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Home / Wheel Loaders / Komatsu Wheel Loaders / Komatsu WA95-3

Komatsu WA95-3 Troubleshooting

The Komatsu WA95-3 wheel loader is powered by 269 cu.in (4.4L) Komatsu 4D106E2 4-cylinder direct injection liquid-cooled diesel engine with a rated power of 75 hp (55 kW) at 2500 rpm. The Komatsu WA95-3 is equipped with a hydrostatic transmission, power steering system, hydraulic wet disc brakes, and 455/70R20 standard tires. The hydraulic system has a pump with fluid flow rate of 23.7 gpm (90 lpm). The hydraulic pressure is 2755 psi (190 bar). The wheel loader has a rated operating capacity of 5620 lbs (2555 kg) and tipping load of 11240 lbs (5110 kg). The maximum lift height is 135.6" (3445 mm) to hinge pin, and bucket breakout force is 16280 lbs (7400 kg).

Engine Troubleshooting

Engine starts hard or won't start
Air in the fuel lines - Bleed the fuel lines.
Fuel filter plugging - Clean the filter or install new filter element.
Clogged or defective injection nozzles - Service or change injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is out of adjustment - Adjust to proper valve clearance.
Fuel injection pump malfunctioning - Repair or install new pump.

Diesel starts but immediately stops
Dirty air cleaner - Clean or change cleaner.
Fuel filter plugged - Change filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Clogged or defective injectors - Replace fuel injectors.
Fuel injection pump is broken - Change pump or rebuild it.

Engine stalls after running
Engine not warmed up - Normalize the temperature by warming up the engine.
Fuel filter is plugged - Clean or replace the filter.
Air in fuel system - Bleed fuel system.
Fuel injection nozzles are faulty or clogged - Clean or replace injection nozzles.
Fuel injection pump timing is wrong - Adjust as recommended.

Engine stops while idle
Improperly adjusted low idle speed - Adjustment required.
Defective fuel injection pump - Replace injection pump or repair it.
Clogged or defective injectors - Clean fuel injectors or change it.
Valve clearance is wrong - Adjust to proper valve clearance.

Low engine power
Air filter is plugged - Service or replace the air filter.
Clogged or defective injection nozzles - Test injection nozzles and change if necessary.
Fuel injection pressure is wrong - Test fuel injection pressure and adjust it correctly.
Valve clearance is not correct - Correct valve clearance needs to be set.
Low idle speed setting is incorrect - Correct low idle settings.
Dirt in the fuel hoses or lines - Service fuel hoses and lines.
Cylinder head gasket is blown - Change cylinder head gasket.
Piston rings are defective or leaking - Piston rings need to be replaced.

Engine overheated
Low engine coolant - Top up coolant fluid and check system for leaks.
Engine oil level low - Fill the crankcase with engine oil.
Radiator core is clogged or radiator cap is leaking - Change cap or clean radiator.
Fan belt is broken or worn - Belt replacement is recommended.
Engine overload - Load reducing required.

Low oil pressure
Low crankcase oil level - Fill crankcase to proper oil level.
Clogged oil filter - Change or clean engine oil filter element.
Incorrect engine oil Use correct viscosity oil.
Excessive oil clearance of crankshaft bearing - Bearing replacement required.
Worn oil pump - Install a new pump.

Engine knocks or noises
Engine oil level is insufficient - Fill up the engine oil.
Engine is cold - Warm up the engine.
Wrong setting of fuel injection pump timing - Set it up as required.
Too low idle RPM - Correct the settings.
Clogged or defective injectors - Replace or clean fuel injectors.
Connecting rod is not aligned or defective - Connecting rod needs to be aligned or changed.
Pistons are worn or broken - Have pistons replaced.

