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Home / Wheel Loaders / Hitachi Wheel Loaders / Hitachi ZW80-5B

Hitachi ZW80-5B Troubleshooting

The Hitachi ZW80-5B wheel loader driveline system components: a 177 cu.in (2.9L) Deutz TD2.9L4 vertical four-cylinder turbocharged liquid-cooled diesel engine with a rated power of 63 hp (47 kW), and 2-speed hydrostatic transmission. The open center hydraulic system has a gear pump with a rated capacity of 20.1 gal/min (76 l/min). The Hitachi ZW80-5B is equipped with a hydraulic power steering, boom floating system, and 17.5/65-20 standard tires. The wheel loader has a maximum lift height to hinge pin of 124.6" (3165 mm) and boom breakout force of 8270 lbs (3760 kg). The rated operating capacity is 3585 lbs (1625 kg), and tipping load is 7170 lbs (3250 kg).

Engine Troubleshooting

Engine starts hard or doesn't start
Air in fuel tank - Bleed fuel tank.
Fuel filter element clogging - Replace filter element.
Dirty or faulty injection nozzles - Replace injection nozzles.
Dirt or water in fuel system - Drain water or flush dirt from the system.
Valve clearance is wrong - Correct valve clearance.
Fuel injection pump is damaged - Replace or repair injection pump.

Diesel starts but then stops
Plugged air cleaner - Clean or replace air cleaner element.
Dirty fuel filter - Change filter element.
Fuel injection pump is leaking - Repair any leaks.
Dirty or defective injectors - Test and replace fuel injectors if necessary.
Fuel injection pump is not operating properly - Install a new fuel pump or repair.

Engine stops running suddenly
Engine is cold - Warm up engine as required.
Fuel filter element clogging - Replace the filter element.
Air in fuel tank - Bleed fuel tank.
Defective injection nozzle - Inspect nozzles and replace if necessary.
Fuel injection pump timing is not adjusted - Adjust as recommended.

Engine stops at idle
Wrong adjustment of low idle speed - Correct low idle adjustment.
Fuel injection pump is not working correctly - Replacement or repair required.
Damaged or clogged injectors - Change or clean fuel injectors.
Excessive valve clearance - Check and adjust.

Engine power is too low
Plugged air cleaner - Clean or replace element.
Dirty or damaged injection nozzles - Replace injection nozzles.
Fuel injection pressure is incorrect - Test fuel injection pressure and adjust it correctly.
The valve clearance is incorrect - Correct valve clearance.
Incorrectly set low idle speed - Adjustment required.
Fuel hoses or lines clogging - Fuel lines and hoses need to be cleaned.
Cylinder head gasket is worn - Replace cylinder head gasket.
Piston rings are worn or defective - Replace the piston rings as required.

Engine is overheated
Coolant level is low - Fill the cooling system and check components for leaks or other faults.
Engine oil insufficient - Check and refill engine oil.
Radiator fins are clogged or radiator cap is faulty - Change cap or clean radiator.
Damaged or worn fan belt - Replace as required.
Engine overload - Reduce load on the engine.

Insufficient oil pressure
Oil level is low - Checking oil level and add if necessary.
Oil filter is dirty - Clean or change engine oil filter.
Improper type of engine oil - Use oil of correct viscosity.
Crankshaft bearing has incorrect oil clearance - Replace bearings.
Oil pump malfunction - Install a new pump.

Abnormal engine knocking or noise
Not enough engine oil - Checking oil level and add if necessary.
Engine is not warmed up to required temperature - Warm up to required temperature.
Timing of fuel injection pump is incorrect - Set up as recommended.
Improperly adjusted low idle speed - Correct low idle adjustment.
Clogged or defective injectors - Replace or clean fuel injectors.
Connecting rod misalignment or failure - Connecting rod needs to be replaced or aligned.
Broken or worn pistons - Pistons need to be replaced.

