Page 1 of 14

SERVICE BULLETIN CODE

DESCRIPTION
3 2011 0020
FILING LOCATION

ZX110-3~ZX330-3-205,
SUBJECT ZX140W-3~ZX220W-3-203
NEW SETTING – ZX-3 ISUZU ENGINE FUEL-RELATED SERVICE PARTS

OUTLINE
Supply pump and common rail service parts have been newly set for the Isuzu engine (4JJ, 4H,
6H) employed on ZX-3. This Service Bulletin is to give you the parts list and an explanation on the
replacement methods.

Thoroughly read the safety section in the service manual before starting the work to ensure safe operation.
Welding work, if any, should only be done by qualified welders.

APPLICABLE MODELS / SERVICE BULLETIN NO. FOR EACH MODEL

Machine Model(s): ZX110-3~ZX330-3, ZX140W-3~ZX220W-3

Machine Serial Nos.: Refer to the attached reference.

DESCRIPTION
Refer to the following page(s).

DWN
SA/GI: ZX-3(ALL)-209 CHKD
ZXW-3-048 APPD
 Page 2 of 14
SERVICE BULLETIN CODE
DESCRIPTION
3 2011 0020
FILING LOCATION

ZX110-3~ZX330-3-205,
ZX140W-3~ZX220W-3-203

CONTENTS

1 Application chart by model ………………………………………………………………… 3

2 Parts list ………………………………………………………………………………………… 4

3 Parts replacement method ………………………………………………………………… 6

3-1 Supply pump ………………………………………………………………………… 6

3-1-1 Supply pump connection pipe ……………………………………… 6

3-2 Common rail ………………………………………………………………………… 9

3-2-1 Pressure sensor ………………………………………………………… 9

3-2-2 Pressure limiter ………………………………………………………… 11

3-2-3 Flow damper ……………………………………………………………… 13

 Page 3 of 14
SERVICE BULLETIN CODE
DESCRIPTION
3 2011 0020
FILING LOCATION

ZX110-3~ZX330-3-205,
1 Application chart by model ZX140W-3~ZX220W-3-203

Model Model Code Isuzu Engine Type Applicable S/No.

ZX330-3 1V7
ZX350H-3 1V8
30-ton series ZX350K-3 1V9 6HK1XYSA-01
ZX350L-3 1VD
ZX350LC-3-HCME BFP
ZX200-3 1U1
ZX200-3-HCMC AWS
ZX210-3-AMS BDE
ZX210-3-HCME BFF
ZX210H-3 1U2
ZX210K-3 1U3
ZX225US-3 1U4
ZX225US-3-HCME BFH
ZX225USLC-3M 1U8
ZX225USR-3 1U5
ZX225USR-3-HCME BFJ
20-ton series ZX225USRK-3 1U6 8981795460
ZX190W-3 CHB
ZX190W-3-AMS CHA
ZX190W-3DARUMA CHD
ZX190W-3M CNB
ZX210W-3HCMC AWI
ZX210W-3-AMS CJA
ZX210W-3 CJB
ZX210W-3-HCMC CJC
ZX210W-3DARUMA CJD
ZX220W-3 CKB
ZX220W-3M CPB
ZX240-3 1V1
ZX250H-3 1V2
24-ton series ZX250K-3 1V3 4HK1XYSA-01
ZX250L-3 1VB
ZX240-3-HCMC AWU All serial nos.
ZX270-3 1V4
27-ton series ZX280LC-3 BFK 4HK1XYSA-03
ZX270-3-HCMC AWW
ZX170W-3 CGB
17-ton series 4HK1XYSA-04
ZX170W-3-AMS CGA
ZX160LC-3-AMS BCE
16-ton series ZX160LC-3-HCME BFD
ZX160LC-3 1T1
4JJ1XYSA-01
ZX180LC-3-AMS BCF
18-ton series ZX180LC-3-HCME BFE
ZX180LC-3 1T2
ZX140W-3-AMS CEA
ZX140W-3 CEB
14-ton series 4JJ1XYSA-02
ZX140W-3DARUMA CED
ZX145W-3 CFB
ZX110-3-AMS BCG
ZX110-3-HCME BFW
ZX110M-3-HCME BFX
10-ton series
ZX110-3 1R7
ZX110M-3 1R8
ZX120-3 1R1
ZX130-3-AMS BCH
ZX130-3-HCME BFT
ZX130K-3 1R2 4JJ1XYSA-03
ZX130L-3 1R3
ZX130L-3-HCME BJA
13-ton series ZX135USL-3-HCME BFV
ZX135USOS-3 1RK
ZX135US-3 1R4
ZX135USK-3 1R5
XZ135USL-3 1R6
ZX135US-3M 1R9
 Page 4 of 14
SERVICE BULLETIN CODE
DESCRIPTION
3 2011 0020
FILING LOCATION

ZX110-3~ZX330-3-205,
2 Parts list ZX140W-3~ZX220W-3-203

(1) 4JJ1
Common rail assembly
Supply pump assembly Isuzu P/No. 8980118881
Isuzu P/No. 8973815554
Fuel temperature sensor
Service part no.: already set Pressure limiter
Service part no.: already set

Pressure sensor
Service part no.: already set

Gasket, pressure limiter

Service part no.: already set
SCV Connection pipe
Service part no.: already set Service part no.: new setting

Isuzu supply pump P/No.

