Komatsu WA270-3H Manual

WA270-3H
VEAM340200
Operation & Maintenance
Manual
NOTICE
Komatsu has had the operating and maintenance
instructions translated into all the languages of the
member states in the European Union. Should you
wish to have a version of the operating instructions
in another language, please don’t hesitate to ask at
your local dealer’s.
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this machine.
This manual should be kept near the machine for
reference and periodically reviewed by all personnel who
will come into contact with it.
WARNING
WHEEL LOADER
SERIAL NUMBERS WA270H20564 and up

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Contents
Contents
INFORMATION ON THESE OPERATING INSTRUCTIONS........................0-9
WHY YOU SHOULD READ THESE OPERATING INSTRUCTIONS .......................................... 0-11
THE WA 270-3 - YOUR ECONOMIC MIRACLE.......................................................................... 0-12
THE REMARKABLE ERGONOMICS OF THE WA 270-3 ................................................................ 0-12
TECHNOLOGY WHICH INSPIRES ................................................................................................. 0-12
NOTES ON SAFETY REGULATIONS ......................................................................................... 0-14
CORRECT USE ............................................................................................................................... 0-14
SAFETY NOTES IN THE OPERATING INSTRUCTIONS ................................................................ 0-14
STANDARDS AND GUIDELINES ..................................................................................................... 0-15
CE-CONFORMING EQUIPMENT ............................................................................................... 0-17
CE-CONFORMING EQUIPMENT OF THE MANUFACTURER ACCORDING TO DOCUMENT 419-93-
H1160 ............................................................................................................................................... 0-18
LOADING AND TRANSPORTING THE MACHINE ...................................0-21
LOADING AND TRANSPORTING THE MACHINE ..................................................................... 0-23
SECURING THE ARTICULATED STEERING................................................................................... 0-23
LIFTING THE MACHINE .................................................................................................................. 0-23
DRIVING MACHINE ONTO LOADING AREA OF TRANSPORT VEHICLE ...................................... 0-24
SECURING THE MACHINE DURING TRANSPORT ....................................................................... 0-25
AFTER TRANSPORT....................................................................................................................... 0-25
DIMENSIONS, WEIGHTS, AND OPERATING VALUES ............................................................. 0-26
MACHINE RATINGS .................................................................................................................... 0-27
SAFETY .......................................................................................................1-1
SAFETY INSTRUCTIONS ................................................................................................................. 1-2
SAFETY DEVICES............................................................................................................................. 1-2
EMERGENCY EXIT ........................................................................................................................... 1-2
CLOTHING AND PERSONAL PROTECTION .................................................................................... 1-2
MACHINE MODIFICATIONS .............................................................................................................. 1-3
BEFORE YOU LEAVE THE DRIVER'S SEAT ..................................................................................... 1-3
MOUNTING AND DISMOUNTING ..................................................................................................... 1-3
FIRE PREVENTION AND FIRE FIGHTING........................................................................................ 1-4
PROTECTION AGAINST ASBESTOS DUST ..................................................................................... 1-5
PROTECTION AGAINST INJURIES .................................................................................................. 1-5
WORKING AT HIGH TEMPERATURES.............................................................................................. 1-5
ROLL-OVER PROTECTION SYSTEM (ROPS) ................................................................................. 1-6
ATTACHMENT FOR PROTECTION AGAINST FALLING OBJECTS (FOPS) ................................... 1-6
ATTACHMENTS ................................................................................................................................. 1-6
BATTERY ........................................................................................................................................... 1-7
BEFORE YOU START THE ENGINE ............................................................................................ 1-8
WORKPLACE SAFETY ..................................................................................................................... 1-8
IN THE DRIVER'S CAB ...................................................................................................................... 1-8
IN-DOOR OPERATION ...................................................................................................................... 1-9
GAS, DUST, AND INFLAMMABLE VAPOURS ................................................................................... 1-9
MIRRORS, WINDOWS AND LIGHTING ............................................................................................ 1-9
MACHINE OPERATION ............................................................................................................... 1-10
BEFORE YOU START THE ENGINE ............................................................................................... 1-10
REVERSING .................................................................................................................................... 1-10

