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Home / Wheel Loaders / Komatsu Wheel Loaders / Komatsu WA100M-7

Komatsu WA100M-7 Troubleshooting

The Komatsu WA100M-7 wheel loader driveline system components: Komatsu SAA4D95LE-5 vertical 4-cylinder turbocharged water-cooled diesel engine with a rated power of 88.5 hp (66 kW), and 2-speed hydrostatic transmission. The open center hydraulic system has a gear pump with a rated capacity of 19.8 gal/min (75 l/min). The Komatsu WA100M-7 is equipped with a power steering system, hydraulic wet disc brakes, and 455/70R20 tires. The wheel loader has a maximum lift height to hinge pin of 138.8" (3525 mm) and boom breakout force of 11265 lbs (5120 kg). The rated operating capacity is 6645 lbs (3020 kg), and tipping load is 13290 lbs (6040 kg).

Engine Troubleshooting

Engine difficult to start or will not start
Air in the fuel lines - Bleed the fuel lines.
Fuel filter element is clogged - Change filter element.
Dirty or faulty injection nozzles - Clean or change injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve clearance is not correct - Adjust valve clearance.
Fuel injection pump is broken - Rebuild or change fuel pump.

Diesel starts but immediately stops
Dirty air cleaner - Install new air cleaner element.
Fuel filter element is clogged - Change or clean the filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Dirty or defective injectors - Replace or clean fuel injectors.
Faulty fuel injection pump - Rebuild or replace pump.

Engine stops unexpectedly during operation
Engine is not warmed up to required temperature - Warm up to required temperature.
Fuel filter is plugged - Clean or change the filter.
Air trapped in fuel system - Bleed air.
Fuel injection nozzles fault - Replace injection nozzles.
Fuel injection pump timing is wrong - Adjust the pump as required.

Engine stalls when idling
Improperly adjusted low idle speed - Normalize low idle speed.
Fuel injection pump malfunctioning - Repair or replace injection pump.
Fuel injector fault - Clean fuel injectors or change it.
Excessive valve clearance - Adjust valve clearance.

Engine power loss
Air cleaner is dirty - Clean or replace element.
Dirty or faulty injection nozzles - Change fuel injection nozzles.
Uneven fuel injection pressure - Correct the pressure settings.
Excessive valve clearance - Adjust valve clearance.
Too low idle RPM - Adjust the low idle speed.
Restricted fuel hoses or lines - Clean fuel hoses and lines.
Cylinder-head gasket is broken - Install new cylinder head gasket.
Leaking or defective piston rings - Install new piston rings.

Engine overheating
Lack of engine coolant - Add coolant fluid and inspect the cooling system for leaks.
Low engine oil level - Check oil level and add oil as required.
Clogged radiator fins or damaged radiator cap - Clean radiator or install new cap.
Broken or loose fan belt - Install new fan belt.
Engine overload - Reduce engine load.

Oil pressure is low
Oil level is low - Fill up the engine oil.
Clogged oil filter element - Service or replace engine oil filter.
Different type of engine oil - Use proper viscosity oil.
Crankshaft bearing oil clearance is excessive - Change bearings.
Oil pump is damaged - Check and replace if necessary.

Engine knocks or noises
Engine oil level low - Checking oil level and add if necessary.
Engine is cold - Normalize the temperature by warming up the engine.
Fuel injection pump timing is not adjusted - Check the fuel injection pump timing adjustment.
Too low idle RPM - Correct low idle adjustment.
Fuel injectors are dirty or defective - Clean fuel injectors or change it.
Connecting rod is misaligned or defective - Connecting rod needs to be replaced or aligned.
Worn or broken pistons - Pistons need to be replaced.

Hydrostatic Transmission Troubleshooting

Hydrostatic transmission noises
Oil is dirty or oil level is too low - Change transmission oil or top up to proper level.
Speed control linkage is worn or unadjusted - Replace or adjust linkage.
Defective relief valve - Replace the valve.
Transmission overload - Reduce transmission load.
Worn or defective parts of the hydrostatic transmission - Check hydrostatic transmission components for defect or damage and change if necessary.

Low power
Transmission fluid level is low - Checking transmission fluid level and add if necessary.
Stuck relief valve - Change relief valve.
Worn or unadjusted speed control linkage - Change or adjust linkage.

Transmission oil overheated
Transmission fluid insufficient - Checking transmission fluid level and add if necessary.
Dirty transmission oil filter element - Clean or replace the transmission filter.
Defective or plugged cooling components - Inspect all cooling components and service or replace if necessary.
Transmission overload - The load should be reduced.

Transmission oil leakage
Damaged gaskets or seals - Seals and gaskets replacement required.
Transmission case internal pressure is too high - Check hydrostatic transmission components for defect or damage and change if necessary.
Plugged transmission fluid return tube - Service or replace return tube.

Hydraulics Troubleshooting

Hydraulic system overheats
Hydraulic pressure is not adjusted correctly - Correct setting is required.
Unadjusted or defective main relief valve - Adjust or replace the relief valve.
Dirty hydraulic oil - Fill up with fresh hydraulic oil.
Lack of hydraulic fluid - Need to add fluid.
Hydraulic pump is defective - Repair or replace pump if necessary.

Lift arm won't raise or lower
Lift controls are defective - Inspect and repair if necessary.
Defective hydraulic pump - Install new pump or repair it.
Hydraulic control valve is defective - Repair or change hydraulic valve.
Hydraulic cylinder is broken - Repair or replace hydraulic cylinder.
Hydraulic fluid level low - Checking hydraulic fluid level and add if necessary.

Bucket does not function
Bucket tilt controls malfunction - Check and repair as required.
Damaged hydraulic oil pump - Repair or replace pump if necessary.
Faulty hydraulic control valve - Change or repair hydraulic valve.
Hydraulic bucket cylinder is defective - Repair or change cylinder.
Hydraulic oil level low - Checking hydraulic oil level and add if necessary.

Bucket or lift arm functions slowly
Worn hydraulic oil pump - Test pump performance and replace pump if necessary.
Hydraulic cylinder leaking - Repair leak by replacing the seals.
Hydraulic oil level low - Check and refill the hydraulic oil.
Hydraulic control valve is unadjusted or worn - Repair or set correctly.
Hydraulic pressure has dropped - Set pressure correctly.

Bucket or boom is working jerkily
Air in hydraulic system - Bleed air from hydraulic system.
Plugged hydraulic oil filter - Clean or replace the filter.
Hydraulic oil is contaminated - Change hydraulic oil.
Cylinder rod or tube is scuffed - Replace damaged component.

Hydraulic pump is excessively noisy
Hydraulic system leaking or not enough oil - Repair hydraulic leaks or add oil as required.
Dirty hydraulic filter - Service or replace hydraulic filter.
Plugged suction line - Suction line needs to be cleaned.
Pump sucks air - Need to bleed air.
Pump parts are faulty - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery cannot be charged
Corroded or loose wire connections - Service or tighten cable connections.
Electrical terminal connectors are defective - Terminal connectors should be replaced.
Worn-out battery - Use a new battery.
Loose or damaged belt - Install a new belt or adjust belt tension.

Starter motor turns slow
Low battery capacity - Battery is drained, recharge it.
Battery won’t hold charge - Service or replace the battery.
Disconnected cables or faulty battery terminals - Connect cables correctly or replace terminals.

Starter will not crank
Battery is drained or worn - Change or recharge battery.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Low battery power - Battery is drained, recharge it.
Faulty starter motor - Starter needs to be replaced.

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WHEEL LOADERS SPECIFICATIONS

Caterpillar