-ZEXEL: d Mi Pub.No.EEI7E-11040__ SERVICE MANUAL ° CONSTRUCTION & N & N & OPER RATION | TWO-SPRING NOZZLE HOLDERFOREWORD This service manual describes the construction and operation, disassembly and reassembly, and adjustment of the two-spring nozzle holder. The contents of this manual, including illustrations, drawings and specifications were the latest available at the time of printing. The right is reserved to make changes in specifications and procedures at any time without notice. Refer to the separate service manual listed below to facilitate two-spring nozzle holder maintenance. ZEXEL CORPORATION Service manual Publication number NOZZLE AND NOZZLE HOLDER Repair & maintenance Examples of Damage EE17E-11011NF] o] * oy GC oO] CONTENTS SERVICE PRECAUTIONS wees COMPONENT OUTLINE ....... OUTLINE FEATURES CONSTRUCTION KBL2.1 AND 2.2 TYPES KBL2.3 TYPE ......... KBL2.4 TYPE OPERATION ..... FIRST OPENING PI ESSURE ee SECOND OPENING PRESSURE SPECIAL TOOLS ..... COMMON TOOLS .. KBL2.1-S TYPE TOO! KBL2.1-P TYPE TOOLS KBL2.2-P TYPE TOOLS KBL2.3-S TYPE TOOLS KBL2.4-P TYPE TOOLS KBL2.4-S TYPE TOOLS KBL2.1-S TYPE ...... DISASSEMBLY .. . REASSEMBLY & ‘ADJUSTMENT KBL2.1-P TYPE ... KBL2.2-P TYPE .... DISASSEMBLY REASSEMBLY & ADJUSTMENT KBL2.3-S TYPE . DISASSEMBLY | REASSEMBLY & ADJUSTMENT KBL2.4-P TYPE ... DISASSEMBLY REASSEMBLY & soiree KBL2.4-S TYPE ... DISASSEMBLY REASSEMBLY & ees : TIGHTENING TORQUES ...... KBL2.1-S TYPE & -P TYPE . KBL2.2-P TYPE & 2.3-S TYPE . KBL2.4-P TYPE & -S TYPE .. COMMBVYAAAGHNNN Page21g nozale hoor Wire brush Nozzle holes [ sisnoscten ——topatnmaome =| Top of needie valve Noodle valve tip DANGER! YY Sos SERVICE PRECAUTIONS HANDLING Do not knock or drop the two-spring nozzle holder. In particular, do not damage the injection holes at the tip of the nozzle. © When cleaning the nozzle holder, do not touch the nozzle holes with the wire brush. Use only nozzle cleaning tools when cleaning the nozzle. DISASSEMBLY, REASSEMBLY AND ADJUSTMENT When handling the nozzle needle valve at disassembly and reassembly, hold the top of the needle valve. Do not touch the sliding portion or the tip of the needle valve. Do not knock the needle valve against metal or hard objects. © As the nozzle is a precision part, do not change the needle valve - nozzle pair. © Observe the following warning when adjusting the nozzle on the nozzle tester. The fuel Injected from the nozzle Is under extremely high pressure and can plerce the skin. This Is extremely dangerous. Do not allow fuel Injected from the Nozzle to contact any part of the body. Adjust the nozzle in a well ventilated area. Do not Inhale oll or spray injected from the nozzle.In COMPONENT OUTLINE OUTLINE Vehicle exhaust and noise regulations are becoming increasingly strict, particularly in regard to the reduction of NOx (nitrogen oxides) and particulates. FEATURES The two-spring nozzle holder limits needle valve lift at initial valve opening to throttle the injection quantity. Main injection occurs when the in-line pressure has increased sufficiently to move the needle valve through its full lift. This gives the following features. Improved engine stability at low and intermediate speeds. The two-spring