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Contents
DRIVING ........................................................................................................................................... 1-11
DRIVING ON SLOPES...................................................................................................................... 1-11
EMERGENCY LOWERING SYSTEM .............................................................................................. 1-12
WORKING CLOSE TO OVERHEAD POWER TRANSMISSION LINES .......................................... 1-13
LOADING ......................................................................................................................................... 1-13
GOOD VISION ................................................................................................................................. 1-14
WORKING ON SNOW ..................................................................................................................... 1-14
HEIGHT LIMITATION........................................................................................................................ 1-14
BRAKES ........................................................................................................................................... 1-14
WORKING ON LOOSE SOIL ........................................................................................................... 1-15
PARKING THE MACHINE ................................................................................................................ 1-15
TRANSPORT ............................................................................................................................... 1-16
LOADING AND UNLOADING THE MACHINE.................................................................................. 1-16
TRANSPORT ................................................................................................................................... 1-16
SAFETY MEASURES DURING MAINTENANCE ....................................................................... 1-17
PERSONNEL ................................................................................................................................... 1-17
PRIOR TO START OF MAINTENANCE MEASURES ...................................................................... 1-17
DURING MAINTENANCE ................................................................................................................ 1-20
TYRES ............................................................................................................................................. 1-24
SAFETY LABELS ........................................................................................................................ 1-25
POSITIONS OF SAFETY LABELS................................................................................................... 1-25
OPERATING AND
CONTROL ELEMENTS ...............................................................................2-1
GENERAL VIEW OF THE MACHINE................................................................................................. 2-2
OPERATING AND CONTROL ELEMENTS ........................................................................................ 2-3
GENERAL VIEW ........................................................................................................................... 2-3
MAIN CONTROL PANEL............................................................................................................... 2-3
MAINTENANCE CONTROL PANEL.............................................................................................. 2-3
OPERATING AND CONTROL ELEMENTS ........................................................................................ 2-4
GENERAL VIEW WITH MULTIFUNCTIONAL LEVER, IF INSTALLED ......................................... 2-4
MAIN CONTROL PANEL............................................................................................................... 2-4
MAINTENANCE CONTROL PANEL.............................................................................................. 2-4
CONTROL PANELS ........................................................................................................................... 2-5
WARNING INDICATORS (B AND E).............................................................................................. 2-6
CONTROL AND MEASUREMENT INDICATORS (A, C AND D) .................................................... 2-6
WARNING LIGHT AND INDICATOR FOR EMERGENCY-STEERING (F) ..................................... 2-6
CHECKING THE CONTROL SYSTEM ......................................................................................... 2-6
WARNING INDICATORS .................................................................................................................... 2-7
1. CENTRAL CONTROL LIGHT (CHECK) ................................................................................ 2-7
2. CENTRAL WARNING LIGHT (CAUTION) ............................................................................. 2-8
3. WARNING LIGHT FOR ENGINE COOLANT LEVEL ............................................................. 2-8
4. WARNING LIGHT FOR ENGINE OIL LEVEL ........................................................................ 2-9
5. WARNING LIGHT FOR BRAKE STORAGE- PRESSURE ..................................................... 2-9
6. WARNING LIGHT FOR ENGINE OIL PRESSURE ................................................................ 2-9
7. WARNING LIGHT FOR CHARGING CURRENT ................................................................. 2-10
8. WARNING LIGHT FOR AIR FILTER ..................................................................................... 2-10
9. WARNING LIGHT FOR THE TRANSMISSION GEAR-SHIFT PRESSURE ......................... 2-10
CONTROL AND MEASURING INSTRUMENTS ............................................................................... 2-11
1. CONTROL LIGHT FOR DIRECTION INDICATOR ................................................................ 2-11
2. CONTROL LIGHT FOR HIGH-BEAM HEADLIGHTS............................................................ 2-11
3. CONTROL LIGHT FOR PREHEATER ................................................................................. 2-12
4. CONTROL LIGHT FOR PARKING BRAKE .......................................................................... 2-12
5. SPEEDOMETER.................................................................................................................. 2-12
6. GEAR-SHIFT STATUS INDICATOR ...................................................................................... 2-12
7. FUEL GAUGE ...................................................................................................................... 2-13

