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Komatsu
Compact Loader
WA270-8
Komatsu WA270-8 Service Manual
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YOUR MACHINE SERIAL NUMBERS AND DISTRIBUT
OR
Machine serial No.
Engine serial No.
Product identification
number (PIN)
Manufacturer name
Address
Komatsu Germany GmbH
Hanomag Strasse 9
30449 Hannover
Germany
Distributor name
Address
Phone/Fax
Service personnel
FOREWORD
PRODUCT INFORMA
TION
1-13
14
16
Table of Contents
Table of Contents
19
Eu Directives
4
Safety Information
6
Safety Labels
7
Noise Emission Levels
8
Vibration Level
9
Introduction
10
Main Use of Machine
10
Visibility from Operator's Seat
10
Engine Technology to Conform Exhaust Gas Emission
11
Product Information
12
Location of Product Identification Number (Pin)/Machine Serial No. Plate
12
Location of Engine Number Plate
12
Rops/Fops Serial Plate Location
13
Transmission Serial Plate Location
13
Seat Plate Location
14
Service Meter Location
14
Your Machine Serial Numbers and Distributor
15
Declaration of Conformity
16
Retrofitting by Third-Party Suppliers
17
Explanation of Acronyms
18
Table of Contents
19
Safety
24
Safety Labels
26
Location of Safety Labels
27
Contents of Safety Labels
29
Ensure Safe Operation
37
General Precautions Common to Operation and Maintenance
37
Inspect Machine
37
Keep Machine Clean
37
Precautions before Starting Operation
37
Precautions for Safety-Related Equipment
37
Preparations for Safe Operation
37
Understand the Machine
37
Wear Well-Fitting Clothes and Protective Equipment
37
If any Problem Is Found
38
Precautions for Inside Operator's Compartment
38
Provide Fire Extinguisher and First Aid Kit
38
Actions if Fire Occurs
39
Precautions to Prevent Fire
39
Prevent Fire
39
Precautions When Getting on or off Machine
40
Use Handrails and Steps When Getting on or off Machine
40
Lifting of Personnel Prohibited
41
No Jumping on or off Machine
41
No People on Attachments
41
Precautions When Leaving Machine
41
Precautions When Standing up from Operator's Seat
41
Do Not Get Caught
42
Emergency Exit from Operator's Cab
42
Precautions for Cleaning Cab Glass
42
Precautions Related to Protective Structures
42
Precautions Related to Attachments and Options
43
Precautions When Running Engine Inside Building
43
Unauthorized Modification
43
Do Not Go Close to High-Voltage Cables
44
Investigate and Confirm Jobsite Conditions
44
Precautions for Jobsite
44
Precautions for Operation
44
Precautions When Working on Loose Ground
44
Check Signs and Signalman's Signals
45
Ensure Good Visibility
45
Beware of Asbestos Dust
46
Checks and Adjustment before Starting Engine
46
Start Engine
46
Use Warning Tags
46
In Cold Weather
47
Precautions When Starting Engine
47
Start Engine with Jumper Cables
47
Checks before Operation
48
Precautions for Operation
48
Precautions When Traveling in Forward or Reverse
48
Precautions When Traveling
49
Method of Using Brakes
50
Precautions When Traveling on Slopes
50
Precautions When Operating Machine
51
Prohibited Operations
51
Precautions When Operating on Snow or Frozen Surfaces
52
Precautions When Parking Machine
52
Precautions for Transportation
53
Precautions When Loading and Unloading
53
Precautions for Towing and Being Towed
54
Towing and Being Towed
54
Appoint Leader When Working with Others
55
Display Warning Tag During Inspection and Maintenance
55
Keep Work Place Clean and Tidy
55
Only Authorized Personnel
55
Precautions before Starting Inspection and Maintenance
55
Precautions for Maintenance
55
Select Suitable Place for Inspection and Maintenance
55
Stability
55
End of Service Life
56
Guards
56
Stop Engine before Carrying out Inspection and Maintenance
56
Two Workers for Maintenance When Engine Is Running
57
Precautions for Working at High Places
58
Precautions When Installing, Removing, or Storing Attachments
58
Precautions When Working under Machine or Work Equipment
58
Turn off Ecss Switch before Performing Inspection and Maintenance
58
Handle Battery
59
Precautions for Check and Maintenance
59
Precautions for Welding
59
Turn Battery Disconnect Switch to off Position
