Komatsu wa270pt 3 wheel loader service repair manual sn：wa270h30051 and up

VEBM340200

Shop Manual

WA270-3 WA270PT-3 Wheel Loader WA270-3 WA270PT-3 © 2001 All Rights Reserved Printed in Europe 09-01

Serial-no.

WA270H20051 and up WA270H30051 and up

CONTENTS No. of page

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

00-2

SAFETY

Safety Notice

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 carefully 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 equipment 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.

00-3

Safety Notice

SAFETY

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 completely 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 (-) terminal 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. Also, 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.

00-4

SAFETY

Foreword

Foreword General This shop manual has been prepared as an aid to improve the quality of repairs by giving the service personnel an accurate understanding of the product and by showing them the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components: Structure and Function This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.

Testing and Adjusting This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" to "Causes" are also included in this section.

Disassembly and Assembly This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.

Maintenance Standard This section gives the judgement standards when inspecting disassembled parts.

NOTE: The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

00-5

How to Read the Shop Manual

SAFETY

How to Read the Shop Manual Volumes Shop manuals are issued as a guide to carrying out repairs.

Distribution and Updating Any additions, amendments or other changes will be sent to Komatsu distributors.

Get the most up-to-date information before you start any work.

Filing Method 1.

See the page number on the bottom of the page. File the pages in correct order.

2.

Following examples show how to read the page number.

Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item

3.

Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example.

Example: 10-4 10-4-1 10-4-2 10-5

Added Pages

Symbols So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols: Symbol

=

ÂŤ 4

3 2 5 6

00-6

Item

Remarks

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening torque

Places that require special attention for the tightening torque during assembly.

Coat

Places to be coated with adhesives and libricants, etc.

Oil, water

Places where oil, water or fuel must be added, and the capacity.

Drain

Places where oil or water must be drained, and quantity to be drained.

SAFETY

Hoisting Instructions

Hoisting Instructions = Heavy parts (25kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weigthing 25 kg or more is indicated clearly with the symbol:

4

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1.

Check for removal of all bolts fastening the part to the relative parts.

2.

Check for existence of another part causing interference with the part to be removed.

Wire Ropes 1.

Use adequate ropes depending on the weight of parts to be hoisted, refering to the table below: ÂŤ The allowable load in tons, is given by vertical tensible force. ÂŤ The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used.

Wire ropes: (Standard "Z" or "S" twist ropes without galvanizing)

2.

Rope diameter (mm)

Allowable load (tons)

10

1.0

11.2

1.4

12.5

1.6

14

2.2

16

2.8

18

3.6

20

4.4

22.4

5.6

30

10.0

40

18.0

50

28.0

60

40.0

Sling wire ropes from the middle portion of the hook.

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 maximum strength at the middle portion.

100%

88%

79%

71%

41%

00-7

Hoisting Instructions

3.

SAFETY

Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load.

= Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

4.

Do not sling a heavy load with ropes forming a wide hanging angle from the hook.

When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles.

The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles.

When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°.

α

Gewicht (kg) Load capacity (kg)

kg 2000

1900 1700

2000

1400 1000 1000 500

300

600

900

1200

Lifting angle (α) Hebewinkel (°)

00-8

1500

01

GENERAL

General overwiew WA270-3 .............................01-3 General overwiew WA270PT-3 .........................01-4 Technical datas ................................................ 01-5 Weight table WA270-3 .....................................01-8 Weight table WA270PT-3 ................................ 01-9 List of lubricant and water ............................. 01-10 Maintenance schedule .................................... 01-11 Outlines of service .......................................... 01-12 Torque list .................................................... 01-16 General view of controls and gauges ............ 01-17 Emergency drive ............................................ 01-18

01-1

01-2

GENERAL

DIMENSIONS, OPERATING DATA

WA270-3

270-128

Dimensions, Operating Data Buckets (capacities in accordance with ISO 7546)

m³

2.1

2.4

Specific density

t/m³

1.8

1.6

Bucket weight without teeth

kg

950

1,050

Static tipping weight, straight

kg

9,800

9,600

Stat. tipping weight, 40° articulated

kg

8,600

8,500

Breakout force, hydraulic

kN

107

101

Hydraulic lifting capacity, on ground

kN

112

110

Operating weight

kg

12,300

12,350

a Reach at full lift at 45°

mm

950

1.000

b Dumping height at 45°

mm

2,900

2,860

c Lift height, hinge pin

mm

3,78

3,782

d Height at bucket upper edge

mm

5,075

5,075

e Digging depth, 0°

mm

27

27

f Carry height, hinge pin

mm

460

460

A Overall length

mm

7,060

7,120

B Wheelbase

mm

2,900

2,900

C Bucket width

mm

2.550

2.550

D Width over tyres

mm

2,440

2,440

E Track width

mm

1,880

1,880

F Ground clearance

mm

460

460

H Overall height

mm

3,250

3,250

The 2.1/2.4 m³ standard buckets shown in the table can also be delivered with bolt-on cutting edges, 2.2/2.5 m³.

Special buckets: 3.4 m³ light material bucket

These values refer to 20,5 R25 tyres.

Machine without additional counterweight I:\DTP\BA270GB\ABMES.TBL

01-3

GENERAL

DIMENSIONS, OPERATING DATA

WA270PT-3

Dimensions, Operating Data Buckets (capacities in accordance with ISO 7546)

m³

2,0

Specific density

t/m³

1.75

Bucket weight without teeth

kg

800

Static tipping weight, straight

kg

8200

Stat. tipping weight, 40° articulated

kg

7400

Breakout force, hydraulic

kN

96

Hydraulic lifting capacity, on ground

kN

99

Operating weight *)

kg

12700

a Reach at full lift at 45°

mm

1188

b Dumping height at 45°

mm

2726

c Lift height, hinge pin

mm

3838

d Height at bucket upper edge

mm

5385

e Digging depth, 0°

mm

126

f Carry height, hinge pin

mm

332

A Overall length

mm

7060

B Wheelbase

mm

2900

C Bucket width

mm

2500

D Width over tyres

mm

2440

E Track width

mm

1880

F Ground clearance

mm

460

H Overall height

mm

3250

These values refer to machines with 20,5 R25 tyres. *) Machine without additional counterweight U:\DTP\BA270GB\270PT\ABMES-PT.TBL

01-4

GENERAL

TECHNICAL DATAS

Engine

SPECIFICATIONS Machine model

WA270-3

From Serial No.