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Contents
8. ENGINE COOLANT TEMPERATURE .................................................................................. 2-13
9. TEMPERATURE FOR CONVERTER OIL ............................................................................ 2-13
10. OPERATING HOURS METER ............................................................................................. 2-13
SWITCHES ...................................................................................................................................... 2-14
SWITCHES (WITH MULTIFUNCTIONAL LEVER, IF INSTALLED) .................................................. 2-15
1. START SWITCH................................................................................................................... 2-15
2. TRANSMISSION CUT-OFF SWITCH .................................................................................. 2-16
3. SWITCH FOR FRONT WORKING LIGHTS ........................................................................ 2-16
4. SWITCH FOR REAR WORKING LIGHTS ........................................................................... 2-16
5. LIGHT SWITCH ................................................................................................................... 2-17
6. DIRECTION INDICATOR LEVER ......................................................................................... 2-17
7. LOW-BEAM SWITCH .......................................................................................................... 2-17
8. HORN BUTTON ................................................................................................................... 2-17
9. HAZARD FLASHER SWITCH.............................................................................................. 2-18
10. DRIVING-DIRECTION SWITCH (ONLY WITH INSTALLED MULTIFUNCTIONAL CONTROL
LEVER) ....................................................................................................................................... 2-18
11. KICKDOWN SWITCH .......................................................................................................... 2-18
12. GEAR-SHIFT LOCK (2) (ONLY IF THE MULTI-FUNCTION LEVER IS INSTALLED) ........... 2-19
13. FRONT WINDSCREEN WASHER/WIPER SWITCH........................................................... 2-19
14. REAR WINDSCREEN WASHER/WIPER SWITCH ............................................................. 2-20
15. CIGARETTE LIGHTER ........................................................................................................ 2-20
16. SWITCH FOR INTERIOR LIGHTING .................................................................................. 2-20
17. BATTERY MAIN SWITCH .................................................................................................... 2-20
CONTROL LEVERS, PEDALS......................................................................................................... 2-21
CONTROL LEVERS, PEDALS (WITH MULTIFUNCTIONAL LEVER, IF INSTALLED) ..................... 2-21
1. CONTROL LEVER ............................................................................................................... 2-22
ADJUSTING THE LENGTH OF THE GEAR-SHIFT LEVER ....................................................... 2-22
2. DRIVING DIRECTION LEVER ............................................................................................. 2-22
3. SWITCH LEVER LIMIT-STOP.............................................................................................. 2-22
4. LOCKING LEVER FOR THE WORK HYDRAULIC SYSTEM .............................................. 2-23
5. CONTROL LEVER FOR THE WORK HYDRAULIC SYSTEM ............................................. 2-24
6. MULTIFUNCTIONAL LEVER FOR THE WORK HYDRAULIC SYSTEM.............................. 2-25
7. CONTROL LEVER FOR SPECIAL EQUIPMENT ................................................................ 2-25
ADJUSTING THE ARMREST ...................................................................................................... 2-25
8. BRAKE PEDAL .................................................................................................................... 2-26
9. ACCELERATOR ................................................................................................................... 2-26
10. PARKING BRAKE................................................................................................................. 2-27
STEERING COLUMN ADJUSTMENT .............................................................................................. 2-27
TRACTION DEVICE......................................................................................................................... 2-28
ARTICULATED STEERING CATCH ................................................................................................. 2-28
REVERSING ALARM HORN ............................................................................................................ 2-28
FUSES ............................................................................................................................................. 2-29
FUSE ASSIGNMENT .................................................................................................................. 2-29
SLOW-BLOW FUSES ...................................................................................................................... 2-30
RELAYS ............................................................................................................................................ 2-30
HEATING AND VENTILATION SYSTEM .......................................................................................... 2-31
AIR-CONDITIONING........................................................................................................................ 2-32
OPERATION...............................................................................................2-33
RUNNING IN THE MACHINE ...................................................................................................... 2-34
INSPECTIONS PRIOR TO STARTING............................................................................................. 2-35
VISUAL INSPECTIONS (SEE ALSO SECTION "MAINTENANCE PRIOR TO STARTING") ....... 2-35
ADJUSTMENTS PRIOR TO START-UP ........................................................................................... 2-37
ADJUSTING THE DRIVER'S SEAT (WITHOUT PNEUMATIC SUSPENSION) ........................... 2-37
ADJUSTING THE DRIVER'S SEAT (WITH PNEUMATIC SUSPENSION) .................................. 2-38
FASTENING THE SEAT BELT ..................................................................................................... 2-39
ADJUSTING THE REAR-VIEW MIRROR ................................................................................... 2-39

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Contents
ADJUSTING THE STEERING COLUMN .................................................................................... 2-39
SWITCHING THE ENGINE ON AND OFF ....................................................................................... 2-40
BEFORE STARTING THE ENGINE............................................................................................. 2-40
STARTING THE ENGINE ............................................................................................................ 2-41
AFTER STARTING THE ENGINE ............................................................................................... 2-42
SWITCHING OFF THE ENGINE................................................................................................. 2-43
AFTER MACHINE OPERATION....................................................................................................... 2-43
DRIVING .......................................................................................................................................... 2-44
START-UP ................................................................................................................................... 2-44
STARTING UP ON HILLS AND SLOPES .................................................................................... 2-45
GEAR SHIFTING ............................................................................................................................. 2-46
GEAR SELECTION ..................................................................................................................... 2-46
AUTOMATIC GEAR-SHIFT ......................................................................................................... 2-46
KICK-DOWN FUNCTION............................................................................................................ 2-46
CHANGING THE DRIVING DIRECTION ......................................................................................... 2-48
STEERING AND TURNING.............................................................................................................. 2-48
STOPPING ....................................................................................................................................... 2-49
PARKING THE MACHINE ON SLOPES ..................................................................................... 2-49
CONTROL LEVERS FOR THE WORK HYDRAULIC SYSTEM ....................................................... 2-50
CONTROL LEVER FOR THE WORK UNIT ................................................................................ 2-50
MULTIFUNCTIONAL LEVER FOR THE WORK HYDRAULIC SYSTEM .......................................... 2-51
CONTROL LEVER FOR SPECIAL EQUIPMENT ....................................................................... 2-51
WORKING WITH THE MACHINE .................................................................................................... 2-52
EXCAVATING ............................................................................................................................... 2-52
LEVELLING................................................................................................................................. 2-54
DOZING ...................................................................................................................................... 2-54
LOADING AND TRANSPORTING ............................................................................................... 2-54
LOADING .................................................................................................................................... 2-55
LOADING IN DIAGONAL DIRECTION ....................................................................................... 2-55
V-SHAPED LOADING ................................................................................................................. 2-55
ADJUSTING THE WORK UNIT ....................................................................................................... 2-56
LIFT LIMIT SWITCH ................................................................................................................... 2-56
BUCKET RETURN MECHANISM ............................................................................................... 2-57
BUCKET LEVEL INDICATOR...................................................................................................... 2-57
PRECAUTIONS FOR SPECIAL OPERATIONS ............................................................................... 2-58
WORKING IN WATER ................................................................................................................. 2-58
IF THE WHEEL BRAKE BREAKS DOWN .................................................................................. 2-58
TURNING ON SLOPES, DAMS OR HILLS ................................................................................. 2-58
BRAKING ON SLOPES .............................................................................................................. 2-58
IF THE ENGINE BREAKS DOWN .............................................................................................. 2-58
TYRES ............................................................................................................................................. 2-59
HOW TO HANDLE TYRES ......................................................................................................... 2-59
TYRE AIR PRESSURE................................................................................................................ 2-59
VISUAL INSPECTION................................................................................................................. 2-59
DRIVING LONGER DISTANCES ................................................................................................ 2-60
TYRES AND TYRE PRESSURES .................................................................................................... 2-60
WINTER OPERATION ..................................................................................................................... 2-62
BEFORE THE COLD SEASON ................................................................................................... 2-62
AFTER OPERATION ................................................................................................................... 2-63
AFTER THE COLD SEASON...................................................................................................... 2-63
LONG-TERM SHUTDOWN ............................................................................................................. 2-64
PRIOR TO SHUTDOWN ............................................................................................................. 2-64
DURING SHUTDOWN ................................................................................................................ 2-64
AFTER THE SHUTDOWN .......................................................................................................... 2-64

