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Home / Wheel Loaders / Komatsu Wheel Loaders / Komatsu WA150-5

Komatsu WA150-5 Troubleshooting

The Komatsu WA150-5 wheel loader is powered by Komatsu SAA4D102E-2 4-cylinder turbocharged aftercooled diesel engine with a rated power of 91.2 hp (68 kW) at 2500 rpm. The Komatsu WA150-5 is equipped with a 4-speed transmission, hydraulic power steering, hydraulic wet disc brakes, and 16.9x24 standard tires. The hydraulic system has a pump with fluid flow rate of 32.5 gpm (123 lpm). The hydraulic pressure is 3050 psi (210 bar). The wheel loader has a rated operating capacity of 7020 lbs (3185 kg) and tipping load of 14040 lbs (6370 kg). The max lift height is 138.2 inches (3510 mm) to hinge pin, and boom breakout force is 16370 lbs (7400 kg).

Engine Troubleshooting

Engine hard to start or won't start
Air trapped in fuel system - Bleed air.
Dirty fuel filter - Service or replace the filter.
Faulty or dirty injection nozzles - Test injection nozzles and change if necessary.
Dirt or water in fuel system - Drain water or flush dirt from the system.
The valve clearance is not adjusted - Have it adjusted.
Damaged fuel injection pump - Repair or install new pump.

Engine starts but stalls suddenly
Plugged air cleaner - Clean or replace air cleaner element.
Fuel filter element is dirty - Replace filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Damaged or clogged injectors - Change or clean fuel injectors.
Fuel injection pump malfunctioning - Repair or change injection pump.

Engine stalls after running
Low coolant temperature - Warm up to required temperature.
Fuel filter element is clogged - Replace the filter element.
Air trapped in fuel system - Bleed air.
Fuel injection nozzles are faulty or clogged - If necessary, replace with a new nozzle.
Improper setting of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.

Engine stalls at low idle speed
Incorrect low idle speed adjustment - Test and adjust.
Fuel injection pump is defective - Repair or change injection pump.
Dirty or defective injectors - Test and replace fuel injectors if necessary.
Valve clearance is wrong - Adjust valve clearance according to specifications.

Engine lacks power
Air cleaner is clogged - Service or replace air cleaner.
Defective injection nozzle - Install a new kit of correctly balanced nozzles.
Fuel injection pressure is wrong - Adjust to proper pressure.
Incorrect valve clearance - Adjustment procedure required.
Too low idle RPM - Correct low idle settings.
Fuel hoses or lines are clogged - Service fuel hoses and lines.
Cylinder-head gasket is broken - Replace the gasket as required.
Piston rings are worn or defective - Replace the piston rings as required.

Engine overheated
Lack of coolant in cooling system - Fill the cooling system and check components for leaks or other faults.
Engine oil level is insufficient - Fill the crankcase with engine oil.
Clogged radiator fins or leaking radiator cap - Change cap or clean radiator.
Excessive wear of the fan belt - Replace as required.
Engine overload - Load reducing is recommended.

Oil pressure too low
Oil level is insufficient - Add oil to the engine crankcase.
Dirty oil filter element - Clean or replace engine oil filter element.
Wrong oil viscosity - Use oil of proper viscosity.
Excessive crankshaft bearing oil clearance - Bearing replacement required.
Defective oil pump - Replace as required.

Engine noise or knocking
Engine oil level low - Fill up the engine oil.
Coolant temperature is low - Normalize the temperature by warming up the engine.
Fuel injection pump timing is wrong - Use the correct fuel injection pump timing adjustment.
Improperly adjusted low idle speed - Need to adjust idle speed.
Defective fuel injectors - Test and replace fuel injectors if necessary.
Misaligned or defective connecting rod - Need to change or align the connecting rod.
Pistons are scored or worn - Replace the pistons.

