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Home / Wheel Loaders / Komatsu Wheel Loaders / Komatsu WA65-3

Komatsu WA65-3 Troubleshooting

The Komatsu WA65-3 wheel loader driveline system components: 168 cu.in (2.8L) Komatsu 4D94E 4-cylinder direct injection water-cooled diesel engine with a rated power of 50 hp (37 kW), and 2-speed hydrostatic transmission. The hydraulic system has a pump with a rated capacity of 14.5 gal/min (55 l/min). The system pressure is 2900 psi (200 bar). The Komatsu WA65-3 is equipped with a power steering, hydraulic wet disc brakes, and 365/70R18 tires. The wheel loader has a maximum lift height to hinge pin of 122.6" (3115 mm) and boom breakout force of 8930 lbs (4060 kg). The rated operating capacity is 3850 lbs (1750 kg), and tipping load is 7700 lbs (3500 kg).

Engine Troubleshooting

Engine starts hard or won't start
Air in the fuel system - Air bleeding.
Fuel filter element is dirty - Clean or replace the filter.
Clogged or defective injection nozzles - Service or change injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Excessive valve clearance - Check and adjust as required.
Fuel injection pump is broken - Change or repair the pump.

Diesel starts but immediately shuts off
Air cleaner is clogged - Install new air cleaner element.
Clogged fuel filter - Clean the filter or install new filter element.
Fuel injection pump is leaking - Repair any leaks.
Clogged or defective injectors - Clean or replace fuel injectors.
Defective fuel injection pump - Install a new fuel pump or repair.

Engine shuts off suddenly while running
Engine is not fully warmed up - Warm up to required temperature.
Dirty fuel filter - Replace filter element.
Air in fuel system - Bleed fuel system.
Fuel injection nozzles are damaged or dirty - Clean or replace injection nozzles.
Improper fuel injection timing - Use the correct fuel injection pump timing adjustment.

Engine stops while idling
Incorrect low idle setting - Correct low idle settings.
Fuel injection pump failure - Rebuild or replace pump.
Damaged or clogged injectors - Replace fuel injectors.
Incorrect valve clearance - Adjust valve clearance according to specifications.

Engine power is too low
Dirty air cleaner - Clean or change.
Clogged or defective injection nozzles - Change fuel injection nozzles.
Improper fuel injection pressure - Adjust to proper pressure.
Improper valve clearance - Adjustment procedure required.
Wrong adjustment of low idle speed - Adjust low idling as recommended.
Clogged fuel lines or hoses - Clean fuel hoses and lines.
Damaged cylinder-head gasket - Install new cylinder head gasket.
Piston rings are leaking or defective - Piston rings need to be replaced.

Engine overheated
Engine coolant is insufficient - Add coolant fluid to cooling system and also check it for leaks.
Engine oil insufficient - Fill the crankcase with engine oil.
Defective radiator cap or clogged radiator core - Clean radiator or replace cap.
Broken or loose fan belt - Replace as required.
Engine is under excessive load - Load reducing required.

Oil pressure too low
Lack of oil - Check oil level and add oil as required.
Engine oil filter is plugged - Change or clean engine oil filter element.
Oil grade or viscosity is wrong - Use oil of proper viscosity.
Incorrect crankshaft bearing oil clearance - Replace bearings.
Oil pump malfunction - Repair or replace.

Engine noises or knocks
Low engine oil level - Fill the crankcase with engine oil.
Engine is cold - Warm up the engine.
Improper setting of fuel injection pump timing - Adjust as recommended.
Low idle speed set incorrectly - Normalize low idle speed.
Fuel injectors are dirty or defective - Replace or clean fuel injectors.
Misaligned or faulty connecting rod - Need to replace or align the connecting rod.
Scored or worn 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 defective or unadjusted - Change or adjust linkage.
Relief valve is damaged - Change the valve.
Transmission overloaded - Reduce loading.
Worn or defective transmission components - After disassembly and inspection, replace defective components.

Loss of power
Low fluid level - Check and refill the transmission fluid.
Relief valve malfunction - Replace relief valve as required.
Bent or unadjusted speed control pedal linkage - Adjust or change linkage.

Transmission oil overheating
Transmission fluid level is low - Need to add transmission fluid.
Plugged transmission oil filter - Clean or replace the transmission filter.
Plugged or defective cooling components - Check all cooling components and change or clean if required.
Transmission is under excessive load - Reduce transmission load.

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

Hydraulics Troubleshooting

Hydraulic system has overheating
Hydraulic pressure is not correct - Adjust pressure as required.
Main relief valve failure or improper setting - Set up or change the relief valve.
Hydraulic oil is dirty - Hydraulic oil change required.
Not enough hydraulic fluid in the system - Need to add fluid.
Defective hydraulic pump - Replace or repair pump if necessary.

Lift arm fails to drop or lift
Lift controls malfunction - Replace or repair.
Hydraulic pump not working - Repair or change pump if required.
Faulty hydraulic control valve - Repair or change the valve.
Damaged hydraulic cylinder - Repair or replace hydraulic cylinder.
Hydraulic oil is insufficient - Check and refill the hydraulic oil.

Bucket does not tilt
Defective bucket controls - Repair or replace.
Defective hydraulic pump - Repair or replace pump if necessary.
Hydraulic control valve malfunction - Repair or replace hydraulic valve.
Bucket cylinder failure - Change or repair cylinder.
Hydraulic oil level low - Need to add oil.

Slow boom or bucket action
Defective hydraulic pump - Check pump flow and change pump if necessary.
Oil leaks from hydraulic cylinder - Cylinder seals need to be replaced.
Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.
Hydraulic control valve is unadjusted or worn - Adjust properly or repair.
Hydraulic pressure has dropped - Correct adjustment is required.

Lift arm or bucket is jerky
Air in hydraulic system - Bleed air from hydraulic system.
Hydraulic oil filter is clogged - Clean or install new filter.
Contaminated hydraulic oil - The oil must be changed.
Scored cylinder tube or rod - Replace damaged component.

Excessive hydraulic pump noise
Hydraulic leaks or low oil level - Add hydraulic oil or correct system leaks.
Hydraulic filter clogging - Clean or replace the filter.
Suction line is dirty - Suction line must be serviced.
Air in hydraulic pump - Need to bleed air.
Pump parts are faulty - Rebuild or install new pump.

Electrical Troubleshooting

Battery will not charge
Electrical cable connections are loose or corroded - Clean or tighten connections.
Defective battery terminal clamps - Replace terminal clamps.
Battery dead cell - Use a new battery.
Belt is loose or defective - Adjust belt tension or change the belt.

Starter cranks slowly
Low battery power - Battery is drained, charge it.
Battery drains quickly - Service battery or replace it.
Battery terminals are corroded or wires are disconnected - Connect cables properly or replace terminals.

Starter does not work
Battery is discharged or defective - Change or recharge battery.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Battery voltage is low - Low battery charging, charge as required.
Faulty starter motor - Starter should be changed.

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