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Contents
TROUBLESHOOTING...............................................................................2-65
TROUBLESHOOTING ..................................................................................................................... 2-66
EMERGENCY DRIVING MODE ....................................................................................................... 2-72
STARTING ENGINE WITH JUMPER LEADS................................................................................... 2-73
CONNECTING THE JUMPER LEADS ........................................................................................ 2-73
STARTING THE ENGINE ............................................................................................................ 2-74
DISCONNECTING THE JUMPER LEADS .................................................................................. 2-74
TOWING THE MACHINE ................................................................................................................. 2-74
EMERGENCY STEERING ............................................................................................................... 2-76
CONTROL LIGHTS FOR EMERGENCY STEERING ................................................................. 2-76
EMERGENCY LOWERING SYSTEM .............................................................................................. 2-77
MALFUNKTION OF BRAKE............................................................................................................. 2-78
CHECKING SERVICE BRAKE .................................................................................................... 2-78
CHECKING PARKING BRAKE .................................................................................................... 2-78
MAINTENANCE ...........................................................................................3-1
MAINTENANCE BASICS .............................................................................................................. 3-3
PREPARING THE MACHINE FOR MAINTENANCE ..................................................................... 3-3
OPERATING HOURS METER ...................................................................................................... 3-3
SPARE PARTS............................................................................................................................... 3-3
FLUID FOR THE WASHER SYSTEM ........................................................................................... 3-3
KEEP THE MACHINE CLEAN: ..................................................................................................... 3-4
CAUTION WHEN HANDLING HOT FLUIDS: ............................................................................... 3-4
CHECK DRAINED OIL AND FILTER FOR FOREIGN BODIES: .................................................... 3-4
TOPPING UP FUEL OR OIL; FUEL SIEVE................................................................................... 3-4
CHECKING OIL LEVEL AND OIL-CHANGE: ................................................................................ 3-4
WARNING SIGN ........................................................................................................................... 3-4
WELDING INSTRUCTIONS ......................................................................................................... 3-5
FIRE PREVENTION ...................................................................................................................... 3-5
GASKETS / SEALS ....................................................................................................................... 3-5
OBJECTS IN POCKETS ............................................................................................................... 3-5
CHECKING THE TYRES............................................................................................................... 3-5
PROTECTIVE MEASURES WHEN WASHING THE MACHINE ................................................... 3-6
MUDDY OR WET ENVIRONMENT .............................................................................................. 3-6
DUSTY ENVIRONMENTS ............................................................................................................ 3-6
ENGINE / HYDRAULIC OIL ..........................................................................................................3-7
GREASE ....................................................................................................................................... 3-7
FUEL ............................................................................................................................................. 3-8
BIOLOGICALLY DEGRADABLE HYDRAULIC OILS AND GREASE ............................................. 3-8
STORAGE OF OIL AND FUEL ...................................................................................................... 3-8
COOLANT ..................................................................................................................................... 3-9
FILTERS ........................................................................................................................................ 3-9
WEARING PARTS ......................................................................................................................... 3-9
SPECIFICATIONS OF THE ELECTRICAL SYSTEM................................................................... 3-10
STARTING TORQUES FOR STANDARD NUTS AND BOLTS ...................................................... 3-11
REGULAR REPLACEMENT OF SAFETY-RELATED PARTS ...................................................... 3-12
WEARING PARTS ....................................................................................................................... 3-13
LUBRICANTS AND OPERATING AGENTS ...................................................................................... 3-15
MAINTENANCE SCHEDULE ...................................................................................................... 3-17
MAINTENANCE PRIOR TO STARTING UP ................................................................................ 3-19
COOLING SYSTEM, CHECKING THE COOLANT LEVEL, TOPPING UP COOLANT .................... 3-19
CHECKING ENGINE OIL LEVEL, TOP UP ...................................................................................... 3-20
WATER SEPARATOR, DRAIN WATER AND DIRT DEPOSITS ......................................................... 3-20
FUEL FILTER, DRAIN WATER ......................................................................................................... 3-21
CHECKING DRIVE BELTS ............................................................................................................... 3-21
CHECKING THE FAN AND ITS ATTACHMENT ................................................................................ 3-21

