Information injection-pump assembly
ZEXEL
101631-9600
1016319600
NISSAN-DIESEL
16700C6809
16700c6809
Rating:
Service parts 101631-9600 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-20053
12.
Open Pre:MPa(Kqf/cm2)
9.8{100}
15.
NOZZLE SET
Include in #1:
101631-9600
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-3070
as _
Cross reference number
ZEXEL
101631-9600
1016319600
NISSAN-DIESEL
16700C6809
16700c6809
Zexel num
Bosch num
Firm num
Name
101631-9600
16700C6809 NISSAN-DIESEL
INJECTION-PUMP ASSEMBLY
SD33 * K
SD33 * K
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
2.15
2.1
2.2
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
11.2
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
32.5
31.5
33.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
10.7
Pump speed
r/min
1900
1900
1900
Average injection quantity
mm3/st.
36.6
35
38.2
Max. variation between cylinders
%
0
-4
4
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
7.5
6.5
8.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Timer adjustment
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
550
Advance angle
deg.
0.7
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
1.7
1.2
2.2
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
3.6
3.1
4.1
Timer adjustment_05
Pump speed
r/min
1900
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
P:Negative pressure
(1)Pneumatic governor
(2)Mechanical governor
(3)Acting negative pressure: P1
(4)RACK LIMIT: RAL
(5)Beginning of idle sub spring operation: L1
(6)Injection quantity Q = Q1 or less
----------
RAL=11.7-0.3mm L1=8+0.3mm Q1=3mm3/st
----------
----------
RAL=11.7-0.3mm L1=8+0.3mm Q1=3mm3/st
----------
Speed control lever angle
N:Normal
B:When boosted
S:Stop
(1)Rack position = aa
(2)Rack position corresponding to bb
----------
aa=(1.8)mm bb=18mm
----------
a=20.5deg+-3deg b=11.5deg+-5deg c=0.5deg+-5deg
----------
aa=(1.8)mm bb=18mm
----------
a=20.5deg+-3deg b=11.5deg+-5deg c=0.5deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(130deg)
----------
----------
a=(130deg)
Information:
March 21, 2006
U-89
A-70
D-67
O-77
Beforeor
after failureParts stock action needed PRODUCT SUPPORT PROGRAM FOR REPLACINGTHE FUEL INJECTION PUMP VOLTAGE LOAD PROTECTION CONTROL ON CERTAIN 924G,928G, AND 930G WHEEL LOADERS
12881251 PS41980
This Program can be administered eitherbefore or after failure. In either case the decision whether to apply theProgram is made by the dealer. When reporting the repair, use "PS41980"as the Part number and "7755" as the Group Number. If administered beforefailure, use "56" as the Warranty Claim Description Code and use "T" asthe SIMS Description Code. If administered after failure, use "96" as theWarranty Claim Description Code and use "Z" as the SIMS Description Code. Although this Program is to be administeredas described above on the Affected Product, parts should be removed fromparts stock as soon as possible. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
March 31, 2007PROBLEM
Voltage Load Protection Module may fail due tomoisture entry resulting in unexpected engine shut down.AFFECTED PRODUCT
Model IdentificationNumber
924G DDA375-378,380-780, 782-1538, 1540-1953, 1955-2090, 2093-2105, 2107, 2108, 2111-2113,2115, 2117, 2119-2121, 2125, 2133-2134, 2136, 2201, 2272, 2622, 2627, 2642DFZ350-381, 383-563RBB175-977, 979-982, 984-985RTA150-476, 478, 480WGX285-842WMB295-895
928G DJD323-711,713-972, 974-1179, 1181-1418, 1420-1479, 1481-1577, 1579-1662, 1664-1811,1813-1934, 1936-1939, 1941-1943, 1949, 2315, 2322WLG265-809
IT28G DBT345-1489,1491-1676EWF100-421WAC275-622
930G TFW150-193TWR233-286, 288-637, 639-642, 644,646-669, 671-675, 677-678, 680-681, 683, 685-686, 689-691, 693-697, 699,701-703, 708-711, 713-716, 718, 721-723, 725-726, 729, 731-735, 737-738,740-741, 745, 747, 750-751, 754, 758, 761-764, 767, 769, 772, 774, 777,779-782, 789-791, 793, 800-801, 805-806, 809, 811, 830-831, 864, 874, 878,905, 921, 927-928, 1295, 1634PARTS NEEDED
Qty
Part Number Description
1 2705322 CONTROL GPACTION REQUIRED
***** Parts Stock *****Remove all 2159430 Control Groups from partsstock.***** Affected Product *****Replace 2159430 with 2705322 and confirm theengine operates.SERVICE CLAIM ALLOWANCES
***** Parts Stock *****Submit one claim for all 2159430 Control Groupsremoved from parts stock.***** Affected Product *****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-3000
0-24 mos 100% 1.0 0 0 0 0
3001 - 5000
25 ? 36 mos 33.3% 0.5 0 0 50% 0.5
This is a 1.0 hr job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
U-89
A-70
D-67
O-77
Beforeor
after failureParts stock action needed PRODUCT SUPPORT PROGRAM FOR REPLACINGTHE FUEL INJECTION PUMP VOLTAGE LOAD PROTECTION CONTROL ON CERTAIN 924G,928G, AND 930G WHEEL LOADERS
12881251 PS41980
This Program can be administered eitherbefore or after failure. In either case the decision whether to apply theProgram is made by the dealer. When reporting the repair, use "PS41980"as the Part number and "7755" as the Group Number. If administered beforefailure, use "56" as the Warranty Claim Description Code and use "T" asthe SIMS Description Code. If administered after failure, use "96" as theWarranty Claim Description Code and use "Z" as the SIMS Description Code. Although this Program is to be administeredas described above on the Affected Product, parts should be removed fromparts stock as soon as possible. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
March 31, 2007PROBLEM
Voltage Load Protection Module may fail due tomoisture entry resulting in unexpected engine shut down.AFFECTED PRODUCT
Model IdentificationNumber
924G DDA375-378,380-780, 782-1538, 1540-1953, 1955-2090, 2093-2105, 2107, 2108, 2111-2113,2115, 2117, 2119-2121, 2125, 2133-2134, 2136, 2201, 2272, 2622, 2627, 2642DFZ350-381, 383-563RBB175-977, 979-982, 984-985RTA150-476, 478, 480WGX285-842WMB295-895
928G DJD323-711,713-972, 974-1179, 1181-1418, 1420-1479, 1481-1577, 1579-1662, 1664-1811,1813-1934, 1936-1939, 1941-1943, 1949, 2315, 2322WLG265-809
IT28G DBT345-1489,1491-1676EWF100-421WAC275-622
930G TFW150-193TWR233-286, 288-637, 639-642, 644,646-669, 671-675, 677-678, 680-681, 683, 685-686, 689-691, 693-697, 699,701-703, 708-711, 713-716, 718, 721-723, 725-726, 729, 731-735, 737-738,740-741, 745, 747, 750-751, 754, 758, 761-764, 767, 769, 772, 774, 777,779-782, 789-791, 793, 800-801, 805-806, 809, 811, 830-831, 864, 874, 878,905, 921, 927-928, 1295, 1634PARTS NEEDED
Qty
Part Number Description
1 2705322 CONTROL GPACTION REQUIRED
***** Parts Stock *****Remove all 2159430 Control Groups from partsstock.***** Affected Product *****Replace 2159430 with 2705322 and confirm theengine operates.SERVICE CLAIM ALLOWANCES
***** Parts Stock *****Submit one claim for all 2159430 Control Groupsremoved from parts stock.***** Affected Product *****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-3000
0-24 mos 100% 1.0 0 0 0 0
3001 - 5000
25 ? 36 mos 33.3% 0.5 0 0 50% 0.5
This is a 1.0 hr job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
Have questions with 101631-9600?
Group cross 101631-9600 ZEXEL
Nissan-Diesel
101631-9600
16700C6809
INJECTION-PUMP ASSEMBLY
SD33
SD33