SERVICE MANUAL Wheel Loader W270C W300C
Print No. 47357329
W270C - W300C Wheel Loader Service Manual 47357329
Table of Contents Description
Section No.
General
Tab 1
Section Index - General Standard Torque Specifications
1001
Fluids and Lubricants
1002
Metric Conversion Chart
1003 Tab 2
Engines Section Index - Engines Engine and Radiator Removal and Installation
2000
Stall Tests
2002
After Cooler
2003
For Engine Repair, See the Engine Service Manual 84394558 Fuel System
Tab 3
Section Index - Fuel System For Fuel System Repair, See the Engine Service Manual 84394558 Electrical
Tab 4
Section Index - Electrical Removal and Installation of Starter and Alternator
4001
Electrical Specifications and Troubleshooting
4002
Batteries
4003
Jump post option
4003a
Instrument Cluster
4005
Rear view Camera and Monitor
4006
Steering
Tab 5
Section Index - Steering Removal and Installation of Steering Components
5001
Steering Specifications, Pressure Checks, and Troubleshooting
5002
Steering Cylinders
5005
Center Pivot
5006
Auxiliary Steering Motor and Pump
5008
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
47357329
Copyright Š 2012 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued February, 2012
W270C - W300C Wheel Loader Service Manual 47357329
Table of Contents Description Joystick Steering System (JSS) (Optional) Power Train
Section No. 5009 Tab 6
Section Index - Power Train Removal and Installation of Power Train Components
6001
Transmission Specifications, Pressure Checks, and Troubleshooting
6002
Transmission
6003
Front Axle
6004
Rear Axle
6004
Drive Shafts, Center Bearing, and Universal Joints
6005
Wheels and Tires
6006
Transmission Control Valve
6007
Brakes
Tab 7
Section Index - Brakes Removal and Installation of Brake Components
7001
Hydraulic Brake Troubleshooting
7002
Brake Pump
7003
Brake Accumulators
7004
Parking Brake
7008
Hydraulics
Tab 8
Section Index - Hydraulics Removal and Installation of Hydraulic Components
8001
Hydraulic Specifications, Troubleshooting, and Pressure Checks
8002
Cleaning the Hydraulic System
8003
Hydraulic Pump
8004
Loader Control Valve
8005
Cylinders
8006
Ride Control Accumulator
8013
Ride Control Valve
8014
W270C - W300C Wheel Loader Service Manual 47357329
Table of Contents Description
Section No.
Mounted Equipment
Tab 9
Section Index - Mounted Equipment Air Conditioning Troubleshooting and System Checks For Systems with HFC-134a Refrigerant
9002
Air Conditioner System Service
9003
Removal and Installation of Air Conditioning and Heater Components
9004
Loader
9006
Rollover Protective Structure (ROPS) Cab Structural Frame (CSF)
9007
Cab Glass Installation
9010
Electrical Schematic Foldouts and Hydraulic Schematic Foldout
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
47357329
In Rear Pocket
Copyright © 2012 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued February, 2012
SECTION INDEX
GENERAL Section Title
Section Number
Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1001 Fluids and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1002 Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
47357329
Copyright © 2012 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued February, 2012
1001 Section 1001 GENERAL TORQUE SPECIFICATIONS
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
47357329
Copyright © 2012 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued February, 2012
1001-3
TORQUE SPECIFICATIONS - DECIMAL HARDWARE Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphities, Molydisulfide greases, or other extreme pressure lubricants are used.
Grade 5 Bolts, Nuts, and Studs
Grade 8 Bolts, Nuts, and Studs
PoundInches
Newton metres
1/4 inch
144 to 180
16 to 20
5/16 inch
288 to 348
33 to 39
3/8 inch
540 to 648
61 to 73
Size
PoundInches
Newton metres
Size
PoundFeet
Newton metres
1/4 inch
108 to 132
12 to 15
7/16 inch
70 to 84
95 to 114
5/16 inch
204 to 252
23 to 28
1/2 inch
110 to 132
149 to 179
3/8 inch
420 to 504
48 to 57
9/16 inch
160 to 192
217 to 260
5/8 inch
220 to 264
298 to 358
Size
PoundFeet
Newton metres
3/4 inch
380 to 456
515 to 618
7/16 inch
54 to 64
73 to 87
7/8 inch
600 to 720
814 to 976
1/2 inch
80 to 96
109 to 130
1.0 inch
900 to 1080
1220 to 1465
9/16 inch
110 to 132
149 to 179
1-1/8 inch
1280 to 1440
1736 to 1953
5/8 inch
150 to 180
203 to 244
1-1/4 inch
1820 to 2000
2468 to 2712
3/4 inch
270 to 324
366 to 439
1-3/8 inch
2380 to 2720
3227 to 3688
7/8 inch
400 to 480
542 to 651
1-1/2 inch
3160 to 3560
4285 to 4827
1.0 inch
580 to 696
787 to 944
1-1/8 inch
800 to 880
1085 to 1193
1-1/4 inch
1120 to 1240
1519 to 1681
1-3/8 inch
1460 to 1680
1980 to 2278
1-1/2 inch
1940 to 2200
2631 to 2983
Size
47357329
NOTE: Use thick nuts with Grade 8 bolts.
