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Home / Wheel Loaders / Hitachi Wheel Loaders / Hitachi ZW30-5B

Hitachi ZW30-5B Troubleshooting

The Hitachi ZW30-5B wheel loader is powered by 100.5 cu.in (1.7L) Kubota D1703-M-DI-E4B 4-cycle 3-cylinder naturally aspirated liquid-cooled diesel engine with a rated power of 24 hp (17.9 kW) at 2200 rpm. The Hitachi ZW30-5B is equipped with a two-speed hydrostatic transmission, hydraulic power steering, boom floating system, and 12.5/70-16 standard tires. The open center hydraulic system has a gear pump with fluid flow rate of 9.2 gpm (35 lpm). The wheel loader has a rated operating capacity of 1665 lbs (755 kg) and tipping load of 3330 lbs (1510 kg). The maximum lift height is 105.7" (2685 mm) to hinge pin, and bucket breakout force is 4630 lbs (2105 kg).

Engine Troubleshooting

Engine difficult to start or will not start
Air in fuel tank - Bleed fuel tank.
Fuel filter plugged - Install new filter element.
Fuel injection nozzles are damaged or dirty - Service or change injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve out of adjustment - Adjustment procedure required.
Fuel injection pump is not operating properly - Rebuild or replace pump.

Engine starts but then stops
Dirty air cleaner - Clean or replace air cleaner element.
Fuel filter plugging - Clean or replace the filter.
Fuel injection pump is leaking - Repair any leaks.
Damaged or clogged injectors - Replace or clean fuel injectors.
Faulty fuel injection pump - Replacement or repair required.

Engine shuts off suddenly during operation
Engine not warmed up - Warm up engine as required.
Fuel filter element clogging - Replace filter element.
Air trapped in fuel system - Bleed air.
Defective injection nozzle - Change fuel injection nozzles.
Fuel injection pump timing is wrong - Set the fuel pump timing correctly.

Engine stalls while idling
Incorrectly set low idle speed - Normalize low idle speed.
Fuel injection pump damage - Rebuild or install a new injection pump.
Defective fuel injectors - Replace or clean fuel injectors.
Improper valve clearance - Adjustment procedure required.

Loss of engine power
Air filter is clogged - Clean or change filter.
Dirty or damaged injection nozzles - Change fuel injection nozzles.
Incorrect fuel injection pressure - Adjust to correct pressure.
The valve clearance is not adjusted - Adjust valve clearance according to specifications.
Low idle speed setting is incorrect - Correct low idle adjustment.
Fuel lines or hoses are dirty - Clean fuel system hoses and lines.
Damaged cylinder-head gasket - Replace cylinder head gasket.
Defective or worn piston rings - Change piston rings.

Engine overheating
Low coolant level - Fill radiator to proper level and check components for faults.
Low engine oil level - Check and refill engine oil.
Radiator core is dirty or radiator cap is damaged - Clean radiator or replace cap.
Fan belt is loose or defective - Change the fan belt.
Diesel engine is overloaded - Load reducing is recommended.

Insufficient oil pressure
Low crankcase oil level - Checking oil level and add if necessary.
Plugged engine oil filter - Service or replace engine oil filter.
Incorrect oil viscosity - Fill up with the proper oil viscosity.
Excessive crankshaft bearing oil clearance - Bearings need to be reinstalled.
Oil pump is worn or damaged - Install a new pump.

Engine noise or knocking
Insufficient engine oil - Fill the crankcase with engine oil.
Engine is not warmed up to required temperature - Warm up the engine.
Incorrect adjustment of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.
Incorrectly adjusted low idle speed - Correct low idle settings.
Dirty or defective injectors - Replace or clean fuel injectors.
Connecting rod is not aligned or defective - Align or replace connecting rod.
Worn or scored pistons - Pistons replacement required.