ASSY SCV kit Fuel temperature sensor Connection pipe
8973815550~3 8981454840
8980235810 8981818470
8973815554 8981455010
Isuzu common rail P/No.
ASSY Pressure sensor Pressure limiter Gasket, pressure limiter
8980118881 8981197900 8980325490 1156410460

(2) 4HK1
Common rail assembly
Supply pump assembly Isuzu P/No.: 8973060632
Isuzu P/No. 8973060449 SCV
Service part no.: already set Pressure limiter
Service part no.: already set

Pressure sensor Gasket, pressure limiter

Service part no.: already set Service part no.: already set

Fuel temperature sensor

Service part no.: already set Connection pipe Flow damper
Service part no.: new setting Service part no.: new setting

Isuzu supply pump P/No.

ASSY SCV kit Fuel temperature sensor Connection pipe
8973060449 8980436870 8980235810 8981818480
Isuzu common rail P/No.
ASSY Pressure sensor Pressure limiter Gasket, pressure limiter Flow damper
8973060632 8973186840 8973186910 1156410460 8981818590
 Page 5 of 14
SERVICE BULLETIN CODE
DESCRIPTION
3 2011 0020
FILING LOCATION

ZX110-3~ZX330-3-205,
(3) 6HK1 ZX140W-3~ZX220W-3-203
Supply pump assembly
Common rail assembly
Isuzu P/No. 8980915651
Isuzu P/No. 8981529500
Pressure limiter
Fuel temperature sensor Service part no.: already set
Service part no.: already set SCV
Service part no.: new setting

Gasket, pressure limiter

Service part no.: already set
Pressure sensor
Connection pipe Service part no.: already set
Service part no.: new setting

Isuzu supply pump P/No.

ASSY SCV kit Fuel temperature sensor Connection pipe
8980915651 8981818310 8980235810 8981818490
Isuzu common rail P/No.
ASSY Pressure sensor Pressure limiter Gasket, pressure limiter Flow damper
8981529500 8973186840 8973813460 1156410460 8981818600
 Page 6 of 14
SERVICE BULLETIN CODE
DESCRIPTION
3 2011 0020
FILING LOCATION
3 Parts replacement method ZX110-3~ZX330-3-205,
ZX140W-3~ZX220W-3-203
3-1 Supply pump

3-1-1 Supply pump connection pipe

1. Remove the supply pump from the engine. For the removal method, refer to the Service
Bulletins (4JJ1: No. 08067, 4HK1: 06208) and Isuzu Service Manual.

2. Remove the connection pipe.

Connection pipe Connection pipe Connection pipe

First, wash the joints and the vicinity. Then, using nylon brush and air blower, etc., wash
again carefully.
Lightly loosen the nuts on both sides and wash the joints again.
Completely loosen the nuts on both sides to remove the connection pipe from the delivery
valve holder.

Caution
If you’re working with a 6H-use supply pump (HP4 type), begin remove the next side only
after you've completed removing the first side.
Use a double spanner to loosen the nuts.
Work carefully, making sure that foreign substances don’t enter from the joints.

3. Install the new connection pipe.

Confirm that there are no scratches on the connection pipe and delivery valve holder seats.
Place the connection pipe against the delivery valve holder, being careful not to scratch the
seat surface.

Place the pipe-end against

the seat surface properly.

Caution
Always use a new connection pipe.
Place the pipe-end against the seat surface properly.
 Page 7 of 14
SERVICE BULLETIN CODE
DESCRIPTION
3 2011 0020
FILING LOCATION

ZX110-3~ZX330-3-205,
Fix the connection pipe with one hand, and using your ZX140W-3~ZX220W-3-203
other hand, tighten the nut to properly put the pipe and
seat surfaces together.

Fix in place

Put together

Caution
Temporarily tighten the nuts on both sides with your hands.
Tighten carefully so that you don’t end up tightening the nut at a tilted angle.
Tighten, making sure that the pipe doesn’t slip out of place during the work.

Tighten the other nut in the same way as you did in .

Caution
Tighten the nut, making sure that the pipe is not tilted.
Work carefully so that the nut doesn’t get stuck, and put the two surfaces together.

