____________________________________________________________________________________

Home / Wheel Loaders / Hitachi Wheel Loaders / Hitachi ZW40-5B

Hitachi ZW40-5B Troubleshooting

The Hitachi ZW40-5B wheel loader driveline system components: a 111.4 cu.in (1.8L) Kubota D1803-CR-TI-E4B 4-cycle vertical 3-cylinder turbocharged liquid-cooled diesel engine with a rated power of 40 hp (29.3 kW), and 2-speed hydrostatic transmission. The open center hydraulic system has a pump with a rated capacity of 10.4 gal/min (39.5 l/min). The Hitachi ZW40-5B is equipped with a power steering system, hydraulic wet disc brakes, and 15.5/60-18 tires. The wheel loader has a maximum lift height of 119.3" (3030 mm) and bucket breakout force of 8030 lbs (3650 kg). The rated operating capacity is 2255 lbs (1025 kg), and tipping load is 4510 lbs (2050 kg).

Engine Troubleshooting

Engine difficult to start or won't start
Air in fuel system - Bleed fuel system.
Fuel filter plugged - Change filter element.
Burnt or clogged injection nozzle - Change fuel injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Incorrect valve clearance - Correct valve clearance.
Fuel injection pump is damaged - Install a new fuel pump or repair.

Diesel starts but stalls immediately
Air cleaner is clogged - Clean or change cleaner.
Fuel filter element is clogged - Clean or replace the filter.
Fuel injection pump is leaking - Repair any leaks.
Fuel injectors are dirty or defective - Replace fuel injectors.
Fuel injection pump malfunctioning - Rebuild or change fuel pump.

Engine shuts off suddenly while running
Engine is not preheated - Warm up to required temperature.
Fuel filter element clogging - Install new filter element.
Air trapped in fuel system - Bleed air.
Dirty or faulty injection nozzles - Inspect nozzles and replace if necessary.
Timing of fuel injection pump is incorrect - Set it up as required.

Engine stops when idling
Low idle speed adjustment is incorrect - Adjustment required.
Damaged fuel injection pump - Install a new fuel pump or repair.
Dirty or defective injectors - Test and replace fuel injectors if necessary.
Improper valve clearance - Have it adjusted.

Engine power is too low
Clogged air filter - Change or service air filter element.
Faulty or dirty injection nozzles - Service or change injection nozzles.
Incorrect fuel injection pressure - Test fuel injection pressure and adjust it correctly.
The valve clearance is incorrect - Adjust to proper valve clearance.
Too low idle RPM - Adjust low idle speed.
Dirt in the fuel lines or hoses - Clean fuel system lines and hoses.
Worn cylinder head gasket - Change cylinder head gasket.
Leaking or damaged piston rings - Piston rings replacement required.

Engine overheats
Not enough coolant - Fill radiator to proper level and check components for faults.
Engine oil level is insufficient - Need to add engine oil.
Radiator core is dirty or radiator cap is damaged - Clean radiator or replace cap.
Broken or loose fan belt - Replace as required.
Diesel engine overloaded - Reduce load on the engine.

Low oil pressure
Not enough oil in the engine - Fill the crankcase with oil.
Oil filter element clogging - Change or service engine oil filter.
Different type of engine oil - Use oil of proper viscosity.
Incorrect oil clearance in main bearing - Bearings need to be reinstalled.
Oil pump is damaged - Repair or replace.

Engine knocks or noises
Engine oil insufficient - Fill the crankcase with engine oil.
Low coolant temperature - Warm up to required temperature.
Improper fuel injection timing - Use the correct fuel injection pump timing adjustment.
Incorrect low idle setting - Adjustment required.
Fuel injector fault - Clean fuel injectors or change it.
Connecting rod is misaligned or defective - Align or replace connecting rod.
Pistons are worn or broken - Install new pistons.

Hydrostatic Transmission Troubleshooting

HST transmission is excessively noisy
Dirty transmission fluid or insufficient fluid level - Add fluid to the correct level or fill the transmission with fresh fluid.
Speed control linkage is worn or unadjusted - Repair or adjust linkage.
Relief valve is damaged - Replace valve as required.
Excessive transmission load - Load needs to be reduced.
Worn or defective transmission components - After disassembling and inspection, change defective components.

Power is too low
Lack of transmission fluid - Need to add transmission fluid.
Relief valve failure - Replace relief valve as required.
Worn or unadjusted speed control linkage - Adjust or replace linkage.

Transmission oil over heats
Transmission oil level is low - Fill the transmission housing with oil.
Dirty transmission fluid filter - Clean or change transmission fluid filter.
Damaged or clogged cooling components - Check all cooling components and change or repair if required.
Transmission is under excessive load - Reduce transmission load.

External fluid leaks
Damaged gaskets or seals - Install new components.
Transmission case internal pressure is too high - Change defective components.
Oil drain pipe is plugged - Check pipe and service if necessary.

Hydraulics Troubleshooting

Hydraulic system overheats
Incorrect hydraulic pressure setting - Adjust pressure as required.
Main relief valve improper adjustment or failure - Adjust or replace the relief valve.
Contaminated hydraulic oil - Change hydraulic oil.
Hydraulic oil level is insufficient - Check oil level and add hydraulic oil as required.
Hydraulic pump is worn - Change or repair hydraulic pump if required.

Lift arm can't drop or lift
Faulty lift controls - Change or repair.
Hydraulic pump is broken - Install new pump or repair it.
Damaged hydraulic control valve - Replace or repair the valve.
Faulty hydraulic cylinder - Repair or install a new lift cylinder.
Insufficient hydraulic oil - Need to add oil.

Bucket won't move
Bucket controls are faulty - Repair or change.
Hydraulic pump failure - Install new pump or repair it.
Hydraulic control valve is faulty - Change or repair hydraulic valve.
Bucket cylinder is faulty - Repair or replace cylinder.
Hydraulic fluid is insufficient - Checking hydraulic fluid level and add if necessary.

Slow bucket or lift arm action
Hydraulic pump is worn - Test the pump performance and change pump if required.
Oil leaks from hydraulic cylinder - Repair leak by replacing the seals.
Low hydraulic oil level - Checking hydraulic oil level and add if necessary.
Hydraulic control valve is not set properly or defective - Repair or set properly.
Hydraulic pressure is low - Adjust it correctly.

Bucket or boom is moving jerkily
Air in hydraulic system - Bleed hydraulic system.
Hydraulic oil filter is clogged - Change or clean oil filter.
Hydraulic oil is dirty - Hydraulic oil change required.
Scratched cylinder rod or tube - Change failed component.

Hydraulic pump is excessively noisy
Hydraulic leakage or lack of oil - Repair hydraulic leaks or add oil as required.
Hydraulic filter clogging - Clean or install new filter.
Dirty suction line - Suction line must be serviced.
Air in hydraulic pump - Air bleeding is required.
Pump components are worn out - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery will not charge
Electrical wire connections are corroded or loose - Tighten or clean connections.
Electrical terminal connectors are faulty - Install new terminal connectors.
Battery dead cell - Battery change required.
Belt is damaged or loose - Adjust belt tension or change the belt.

Starter motor cranks slow
Low battery capacity - Charge the battery.
Battery discharges quickly - Service charging system or replace battery.
Battery cables are disconnected or terminals are faulty - Check cables and clean or change terminals.

Starter will not crank
Battery is discharged or defective - Recharge or change battery.
Wiring harness is disconnected or improperly connected - Check wiring harness and connect as required.
Low battery power - Recharge the battery.
Starter motor is damaged - Repair or change starter.

____________________________________________________________________________________

WHEEL LOADERS SPECIFICATIONS

Bobcat

Caterpillar

Case

Doosan

John Deere

Kubota

Hitachi

JCB

Komatsu