Professional Documents
Culture Documents
Shop Manual
WA270-3
WA270PT-3
Wheel Loader Serial-no.
WA270-3 WA270H20051 and up
WA270PT-3 WA270H30051 and up
© 2001
All Rights Reserved
Printed in Europe 09-01
CONTENTS
No. of page
00 SAFETY ............................................................................. 00-3
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 ca-
refully 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.
00-3
Safety Notice SAFETY
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:
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 ad-
vance notice. Use the specifications given in the book with the latest date.
00-5
How to Read the Shop Manual SAFETY
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:
10-4
10-4-1
10-4-2 Added Pages
10-5
Symbols
So that the shop manual can be of ample practical use, important safety and quality portions are marked with
the following symbols:
«
Caution Special technical precautions or other precautions for preserving stan-
dards are necessary when performing the work.
00-6
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 4
symbol:
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:
« The allowable load in tons, is given by vertical tensible force.
« 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)
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
00-7
Hoisting Instructions SAFETY
3. 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 beco-
mes 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
kg
(kg)
2000
1900
1700
2000
capacity
1400
(kg)
1000
Gewicht
1000
500
Load
00-8
01 GENERAL
01-1
01-2
GENERAL DIMENSIONS, OPERATING DATA
WA270-3
270-128
I:\DTP\BA270GB\ABMES.TBL
01-3
GENERAL DIMENSIONS, OPERATING DATA
WA270PT-3
U:\DTP\BA270GB\270PT\ABMES-PT.TBL
01-4
GENERAL TECHNICAL DATAS
SPECIFICATIONS
Alternator 24 V
Battery 12 V x 2 / 105Ah
Tire 20.5R25
Axle, wheel
Outside Bucket
5757 mm
01-5
GENERAL TECHNICAL DATAS
Structure Hydrostatic
(bar) 210
Cut-off pressure
(bar) 165
Set pressure for steering Orbit-roll valve type
(bar) 200
Steering cylinder
No. bore x stroke (mm) 2 75 x 337
equipment
Work
3. 27,2 km/h
Travel speed 4. 41,8 km/h
01-6
GENERAL TECHNICAL DATAS
Structure Hydrostatic
Steering cylinder
No. bore x stroke (mm) 2 75 x 337
equipment
Two lever
Multi function lever
3. 27,2 km/h
Travel speed 4. 41,8 km/h
01-7
GENERAL WEIGHT TABLE
Unit: kg
01-8
GENERAL WEIGHT TABLE
Unit: kg
01-9
GENERAL LUBRICATION CHART
CCMC D4
EO 1540 A -10° to 50°C SAE 15W-40 ¹)
or, if not available,
Engine EO engine oil EO 1030 A -25° to 20°C SAE 10W-30 16
API CE or
NRS -40° to 20°C SAE 05W-30
API CF -4 ²)
CCMC D4
Transmission EO engine oil EO 10 or, if not available, - SAE 10W 17
API CD
HYD hydraulic oil HYD 0530 HVLP, HVLP D -35° to 50°C ISO VG 46 ¹)
CCMC D4
or EO engine oil EO 10 or, if not available, -35° to 40°C SAE 10W
Hydraulic system,
API CD 120
steering, brakes
HEES
or BIO-E-HYD ISO VG 46
BIO-E-HYD 0530 (to VDMA fluid -35° to 50°C
hydraulic oil
technology)
SP-C long-term
coolant with Anti-frost and rust
Cooling system SP-C 56
anti-frost and rust protection
protection
Multi-purpose
Grease nipples,
grease on a lithium MPG-A KP2N-20 - NLGI 2
central lubrication
basis
Coolant
Air-conditioning Refrigerating NRS R134a (CFC-free) 1000 g
machine oil NRS PAG (Polyalcohol glycol oil) 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.