nozzle holder has been developed to reduce NOx (nitrogen oxides) and particulates from direct injection diesel engine exhaust. © Decreased engine hunting and surge. Decreased noise at idling. ecreased idling speed because of improved engine stability. © Stabilized fuel injection characteristics from the injection pump and nozzle system, and easier matching of governor characteristics to engine demand.TYPES The two-spring nozzle holder: is generally classified into two types in accordance wi the pre-lift adjusting method. These two types are the shim adjustment type and the lift piece adjustment type. Shim adjustment types are the KBL2.1 type and the KBL2.2 type. Shim adjustment type fro COMPONENT OUTLINE Lift piece adjustment types are the KBL2.3 type and the KBL2.4 type. Two-spring nozzle holders are further classified in accordance with the nozzle body diameter (ie, the diameter of the nozzle body's thickest part). These are the S type (#17 mm), and the P type ($14.3 mm). KBL2.1-S ‘Second spring First spring Pro-ttt Nowe Ful it KBL2.1-P KBL2.2-P Second ring Second spring First spring sie Nozzle Prem Fain Nozio notaLift plece adjustment type [2] COMPONENT OUTLINE KBL2.3-S First sping ‘Second spring Lit piece Nozzle D=98.9 d=43.8 ADJUSTMENT OUTLINE Unit: mm TA opening teas | opening pressure | Presit | Remars I= KBL2.1-8 De ntt5 d= 445 Screw Seaneeees ‘Open method Kae [Bis gags [See De y7.2 d=43.6 | Open method a 4 KaL22P |B» days [Dey72 d=4a6 [Da972 d= 43.0 |OPen method aI KBL2.3-8 |Screw artes d= gas [tit piece Closed method Kaige |B a= 408 |e g72 d=4ae |lift piece Closed method kei2.4.s [Shim Bi o9 d= 948 [Lit piece Closed method3] CONSTRUCTION KBL2.1 AND 2.2 TYPES ‘Adjusting sorew (tor second opening ‘pressure adjustment) ‘Shim (for pre-tt adjuster ‘Tho figure shows the KBL2.1-S type. ‘Second spring L: Full needie vaive lit €: Noodle valve prot The construction of the KBL2.1 and KBL2.2 two-spring nozzle holders is basically -mthe same. The nozzle holder has two springs and two pushrods. A clearance (pre-lit) is provided between the two pushrods. (With the KBL2.2 type, pre-lift is provided between one Bushrod and a spring seat.) he nozzle opening pressure is determined by the first spring. After the nozzle has been opened by the increase in in-line pressure, the needle valve is lifted through the previously determined lift, and the first pushrod contacts the second pushrod. In-line pressure increases until it exceeds the combined forces of the two springs, when. it this ington ie the needle valve. '@ first spring (for nozzle opening pressure) is adjusted ustig a shim, y With the KBL2.7 type, the second spring is adjusted using an adjusting screw. ‘the KBL2.2 type, the second spring is adjusted using an adjusting shim.3] CONSTRUCTION KBL2.3 TYPE [3 fH iil Feat org Paseo ‘Second spring ud Sing sot ls oo tA Lin pace “| syame Nowe Needle valve Li Fu need va it 6 Noodavao prot The KBL2.3 type two-spring nozzle holder differs from the KBL2.1 and 2.2 types as follows. The positions of the first and second springs are reversed, with the first spring located at the top. (With the KBL2.1 and 22 types, the first spring is located at the © Pre-lift it te