WA270H20051

Model

Komatsu S6D102E-1

Type No. of cylinders bore x stroke

(mm)

Piston displacement

(cm³)

5.900

Flywheel horsepower Maximum torque

(kW (PS))

103,5 (141)

(Nm / rpm)

566 / 1,600

Starting motor

24 V

Alternator

24 V

Rim pull

Power train

Torque converter Transmission Reduction gear

12 V x 2 / 105Ah 108 kN 3-element, 1-stage, single-phase (30H046) Automatic 4-gear (Full-power-shift) with kick-down Spiral bevel gear

Differential

Limited slip differential

Final drive

Planetary gear single stage

Drive type

Front-, rear-wheel drive

Tire Axle, wheel

WA270H30051

4-cycle, water-cooled, in-line, 6-cylinder, direct injection, with turbocharger 6 102 x 120

Battery

Brakes

WA270PT-3

Turning circle

20.5R25 Inside tire 5243 mm Outside Bucket 5757 mm

Main brake Parking brake up to serial-no. WA270H21037 from serial-no. WA270H21038

Hydraulic operated brake with accumulator Wet type disc brakes Mechanical operated drum brake Mechanical operated disc brake

01-5

Steering system

GENERAL

TECHNICAL DATAS

Machine model

WA270-3

Serial No.

WA270H20051 and up

Type

Articulated steering

Structure

Hydrostatic

Hydraulic pumps

Control valve

Weights

Travel speed

Work equipment

Cylinder

Hydraulic system

Delivery

01-6

Work- and Steering-/Switch/Brake- and Servo pump 110 / 94 / 21

(l/min.)

Set pressure for work equipment Cut-off pressure

3-spool type 210

(bar)

(bar)

165 Orbit-roll valve type 200

Boom cylinder No. bore x stroke

(mm)

Reciprocating piston 2 130 x 723

Bucket cylinder No. bore x stroke

(mm)

Reciprocating piston 1 150 x 507

Steering cylinder No. bore x stroke

(mm)

2 75 x 337

Set pressure for steering

(bar)

Work equipment lever type

Single lever FORWARD

1.

2.

3.

4.

REVERSE

1. 7,2 km/h 2. 12,7 km/h 3. 27,2 km/h

Travel speed

Operating weight

7,2 km/h 12,7 km/h 27,2 km/h 41,8 km/h

11.900 kg

Steering system

GENERAL

TECHNICAL DATAS

Machine model

WA270PT-3

Serial No.

WA270H30051 and up

Type

Articulated steering

Structure

Hydrostatic

Hydraulic pumps

Weights

Travel speed

Work equipment

Control valve Cylinder

Hydraulic system

Delivery

Work hydraulic pump / Servo pump 175 / 23

(l/min.)

Set pressure for work equipment

(bar)

210

Set pressure for steering

(bar)

180

Boom cylinder No. bore x stroke

(mm)

Reciprocating piston 2 120 x 714

Bucket cylinder No. bore x stroke

(mm)

Reciprocating piston 2 110 x 800

Steering cylinder No. bore x stroke

(mm)

2 75 x 337

Work equipment lever type

Single lever Two lever Multi function lever FORWARD

1.

2.

3.

4.

REVERSE

1. 7,2 km/h 2. 12,7 km/h 3. 27,2 km/h

Travel speed

Operating weight

7,2 km/h 12,7 km/h 27,2 km/h 41,8 km/h

12,700 kg

01-7

GENERAL

WEIGHT TABLE

WEIGHT TABLE WA270-3 This weight table is a guide for use when transporting or handling components.

Unit: kg Machine model From Serial No. Engine

Machine model

WA270-3

From Serial No.

WA270H20051 453

Radiator

WA270-3

WA270H20051

Boom cylinder (each) Bucket cylinder

Transmission

285

Engine hood

85.0

Center drive shaft

10.5

Front frame

990

Front drive shaft

12.3

Rear frame

707.5

Rear drive shaft

22.0

Bucket link

46

Front axle

672

Bellcrank

257

Rear axle

680

Boom (including bushing)

854

Axle pivot

67.0

Bucket (with BOC)

910

Wheel (each)

Counterweight

1238

Tire (each)

Fuel tank

180

Orbit-roll valve

10.0

Battery (each)

29.0

Priority valve

7.5

Cab

410

OperatorÂ’s seat

45

Steering cylinder (each) Hydraulic tank Main control valve

01-8

116.5

Hydraulic pump

GENERAL

WEIGHT TABLE

WEIGHT TABLE WA270PT-3 This weight table is a guide for use when transporting or handling components.

Unit: kg Machine model From Serial No. Engine

Machine model

WA270PT-3

From Serial No.

WA270H30051 460

Radiator

WA270PT-3

WA270H30051

Boom cylinder (each)

85.0

Bucket cylinder

67.5

Transmission

380

Engine hood

85.0

Center drive shaft

10.5

Front frame

990

Front drive shaft

12.3

Rear frame

707.5

Rear drive shaft

22.0

Bucket link

30.0

Front axle

672

Bellcrank

46.1

Rear axle

680

Boom

532

Axle pivot

67.0

Bucket 2.0 m³

910

Wheel (each)

Counterweight

1238

Tire (each)

Fuel tank

180

Orbit-roll valve

10.0

Battery (each)

29.0

Priority valve

7.5

Cab

410

Operator s seat

45

Quick coupler

300

Steering cylinder (each) Hydraulic tank Main control valve

116.5

Hydraulic pump

01-9

GENERAL

LUBRICATION CHART

LUBRICANTS AND OPERATING EQUIPMENT LUBRICANTS AND OPERATING EQUIPMENT BI abbreviations *), specifications and filling quantities

WA270-3 Lubricants and operating equipment

BI abbreviation

Quality class

Temperature range

Viscosity class

Filling quantity in litres (approx.)