01-10
GENERAL MAINTENANCE CHART
MAINTENANCE SCHEDULE
CHECKLIST PRIOR TO STARTING UP EVERY 500 OPERATING HOURS
Checking coolant level, top up Fuel filter, change filter cartridges
Checking engine oil level, top up Cooling system, check antifreeze in coolant
Water separator, drain water and dirt deposits
Fuel filter, drain water EVERY 1000 OPERATING HOURS
Checking drive belts Transmission, change oil and oil filter
Checking fan (at least every 12 months)
Checking electrical connections Engine, check valve clearance
Checking fuel level, top-up Service brake, change oil filter
Checking control panels Drive belts, check tension pulley and fan bearing
Checking parking brake Turbocharger, check mounts and play
Checking service brake Axles, oil change (at least every 12 months)
Checking horn and reversing horn Lubrication:
Checking lighting for function, dirt and damage 1. Pivot steering (2 points)
Checking exhaust, exhaust gas colour and 2. Propeller shaft intermediate
exhaust noise bearing (1 point)
Checking measuring instruments 3. Universal joint on front cardan
Checking steering wheel play and function shaft (5 points)
Checking rear-view mirror for alignment, dirt
and damage EVERY 2000 OPERATING HOURS
Cooling system, changing coolant and cleaning
interior (at least every 24 months)
INITIAL MAINTENANCE Check vibration absorber
AFTER THE FIRST 100 OPERATING HOURS Check turbocharger and clean
Transmission, change oil and filters Check three-phase generator and starter
Service brake, change oil filter Air-conditioning, change filter elements
Pressure tank, check gas pressure
AFTER THE FIRST 250 OPERATING HOURS Hydraulic system, oil change, change filter element
Fuel tank, drain water (at least every 12 months)
Fuel filter, change cartridges
Hydraulic system, change oil filter elements EVERY 4000 OPERATING HOURS
Check water pump
AFTER THE FIRST 500 OPERATING HOURS
Axles, oil change
MAINTENANCE AS REQUIRED
Air filter: Installation and removal of filter elements,
REGULAR MAINTENANCE cleaning filter elements, changing safety filter
EVERY 100 OPERATING HOURS Dust pre-extractor "turbo II": check, clean
Hydraulic system, checking oil level, top up Cleaning the radiator
Cleaning fresh-air filter elements Windscreen washer, checking fluid level, top up
Lubrication: Rear axle bolts (2 points) Transmission, checking oil level, top
Replacing bucket teeth
EVERY 250 OPERATING HOURS Fuel tank, draining water and dirt deposits
Engine, change oil and oil filter cartridge Tyres, checking air pressure
(at least every 6 months) Air-conditioning, cleaning condenser
Checking air induction system Checking air-conditioning
Air-conditioning, check tension of the compressor Checking the coolant level
Van-belt
Batteries, check
Axles, check oil levels
Wheel nuts, check, retighten
Lubrication:
1. Bucket bolts (2 points)
2. Tilt rod bolts (2 points)
3. Tilt cylinder bolts (2 points)
4. Lift cylinder bolts (4 points)
5. Boom bolts (2 points)
6. Bucket tilt lever bolts(1point)
7. Steering cylinder bolts (4 points)
01-11
GENERAL MAINTENANCE GUIDLINE
OUTLINES OF SERVICE
OIL:
• The oil in the engine and the hydraulic system is subject to extre-
me 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
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.
01-13
GENERAL MAINTENANCE GUIDLINE
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
GENERAL MAINTENANCE GUIDLINE
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
Strength class
Tread diameter Width across
of the bolt (mm) flat (mm) 8.8
(a) (b)
Nm kpm
M 6 10 10 1
M 8 13 24 2,4
M 10 17 (15) 48 4,8
M 12 19 83 8,3
M 14 22 130 13
M 16 24 200 20
M 18 27 280 28
M 20 30 390 39
M 22 32 520 52
M 24 36 670 67
M 27 41 980 98
M 30 46 1330 133
M 33 50 1790 179
M 36 55 2310 231
M 39 60 2970 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
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 GENERAL VIEW
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 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
NOTE:
The machine will only drive in 2nd gear, irrespec-
tive of position of gear lever.
From serial-no.
WA270H21038and up on WA270-3
WA270H30132and up on WA270PT-3
01-18
STRUCTURE AND FUNCTION POWER TRAIN
10-1
STRUCTURE AND FUNCTION POWER TRAIN
10-2
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
Outline:
The motive force from engine (3) passes through The motive force from the output shaft of
the engine flywheel and is transmitted to torque the transmission passes through center drive
converter (2), which is connected to the input shaft shaft (6), front drive shaft (5) and rear drive
of transmission (1). shaft (7), and is then transmitted to front
The transmission has six hydraulically actuated axle (4) and rear axle (8) to drive the wheels.
clutches, and these provide four speed ranges for
FORWARD and three for REVERSE. The trans-
mission speed ranges are selected manually.