provided between the lift piece and the spring seat. (With the KBL2.1 type, pre-lift is provided between the first and second pushrods; with the KBL2.2 type, pre-lift is provided between the pushrod and a spring seat.) © Pre-lift is adjusted at the factory. (Pre-lift is ensured through, the assembly of the nozzle, spacer and lift piece.) © Full needle valve lift, second opening pressure and pre-lift can be measured simultaneously.KBL2.4 TYPE oo] CONSTRUCTION Fest spring Spring soat ‘Second spring Pushrod ‘Tho figure shows the KBL2.4-S type. ~ The KBL2.4 type two-spring nozzle holder differs from the KBL2.1 and 2.2 types as follows. The positions of the first and second springs are reversed, with the first spring located at the top. (With the KBL2.1 and 2.2 types, the first spring is located at the bottom.) @The nozzle holder body is a unified construction, decreasing the number of component parts. L: Full needle valve it Noodle valve pre-it Pushrod Spring soat ‘Second spring Needie valve © Pre-lift is provided between the lift piece and the spring seat. (With the KBL2.1 type, pre-lift is provided between the first and second pushrods; with the KBL2.2 ‘ype, pre-lift is provided between the pushrod and a spring seat.) © Prevlift is adjusted at the factory. (Pre-lift is ensured through the assembly of the nozzle, spacer and lift piece.) © Full needle valve lift, second opening Pressure and pre-lift can be measured simultaneously.[4] OPERATION FIRST OPENING PRESSURE (Opening pressures are described only for the KBL2.1 nozzle holder.) The force of the high pressure fuel delivered by the injection pump acts to push the needle valve up. When this force exceeds the set force of the first spring, the nozzle’s needle valve pushes the first pushrod up and the valve opens. (First opening pressure is represented by point E in the bottom left hand figure, and point A in the bottom right hand figure.) SECOND OPENING PRESSURE When the first pushrod has been lifted through the pre-lift, it contacts the second pushrod. As the set force of the second spring is acting on the second pushrod, the — combined forces of both the first spring and the second spring then act on the needie valve, which will not lift unless these forces are overcome. When the high pressure fuel (ie, in-line pressure) overcomes the combined forces of the first and second springs, the needle valve is again ited and main injection can begin. (Second opening pressure is represented by point F in the bottom left hand figure and B ~ C in the bottom right hand figure.) Second spring Second puted First sping First pushrod Noodle valve Nozao 6 \ Lit (mm) F L dl. 7! Injection rate ‘ ' Gm/*) | : Pe Invine pressure t ib [Noodle vave it (mm) ‘A~B _ : First spring's set force B~C~D : Combined forces of fst and second springs Pi First opening pressure P2 ‘Second opening pressurefon SPECIAL TOOLS The following special tools (in addition to general tools) are required for disassembly, reassembly and adjustment of the two-spring nozzle holder. COMMON TOOLS Key Part name Partno | Q'ty Application 1 [Nozzle tester 05785-1010 | 1 |For adjusting two-spring nozzle holder 1/1 | Nozzle tester 105785-0030 1 1/2 |Pressure gauge 157955-2000 | 1 |Maximum scale: 50 MPa {500 kgf/cm2} 1/3. | Injection pipe 157856-0520 | 1 |M14x1.5;M12x1.5 1/4. | Injection pipe 157856-6320 | 1 |M14x1.5;M14x1.5 2 Nozzle cleaning kit 105789-0010 | 1 |For cleaning nozzle 3 | Torque wrench conmerioty wetatin | 1 4 Micrometer Commercial evaisbie | 1 | For measuring adjusting shim thickness 1. 