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Home / Wheel Loaders / Komatsu Wheel Loaders / Komatsu WA80M-8

Komatsu WA80M-8 Troubleshooting

The Komatsu WA80M-8 wheel loader driveline system components: Komatsu S4D98E-6VHA 4-stroke 4-cylinder turbocharged diesel engine with a rated power of 72 hp (53.7 kW), and 2-speed hydrostatic transmission. The hydraulic system has a gear pump with a rated capacity of 16 gal/min (60.5 l/min) or 26.5 gal/min (100.5 l/min). The Komatsu WA80M-8 is equipped with a power steering system, hydraulic wet disc brakes, and 405/70R20 tires. The wheel loader has a maximum lift height to hinge pin of 127.2" (3230 mm) and boom breakout force of 11220 lbs (5100 kg). The rated operating capacity is 5180 lbs (2355 kg), and tipping load is 10360 lbs (4710 kg).

Engine Troubleshooting

Engine difficult to start or won't start
Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter element is clogged - Clean the filter element.
Fuel injection nozzles are damaged - Clean or change injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Improper valve clearance - Adjust valve clearance.
Fuel injection pump is defective - Replace injection pump or repair it.

Engine starts but stalls suddenly
Plugged air filter - Replace or clean air filter element.
Dirty fuel filter - Replace filter element.
Fuel injection pump is leaking - Repair any leaks.
Defective or clogged fuel injectors - Change or clean fuel injectors.
Fuel injection pump is defective - Rebuild or change fuel pump.

Diesel shuts off while driving
Coolant temperature is low - Warm up engine as required.
Fuel filter element is dirty - Service or replace the filter.
There is air in the fuel system - Bleed the system.
Dirty or faulty injection nozzles - Replace injection nozzles.
Improper fuel injection timing - Set it up as required.

Engine stops while idling
Low idle speed setting is not correct - Test and adjust.
Fuel injection pump damage - Repair or install a new fuel pump.
Fuel injector fault - Test and replace fuel injectors if necessary.
Excessive valve clearance - Check and adjust.

Diesel power loss
Air cleaner is clogged - Service or replace air cleaner.
Defective injection nozzle - Service or change injection nozzles.
Uneven fuel injection pressure - Correct the pressure settings.
The valve clearance is incorrect - Adjust valve clearance.
Incorrect low idle speed adjustment - Adjust as required.
Fuel lines or hoses are dirty - Fuel lines and hoses need to be cleaned.
Leaking cylinder head gasket - Replace cylinder head gasket.
Worn or damaged piston rings - Change piston rings.

Engine is overheated
Low coolant level - Add coolant fluid to cooling system and also check it for leaks.
Engine oil level is low - Add oil to the engine crankcase.
Clogged radiator core or leaking radiator cap - Install new cap or clean radiator.
Loose or defective fan belt - Replace as required.
Engine is overloaded - Reduce engine load.

Oil pressure is insufficient
Lack of oil - Fill the crankcase with oil.
Engine oil filter is plugged - Clean or replace engine oil filter element.
Improper type of engine oil - Use the specified type of engine oil.
Crankshaft bearing oil clearance is incorrect - Bearing needs to be changed.
Oil pump malfunction - Check and replace if necessary.

Abnormal engine knocking or noise
Insufficient engine oil - Fill the crankcase with engine oil.
Coolant temperature is low - Warm up engine as required.
Improper fuel injection timing - Use the correct fuel injection pump timing adjustment.
Low idle speed setting is not correct - Need to adjust idle speed.
Fuel injectors are faulty or clogged - Change or clean fuel injectors.
Faulty or misaligned connecting rod - Need to replace or align the connecting rod.
Worn or scored pistons - Install new pistons.

Hydrostatic Transmission Troubleshooting

HST transmission makes noise
Contaminated transmission fluid or low fluid level - Fill to required level or change the fluid.
Speed control linkage is defective or unadjusted - Repair or adjust linkage.
Relief valve is stuck - Replace valve as required.
Transmission overloaded - Reduce transmission load.
Defective or worn transmission parts - After disassembling and inspection, change defective components.

Loss of power
Transmission oil insufficient - Add oil to the transmission housing.
Defective relief valve - Change relief valve.
Speed control linkage is defective or unadjusted - Replace or adjust linkage.

Transmission oil overheated
Insufficient transmission fluid - Need to add transmission fluid.
Dirty transmission oil filter element - Service or change transmission oil filter.
Damaged or clogged cooling components - Inspect all cooling components and replace or repair if necessary.
Transmission is under excessive load - Load needs to be reduced.

Transmission fluid leakage
Damaged gaskets or seals - Seals and gaskets replacement required.
High internal transmission housing pressure - Change defective parts.
Oil drain line is clogged - Clean or change the line.

Hydraulics Troubleshooting

Hydraulic system is overheated
Incorrect hydraulic pressure setting - Correct setting is required.
Main relief valve improper adjustment or failure - Adjust or replace the relief valve.
Dirty hydraulic oil - The oil must be changed.
Hydraulic oil level is insufficient - Fill the hydraulic system with oil.
Hydraulic pump is defective - Change or repair hydraulic pump if required.

Boom cannot be lowered or raised
Defective lift controls - Change or repair.
Hydraulic pump not working - Repair or install new hydraulic pump.
Damaged hydraulic control valve - Repair or change hydraulic valve.
Defective hydraulic cylinder - Repair or replace hydraulic cylinder.
Hydraulic fluid level low - Fill the system to proper hydraulic fluid level.

Bucket can't tilt
Defective bucket controls - Repair or change.
Defective hydraulic pump - Replace or repair pump if necessary.
Hydraulic control valve is faulty - Install a new hydraulic valve or repair it.
Hydraulic bucket cylinder is defective - Repair or install a new cylinder.
Low hydraulic oil level - Fill the system to proper hydraulic oil level.

Boom or bucket functions slowly
Worn hydraulic oil pump - Flow-rate pump and change pump if necessary.
Oil leaks from hydraulic cylinder - Replace cylinder piston seals.
Low hydraulic oil level - Need to add oil.
Damaged or incorrect adjusted hydraulic control valve - Repair or set correctly.
Hydraulic pressure is low - Adjust pressure correctly.

Lift arm or bucket jerks when working
Air in the hydraulic system - Bleed air from hydraulic system.
Hydraulic oil filter clogging - Clean or install new filter.
Hydraulic fluid is dirty - Change hydraulic fluid.
Cylinder rod or tube is scratched - Change defective component.

Hydraulic pump is noisy
Low oil level or hydraulic leaks - Add hydraulic oil or correct system leaks.
Dirty hydraulic filter - Service or replace hydraulic filter.
Dirty suction line - Clean suction line as required.
Pump is sucking air - Air bleeding is required.
Worn pump components - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery won’t charge
Electrical cable connections are loose or corroded - Clean or tighten wiring connections.
Defective electrical terminal connectors - Install new terminal connectors.
Worn-out battery - Change the battery.
Worn or loose belt - Need to adjust belt tension or replace belt.

Starter cranks slow
Low battery output voltage - Recharge the battery.
Battery is not holding charge - Service battery or replace it.
Disconnected wires or corroded battery terminals - Check cable connections and change or clean terminals.

Starter will not crank
Battery is discharged or defective - Replace or charge as required.
Battery wiring is disconnected or improperly connected - Inspect wiring and connect as required.
Low battery voltage - Recharge the battery.
Starter motor failure - Change or repair starter.

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