Engine

EO engine oil

EO 1540 A EO 1030 A NRS

CCMC D4 or, if not available, API CE or API CF -4 ²)

-10° to 50°C -25° to 20°C -40° to 20°C

SAE 15W-40 ¹) SAE 10W-30 SAE 05W-30

16

Transmission

EO engine oil

EO 10

CCMC D4 or, if not available, API CD

-

SAE 10W

17

Axles with multi-disc locking differential

GO gearbox oil

GO 90 LS

API GL5+LS

-

SAE 90 ¹) SAE 85W-90 SAE 80W-90

HYD hydraulic oil

HYD 0530

HVLP, HVLP D

-35° to 50°C

ISO VG 46 ¹)

or EO engine oil

EO 10

CCMC D4 or, if not available, API CD

-35° to 40°C

SAE 10W

-35° to 50°C

WA270PT-3

Hydraulic system, steering, brakes

or BIO-E-HYD hydraulic oil

BIO-E-HYD 0530

HEES (to VDMA fluid technology)

SP-C long-term coolant with anti-frost and rust protection

SP-C

Anti-frost and rust protection

Fuel tank

Diesel fuel ³)

CFPP class B CFPP class D CFPP class E CFPP class F

DIN-EN 590

Grease nipples, central lubrication

Multi-purpose grease on a lithium basis

MPG-A

KP2N-20

Air-conditioning

Coolant Refrigerating machine oil

Cooling system

NRS NRS

2x25.5

120 ISO VG 46

56

up to 0°C up to -10°C up to -15°C up to -20°C -

R134a (CFC-free) PAG (Polyalcohol glycol oil)

185

NLGI 2

1000 g 150 cm ³

The specified filling capacities are approximate guidelines; test specifications are binding. The selection of the viscosity class depends on the predominantly existing outside temperature. The temperature limits are to be regarded as guidelines which can be exceeded up or down for a brief period. *) Works filling **) Top-up quantity ²) If no engine oil of the API CE or API CF-4 specification is available, API CC or API CD-classified engine oil can be used alternatively. The oil change intervals must be split in half in this case, however. ³) If the fuel sulphur content is between 0.5 and 1.0 %, the oil change interval must be 1/2 normal. With a sulphur content of more than 1.0 %, the oil change interval must be 1/4 normal. ****) BI codes are the "standard lubricants" for construction machinery and vehicles of the Hauptverband der Deutschen Bauindustrie e.V. (BI). The brochure "Regelschmierstoffe für Baumaschinen- und Fahrzeuge" (Standard Lubricants for Construction Machinery and Vehicles" can be obtained from bookstores or Bauverlag GmbH, Wiesbaden and Berlin, under the ISBN no.

3-7625-3102-1.

01-10

GENERAL

MAINTENANCE CHART

MAINTENANCE SCHEDULE CHECKLIST PRIOR TO STARTING UP Checking coolant level, top up Checking engine oil level, top up Water separator, drain water and dirt deposits Fuel filter, drain water Checking drive belts Checking fan Checking electrical connections Checking fuel level, top-up Checking control panels Checking parking brake Checking service brake Checking horn and reversing horn Checking lighting for function, dirt and damage Checking exhaust, exhaust gas colour and exhaust noise Checking measuring instruments Checking steering wheel play and function Checking rear-view mirror for alignment, dirt and damage

INITIAL MAINTENANCE AFTER THE FIRST 100 OPERATING HOURS Transmission, change oil and filters Service brake, change oil filter AFTER THE FIRST 250 OPERATING HOURS Fuel tank, drain water Fuel filter, change cartridges Hydraulic system, change oil filter elements AFTER THE FIRST 500 OPERATING HOURS Axles, oil change

REGULAR MAINTENANCE EVERY 100 OPERATING HOURS Hydraulic system, checking oil level, top up Cleaning fresh-air filter elements Lubrication: Rear axle bolts (2 points) EVERY 250 OPERATING HOURS Engine, change oil and oil filter cartridge (at least every 6 months) Checking air induction system Air-conditioning, check tension of the compressor Van-belt Batteries, check Axles, check oil levels Wheel nuts, check, retighten Lubrication: 1.

2.

3.

4.

5.

6.

7.

Bucket bolts (2 Tilt rod bolts (2 Tilt cylinder bolts (2 Lift cylinder bolts (4 Boom bolts (2 Bucket tilt lever bolts(1point) Steering cylinder bolts (4

EVERY 500 OPERATING HOURS Fuel filter, change filter cartridges Cooling system, check antifreeze in coolant EVERY 1000 OPERATING HOURS Transmission, change oil and oil filter (at least every 12 months) Engine, check valve clearance Service brake, change oil filter Drive belts, check tension pulley and fan bearing Turbocharger, check mounts and play Axles, oil change (at least every 12 months) Lubrication: 1. Pivot steering (2 points) 2. Propeller shaft intermediate bearing (1 point) 3. Universal joint on front cardan shaft (5 points)

EVERY 2000 OPERATING HOURS Cooling system, changing coolant and cleaning interior (at least every 24 months) Check vibration absorber Check turbocharger and clean Check three-phase generator and starter Air-conditioning, change filter elements Pressure tank, check gas pressure Hydraulic system, oil change, change filter element (at least every 12 months) EVERY 4000 OPERATING HOURS Check water pump

MAINTENANCE AS REQUIRED Air filter: Installation and removal of filter elements, cleaning filter elements, changing safety filter Dust pre-extractor "turbo II": check, clean Cleaning the radiator Windscreen washer, checking fluid level, top up Transmission, checking oil level, top Replacing bucket teeth Fuel tank, draining water and dirt deposits Tyres, checking air pressure Air-conditioning, cleaning condenser Checking air-conditioning Checking the coolant level

points) points) points) points) points) points)

01-11

GENERAL

OUTLINES OF SERVICE OIL: •

•

• •

•

• •

The oil in the engine and the hydraulic system is subject to extreme conditions (high temperatures, high pressure). The quality decreases, therefore, as operation increases.

Always use oil types complying with the operation and temperature specifications in the operation and maintenance manual. Always observe prescribed oil change intervals.

Special attention must be paid when storing, handling and, in particular, topping up oil and grease to prevent these from becoming soiled. The majority of functional faults are caused by unclean oil.

Never mix different types or brands of oil.

Always top up the prescribed oil quantities.

Functional disturbances can be caused by too much or too little oil.

If the oil in the work hydraulic system is not clear (milky), oil or air is probably penetrating the circuit. In this case, contact you local Komatsu dealer.

If changing oil, change corresponding oil filter as well.

We recommend having a regular oil analysis carried out by your local Komatsu dealer in order to establish the condition of the machine.

GREASE: • Grease is used to prevent wear and build-up of noise.

• Grease nipples not mentioned in the service section are for overhaul purposes; for this reason, they do not need to be greased.

• If a part becomes sluggish after long use, lubricate with grease.

• Wipe off any old grease which is pressed out when lubricating.

Any sand or dirt in the grease causes considerable wear.

01-12

MAINTENANCE GUIDLINE

GENERAL

MAINTENANCE GUIDLINE

FUEL: • The fuel injection pump is a precision instrument. Fuel containing water or dirt causes damage to the fuel injection pump.

• Take maximum care when storing fuel or refuelling to avoid any soiling.

• Always use the fuel prescribed in the operation and maintenance manual.

• Paraffin can precipitate from fuel at temperatures below -15 °C and block filters and lines. Always use suitable fuel if working in this temperature range.

• Always top up fuel at the end of each working day to prevent air humidity precipitating and water forming in the fuel tank.

• If you want to drain dirt and water from the fuel tank, wait at least ten minutes after filling so that the swirling foreign bodies can settle again.

• Fuel system will have to be bled if it has been run dry or the filter has been changed.

• Engine oil change periods will have to be reduced by half if fuel is being used with a sulphur content of 0.5 to 1.0 % and reduced to one quarter if fuel with a sulphur content of more than 1.0 % is being used.

BIOLOGICALLY DEGRADABLE HYDRAULIC OILS AND GREASE: • Biologically degradable hydraulic oils and grease - on a diester oil basis - can be used in Komatsu machines. Please contact our works dealers for the products approved by us and most suitable for your requirements.

STORAGE OF OIL AND FUEL: • Store oil and fuel indoors to prevent it being contaminated by water, dirt or other foreign bodies.

• If storing for longer periods, lay the drum on its side so that the filler opening is located at the side. This prevents moisture from forming inside the drum.

• Drums being stored in the open must be covered with watertight foil or other appropriate measures taken to protect them.

• Always use the principle "first in, first out" to prevent any loss in quality if storing for longer periods of time, i.e. always use the oldest oil or fuel first.

01-13

GENERAL

COOLANT: • Always mix coolant according to specifications of machine-related section of the maintenance manual.

• River water contains large quantities of calcium and other foreign bodies. If using this type of water, scale collects in the engine and the radiator and restricts heat exchange which can result in overheating.

• Do not use water which is also not suitable as drinking water.

• When using anti-freeze, always observe the instructions in the operating and maintenance manual.

• Our machines are supplied with original antifreeze from Komatsu.

This antifreeze prevents corrosion in the cooling system, among other things, lubricates moving parts, raises the boiling point of the coolant and must therefore also be used at hot working sites.

• Anti-freeze is inflammable and particular attention must therefore be paid that it does not come into contact with naked flames.

• If the anti-freeze level is too low, it can cause overheating and corrosion to the cooling system because of the air in the coolant.

• If the engine overheats and it is necessary to top up with coolant, wait until the engine has cooled down before topping up.

FILTERS: Filters are extremely important safety components. They prevent foreign bodies from entering individual circuits and sections of equipment and causing damage there.

• Change all filters regularly. Further details in this respect can be found in the operating and maintenance manual. The filters will have to be changed more frequently if working under extreme conditions depending on the type of oil and fuel being used, e.g. with a high sulphur content.

• Never attempt to clean cartridge filters and use them again. Always replace these filters with new ones. If changing oil filters, check whether there are any metal particles inside the old filter. If this is the case, contact your local Komatsu dealer.

• Do not open the package with the replacement filters until immediately before installing.

• Always use original filters from Komatsu.

01-14

MAINTENANCE GUIDLINE

GENERAL

MAINTENANCE GUIDLINE

DETAILS OF ELECTRICAL SYSTEM: • Never remove or alter electrical components installed in the machine.

• Never install any other electrical components other than those approved by Komatsu.

• Pay attention that no water enters the electrical system if washing the machine or working in the rain.

• Wet wiring or damaged insulation can result in insulation faults in the electrical system and, consequently, functional faults in the machine.

• If working close to the coast, clean the machinery carefully to prevent any corrosion.

• A foreign source of power must never be connected to the fuses, the starter switch or the battery relay.

• Maintenance of the electrical system consists of: 1. checking the tension of the belt for the three-phase generator 2. checking the belt of the three-phase generator for damage and wear 3. checking the acid level in the battery.

WEARING PARTS: • Wearing parts such as filter cartridge, air filter element, exhauster, must be changed when carrying out regular maintenance work or when the respective wear or dirt level limit has been reached.

• This work must be carried out regularly and correctly at the prescribed intervals in order to ensure economical use of the machine.

• Only use original KOMATSU spare parts • Always quote the part number as listed in the spare parts catalogue when ordering spare parts.

01-15

GENERAL

TORQUE LIST

TORQUE LIST

Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table.

The tightening torque is determined by the width across flats of the nut and bolt.

If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

Tread diameter of the bolt (mm) (a)

Width across flat (mm) (b)

M 6 M 8 M 10 M 12 M 14 M 16 M 18 M 20 M 22 M 24

10 13 17 19 22 24 27 30 32 36

M 27 M 30 M 33 M 36 M 39

41 46 50 55 60

(15)

Strength class 8.8 Nm

kpm

10 24 48 83 130 200 280 390 520 670

1 2,4 4,8 8,3 13 20 28 39 52 67

980 1330 1790 2310 2970

98 133 179 231 297

NOTE When tightening panels or other parts having tightening fixtures made of plastic, be careful not to use excessive tightening torque: doing so will damage the plastic parts.

01-16

GENERAL

CONTROLS AND GAUGES

GENERAL VIEW OF CONTROLS AND GAUGES GENERAL VIEW 1 Main monitor 2 Horn switch 3 Hazard lamp switch 4 Directional lever 5 Speed control lever 7 Speed control lever stopper 8 Wiper switch 9 Emergency switch 10 Parking brake lever 11 Brake pedal 12 Steering column tilt lever 13 Accelerator pedal 14 Cigarette lighter 15 Lamp switch 16 Turn signal lever 17 Dimmer switch 18 Starting switch 19 Car radio 20 Kickdown switch 21 Lift arm and bucket control lever 22 Attachement cylinder control lever 23 Safety lock 24 Air-conditioner switch 25 Maintenance monitor MAIN MONITOR 30 Turn signal pilot lamp 31 High beam pilot lamp 32 Centralized checking lamp 33 Engine pre-heating pilot lamp 34 Pilot lamp for front working lamp 35 Pilot lamp for rear working lamp 36 Transmission cut-off selector pilot lamp 37 Parking brake pilot lamp 38 Central warning lamp 39 Speedometer 40 Transmission shift indicator 41 ALS Electronic 44 Emergency steering operating monitor

GENERAL VIEW

Main monitor

MAINTENANCE MONITOR 50 Fuel gauge 51 Engine cooling water temperature gauge 52 Torque converter oil temperature gauge 57 Service meter 58 Air cleaner clogging warning pilot lamp 59 Battery-charging indicator lamp 60 Brake oil pressure warning pilot lamp 61 Engine oil pressure warning lamp 62 Transmission oil pressure warning pilot lamp 63 Engine water level warning lamp

Maintenance monitor

01-17

GENERAL

EMERGENCY DRIVE

EMERGENCY DRIVE From serial-no.