10-3
STRUCTURE AND FUNCTION POWER TRAIN
10-4
STRUCTURE AND FUNCTION POWER TRAIN
10-5
STRUCTURE AND FUNKTION TORQUE CONVERTER
10-6
STRUCTURE AND FUNKTION TORQUE CONVERTER
3
1
2 5
270_065a
10-7
STRUCTURE AND FUNKTION TORQUE CONVERTER
TORQUE CONVERTER
10-8
STRUCTURE AND FUNKTION TORQUE CONVERTER
Power flow:
Oil flow:
10-9
STRUCTURE AND FUNKTION TORQUE CONVERTER
TORQUE CONVERTER
PRINCIPLE OF OPERATION
The torque converter operates using the so called The oil re-entering the turbine causes a re-
Trilok system. That means, by higher turbine rpm it action torque. The relationship, turbine torque
operates with the advantages characteristics of a / impeller torque is referred to as the torque
fluid flywheel. The torque converter is designed to conversion. This increases as the rpm dif-
fit the engine power so that there is an optimal ference between the two (impeller and tur-
power transfer. bine) increases. As the output rpm increases
so the transferred torque decreases. The
The torque converter consists of three main parts: torque variation takes place automatically.
Impeller, turbine and stator (reaction part). When the turbine rpm reaches about 80%
of the impeller rpm then the torque conver-
The three parts have ring formed shovels and are sion is 1 : 0 ; that is the turbine torque is the
fitted together so that the oil flows through them in same as the impeller torque.
the order: impeller, turbine, stator. The transmis- The torque converter is now working like a
sion oil pump continually pumps oil through the fluid flywheel.
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 tur-
bine. 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.
engine
To the
gear-box
Condition on taking
up the drive Stator Machine is not moving
Middle position
Drive engaged
10-10
STRUCTURE AND FUNCTION TRANSMISSION
POWERSHIFT TRANSMISSION
The full powershift gearbox is of the layshaft type During a gear change the pressure drops
construction. The gear change is hydraulically op- off and rises again, to complete the gear
erated through multi-disc clutch packs. See fig 1. change, to 16+2 bar.
All gears are in permanent mesh and run on roller The signal for the gear change comes from
bearings. The gears, bearings and clutch packs the fully automatic EST 25.
are lubricated with cooled oil. The four speed re- The solenoid valve (M6) (expansion valve)
versing gearbox has six clutch packs. The required is always energised and is de-energised for
gear is operated through a clutch pack. An axial a programmed time during gear changing.
movable piston, under hydraulic pressure, com- At the start of a gear change the expansion
presses the clutch pack and so engages the se- valve is kept energised for a short pro-
lected gear. grammed time. During this time the clutch
Pressure springs ensure that the piston is returned pack can be filled at high pressure. After the
to the neutral position when the hydraulic pressure clutch pack is filled the expansion valve is
is released, so releasing the clutch pack. The gear- de energised and the clutch pack picks up
box and clutch pack construction is given in detail the drive with modulated pressure. When
in figs. 1,6 and 7. the drive is taken up the expansion valve is
energised again and the system pressure
TRANSMISSION CONTROL holds the selected gear until a further gear
Gear change control see oil flow scheme fig. 7 and 8. change is made.
The bleeding valve (EV) is provided to keep
Oil for the torque convertor, gearbox lubrication and the area behind the pressure governing
the gear change clutch packs is supplied form a valve full with oil.
pump. The pump is mounted in the gearbox and is When changing down from 2nd to 1st gear
driven directly from the engine. a hydraulic overlap is allowed so that the
Pump capacity : Q = 52 l/min, at 2000 engine rpm. 2nd clutch pack is still engaged even though
The pump takes oil from the transmission sump 1st gear is being engaged. The spring accu-
through a course filter. The oil is then delivered mulator in the forward clutch pack (KV) cir-
under pressure, through an externally mounted fine cuit holds the forward clutch pack with 10
filter, to the max. pressure control valve (SDV). Oil bar hydraulic pressure so that traction is
under pressure is now available in the pressure maintained during gear changing.
governing valve (DSV), and at the solenoid valves
1, 2, 3, 4 and 5 for the clutch packs. The pressure The servo pressure for moving the gear
governing valve is responsible for the pressure build change valves is reduced to 10 bar with the
up in the clutch packs after each gear change. use of a restrictor. The servo pressure is
controlled with the solenoid valves M1, M2,
M3, M4 and M5.
P. Pressure in bar
t. Time in sec.
p1. Modulation begin
p2. Modulation end
ps. System pressure - modulated
10-11
STRUCTURE AND FUNCTION TRANSMISSION
The oil flows from the heat exchanger into the lu-
brication circuit of the gearbox so that this circuit is
supplied with cooled oil for lubrication.