59
Use Proper Tools
59
Precautions for High-Temperature Coolant
60
Precautions When Using Hammer
60
Handle High-Pressure Hoses and Piping
61
Precautions for High-Pressure Fuel
61
Precautions for High-Pressure Oil
61
Precautions for High-Temperature Oil
61
Precautions for High-Temperature Parts
61
Chemical Hazard
62
Handle Accumulator and Gas Spring
62
Maintenance of Air Conditioner
62
Precautions for Compressed Air
62
Precautions for Disposing of Waste Materials
62
Precautions for Noise
62
Handle Tires
63
Method for Selecting Window Washer Fluid
63
Periodic Replacement of Defined Life Parts
63
Tires
63
Precautions for Storing Tires
64
General Character and Precautions for Handling
65
Other Precautions
65
Precautions for Adding
65
Precautions for Def
65
Precautions for Fire Hazard and Leakage
65
Precautions for Storing
65
Operation
67
General View
68
Machine Equipment Name
68
Controls and Gauges Names
69
Other Equipment Name
73
Explanation of Components
76
Explanation of Machine Monitor Equipment
76
Switches
158
Control Levers and Pedals
173
Other Components
176
Checks and Adjustment before Starting Engine
215
Machine Operations and Controls
215
Method for Starting Engine
240
Method for Operations and Checks after Starting Engine
244
Method for Stopping Engine
247
Method for Starting Machine (Travel Forward and Reverse, and Shifting Gear) and Stopping Machine
248
Method for Steering Machine
256
Method for Operating Work Equipment
257
Precautions for Operation
259
Recommended Applications
260
Method for Adjusting Work Equipment Posture
265
Remote Positioner
265
Method for Parking Machine
270
Lock
272
Method for Checking after Finishing Work
272
Handle Tire
275
Handle Air Conditioner
277
Explanation of Air Conditioner Equipment
278
Method for Operating Air Conditioner
283
Loading and Unloading with Trailer
287
Transportation
287
Transportation Procedure
287
Method for Lifting Machine
291
Cold Weather Operation
293
Cold Weather Operation Information
293
After Cold Weather Season
294
Precautions after Daily Work Completion
294
Precautions in Cold Weather
294
Maintenance During Long-Term Storage
295
Precautions for Long-Term Storage
295
Preparation for Long-Term Storage
295
Starting Machine after Long-Term Storage
295
Actions When Running out of Fuel
297
Precautions for Towing Machine
297
Troubles and Actions
297
Precautions for Discharged Battery
301
Other Trouble
304
Maintenance
311
Always Use Clean Washer Fluid
312
Check Drained Oil and Used Filter
312
Check Service Meter Reading
312
Fresh and Clean Lubricants
312
Komatsu Genuine Lubricants
312
Komatsu Genuine Replacement Parts
312
Precautions for Adding Def
312
Precautions for Maintenance
312
Precautions for Refilling Oil or Fuel
312
Welding Instructions
312
Avoid Mixing Oil
313
Bleed Air from Hydraulic Circuit
313
Checks after Inspection and Maintenance
313
Dusty Jobsites
313
Lock Inspection Covers
313
Precautions for Scr Assembly
313
Precautions When Installing Hydraulic Hoses
313
Close Engine Side Cover Securely
314
Fuel and Lubricants to Match the Ambient Temperature
314
Handle Oil, Fuel, Coolant, and Performing Oil Clinic
315
Outline of Maintenance
315
Handle Electrical Components
319
Standard Tightening Torque for Bolts and Nuts
320
Maintenance Schedule
322
Maintenance Schedule Table
322
Maintenance Interval When Diesel Fuel Mixed with Bio-Fuel Is Used
323
Initial 10 Hours Maintenance (Only for the First 100 Hours)
325
Initial 250 Hours Maintenance (Only after the First 250 Hours)
325
Maintenance Procedure
325
Method for Checking, Cleaning and Replacing Air Cleaner
325
When Required
325
Method for Cleaning Inside of Cooling System
330
Method for Checking Oil Level in Transfer Case and Adding Oil
334
Method for Checking Oil Level in Axle Case and Adding Oil
336
Method for Cleaning Engine Damper Breather
336
Method for Cleaning Axle Breather
337
Method for Cleaning Air Conditioner Condenser
338
Method for Cleaning Fins by Rotating Cooling Fan in Reverse
339
Method for Cleaning Radiator Fin and Cooler Fin
339
Method for Reversing Manual Operation Fan
339
Method for Cleaning Fin with Compressed Air
