ZX200-3 Product Id.# *HCM1U100K00205787* Does any one know what is the maximum hours a machine like this should run before changing out the electronic injectors. Caterpillar Machines are usually in the 6000 HR to 8000Hr area that i've seen. This machine has a Isuzu AI-4HK1XYSA-02 engine that I have adjusted the valves on another exact model. Looking for some technical manual info for installing the injectors. I realize that the injectors probably would need to be calibrated by an electronic service tool. Am wondering if Diesel Laptops Off- Road Service Tool would do it or is it a call the John Deere Dealer or Hitachi Dealer. The reason I am asking is that I know a gentleman that ran his too long and blew hole down the side of a liner. Cheaper to change out before causing engine damage., Any info appreciated. Simon
1. Fuel Injection Pipe Clip 2. Fuel Injection Pipe 3. Fuel Injector Leak-Off Pipe 4. Fuel Injector 5. Fuel Injector Clamp 6. Fuel Injector Clamp Bolt 7. EGR Adapter 8. EGR Cooler 9. EGR Valve 10. Cylinder Head Cover 11. Fuel Injector Harness Bracket 12. Fuel Injector Terminal
The fuel system consists of many tiny holes and spaces that allow the movement of fuel from one place to another. These holes and spaces are milled to extremely high precision. This is especially true of the fuel injectors. The fuel injector is very sensitive to foreign material. Foreign material will result in fuel system breakdown. Exercise great care not to allow the entry of foreign material into the fuel system or fuel injectors during the removal and installation procedure. Caution: To avoid electric shock; Set the switch to the ‘OFF’ position and disconnect battery negative cable before checking or repairing the fuel injector, wiring or/and connectors. Removal 1. Remove the engine harness, the EGR valve, the pressure sensor, and all of the fuel injector connectors. 2. Remove the EGR valve and the EGR adapter. 3. Tape the EGR case holes shut to prevent the entry 4. Remove the cylinder head cover. * 4HK1 is shown for illustration. 5. Alternately loosen the fuel injector terminal nuts a little at a time in sequence. Several loosening cycles should be required before the nuts are loose. 6. Loosen the fuel injector harness bracket bolts. Remove the inside connector and the harness bracket. 7. Remove the fuel injector leak-off pipe. 8. Remove the lower cover. of foreign material. 1. Harness Bracket 2. Harness Connector 3. Fuel Injector Terminal 4. Fuel Leak Off Pipe
9. Remove the fuel injection pipe clips and the injection pipes. 10. Loosen the fuel injector clamp fixing bolts and remove the fuel injectors. If the fuel injectors are difficult to remove, use the fuel injector remover. Install the fuel injector remover to the leak-off pipe attachment part on the fuel injector. Use a sliding hammer to force the fuel injector clamp off the fuel injector. Caution: Do not remove the fuel injector sleeve. Special tool Fuel injector remover: 380.002.601 Sliding hammer: 5-8840-0019 (J-23907) 11. Mark each fuel injector with the number of the cylinder from which it was removed. Store the fuel injectors in a safe place. Position the fuel injector so that the nozzle is protected. Caution: • Do not tamper with the electromagnetic portion of the fuel injector. Reduced electromagnetic function will result in injector failure. Recording Fuel Injector Flow Rate Information from the QR plate on the replaced injector housing; Record all numbers of replaced fuel injector's from QR plate.
Installation Important: Install each of the fuel injectors on its original position. (the cylinder from which it was removed) 1. Install a new gasket and O-ring to each of the fuel injector clamps. Refer to the illustration. 2. Apply molybdenum to the threads and seating surfaces of the clamp bolts. 3. Install the fuel injector clamps to the cylinder head. 4. Temporarily tighten the clamp bolts. 5. Apply a thin coat of engine oil to the outer surface of the fuel injector side sleeve nuts. 6. Install the fuel injector pipes to the position shown in the illustration. 7. Use a spanner to carefully the sleeve nuts until the fuel injector pipes contact the fuel injector and common rail. 8. Tighten the fuel injection pipe clips to the specified torque. Tightening torque: 6 N⋅m (0.6 kg⋅m/53 lb in) Name 1. Fuel Injection Pipe 2. Pipe Clip 9. Final tighten the injection clamp bolts to the specified torque. Tightening torque: 30 N⋅m (3.1 kg⋅m/22 lb ft) 10. Tighten the injection pipes to the specified torque. Tightening torque: 44 N⋅m (4.5 kg⋅m/32 lb ft)
Wow. That is quite a procedure. I am super clean but will have to read it over a few more times . Thanks for the info. If I have any more questions I will reach out to you. Simon
11. Install the nozzle leak off pipes together with the new gaskets. Tighten the pipes to the specified torque. Tightening torque: 12 N⋅m (1.2 kg⋅m/106 lb in) 12. Install the fuel injector harness connectors. Work from the inside out. 13. Install the harness bracket and tighten the bolts to the specified torque. Tightening torque: 4HK1: 48 N⋅m (4.9 kg⋅m/35 lb ft) 14. Install the fuel injector terminal nuts to the injector. 15. Alternately tighten each nut 2 or 3 turns at a time until the specified torque is reached. Tightening torque: 2 N⋅m (0.2 kg⋅m/18 lb in) Caution: Do not overtighten the nuts. Damage to the terminal studs will result.
16. Install the gasket to the cylinder head cover. 17. Install the cylinder head cover and tighten the bolts to the specified torque. Tightening torque: 4HK1: 18 N⋅m (1.8 kg⋅m/13 lb ft) 18. Install the gasket to the EGR valve and tighten the bolts to the specified torque. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) 19. Install the gasket to the EGR adapter and tighten the bolts to the specified torque. Tightening torque: 24 N⋅m (2.4 kg⋅m/18 lb ft) 20. Attach the engine harness connectors. Each composite connector should make a loud click when it is securely attached.
Injector life will depend on your fuel conditions, and maintenance. Its not a bad idea to change injectors at 6000-8000hrs for preventative maintenance. Theres also a "last chance filter" in your injection pump. You should probably clean/replace that before you replace injectors. I believe you will need Hitachi to program in the injector codes, as Deere doesn't have access to all the isuzu engine software. There may be aftermarket software that can program in the codes, but I am not familiar with any.
Gary, THANK YOU..(from someone who doesn’t work on common rail systems) THAT was a concise explanation that anyone can follow.