10-12
STRUCTURE AND FUNCTION TRANSMISSION
1. Drive flange
2. Torque converter
3. Forward clutch pack (KV)
4. 1st clutch pack (K1)
5. Torque converter and
gearbox pump
6. 1st. PTO
7. 2nd clutch pack (K2)
8. 3rd clutch pack (K3)
9. Parking brake (Drum brake)
10. Output front axle
11. Speedo drive (mechanical)
12. Oil sump
13. Output rear axle
14. 4th clutch pack
15. Reveres clutch pack (KR)
16. Idler gear
17. KV-gear
18. K4-gear
10-13
STRUCTURE AND FUNCTION TRANSMISSION
TO FIG. 1
Turbine
drive
Idler gear
10-14
STRUCTURE AND FUNCTION TRANSMISSION
FIG. 2
10-15
STRUCTURE AND FUNCTION TRANSMISSION
FIG. 3
Construction of the main control valve see fig. 5
10-16
STRUCTURE AND FUNCTION TRANSMISSION
FIG. 4
1. Pipe to over lap valve 2nd gear clutch pack Pipe connections from channel plate
2. Breather to the clutch packs:
6. 1st (K1)
Filter separate mounting: 7. Forwards (KV)
3. Connection from filter 8. Reverse (KR)
4. Connection to filter 9. 2nd (K2)
5. PTO 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 TRANSMISSION
10-18
STRUCTURE AND FUNCTION TRANSMISSION
INDUCTIVE SENDER
Adjustment:
Gear
PROXIMITY SWITCH:
To recognise loading of the injection pump.
10-19
STRUCTURE AND FUNCTION TRANSMISSION
10-20
STRUCTURE AND FUNCTION TRANSMISSION
Pressure and temp. check points: 63. Torque converter outlet M14x1.5
51. Torque converter inlet M10x1 (Temp. 100°C, short time 120°C
(Opening press. 8.5 bar) and opening pressure 5 bar)
53. Forwards clutch pack KV M10x1 65. System pressure 16+2 bar M10x1
55. Reverse Clutch pack KR M10x1 66. Pressure reducing valve 10 bar M10x1
56. Clutch pack K1 M10x1
57. Clutch pack K2 M10x1 Volume check points:
58. Clutch pack K3 M10x1 15. Connection to heat exchanger M26x1.5
60. Clutch pack K4 M10x1 16. Connection from heat exchanger M26x1.5
Scheme code G - 4-speed version: Scheme code G - 3-speed version (20 km/h):
l Solenoid energized l Solenoid energized
FORWARD REVERSE NEUTRAL FORWARD REVERSE NEUTRAL
GEAR 1 2 3 4 1 2 3 GEAR 1 2 3 1 2
M1 l l l M1 l l
M2 l l M2 l l
M3 l l l M3 l l
M4 l l l l M4 l l l l l
M5 l M5 l
M6 ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ M6 ¡ ¡ ¡ ¡ ¡ ¡
M7 ¡ M7 ¡
Clutch KV KV KV K4 KR KR KR K3 Clutch KV KV K4 KR KR K3
Clutch K1 K2 K3 K3 K1 K2 K3 Clutch K1 K2 K2 K1 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 TRANSMISSION
10-22
Clutch pressure
Refer also to fig. 6 and 7
Reduced pressure
17. Thermostat valve Modulated pressure
18. Heat changer Torque converter input pressure
Press. drop ≤ 1bar Torque converter output pressure
19. Filter Lubrication
Filtration µm: ß30≥20 ß10≥1.5 Return to sump
Filtration area cm2: 2450
20. Oil pump
p=16+2 bar
Qp=52 l/min-1 at 2000rpm
21. Check valves 0,15bar
STRUCTURE AND FUNCTION
10-23
TRANSMISSION
10-23
STRUCTURE AND FUNCTION TRANSMISSION
STRUCTURE AND FUNCTION TRANSMISSION
10-25
STRUCTURE AND FUNCTION TRANSMISSION
THERMOSTAT VALVE
Opening temperature: 87 ± 2 °C
Completely open: 102 °C
1. End screw
2. seal ring
3. Pin
4. Spring plate
5. Wax element
6. Pressure spring
7. Thermostat housing
8. Valve body
9. Sensor torque converter oil temperature
Up to SN WA270H20563
9
SN WA270H20564 and up
7 9
270_063a
10-26
STRUCTURE AND FUNCTION REVERSE TRANSMISSION 4WG-160
GEAR PATTERN
10-27
STRUCTURE AND FUNCTION REVERSE TRANSMISSION 4WG-160
1. Lifting lugs
2. Input flange - input through universal shaft
3. Transmission suspension threads M20
4. Output flange - converter side
5. Oil drain plug with magnetic insert M38x1,5
6. Model identification plate
7. 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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