FUEL INJECTION NOZZLE AND NOZZLE HOLDER MIP-018TABLE OF CONTENTS Page 1. DESCRIPTION . 10... 0.2 cece eee ent eee e tenes 1 PU (6) 1 B.NOZZLE . oo. e eet ete 2 3-1. TYPE OF NOZZLE 2 32. IDENTIFICATION MARK. 2 3-3. DESIGN AND OPERATION . 2 3-4, PINTLE NOZZLE . 3 35, HOLE NOZZLE . 4 4. NOZZLE HOLDER ...... 0... 2. cece eee eee eee nett eee renee 5 41. FUNCTION 5 4-2, IDENTIFICATION MARK . 5 43, DESIGN AND OPERATION 6 GB. TESTING «0.0... eee eee eee 7 5-1, OPENING PRESSURE TEST . 7 5-2. LEAKAGE TEST .........- 8 53. CHATTER AND SPRAY PATTERN TEST 8 6. REPAIR: . 9 . GENERAL INFORMATION 9 . DISASSEMBLY . 9 CLEANING AND INSPECTION . 10 |) ASSEMBLY .......---200002 2-5 - 12nozzie NOZZLE EDGE-TYPE CONNECTION SPRING INTERMEDIATE RETAINING HOLDER FILTER bucT om SPRING SEAT PLATE NUT FUEL INLET LEAK-OFF GLAND SHIMS. DOWEL VALVE PRESSURE NOZZLE CONNECTION NUT PIN CHAMBER Fig, 1 Cross-Sectional View of KDAL-21mm Nozzle 1. DESCRIPTION The function of injection nozzle assembly is to direct a metered amount of fuel recieved from the injection pump into the engine combustion chamber. Spray pattern of injection has been controlled so as to produce the most efficient engine performance. This assembly consists of two principal parts, namely the injection nozzle and the nozzle holder. 2. OPERATION (Fig. 1) Operation of the injection nozzle assembly is simple and positive. The metered quantity of fuel from the injection pump enters the nozzle holder through the fuel inlet and passes through connection ducts to the pressure chamber just above the nozzle valve seat. At the instant the pressure of fuel acting on the differential area of the valve exceeds a predetermined spring load, it lifts the valve from its seat and fuel flows from the nozzle until delivery from the pump ceases. Then, a positive cut-off of fuel occurs as the valve is seated by the nozzle spring. A certain amount of fuel seeped between lapped surfaces of nozzle valve and body is necessary for lubrication, This leakage oi! accumulates in the spring cavity and drains through to leak-off connection provided for this purpose.3. NOZZLE 3-1. TYPE OF NOZZLE There are mainly two kinds of nozzles, such as pintle and hole type nozzles, These two main types comprise a number of varing designs depending on the requirements and type of engine. See Fig. 2. Generally, pintle nozzles are used in engines with adequate air turbulence, eg. those with _pre-combustion chamber, air cell or turbulence SPRAY ANGLE SPRAY HOLE CONE ANGLE chamber, while hole nozzles are used -PINTLE TYPE HOLE TYPE in engines with direct jet injection. Fig. 2 NOZZLE BODY 32. IDENTIFICATION MARK Information on the identification marks of nozzle is the following. ND-DN 4SD 24 ND-DN 8S 1 ND-DL 1108 916 ND-DL 100T 728 ND-DLL 140S 256 1) ND - Manufactured by NIPPONDENSO 2) D ~- Nozzle 3} N_ - Pintle type nozzle L_- Hole type nozzle 4) L_- Long shank and long collar 5) 4 - Spray angle in degrees (pintle type nozzles) 110 - Spray hole cone angle in degrees (hole type nozzles) 6) S - Body collar diameter ...... 17mm T Body collar diameter . 22mm 7) D ~ Throttling nozzle 8) 24 - Design number 3-3. DESIGN AND OPERATION Nozzle consists of nozzle body and valve, which are made of high-grade steel, and ground and lapped together to provide a high-class fit. Therefore, valve and body can not be replaced individually. Always replace them together as a single unit, See Fig. 2. The fuel delivered by the injection pump at a high pressure (80 to 300 kg/em? or 1100 to 4300 psi) should be correctly distributed in the combustion chamber by the nozzle in the most favorable shape of spray both in regard to space and time.3-4, PINTLE NOZZLE The valve of pintle nozzle at its injection end is fitted with a special designed injection pintle which, with a slight clearance, projects into the injection hole of the nozzle body. By varing the size and shape of the pintle, as shown in Fig. 3, the injection spray can be made to meet every requirement. Moreover, the pintle prevents the formation of carbon deposits in the injection hole. The opening pressure of the pintle nozzle is generally between 80 to 160 kg/cm? (1100 to 2300 psi). The delay or throttling-type nozzle is a pintle nozzle which is almost used in engines with pre-combustion chamber. Fig. 5 shows a comparison of oper- ations of conventional pintle type nozzle and throttling-type nozzle, These two type nozzles are quite similar except increased orifice length and greater pintle protrusion of the throttling type, The throttling nozzle was developed to give smoother combustion by re ducing the initial rate of injection during ignition lag period. The re- lations of the orifice area vs. the valve lift for both nozzles are shown in Fig. 5. This shows that the orifice area for the throttling nozzle is very small up to L2 mm valve lift, whereas with the regular pintle nozzle the orifice area increases rapidly above L1 mm valve lift, LARGE SPRAY ANGLE SMALL SPRAY ANGLE Fig. 3 w ®) © ro Co CO ; , LAL ELE» DAM: a is) © Operation of throttling type nozzle rina 3 /f g anit Wee g Cc = 3 Teens roe q G VALVE LIFT Fig. 5 Comparative rate of orifice areas of pintle and throttling type nozzles,35. HOLE NOZZLE Unlike the pintle nozzles, the valve end of the hole nozzle has no injection pintle but a taper which serves as a valve seat. There are single- hole and multi-hole nozzles. Single- hole nozzles have only one spray hole which is drilled either centrally or laterally. On mutti-hole nozzles, the spray holes form an angle in relation to each other, the hole angle (up to 180°). To obtain the most favorable distribution of the fuel in the combustion chamber, up to 8 holes are provided, according to re- quirements, mostly symmetrically. Hole diameter and hole length affect the shape and depth of penetration of the spray. The conventional nozzie types are available with spray hole diameters from 0.2mm onwards, the different diameters rising in stages by 0,02 mm each, The different nozzle sizes of hole nozzles are distinguished by the letter S and T (Refer to page 2.). Holle nozzles are used in engines with direct jet inje the hole nozzle assumes the essential part of fuel distribution. Fig. 6 Hole Nozzles n. On such engines, The opening pressure of these nozzles mostly lies between 175 and 300 kg/cm? (2500 and 4300 psi. COLLAR NOZZLE Fig. 7. Standard-type Hole Nozzle (DL. . ) ‘compared with a Long-collar Hole Nozzle (DLL. . )4, NOZZLE HOLDER 4-1. FUNCTION The nozzle holder serves to fix the nozzle in the engine cylinder and to connect it with the fuel delivery pipe. The nozzle opening pressure can be set by means of shim-adjustment or screw-adjustment. 42, IDENTIFICATION MARK Identification marks are marked on the nozzle holder body for easily identifying it. Information on the identification marks is as follows: ND-KB 55SD319 ND-KBA38 S1 NO-KCA30SD2 NO-KD 43S 53 1) ND - Manufactured by NIPPONDENSO 2) K - Nozzle holder 3) B - Mounted on engine cylinder by means of flange. C - Mounted on engine cylinder by screw-in thread. (Retaining nut) D_- Mounted on engine cylinder by retaining screw. 4) A - Pressure spring can be installed from nozzle body side. 5) 55 3 Fitting dimension 43 6) Ss Nozzle body collar diameter . T - Nozzle body collar diameter . 7) D_ - Throttling nozzle 8) 319 3}. Design number 5343, DESIGN AND OPERATION Fig. 8 shows basic design. The pressure spring incorporated in the nozzle holder presses the valve on its seat through the pressure pin. Therefore, the nozzle opening pressure is adjusted by the initial stress on pressure spring, which is changed by means of adjusting screw. A bar filter is positioned in the fuel inlet of the nozzle holder (in the connecting pipe) to prevent foreign materials from damaging the nozzle or plugging the orifices. According to installation method, nozzle holders are classified into KB, KC and KD types. With KBA and KCA type nozzle holders which have no adjusting screw, the nozzle opening pressure is adjusted by means of adjusting shims between the pressure spring and nozzle holder body as shown in Fig, 9. The nozzle assembly is lubricated by a small