Follow the following tightening sequence to tighten the nut to the specified torque using a
torque wrench.
Tightening torque: 10±5 N m
For the nut numbers, see below.
Tightening sequence: #1 → #2
4JJ1, 4HK1-use HP3 6HK1-use HP4

Caution
In the case of 6HK1-use HP4, to prevent the pipes from becoming loose, tighten one
connection pipe (tighten to the specified torque with a digital angle wrench) and then,
tighten the other connection pipe.
To prevent the pipe from becoming loose, move onto the tightening work in the next
process immediately after tightening one pipe to the specified torque.
 Page 8 of 14
SERVICE BULLETIN CODE
DESCRIPTION
3 2011 0020
FILING LOCATION

ZX110-3~ZX330-3-205,
Use a digital angle wrench to tighten the nut. Refer to the ZX140W-3~ZX220W-3-203
chart below for the standard.

4JJ1, 4HK1-use HP3

Standard
Tightening sequence #1(75°) → #2(75°) → #1(75°) → #2(75°)
Pipe diameter
(tightening angle) [ Tightening angle: 150° (75°+ 75°) ]
6.35
Monitor torque 22N m or more

6HK1-use HP4
Standard
delivery valve holder cylinder
Pipe diameter #1(75°) → #2(75°) → #3(75°) → #4(75°)
Tightening sequence
6.35 →#1(75°) → #2(75°) → #3(75°) → #4(75°)
(tightening angle)
[ Tightening angle: 150° (75°+ 75°) ]
Monitor torque 22N m or more 27N m or more

Caution
Work carefully, making sure that you don’t strike the pipe or over-exert pressure.

4. Install the supply pump to the engine.

Refer to the Service Bulletin and Service Manual for the pump installation method just as you
did for the removal.
 Page 9 of 14
SERVICE BULLETIN CODE
DESCRIPTION
3 2011 0020
FILING LOCATION

ZX110-3~ZX330-3-205,
3-2 Common rail ZX140W-3~ZX220W-3-203

3-2-1 Pressure sensor

1. Remove the common rail from the engine. For the removal method, refer to the Isuzu Service
Manual.

2. Remove the pressure sensor from the common rail.

Pressure sensor
Pressure sensor Pressure sensor

First, wash the joints and the vicinity. Then, using nylon brush and air blower, etc., wash
again carefully.
Using deep socket (width across flats: 30), turn the pressure sensor counter-clockwise to
loosen it slightly. Wash the joints and vicinity again.
Remove the pressure sensor from the common rail body.
Caution
Work carefully, making sure that foreign substances don’t enter from the joints.

3. Install the pressure sensor to the common rail.

Apply clean grease to the seal and screw of a new pressure sensor.
Grease to be used: Kyodo Yushi Plus Guard (NLGI Grade No. 1)

Apply grease to the seal and screw.

Caution
Be sure to use new pressure sensors only.
Make sure that foreign substances don’t stick (to the seal, screw, connector).
Using a replacement part that has dropped is prohibited.
To decrease torque inconsistency, properly apply grease.

After completing the replacement work, immediately install the pressure sensor to the
common rail.
Caution
Work carefully, making sure that foreign substances don’t enter from the common rail
joints.
 Page 10 of 14
SERVICE BULLETIN CODE
DESCRIPTION
3 2011 0020
FILING LOCATION

ZX110-3~ZX330-3-205,
With your hands, turn the pressure sensor clockwise and ZX140W-3~ZX220W-3-203
temporarily tighten until it can't be turned anymore.
Caution
Don’t hold the connector when you are tightening.

Using deep socket (width across flats: 30) and torque wrench, turn the pressure sensor
counter-clockwise to acclimatize it according to the following tightening process.

(Angular tightening process)

(1) Tighten to tightening torque 15±3 N m.
(2) Next, tighten at tightening angle 7±2°.

Using deep socket (width across flats: 30), loosen the pressure sensor that was tightened
for acclimatization by turning it counter-clockwise.

Caution
Don’t remove the pressure sensor from the common rail body.

Using deep socket (width across flats: 30) and torque wrench, turn the pressure sensor
clockwise to completely tighten it according to the following process.

(Angular tightening process)

(1) Tighten to tightening torque 15±3 N m.
(2) Next, tighten at tightening angle 30±1°.
(3) Confirm that the tightening monitor torque is within 60≤T≤250 N m.

4. Install the common rail to the engine.

Refer to the Isuzu Service Manual for the installation method just as you did for the removal.
 Page 11 of 14
SERVICE BULLETIN CODE
DESCRIPTION
3 2011 0020
FILING LOCATION

ZX110-3~ZX330-3-205,
3-2-2 Pressure limiter ZX140W-3~ZX220W-3-203

1. Remove the common rail from the engine.

Refer to the Isuzu Service Manual for the removal method.