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Contents
CHECKING ELECTRICAL CONNECTIONS .................................................................................... 3-22
CHECKING FUEL LEVEL, TOP UP ................................................................................................. 3-23
CHECKING CONTROL PANELS ..................................................................................................... 3-23
OTHER PRE-START MAINTENANCE MEASURES ........................................................................ 3-24
MAINTENANCE DURING THE RUNNING-IN PERIOD .............................................................. 3-25
AFTER THE FIRST 100 OPERATING HOURS ................................................................................ 3-25
TRANSMISSION, CHANGE OIL AND FILTERS .......................................................................... 3-25
OPERATING BRAKE, CHANGE OIL FILTER .............................................................................. 3-25
AFTER THE FIRST 250 OPERATING HOURS ................................................................................ 3-25
FUEL TANK, DRAIN WATER ....................................................................................................... 3-25
FUEL FILTER, CHANGE CARTRIDGES ..................................................................................... 3-25
HYDRAULIC SYSTEM, CHANGE OIL FILTER INSERTS ........................................................... 3-25
AFTER THE FIRST 500 OPERATING HOURS ................................................................................ 3-25
AXLES, OIL CHANGE................................................................................................................. 3-25
MAINTENANCE EVERY 100 OPERATING HOURS ................................................................... 3-26
HYDRAULIC SYSTEM, CHECKING OIL LEVEL, TOPPING UP OIL ............................................... 3-26
CLEANING THE FRESH-AIR FILTER INSERTS .............................................................................. 3-27
LUBRICATION .................................................................................................................................. 3-27
MAINTENANCE EVERY 250 OPERATING HOURS ................................................................... 3-28
ENGINE, CHANGE OIL AND OIL FILTER CARTRIDGE .................................................................. 3-28
CHECKING THE AIR ASPIRATION SYSTEM ................................................................................... 3-29
AIR-CONDITIONING, CHECK TENSION OF THE COMPRESSOR V-BELT .................................... 3-30
INSPECTION .............................................................................................................................. 3-30
ADJUSTMENT ............................................................................................................................ 3-30
CHANGE ..................................................................................................................................... 3-30
BATTERIES, CHECKING THE ACID LEVEL .................................................................................... 3-31
BATTERY RECHARGING ................................................................................................................ 3-32
AXLES, CHECK OIL LEVELS .......................................................................................................... 3-33
WHEEL NUTS, CHECK, RETIGHTEN ............................................................................................ 3-33
LUBRICATION .................................................................................................................................. 3-34
MAINTENANCE EVERY 500 OPERATING HOURS ................................................................... 3-35
FUEL FILTER, CHANGE FILTER CARTRIDGES ............................................................................. 3-35
BLEEDING THE FUEL SYSTEM ................................................................................................ 3-36
MAINTENANCE EVERY 1000 OPERATING HOURS ................................................................. 3-37
TRANSMISSION, CHANGE OIL AND FILTERS ............................................................................... 3-37
ENGINE, ADJUSTING THE VALVE CLEARANCE ............................................................................ 3-39
SERVICE BRAKE, CHANGE OIL FILTER ........................................................................................ 3-39
DRIVE BELTS, CHECK TENSION PULLEY AND FAN BEARING .................................................... 3-40
TURBOCHARGER, CHECKING THE ATTACHMENT AND PLAY ..................................................... 3-41
CHECKING THE GAS PRESSURE ................................................................................................. 3-41
AXLES, OIL CHANGE ...................................................................................................................... 3-42
LUBRICATION .................................................................................................................................. 3-43
COOLING SYSTEM, EXCHANGING COOLANT AND CLEANING THE SYSTEM .......................... 3-44
DRAINING OFF THE COOLANT ................................................................................................ 3-45
CLEANING THE COOLING SYSTEM ......................................................................................... 3-45
FILLING UP COOLANT .............................................................................................................. 3-45
MAINTENANCE EVERY 2000 OPERATING HOURS ................................................................. 3-46
CHECK SHOCK ABSORBER ........................................................................................................... 3-46
CHECKING THE COOLING SYSTEM ............................................................................................. 3-46
CHECKING AND CLEANING THE TURBOCHARGER .................................................................... 3-47
CHECK THREE-PHASE GENERATOR AND STARTER ................................................................... 3-47
AIR-CONDITIONING, CHANGING THE FILTER INSERTS .............................................................. 3-47
HYDRAULIC SYSTEM, OIL CHANGE, CHANGING THE FILTER INSERT ..................................... 3-48
MAINTENANCE EVERY 4000 OPERATING HOURS ................................................................. 3-50
CHECK WATER PUMP .................................................................................................................... 3-50

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Contents
MAINTENANCE AS REQUIRED ................................................................................................. 3-51
AIR FILTER: INSTALLATION AND REMOVAL OF FILTER ELEMENTS
CLEANING FILTER INSERTS AND CHANGING SAFETY FILTER .................................................. 3-51
AIR FILTER DESIGN ................................................................................................................... 3-51
WHEN IS MAINTENANCE NECESSARY? ................................................................................. 3-51
CLEANING OR EXCHANGING THE FILTER INSERT ................................................................ 3-52
CLEANING WITH COMPRESSED AIR ....................................................................................... 3-52
CLEANING WITH WATER OR DETERGENT ............................................................................. 3-52
CHECKING THE FILTER INSERT............................................................................................... 3-52
CHANGING THE SAFETY FILTER ............................................................................................. 3-53
ASSEMBLING THE AIR FILTER INSERT .................................................................................... 3-53
DUST PRE-EXTRACTOR "TURBO II": CHECK, CLEAN ................................................................. 3-53
CLEANING THE RADIATOR ............................................................................................................ 3-54
WINDSCREEN WASHER, CHECKING FLUID LEVEL,
TOPPING UP ................................................................................................................................... 3-54
TRANSMISSION, CHECKING OIL LEVEL, TOPPING UP OIL ........................................................ 3-55
REPLACING BUCKET TEETH......................................................................................................... 3-56
FUEL TANK, DRAINING WATER AND DIRT DEPOSITS.................................................................. 3-57
TYRES, CHECKING AIR PRESSURE.............................................................................................. 3-57
AIR-CONDITIONING, CLEANING CONDENSER ............................................................................. 3-57
CHECKING AIR-CONDITIONING .................................................................................................... 3-58
CHECKING THE COOLANT LEVEL ........................................................................................... 3-58
TECHNICAL DETAILS ................................................................................4-1
TECHNICAL DETAILS ................................................................................................................... 4-2
NOISE EMISSION LEVELS ............................................................................................................... 4-3
VIBRATION LEVEL ............................................................................................................................ 4-3
LIMIT VALUES FOR SLOPES ............................................................................................................ 4-3
MAXIMUM SLOPE ANGLE FOR OPERATING THE MACHINE .................................................... 4-3
SPECIAL EQUIPMENT,
AUXILIARY EQUIPMENT ............................................................................5-1
ALS - ELECTRONIC .......................................................................................................................... 5-2
STRUCTURE AND FUNCTIONING PRINCIPLE OF THE ALS-ELECTRONICS ................................ 5-2
PRECAUTIONARY MEASURES FOR SWITCHING ON THE ALS-ELECTRONICS.......................... 5-2
OPERATING THE ALS-ELECTRONICS ............................................................................................. 5-3
PRECAUTIONS WHEN HANDLING THE ACCUMULATOR............................................................... 5-3

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Contents

INFORMATION ON THESE
OPERATING INSTRUCTIONS

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Information on these Operating Instructions

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Information on these Operating Instructions
WHY YOU SHOULD READ THESE
OPERATING INSTRUCTIONS
The machine must be operated, cleaned, and maintained very carefully
to ensure safe and troublefree operation. If you operate the machine
correctly, these operating instructions will help you to avoid injuries and
damage to property. To ensure this, these operating instructions take
into account all applicable legal regulations and directives; the operating
instructions comprise the following information:
• Notes on the Operating Instructions
• Notes on Transport
• Notes on Safety Regulations
• Operating Instructions
• Troubleshooting
• Maintenance Instructions
• Technical Data
• Notes on Lubricants and Operating Agents
The operating instructions are part of the machine and must always be
available at hand in the machine. If the operating instructions have been
lost or if they have become unreadable, because they are dirty, you may
receive a new copy from Komatsu or your local Komatsu dealer. If the
machine is resold, the operating instructions, the EU Declaration of
Conformity (CE), and the licence are to be handed over to the new owner.
The owner of the machine has to ensure that
•all persons driving the machine have the legally required
minimum age and are physically and mentally fit to perform the
tasks they are charged with.
•all persons in charge with operating or maintaining the machine
are appropriately instructed before operation or maintenance
is started. They must have completely read and understood
these operating instructions. In particular, this applies to the
following section "Notes on Safety Regulations" and the chapter
"Safety".
•all persons driving the machine have read the accompanying
leaflet "Notes on Operation of Komatsu Construction Mach-
ines in Public Traffic" - applying to operation of construction
machines with a maximum speed of 20 km/h on German public
roads.
• the machine is correctly operated.
•the machine is not improperly modified.
Please note:
If the owner modifies safety-related parts of the machine, the certificate
of conformity of the manufacturer will lapse and the person who has
performed the modification has to issue a new certificate. Should you
have any questions concerning this point, please do not hesitate to ask
Komatsu.
Our continuous effort to improve the machine's design may lead to
changes of machine details. However, the introduction of these
improvements does not oblige us to perform them on machines which
have already been delivered and are already in use.