Issued 02-12
Printed in E.C.
1001-4
TORQUE SPECIFICATIONS - METRIC HARDWARE Use the following torques when specifications are not given. These values apply to fasteners with coarse threads as received from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used.
Grade 8.8 Bolts, Nuts, and Studs 8.8
Size
PoundInches
Grade 10.9 Bolts, Nuts, and Studs 10.9
Size
PoundInches
Newton metres
M4
36 to 48
4 to 5
M5
84 to 96
9 to 11
M6
132 to 156
15 to 18
M8
324 to 384
37 to 43
PoundFeet
Newton metres
Newton metres
M4
24 to 36
3 to 4
Size
M5
60 to 72
7 to 8
M10
54 to 64
73 to 87
M6
96 to 108
11 to 12
M12
93 to 112
125 to 150
M8
228 to 276
26 to 31
M14
149 to 179
200 to 245
M10
456 to 540
52 to 61
M16
230 to 280
310 to 380
M20
450 to 540
610 to 730
Newton metres
M24
780 to 940
1050 to 1275
Size
PoundFeet
M30
1470 to 1770
2000 to 2400
M12
66 to 79
90 to 107
M36
2580 to 3090
3500 to 4200
M14
106 to 127
144 to 172
M16
160 to 200
217 to 271
M20
320 to 380
434 to 515
M24
500 to 600
675 to 815
M30
920 to 1100
1250 to 1500
M36
1600 to 1950
2175 to 2600
47357329
Grade 12.9 Bolts, Nuts, and Studs 12.9
Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.
Issued 02-12
Printed in E.C.
1001-5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS 37 Degree Flare Fitting
Straight Threads with O-ring
Tube OD Hose ID
Thread Size
PoundInches
Newton metres
Tube OD Hose ID
Thread Size
PoundInches
Newton metres
1/4 inch 6.4 mm
7/16-20
72 to 144
8 to 16
1/4 inch 6.4 mm
7/16-20
144 to 228
16 to 26
5/16 inch 7.9 mm
1/2-20
96 to 192
11 to 22
5/16 inch 7.9 mm
1/2-20
192 to 300
22 to 34
3/8 inch 9.5 mm
9/16-18
120 to 300
14 to 34
3/8 inch 9.5 mm
9/16-18
300 to 480
34 to 54
1/2 inch 12.7 mm
3/4-16
180 to 504
20 to 57
1/2 inch 12.7 mm
3/4-16
540 to 804
57 to 91
5/8 inch 15.9 mm
7/8-14
300 to 696
34 to 79 Tube OD Hose ID
Thread Size
PoundFeet
Newton metres
Tube OD Hose ID
Thread Size
PoundFeet
Newton metres
5/8 inch 15.9 mm
7/8-14
58 to 92
79 to 124
3/4 inch 19.0 mm
1-1/16-12
40 to 80
54 to 108
3/4 inch 19.0 mm
1-1/16-12
80 to 128
108 to 174
7/8 inch 22.2 mm
1-3/16-12
60 to 100
81 to 135
7/8 inch 22.2 mm
1-3/16-12
100 to 160
136 to 216
1.0 inch 25.4 mm
1-5/16-12
75 to 117
102 to 158
1.0 inch 25.4 mm
1-5/16-12
117 to 187
159 to 253
1-1/4 inch 31.8 mm
1-5/8-12
125 to 165
169 to 223
1-1/4 inch 31.8 mm
1-5/8-12
165 to 264
224 to 357
1-1/2 inch 38.1 mm
1-7/8-12
210 to 250
285 to 338
1-1/2 inch 38.1 mm
1-7/8-12
250 to 400
339 to 542
Split Flange Mounting Bolts PoundInches
Newton metres
5/16-18
180 to 240
20 to 27
3/8-16
240 to 300
27 to 34
7/16-14
420 to 540
47 to 61
Size
PoundFeet
Newton metres
1/2-13
55 to 65
74 to 88
5/8-11
140 to 150
190 to 203
Size
47357329
Issued 02-12
Printed in E.C.
