____________________________________________________________________________________

Home / Wheel Loaders / Komatsu Wheel Loaders / Komatsu WA100M-6

Komatsu WA100M-6 Troubleshooting

The Komatsu WA100M-6 wheel loader is powered by Komatsu SAA4D95LE-5 4-cylinder turbocharged diesel engine with a rated power of 88.5 hp (66 kW) at 2350 rpm. The Komatsu WA100M-6 is equipped with a two-range hydrostatic transmission, power steering system, hydraulic wet disc brakes, and 455/70R20 standard tires. The hydraulic system has a pump with fluid flow rate of 19.8 gpm (75 lpm). The hydraulic pressure is 3915 psi (270 bar). The wheel loader has a rated operating capacity of 6470 lbs (2940 kg) and tipping load of 12940 lbs (5880 kg). The max lift height is 139.4 inches (3540 mm) to hinge pin, and boom breakout force is 16700 lbs (7590 kg).

Engine Troubleshooting

Engine difficult to start or will not start
Air in fuel system - Bleed fuel system.
Fuel filter element is clogged - Change the filter element.
Fuel injection nozzles are damaged - Change fuel injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is wrong - Correct valve clearance needs to be set.
Fuel injection pump is broken - Replace or rebuild injection pump.

Diesel starts but immediately stops
Air filter is dirty - Clean or replace element.
Dirty fuel filter - Change filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Fuel injectors are dirty or defective - Replace or clean fuel injectors.
Fuel injection pump failure - Rebuild or replace pump.

Engine shuts off suddenly during operation
Coolant temperature is low - Warm up to required temperature.
Fuel filter element is dirty - Service or replace the filter.
Air in fuel tank - Bleed fuel tank.
Fuel injection nozzles are damaged or dirty - Check and replace nozzles if required.
Fuel injection pump timing is wrong - Set up as recommended.

Engine stalls at low idle speed
Low idle speed setting is not correct - Adjust low idling as recommended.
Damaged fuel injection pump - Replace or repair injection pump.
Defective fuel injectors - Change or clean fuel injectors.
The valve clearance is incorrect - Correct valve clearance needs to be set.

Engine lacks power
Air filter is clogged - Change or service air filter element.
Fuel injection nozzles are damaged - Clean or replace injection nozzles.
Incorrect fuel injection pressure - Test fuel injection pressure and adjust it correctly.
Valve clearance is out of adjustment - Adjustment procedure required.
Low idle speed setting is not correct - Adjust low idling as recommended.
Fuel hoses or lines are dirty - Clean fuel lines and hoses.
Cylinder head gasket defective - Install new cylinder head gasket.
Worn or broken piston rings - Change piston rings.

Engine overheated
Low coolant level - Refill to the correct level and inspect system for leaks.
Low engine oil level - Check oil level and add oil as required.
Damaged radiator cap or dirty radiator core - Clean radiator or install new cap.
Damaged or worn fan belt - Replace the fan belt.
Engine is under excessive load - Reduce engine load.

Oil pressure is insufficient
Engine oil insufficient - Checking oil level and add if necessary.
Clogged oil filter - Clean or change engine oil filter.
Incorrect engine oil Fill up with the correct oil viscosity.
Excessive main bearing oil clearance - Install new bearings.
Worn oil pump - Remove and inspect oil pump.

Engine knocks or noises
Low engine oil level - Fill up the engine oil.
Engine is cold - Normalize the temperature by warming up the engine.
Timing of fuel injection pump is incorrect - Adjust according to specifications.
Improperly adjusted low idle speed - Need to adjust idle speed.
Fuel injector fault - Replace fuel injectors.
Connecting rod is defective or not aligned - Align or replace connecting rod.
Broken or worn pistons - Have pistons replaced.

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.
Speed control linkage is defective or unadjusted - Adjust or change linkage.
Relief valve is damaged - Install a new valve.
Transmission overloaded - The load should be reduced.
Worn or defective parts of the hydrostatic transmission - Replace or repair defective components.

Power is too low
Insufficient transmission fluid - Checking transmission fluid level and add if necessary.
Relief valve failure - Change the valve.
Worn or out of adjustment speed control linkage - Adjust or change linkage.

Transmission oil over heats
Transmission fluid insufficient - Add fluid to the transmission housing.
Dirty transmission oil filter element - Clean or change transmission oil filter.
Cooling components are defective or plugged - Inspect all cooling components and service or replace if necessary.
Transmission overloaded - Reduce transmission load.

Transmission fluid leaking
Damaged gaskets or seals - Seals and gaskets replacement required.
Internal transmission housing pressure is too high - Replace worn components.
Oil drain pipe is plugged - Check pipe and service if necessary.

Hydraulics Troubleshooting

Hydraulic system has overheating
Hydraulic pressure is not adjusted correctly - Set pressure correctly.
Main relief valve is defective or unadjusted - Set up or change the relief valve.
Dirty hydraulic fluid - The fluid must be changed.
Hydraulic oil level is insufficient - Fill the hydraulic system with oil.
Hydraulic pump is worn - Repair or install new hydraulic pump.

Lift arm cannot be raised or lowered
Lift controls are defective - Change or repair.
Hydraulic pump malfunction - Install new pump or repair it.
Hydraulic control valve failure - Repair or change hydraulic valve.
Damaged hydraulic cylinder - Repair or install a new lift cylinder.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.

Bucket is not working
Bucket controls are faulty - Replace or repair.
Hydraulic pump is broken - Repair or replace pump if necessary.
Defective hydraulic control valve - Replace or repair the valve.
Bucket cylinder failure - Replace or repair cylinder.
Hydraulic oil is insufficient - Fill the system to proper hydraulic oil level.

Boom or bucket functions slowly
Faulty hydraulic oil pump - Flow-rate pump and change pump if necessary.
Leaking hydraulic cylinder - Repair leak by replacing the seals.
Hydraulic fluid level low - Add fluid as required.
Damaged or incorrect adjusted hydraulic control valve - Set properly or repair.
Hydraulic system loosing pressure - Set pressure correctly.

Jerky operation of the bucket or boom
Air leaks in hydraulic system - Bleed air from system.
Plugged hydraulic oil filter - Change or clean oil filter.
Dirty hydraulic oil - The oil must be changed.
Scratched cylinder rod or tube - Change defective component.

Hydraulic pump makes excessive noise
Insufficient oil level or leaking hydraulic system - Top up hydraulic oil or remedy leakage in system.
Hydraulic filter clogging - Service or replace hydraulic filter.
Dirty suction line - Service the suction line.
Pump is sucking air - Need to bleed air.
Pump parts are damaged - Replace or rebuild the pump.

Electrical Troubleshooting

Battery won’t charge
Loose or corroded wire connections - Service or tighten connections.
Defective battery terminal connectors - Replace terminal connectors.
Battery dead cell - Install a new battery.
Belt is loose or defective - Replace belt or adjust belt tension.

Starter turning slow
Battery power is low - Low battery charging, charge as required.
Battery is draining quickly - Service or change the battery.
Bad terminals or disconnected battery cables - Check cables and service or change terminals.

Starter motor won't turn
Battery is discharged or defective - Change or recharge battery.
Disconnected or improperly connected wiring harness - Inspect battery wiring harness and connect as required.
Low battery voltage - Low battery charging, charge as required.
Starter motor is damaged - Change or repair starter.

____________________________________________________________________________________

____________________________________________________________________________________

WHEEL LOADERS SPECIFICATIONS

Caterpillar