WA270H20051 up to H21038 on WA270-3 WA270H30051 up to H30132 on WA270PT-3

The machine is fitted with a fully automatic transmission. Gear changing and driving the machine is no longer possible if there is a fault in the control unit. An emergency drive can be switched on in this case.

The emergency drive is only designed to remove the machine from a danger zone or drive to the next repair workshop on its own.

Press the brake pedal when starting the engine and make sure that no-one is in the danger area.

Switching on emergency drive in the event of a fault in the control unit for automatic gear shift:

1. Stop the engine.

2. Apply parking brake and set drive direction lever to neutral.

3. Push the emergency switch (2) lock (1) to the side, hold in this position and press the switch. The emergency drive is now switched on and the control lamp in the switch lights up.

4. Press the brake pedal, start the engine and release the parking brake.

5. Set the drive direction lever to forwards or reverse, release brake pedal slowly and move off slowly.

NOTE: The machine will only drive in 2nd gear, irrespective of position of gear lever.

Turn off the emergency drive only when starting switch is turned off!

From serial-no.

WA270H21038and up on WA270-3 WA270H30132and up on WA270PT-3 new transmission, without emergency steering switch

01-18

NOTE: The emergency switch might be located in another place (above the parking brake lever).

STRUCTURE AND FUNCTION

10

POWER TRAIN

STRUCTURE AND FUNCTION

Power train ...................................................... 10-3 Power train system .......................................... 10-4 Torque converter and gearbox piping ............... 10-6 Torque converter .............................................. 10-8 Principle of operation ..................................... 10-10 Powershift transmission ................................. 10-11 Gear change control ...................................... 10-11 Construction of transmission 4WG-150 .......... 10-13 Electro-hydraulic control valve ....................... 10-18 Inductive sender / Proximity switch ................ 10-19 Pressure check points for 4WG - 150 ........... 10-29 Solenoid expansions valve and overlap valve ................................................. 10-29 Transmission hydraulic system diagram ............................................. 10-31 Control valve with solenoid expansions valve ........................................... 10-33 Thermostat valve ............................................ 10-38 Drive shaft ..................................................... 10-41 Front and rear axle ......................................... 10-42 Differential ..................................................... 10-43 Wheel hub ..................................................... 10-46 Axle mountings ............................................... 10-51 Steering articulation joint ................................ 10-52 Assembly of the steering joint ......................... 10-53 Steering system ............................................. 10-61 Steering column, orbit roll .............................. 10-62 Hydraulic steering system .............................. 10-63 Control sleeve ................................................ 10-68 Steering and working hydraulic pump .............................................. 10-70 Steering orbit roll ........................................... 10-71 Steering valve block ...................................... 10-72 Steering damper ............................................ 10-74 Steering cylinder location ............................... 10-75 Steering cylinder ............................................ 10-76 Emergency steering pump ............................. 10-77

Brake system ............................................... 10-102 Brake system circuit .................................... 10-103 Gear pump .................................................. 10-104 Pressure filter .............................................. 10-105 Brake pressure regulating valve .................. 10-106 Brake operation ........................................... 10-107 Brake valve .................................................. 10-108 Pressure switch ........................................... 10-111 Accumulator (Brake system) ....................... 10-112 Hydraulic accumulator ................................. 10-113 Main brakes ................................................. 10-114 Piston seals ................................................. 10-115 Hand brake (parking brake) ......................... 10-116 Work equipment hydraulic system ............... 10-132 Pilot servo system ....................................... 10-133 Oil cooler system ......................................... 10-134 Work equipment hydraulic system diagram ........................................... 10-136 Steering and working hydraulic pump ............................................ 10-138 Cut-off valve ................................................ 10-139 Main control valve ........................................ 10-140 Shock and anticavitation valve ..................... 10-142 Anticavitation valve ...................................... 10-143 Pressure control valve ................................. 10-144 Joystick, servo control valve ........................ 10-145 Lift cylinder .................................................. 10-147 Tilt cylinder ................................................... 10-149 ALS-Control unit .......................................... 10-150 ALS hydraulic system .................................. 10-151 Hydraulic accumulator ................................. 10-154 Lifting frame ................................................. 10-156 Bucket positioner and boom kick-out ........... 10-160 Machine monitor system .............................. 10-165 Pre-heater plug ............................................ 10-172 Electric wiring diagrams ............................... 10-170 Air-conditioner ............................................. 10-301

10-1

STRUCTURE AND FUNCTION

10-2

POWER TRAIN

STRUCTURE AND FUNCTION

POWER TRAIN

POWER TRAIN

1. Transmission 2. Torque converter 3. Engine

4. Front axle 5. Front drive shaft 6. Center drive shaft

7. Rear drive shaft 8. Rear axle

Outline:

The motive force from engine (3) passes through the engine flywheel and is transmitted to torque converter (2), which is connected to the input shaft of transmission (1).

The transmission has six hydraulically actuated clutches, and these provide four speed ranges for FORWARD and three for REVERSE. The transmission speed ranges are selected manually.

The motive force from the output shaft of the transmission passes through center drive shaft (6), front drive shaft (5) and rear drive shaft (7), and is then transmitted to front axle (4) and rear axle (8) to drive the wheels.

10-3

STRUCTURE AND FUNCTION

POWER TRAIN SYSTEM

10-4

POWER TRAIN

STRUCTURE AND FUNCTION

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

Front tire Final drive Wet type multiple disc brake Differential Front axle Front drive shaft Flange bearing Center drive shaft Parking brake Transmission Rear drive shaft Final drive Wet type multiple disc brake Differential Rear axle Rear tire Engine Torque converter Steering and working hydraulic pump Torque convertor and gear box pump Switch pump Brake and servo pump Emergency steering pump

POWER TRAIN

Outline:

The motive force from engine (17) passes through the flywheel and is transmitted to torque converter (18).

The torque converter uses oil as a medium.

It converts the transmitted torque in accordance with the change in the load, and transmits the motive force to the input shaft of the transmission.

In addition, the motive force of the engine passes through the pump drive gear of the torque converter, and is transmitted to steering and working hydraulic pump (19) and to the switch pump (21), so that the pumps are operated in this way.

Transmission (10) operates the directional spool and speed spool of the transmission valve through the solenoid valves, and actuates the six hydraulically actuated clutches to select one of the four FORWARD or REVERSE speeds.

The transmission speed range is selected automatically.

The output shaft of transmission (10) transmits the power to the front and rear axles.