0-12
Information on these Operating Instructions
If these improvements result in minor changes, these minor changes will
not be described in the operating instructions. Should you require new
available information about your machine or have any questions
concerning the information given in the operating instructions, please do
not hesitate to contact either Komatsu or your responsible Komatsu dealer.
These operating instructions may refer to attachments and special
equipment not available from your local Komatsu dealer. Should you
require attachments or special equipment, ask your responsible Komatsu
dealer.
THE WA 270-3 - YOUR ECONOMIC MIRACLE
The WA 270-3 is a wheel loader with ideal features for a completely
rounded off application.
The fast, two-stage work hydraulic system and the first-rate acceleration
of the turbo diesel-engine permit short cycle times, thus increasing
productivity. At the same time, the WA 270-3’s small fuel consumption
turns it into an economical wheel loader with excellent fuel efficiency.
THE REMARKABLE ERGONOMICS OF THE WA 270-3
The cab is connected to the chassis via a hydraulic bearing. The
transmission is suspended floating on rubber bumpers; important tubes
and clamps are also mounted on rubber. These measures considerably
reduce the vibrations which can be perceived in the cab. Also the noise
level on the ear of the driver is brought down to 74 decibels (A). The
Automatic Load Stabilising electronics (ALS) is available as a special
accessory, helping to reduce oscillations and vibrations starting from
speeds above 5 k.p.h., thus protecting driver and machine.
The monitoring system is arranged centrally and consists of the main
and the maintenance control panel. Around the monitoring system, the
operating elements are positioned in such a way that you have free sight
onto the monitoring system during all operations. The steering wheel
and the gearshift lever only require small effort for operation so that they
both can be used at the same time. Together with the work unit, you can
operate the KICK-DOWN switch which is integrated into the working lever.
The control panel and the steering column are encased. The result is a
clearly arranged foot compartment without sharp edges and recesses,
contributing to the high standard of driving conveniences.
The rear cabin tie-bar is mounted very deep on the cab wall, thus ensuring
excellent visual conditions also to the back.
TECHNOLOGY WHICH INSPIRES
The wheel loader WA 270-3 has a dumping height of 2940 mm and a top
dumping angle of 53.5°. These features allow it to load almost every
dump truck. The lifting limit of the boom, which you can use to pre-select
the desired lifting height, additional reduces the cycle time. The bevelled
rear permits to drive into the material, which you want to pile up, right up
to the rear wheels of the machine.

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The fully hydraulic oil-bath brakes cannot freeze and require no longer
any draining of the brakes. The service life of the brakes increases
considerably. A drum brake is used as parking brake.
The WA 270-3 is provided with novelties which are helping to reduce
clearly the time needed for maintenance. EDIMOS II, the electronic defect
diagnosis system, and the centrally arranged lubricating points make
maintenance. much easier for you. The integrated mudguard engine-
shutter units permit easy access to all maintenance locations.
AND WHAT ABOUT ENVIRONMENTAL CARE?
The low-exhaust engine of the WA 270-3 fulfills the EU standard planned
for 1998. The air-conditioning (special equipment) is filled with R134a, a
non-polluting refrigerant.

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NOTES ON SAFETY REGULATIONS
The procedures and precautionary measures concerning operation and
maintenance only apply on the provision that the machine is used as
intended.
CORRECT USE
A loader is a machine which has its own drive and which is moving on
either tracks or wheels. By moving in forward direction, a loader can load
material or cut the ground with the work unit (use of bucket) provided for
loading which is attached to its front.
The standard working cycle of a loader comprises filling and lifting the
loading bucket, transporting material, and emptying the loading bucket.
If you use the machine for any other purpose than specified above, we
will not accept any responsibility for safety. All considerations concerning
safety will then be up to the owner or the operating and maintenance
personnel. In any case, neither you nor any other person are/is authorised
to perform work and functions explicitly prohibited in these operating
instructions.
SAFETY NOTES IN THE OPERATING INSTRUCTIONS
Most accidents are caused by disregard of basic safety regulations during
operation and maintenance of machines. In order to avoid accidents and
thus damage to persons and property, read all applicable safety notes
and warnings in these operating instructions and on the machine, before
you start operation or maintenance of the machine and always adhere to
these safety notes and warnings.
The chapter "Safety" starting on page 1-1 contains a summary of all
safety notes applying to this machine. We cannot, however, predict all
circumstances resulting in potentially dangerous situations when operating
and maintaining the machine. For this reason, it may be possible that the
safety notes in these operating instructions and on the machine do not
comprise all possible safety measures. If procedures or measures are
required which are not recommended or approved, you must ensure that
performing them is neither dangerous nor involving potential damage to
the machine. Should you have any doubt concerning safety of a procedure,
either directly contact Komatsu or your responsible Komatsu dealer.
The following signal words are used to indicate safet notes in these
operating instructions and on the labels attached to the machine:
DANGER This word is used in the safety notes and on
safety labels in situations or places where severe
injuries cannot be ruled out, if the danger is not
avoided. The safety notes or labels contain
precautionary measures which must be heeded
to avoid this danger.

