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Home / Wheel Loaders / Hitachi Wheel Loaders / Hitachi ZW80

Hitachi ZW80 Troubleshooting

The Hitachi ZW80 wheel loader driveline system components: a 203.2 cu.in (3.3L) Kubota V3307-DI-T four-cycle four-cylinder direct injection turbocharged liquid-cooled diesel engine with a rated power of 63 hp (47.3 kW), and 2-speed hydrostatic transmission. The open center hydraulic system has a pump with a rated capacity of 19 gal/min (72 l/min). The Hitachi ZW80 is equipped with a power steering system, hydraulic wet disc brakes, and 17.5/65-20 tires. The wheel loader has a maximum lift height of 124.4" (3160 mm) and bucket 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

Diesel hard to start or doesn't start
Air in fuel system - Bleed fuel system.
Fuel filter element clogging - Filter maintenance required.
Fuel injection nozzles are clogged or faulty - Replace injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve clearance is wrong - Need to adjust valve clearance.
Defective fuel injection pump - Rebuild or install a new injection pump.

Engine starts but stalls immediately
Air cleaner is clogged - Clean or replace element.
Fuel filter element is dirty - Service or replace the filter.
Fuel injection pump has loose connections - Tighten the connections.
Dirty or defective injectors - Replace or clean fuel injectors.
Faulty fuel injection pump - Repair or install new pump.

Engine stalls during operation
Engine not warmed up - Warm up engine as required.
Fuel filter element clogging - Change filter element.
Air trapped in fuel system - Bleed air.
Fuel injection nozzles are damaged or dirty - Clean or change injection nozzles.
Wrong setting of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.

Engine stops while idle
Incorrect low idle speed adjustment - Adjustment required.
Faulty fuel injection pump - Replacement or repair required.
Clogged or defective injectors - Change or clean fuel injectors.
The valve clearance is not adjusted - Correct valve clearance.

Loss of engine power
Clogged air filter - Clean or replace element.
Fuel injection nozzles are damaged - Install a new kit of correctly balanced nozzles.
Incorrect fuel injection pressure - Adjust pressure to proper level.
Valve clearance is not correct - Adjustment procedure required.
Incorrectly adjusted low idle speed - Adjust low idling as recommended.
Fuel lines or hoses are clogged - Clean fuel system lines and hoses.
Cylinder-head gasket is leaking - Replace the gasket as required.
Piston rings are broken or leaking - Change piston rings.

Engine overheated
Insufficient coolant fluid - Add coolant fluid to cooling system and also check it for leaks.
Low engine oil level - Fill up the engine oil.
Dirty radiator core or faulty radiator cap - Change cap or clean radiator.
Excessive wear of the fan belt - Fan belt must be replaced.
Engine is overloaded - Load reducing required.

Oil pressure too low
Oil level is insufficient - Check oil level and add oil as required.
Clogged oil filter - Replace or clean engine oil filter element.
Different type of engine oil - Fill up with the correct oil viscosity.
Incorrect oil clearance in main bearing - Install new bearings.
Oil pump failure - Inspect and change as required.

Engine noise or knocking
Engine oil insufficient - Check oil level and add oil as required.
Low coolant temperature - Warm up engine as required.
Improper setting of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.
Incorrectly adjusted low idle speed - Correct the settings.
Clogged or defective injectors - Replace or clean fuel injectors.
Connecting rod failure or misalignment - Replace or align connecting rod.
Scored or worn pistons - Replace the pistons as required.

Hydrostatic Transmission Troubleshooting

Hydrostatic transmission makes excessive noise
Transmission fluid is dirty or fluid level is too low - Pour fresh fluid or add transmission fluid to proper level.
Bent or unadjusted speed control pedal linkage - Adjust or install new linkage.
Relief valve failure - Replace valve as required.
Transmission is under excessive load - Reduce transmission load.
Worn or defective parts of the hydrostatic transmission - Change or repair defective parts.

Power is too low
Transmission fluid insufficient - Add fluid to the transmission housing.
Stuck relief valve - Change relief valve.
Worn or unadjusted speed control linkage - Replace or adjust linkage.

Transmission fluid over heats
Insufficient transmission fluid - Checking transmission fluid level and add if necessary.
Transmission oil filter element clogging - Clean or change transmission oil filter.
Plugged or defective cooling components - Check all cooling components and clean or replace if required.
Transmission is under excessive load - Reduce the load is required.

Transmission oil leakage
Broken seals or gaskets - Install new seal or gaskets.
Transmission case internal pressure is too high - Change defective components.
Clogged transmission fluid return pipe - Clean or change return pipe.

Hydraulics Troubleshooting

Hydraulic system is overheated
Hydraulic pressure is incorrect - Adjust pressure as required.
Misadjusted or defective main relief valve - Replace or set up the relief valve.
Dirty hydraulic oil - Fill up with fresh hydraulic oil.
Hydraulic oil level is low - Add oil to the hydraulic system.
Faulty hydraulic oil pump - Replace or repair pump if necessary.

Boom does not raise or lower
Damaged lift controls - Replace or repair.
Hydraulic pump is broken - Repair or replace pump if necessary.
Hydraulic control valve failure - Repair or change hydraulic valve.
Hydraulic cylinder is faulty - Repair or change hydraulic cylinder.
Insufficient hydraulic oil - Check and refill the hydraulic oil.

Bucket tilt does not work
Bucket tilt controls malfunction - Repair or change.
Hydraulic pump failure - Repair or change pump if required.
Hydraulic control valve is defective - Install a new hydraulic valve or repair it.
Hydraulic bucket cylinder is defective - Change or repair cylinder.
Low hydraulic oil level - Need to add oil.

Boom or bucket is working slowly
Hydraulic pump is worn - Flow-rate pump and change pump if necessary.
Hydraulic cylinder oil leakage - Cylinder seals need to be replaced.
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.
Hydraulic control valve is not set properly or defective - Adjust properly or repair.
Hydraulic pressure loss - Hydraulic pressure must be set correctly.

Lift arm or bucket is moving jerkily
Hydraulic system is leaking air - Need to bleed air.
Clogged hydraulic oil filter element - Replace or clean the filter.
Hydraulic oil is dirty - Change hydraulic oil.
Cylinder tube or rod scoring - Change damaged component.

Hydraulic pump makes excessive noise
Low oil level or hydraulic leaks - Correct hydraulic leaks or top up oil as needed.
Hydraulic filter clogging - Service or replace hydraulic filter.
Clogged suction line - Suction line must be serviced.
Air in hydraulic pump - Bleed air.
Damaged pump components - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery is not charging
Corroded or loose cable connections - Clean or tighten connections.
Faulty battery terminal clamps - Terminal clamps should be changed.
Faulty cell in battery - Replace the battery.
Belt is defective or loose - Install a new belt or adjust belt tension.

Starter turning slow
Low battery output - Recharge the battery.
Battery drains quickly - Battery needs service or replacement.
Disconnected wiring or bad battery terminals - Connect wiring properly or install new terminals.

Starter motor won't turn
Battery is discharged or worn - Change or recharge battery.
Battery wiring is disconnected or improperly connected - Inspect wiring and connect as required.
Low battery output voltage - Battery is drained, charge it.
Starter motor failing - Replace or repair starter.

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WHEEL LOADERS SPECIFICATIONS

Bobcat

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John Deere

Kubota

Hitachi

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