At the front, the power is transmitted to front axle (5) through center drive shaft (8), flange bearing (7), and front drive shaft (6).

At the rear, the power is transmitted to rear axle (15) through rear drive shaft (11).

The motive force transmitted to front axle (5) and rear axle (15) has its speed reduced by the bevel gear and pinion gear of differentials (4) and (14), and is then transmitted to the sun gear shaft through the differential mechanism.

The motive force of the sun gear is rduced further by the planetary mechanism (2/ 12)and is transmitted to the wheels through the axle shaft.

10-5

STRUCTURE AND FUNKTION

TORQUE CONVERTER

TORQUE CONVERTER AND GEARBOX PIPING Up to SN WA270H20563

1.

2.

3.

4.

Power shift gearbox Thermostat valve Engine radiator Transmission heat exchanger in the main radiator 5. Transmission heat radiator next to the main radiator 6. Sensor torque converter oil temperature

10-6

STRUCTURE AND FUNKTION

TORQUE CONVERTER

TORQUE CONVERTER AND GEARBOX PIPING SN WA270H20564 and up Schematic sketch only!

3 1

5

2 4

270_065a

1.

2.

3.

4.

Power shift gearbox Thermostat valve Engine radiator Transmission heat radiator next to the main radiator 5. Sensor torque converter oil temperature

10-7

STRUCTURE AND FUNKTION

TORQUE CONVERTER

TORQUE CONVERTER

1. Engine flywheel 2. Torque converter drive bell-housing 3. Drive plate 4. Turbine 5. Torque converter housing with impeller 6. Stator

10-8

7.

8.

9.

10.

11.

Turbine output gear Turbine output shaft Hydraulic pump drive shaft Transmission housing Torque converter housing

Specifications : Model: Type:

30H046 3 part single stage Convertion grade: 2.9 : 1

STRUCTURE AND FUNKTION

TORQUE CONVERTER

Power flow: •

The torque converter is mounted between the engine and the gear box. The power from the engine flows through the flywheel and the torque converter drive plate (3) into the torque converter housing which contains the impeller (5). The rotating power of the torque converter impeller is transmitted through oil, to the turbine (4), the output shaft (8), and the drive gear (7) and so to the gear box. The hydraulic pumps are driven by the hydraulic pump drive shaft (9).

Oil flow: •

Oil from the transmission pump flows through a filter to the inlet port (A). Further through an oil channel between the stator and impeller into the impeller (5).

The impeller imparts the oil with centrifugal force, the oil flows into the turbine (4) and transfers this centrifugal force into rotating energy in the turbine.

The turbine rotates the output shaft (8) and, in turn, the gearbox.

When leaving the turbine (4) the oil enters the stator (6) and is diverted back into the torque converter impeller. Some of the oil is allowed to flow through a channel and out of the torque converter (B) to the oil cooler.

10-9

STRUCTURE AND FUNKTION

TORQUE CONVERTER

TORQUE CONVERTER PRINCIPLE OF OPERATION

The torque converter operates using the so called Trilok system. That means, by higher turbine rpm it operates with the advantages characteristics of a fluid flywheel. The torque converter is designed to fit the engine power so that there is an optimal power transfer.

The torque converter consists of three main parts: Impeller, turbine and stator (reaction part).

The three parts have ring formed shovels and are fitted together so that the oil flows through them in the order: impeller, turbine, stator. The transmission oil pump continually pumps oil through the torque converter when the engine is running. This allows the torque converter to operate effectively and multiply the engine torque. Heat generated during this process is removed by the oil. The oil is thrown out of the impeller and passes into the turbine. The turbine is driven by the force of the oil entering it, the oil changes its direction of flow on entering the turbine. Depending on the degree of direction change, the turbine transfers more or less torque to the gear-box input shaft. After leaving the turbine the oil enters the stator. This causes the oil to again change direction so that it can re enter the impeller.

The oil re-entering the turbine causes a reaction torque. The relationship, turbine torque / impeller torque is referred to as the torque conversion. This increases as the rpm difference between the two (impeller and turbine) increases. As the output rpm increases so the transferred torque decreases. The torque variation takes place automatically.

When the turbine rpm reaches about 80% of the impeller rpm then the torque conversion is 1 : 0 ; that is the turbine torque is the same as the impeller torque.

The torque converter is now working like a fluid flywheel.

Operation principle of a hydrodynamic torque converter: Turbine

Impeller From engine

T = Impeller torque P T = Turbine torque T T = Stator torque R

To the gear-box Condition on taking up the drive Middle position Drive engaged

10-10

Stator

Machine is not moving

STRUCTURE AND FUNCTION

TRANSMISSION

POWERSHIFT TRANSMISSION

The full powershift gearbox is of the layshaft type construction. The gear change is hydraulically operated through multi-disc clutch packs. See fig 1.

All gears are in permanent mesh and run on roller bearings. The gears, bearings and clutch packs are lubricated with cooled oil. The four speed reversing gearbox has six clutch packs. The required gear is operated through a clutch pack. An axial movable piston, under hydraulic pressure, compresses the clutch pack and so engages the selected gear.

Pressure springs ensure that the piston is returned to the neutral position when the hydraulic pressure is released, so releasing the clutch pack. The gearbox and clutch pack construction is given in detail in figs. 1,6 and 7.

TRANSMISSION CONTROL

Gear change control see oil flow scheme fig. 7 and 8.

Oil for the torque convertor, gearbox lubrication and the gear change clutch packs is supplied form a pump. The pump is mounted in the gearbox and is driven directly from the engine.

Pump capacity : Q = 52 l/min, at 2000 engine rpm.

The pump takes oil from the transmission sump through a course filter. The oil is then delivered under pressure, through an externally mounted fine filter, to the max. pressure control valve (SDV). Oil under pressure is now available in the pressure governing valve (DSV), and at the solenoid valves 1, 2, 3, 4 and 5 for the clutch packs. The pressure governing valve is responsible for the pressure build up in the clutch packs after each gear change.

During a gear change the pressure drops off and rises again, to complete the gear change, to 16+2 bar.

The signal for the gear change comes from the fully automatic EST 25.

The solenoid valve (M6) (expansion valve) is always energised and is de-energised for a programmed time during gear changing.

At the start of a gear change the expansion valve is kept energised for a short programmed time. During this time the clutch pack can be filled at high pressure. After the clutch pack is filled the expansion valve is de energised and the clutch pack picks up the drive with modulated pressure. When the drive is taken up the expansion valve is energised again and the system pressure holds the selected gear until a further gear change is made.

The bleeding valve (EV) is provided to keep the area behind the pressure governing valve full with oil.

