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Home / Wheel Loaders / Hitachi Wheel Loaders / Hitachi ZW100

Hitachi ZW100 Troubleshooting

The Hitachi ZW100 wheel loader is powered by 230 cu.in (3.8L) Kubota V3800-T-CRS four-cylinder direct injection turbocharged diesel engine with a rated power of 93 hp (69 kW). The Hitachi ZW100 is equipped with a two-speed hydrostatic transmission, hydraulic power steering, boom floating system, and 15.5x25 standard tires. The hydraulic system has a pump with fluid flow rate of 28.5 gpm (108 lpm). The hydraulic pressure is 3000 psi (206 bar). The wheel loader has a rated operating capacity of 4500 lbs (2045 kg) and tipping load of 9000 lbs (4090 kg). The maximum lift height is 137.8" (3500 mm) to hinge pin, and bucket breakout force is 13685 lbs (6220 kg).

Engine Troubleshooting

Engine starts up hard or doesn't start
Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter element is dirty - Filter maintenance required.
Fuel injection nozzles are faulty or clogged - Install a new kit of correctly balanced nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Valve out of adjustment - Have it adjusted.
Fuel injection pump is not operating properly - Replacement or repair required.

Engine starts but immediately stalls
Clogged air filter - Change or service air filter element.
Fuel filter element clogging - Clean or replace the filter.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Fuel injectors are faulty or clogged - Test and replace fuel injectors if necessary.
Fuel injection pump is broken - Install a new pump or rebuild.

Engine shuts off suddenly while running
Coolant temperature is low - Normalize the temperature by warming up the engine.
Fuel filter is plugged - Replace filter element.
Air in the fuel system - Air bleeding.
Fuel injection nozzles are damaged - Change fuel injection nozzles.
Improper fuel injection timing - Adjust fuel injection pump as required.

Engine shuts off while idling
Improperly adjusted low idle speed - Adjust the low idle speed.
Fuel injection pump is not working correctly - Install a new fuel pump or repair.
Clogged or defective injectors - Clean or replace fuel injectors.
Valve out of adjustment - Adjust valve clearance.

Diesel engine is losing power
Plugged air filter - Install new air filter element.
Defective or clogged injection nozzle - Test injection nozzles and change if necessary.
Incorrect fuel injection pressure - Adjust to proper pressure.
Improper valve clearance - Adjust to proper valve clearance.
Low idle speed set incorrectly - Correct low idle adjustment.
Restricted fuel lines or hoses - Clean fuel system hoses and lines.
Leaking cylinder head gasket - Gasket should be replaced.
Leaking or defective piston rings - Change piston rings.

Engine overheating
Lack of coolant in cooling system - Top up coolant fluid and check system for leaks.
Engine oil level low - Checking oil level and add if necessary.
Defective radiator cap or clogged radiator fins - Clean radiator or change cap.
Fan belt slipping or worn - Replace as required.
Engine overloaded - Reduce engine load.

Insufficient oil pressure
Engine oil insufficient - Checking oil level and add if necessary.
Plugged engine oil filter - Service or replace engine oil filter.
Wrong oil viscosity - Fill up with the correct oil viscosity.
Excessive oil clearance of crankshaft bearing - Change bearings.
Defective oil pump - Install a new pump.

Engine noises or knocks
Insufficient engine oil - Check and refill engine oil.
Engine is not fully warmed up - Warm up to required temperature.
Improper setting of fuel injection pump timing - Adjust fuel injection pump as required.
Low idle speed set incorrectly - Need to adjust idle speed.
Dirty or defective injectors - Test and replace fuel injectors if necessary.
Connecting rod misalignment or failure - Need to align or replace the connecting rod.
Piston wear or scoring - Replace the pistons.

Hydrostatic Transmission Troubleshooting

HST transmission noises
Insufficient oil level or contaminated oil - Add oil to proper level or pour fresh transmission oil.
Speed control linkage is worn or unadjusted - Replace or adjust linkage.
Relief valve failure - Change relief valve.
Transmission overloaded - The load should be reduced.
Damaged or worn components of hydrostatic transmission - Replace or repair defective components.

Loss of power
Transmission fluid insufficient - Check and refill the transmission fluid.
Relief valve malfunction - Install a new valve.
Bent or unadjusted speed control pedal linkage - Adjust or replace linkage.

Transmission fluid overheating
Low oil level - Check transmission oil level and add oil as required.
Clogged transmission fluid filter - Service or replace the transmission fluid filter.
Plugged or defective cooling components - Check all cooling components and change or repair if required.
Transmission overloaded - Reduce transmission load.

Transmission oil leaks
Seals or gaskets are worn - 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 incorrect - Adjust pressure as required.
Main relief valve improper adjustment or failure - Adjust or replace the relief valve.
Hydraulic fluid is dirty - Fill up with fresh hydraulic fluid.
Not enough hydraulic fluid in the system - Fill the hydraulic system with oil.
Hydraulic pump is faulty - Replace or repair pump if necessary.

Lift arm cannot be raised or lowered
Faulty lift controls - Repair or replace.
Hydraulic pump failure - Install new pump or repair it.
Hydraulic control valve is defective - Repair or replace the valve.
Hydraulic cylinder not working - Repair or replace hydraulic cylinder.
Insufficient hydraulic oil - Checking hydraulic oil level and add if necessary.

Bucket is not working
Bucket tilt controls malfunction - Repair or replace.
Defective hydraulic pump - Repair or change pump if required.
Hydraulic control valve failure - Change or repair hydraulic valve.
Damaged bucket cylinder - Repair or change cylinder.
Insufficient hydraulic oil - Need to add oil.

Slow bucket or lift arm action
Hydraulic pump is faulty - Test pump performance and replace pump if necessary.
Hydraulic cylinder leaking - Replace cylinder piston seals.
Hydraulic fluid level low - Checking hydraulic fluid level and add if necessary.
Hydraulic control valve is not set properly or defective - Repair or set correctly.
Low hydraulic pressure - Set pressure correctly.

Bucket or boom is working jerkily
There is air in the hydraulic system - Air bleeding is required.
Hydraulic oil filter clogging - Clean or replace the filter.
Hydraulic fluid is contaminated - Hydraulic fluid change required.
Cylinder tube or rod is scored - Replace failed component.

Hydraulic pump is excessively noisy
Hydraulic system leaking or not enough oil - Add hydraulic oil or correct system leaks.
Dirty hydraulic filter - Service or change hydraulic filter.
Suction line clogging - Need to clean the suction line.
Pump is sucking air - Bleed air from hydraulics.
Pump components are faulty - Install new hydraulic pump or rebuild it.

Electrical Troubleshooting

Battery will not charge
Electrical cable connections are loose or corroded - Tighten or service connections.
Battery terminal clamps are faulty - Install new terminal clamps.
Battery bad cell - Replace the battery.
Defective or loose belt - Adjust belt tension or replace belt.

Starter turns slowly
Low battery power - Low battery charging, charge as required.
Battery does not hold charge - Service charging system or replace battery.
Wires are disconnected or battery terminals are corroded - Check cables and clean or change terminals.

Starter is not cranking
Battery is drained or defective - Recharge or change battery.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Battery voltage is low - Charge the battery.
Defective starter motor - Starter should be replaced.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders