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Home / Wheel Loaders / Komatsu Wheel Loaders / Komatsu WA100M-8

Komatsu WA100M-8 Troubleshooting

The Komatsu WA100M-8 wheel loader is powered by 186 cu.in (3.1L) Komatsu SAA4D94LE-3 vertical 4-cylinder liquid-cooled diesel engine with a rated power of 93.6 hp (69.8 kW) at 2000 rpm. The Komatsu WA100M-8 is equipped with a 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 20 gpm (75.8 lpm) or 31.6 gpm (120 lpm). The wheel loader has a rated operating capacity of 6690 lbs (3040 kg) and tipping load of 13380 lbs (6080 kg). The maximum lift height is 138.6" (3520 mm) to hinge pin, and bucket breakout force is 13550 lbs (6160 kg).

Engine Troubleshooting

Diesel engine hard to start or doesn't start
Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter element is clogged - Replace the filter element.
Clogged or defective injection nozzles - Install a new kit of correctly balanced nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Incorrect valve clearance - Adjust valve clearance according to specifications.
Fuel injection pump is broken - Rebuild or install a new injection pump.

Engine starts but stalls immediately
Clogged air filter - Clean or replace element.
Fuel filter plugging - Change filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Damaged or clogged injectors - Test and replace fuel injectors if necessary.
Fuel injection pump is defective - Install a new pump or rebuild.

Engine shuts off suddenly while running
Coolant temperature is low - Warm up to required temperature.
Fuel filter plugging - Change filter element.
Air in fuel system - Bleed fuel system.
Fuel injection nozzles are clogged or faulty - Clean or change injection nozzles.
Fuel injection pump timing is not adjusted - Set it up as required.

Engine stalls while idle
Incorrect low idle setting - Adjust the low idle speed.
Fuel injection pump is faulty - Repair or change injection pump.
Fuel injectors are dirty or defective - Test and replace fuel injectors if necessary.
Incorrect valve clearance - Adjust valve clearance according to specifications.

Lack of engine power
Air cleaner is dirty - Install new air cleaner element.
Dirty or damaged injection nozzles - Install a new kit of correctly balanced nozzles.
Incorrect fuel injection pressure - Adjust to correct pressure.
The valve clearance is not adjusted - Adjust to proper valve clearance.
Low idle speed adjustment is incorrect - Correct low idle settings.
Dirt in the fuel lines or hoses - Service fuel lines and hoses.
Cylinder head gasket defective - Install a new gasket.
Piston rings are worn or damaged - Replace the piston rings as required.

Engine overheating
Insufficient coolant - Refill to the correct level and inspect system for leaks.
Not enough engine oil - Fill the crankcase with engine oil.
Clogged radiator core or leaking radiator cap - Install new cap or clean radiator.
Fan belt is worn or faulty - Replace as required.
Engine overloaded - Reduce engine load.

Oil pressure is insufficient
Engine oil level low - Need to add oil.
Engine oil filter is plugged - Change or clean engine oil filter element.
Oil grade or viscosity is incorrect - Drain and refill with oil of correct grade and viscosity.
Crankshaft bearing oil clearance is excessive - Replace bearings.
Oil pump is worn or damaged - Replace as required.

Engine knocking or noise
Not enough engine oil - Fill the crankcase with engine oil.
Engine not warmed up - Warm up the engine.
Timing of fuel injection pump is incorrect - Adjust according to specifications.
Incorrectly adjusted low idle speed - Adjustment required.
Clogged or defective injectors - Test and replace fuel injectors if necessary.
Connecting rod is misaligned or worn - Align or change connecting rod.
Broken or worn pistons - Have pistons replaced.

Hydrostatic Transmission Troubleshooting

HST transmission noises
Fluid is contaminated or fluid level is insufficient - Top up to proper level or change transmission fluid.
Speed control pedal linkage is damaged or out of adjustment - Adjust or repair linkage.
Relief valve malfunction - Install a new valve.
Excessive loading - Load needs to be reduced.
Transmission parts are worm or defective - After disassembly and inspection, replace defective components.

Power is too low
Transmission fluid insufficient - Need to add transmission fluid.
Defective relief valve - Change relief valve.
Bent or unadjusted speed control pedal linkage - Adjust or repair linkage.

Transmission fluid overheats
Low oil level - Add oil to the transmission housing.
Plugged transmission oil filter - Service or replace the transmission oil filter.
Cooling components are plugged or defective - Inspect all cooling components and service or replace if necessary.
Transmission overload - Reduce transmission load.

External fluid leaks
Damaged gaskets or seals - Gaskets or seal replacement required.
High internal transmission case pressure - Change defective components.
Oil return tube is plugged - Clean or replace the tube.

Hydraulics Troubleshooting

Hydraulic system overheated
Incorrect hydraulic pressure setting - Adjust it correctly.
Main relief valve is defective or unadjusted - Adjust or change relief valve.
Hydraulic oil contamination - The oil must be changed.
Hydraulic fluid level is insufficient - Add fluid to the hydraulic system.
Hydraulic pump is defective - Repair or replace pump if necessary.

Boom does not raise or lower
Damaged lift controls - Inspect and repair if necessary.
Damaged hydraulic oil pump - Replace or repair pump if necessary.
Hydraulic control valve is faulty - Replace or repair the valve.
Defective hydraulic cylinder - Repair or replace hydraulic cylinder.
Insufficient hydraulic fluid - Fill the system to proper hydraulic fluid level.

Bucket does not tilt
Defective bucket controls - Repair or replace.
Defective hydraulic pump - Replace or repair pump if necessary.
Hydraulic control valve is faulty - Repair or change hydraulic valve.
Bucket cylinder failure - Install a new cylinder or repair it.
Hydraulic oil level low - Check and refill the hydraulic oil.

Boom or bucket is working slowly
Defective hydraulic pump - Check pump performance and change it if necessary.
Oil leaks from hydraulic cylinder - Install new cylinder seals.
Low hydraulic oil level - Fill the system to proper hydraulic oil level.
Worn or unadjusted hydraulic control valve - Adjust correctly or repair.
Hydraulic pressure is low - Correct adjustment is required.

Bucket or boom movements are jerky
Air in the hydraulic system - Need to bleed air.
Hydraulic oil filter element is dirty - Replace or clean the filter.
Hydraulic fluid is dirty - Hydraulic fluid change required.
Cylinder tube or rod is scored - Replace worn component.

Hydraulic pump is noisy
Hydraulic system leaking or not enough oil - Add hydraulic oil or correct system leaks.
Hydraulic filter is dirty - Clean or install new filter.
Plugged suction line - Service the suction line.
Pump is sucking air - Bleed air.
Pump components are damaged - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery cannot be charged
Corroded or loose electrical wire connections - Tighten or service cable connections.
Faulty battery terminal clamps - Terminal clamps need to be replaced.
Battery faulty cell - Install a new battery.
Loose or worn belt - Adjust belt tension or install a new belt.

Starter motor turns slow
Battery power is low - Battery is drained, charge it.
Battery drains quickly - Service battery or replace it.
Disconnected wiring or bad battery terminals - Check cables and clean or change terminals.

Starter will not work
Battery is discharged or worn - Recharge or replace battery.
Battery wires are disconnected or incorrectly connected - Check wires and connect correctly.
Battery power is low - Battery needs to be recharged.
Damaged starter motor - Starter should be changed.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders