CONFIDENTIAL
Page 1 of 1
SERVICE BULLETIN CODE
DESCRIPTION 3 2007 068B
FILING LOCATION
ZX-3 ALL-238
SUBJECT (Revised)
NEW ZX-3 FUEL FILTER
REVISED
CORRECTION OF ERRORS
There are several corrections in Service Bulletin ZX-3 ALL-238 which we previously issued.
Addition of page 11/11
[Reason for the revision to the Service Bulletin]
"Serial number break of mass-produced machines (for reference)" is added to page 11.
DWN
CHKD
WHITE APPD
CONFIDENTIAL
Page 1 of 11
SERVICE BULLETIN CODE
DESCRIPTION 3 2007 068B
FILING LOCATION
ZX-3 ALL-238
SUBJECT (Revised)
NEW ZX-3 FUEL FILTER
OUTLINE
Blocked fuel filter has been confirmed as the cause of ZX-3 engine trouble. As modification, mesh
size-modified pre-filter and bigger-size main filter have been set up as new parts. If there have
been any faults or if there are machines that use poor-quality oil, we ask that you order the neces-
sary parts (kit no. 9288272) to carry out modifications.
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): ZX-3 Middle-size Excavators
Machine Serial Nos.: Refer to the following page.
DESCRIPTION
Refer to the following page(s).
DWN
CHKD
SA/GI: ZX-3 ALL-059 WHITE APPD
CONFIDENTIAL
Page 2 of 11
SERVICE BULLETIN CODE
DESCRIPTION 3 2007 068B
FILING LOCATION
ZX-3 ALL-238
(Revised)
CONTENTS
1 PREPARATORY WORK ............................................................................................. 3
2 PRE-FILTER ELEMENT REPLACEMENT ................................................................. 5
3.1 Main filter replacement (ZX200-3 ~ 270-3) ..............................................................6
3.2 Main filter replacement (ZX330-3, 225US-3, 225USR-3) ........................................8
4 AFTER WORK INSPECTION ..................................................................................... 9
5 MODIFIED MODELS AND SERIAL NUMBERS ........................................................ 9
CONFIDENTIAL
Page 3 of 11
SERVICE BULLETIN CODE
DESCRIPTION 3 2007 068B
FILING LOCATION
ZX-3 ALL-238
(Revised)
ZX-3 FUEL PRE-FILTER ELEMENT AND FUEL MAIN FILTER
REPLACEMENT INSTRUCTIONS
1 PREPARATORY WORK
1 Verify the parts of the replacement kit that is featured on the list.
List of the parts of the replacement kit (kit no, 9288272)
PART No. PART NAME QTY REMARKS
4676385 Pre-filter element kit 1 Including a case-use O-ring and drain-plug-use gasket
4681858 Main filter element kit 1 Including a case-use O-ring and drain-plug-use gasket
Part number dedicated to the kit: 4681858
(containing the same parts as those in kit no. 4679981)
4653189 Case (clear) 1 Replace with the main filter case.
4653193 Drain plug 1 Attach to the case of the new main filter.
8112287 Bracket 1 For ZX200-3 - 270-3
J271030 Bolt 1 For ZX200-3 - 270-3
4681999 Vinyl hose (450 mm) 1 Pre-filter-use drain hose
4679927 Vinyl hose (650 mm) 1 Main filter-use drain hose
CONFIDENTIAL
Page 4 of 11
SERVICE BULLETIN CODE
DESCRIPTION 3 2007 068B
FILING LOCATION
ZX-3 ALL-238
(Revised)
1 Close the cock found at the bottom of the fuel tank.
Fuel cock
2 Loosen the air-release plug and drain plug of each filter to release the fuel.
(Have ready a drain-receptacle of 2L or larger.)
Air-release plug
Air-release plug
Clear case
Clear case
Drain plug
Drain plug
Pre-filter Main filter
3 Have ready an exclusive filter wrench (P/No. 4646133).
(Using a general-purpose wrench can cause the clear case to break.)
Exclusive tool
(P/No. 4646133)
CONFIDENTIAL
Page 5 of 11
SERVICE BULLETIN CODE
DESCRIPTION 3 2007 068B
FILING LOCATION
ZX-3 ALL-238
(Revised)
2 PRE-FILTER ELEMENT REPLACEMENT
1 Remove the drain plug.
2 Using the exclusive filter wrench, remove the clear case.
3 Replace the element with the modified one contained in the kit.
The filters of the new and old elements are different. Make sure to install the yellow-colored element.
Old element (P/No. 4649267, mesh size: 17.0 μm): green-colored
New element (P/No. 4676385, mesh size: 5.5 μm): yellow-colored
4 Install the clear case.
At this time, replace the O-ring with the new one contained in the kit.
The case should be tightened using the exclusive filter wrench.
Clear case tightening torque: 30 ± 2 N·m
5 Install the drain plug on the clear case.
At this time, replace the O-ring with the new one contained in the kit.
6 Tighten the drain plug and air-release plug.
Air-release plug tightening torque: 10 ± 2 N·m
Drain plug tightening torque: 2.5 ± 0.5 N·m
7 Install the drain hose (P/No. 4681999) contained in the kit onto the drain plug pipe. The hose is longish, so cut it at
about 50 mm point from the under cover.
