) Disconnect two hoses from joint (3). 2) Disconnect hoses (4), (5) from hydraulic tank. 3) Disconnect two hoses (6) from the back of the hydraulic tank. 3. Hydraulic tank 1) Insert eye-bolts on top of hydraulic tank and sling tank. 2) Remove three mounting bolts (7) of the hydrau- lic tank and lift off hydraulic tank slowly. Hydraulic tank: 120 kg Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Loosen the pressure relief screw slowly to release the pressure inside the hydraulic tank. Then oper- ate the steering wheel and control levers several times to release the remaining pressure in the hy- draulic piping. • Loosen plug under the hydraulic tank and drain hy- draulic oil. Hydraulic oil: 120 l 1. Maintenance cover Open cover (1) from hydraulic tank and remove the mounting bolts (2) from bracket.
- 21. 30-25 INSTALLATION OF HYDRAULIC TANK ASSEMBLY DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK • Carry out installation in the reverse order to re- moval. « Temporarily tighten the mounting bolts, and tighten them fully after positioning. Mounting bolts: 115 Nm • Refilling with oil (hydraulic tank) Add oil through the oil filler to specified level. « Run the engine to circulate the oil through the system. Then check the oil level again.
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- 23. 30-26 REMOVAL OF HYDRAULIC FILTER ASSEMBLY 3. Filter Remove filter element (4). DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER 2. Cover Remove mounting bolts (2), then remove cover (3) from hydraulic tank. Loosen the pressure relief screw slowly to release the pressure inside the hydraulic tank. 1. Maintenance cover Open cover (1) from hydraulic tank.
- 24. 30-27 INSTALLATION OF HYDRAULIC FILTER ASSEMBLY DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER • Carry out installation in the reverse order to re- moval. « Replace the O-ring with a new part. « Check that the new O-ring is fitted securely in the groove, and be careful not to get it caught. Mounting bolts: 70 Nm • Refilling with oil (hydraulic tank) Add oil through the oil filler to the specified level. « Run the engine to circulate the oil through the system. Then check the oil level again. « Bleeding air out off the filter room. For details, see the operating manual.
- 25. 30-28 DISASSEMBLY AND ASSEMBLY STEERING CYLINDER REMOVAL OF STEERING CYLINDER ASSEMBLY 2. Hydraulic piping Disconnect hoses (2) and (3) from cylinder. Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Loosen the pressure relief screw slowly to release the pressure inside the hydraulic tank. Then oper- ate the steering wheel and control levers several times to release the remaining pressure in the hy- draulic piping. 1. Front cover Remove front cover (1). 3. Cylinder 1) Remove lock bolt (4), and pull out pin (5). « Note the number and thickness of the shims, and use as a guideline when assembling.