Hydrostatic Transmission Troubleshooting

Hydrostatic transmission noises
Transmission fluid is dirty or fluid level is too low - Pour fresh fluid or add transmission fluid to proper level.
Speed control linkage is worn or unadjusted - Adjust or replace linkage.
Relief valve is stuck - Replace relief valve.
Excessive loading - Reduce transmission load.
Worn or defective parts of the hydrostatic transmission - After disassembling and inspection, change defective components.

Loss of power
Insufficient transmission fluid - Check and refill the transmission fluid.
Relief valve malfunction - Install a new valve.
Speed control linkage is defective or unadjusted - Repair or adjust linkage.

Transmission oil over heats
Transmission fluid insufficient - Need to add transmission fluid.
Dirty transmission fluid filter element - Clean or change transmission fluid filter.
Clogged or damaged cooling components - Inspect all cooling components and service or replace if necessary.
Transmission overloaded - Load needs to be reduced.

External oil leaks
Seals or gaskets are worn - Install new components.
High internal transmission case pressure - Change defective components.
Clogged transmission fluid return pipe - Clean or change return pipe.

Hydraulics Troubleshooting

Hydraulic system has overheating
Hydraulic pressure incorrectly adjusted - Hydraulic pressure must be set correctly.
Main relief valve is damaged or adjusted improperly - Adjust or change relief valve.
Dirty hydraulic fluid - Hydraulic fluid change required.
Hydraulic fluid level is insufficient - Check and refill the hydraulic fluid.
Faulty hydraulic oil pump - Change or repair hydraulic pump if required.

Boom does not raise or lower
Lift controls are faulty - Repair or change.
Hydraulic pump failure - Replace or repair pump if necessary.
Damaged hydraulic control valve - Replace or repair the valve.
Hydraulic cylinder is faulty - Repair or change hydraulic cylinder.
Hydraulic oil level low - Fill the system to proper hydraulic oil level.

Bucket is not working
Damaged bucket controls - Replace or repair.
Hydraulic pump is broken - Change or repair hydraulic pump if required.
Hydraulic control valve is defective - Install a new hydraulic valve or repair it.
Bucket cylinder failure - Repair or replace cylinder.
Hydraulic oil level low - Need to add oil.

Slow boom or bucket action
Faulty hydraulic oil pump - Check pump performance and change it if necessary.
Hydraulic cylinder leaking - Change cylinder piston seals.
Hydraulic fluid level low - Fill the system to proper hydraulic fluid level.
Damaged or incorrect adjusted hydraulic control valve - Adjust correctly or repair.
Hydraulic pressure is low - Set pressure correctly.

Jerky operation of the bucket or boom
Air in hydraulic system - Bleed air from hydraulic system.
Hydraulic oil filter element is dirty - Replace or clean the filter.
Hydraulic fluid is dirty - Change hydraulic fluid.
Cylinder tube or rod scoring - Replace defective component.

Excessive hydraulic pump noise
Hydraulic leaks or low oil level - Repair hydraulic leaks or add oil as required.
Clogged hydraulic filter - Service or change hydraulic filter.
Dirty suction line - Clean suction line as required.
Air in hydraulic pump - Remove air from hydraulics.
Pump parts are faulty - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery cannot be charged
Electrical cable connections are corroded or loose - Clean or tighten connections.
Battery terminal clamps are faulty - Terminal clamps need to be replaced.
Battery bad cell - Battery replacement required.
Defective or loose belt - Belt needs to be adjusted or changed.

Starter turns slow
Low battery voltage - Charge the battery.
Battery is draining quickly - Battery needs to be serviced or replaced.
Disconnected battery cables or bad terminals - Check wiring connections and replace or clean terminals.

Starter motor is not working
Battery is low or faulty - Replace or charge as required.
Wiring harness is disconnected or improperly connected - Check wiring harness and connect as required.
Low battery capacity - Charge the battery.
Starter motor failing - Repair or install a new starter.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders