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Home / Wheel Loaders / Komatsu Wheel Loaders / Komatsu WA80-5

Komatsu WA80-5 Troubleshooting

The Komatsu WA80-5 wheel loader driveline system components: Komatsu 4D95-LE3 4-cycle 4-cylinder water-cooled diesel engine with a rated power of 60 hp (45 kW), and 2-speed hydrostatic transmission. The hydraulic system has a gear pump with a rated capacity of 15 gal/min (57 l/min). The system relief pressure is 3190 psi (220 bar). The Komatsu WA80-5 is equipped with a power steering system, hydraulic wet disc brakes, and 405/70R18 tires. The wheel loader has a maximum lift height of 126.4" (3210 mm) and bucket breakout force of 10165 lbs (4620 kg). The rated operating capacity is 4770 lbs (2165 kg), and tipping load is 9540 lbs (4330 kg).

Engine Troubleshooting

Engine starts up hard or doesn't start
Air trapped in fuel system - Bleed air.
Dirty fuel filter - Change filter element.
Faulty or dirty injection nozzles - Inspect nozzles and replace if necessary.
Water or dirt in fuel system - Drain, flush, and service the system.
Incorrect valve clearance - Check and adjust.
Fuel injection pump failure - Rebuild or change fuel pump.

Diesel starts but stalls immediately
Air filter is plugged - Install new air filter element.
Clogged fuel filter - Replace the filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Dirty or defective injectors - Inspect fuel injectors and change as required.
Fuel injection pump is not working correctly - Install a new pump or rebuild.

Engine stops running suddenly
Low coolant temperature - Warm up to required temperature.
Clogged fuel filter - Change the filter element.
Air in fuel system - Bleed fuel system.
Clogged or burnt injection nozzle - Check injection nozzles and replace if required.
Incorrect adjustment of fuel injection pump timing - Set the fuel pump timing correctly.

Engine stops when idle
Low idle speed set incorrectly - Test and adjust.
Fuel injection pump is defective - Repair or replace injection pump.
Defective fuel injectors - Change or clean fuel injectors.
Valve clearance is not correct - Adjust valve clearance.

Loss of engine power
Clogged air cleaner - Clean or change.
Defective injection nozzle - Check and replace nozzles if required.
Improper fuel injection pressure - Correct the pressure settings.
Improper valve clearance - Adjustment procedure required.
Incorrectly adjusted low idle speed - Adjust as required.
Fuel lines or hoses clogging - Clean fuel system lines and hoses.
Worn cylinder head gasket - Install a new gasket.
Defective or worn piston rings - Replace the piston rings as required.

Engine overheats
Low coolant level - Add coolant fluid to cooling system and also check it for leaks.
Not enough engine oil - Add oil to the engine crankcase.
Clogged radiator fins or damaged radiator cap - Change cap or clean radiator.
Fan belt slipping or worn - The fan belt needs to be replaced.
Engine overloaded - Reduce load on the engine.

Oil pressure is low
Not enough oil in the engine - Add oil to the engine crankcase.
Engine oil filter is plugged - Clean or change engine oil filter.
Incorrect engine oil Use the specified type of engine oil.
Crankshaft bearing has excessive oil clearance - Replace bearings.
Defective oil pump - Install a new pump.

Abnormal engine noise or knocking
Lack of engine oil - Fill the crankcase with engine oil.
Engine not warmed up - Warm up the engine.
Improper setting of fuel injection pump timing - Check the fuel injection pump timing adjustment.
Incorrectly adjusted low idle speed - Adjust as required.
Fuel injector fault - Inspect fuel injectors and change as required.
Connecting rod is worn or misaligned - Alignment procedure or replacement is required.
Worn or scored pistons - Pistons need to be replaced.

Hydrostatic Transmission Troubleshooting

Hydrostatic transmission is excessively noisy
Insufficient oil level or contaminated oil - Fill to required level or change the transmission oil.
Defective or not adjusted speed control pedal linkage - Repair or adjust linkage.
Stuck relief valve - Change relief valve.
Excessive loading - Load needs to be reduced.
Damaged or worn components of hydrostatic transmission - After disassembling and inspection, change defective components.

Lack of power
Low fluid level - Add fluid to the transmission housing.
Relief valve is damaged - Install a new valve.
Speed control linkage is defective or unadjusted - Adjust or change linkage.

Transmission fluid overheating
Transmission fluid level is low - Need to add transmission fluid.
Plugged transmission oil filter - Service or replace the transmission oil filter.
Defective or plugged cooling components - Check all cooling components and repair or change if required.
Transmission overload - Reduce the load is required.

Transmission oil leakage
Seals or gaskets are broken - Seals and gaskets need to be replaced.
High internal transmission housing 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 correctly.
Unadjusted or defective main relief valve - Adjust the valve or replace if necessary.
Hydraulic oil is dirty - Change hydraulic oil.
Lack of hydraulic oil - Check oil level and add hydraulic oil as required.
Faulty hydraulic oil pump - Repair or install new hydraulic pump.

Lift arm cannot be raised or lowered
Lift controls are faulty - Repair or replace.
Hydraulic pump not working - Replace or repair pump if necessary.
Hydraulic control valve is defective - Repair or replace the valve.
Hydraulic cylinder is broken - Repair or change hydraulic cylinder.
Hydraulic oil level low - Checking hydraulic oil level and add if necessary.

Bucket is not working
Damaged bucket controls - Repair or replace.
Hydraulic pump is broken - Install new pump or repair it.
Hydraulic control valve is faulty - Repair or replace the valve.
Bucket cylinder is faulty - Change or repair cylinder.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.

Slow bucket or lift arm operation
Hydraulic pump is faulty - Test pump performance and replace pump if necessary.
Hydraulic cylinder oil leakage - Repair leak by replacing the seals.
Low hydraulic fluid level - Fill the system to proper hydraulic fluid level.
Worn or unadjusted hydraulic control valve - Repair or set correctly.
Low hydraulic pressure - Set pressure correctly.

Lift arm or bucket is jerky
There is air in the hydraulic system - Bleed air from hydraulic system.
Dirty hydraulic oil filter - Service or replace the hydraulic filter.
Hydraulic oil is dirty - Hydraulic oil change required.
Cylinder rod or tube is scratched - Change failed component.

Excessive hydraulic pump noise
Lack of oil or hydraulic leakage - Repair hydraulic leaks or add oil as required.
Hydraulic filter clogging - Clean or replace the filter.
Suction line is dirty - Service the suction line.
Pump sucks air - Bleed air.
Pump parts are worn out - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery does not charge
Electrical wire connections are loose or corroded - Tighten or clean electrical wiring connections.
Faulty electrical terminal connectors - Change terminal connectors.
Battery failing - Battery replacement required.
Worn or loose belt - Belt needs to be adjusted or replaced.

Starter turning slow
Low battery voltage - Recharge the battery.
Battery will not hold charge - Service battery or change it.
Bad battery terminals or disconnected wiring - Check cable connections and replace or service terminals.

Starter motor won't turn
Battery is discharged or defective - Change or recharge battery.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Battery power is low - Battery is drained, recharge it.
Starter motor is defective - Repair or install a new starter.

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