340
Method for Reversing Automatic Operation Fan
340
Method for Inverting and Replacing Bolt on Cutting Edge
342
Method for Replacing Bucket Teeth
342
Method for Checking and Maintenance Air Conditioner
346
Method for Checking Window Washer Fluid Level, Adding Fluid
346
Method for Replacing Slow-Blow Fuse
348
Method for Checking Function of Brake Accumulator
349
Method for Checking Function of Ecss Accumulator
349
Select and Check Tires
350
Method for Cleaning and Replacing Fuel Tank Breather Element
351
Checks before Starting
353
Every 100 Hours Maintenance
354
Every 50 Hours Maintenance
354
Method for Draining Water and Sediment from Fuel Tank
354
Method for Lubricating Work Equipment
354
Method for Lubricating Rear Axle Pivot Pin
355
Method for Checking Oil Level in Hydraulic Tank, Adding Oil
356
Method for Cleaning Air Conditioner Fresh Air Filter
357
Every 250 Hours Maintenance
358
Method for Lubricating Steering Cylinder Pin
358
Method for Checking Battery Electrolyte Level
359
Method for Checking and Adjusting Air Conditioner Compressor Belt Tension
361
Method for Testing Parking Brake
361
Method for Checking Looseness of Wheel Hub Bolts, Retightening Bolts
363
Method for Cleaning Air Conditioner Recirc Air Filter
363
Every 500 Hours Maintenance
364
Method for Checking Function of Brake Accumulator
364
Method for Replacing Fuel Prefilter Cartridge
366
Every 1000 Hours Maintenance
369
Method for Replacing Fuel Main Filter Cartridge
369
Method for Cleaning Transfer Case Breather
371
Method for Replacing Hst Oil Filter Cartridge
373
Every 2000 Hours Maintenance
374
Method for Changing Oil in Hydraulic Tank, Cleaning Hydraulic Tank Strainer
374
Method for Checking All Tightening Points of Engine Intake Pipe Clamps
374
Method for Checking and Replacing Alternator Belt
374
Method for Lubricating Center Hinge Pin
374
Method for Replacing Hydraulic Oil Filter Cartridge
377
Method for Replacing Hydraulic Tank Breather Element
378
Method for Changing Oil in Axle Case
379
Method for Cleaning Brake Circuit Strainer
381
Method for Replacing Air Conditioner Fresh/Recirc Air Filters
381
Method for Checking Brake Disc Wear Amount
382
Method for Checking Function of Ppc Accumulator
383
Method for Checking Alternator
384
Method for Checking and Adjusting Engine Valve Clearance
384
Method for Checking Vibration Damper
384
Method for Replacing Kccv Filter Element
384
Method for Replacing Def Filter
387
Method for Replacing Def Tank Breather Element
390
Every 4000 Hours Maintenance
391
Replace Defined Life Parts
391
Method for Lubricating Drive Shaft
392
Method for Checking and Adjusting Air Conditioner Compressor
393
Method for Checking for Looseness of Engine High-Pressure Piping Clamp, Hard- Ening of Rubber
393
Method for Checking Starting Motor
393
Method for Checking Water Pump
393
Every 4500 Hours Maintenance
394
Every 8000 Hours Maintenance
394
Every 9000 Hours Maintenance
394
Method for Cleaning Def Tank
394
Method for Cleaning Kdpf
394
Method for Replacing Fuel Spray Prevention Cap
394
Method for Replacing Starting Motor
394
End of Service Life
395
Method for Replacing Def Hose
395
Specifications
397
Specifications:wa270-8
398
Attachments and Options
401
Bucket and Tire Selection
402
Explanation of Components on Machines with Quick Coupler
403
Handle Hydraulic Type Quick Coupler
403
Method for Removing Attachment
404
Method for Installing Attachment
405
Explanation of Components on Machines with Fork
408
Handle Fork
408
Machine Operations and Controls
409
Lcd Unit
415
Pcs (Proportional Control Switch)
415
Method for Setting Pcs
417
Auto-Greasing
419
Initial 10 Hours Maintenance (Only for the First 100 Hours)
422
Replacement Parts
425
Defined Life Parts List
426
Periodic Replacement of Defined Life Parts
426
Consumable Parts
427
Consumable Parts List
427
Lubrication Chart
428
Recommended Fuel, Coolant, and Lubricant
428
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Komatsu WA270-8 Specifications
General
Brand
Komatsu
Model
WA270-8
Category
Compact Loader
Language
English
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