Komatsu Wheel Loader WA270-8 service & repair manual

Description Komatsu Wheel Loader WA270-8 service & repair manual

Komatsu Wheel Loader WA270-8 pdf workshop service & repair manual

Serial numbers:
A28001 and up
H75051 and up
83001 and up

Technical documentation, specifications, testing, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

SERVICE MANUAL CONTENT:
FOREWORD, SAFETY, BASIC INFORMATION
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIRE
ACTIONS IF FIRE OCCURS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS
PRECAUTIONS FOR DEF
STORE AdBlue/DEF
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRACTICAL USE OF KOMTRAX
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
HOW TO READ ELECTRICAL WIRE CODE
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE

SPECIFICATIONS
SPECIFICATION DRAWING
WEIGHT TABLE
TABLE OF FUEL, COOLANT, AND LUBRICANTS

STRUCTURE AND FUNCTION
UREA SCR SYSTEM
LAYOUT DRAWING OF UREA SCR SYSTEM
UREA SCR SYSTEM DIAGRAM
FUNCTION OF UREA SCR SYSTEM
COMPONENT PARTS OF UREA SCR SYSTEM
BOOT-UP SYSTEM
LAYOUT DRAWING OF BOOT-UP SYSTEM
SYSTEM OPERATING LAMP SYSTEM
BATTERY DISCONNECT SWITCH
PREHEATING SYSTEM
ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE SYSTEM
ENGINE CONTROL SYSTEM
AUTOMATIC IDLE STOP SYSTEM
COMPONENT PARTS OF ENGINE SYSTEM
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM
COOLING FAN CONTROL SYSTEM
COMPONENT PARTS OF COOLING SYSTEM
CONTROL SYSTEM
LAYOUT DRAWING OF CONTROL SYSTEM
MACHINE MONITOR SYSTEM
REARVIEW MONITOR SYSTEM
KOMTRAX SYSTEM
COMPONENT PARTS OF CONTROL SYSTEM
HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC SYSTEM
CLSS
COMPONENT PARTS OF HYDRAULIC SYSTEM
POWER TRAIN SYSTEM
LAYOUT DRAWING OF POWER TRAIN SYSTEM
OPERATION OF POWER TRAIN SYSTEM
DIRECTIONAL SELECTOR SWITCH CONTROL FUNCTION
HST CONTROL SYSTEM
HST CHARGE SYSTEM
HST PUMP CONTROL SYSTEM
HST CONTROLLER GEAR SHIFT CONTROL FUNCTION
TRANSFER CLUTCH CONTROL FUNCTION
HST SYSTEM PROTECTION FUNCTION
MAXIMUM SPEED LOW FUEL CONSUMPTION CONTROL
KOMATSU TRACTION CONTROL SYSTEM (KTCS)
COMPONENT PARTS OF POWER TRAIN SYSTEM
WORK EQUIPMENT SYSTEM
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
WORK EQUIPMENT CONTROL SYSTEM
WORK EQUIPMENT LOCK SYSTEM
BUCKET POSITIONER SYSTEM
FORK POSITIONER SYSTEM
REMOTE POSITIONER SYSTEM
ECSS
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM
STEERING SYSTEM
LAYOUT DRAWING OF STEERING SYSTEM
STEERING COLUMN
COMPONENT PARTS OF STEERING SYSTEM
BRAKE SYSTEM
LAYOUT DRAWING OF BRAKE SYSTEM
PARKING BRAKE CONTROL SYSTEM
COMPONENT PARTS OF BRAKE SYSTEM
AUTO-GREASING SYSTEM
LAYOUT DRAWING OF AUTO-GREASING SYSTEM
SPECIFICATIONS OF AUTO-GREASING SYSTEM
FUNCTION OF AUTO-GREASING SYSTEM
COMPONENT PARTS OF AUTO-GREASING SYSTEM
UNDERCARRIAGE AND FRAME
FRAME, AXLE MOUNT AND CENTER HINGE PIN
TIRE
WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT
STRUCTURE OF BUCKET
CAB AND ITS ATTACHMENTS
ROPS CAB
CAB MOUNT

STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR MACHINE
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE

TESTING AND ADJUSTING
RELATED INFORMATION ON TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
TEST ENGINE SPEED
TEST BOOST PRESSURE
TESTING EXHAUST GAS TEMPERATURE
TEST EXHAUST GAS COLOR
TEST AND ADJUST VALVE CLEARANCE
TEST COMPRESSION PRESSURE
TEST BLOWBY PRESSURE
TEST ENGINE OIL PRESSURE
TEST EGR VALVE AND VGT OIL PRESSURE
TEST FUEL PRESSURE
TEST FUEL DISCHARGE, RETURN AND LEAKAGE
BLEED AIR FROM FUEL SYSTEM
TEST FUEL CIRCUIT FOR LEAKAGE
HANDLE CYLINDER CUT-OUT MODE OPERATION
HANDLE NO-INJECTION CRANKING OPERATION
TEST KDPF, SCR AND MUFFLER STACK FOR LOOSENESS AND DAMAGE
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION
TEST ALTERNATOR BELT
TEST AUTOMATIC TENSIONER
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER
TEST SCR RELATED FUNCTIONS
CLEAN AdBlue/DEF TANK
POWER TRAIN
TEST AND ADJUST HST OIL PRESSURE
TEST THE CONTROL PRESSURE OF TRANSFER CLUTCH
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE
STEERING SYSTEM
TEST STEERING WHEEL
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE
BLEED AIR FROM STEERING CYLINDER CIRCUIT
BRAKE SYSTEM
RELEASE REMAINING PRESSURE IN BRAKE ACCUMULATOR CIRCUIT
TEST WHEEL BRAKE OIL PRESSURE
TEST AND ADJUST BRAKE ACCUMULATOR CHARGE PRESSURE
BLEED AIR FROM BRAKE CIRCUIT
TEST BRAKING PERFORMANCE
TEST BRAKE PEDAL
TEST LOWERING OF WHEEL BRAKE PRESSURE
TEST WEAR OF WHEEL BRAKE DISC
TEST PARKING BRAKE OIL PRESSURE
TEST PARKING BRAKE PERFORMANCE
RELEASE PARKING BRAKE MANUALLY
TEST WEAR AMOUNT OF PARKING BRAKE DISC
HYDRAULIC SYSTEM
RELEASE REMAINING PRESSURE FROM WORK EQUIPMENT CIRCUIT
TEST AND ADJUST WORK EQUIPMENT OIL PRESSURE
TEST AND ADJUST WORK EQUIPMENT PPC OIL PRESSURE
BLEED AIR FROM WORK EQUIPMENT CIRCUIT
TEST COOLING FAN SPEED
TEST COOLING FAN CIRCUIT OIL PRESSURE
BLEED AIR FROM COOLING FAN CIRCUIT
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE AND CHARGE ACCUMULATOR WITH NITROGEN GAS
WORK EQUIPMENT
TEST AND ADJUST BUCKET POSITIONER
TEST AND ADJUST BOOM POTENTIOMETER LEVER
CAB AND ITS ATTACHMENTS
TEST DIRECTIONAL LEVER
TEST MULTIFUNCTION MONO-LEVER
TEST ACCELERATOR PEDAL
ELECTRICAL SYSTEM
SET AND ADJUST EACH EQUIPMENT
SET AND OPERATE MACHINE MONITOR
METHOD FOR STARTING UP KOMTRAX TERMINAL
ADJUST REARVIEW CAMERA ANGLE
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLE BATTERY DISCONNECT SWITCH
TEST DIODES
AUTO-GREASING DEVICE
BLEED THE AIR OF AUTO-GREASING SYSTEM
CHANGING OF LUBRICATION TIME AND LUBRICATION INTERVAL TIMES
Pm CLINIC
Pm CLINIC SERVICE

