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Home / Wheel Loaders / Komatsu Wheel Loaders / Komatsu WA100-3

Komatsu WA100-3 Troubleshooting

The Komatsu WA100-3 wheel loader driveline system components: 238 cu.in (3.9L) Komatsu S4D102 4-cylinder turbocharged water-cooled diesel engine with a rated power of 82 hp (62 kW), and hydrostatic transmission. The hydraulic system has a pump with a rated capacity of 19.8 gal/min (75 l/min). The system relief pressure is 3480 psi (240 bar). The Komatsu WA100-3 is equipped with a hydraulic power steering, hydraulic wet disc brakes, and 16.9x24 tires. The wheel loader has a maximum lift height of 140.4" (3565 mm) and breakout force of 14520 lbs (6600 kg). The rated operating capacity is 6180 lbs (2810 kg), and tipping load is 12360 lbs (5620 kg).

Engine Troubleshooting

Engine difficult to start or doesn't start
Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter plugging - Service the filter.
Fuel injection nozzles are faulty or clogged - Install a new kit of correctly balanced nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
The valve clearance is not adjusted - Adjust to proper valve clearance.
Fuel injection pump is faulty - Install a new fuel pump or repair.

Engine starts but then stops
Air filter is plugged - Install new air filter element.
Clogged fuel filter - Change or clean the filter element.
Fuel injection pump is leaking - Repair any leaks.
Dirty or defective injectors - Clean fuel injectors or change it.
Fuel injection pump malfunction - Install a new fuel pump or repair.

Engine stops suddenly during operation
Engine is not preheated - Warm up engine as required.
Dirty fuel filter - Replace the filter element.
Air in fuel tank - Bleed fuel tank.
Fuel injection nozzles are faulty or clogged - If necessary, replace with a new nozzle.
Wrong setting of fuel injection pump timing - Adjust fuel injection pump as required.

Engine stalls at low idle speed
Incorrect low idle speed adjustment - Adjustment required.
Fuel injection pump is broken - Repair or install a new fuel pump.
Fuel injectors are faulty or clogged - Replace or clean fuel injectors.
The valve clearance is not adjusted - Check and adjust as required.

Lack of engine power
Dirty air cleaner - Clean or replace air cleaner element.
Damaged or dirty injection nozzles - Check and replace nozzles if required.
Incorrect fuel injection pressure - Adjust to correct pressure.
Valve clearance is not correct - Have it adjusted.
Low idle speed adjustment is incorrect - Adjust as required.
Restricted fuel lines or hoses - Clean fuel system hoses and lines.
Leaking cylinder head gasket - Change cylinder head gasket.
Piston rings are broken or leaking - Replace piston rings.

Engine overheated
Insufficient coolant fluid - Add coolant fluid to cooling system and also check it for leaks.
Engine oil level is low - Fill up the oil to required level.
Dirty radiator core or defective radiator cap - Install new cap or clean radiator.
Loose or damaged fan belt - Replace as required.
Diesel engine overloaded - Load reducing required.

Oil pressure is insufficient
Not enough oil in the engine - Check and refill the oil.
Oil filter clogging - Replace or clean engine oil filter element.
Wrong oil viscosity - Use proper viscosity oil.
Excessive main bearing oil clearance - Bearings need to be reinstalled.
Worn oil pump - Install a new pump.

Engine noises or knocks
Engine oil insufficient - Fill up the engine oil.
Engine is not fully warmed up - Warm up to required temperature.
Improper setting of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.
Incorrect low idle speed adjustment - Adjustment required.
Dirty or defective injectors - Replace fuel injectors.
Connecting rod is worn or misaligned - Connecting rod needs to be replaced or aligned.
Piston wear or scoring - Replace the pistons.

Hydrostatic Transmission Troubleshooting

Hydrostatic transmission makes noise
Transmission oil is contaminated or oil level is insufficient - Fill to required level or change the transmission oil.
Worn or out of adjustment speed control linkage - Adjust or repair linkage.
Relief valve is damaged - Replace relief valve as required.
Excessive loading - Reduce transmission load.
Defective or worn transmission parts - Replace or repair defective components.

Power is insufficient
Transmission fluid insufficient - Add fluid to the transmission housing.
Relief valve malfunction - Replace the valve.
Worn or out of adjustment speed control linkage - Adjust or change linkage.

Transmission overheats
Insufficient transmission oil - Check and refill the transmission oil.
Clogged transmission oil filter element - Service or change transmission oil filter.
Cooling components are clogged or damaged - Inspect all cooling components and service or replace if necessary.
Transmission overload - The load should be reduced.

Transmission fluid leaks
Broken seals or gaskets - Install new gaskets or seal.
Internal transmission housing pressure is too high - Check transmission parts for damage or wear and replace if required.
Plugged oil return tube - Clean or replace return tube.

Hydraulics Troubleshooting

Hydraulic system overheating
Hydraulic pressure is incorrect - Adjust pressure correctly.
Defective or misadjusted main relief valve - Set up or change the relief valve.
Dirty hydraulic oil - Fill up with fresh hydraulic oil.
Not enough hydraulic oil in the system - Fill the hydraulic system with oil.
Hydraulic pump is worn - Install new pump or repair it.

Boom won't lower or raise
Lift controls are faulty - Inspect and repair if necessary.
Hydraulic pump malfunction - Repair or change pump if required.
Hydraulic control valve failure - Repair or change the valve.
Defective hydraulic cylinder - Repair or replace hydraulic cylinder.
Insufficient hydraulic oil - Need to add oil.

Bucket can't tilt
Defective bucket controls - Repair or replace.
Hydraulic pump not working - Install new pump or repair it.
Hydraulic control valve failure - Install a new hydraulic valve or repair it.
Hydraulic bucket cylinder is defective - Replace or repair cylinder.
Hydraulic fluid is insufficient - Add fluid as required.

Bucket or lift arm functions slowly
Faulty hydraulic oil pump - Check pump performance and change it if necessary.
Leaking hydraulic cylinder - Change cylinder piston seals.
Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.
Faulty or incorrect setting hydraulic control valve - Adjust properly or repair.
Low hydraulic pressure - Adjust pressure correctly.

Lift arm or bucket movements are jerky
Air in the hydraulic system - Bleed air from hydraulic system.
Hydraulic oil filter is clogged - Replace or clean the filter.
Contaminated hydraulic oil - The oil must be changed.
Cylinder rod or tube is scratched - Replace defective component.

Excessive hydraulic pump noise
Hydraulic leakage or lack of oil - Correct hydraulic leaks or top up oil as needed.
Plugged hydraulic filter - Clean or install new filter.
Plugged suction line - Service the suction line.
Pump is sucking air - Need to bleed air.
Worn pump components - Replace or rebuild the pump.

Electrical Troubleshooting

Battery is not charging
Corroded or loose wire connections - Tighten or clean electrical wiring connections.
Defective electrical terminal connectors - Terminal connectors should be replaced.
Battery failing - Battery change required.
Defective or loose belt - Adjust belt tension or replace belt.

Starter cranks slow
Low battery output voltage - Battery needs to be recharged.
Battery drains quickly - Battery needs service or replacement.
Disconnected wiring or bad battery terminals - Check wiring connections and replace or clean terminals.

Starter motor won't turn
Battery is low or faulty - Recharge or change battery.
Battery wires are disconnected or incorrectly connected - Check wires and connect correctly.
Battery power is low - Battery is drained, charge it.
Starter motor is damaged - Repair or change starter.

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WHEEL LOADERS SPECIFICATIONS

Caterpillar