8 Tighten the air-release plug and drain plug.
CONFIDENTIAL
Page 6 of 11
SERVICE BULLETIN CODE
DESCRIPTION 3 2007 068B
FILING LOCATION
ZX-3 ALL-238
(Revised)
3.1 Main filter replacement (ZX200-3 ~ ZX270-3)
1 Tentatively remove the main filter assembly from the cover.
2 Using bolt P/No. J271030 contained in the kit, install kit-bracket P/No. 8112287 on the machine cover.
3 Install the removed main filter on the above bracket.
Bracket (P/No. 8112287)
Bolt (P/No. J271045)
Bolt (P/No. J271080)
Bolt (P/No. J271030 ~ 3)
Main fuel filter
4 Using exclusive filter wrench P/No. 4646133, remove the clear case.
5 Replace the element with the modified element contained in the kit.
The new and old elements are different in size.
Old element (P/No. 4642641)
New element (P/No. 4681858)
Install this.
Existing main filter New bigger-size main filter element
element (P/No. 4681858)
CONFIDENTIAL
Page 7 of 11
SERVICE BULLETIN CODE
DESCRIPTION 3 2007 068B
FILING LOCATION
ZX-3 ALL-238
(Revised)
6 Install the modified clear case (P/No. 4653189) contained in the kit.
At this time, use a new O-ring contained in the kit.
The case should be tightened using the exclusive filter wrench.
Clear case tightening torque: 30 ± 2 N·m
7 Install the drain plug contained in the kit on the clear case.
At this time, use a new O-ring contained in the kit.
8 Tighten the drain plug and air-release plug.
Air-release plug tightening torque: 10 ± 2 N·m
Drain plug tightening torque: 2.5 ± 0.5 N·m
9 Install drain hose P/No. 4679927 contained in the kit onto the drain plug pipe.
The hose is longish, so cut it at about 50 mm point from the under cover.
10 Tighten the air-release plug and drain plug.
CONFIDENTIAL
Page 8 of 11
SERVICE BULLETIN CODE
DESCRIPTION 3 2007 068B
FILING LOCATION
ZX-3 ALL-238
(Revised)
3.2 Main filter replacement (ZX330-3, ZX225US-3, ZX225USR-3)
1 Using exclusive filter wrench P/No. 4646133), remove the clear case.
2 Replace the element with the modified element contained in the kit.
The new and old elements are different in size.
Old element (P/No. 4642641)
New element (P/No. 4681858)
Install this.
Existing main filter New bigger-size main filter element
element (P/No. 4681858)
3 Install the modified clear case (P/No. 4653189) contained in the kit.
At this time, use a new O-ring contained in the kit.
The case should be tightened using the exclusive filter wrench.
Clear case tightening torque: 30 ± 2 N·m
4 Install the drain plug contained in the kit on the clear case.
At this time, use a new O-ring contained in the kit.
5 Tighten the drain plug and air-release plug.
Air-release plug tightening torque: 10 ± 2 N·m
Drain plug tightening torque: 2.5 ± 0.5 N·m
6 Install drain hose P/No. 4679927 contained in the kit onto the drain plug pipe.
The hose is longish, so cut it at about 50 mm point from the under cover.
7 Tighten the air-release plug and drain plug.
CONFIDENTIAL
Page 9 of 11
SERVICE BULLETIN CODE
DESCRIPTION 3 2007 068B
FILING LOCATION
ZX-3 ALL-238
(Revised)
4 AFTER WORK INSPECTION
1 Open the cock found at the bottom of the fuel tank.
2 Release the air from the fuel system. For the air-release method, refer to the Operator's Manual.
3 Start the engine and verify that no fuel is leaking.
5 MODIFIED MODELS AND SERIAL NUMBERS
The machines with the serial numbers listed below have already been modified as described in this Service Bulletin.
MODELS MODEL CODE S/N
ZX200-3 1U1 202785 and above
ZX210N-3-HCME BFG 600746 and above
ZX210N-3-AMS BDF 600746 and above
ZX225US-3 1U4 203604 and above
ZX225USR-3 1U5 202889 and above
ZX225USLC-3M (U.S.A) 1U8 501080 and above
ZX240-3 1V1 21314 and above
ZX270-3 1V4 31067 and above
ZX330-3 1V7 52014 and above
CONFIDENTIAL
Page 10 of 11
SERVICE BULLETIN CODE
DESCRIPTION 3 2007 068B
FILING LOCATION
ZX-3 ALL-238
(Revised)
How to drain the water from the fuel filter (main filter and pre-filter)
Main filter
Pre-filter
Example: ZX200-3
< Procedure for draining the water >
Main filter Pre-filter 1 Have ready a draining receptacle (A).
(Place the draining receptacle on the shoe.)
2 Loosen the drain plug (B).
3 The water inside the filter will drain.
(When the filter is filled with water, the float (C)
will surface. Continue to drain until the float (C)
sinks to the case bottom.
4 Tighten the drain plug (B).
(Tightening the case too tight can cause it to
break, so do this work carefully.)
5 Remove the draining receptacle (A).
Caution
If water fails to be drained out even after loosening
the drain plug (B), loosen the plug (D) as well. After
Undercover Undercover
the work, do not forget to tighten the plug (D).
CONFIDENTIAL
Page 11 of 11
SERVICE BULLETIN CODE
DESCRIPTION 3 2007 068B
FILING LOCATION
ZX-3 ALL-238
(Revised)
Serial number break of mass-produced machines (for reference)
Pre-filter change Main filter change
New Old New Old
Filter assembly
Element kit
ZX200-3 series
ZX225US, USR-3 series
ZX240, 270-3 series
ZX330-3 series