105785-1010 13 aan RTE 2 8 7. swi Mraxas 498 92 200 114 9 Max. 3, Commercially avallable 4. Commercially availableSPECIAL TOOLS KBL2.1-S TYPE SPECIAL TOOLS Key Part name Partno | Qty Application 1 [Adjusting device 105789-0540 | 1 |For adjusting needle valve pre-ift assembly 1 | Adjusting device 157692-0220 | 1 |Part of Key No 1 1/2 |Dial gauge 157954-3800 | 1 {Measuring range: 0~ 10mm (x0.01mm) 18 |Base 157892-1800 | 1 |For adjusting zero point 1/4 |Pin 15792-1100 | 1 |Length: 60.5 mm 2 |Torque spanner commacisyowiaie | 1 | SW17 mm 3 | Socket wrench 187914-2800 | 1 |For removing/installing nozzle retaining nut; SW19 mm 4_ [Plate 187944-9520 | 1 _|For supporting nozzle holderen] SPECIAL TOOLS 1. 105789-0540 Ww V3 V4 va Ss 4. 157944-9520SPECIAL TOOLS KBL2.1-P TYPE SPECIAL TOOLS Key Part name Partno | Qty Application 1 [Adjusting device | 105789-0590 | 1 11 Adjusting device | 157892-2220 | 1 1/2. |Dial gauge 157954-3800 | 1 |Measuring range: 0~5 mm (x0.01 mm) 13. |Pin 157892-3000 | 1 |Length 60.4 mm 1/4 |Base 157892-3300 | 1 |For setting zero point 2 [Plate 187992-2521 | 1 |For supporting nozzle holder 3 |Scraper 157890-6200 | 1 |For cleaning nozzle seat 4_|Scraper 457890-6300 | 1 |For cleaning nozzle fuel oil chamber 105789-06( The adlusting device is available without the cial gauge (157954-3800). The part number is ~~ 1._105789-0590 2. 157992-2521 3. 157890-6200 “ 998 al 4. 157890-6300 355] SPECIAL TOOLS KBL2.2-P TYPE SPECIAL TOOLS Key Part name Partno | Qty Application 7 [Dial gauge 157954-3800 | 1 |Measuring range: O~5 mm (X0.01 mm) 2 |Connector assembly | 157892-3620 | 1 3. |Pin 157892-3500 | 1 |Length: 45 mm 4 |Plate 17992-2820 | 1 |For supporting nozzle holder 5 | Torque spanner Commercially | 1 | For tightening connector assembly available (SW17 mm); Tightening torque: 20~25 Nem {2.0~2.5 kgf-m} 6 | Scraper 187890-6200 | 1 |For cleaning nozzle seat 7_|Scraper 157890-6300 | 1 |For cleaning nozzle fuel oil chamber 1. 157954-3800 2. 157892-3620 4, 157992-2820 3. 157892-3500 5. Commercially available 6. 157890-6200 M14x1.0 7. 157890-6300[5] SPECIAL TOOLS KBL2.3-S TYPE SPECIAL TOOLS 1. FOR LARGE HINO TRUCKS Key Part name Partno | Qty Application 1 [Adjusting device | 105789-0680 | 1 1 [Adjusting device | 187892.4120 | 1 |Part of key no 1 4/11 | Holder 157892-4100 | 1 |For installing cap nut; M10x 1.0 1/112 | Holder 17892-5400 | 1 |For installing cap nut; M10X 1.25 4/13 | Nut 187892-1000 | 1 |For securing dial gauge 4/2, |Dial gauge 157954-2800 | 1 |Measuring range: 0~5 mm (x0.01) 13 |Pin 187892-4200 | 1 |L=160 mm (excluding length of thread) 4/4 |Pin 17892-4300 | 1 |L=110 mm (excluding length of thread) 4/6 Retaining nut 187@92-4020 | 1 116/ | Retaining nut 17892-4000 | 1 |M19x0.75; SW22 mm, L=84 mm 11612 | Gasket 026508-1140 | 1 |For plug; D= $11.4, d= 48.2, t= 1.0 mm 116/3 | Plug 17892-1600 | 1 |MBx1.0, SW12 mm 177 |Gasket 18792-1500 | 1 |D=915.9,d=9122, t=1.0 mm 2 |Plate 18794-9520 | 1 |For supporting nozzle holder 3 |Wrench 18791-8100 | 1 |For adjusting first opening pressure; SWS mm 4 |Wrench 187914-2800 | 1 |For removing/instaling retaining nut; swig mm 8 |Wrench 187914-0500 | 1 |For removing/installing adjustment retaining nut; mm The adjusting device is available without the 105789-0690. dial gauge (157954-3800). The part number is 2. FOR MEDIUM-SIZED HINO TRUCKS Key Part name Partno | a'ty Application 1 [Adjusting device | 105789-0700 | 1 4 | Adjusting device ‘| 157892-4420 | 1 | Part of key no 1 1/1/1 | Holder 157892-4400 1 |For installing cap nut; M8 x 1.0 4/173 | Nut 157892-1000 | 1 |For securing dial gauge 1/2 |Dial gauge 187954-3800 | 1 |Measuring range: 0~5 mm (x0.01) 15. | Pin 187892-4700 | 1 |L=85 mm (excluding length of thread) 1/6 | Retaining nut 15792-4020 | 1 4/e/t | Retaining nut 157892-4000 | 1 |M19x0.75; SW22 mm, L=84 mm 1/62 | Gasket 26508-1140 | 1 |For plug; D= 411.4, d= 48.2, t= 1.0 mm Continued on next page5] SPECIAL TOOLS 2. FOR MEDIUM-SIZED HINO TRUCKS (continued) Key Part name Partno | Q'ty Application 1/63 | Plug 157892-1600 | 1 _|M8X1.0, SWi2 mm 17 |Gasket 157892-1500 | 1 |D= 415.9, d= 412.2, t=1.0 mm 2 |Plate 18794-9520 | 1 |For supporting nozzle holder 3. |Wrench 15791-8100 | 1 |For adjusting first opening pressure; SWS mm 4 |Wrench 157914.2800 | 1 | For removinginsaling retaining nut mm 5 [Wrench 187914-0500 | 1 |For removingjinstalling adjustment retaining nut; 2 mm The adjusting device is available without the dial gauge (157954-3800). The part number is > 105789-0710.SPECIAL TOOLS 1. 105789-0680, -0700 Ww swig 80° table 4 fe “ 13 M2.8x0.45 60 V4 10 1 M2.5x045 a M2.5x045 a 18 /5 16 9x0. V7, 9 ~ swi2 161 Mex1g) oe Te x yd. | were 1 m 2._157944-9520 3. 157911-8100 (One example of ‘an assombled pate5] SPECIAL TOOLS KBL2.4-P TYPE SPECIAL TOOLS Key Part name Partno | Q'ty Application 1 [Adjusting device 05789-0720 | 1 4/1 | Adjusting device 157892-5020 | 1 |Part of key no 1 111 |Holder 157892-5000 | 1 |M8x1.25 11/2 | Nut 157892-1000 | 1 |For fixing dial gauge 1/2 | Dial gauge 187954-3800 | 1 |Measuring range: 0~5 mm (x0.01) 13 |Pin 187892-5200 | 1 |L=100 mm (excluding length of thread) 1/4 |Pin 157892-5700 | 1 |L=120 mm (excluding length of thread) 1/5 |Retaining nut 187892-5120 | 1 1/5/1 | Retaining nut 187892-5100 | 1 |M15x0.5; SW17, L=70 mm 1/512 | Gasket 026508-1140 | 1 |For plug; D= 411.4, d= 48.2, t=1.omm 1/513 | Plug 157892-1600 | 1 |MBx1.0; SW12 mm 16 | Gasket 157892-3200 | 1 |For retaining nut; D= 413.2, d= 410.2, t=1.0 mm 2 |Plate 157992-2820 | 1 |For supporting nozzle holder 3 |Plate 18794-9520 | 1 |For supporting flange type nozzle holder The adjusting device is available without the dial gauge (157954-3800). The part number is 105789-0730.lon SPECIAL TOOLS 1. 