1001-6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS O-ring Boss End Fitting or Lock Nut
O-ring Face Seal End Nom. SAE Dash Size
Tube OD
Thread Size
PoundInches
Newton metres
Thread Size
PoundInches
Newton metres
-4
1/4 inch 6.4 mm
9/16-18
120 to 144
14 to 16
7/16-20
204 to 240
23 to 27
-6
3/8 inch 9.5 mm
11/16-16
216 to 240
24 to 27
9/16-18
300 to 360
34 to 41
-8
1/2 inch 12.7 mm
13/16-16
384 to 480
43 to 54
3/4-16
540 to 600
61 to 68
Thread Size
PoundFeet
Newton metres
7/8-14
60 to 65
81 to 88
1-1/16-12
85 to 90
115 to 122
-10
Nom. SAE Dash Size
5/8 inch 15.9 mm
Tube OD
1-14
552 to 672
62 to 76
Thread Size
PoundFeet
Newton metres
1-3/16-12
95 to 100
129 to 136
-12
3/4 inch 19.0 mm
1-3/16-12
65 to 80
90 to 110
1-5/16-12
115 to 125
156 to 169
-14
7/8 inch 22.2 mm
1-3/16-12
65 to 80
90 to 110
1-5/8-12
150 to 160
203 to 217
-16
1.0 inch 25.4 mm
1-7/16-12
92 to 105
125 to 140
1-7/8-12
190 to 200
258 to 271
-20
1-1/4 inch 31.8 mm
1-11/16-12
125 to 140
170 to 190
-24
1-1/2 inch 38.1 mm
2-12
150 to 180
200 to 254
47357329
Issued 02-12
Printed in E.C.
Section 2000
CNH Italia S.p.A. Via Plava, 80 10135 Torino Italia
47357329
Copyright © 2012 CNH Italia S.p.A. All rights reserved. Printed in E.C. Issued February, 2012
2000
ENGINE AND RADIATOR REMOVAL AND INSTALLATION
2000-2
TABLE OF CONTENTS Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47357329
Issued 02-12
3 3 12 21 21 22
Printed in E.C.
2000-3
ENGINE Removal
STEP 8
NOTE: Put caps on the fittings and plugs in the hoses to prevent foreign material from entering the system when disconnecting fuel lines or hydraulic hoses.
STEP 1
W270R613
Put the master disconnect switch (1) in the off position. W270R612
Park the machine on a level surface and lower the bucket to the ground. Put the articulation lock (1) in the locked position.
STEP 9 Drain the engine radiator coolant.
STEP 10
STEP 2
Drain the engine oil.
Key in the run position, engine off, place the pilot control switch in the normal operation position.
STEP 11
STEP 3 Move the loader hydraulic control handle to the raise and lower position in order to release any hydraulic pressure in the lift circuit.
STEP 4 Move the loader control handle in and out of the tilt position several times, this will relieve any pressure in the pilot accumulator.
STEP 5 Release the pressure in the ride control accumulator with the bleeder valve in the ride control valve.
STEP 6 Depress the brake pedal several times to discharge brake accumulators.
W270R614
Loosen the hose clamp (1) on the air box snorkel under the air inlet hood.
STEP 7 Slowly loosen the filler cap on the hydraulic oil tank to release air pressure. 47357329
Issued 02-12
Printed in E.C.
2000-4
STEP 12
STEP 14
W270R615
Remove the mounting bolts on the exhaust stack hood. Attach lifting equipment to the exhaust stack. Remove the exhaust stack hood (1).
W270R618
Remove the left bracket (1) and right bracket (2).
STEP 15
STEP 13
W270R651
Remove the hydraulic oil lines (1). W270R617
Disconnect the deaeration tank overflow hose (2). Remove the P-clamps (1) that secure the overflow hose to the wall and brackets. Position the overflow hose away from the engine and engine wall.
47357329
Issued 02-12
Printed in E.C.
2000-5
STEP 16
STEP 18
W270R619
W270R621
Remove the after air cooler tube (1) . Remove the bulkheads (2).
Remove the before air coller tube (1). Remove the upper radiator tube (2).
STEP 17
STEP 19
W270R622 W270R620
Remove the oil dipstick P-clamp (3) . Pull the oil dipstick tube (1) through the wall. Label and disconnect the hood lift strut electrical connector (2).
47357329
Label and disconnect the humidity sensor electrical connector (1). Remove the turbo inlet tube (2). Label and disconnect the air filter restriction sensor electrical connector (3).
Issued 02-12
Printed in E.C.
2000-6
STEP 20
STEP 22
W270R623
Remove the wire harness P-clamp (1). Loosen the hose clamp on the air box snorkel (2). Disconnect the air box snorkel (3).
W270R625
Remove the air box assembly.
STEP 23
STEP 21
W270R626
Remove the lower radiator tube (1) . W270R624
Remove the lower, right panel (1) on the engine wall.
47357329
Issued 02-12
Printed in E.C.
2000-7
STEP 24
STEP 26
W270R627
Attach lifting equipment to the engine wall. Remove the engine wall’s hold-down bolts. Lift and remove the engine wall.
Remove two bolts (2), washers (3), and nuts (4). Remove the air box snorkel (1) .
STEP 25
STEP 27
W270R630
W270R631 W270R628
Remove the turbo exhaust tube (1).
47357329
Disconnect the inlet and outlet heater core heater hoses (1).
Issued 02-12
Printed in E.C.
2000-8
STEP 28
STEP 31
W270R632
Disconnect the starter battery cables (1) and starter switch wire (2).
STEP 29
W270R634
Label and disconnect the engine control module electrical connector (1).
STEP 32
W270R703
Disconnect the following from the crank case ventilation/fuel filter bracket assembly: ● ● ● ● ● ● ● ● ●
Fuel pump electrical connector; Water sensor electrical connector; Ground wire; Wire harness P-clamp; Crank case filter inlet hose; Crank case filter outlet hose; Crank case filter oil return hose; Fuel pump inlet tube; Fuel pump outlet tube.
W270R635
Disconnect the fuel return line (1). Disconnect the battery positive wire (2) on the air grid heater.
STEP 30 Remove the crank case ventilation/fuel filter bracket assembly.
47357329
Issued 02-12
Printed in E.C.
2000-9
STEP 33
STEP 35
W270R638 W270R636
Disconnect the engine ground wires (1). Remove the wire harness P-clamp (2).
STEP 34
Label and disconnect the A/C compressor electrical connector (1). Label and disconnect the A/C pressure switch electrical connector (4). Remove the alternator power wire (3). Label and disconnect the bulk electrical connector (5). Remove the A/C compressor (2). Position the A/C compressor (2) away from the engine.
STEP 36
W270R637
Remove the engine serpentine belt (1).
W270R639
Remove the wire harness P-clamps (1).
47357329
Issued 02-12
Printed in E.C.
2000-10
STEP 37
STEP 39
W270R640
Remove the engine oil drain tube (1).
W270R642
Remove the hydraulic oil return tube P-clamp (1). Position the hydraulic oil return tube away from the converter housing cover plate.
STEP 38
STEP 40
W270R641
Attach lifting equipment to the engine. Support the engine.
W270R643
Remove the converter housing cover plate (1).
47357329
Issued 02-12
Printed in E.C.
2000-11
STEP 41
STEP 43
W270R644
Remove the flex plate bolts (1).
W270R646
Remove the front engine mounts (1) and engine mount plate (2).
STEP 42
STEP 44
W270R645
Remove the harmonic balancer (1).
W270R647
Remove the bell housing bolts (1).
STEP 45
W270R641
Remove the engine. 47357329
Issued 02-12
Printed in E.C.
2000-12
Install
STEP 48
STEP 46
W270R649
W270R641
Carefully lower the engine into the chassis.
STEP 47
Install the engine mount plate (5) and the engine mount brackets (1), but do not tighten the bolts to a torque value. Tighten the engine bracket upper bolts (2) to a torque of 171 - 231 N·m (126 - 170 lb ft). Tighten the engine bracket lower bolts (3) to a torque of 69 - 80 N·m (51 - 59 lb ft). Tighten the engine mount plate bolts (4) to a torque of 386 - 434 N·m (285 - 320 lb ft). Tighten the engine bracket-to-engine mount plate bolts (6) to a torque of 397 - 447 N·m (293 - 330 lb ft).
STEP 49
W270R647
Install the bell housing bolts (1). Tighten the bell housing bolts (1) to a torque of 54 - 60 N·m (40 - 44 lb ft).
W270R650
Install the harmonic balancer (1). Tighten the harmonic balancer bolts (2) to a torque of 115 N·m (85 lb ft).
47357329
Issued 02-12
Printed in E.C.
2000-13
STEP 50
STEP 52
W270R644
W270R631
Install the flex plate bolts (1). Tighten the flex plate bolts (1) to a torque of 33 - 41 N¡m (24 - 30 lb ft).
Connect the inlet and outlet heater core heater hoses (1).
STEP 51
STEP 53
W270R642 W270R643
Apply DOW 732 RTV SILICONE CLEAR to the converter housing cover plate (1). Install the converter housing cover plate (1).
47357329
Reposition the hydraulic oil return tube. Install the hydraulic oil return tube P-clamp (1).
Issued 02-12
Printed in E.C.
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2000-14
STEP 54
STEP 56
W270R641 W270R630
Install the air box snorkel (1). Install two bolts (2), washers (3), and nuts (4).
Remove lifting equipment from the engine.
STEP 57
STEP 55
W270R627
Install the engine wall. W270R628
STEP 58
Install the turbo exhaust tube (1).
W270R626
Install the lower radiator tube (1). 47357329
Issued 02-12
Printed in E.C.
2000-15
STEP 59
STEP 61
W270R625
W270R624
Install the air box.
Install the lower, right panel (1) on the engine wall.
STEP 60
STEP 62
W270R622 W270R623
Install the wire harness P-clamp (1). Connect the air box snorkel (3). Tighten the hose clamp on the air box snorkel (2).
47357329
Install the turbo intlet tube (2). Connect the humidity sensor electrical connector (1). Connect the air filter restriction sensor electrical connector (3).
Issued 02-12
Printed in E.C.
2000-16
STEP 63
STEP 65
W270R621
Install the upper radiator tube (2). Install the before air cooler tube (1).
Install the wire harness P-clamps (1).
STEP 64
STEP 66
W270R639
W270R640
Install the engine oil drain tube (1).
47357329
W270R637
Install the engine serpentine belt (1).
Issued 02-12
Printed in E.C.
2000-17
STEP 67
STEP 69
W270R638
Install the A/C compressor (2). Connect the A/C compressor electrical connector (1). Connect the A/C pressure switch electrical connector (4). Connect the alternator power wire (3). Connect the bulk electrical connector (5).
W270R635
Connect the fuel return line (1). Connect the battery positive wire (2) on the air grid heater.
STEP 70
STEP 68
W270R636
Connect the engine ground wires (1). Install the wire harness P-clamp (2).
W270R634
Connect the engine control module electrical connector (1).
STEP 71 Install the crank case ventilation/fuel filter bracket assembly.
47357329
Issued 02-12
Printed in E.C.
2000-18
STEP 72
STEP 74
W270R703
W270R620
Connect the following on the crank case ventilation/ fuel filter bracket assembly:
Connect the hood lift strut electrical connector (2). Slip the oil dipstick tube (1) through the engine wall. Install the dipstick tube P-clamp (3).
● ● ● ● ● ● ● ● ●
Fuel pump electrical connector Water sensor electrical connector Ground wire Wire harness P-clamp Crankcase filter inlet hose Crankcase filter outlet hose Crankcase filter oil return hose Fuel pump inlet tube Fuel pump outlet tube
STEP 75
STEP 73
W270R619
Install the bulkheads (2). Install the after air cooler tube (1).
W270R632
Connect the starter battery cables (1) and starter switch wire (2).
47357329
Issued 02-12
Printed in E.C.
2000-19
STEP 76
STEP 79
W270R651
Install the hydraulic lines (1).
W270R615
Lower the exhaust stack hood (1) in front of the engine wall and onto the left bracket, right bracket, and hydraulic oil tank. Install the exhaust stack hood mounting bolts.
STEP 77
STEP 80
W270R618
Install the left bracket (1) and right bracket (2).
STEP 78
W270R614
Attach the air box snorkel to the air inlet hood. Tighten the air box snorkel hose clamp (1).
STEP 81 Check and adjust all fluid levels.
W270R652
Install the P-clamps (2) and overflow tube (1) to the engine wall, left bracket, and deaeration tank (3). 47357329
Issued 02-12
Printed in E.C.