Hydrostatic Transmission Troubleshooting

HST transmission noises
Oil is dirty or oil level is too low - Add oil to the correct level or fill the transmission with fresh oil.
Speed control linkage is worn or unadjusted - Change or adjust linkage.
Relief valve failure - Replace the valve.
Transmission overloaded - Reduce the load is required.
Transmission components are damaged or worn - After disassembling and inspection, change defective components.

Power is too low
Transmission oil level is low - Check and refill the transmission oil.
Relief valve is stuck - Replace valve as required.
Speed control pedal linkage is damaged or out of adjustment - Adjust or repair linkage.

Transmission fluid overheats
Transmission oil insufficient - Add oil to the transmission housing.
Transmission fluid filter element is clogged - Service or change transmission fluid filter.
Cooling components are defective or plugged - Check all cooling components and clean or replace if required.
Excessive transmission load - Reduce the load is required.

Transmission fluid leaking
Seals or gaskets are worn - Install new seal or gaskets.
High internal transmission housing pressure - Replace worn components.
Plugged oil return tube - Clean or replace return tube.

Hydraulics Troubleshooting

Hydraulic system is overheated
Hydraulic pressure is not adjusted correctly - Correct adjustment is required.
Faulty or improperly adjusted main relief valve - Set up or change the relief valve.
Dirty hydraulic fluid - The fluid must be changed.
Hydraulic fluid level is insufficient - Check and refill the hydraulic fluid.
Defective hydraulic pump - Repair or change pump if required.

Lift arm cannot be raised or lowered
Lift controls malfunction - Repair or replace.
Defective hydraulic pump - Repair or install new hydraulic pump.
Hydraulic control valve failure - Repair or change the valve.
Hydraulic cylinder failure - Change or repair lift cylinder.
Insufficient hydraulic fluid - Checking hydraulic fluid level and add if necessary.

Bucket is not working
Bucket tilt controls malfunction - Repair or replace.
Defective hydraulic pump - Install new pump or repair it.
Hydraulic control valve failure - Repair or change hydraulic valve.
Bucket cylinder failure - Repair or replace cylinder.
Low hydraulic oil level - Checking hydraulic oil level and add if necessary.

Boom or bucket runs slowly
Hydraulic pump is faulty - Check hydraulic pump flow and replace pump if necessary.
Leaking hydraulic cylinder - Correct leakage by changing the seals.
Insufficient hydraulic fluid - Fill the system to proper hydraulic fluid level.
Defective or not adjusted hydraulic control valve - Repair or set properly.
Hydraulic pressure is low - Correct setting is required.

Lift arm or bucket is jerky
Air leaks in hydraulic system - Air bleeding is required.
Dirty hydraulic oil filter element - Service or change the hydraulic filter.
Hydraulic oil is dirty - Fill up with fresh hydraulic oil.
Cylinder rod or tube is scuffed - Replace worn component.

Hydraulic pump is excessively noisy
Not enough oil or hydraulic system leaking - Add hydraulic oil or correct system leaks.
Hydraulic filter clogging - Change or clean oil filter.
Suction line clogging - Suction line needs to be cleaned.
Air in hydraulic pump - Need to bleed air.
Pump components are faulty - Rebuild or install new pump.

Electrical Troubleshooting

Battery is not charging
Loose or corroded wire connections - Clean or tighten connections.
Defective battery terminal clamps - Replace terminal clamps.
Battery is defective - Change the battery.
Belt is defective or loose - Adjust belt tension or install a new belt.

Starter cranks slowly
Battery power is low - Low battery charging, charge as required.
Battery does not hold charge - Battery needs to be serviced or replaced.
Bad battery terminals or disconnected wiring - Connect wires correctly or change terminals.

Starter motor is not working
Battery is drained or defective - Recharge or change battery.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Low battery power - Low battery charging, charge as required.
Defective starter motor - Change or repair starter.

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WHEEL LOADERS SPECIFICATIONS

Wheel Loaders, Skid Steers, and Compact Track Loaders