Technical Information

Bulletin # 031104
November 4, 2003
Subject: Hydraulic Fuel Injection System
a) Potential Fire Hazard
b) Purging Procedure
c) Recommended System Modifications
A potential fire hazard exists on Ajax engines with hydraulic fuel injection:

1) An incorrect purging procedure can allow hydraulic fluid to

contact a hot exhaust pipe and ignite. Use the following procedure:

Hydraulic System Purging Procedure:

1. Shut the engine off.

2. Pressurize the hydraulic reservoir to 15-20 psig.
3. Open the flow control valve (at control box) for the gas injection valve line to be purged.
4. Connect a 10”-12” length of clear plastic 3/8” hose to the bleed valve.
5. Slowly open the bleed valve while directing purged fluid and bubbles into a clean container for reclamation.
6. After the fluid runs without bubbles, close the bleed valve.
7. Close the flow control valve at the control box.
8. Check the reservoir’s fluid level. Be certain to depressurize the reservoir before replenishing the fluid.
Note
Use Ajax® hydraulic fluid p/n YAE-2150-2.
Do not use other fluids.

2) A damaged purge valve assembly can allow hydraulic fluid to leak and contact a hot
exhaust pipe and ignite .
As seen in Figure 1, the bleed valve is assembled to the cap of the injection valve by use of a
pipe nipple and pipe tee. These assembled parts can be bumped and damaged when servicing
adjacent components such as cylinder heads. The pipe nipple can also be damaged if the gas
injection valve assembly is mishandled during servicing.

Traditional bleed valve location for

purging of the hydraulic injection system.

Figure 1
 As seen in Figure 2, relocation of the bleed valve to the topmost part of the gas injection valve
minimizes damage potential, and permits more efficient purging of the hydraulic system.

Relocated bleed valve Bend tubing to 45º for

for improved purging optimum fluid flow and
of the hydraulic vibration resistance
injection system.

Clear plastic 3/8” hose

temporarily connected
Figure 2 for purging the system.

Convert to the current design by replacing the injection valve’s cap with the current design.
A parts kit for the conversion is available, or individual pieces can be specified. See the
appropriate table below for a kit P/N or the individual P/Ns.

See Figure 2 for a typical installation of the current design.

“Top Purge Conversion Kit”

(one per Gas Injection Valve)

p/n: SPEC 7456-S p/n: SPEC 7456-SS

(steel valve & fittings) (ss valve & fittings)
Item Description P/N Qty Item Description P/N Qty
1 Valve Cap A-2565-F-4 1 1 Valve Cap A-2565-F-4 1
2 Bleed Valve BM-10936 1 2 Bleed Valve BM-16580-2 1
3 3/8 Tube x ¼ NPT BM-11573-S-6-4 1 3 3/8 Tube x ¼ NPT BM-11573-SS-6-4 1
Reducer, ¼ NPT(F) Reducer, ¼ NPT(F)
4 BM-21147-S-4-2 1 4 BM-21147-SS-4-2 1
x 1/2 NPT(M) x 1/2 NPT(M)
5 ¼ Tube Nut & Ferrules BM-21163-S-4 1 5 ¼ Tube Nut & Ferrules BM-21163-SS-4 1
6 3/8 Tube Nut & Ferrules BM-21163-S-6 1 6 3/8 Tube Nut & Ferrules BM-21163-SS-6 1
7 ¼ Tubing, 316SS BM-21071-2-035 4’ 7 ¼ Tubing, 316SS BM-21071-2-035 4’
8 3/8 Tubing, 316SS BM-21071-3-035 4’ 8 3/8 Tubing, 316SS BM-21071-3-035 4’