Hydrostatic Transmission Troubleshooting

Hydrostatic transmission is making noise
Oil is dirty or oil level is too low - Add oil to proper level or pour fresh transmission oil.
Speed control linkage is worn or unadjusted - Adjust or repair linkage.
Defective relief valve - Change relief valve.
Excessive loading - Load needs to be reduced.
Damaged or worn components of hydrostatic transmission - Check hydrostatic transmission components for defect or damage and change if necessary.

Low power
Transmission fluid level is low - Checking transmission fluid level and add if necessary.
Relief valve failure - Replace the valve.
Speed control linkage is worn or unadjusted - Adjust or replace linkage.

Transmission oil overheats
Transmission oil insufficient - Fill the transmission housing to proper oil level.
Transmission fluid filter element clogging - Service or change transmission fluid filter.
Cooling components are clogged or damaged - Check all cooling components and repair or change if required.
Excessive transmission load - Reduce transmission load.

Transmission fluid leaking
Seals or gaskets are worn - Install new seal or gaskets.
Internal transmission housing pressure is too high - Replace worn components.
Oil drain pipe is plugged - Check pipe and service if necessary.

Hydraulics Troubleshooting

Hydraulic system overheated
Hydraulic pressure incorrectly adjusted - Hydraulic pressure must be set correctly.
Main relief valve is faulty or misadjusted - Replace or set up the relief valve.
Hydraulic fluid contamination - Hydraulic fluid change required.
Hydraulic fluid level is insufficient - Add fluid to the hydraulic system.
Hydraulic pump is worn - Replace or repair pump if necessary.

Boom fails to lift or drop
Damaged lift controls - Inspect and repair if necessary.
Defective hydraulic pump - Install new pump or repair it.
Defective hydraulic control valve - Install a new hydraulic valve or repair it.
Damaged hydraulic cylinder - Install a new boom cylinder or repair it.
Insufficient hydraulic oil - Need to add oil.

Bucket does not function
Damaged bucket controls - Inspect and repair if necessary.
Damaged hydraulic oil pump - Install new pump or repair it.
Defective hydraulic control valve - Repair or replace hydraulic valve.
Broken bucket cylinder - Install a new cylinder or repair it.
Low hydraulic fluid level - Fill up the hydraulic fluid.

Boom or bucket moves slowly
Faulty hydraulic oil pump - Check pump capacity and change if necessary.
Hydraulic cylinder leaking - Change cylinder piston seals.
Insufficient hydraulic fluid - Checking hydraulic fluid level and add if necessary.
Hydraulic control valve is defective or set improper - Repair or adjust properly.
Hydraulic pressure loss - Adjust it correctly.

Jerky operation of the bucket or boom
Air in hydraulic system - Bleed hydraulic system.
Dirty hydraulic oil filter element - Service or replace the hydraulic filter.
Dirty hydraulic oil - The oil must be changed.
Cylinder tube or rod is scored - Replace defective component.

Hydraulic pump is excessively noisy
Leaking hydraulic system or insufficient oil level - Repair hydraulic leaks or add oil as required.
Clogged hydraulic filter - Change or clean oil filter.
Suction line is clogged - Need to service the suction line.
Pump sucks air - Bleed air.
Faulty pump parts - Rebuild or install new pump.

Electrical Troubleshooting

Battery is not charging
Corroded or loose electrical wire connections - Tighten or service cable connections.
Defective battery terminal clamps - Install new terminal clamps.
Battery bad cell - Replace the battery.
Damaged or loose belt - Adjust belt tension or change the belt.

Starter motor turns slow
Battery voltage is low - Battery is drained, recharge it.
Battery drains quickly - Service battery or change it.
Bad terminals or disconnected battery cables - Check cables and service or change terminals.

Starter is not cranking
Battery is low or faulty - Recharge or replace battery.
Disconnected or improperly connected wiring harness - Inspect battery wiring harness and connect as required.
Battery power is low - Battery is drained, charge it.
Defective starter motor - Starter needs to be changed.

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WHEEL LOADERS SPECIFICATIONS

Caterpillar