Komatsu WA270-7 Wheel Loader Service Repair Manual SN 80001 & Up

Komatsu WA270-7 Wheel Loader Service Repair Manual SN 80001 & Up

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This service manual contains detailed maintenance, service, repair and troubleshooting procedures for the Komatsu WA270-7 Wheel Loader. The service manual is a must for all WA270-7 Wheel Loader owners, operators and mechanics. Print off the pages including detailed diagrams and accurate illustrations you need at any time and save time and money on repair.

Komatsu WA270-7 Wheel Loader Service Manual Topics:

Specifications
Specification drawing
Specifications
Weight table
Table of fuel, coolant, and lubricants

Structure and function
Engine and cooling system
Engine related parts
KVGT
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDPF
Cooling system
Cooling fan motor
Power train
Power train system
Layout of power train parts
Damper
HST pump
HST motor1
HST motor2
Transfer
Clutch solenoid valve
Drive shaft
Axle
Differential
Torque proportional differential
Limited slip differential
Final drive
Steering system
Layout of steering devices
Steering column
Priority valve
Cushion valve
Emergency steering valve
Orbitrol valve
2way restrictor valve
Brake system
Layout of brake parts
Brake accumulator charge valve
Brake valve
Brake accumulator
Slack adjuster
Brake
Parking brake control
Parking brake
Parking brake solenoid valve
Undercarriage and frame
Axle mount
Center hinge pin
Tire
Hydraulic system
Hydraulic component layout
Work equipment control
Hydraulic tank
Double type gear pump
Steering and work equipment pump
Control valve
CLSS
Hydraulic circuit diagram and names of valves
Self-pressure reducing valve
Work equipment PPC valve
Work equipment lock solenoid valve
PPC circuit accumulator
ECSS accumulator
Work equipment
Work equipment linkage
Bucket
Cab and its attachments
ROPS cab
Cab mount
Electrical system
Engine control system
Preheating system
Engine output limit function
Automatic warm-up function
Parking brake control system
System operating lamp function
Battery disconnect switch function
HSTcontroller system
Machine monitor system
Rearview monitor system
KOMTRAX system
System component parts
Sensor

Standard value tables
Standard service value table
Standard value table for engine
Standard value table for machine
Standard value table for electrical system
30 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
Testing engine speed
Testing boost pressure
Testing exhaust gas temperature
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Testing EGR valve and KVGT driving oil pressure
Testing fuel pressure
Testing fuel discharge, return and leakage
Bleeding air from fuel system
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling no-injection cranking operation
Testing of KDPF and muffler stack for looseness and damage
Testing of installed condition of cylinder heads and manifolds
Testing engine piping for damage and looseness
Testing and adjusting air conditioner compressor belt tension
Replacing alternator belt
Power train
Testing oil leakage from axle final drive
Testing drive shaft for looseness, backlash, and damage
Testing accelerator pedal
Testing and adjusting HSToil pressure
Testing transfer clutch control pressure
Steering system
Testing directional lever
Testing steering wheel
Testing work equipment control lever
Testing and adjusting steering circuit oil pressure
Bleeding air from steering cylinder circuit
Brake system
Testing brake pedal
Testing braking performance
Testing and adjusting of accumulator charge pressure
Testing wheel brake oil pressure
Testing lowering of wheel brake pressure
Testing wear of wheel brake disc
Bleeding air from wheel brake circuit
Releasing remaining pressure in brake accumulator circuit
Testing parking brake performance
Testing wear of parking brake disc
Testing parking brake release pressure
Method of releasing parking brake manually
Hydraulic system
Testing cooling fan speed
Testing cooling fan pump circuit oil pressure
Bleeding air from hydraulic fan circuit
Testing and adjusting work equipment PPC oil pressure
Testing and adjusting work equipment oil pressure
Bleeding air from work equipment circuit
Releasing remaining pressure from work equipment circuit
Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas
Work equipment
Testing and adjusting bucket positioner and bucket proximity switch
Testing and adjusting boom position detection lever
Electrical system
Adjusting replaced, reassembled or added sensor, controller, etc monitor
Special functions of machine monitor
Adjusting rearview camera angle
Handling voltage circuit of engine controller
Handling battery disconnect switch
Testing diodes
Pm clinic
Pm Clinic service
Check sheet