TROUBLESHOOTING
ABBREVIATION LIST
RELATED INFORMATION ON TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION
PROCEDURE FOR TESTING AND TROUBLESHOOTING
SYMPTOM AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM
CONNECTORS LIST AND LAYOUT
CONNECTOR CONTACT IDENTIFICATION
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
FUSE LOCATION TABLE
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR
PROCEDURES FOR CREATING HARNESS CHECKER ON MACHINE MONITOR LCD UNIT
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])
FAILURE CODES TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
TROUBLESHOOTING OF ENGINE (S-MODE)
TROUBLESHOOTING FOR AUTO-GREASING SYSTEM

DISASSEMBLY AND ASSEMBLY
ABBREVIATION LIST
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST
SKETCHES OF SPECIAL TOOLS
ENGINE AND COOLING SYSTEM
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
REMOVE AND INSTALL INJECTOR ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
REMOVE AND INSTALL EGR VALVE ASSEMBLY
REMOVE AND INSTALL EGR COOLER ASSEMBLY
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT
REMOVE AND INSTALL ALTERNATOR BELT
REMOVE AND INSTALL ALTERNATOR ASSEMBLY
REMOVE AND INSTALL AUTOMATIC TENSIONER
REMOVE AND INSTALL RADIATOR ASSEMBLY
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY
REMOVE AND INSTALL ENGINE ASSEMBLY
REMOVE AND INSTALL ENGINE FRONT OIL SEAL
REMOVE AND INSTALL ENGINE REAR OIL SEAL
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER
REMOVE AND INSTALL KDPF ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY
REMOVE AND INSTALL SCR ASSEMBLY
REMOVE AND INSTALL KDPF, SCR ASSEMBLY
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY
REMOVE AND INSTALL KCCV ASSEMBLY
REMOVE AND INSTALL VGT ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE
REMOVE AND INSTALL AdBlue/DEF INJECTOR
REMOVE AND INSTALL AdBlue/DEF PUMP
REMOVE AND INSTALL AdBlue/DEF HOSE
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
POWER TRAIN
REMOVE AND INSTALL HST PUMP ASSEMBLY
REMOVE AND INSTALL HST MOTOR ASSEMBLY
REMOVE AND INSTALL TRANSFER ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRANSFER ASSEMBLY
REMOVE AND INSTALL FRONT AXLE ASSEMBLY
REMOVE AND INSTALL REAR AXLE ASSEMBLY
DISASSEMBLE AND ASSEMBLE AXLE HOUSING ASSEMBLY
DISASSEMBLE AND ASSEMBLE DIFFERENTIAL ASSEMBLY
UNDERCARRIAGE AND FRAME
REMOVE AND INSTALL CENTER HINGE PIN
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY
HYDRAULIC SYSTEM
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY
REMOVE AND INSTALL QUICK COUPLER LS PRESSURE RISE VALVE ASSEMBLY
WORK EQUIPMENT
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY
CAB AND ITS ATTACHMENTS
REMOVE AND INSTALL OPERATORS CAB AND FLOOR FRAME ASSEMBLY
REMOVE AND INSTALL OPERATORS CAB GLASS (ADHERED GLASS)
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY
REMOVE AND INSTALL OPERATORS SEAT ASSEMBLY
REMOVE AND INSTALL SEAT BELT
ELECTRICAL SYSTEM
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER CONTROLLER ASSEMBLY
REMOVE AND INSTALL MONITOR CONTROLLER ASSEMBLY
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR
REMOVE AND INSTALL KDPF TEMPERATURE SENSOR
REMOVE AND INSTALL KDPF DIFFERENTIAL PRESSURE SENSOR
REMOVE AND INSTALL SCR TEMPERATURE SENSOR
REMOVE AND INSTALL AMMONIA SENSOR
REMOVE AND INSTALL SCR OUTLET NOx SENSOR
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY

MAINTENANCE STANDARD
ABBREVIATION LIST
ENGINE AND COOLING SYSTEM
MAINTENANCE STANDARD OF ENGINE MOUNT
MAINTENANCE STANDARD OF DAMPER
MAINTENANCE STANDARD OF COOLING FAN MOTOR
POWER TRAIN
MAINTENANCE STANDARD OF DRIVE SHAFT
MAINTENANCE STANDARD OF TRANSFER
MAINTENANCE STANDARD OF TRANSFER MOUNT
MAINTENANCE STANDARD OF FRONT AXLE
MAINTENANCE STANDARD OF REAR AXLE
MAINTENANCE STANDARD OF PROPORTIONING DIFFERENTIAL
MAINTENANCE STANDARD OF LIMITED SLIP DIFFERENTIAL
MAINTENANCE STANDARD OF FRONT FINAL DRIVE
MAINTENANCE STANDARD OF REAR FINAL DRIVE
STEERING SYSTEM
MAINTENANCE STANDARD OF STEERING COLUMN
MAINTENANCE STANDARD OF PRIORITY VALVE
MAINTENANCE STANDARD OF STEERING CYLINDER
MAINTENANCE STANDARD OF SECONDARY STEERING VALVE
BRAKE SYSTEM
MAINTENANCE STANDARD OF BRAKE CIRCUIT ACCUMULATOR CHARGE VALVE
MAINTENANCE STANDARD OF SLACK ADJUSTER
MAINTENANCE STANDARD OF FRONT BRAKE
MAINTENANCE STANDARD OF REAR BRAKE
MAINTENANCE STANDARD OF PARKING BRAKE
MAINTENANCE STANDARD OF PARKING BRAKE SOLENOID VALVE
UNDERCARRIAGE AND FRAME
MAINTENANCE STANDARD OF FRAME, AXLE MOUNT AND CENTER HINGE PIN
HYDRAULIC SYSTEM
MAINTENANCE STANDARD OF HYDRAULIC TANK
MAINTENANCE STANDARD OF BRAKE AND COOLING FAN PUMP AND TRANSFER LUBRICATION PUMP
MAINTENANCE STANDARD OF STEERING AND WORK EQUIPMENT PUMP
MAINTENANCE STANDARD OF CONTROL VALVE
MAINTENANCE STANDARD OF SELF-PRESSURE REDUCING VALVE
MAINTENANCE STANDARD OF MULTIFUNCTION MONO-LEVER PPC VALVE
MAINTENANCE STANDARD OF WORK EQUIPMENT LOCK SOLENOID VALVE
WORK EQUIPMENT
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE
MAINTENANCE STANDARD OF BUCKET
MAINTENANCE STANDARD OF LIFT CYLINDER
MAINTENANCE STANDARD OF BUCKET CYLINDER
CAB AND ITS ATTACHMENTS
MAINTENANCE STANDARD OF CAB MOUNT

APPENDIX
AIR CONDITIONER SYSTEM
PRECAUTIONS FOR REFRIGERANT
AIR CONDITIONER COMPONENT
SPECIFICATIONS OF AIR CONDITIONER
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE
OUTLINE OF REFRIGERATION CYCLE
COMPONENT PARTS OF AIR CONDITIONER SYSTEM
AIR CONDITIONER UNIT
COMPONENT PARTS OF AIR CONDITIONER UNIT
AIR CONDITIONER CONTROLLER
COMPRESSOR
CONDENSER
RECEIVER DRIER
SENSORS FOR AIR CONDITIONER SYSTEM
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER
AIR CONDITIONER SYSTEM DIAGRAM
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR
CHECK TEMPERATURE CONTROL FUNCTION
METHOD FOR CHECKING TEMPERATURE CONTROL FUNCTION
TEST VENT (MODE) CHANGEOVER
METHOD FOR TESTING VENT (MODE) CHANGEOVER
TESTING FRESH/RECIRC AIR CHANGEOVER
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER
TEST EVAPORATOR TEMPERATURE SENSOR
TEST RELAYS
METHOD FOR TESTING RELAYS
AIR CONDITIONER TROUBLESHOOTING
TROUBLESHOOTING USING GAUGE PRESSURE
CONNECTION OF SERVICE TOOL
METHOD FOR CONNECTING SERVICE TOOL
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS
HANDLE COMPRESSOR OIL

CIRCUIT DIAGRAMS
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC AUTO-GREASING DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM

Engine SAA6D107E-3 workshop service repair manual