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Home / Wheel Loaders / Hitachi Wheel Loaders / Hitachi ZW150-6

Hitachi ZW150-6 Troubleshooting

The Hitachi ZW150-6 wheel loader driveline system components: Cummins QSB4.5 four-stroke four-cylinder direct injection turbocharged liquid-cooled diesel engine with a rated power of 142 hp (106 kW), and four-speed hydro transmission with powershift gearbox. The hydraulic system has a pump with a rated capacity of 51.2 gal/min (194 l/min). The Hitachi ZW150-6 is equipped with a hydraulic power steering, boom floating system, and 20.5R25 tires. The wheel loader has a maximum lift height to hinge pin of 151.2" (3840 mm) and boom breakout force of 22480 lbs (10220 kg). The rated operating capacity is 9965 lbs (4520 kg), and tipping load is 19930 lbs (9040 kg).

Engine Troubleshooting

Engine difficult to start or will not start
Air in fuel tank - Bleed fuel tank.
Clogged fuel filter - Service the filter.
Dirty or faulty injection nozzles - Inspect nozzles and replace if necessary.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Incorrect valve clearance - Adjust valve clearance.
Fuel injection pump is not operating properly - Replace or repair injection pump.

Engine stalls after starting
Clogged air filter - Replace or clean air filter element.
Fuel filter element is dirty - Replace the filter element.
Fuel injection pump is leaking - Repair any leaks.
Damaged or clogged injectors - Replace or clean fuel injectors.
Faulty fuel injection pump - Repair or install a new fuel pump.

Engine stops running suddenly
Engine is not fully warmed up - Warm up to required temperature.
Fuel filter is plugged - Clean or replace the filter.
Air in the fuel lines - Bleed the fuel lines.
Faulty or dirty injection nozzles - Service or change injection nozzles.
Wrong setting of fuel injection pump timing - Adjust according to specifications.

Engine stops when idle
Incorrect low idle setting - Adjust low idle speed.
Damaged fuel injection pump - Repair or replace injection pump.
Dirty or defective injectors - Replace fuel injectors.
Incorrect valve clearance - Adjustment procedure required.

Engine power is too low
Plugged air filter - Clean or change.
Clogged injection nozzle - Clean or change injection nozzles.
Uneven fuel injection pressure - Adjust to proper pressure.
The valve clearance is incorrect - Have it adjusted.
Incorrectly set low idle speed - Correct low idle settings.
Dirt in the fuel lines or hoses - Clean fuel system lines and hoses.
Damaged cylinder-head gasket - Replace the gasket as required.
Damaged or leaking piston rings - Piston rings need to be replaced.

Engine overheating
Low engine coolant - Top up coolant fluid and check system for leaks.
Lack of engine oil - Check oil level and add oil as required.
Defective radiator cap or clogged radiator fins - Install new cap or clean radiator.
Loose or defective fan belt - Change the fan belt.
Diesel engine is overloaded - Load reducing is recommended.

Oil pressure too low
Oil level is insufficient - Fill crankcase to proper oil level.
Oil filter clogging - Service or change engine oil filter element.
Wrong oil viscosity - Drain and refill with oil of correct grade and viscosity.
Crankshaft bearing has incorrect oil clearance - Bearings need to be reinstalled.
Oil pump is damaged - Inspect and change as required.

Engine knocking or noise
Insufficient engine oil - Check and refill engine oil.
Engine is not fully warmed up - Warm up the engine.
Fuel injection pump timing is wrong - Adjust as recommended.
Low idle speed adjustment is incorrect - Adjustment required.
Fuel injectors are dirty or defective - Inspect fuel injectors and change as required.
Faulty or misaligned connecting rod - Connecting rod needs to be aligned or changed.
Pistons are worn or scored - Pistons need to be replaced.

Transmission Troubleshooting

Insufficient transmission fluid pressure
Transmission oil level is low - Add oil to the transmission housing.
Transmission fluid filter element is clogged (if equipped) - Replace or service transmission fluid filter.
Defective relief valve - Install a new valve.

Transmission makes noise
Insufficient transmission fluid - Need to add transmission fluid.
Transmission oil is dirty - Fill up with fresh transmission oil.
Damaged gears or incorrect backlash - Change worn gears or adjust backlash correctly.
Worn or broken bearings - Bearings need to be changed.
Worn or damaged gear shift forks - Shift forks need to be replaced.
Shaft splines are damaged or worn - Shaft need to be replaced.

Gear shift is hard
Rusty or worn gear shift linkage - Replace or lubricate the shift linkage.
Damaged or worn gear shift forks - Shift forks need to be replaced.
Worn out parts of the gearshift mechanism - Replace worn parts.
Malfunction or incorrect clutch adjustment - Adjust clutch or replace if required.

External oil leaks
High transmission oil level - Correct the oil level.
Broken seals or gaskets - Install new gaskets or seal.

Hydraulics Troubleshooting

Hydraulic system has overheating
Hydraulic pressure incorrectly adjusted - Set pressure correctly.
Main relief valve is damaged or adjusted improperly - Adjust or change relief valve.
Contaminated hydraulic oil - Fill up with fresh hydraulic oil.
Lack of hydraulic fluid - Check and refill the hydraulic fluid.
Faulty hydraulic oil pump - Repair or change pump if required.

Boom does not raise or lower
Lift controls are damaged - Repair or replace.
Damaged hydraulic oil pump - Repair or change pump if required.
Hydraulic control valve failure - Replace or repair the valve.
Broken hydraulic cylinder - Change or repair lift cylinder.
Hydraulic oil level low - Need to add oil.

Bucket is not working
Bucket tilt controls are defective - Repair or replace.
Defective hydraulic pump - Change or repair hydraulic pump if required.
Defective hydraulic control valve - Repair or replace the valve.
Broken bucket cylinder - Repair or replace cylinder.
Low hydraulic oil level - Fill the system to proper hydraulic oil level.

Slow bucket or lift arm action
Faulty hydraulic oil pump - Check pump capacity and change if necessary.
Hydraulic cylinder leaking - Change cylinder piston seals.
Low hydraulic fluid level - Add fluid as required.
Damaged or incorrect adjusted hydraulic control valve - Set correctly or repair.
Hydraulic system loosing pressure - Correct setting is required.

Bucket or boom movements are jerky
Air leaks in hydraulic system - Bleed air from hydraulic system.
Hydraulic oil filter clogging - Clean or install new filter.
Contaminated hydraulic fluid - The fluid must be changed.
Scored cylinder tube or rod - Change failed component.

Excessive hydraulic pump noise
Lack of oil or hydraulic leakage - Repair hydraulic leaks or add oil as required.
Plugged hydraulic filter - Clean or install new filter.
Dirty suction line - Need to service the suction line.
Pump sucks air - Bleed air from hydraulics.
Pump components are damaged - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery is not charging
Loose or corroded cable connections - Service or tighten cable connections.
Battery terminal connectors are faulty - Install new terminal connectors.
Faulty cell in battery - Replace the battery.
Defective or loose belt - Install a new belt or adjust belt tension.

Starter cranks slow
Battery capacity is low - Low battery charging, charge as required.
Battery will not hold charge - Service battery or change it.
Disconnected battery cables or bad terminals - Connect wiring correctly or install new terminals.

Starter doesn't crank
Battery is drained or defective - Charge or replace the battery.
Wiring harness is disconnected or improperly connected - Check wiring harness and connect as required.
Low battery capacity - Battery is drained, charge it.
Starter motor failing - Starter should be replaced.

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