Troubleshooting
Related information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Checks before troubleshooting
Inspection procedure before troubleshooting
Preparation for troubleshooting of electrical system
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information described in troubleshooting table
Procedure for troubleshooting wiring harness of pressure sensor system for open circuit
Connector list and layout
Connector contact identification
T-branch box and T-branch adapter table
Fuse location table
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement
Precautions when performing troubleshooting of machine monitor
Processing procedure of harness checker for troubleshooting of machine monitor LCD unit
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors)
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 of hydraulic and mechanical system (H-mode)
Information described in troubleshooting table (H-mode)
System chart of hydraulic and mechanical systems
Failure mode and cause table
Troubleshooting of engine (S-mode)
Information described in troubleshooting table (S mode)
S-1 Engine does not crank when starting switch is turned to START position
S-2 Engine cranks but no exhaust smoke comes out
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)
S-4 Engine startability is poor
S-5 Engine does not pick up smoothly
S-6 Engine stops during operation
S-7 Engine runs rough or is unstable
S-8 Engine lacks power
S-9 KDPF gets clogged in a short time
S-10 Engine oil consumption is excessive
S-11 Engine oil becomes contaminated early
S-12 Fuel consumption is excessive
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
S-14 Oil pressure drops
S-15 Fuel mixes into engine oil
S-16 Water mixes into engine oil (milky)
S-17 Coolant temperature rises too high (overheating)
S-18 Unusual noise is heard
S-19 Vibration is excessive
S-20 Air cannot be bled from fuel circuit
S-21 Active regeneration is executed frequently
S-22 Active regeneration takes time
S-23 White smoke is exhausted during active regeneration
50 Disassembly and assembly
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
Removal and installation of supply pump assembly
Removal and installation of injector assembly
Removal and installation of cylinder head assembly
Removal and installation of engine hood assembly
Removal and installation of grille assembly
Removal and installation of radiator core assembly
Removal and installation of aftercooler
Removal and installation of hydraulic oil cooler
Removal and installation of engine assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of cooling fan and fan motor assembly
Removal and installation of KDPF assembly
Disassembly and assembly of KDPF assembly
Removal and installation of KCCV assembly
Removal and installation of air cleaner assembly
Removal and installation of KVGTassembly
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
Removal and installation of alternator belt
Removal and installation of fuel tank assembly

Power train
Removal and installation of transfer assembly
Disassembly and assembly of transfer assembly
Disassembly and assembly of parking brake assembly
Disassembly and assembly of differential assembly
Removal and installation of front axle assembly
Removal and installation of rear axle assembly
Disassembly and assembly of axle housing assembly
Undercarriage and frame
Removal and installation of center hinge pin
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Removal and installation of hydraulic pump assembly
Removal and installation of HST motor1 assembly
Removal and installation of HST motor2 assembly
Disassembly and assembly of hydraulic cylinder assembly

Work equipment
Removal and installation of work equipment assembly

Cab and its attachments
Removal and installation of operator’s cab and floor frame assembly
Removal and installation of operator’s cab glass (adhered glass)
Removal and installation of operator’s seat assembly
Removal and installation of seat belt

Electrical system
Removal and installation of machine monitor assembly
Removal and installation of engine controller assembly
Removal and installation of HSTcontroller assembly
Removal and installation of air conditioner controller assembly
Removal and installation of monitor controller assembly
Removal and installation of mass air flow and temperature sensor
Removal and installation of KOMTRAX terminal assembly

Air conditioner unit
Removal and installation of air conditioner compressor
Removal and installation of air conditioner condenser
Removal and installation of air conditioner unit assembly

Maintenance standard
Engine and cooling system
Engine related parts
Cooling fan motor
Power train
Damper
Transfer
Drive shaft
Axle
Differential
Limited slip differential
Final drive
Steering system
Steering column
Priority valve
Emergency steering valve
Steering cylinder
Brake system
Brake accumulator charge valve
Slack adjuster
Brake
Parking brake
Parking brake solenoid valve
Undercarriage and frame
Axle mount
Center hinge pin
Hydraulic system
Hydraulic tank
Double type gear pump
Steering and work equipment pump
Control valve
Self-pressure reducing valve
Work equipment PPC valve
Work equipment lock solenoid valve
Work equipment
Work equipment linkage
Bucket
Work equipment cylinder
Cab and its attachments
Cab mount
Electrical system
Bucket positioner
Fork positioner
Remote boom positioner
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Air conditioner controller
Compressor
Condenser
Receiver drier
Sunlight sensor
Outer temperature sensor (outside air temperature sensor)
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Parts and connectors layout
Testing with self-diagnosis function
How to open the electrical system abnormality record screen in service mode of the machine monitor
Testing temperature control system
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing evaporator temperature sensor
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
Information in troubleshooting table
Failure code list related to air conditioner
A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
A-4 Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
Handling of compressor oil
90 Diagrams and drawings
Hydraulic circuit diagram
Symbols in hydraulic circuit diagram
Hydraulic circuit diagram
Electric circuit diagram
Symbols in electric circuit diagram
Electrical circuit diagram of machine body
Electrical circuit diagram of floor
Index

Covers: Komatsu WA270-7 Wheel Loader (Serial No. 80001 and up)
Pages: 2,056
Format: PDF
Compatibility: Windows/Mac/Tablet
File size: 57mb
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