Hydrostatic Transmission Troubleshooting

Hydrostatic transmission noise
Transmission fluid is dirty or fluid level is too low - Top up to proper level or change transmission fluid.
Speed control pedal linkage is damaged or out of adjustment - Adjust or replace linkage.
Relief valve is damaged - Replace valve as required.
Excessive transmission load - Reduce loading.
Defective or worn transmission parts - Replace or repair defective components.

Power is insufficient
Lack of transmission oil supply - Check transmission oil level and add oil as required.
Relief valve is stuck - Replace valve as required.
Worn or unadjusted speed control linkage - Adjust or repair linkage.

Transmission fluid overheating
Transmission oil level is low - Need to add transmission oil.
Transmission oil filter element clogging - Service or change transmission oil filter.
Damaged or clogged cooling components - Inspect all cooling components and replace or clean if necessary.
Excessive loading - Reduce loading.

Transmission oil leakage
Damaged seals or gaskets - Seals and gaskets replacement required.
High internal transmission case pressure - Change defective components.
Clogged transmission fluid return pipe - Clean or change return pipe.

Hydraulics Troubleshooting

Hydraulic system overheats
Hydraulic pressure incorrectly adjusted - Correct setting is required.
Main relief valve malfunction or improper adjustment - Adjust relief valve or change if required.
Contaminated hydraulic oil - Fill up with fresh hydraulic oil.
Hydraulic oil level is low - Fill up the hydraulic oil.
Hydraulic pump is faulty - Repair or replace pump if necessary.

Lift arm cannot be raised or lowered
Defective lift controls - Check and repair as required.
Hydraulic pump malfunction - Repair or change pump if required.
Hydraulic control valve is defective - Install a new hydraulic valve or repair it.
Broken hydraulic cylinder - Change or repair lift cylinder.
Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.

Bucket does not tilt
Bucket controls are faulty - Repair or change.
Hydraulic pump malfunction - Repair or change pump if required.
Hydraulic control valve is faulty - Repair or change the valve.
Defective bucket cylinder - Replace or repair cylinder.
Hydraulic fluid is insufficient - Add fluid as required.

Bucket or lift arm runs slowly
Worn hydraulic oil pump - Test the pump flow rate and install new pump if required.
Oil leaks from hydraulic cylinder - Correct leakage by changing the seals.
Hydraulic oil is insufficient - Need to add oil.
Damaged or incorrect adjusted hydraulic control valve - Repair or adjust correctly.
Low hydraulic pressure - Set pressure correctly.

Bucket or boom is moving jerkily
Air in the hydraulic system - Air bleeding is required.
Dirty hydraulic oil filter element - Clean or replace the filter.
Contaminated hydraulic oil - Fill up with fresh hydraulic oil.
Scratched cylinder rod or tube - Change defective component.

Hydraulic pump is excessively noisy
Hydraulic system leaking or not enough oil - Add hydraulic oil or correct system leaks.
Clogged hydraulic filter - Service or replace hydraulic filter.
Dirty suction line - Service the suction line.
Pump is sucking air - Bleed air.
Damaged pump components - Rebuild or replace hydraulic pump.

Electrical Troubleshooting

Battery is not charging
Corroded or loose cable connections - Service or tighten cable connections.
Battery terminal connectors are faulty - Terminal connectors should be replaced.
Bad cell in battery - Install a new battery.
Belt is damaged or loose - Adjust belt tension or replace belt.

Starter turns slow
Low battery capacity - Battery needs to be recharged.
Battery is not holding charge - Service charging system or change battery.
Bad terminals or disconnected battery cables - Check wiring connections and replace or clean terminals.

Starter is not cranking
Battery is low or faulty - Battery needs to be recharged or replaced.
Battery wires are disconnected or incorrectly connected - Check wires and connect correctly.
Battery power is low - Battery is drained, recharge it.
Starter motor is defective - Replace or repair starter.

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