When changing down from 2nd to 1st gear a hydraulic overlap is allowed so that the 2nd clutch pack is still engaged even though 1st gear is being engaged. The spring accumulator in the forward clutch pack (KV) circuit holds the forward clutch pack with 10 bar hydraulic pressure so that traction is maintained during gear changing.

The servo pressure for moving the gear change valves is reduced to 10 bar with the use of a restrictor. The servo pressure is controlled with the solenoid valves M1, M2, M3, M4 and M5.

Pressure curve during gear change: P. t. p1. p2. ps.

Pressure in bar Time in sec.

Modulation begin Modulation end System pressure - modulated

10-11

STRUCTURE AND FUNCTION

The pressure control valve (SDV) limits the max. pressure, the excess oil is sent to the torque converter and the lubrication system.

The oil flow to the torque converter is protected from high pressure with a safety valve. (Opening pressure 8.5 bar).

The oil in the torque converter is used to transmit the drive torque using the hydrodynamic principle.

(See chapter Torque converter).

To prevent cavitation the torque converter must be kept full with oil. This is achieved by using a torque converter pressure holding valve in the outlet line from the torque converter.

The oil coming out of the torque converter is sent through a heat exchanger. (Oil-water or oil-air).

A thermostat is fitted in the heat exchanger circuit to enable a quick oil warm-up time.

The oil flows from the heat exchanger into the lubrication circuit of the gearbox so that this circuit is supplied with cooled oil for lubrication.

The main oil control valve contains 5 solenoid valves. (See fig. 8). Operation of the valves and the gear change can be seen in figs. 6 and 7. There is a different solenoid combination for each gear.

The electric switching of the gears enables a light and exact gear change. The cables allow for simpler machine construction.

10-12

TRANSMISSION

PTO

There is a PTO to enable the main hydraulic pumps to be driven when the engine is running.

Emergency steering pump

Mounting of an emergency steering pump is provided. (Axial piston pump, capacity : 16cm3 / U).

Speedo drive An electronic system is used.

The speedometer signal is taken from the gearbox output shaft.

STRUCTURE AND FUNCTION

TRANSMISSION

CONSTRUCTION OF POWERSHIFT TRANSMISSION 4WG-150 FIG. 1

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

Drive flange Torque converter Forward clutch pack (KV) 1st clutch pack (K1) Torque converter and gearbox pump 1st. PTO 2nd clutch pack (K2) 3rd clutch pack (K3) Parking brake (Drum brake) Output front axle Speedo drive (mechanical) Oil sump Output rear axle 4th clutch pack Reveres clutch pack (KR) Idler gear KV-gear K4-gear

10-13

STRUCTURE AND FUNCTION

TRANSMISSION

TO FIG. 1

1.

3.

4.

7.

8.

14.

15.

16.

17.

18.

Drive gear from turbine shaft Forward clutch pack (KV) 1st clutch pack (K1) 2nd clutch pack (K2) 3rd clutch pack (K3) 4th clutch pack (K4) Reveres clutch pack (KR) Idler gear Gear drive for emergency steering pump Output drive gear

A. B. C. D. E.

Drive gear turbine shaft Drive gear clutch KR Drive gear clutch K4 Idler gear between KV and K4 Drive gear clutch KV

FRONT VIEW (TO CONVERTER) •

Turbine shaft to clutch drive Turbine drive

Idler gear

10-14

STRUCTURE AND FUNCTION

TRANSMISSION

CONSTRUCTION OF TRANSMISSION 4WG - 150 / FRONT VIEW FIG. 2

1.

2.

3.

4.

5.

6.

7.

Drive flange - direct to the flywheel Transport plate Electro - hydraulic control valve Turbine rpm inductive sender (in put rpm) Connection to the heat exchanger Oil pick up pipe Oil drain screw M22x 1.5

8.

9.

10.

11.

Oil level mark Oil filler pipe and dip stick Out put rpm inductive sender Counter shaft

10-15

STRUCTURE AND FUNCTION

TRANSMISSION

CONSTRUCTION OF TRANSMISSION 4WG-150 / SIDE VIEW FIG. 3 Construction of the main control valve see fig. 5

1.

2.

3.

4.

5.

6.

7.

Drive flange Torque converter Bell housing Connection to heat exchanger Emergency steering pump Output to front axle with drum brake Name plate

10-16

8. Oil drain screw M22x1.5 9. Output to rear axle 10. Oil filler pipe and dip stick 11. Turbine rpm inductive sender 12. Check point torque converter output pressure

STRUCTURE AND FUNCTION

TRANSMISSION

CONSTRUCTION OF TRANSMISSION 4WG-150 / REAR VEIW FIG. 4

1. Pipe to over lap valve 2nd gear clutch pack 2. Breather Filter separate mounting: 3. Connection from filter 4. Connection to filter 5. PTO

Pipe connections from channel plate to the clutch packs: 6. 1st (K1) 7. Forwards (KV) 8. Reverse (KR) 9. 2nd (K2) 10. 3rd (K3) 11. 4th (K4) 12. Output to front axle with drum brake 13. Emergency steering pump S. Oil pick up pipe M33x2 D. Pressure connection M22x1.5 14. Connection to overlap valve 15. Check valve for the overlap valve

10-17

STRUCTURE AND FUNCTION

CONSTRUCTION OF TRANSMISSION 4WG-150 ELECTRO-HYDRAULIC CONTROL VALVE FIG. 5

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Pipe from over lap valve to 2nd clutch pack (K2) Electro - hydraulic control valve Over lap valve bleed pipe Solenoid and expansions valve Overlap valve Pressure pipes from accumulator to forwards clutch pack (KV) Accumulator Pressure test point, system pressure Accumulator pressure pipes (10 bar) Connection 2nd clutch pack (K2) Connection from overlap valve Check valve for the overlap valve

10-18

TRANSMISSION

STRUCTURE AND FUNCTION

TRANSMISSION

INDUCTIVE SENDER

The inductive sender is used to pick-up the engine RPM to control the gear change down cut-off. It is mounted on the gearbox, easy to reach and has no mechanical wear.

The sender is connected to the electronic control unit with two wires.

For operation of the speed dependant automatic gear change, an inductive sender is fitted to pick up the out-put RPM, it also operates the electronic tacho.

Adjustment: The adjustment is with shims. The gap is 0.5 + 0.5mm

PROXIMITY SWITCH:

To recognise loading of the injection pump.

A proximity switch is fitted to the injection pump control to pick up the loading of the injection pump, (RPM). At approximately 1600 RPM a plus signal is sent to the input plug ED9 of the electronic control unit.