2. Remove the pressure limiter from the common rail.

Pressure limiter
Pressure limiter Pressure limiter

First, wash the joints and the vicinity. Then, using nylon brush and air blower, etc., wash
again carefully.
Using socket (width across flats: 14), turn the hollow screw counter-clockwise to loosen it
slightly. Wash the joints and vicinity again. Remove the hollow screw carefully, making sure
that the washer doesn’t drop.
Using socket (width across flats: 19), turn the pressure limiter counter-clockwise to loosen
it slightly. Wash the joints again and then, remove the pressure limiter from the common rail
body.

Caution
Work carefully, making sure that foreign substances don’t enter from the joints.

3. Install the pressure limiter to the common rail.

After completing the removal work, immediately install the pressure limiter to the common
rail body.

Caution
Be sure to use new pressure limiters only.
Make sure that foreign substances don’t stick (particularly to the seal).
Using a replacement part that has dropped is prohibited.
Work carefully, making sure that foreign substances don’t enter from the common rail
joints.

With your hands, turn the pressure limiter clockwise and temporarily tighten until it can’t be
turned anymore.
 Page 12 of 14
SERVICE BULLETIN CODE
DESCRIPTION
3 2011 0020
FILING LOCATION

ZX110-3~ZX330-3-205,
Using deep socket (width across flats: 19) and torque ZX140W-3~ZX220W-3-203
wrench, turn the pressure limiter clockwise to completely
tighten it according to the following process.

(Angular tightening process)

(1) Tighten to tightening torque 30±3 N m.
(2) Next, tighten at tightening angle 24±1°.
(3) Confirm that the tightening monitor torque is within 60 T 260 N m.

Install the hollow screw and washer to the pipe.

Caution
Be sure to use new hollow screws and washers only.
Confirm that there are no foreign substances or scratches on the installation surface.
Don’t touch with dirty hands.
Using a replacement part that has dropped is prohibited.
One at a time, install the washers to both sides of the pipe.

With your hands, temporarily tighten the pressure limiter screw.

Using socket (width across flats: 14) and torque wrench, turn the hollow screw clockwise to
completely tighten it to 20.1 N m (17.7-22.6 N m).

4. Install the common rail to the engine.

Refer to the Isuzu Service Manual for the installation method just as you did for the removal.
 Page 13 of 14
SERVICE BULLETIN CODE
DESCRIPTION
3 2011 0020
FILING LOCATION

ZX110-3~ZX330-3-205,
3-2-3 Flow damper ZX140W-3~ZX220W-3-203

1. Remove the common rail from the engine. Refer to the Isuzu Service manual for the removal
method.

2. Remove the flow damper from the common rail.

Flow damper

Flow damper

Caution
Always carry out this flow damper-related work for each cylinder.

First, wash the joints and the vicinity. Then, using nylon brush and air blower, etc., wash
again carefully.
Using socket (width across flats: 19), turn the flow damper counter-clockwise to loosen it
slightly. Wash the joints and vicinity again.

Remove the flow damper from the common rail body. If there are still parts inside the flow
damper, use clean a pair of tweezers, magnet, etc. to remove them carefully so that you
don’t scratch the surroundings.

Stopper Spring

Flow damper
components

Piston Body

Caution
Remove the flow damper carefully so that internal parts don’t drop.
Remove the components (stopper, piston, spring, body) without fail.
Work carefully, making sure that foreign substances don’t enter from the common rail
joints.
 Page 14 of 14
SERVICE BULLETIN CODE
DESCRIPTION
3 2011 0020
FILING LOCATION

ZX110-3~ZX330-3-205,
3. Install the flow damper to the common rail. ZX140W-3~ZX220W-3-203
After completing the removal work, immediately
assemble the flow damper to the common rail body.
Caution
Be sure to use new flow dampers only.
Make sure that foreign substances don’t stick (particularly to the screws and stopper
surface).
Using a replacement part that has dropped is prohibited.
Work carefully, making sure that foreign substances don’t enter from the common rail
joints.

With your hands, turn the flow damper clockwise and temporarily tighten until it can’t be
turned anymore.
Caution
Don’t hold the screws when you are tightening.

Using socket (width across flats: 19) and torque wrench, turn the flow damper clockwise to
completely tighten it according to the following process.

(Angular tightening process)

(1) Tighten to tightening torque 30±3 N m.
(2) Next, tighten at tightening angle 18±1°.
(3) Confirm that the tightening monitor torque is within 90≤T≤280 N m.

4. Install the common rail to the engine.

Refer to the Isuzu Service Manual for the installation method just as you did for the removal.