amount of fuel which seeps between the lapped surfaces of the nozzle body and valve. This leakage accumulates around the pressure pin and spring, and flows out through the leak-off connection, ADJUSTING “ScREW CONNECTING _-PRESSURE PIPE ‘SPRING YT ry NOZZLE | HOLDER BoDY 70S Nee pressure sar ricter, LE piN L-wozzte fo Fig. 8 KB type nozzle holder flange mounting NOZZLE HOLDER assy SCREW NUT PACKING RING WASHER ADJUSTING ‘WASHER PRESSURE, ‘SPRING PRESSURE PIN DISTANCE PIECE RETAINING NUT NOZZLE BODY NOZZLE NEEDLE Fig.9 KC type nozzle holder mounting by scew-in thread (Retaining nut)5. TESTING Important: Always use clean, filtered fuel when testing injection nozzle per- formance. Testing nozzles with dirty fuel will severely damage the precision parts of the nozzle. Caution: The nozzle tip should always be directed away from the operator. Fuel from the spray orifices can penetrate clothing and skin, causing serious personal injury. Before applying pressure to the nozzle tester, be sure that all connections are tight, and that the fittings are not damaged. Fluid escaping from a very small hole can be almost invisible. Use a piece of cardbord or wood, rather than hands, to search for suspected leaks, If injured by escaping fluid, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediately. 6-1, OPENING PRESSURE TEST To make the opening pressure test, connect the injection nozzle assembly to a hand-operated test pump. Fig. 5 illustrates the Nozzle Tester connected to the injection nozzle assembly. aeegune 2 SS Note: NIPPONDENSO NHT-2 type Nozzle hand tester is available for testing spray nozzle and injection nozzle assembly. Procedure For Test And Adjust a. Pump the handle several times to Fig. 10 flush out nozzle fittings, then tighten the fittings, b. Expel air from the nozzle by operating the pump handle for several strokes. Then raise the pressure slowly and steadily, Observe the gauge pressure at which the valve opens. Recheck by completely releasing the pressure, and gradually building pressure until the valve opens. c A new nozzle or a used nozzle with a new pressure spring should open at the specified pressure. In nozzles which have been in service, the spring and pin will have taken a normal set. If the opening pressure is not correct, disassemble the injection nozzle assembly and adjust by means of shims or adjusting screw. In the case of shim ad- justment, change shims until nozzle opens at the proper pressure.5-2. LEAKAGE TEST To check for a leaking nozzle, wipe the nozzle dry. Bring the pressure up slowly to 285 psi {20 bar) below the specified opening pressure, and watch for an accumulation of fual from the spray orifice, indicating a bad seat. If the nozzle drips within 10 seconds, replace the nozzle assembly. Check for leakage around the nozzle thread fitting, indicating a bad seat between the nozzle and nozzle holder. If leakage is observed, tighten the nozzle retaining nut to specified torque. Replace the injection nozzle if leakage continues. 5-3. CHATTER AND SPRAY PATTERN TEST These tests are a little bit different depending on types of nozzles as follows: a, Pintle Type (DNS) Chatter Test The pintle nozzle should chatter audibly over the entire range of attainable lever velocity. Occasionable chatterless periods in the intermediate range are acceptable. Spray Pattern Test Well atomized even spray, irrespective of test velocity (observe spray angle). b, Throttling Pintle Type (DN ~-- SD) Chatter Test The throttling nozzle chatters very softly. A chatter test on this nozzle is feasible with only low test velocity. When the test velocity is increased the oil emerges with a hissing noise. Spray Pattern Test Until the hissing noise is reached the spray emerges in streams. An estimate of the spray pattern is feasible only when the lever movement is accelerated until the hissing noise is caused. c. Hole Type, Standard Design (seat dia. 3.0 m/m and large) DL S$ (or T) DLL~~-S DLLA--S Chatter Test This type of nozzle chatters in the whole range of attainable lever velocity. Occasionable chatterless periods are acceptable. On nozzles with one or two spray holes of small dia., chattering ceases when the lever movement is ac- celerated (throttling effect}. Spray Pattern Test In non-chattering ranges non-atomized streams are formed; at rapid lever velocity the sprays are compact and finely atomized. d. Hole Type, With Reduced Seat Diameter (2.5 m/m and smaller) Chatter Test This kind of nozzle chatters very softly and only when hand lever movement is very rapid. Spray Pattern Test Until the chattering range is reached, the test oil emerges as non-atomized streams. At rapid velocity sprays are compact and finely atomized. —8-Failure to chatter may be caused by a binding or bent nozzle valve, A partially clogged or eroded orifice will usually cause the spray to deviate from the correct angle, and be streaky rather than finely atomized. Disassemble the nozzle for cleaning or reconditioning if it fails to chatter or spray properly. 6. REPAIR 61. GENERAL INFORMATION Since dirt and water are the worst contaminations in the fuel injection system, the working area, tools, and cleaning materials must be kept spotlessly clean, Whenever possible, work in an isolated, dust-free area. Cover the work bench with clean paper before beginning disassembly of injection nozzle. As parts are disassembled, place them in a pan of clean diesel fuel and leave them there until needed. Do not permit these parts to strike each other. Use a separate pan of clean diesel fuel for washing parts just before assembly. Note: In the following repair procedures, the explanatory illustrations are for KDAL injection Nozzle. 62. DISASSEMBLY Use the following procedure for dis- assembling the injection nozzle as- sembly. 1. Clamp the nozzle holder assembly at the nozzle holder body in vise. (for KC and KD type nozzle holders) For KB type nozzle holder, place the holder in a holding fixture and clamp in vise. 2. Remove the nozzle retaining nut by using suitable wrenches. Re- move the spray nozzle and spring ve ; R fh ‘A—Nozzle © —Glend Nut retainer or plate. Remove the B —Nozzle Retaining D —Nozzle Holder spring seat, spring and shims. Nut Fig. 11 Assembled KDAL-21 mm. Injection NozzleNOZZLE HOLDER SHIM SPRING ‘SPRING SEAT INTERMEDIATE PLATE NOZZLE . NOZZLE RETAINING @ NUT Fig. 12 Exploded View of KDAL Injection Nozzle Withdraw the nozzle valve from the nozzle. If valve is stuck, it may be necessary to soak the nozzle assembly in Bendix cleaner, acetone, or other commecial cleaners sold especially for freeing stuck valves. Caution: Use these nozzle cleaning fluids in accordance with the manufacture’s instructions. The valve and nozzle are individually fitted and hand lapped. Keep these mated parts together, and do not permit the lapped surfaces to come in contact with : any hard substance. Do not touch the valve unless hands are not wet with fuel. 63, CLEANING AND INSPECTION e a. NOZZLE ASSEMBLY Remove anti-corrosive grease from new or reconditioned nozzles by washing them thoroughly in diesel fuel. Remove carbon from used nozzles, and clean by washing in diesel fuel. If parts are coated with hardened carbon or lacuer, it may be necessary to use @ brass wire brush. important: Never use a steel brush to clean nozzles as this will distort the spray orifices, After removing carbon or lacquer from the exterior of nozzle, inspect the lapped machined surface (B, Fig. 13) for nicks or scratches, Inspect the piston (large) part of nozzle valve to see that it is not scratched or scored. if any of these conditions are present, replace the nozzle assembly (See Figs. 12 and 13}.Inspect condition of seat for nozzle valve and nozzle. Contact area of seat (both parts) must not be scored or pitted. Use the inspection magnifier to aid making inspection, Note: A bad nozzle valve will cause fuel to drip from the nozzle. This condition usually will be noted when making “Leakage Test” described on page 8. Further inspect the nozzle assembly by performing a slide test (Fig, 13). Use the following procedure: a. Dip the nozzle valve (A) in clean diesel fuel, Inspect