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Home / Wheel Loaders / Komatsu Wheel Loaders / Komatsu WA65-6

Komatsu WA65-6 Troubleshooting

The Komatsu WA65-6 wheel loader is powered by 202 cu.in (3.3L) Komatsu 4D95LWE-5 4-cylinder water-cooled diesel engine with a rated power of 55 hp (41 kW) at 2350 rpm. The Komatsu WA65-6 is equipped with a two-speed hydrostatic transmission, power steering system, hydraulic disc brakes, and 12.0x18 standard tires. The hydraulic system has a pump with fluid flow rate of 14 gpm (53 lpm). The hydraulic pressure is 2900 psi (200 bar). The wheel loader has a rated operating capacity of 4015 lbs (1825 kg) and tipping load of 8030 lbs (3650 kg). The maximum lift height is 122.6" (3115 mm) to hinge pin, and bucket breakout force is 8325 lbs (3785 kg).

Engine Troubleshooting

Engine starts up hard or won't start
Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter element is clogged - Service the filter.
Fuel injection nozzles are dirty or defective - Replace injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve out of adjustment - Adjust to proper valve clearance.
Fuel injection pump failure - Replacement or repair required.

Engine starts but then stops
Plugged air cleaner - Service or replace air cleaner.
Fuel filter element clogging - Change the filter element.
Fuel injection pump has loose connections - Tighten the connections.
Fuel injectors are faulty or clogged - Change or clean fuel injectors.
Fuel injection pump is faulty - Rebuild or change fuel pump.

Engine stops unexpectedly during operation
Coolant temperature is low - Normalize the temperature by warming up the engine.
Fuel filter element is dirty - Replace the filter element.
Air in the fuel pipes - Bleed the fuel pipes.
Faulty or dirty injection nozzles - Check and replace nozzles if required.
Improper fuel injection timing - Use the correct fuel injection pump timing adjustment.

Engine stops when idle
Incorrect low idle setting - Normalize low idle speed.
Fuel injection pump is not working correctly - Change pump or rebuild it.
Clogged or defective injectors - Clean or replace fuel injectors.
The valve clearance is incorrect - Adjustment procedure required.

Engine power is too low
Plugged air filter - Clean or change filter.
Clogged or burnt injection nozzle - Clean or change injection nozzles.
Uneven fuel injection pressure - Adjust to correct pressure.
Improper valve clearance - Adjust valve clearance.
Low idle speed setting is incorrect - Correct low idle settings.
Dirty fuel hoses or lines - Service fuel lines and hoses.
Damaged cylinder-head gasket - Change cylinder head gasket.
Leaking or damaged piston rings - Change piston rings.

Engine overheats
Coolant level is low - Add coolant fluid to cooling system and also check it for leaks.
Engine oil level low - Fill the crankcase with engine oil.
Radiator fins are dirty or radiator cap is defective - Clean radiator or change cap.
Fan belt is loose or defective - Install new fan belt.
Engine overloaded - Reduce engine load.

Oil pressure too low
Not enough oil in the engine - Fill the crankcase with oil.
Oil filter clogged - Service or change engine oil filter element.
Oil grade or viscosity is wrong - Use proper viscosity oil.
Incorrect oil clearance in crankshaft bearing - Bearings need to be reinstalled.
Defective oil pump - Replace as required.

Engine knocking sound or abnormal noise
Low engine oil level - Fill up the oil to required level.
Coolant temperature is low - Warm up engine as required.
Wrong setting of fuel injection pump timing - Adjust the pump as required.
Wrong adjustment of low idle speed - Correct low idle settings.
Damaged or clogged injectors - Change or clean fuel injectors.
Connecting rod failure or misalignment - Align or replace connecting rod.
Scored or worn pistons - Pistons replacement required.

Hydrostatic Transmission Troubleshooting

Hydrostatic transmission noise
Transmission fluid is dirty or fluid level is too low - Pour fresh fluid or add transmission fluid to proper level.
Worn or out of adjustment speed control linkage - Repair or adjust linkage.
Stuck relief valve - Change relief valve.
Transmission overloaded - Reduce loading.
Transmission components are damaged or worn - Change or repair defective parts.

Low power
Transmission oil insufficient - Fill up the transmission oil.
Stuck relief valve - Replace relief valve.
Bent or unadjusted speed control pedal linkage - Adjust or change linkage.

Transmission fluid overheated
Insufficient transmission oil - Check and refill the transmission oil.
Transmission oil filter is dirty - Clean or replace the transmission filter.
Clogged or damaged cooling components - Inspect all cooling components and service or replace if necessary.
Transmission overloaded - Reduce loading.

Transmission oil leakage
Seals or gaskets are worn - Seals and gaskets replacement required.
Internal transmission housing pressure is too high - Check transmission parts for damage or wear and replace if required.
Plugged transmission fluid return tube - Service or replace return tube.

Hydraulics Troubleshooting

Hydraulic system overheated
Hydraulic pressure is incorrect - Adjust it correctly.
Defective or misadjusted main relief valve - Adjust or replace the relief valve.
Hydraulic fluid is contaminated - Fill up with fresh hydraulic fluid.
Lack of hydraulic fluid - Fill the hydraulic system with oil.
Hydraulic pump is defective - Install new pump or repair it.

Lift arm can't drop or lift
Faulty lift controls - Inspect and repair if necessary.
Damaged hydraulic oil pump - Repair or install new hydraulic pump.
Faulty hydraulic control valve - Repair or replace the valve.
Hydraulic cylinder malfunction - Replace or repair boom cylinder.
Hydraulic oil is insufficient - Fill the system to proper hydraulic oil level.

Bucket does not function
Damaged bucket controls - Repair or replace.
Hydraulic pump malfunction - Change or repair hydraulic pump if required.
Damaged hydraulic control valve - Install a new hydraulic valve or repair it.
Broken bucket cylinder - Replace or repair cylinder.
Low hydraulic oil level - Check and refill the hydraulic oil.

Slow bucket or lift arm operation
Defective hydraulic pump - Test pump performance and replace pump if necessary.
Hydraulic cylinder leaking - Replace cylinder piston seals.
Low hydraulic oil level - Fill the system to proper hydraulic oil level.
Defective or not adjusted hydraulic control valve - Repair or set correctly.
Hydraulic pressure loss - Correct adjustment is required.

Lift arm or bucket is moving jerkily
Air in hydraulic system - Bleed hydraulic system.
Plugged hydraulic oil filter - Clean or change the filter.
Contaminated hydraulic fluid - Hydraulic fluid change required.
Scored cylinder tube or rod - Replace failed component.

Hydraulic pump is noisy
Low oil level or hydraulic leaks - Correct hydraulic leaks or top up oil as needed.
Plugged hydraulic filter - Service or replace hydraulic filter.
Suction line is clogged - Need to clean the suction line.
Pump sucks air - Air bleeding is required.
Pump parts are faulty - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery will not charge
Loose or corroded cable connections - Clean or tighten wiring connections.
Battery terminal clamps are faulty - Terminal clamps need to be replaced.
Battery faulty cell - Change the battery.
Belt is worn or loose - Need to adjust belt tension or replace belt.

Starter cranks slowly
Battery power is low - Low battery charging, charge as required.
Battery is draining quickly - Service or change the battery.
Disconnected wiring or bad battery terminals - Connect wiring properly or install new terminals.

Starter does not work
Battery is low or faulty - Recharge or replace battery.
Wire harness is disconnected or incorrectly connected - Check wire harness and connect as required.
Battery voltage is low - Battery is drained, recharge it.
Starter motor is faulty - Starter needs to be changed.

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