Hitachi Zaxis 330-3 Hydraulic Excavator Service Repair Manual

High-Powered Engine for Greater Production · Bigger engine output · Advanced electronic control including IT* *Information Technology Low Fuel Consumption for Cost Savings · Low fuel consumption with higher fuel efficiency · Great reduction in engine oil consumption · Low maintenance costs by simplified maintenance High Reliability and Durability · Extended service life with strengthened engine body · Enhanced reliability to suit job needs Enhanced Environmental Preservation · Complying with the 2006 Emission Regulations in the EU, US and Japan · Low noise design · Vibration suppression •Advanced Fuel Supply System Dual high-performance fuel filters are provided in the fuel supply system to eliminate dirt from fuel to the engine. An electric pump with filter element is also provided for stable fuel suction. TECHNOLOGICAL SOLUTIONS Key Features of the New-Generation Engines Fuel Tank Fuel Filter (Prefilter) Fuel Filter (Main Filter) Electric Pump (with Strainer) Engine •Cold Starting Ability The Isuzu engine, featuring good low-temperature starting ability, is further retrofitted to suit job needs. •Stable Operation at High Altitudes The new engine automatically makes the effective control of fuel injection in response to changes in atmospheric pressure at high altitudes. So there is no need for engine adjustment at high altitudes up to 4000 m. •Common Rail Type Fuel Injection System The common rail is designed to uniformly distribute pressurized fuel to respective electronic injectors. This enables efficient combustion, and reduces emissions including PM*. *Particulate Matter •Cooled EGR* System The cooled EGR* system lets part of exhaust gas mix with suction air for efficient recombustion to reduce emissions (NOx*) and fuel consumption. *Nitrogen Oxides Electric Pump Manual Pump Fuel Filters Fuel Filters Fuel Pump Common Rail Pressure Sensor Common Rail Injectors Control Unit Fuel Tank EGR Cooler Control Unit EGR Regulating Valve Exhaust Intake Air Cylinder Head Coolant •Coming Emission Regulations Tier 3 in the EU, US and Japan Output Range P(kW) 130 P < 560 75 P < 130 Models ZAXIS240/270 ZAXIS200 NOx + HC (g/kWh) 3.6 3.6 HC (g/kWh) 0.4 0.4 CO (g/kWh) 3.5 5.0 PM (g/kWh) 0.17 0.2 Diesel Plume (%) 25 25 Enforcement 10/2006 10/2007 Japan Tier 3 US EPA Tier 3 Output Range P(kW) 130 P < 560 75 P < 130 Models ZAXIS240/270 ZAXIS200 NOx + HC (g/kWh) 4.0 4.0 CO (g/kWh) 3.5 5.0 PM (g/kWh) 0.2 0.3 Enforcement 1/2006 1/2007 EU Stage A Cam Angle Sensor Crank Rotation Sensor Sensors (Boost Pressure, Radiator, Temperature and Others) Pressure Limiter Flow Damper New-Generation Engine Development Concept 1 4 3 2 NEW SALES MANUAL The New-Generation Engines (4-Cylinder) On the ZX200-3, ZX240-3 and ZX270-3 200/240/270 Output Range P(kW) 130 P < 560 75 P < 130 Models ZAXIS240/270 ZAXIS200 NOx + HC (g/kWh) 4.0 4.0 CO (g/kWh) 3.5 5.0 PM (g/kWh) 0.2 0.3 Enforcement 1/2006 1/2007 Copyright of this manual belongs to Hitachi Construction Machinery. Duplication, reproduction, transfer and the like are prohibited. Never hand this manual over to customers. Reproduction of any figures, illustrations, graphs and statement for the sake of advertising are prohibited. Photographs, names and data may differ in part from the final specifications. KS-E492 05.07(eT/KA, HT) Hitachi Construction Machinery Co., Ltd. www.hitachi-c-m.com Hitachi Authorized Dealer Use Only 2005.09

•Extended Service Life The service life of the new engine is greatly increased by about 80% over the conventional. 1 High-Powered Engine for Greater Production New P Mode Vs. Conventional P Mode 120 100 80 ZAXIS 200 % Index (Conventional = 100%) Conventional Model •17%* Increase in Production with Low Fuel Consumption Equivalent to the Conventional *Data on the ZAXIS270 Using the new-generation engine makes possible an impressive increase in production and fuel efficiency for fuel savings. This new OHC 4-valve engine increases air suction to cylinders to boost combustion efficiency. With the overhead camshaft (OHC) (featuring stable valve opening/closing at a high speed) and the common rail type electronic fuel injection system, efficient combustion can be achieved to boost output significantly. ZAXIS200 Engine model Max. output (HP mode) Displacement (No. of cylinders) Engine type Emission Regulations Weight 4HK1 (New) 122 kW/2 000 rpm 5 193 cc (4-Cylinder) OHC 4-valve Tier3 480 kg ZX200-3 6BG1 (Conventional) 110 kW/2 100 rpm 6 494 cc (6-Cylinder) OHV 2-valve Tier2 490 kg ZX200 ZAXIS240 4HK1 (New) 132 kW/2 000 rpm 5 193 cc (4-Cylinder) OHC 4-valve Tier3 480 kg ZX240-3 6BG1 (Conventional) 125 kW/2 000 rpm 6 494 cc (6-Cylinder) OHV 2-valve Tier2 490 kg ZX230 ZAXIS270 4HK1 (New) 140 kW/2 100 rpm 5 193 cc (4-Cylinder) OHC 4-valve Tier3 480 kg ZX270-3 6BG1 (Conventional) 132 kW/2 150 rpm 6 494 cc (4-Cylinder) OHV 2-valve Tier2 490 kg ZX270 120 100 80 ZAXIS 240 % 120 100 80 ZAXIS 270 % (Production and Fuel Consumption in a Cycle of 90 o Swing and Loading on Dump Truck) Output and Displacement •Significant Reduction in Oil Consumption About 60% reduction in engine oil consumption can be achieved over the conventional thanks to the precision-finished cylinder blocks. This also eliminates the replenishing of engine oil in 500-hour operating period at oil change intervals. •Great 15%* Reduction in Fuel Consumption *Data on the ZAXIS240 A great reduction (10% to 15%) in fuel consumption can be accomplished while maintaining high production in the new E mode, which is equivalent to the conventional P mode, thanks to the new engine and high operating efficiency. •Meeting Two Contradictive Needs- High Production and Low Fuel Consumption Fuel consumption is further reduced with the cooled EGR* system that increases fuel efficiency dramatically. *Exhaust Gas Recirculation ZAXIS200 ZAXIS240 ZAXIS270 Fuel Reduction L 16 500 21 500 14 500 ¥* 1 1 490 000 1 940 000 1 310 000 Euro* 2 $* 3 *1 : ¥90/L *2 : Euro/L *3 : $/L Fuel Cost Savings in 5000 Operating Hours New E Mode Vs. Conventional P Mode Operating conditions: Continuous loading on dump truck 2 Low Fuel Consumption for Cost Savings New P Mode Vs. Conventional P Mode 120 100 80 ZAXIS 200 % Index (Conventional Model = 100%) 120 100 80 ZAXIS 240 % 120 100 80 ZAXIS 270 % (Production and Fuel Consumption in a Cycle of 90 o Swing and Loading on Dump Truck) Oil Consumption New Model Conventional Model Engine Oil Consumption Operating Hours About 60% Reduction 12% Increase •Extended Service Life with Strengthened Engine Body The reliability and durability of the engine are greatly increased by thickening and enlarging component parts. Thus, strength and rigidity are increased, yet its weight is unchanged, equivalent to the conventional engine, despite of 4-cylinder design. New Engine (Weight 480 kg) (OHC 4-Valve) Conventional Engine (Weight 490 kg) (OHV 2-Valve) OHC Valve Mechanism Increased Journal Pin Dia Increased Crank Pin Dia Thickened Ladder Frame Thickened Cylinder Block OHV Valve Mechanism Drawn in scale similar to new engine 3 High Reliability and Durability (Weight kg) •Further Enhanced Durability of Proven Isuzu Engine The proven Isuzu engine, with sales amounted to 30 000(Until Feb,2004) units in the world, is further retrofitted to suit job needs, enhancing durability and reliability. More specifically, the piston and water pump shaft bearing are strengthened, seals are improved, and oil pan and filter capacities are increased. 4 Enhanced Environmental Preservation •Complying with the 2006 Emission Regulations in EU, US and Japan The new-generation clean engine is environmentally friendly. Emissions can be reduced with the common rail type electronic fuel injection system featuring effective control of combustion. •Engine Vibration Suppression The Isuzu engine, featuring low vibration, helps reduce machine vibration and shocks. •Low Noise Design Engine sound can be suppressed by 5 dB with the strengthened, rugged engine body. The HS* cooling fan is utilized to reduce air flow resistance and blow noise. This contributes to reducing machine noise. *HItachi Silent Engine Speed(rpm) Engine Noise 600 800 2 000 2 100 Noise Level (dB A) Conventional Engine New Engine 5 dB Reduction ZX200-3 / ZX240-3 / ZX270-3 Service Life Service Life (Hitachi Data) New Engine Conventional Engine 2 3 Production Fuel Consumption Production Fuel Consumption Production Fuel Consumption Production Fuel Consumption Production Fuel Consumption Production Fuel Consumption 80% Increase 10% Reduction 13% Reduction 15% Reduction 17% Increase 11% Increase Conventional Model Conventional Model Conventional Model Conventional Model Conventional Model

Hitachi Zaxis 330-3 Hydraulic Excavator Service Repair Manual

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