valve in nozzle (0). b, Hold nozzle vertical, and pull valve out about 1/3 of its engaged length (o). ©. Release valve. Valve should slide down to its seat by its own weight. Always replace a nozzle assembly if the valve does not fall freely to its seat. Remove any carbon that may be present in the spray orifices of the nozzle assembly before reassembling on nozzle holder. To clean carbon from the spray orifice (Fig. 14), use cleaning wire smaller than normal orifice size (D). Note: Stoning the wire to provide a flat surface on one side will help in reaming carbon from a clogged hole. -u- A—Nozzle Valve C — Free-Fall Distance B — Lapped Surface D — Nozzle Fig. 13 Nozzle Assembly Slide Test A~Pin Vise C— Orifice B—Nozzle — D — Cleaning Wire Fig. 14 Cleaning Nozzle Orificesb, NOZZLE RETAINING NUT Remove carbon deposits on both inner and outer surfaces of the nozzle retaining nut. Inspect the retaining nut for cracks caused by overtightening or a damaged lower seating surface. A seating surface may be restored by rubbing the surface on emory cloth. Any nozzle retaining, nut which cannot be reconditioned, must be replaced with a new one. ¢. INTERMEDIATE PLATE Examine the lapped surfaces for nicks, scratches, or worn areas which would permit the fuel to leak past, Replace the intermediate plate if the lapped surfaces are damaged or worn. d. SPRING SEAT Inspect the spring seat for splitting, cracking, or excessive wear. Replace seat if any of these conditions are evident. e. NOZZLE VALVE SPRING Examine springs for pitting, or excessive wear. Replace any spring that appears questionable. f. EDGE TYPE FILTER The edge type filter may be cleaned by applying compressed air to the fuel passageway at the nozzle end of the holder body. The filter is pressed into the holder, and is not removable for service. 64. ASSEMBLY As the parts are cleaned, immerse them in clean diesel fuel. Insert the valve into the nozzle while holding parts below the fuel level in pan. Assemble nozzle into nozzle holder while wet with diesel fuel. Important: Do not attempt to dry part with towels or compressed air, because of the danger of dust particles remaining on the pressure faces of valve body and nozzle holder. Place shims, spring, and spring seat in nozzle holder while still wet with diesel fuel, Position the intermediate plate on nozzle holder. Note that the dowels (spring pins) in plate will permit it to be installed only one way. =12-NIPPONDENSO LOCAL OFFICE NIPPONDENSO OF LOS ANGELES, INC. ‘957 East 230th Street Carson, California 90745, PHONE (213) 7753131 TELEX 691695 USA. (Local) 43-7660 NIDENSO CMTN NIPPONDENSO CANADA LTD. Unit 29, 4500 Sheopard Ave, East, Agincourt, PHONE (416) 291-5558 TELEX 623297 Ontario MIS 326, Canada 09 NIDENSO TOR 0 NIPPONDENSO SALES, INC. ' 21840 West Nine Mile Road, Southfield, Michigan PHONE (313) 352-4440 TELEX 0230269 48078, U.S.A. aay NIDENSO SOFD NIPPONDENSO SALES, INC. SERVICE CENTER i 312 Viking load, Cedar Falls, iowa 50613, US. PHONE (319) 277-4140 TELEX 465643 (Nippendenso Sales, Inc ) Post Office Box 189 Cedar Falls, towa 50813! NIPPONDENSO THAILAND SALES, CO., LTD. e 2122 New Petchburi Road Greater Bangkok, Thailond PHONE 929963, 920084, 920966 NIPPONDENSO THAILAND CO., LTD. ‘369 Soi Teparak, Samrong Nua Samutprakarn, Thailand PHONE 940481,940482 TELEX BK2507 NIPPONDENSO (AUSTRALIA) PTY. LTD. ‘Comer of Kororoit Creek Road & Grieve Parade, PHONE 399-1177,1434 TELEX 32758 Altona, Victoria Australis NOAUST 4A32758 (Private Bag No. 6, Altona, Victoria 3018, Australia) NIPPONDENSO (EUROPE) B.V. 161 Pampuslaan, Weesp, The Netherlands PHONE 0204015262 TELEX 15114 NOWP NL NIPPONDENSO DO BRASIL REFRIGERACAO S.A. Extrads de Piraporinha, KM23 Bloco I-¢ Se0 Bernardo PHONE 267-0846 TELEX 1172106 do Campo S60 Paulo, Braz TOTS BR NIPPONDENSO CO., LTD. NEW YORK OFFICE . GIO Toyote Motor Saiga, U.S.A. Ino PHONE (201) 935-9429 TELEX 0133470 50 Potito Avenue Lyndhurst, New Jersey 07071, NIPPONDENSO LYN USA. December, 1977 e No: MiP—018 Prepared by NIPPONDENSO CO.,LTD. ‘SERVICE DEPARTMENT Kariya, Aichi, Japan