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Hitachi Zaxis 200 Fuel Injector Change-Out

Discussion in 'Excavators' started by Simon C, Jan 10, 2021.

  1. Simon C

    Simon C Well-Known Member

    Joined:
    Jul 1, 2015
    Messages:
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    Occupation:
    Heavy Equipment Mechanic
    Location:
    Rocky Mountain House , AB., Canada
    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
     
  2. GaryHoff

    GaryHoff Senior Member

    Joined:
    Feb 25, 2009
    Messages:
    808
    Occupation:
    Heavey Equipment Mechanic
    Location:
    Alberta, Canada
    4hk1 part1.jpg
    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
     
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  3. GaryHoff

    GaryHoff Senior Member

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    Occupation:
    Heavey Equipment Mechanic
    Location:
    Alberta, Canada
    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
    4hk1 part2.jpg
    4. Remove the cylinder head cover.
    * 4HK1 is shown for illustration.
    4hk1 part3.jpg
    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.
    4hk1 part4.jpg
    1. Harness Bracket
    2. Harness Connector
    3. Fuel Injector Terminal
    4. Fuel Leak Off Pipe
     
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  4. GaryHoff

    GaryHoff Senior Member

    Joined:
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    Occupation:
    Heavey Equipment Mechanic
    Location:
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    9. Remove the fuel injection pipe clips and the
    injection pipes.
    4hk1 part5.jpg

    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)

    4hk1 part6.jpg

    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.
     
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  5. GaryHoff

    GaryHoff Senior Member

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    Occupation:
    Heavey Equipment Mechanic
    Location:
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    4hk1 part7.jpg

    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.

    4hk1 part8.jpg
    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)
    4hk1 part5.jpg
    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)
     
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  6. Simon C

    Simon C Well-Known Member

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    Heavy Equipment Mechanic
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    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
     
  7. GaryHoff

    GaryHoff Senior Member

    Joined:
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    Occupation:
    Heavey Equipment Mechanic
    Location:
    Alberta, Canada
    4hk1 part9.jpg
    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)

    4hk1 part10.jpg

    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)

    4hk1 part11.jpg

    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.
     
  8. GaryHoff

    GaryHoff Senior Member

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    Occupation:
    Heavey Equipment Mechanic
    Location:
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    4hk1 part12.jpg

    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)

    4hk1 part3.jpg
    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)
    4hk1 part2.jpg

    20. Attach the engine harness connectors. Each
    composite connector should make a loud click
    when it is securely attached.
     
  9. GaryHoff

    GaryHoff Senior Member

    Joined:
    Feb 25, 2009
    Messages:
    808
    Occupation:
    Heavey Equipment Mechanic
    Location:
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    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.
     
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  10. thepumpguysc

    thepumpguysc Senior Member

    Joined:
    Mar 18, 2010
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    6,381
    Occupation:
    Master Inj.Pump rebuilder
    Location:
    Sunny South Carolina
    Gary, THANK YOU..(from someone who doesn’t work on common rail systems)
    THAT was a concise explanation that anyone can follow.
     
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