PSP FOR REDUCING BLACK SMOKE ON CERTAIN E200B AND EL200B EXCAVATORS - PS0466

PSP FOR REDUCING BLACK SMOKE ON CERTAIN E200B AND EL200B EXCAVATORS - PS0466 - MAILED US AND CANADA, CACO

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Caterpillar: Confidential Yellow

PSP FOR REDUCING BLACK SMOKE ON CERTAIN E200B AND EL200B EXCAVATORS - PS0466 - MAILED US AND CANADA, CACO

NOTE: The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.


AU-101
E-96
1290   PS4517
NOTE: This Program can be administered either before or after a
failure. In either case the decision whether to apply the
Program is made by the dealer. When reporting the repair, use
"PS4517" as Part Number, "7755" as Group Number, and "96" as
Description Code.
NOTE: If applicable, it is recommended that this Program be implemented
at the same time as the June 22, 1990 or the June 23, 1990
Service Letter - PS4442 "Product Support Program For Installing A
Hand Priming Pump, Primary Fuel Filter, And Return Line Check
Valve On Certain E200B And EL200B Excavators" and the April 18,
1990 Service Letter - PS4449 "Product Support Program For
Installing A New Governor Drive Gear On Certain E110B, E120B,
E200B, EL200B, 213B, 214B, 224B, E240B, And EL240B Excavators;
CB434 Compactors; 446 Backhoe Loaders; CP563 And CS563
Compactors; AP1050 Pavers; And 3114 And 3116 Engines
(Commercial)."
NOTE: If the June 25, 1990 or the June 27, 1990 Service Letter - PS0456
"Product Support Program For Replacing Eroded Cylinder Head
Injector Sleeves In Certain IT14B Integrated Toolcarriers; E110B,
E120B, E200B, EL200B, 213B, 214B, 224B, E240B, EL240B Excavators;
446 Backhoe Loaders; And 3114 And 3116 Industrial And Generator
Set Engines" has already been implemented, the new injectors have
already been installed and this program does not apply.

Termination Date

August 31, 1991

Problem

New Fuel Injector Groups, which have smaller diameter orifices in the nozzle
tip, can be installed on certain E200B and EL200B Excavators to reduce black
smoke.
Fuel Setting and Fuel Timing have also been changed to new specifications, at
the same time, to maintain the current engine performance.

Affected Product

Model Identification Number
E200B 6KF1-481
6KG1-249
EL200B 7DF1-1041
NOTE: If the June 25, 1990 or the June 27, 1990 Service Letter - PS0456
"Product Support Program For Replacing Eroded Cylinder Head
Injector Sleeves In Certain IT14B Integrated Toolcarriers; E110B,
E120B, E200B, EL200B, 213B, 214B, 224B, E240B, EL240B Excavators;
446 Backhoe Loaders; And 3114 And 3116 Industrial And Generator
Set Engines" has already been implemented, this program does not
apply.

Parts Needed

6 - 7E8729 Injector Group
1 - 4W5140 Plate (Parts Service Engine Information)
1 - 9Y8103 Gasket

Action Required

Replace the existing Injector Groups with the new 7E8729 Injector Groups.
Follow the procedures in the Service Manual along with the following steps to
install the new injectors.
Specifications on the existing Engine Information Plate need to be updated,
as shown below.
1. Remove the fuel injectors in accordance with the procedures shown in the
Service Manuals.
2. Clean the inside of the 7W5479 Injector Sleeves with a small amount of
solvent and 4C5553 Sleeve Cleaning Brush.
NOTE: 4C5553 Sleeve Cleaning Brush itself is available in the parts
system. And it is also included in the 4C4462 Tool Group for
"Removal and Installation of Unit Injector Sleeve". See Special
Instruction Form SEHS9120.
NOTE: Inspect inside of the sleeves and make sure there are no visible
cracks or erosion. If cracks or severe erosion are found, the
June 25, 1990 or the June 27, 1990 Service Letter - PS0456
"Product Support Program For Replacing Eroded Cylinder Head
Injector Sleeves In Certain IT14B Integrated Toolcarriers; E110B,
E120B, E200B, EL200B, 213B, 214B, 224B, E240B, EL240B Excavators;
446 Backhoe Loaders; And 3114 And 3116 Industrial And Generator
Set Engines" needs to be implemented, and this Program does not
apply.
3. Install new 7E8729 Fuel Injector Groups in accordance with the
procedures shown in the Service Manuals.
4. Adjust Injector Synchronization, Fuel Setting, Fuel Timing and Valve
Lash, in accordance with the procedures in the Service Manual.
New specifications for the Fuel Timing and the Fuel Setting are as
follows:
New Fuel Timing: 64.11 +/- 0.05 mm (+/- 0.20 mm for checking)
New Fuel Setting: 8.31 mm
5. Stamp the new specifications of Fuel Setting and Fuel Timing on the new
4W5140 Plate. After the information has been stamped on the new plate,
install the new plate over the existing engine information plate, with
the engine serial number still visible.
NOTE: The other specifications except "Fuel Setting" and "Fuel Timing"
have not been changed, but must be stamped on the new plate.

Service Claim Allowances

Product Caterpillar Dealer Suggested Customer Suggested
smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(D/N) (Cost)  (C/L) (Sell)
0-6000 100% 4 0 0 0 0
0-24
NOTE: This is a 4-hour job.

Parts Disposition

Any parts removed (with the exception of cores used for Caterpillar
Remanufactured parts) can be rendered useless and scrapped immediately upon
completion of the repair.