Adjustment:

Fit a rev. counter to the engine. Move the proximity switch in its long mounting hole so that the LED lights up at an injection pump setting of 1600 RPM, or a voltage of 24v is measured at connector 2 on the proximity switch. The gap between the proximity switch and the injection pump control rod is 1.5 - 3.0mm.

Gear

High idle

Low idle

(Accalerator)

Proximity switch Mounting plate LED Toeque 30 Nm

10-19

STRUCTURE AND FUNCTION

TRANSMISSION

PRESSURE CHECK POINTS 4WG-150 SOLENOID EXPANSION VALVE AND OVERLAP VALVE FIG. 6

Pressure and temp. check points:

Inductive sender:

51. Torque converter inlet (Opening press. 8.5 bar)

M10x1

63. Torque converter outlet (opening pressure 5 bar)

M14x1.5

Volume check points: 15. Connection to heat exchanger M26x1.5 16. Connection from heat exchanger M26x1.5

10-20

1. Turbine rpm 2. Drive rpm Solenoid Valves: M6. Solenoid expansion valve M7. Overlap valve E. Breather

M18x1.5 M18x1.5

STRUCTURE AND FUNCTION

TRANSMISSION

ELECTRO - HYDRAULIC CONTROL VALVE - DETAIL X

Pressure and temp. check points: 51. Torque converter inlet (Opening press. 8.5 bar) 53. Forwards clutch pack KV 55. Reverse Clutch pack KR 56. Clutch pack K1 57. Clutch pack K2 58. Clutch pack K3 60. Clutch pack K4

M10x1 M10x1 M10x1 M10x1 M10x1 M10x1 M10x1

Scheme code G - 4-speed version: l Solenoid energized FORWARD GEAR M1 M2 M3 M4 M5 M6 M7 Clutch Clutch

1 l l l

2

l l

3

4

REVERSE 1 l l

2 l

NEUTRAL

3 l

l

l ¡ ¡ ¡ ¡ ¡ ¡ ¡ KV KV KV K4 KR KR KR K1 K2 K3 K3 K1 K2 K3 ¡

M14x1.5 M10x1 M10x1

Volume check points: 15. Connection to heat exchanger M26x1.5 16. Connection from heat exchanger M26x1.5

Scheme code G - 3-speed version (20 km/h):

l l

63. Torque converter outlet (Temp. 100°C, short time 120°C and opening pressure 5 bar) 65. System pressure 16+2 bar 66. Pressure reducing valve 10 bar

¡ K3

l Solenoid energized FORWARD GEAR M1 M2 M3 M4 M5 M6 M7 Clutch Clutch

1

2

l l l

l l

¡

REVERSE

NEUTRAL

3

1 l l

2 l

l l ¡

l

l

¡

¡

¡

KR KR K1 K2

K3

¡ ¡ KV KV K4 K1 K2 K2

¡ = M6 Solenoid not energised for programmed time during gear change ¡ = M7 Solenoid energised for programmed time during gear change from 2nd to 1st.

10-21

STRUCTURE AND FUNCTION

10-22

TRANSMISSION

17. Thermostat valve 18. Heat changer Press. drop ≤ 1bar 19. Filter Filtration µm: ß30≥20 ß10≥1.5 Filtration area cm2: 2450 20. Oil pump p=16+2 bar Qp=52 l/min-1 at 2000rpm 21. Check valves 0,15bar 22. Spring accumulator 23. Check valve 0,5bar 24. Dashboard torque converter output temerature 25. Dashboard pressure gauge 26. Lubrication 27. Sump 28. Torque converter SDV. Control pressure valve 16+2 bar RDV. Reducing valve 10 bar WSV. Torque converter safety valve 8.5 bar WDV. Torque converter pressure holding valve DSV. Pressure control valve ÜSV. Overlap valve SPV. Expansion valve EV. Breather valve

Refer also to fig. 6 and 7

Clutch pressure Reduced pressure Modulated pressure Torque converter input pressure Torque converter output pressure Lubrication Return to sump

STRUCTURE AND FUNCTION TRANSMISSION

TRANSMISSION HYDRAULIC SYSTEM DIAGRAM

10-23 10-23

STRUCTURE AND FUNCTION

TRANSMISSION

STRUCTURE AND FUNCTION

TRANSMISSION

CONTROL VALVE WITH SOLENOID EXPANSION VALVE AND OVER LAP VALVE FIG. 8

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Expansions valve solenoid Over lap valve Bleed valve Over lap valve solenoid Expansions valve Switch valve 3 Switch valve 5 Switch valve 1 Switch valve 2 Pressure control valve Reducing valve 10 bar Switch valve 4 Control pressure valve 16+2 bar

10-25

STRUCTURE AND FUNCTION

TRANSMISSION

THERMOSTAT VALVE

The thermostat valve is fitted to allow a quick warm up of the gearbox and torque converter temperature. It is mounted between the gearbox and the heat exchanger.

Opening temperature: Completely open:

87 ± 2 °C 102 °C

A. Connection to the gearbox B. Connection to the heat exchanger C. Connection to the return line from the heat exchanger and to the gear box oil sump 1.

2.

3.

4.

5.

6.

7.

8.

9.

End screw seal ring Pin Spring plate Wax element Pressure spring Thermostat housing Valve body Sensor torque converter oil temperature

Up to SN WA270H20563

9

7 SN WA270H20564 and up

7

9

270_063a

10-26

STRUCTURE AND FUNCTION

REVERSE TRANSMISSION 4WG-160

LAYOUT TRANSMISSION 4WG-160 ABB. 1

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Clutch shaft "KR" Power take-off; coaxial; engine-dependent Clutch shaft "KV" Clutch shaft "K2" Clutch shaft "K3" Output flange - rear Abtriebsflansch - wandlerseitig Output shaft Transmission pump Input flange - input through universal shaft Converter IInductive transmitter for engine speed Clutch shaft "K4" Converter relief valve Clutch shaft "K1"

GEAR PATTERN

10-27

STRUCTURE AND FUNCTION

REVERSE TRANSMISSION 4WG-160

INSTALLATION VIEW 4WG-160 / FRONT VIEW ABB. 2

1.

2.

3.

4.

5.

6.

7.

Lifting lugs Input flange - input through universal shaft Transmission suspension threads M20 Output flange - converter side Oil drain plug with magnetic insert M38x1,5 Model identification plate Atachment possibility for oil level tube with oil dip stick (coverter side) 8. Attachment possibility for emergency steering pump

10-28

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