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Information on these Operating Instructions
WARNING This word is used in the safety notes and on safety
labels, if there is a potentially dangerous situation
which may lead to severe injury, if the danger is not
avoided. The safety notes or labels contain
precautionary measures that must be realised to avoid
this danger.
CAUTION This word is used in the safety notes and on safety
labels in dangerous situations which may lead to
minor injury, if the danger is not avoided. It may also
refer to dangers which may lead to damage of the
machine.
NOTE This word is used for precautionary measures which
must be realised to exclude processes which would
shorten the service life of the machine.
IMPORTANT
This word is used for important additional information.
STANDARDS AND GUIDELINES
This machine is labelled with the CE mark indicating that it meets all
basic requirements concerning safety and protection of health of the EU
Machinery Directive 89/392/EEC, its supplements 91/368 EEC and
93/44 EEC for Europe, and the regulation 95/27/EEC. In addition, the
harmonised European standards EN 292-2 and EN 474/1 of 1994, and
EN 474-3 of 1996 were applied for manufacture of the machine. This
fact is documented in the EU Declaration of Conformity (CE) which is
supplied together with the machine.
This means that in those cases in which the machine is modified in such
a way that safety of the machine is affected, the person responsible for
safety of the machine is the one who has arranged for the machine to be
modified. If you use the machine for any other purpose than that defined
as correct use, you are the person who has to ensure that safety is
maintained. Modifications of the machine or use of the machine for any
other purpose than that specified as correct use may require a new CE
mark and thus new issuing of an EU Declaration of Conformity.
If a machine is used in other countries than Germany, it may be possible
that special national safety devices and specifications are missing which
may be required for the application in the relevant country. For example,
for Komatsu-Hanomag machines, the manufacturer has to design the
cab roof in such a way that a warning beacon can be attached to the
roof. However, when driving the machine on roads, this warning beacon
must be covered.
Should you have any questions concerning standards and guidelines in
the respective country the machine is to be used in, please ask your
Komatsu dealer before you start commissioning the machine.
In addition to the operating instructions, you must also adhere to all legal
regulations on public traffic and all applicable regulations on prevention
of accidents. A corresponding leaflet "Notes on Operation of Komatsu
Construction Machines in Public Traffic" - applying to operation of
construction machines with a maximum speed of 20 km/h on German
public roads - has been handed over to the dealer together with the
machine papers.

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The expert inspection for earthmoving machines has to be performed
according to VBG 40 § 50 (VBG: German Administrative Professional
Association). The requirements for this expert inspection are defined in
the paragraphs 1 to 3 as follows:
1) Prior to first commissioning and after major modifications, earthmoving
machines must be inspected by an expert before they are put into
service again.
2) Earthmoving machines must be inspected by an expert at least once
every year. Moreover and depending on the respective operating and
local conditions, they must additionally be inspected by an expert,
when required.
3) The inspection results must be recorded in writing and stored at least
until the next inspection is due.
NOTES ON LATER INSTALLATION OF ELECTRICAL AND
ELECTRONICAL DEVICES AND COMPONENTS
Electrical or electronical devices and/or components installed later emit
electromagnetic radiation which may influence the proper function of
electronic components and parts of the machine. This may impair safety
of the machine and endanger persons. For this reason, strictly adhere to
the following safety notes.
If you later install electrical and electronical devices and/or components
in the machine and connect them to the vehicle electrical system, you
are responsible for any malfunctions of the vehicle electronics or other
components resulting from this installation. Above all, check that all
electrical and electronical components which you install later comply with
the valid version of the EMC directive 89/336/EEC and that they are
labelled with the CE mark.
The following requirements must additionally be met for a later installation
of mobile communication systems (e.g. radio, telephone):
• Only install devices which have a licence referring to valid national
regulations (e.g. BZT-licence in Germany).
• The device must be stationary.
• Only use portable or mobile devices in the cab, if they are connected
to a stationary external aerial.
• Install the sender in such a way that it is physically separated from the
vehicle electronics.
• When installing the aerial, make sure that it is installed correctly with
a good chassis earth connection between the aerial and the chassis
of the vehicle.
In addition, adhere to all information about installation and connection of
cables and maximum power input indicated in the manufacturer's
installation instructions of the machine.

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CE-CONFORMING EQUIPMENT
CE-conforming equipment
WA 270-3H
1 2 3 4 5 --
Type Part No. Volume
m³Load capacity kg
Hydraulic
pressure
bar
Weight
kg
Bucket WA270-3H
42Y-70-H2720 2 - - 870
42Y-70-H2730 2 - - 910
42Y-70-H2640 2,1 - - 880
42Y-70-H2650 2,1 - - 920
42Y-70-H2660 2,2 - - 1000
42Y-70-H2741 2,4 - - 988
42Y-70-H2671 2,4 - - 960
42Y-70-H2681 2,4 - - 1000
42Y-71-H2A51 2,4 - -
42Y-71-H2B21 2,4 - -
42Y-71-H2B41 2,5 - -
I:\dtp\BA270GB\270_ALU\270_ALUPM\CE-270.TBL

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CE-CONFORMING EQUIPMENT OF THE
MANUFACTURER ACCORDING TO DOCUMENT
419-93-H1160
U:\DTP\ZEICHNUN\l\CEAUS.WMF