105789-0720 fa = 71 ‘swig MOx1.25 V2 of gy l« wit wisxag 15/1 5's) 16 15/2 13 yas 5 y28 NS Mex04s “00 0 14 M2.5x0.45 3._157944-9520KBL2.4-S TYPE SPECIAL TOOLS 1, FOR MITSUBISHI VEHICLES SPECIAL TOOLS Key no’ Part name Part no Q'ty Application 1 Adjusting device 105789-0640 | 1 1/1 | Adjusting device 157892-4420 | 1 |Part of key no 1 1/1/14 | Holder 157892-4400 | 1 |M8x1.0 1/1/3 | Nut 157892-1000 | 1 |For securing dial gauge 1/2 | Dial gauge 157954-3800 | 1 |Measuring range: 0~5 mm (x0.01) 1/3 | Pin 157892-4700 | 1 |L=85 mm (excluding length of thread) 1/4 |Pin 157892-5200 | 1 |L=100 mm (excluding length of thread) 1/6 |Pin 157892-5500 | 1 |L=55 mm (excluding length of thread) 1/7 |Pin 157892-5700 | 1 |L=120 mm (excluding length of thread) 1/8 | Retaining nut 157892-4020 | 1 1/8/1 | Retaining nut 157892-4000 | 1 |M19X0.75; SW22 mm, L=84 mm 1/8/2 | Gasket 026508-1140 | 1 |For plug; D=¢11.4, d= 48.2, t= 1.0 mm 1/8/3 | Plug 157892-1600 | 1 |M8x1.0; SWi2mm 1/9 |Gasket 157892-1500 | 1 |For retaining nut; D= 415.9, d= 412.2, t=1.0 mm 2 |Plate 157944-9520 | 1 |For supporting nozzle holder 3 |Wrench 157914-2800 | 1 |For removing/installing retaining nut, SW19 mm 4 |Wrench 157914-0500 | 1 |For removing/installing adjustment retaining nut, SW22 mm ™ The adjusting device is available without the 105789-0650 dial gauge (157954-3800). The part number is 2. FOR NISSAN DIESEL VEHICLES Key Part name Partno | Qty Application 1 Adjusting device | 105789-0660 | 1 1 | Adjusting device | 157892-4120 | 1 | Part of key no 1 1/1/1 | Holder 157892-4100 1 |M10x1.0 1/1/2 | Holder 157892-5400 | 1 |M10x1.25 41/3 | Nut 157892-1000 | 1 |For securing dial gauge 1/2 |Dial gauge 157954-3800 | 1 |Measuring range: 0~5 mm (x0.01) 13_|Pin 187892-4700 | 1 |L=85 mm (excluding length of thread) Continued on next page 19[5] SPECIAL TOOLS 2. FOR NISSAN DIESEL VEHICLES (continued) Key Part name Partno | Q'ty Application 1 [Pin 187682-5300 |_1 |L=60 mm (excluding length of thread) 16 | Pin 187892-5500 | 1 |L=85 mm (excluding length of thread) 1/8. | Retaining nut 187892-4020 | 1 1/8/1 | Retaining nut 187892-4000 | 1 |M19x0.75; SW22 mm, L=84 mm 1/812 | Gasket 026508-1140 | 1 |For plug; D=$11.4, d= 8.2, t=1.0 mm 118/8 | Plug 157892-1600 | 1 |MBX1.0; SW12 mm 119 |Gasket 157892-1500 | 1 |For retaining nut; D= 415.9, d= $12.2, t=1.0 mm 2 |Plate 187944-9520 | 1 |For supporting nozzle holder 3 |Wrench 187914-2800 | 1 |For removing/installing retaining nut, swig mm 4 |Wrench 157914-0500 | 1 |For removing/installing adjustment retaining nut, SW22 mim The adjusting device is available without the dial gauge (157954-3800). The part number is 105789-06705] SPECIAL TOOLS 1. 105789-0640, -0660 a7 v3 ‘8 1 swi7 25045, oh gn aA 1 15 925 4S Ww gos 5, “00 Mesxo4s M2.5x045 2._157944-9520 a16] KBL2.1-S TYPE 2-epring nozzle holder Wire brush (187890-1100) KBL2.1-S TYPE DISASSEMBLY Before disassembly, remove any carbon from the nozzle holder using a wire brush and wash the outside. CAUTION © Do not touch the nozzle holes with the wire brush. © Place all disassembled parts in order of disassembly on the bench. Key no Part name 1 | Nozzle holder body 2 [Pins 3 | Retaining nut 4 | First pushrod 5 | First spring 6 | Stim (or frst ‘opening pressure 2a 7 | Spacer 8 | Setscrow 8 | Shim (or preain ‘adjustment 10 | Second pushrod 11 | Second spring 13 | Adjusting sorew 14 | Looknut 15 | Gasket 16 | Capnut 18 | Eye bott 19 | Gasket 20 | Gasket 21 [inlet connector ‘A | Nozzle§| KBL2.1-S TYPE 1. Position the nozzle holder on the plate No tO7844-2820). ote: Assemble the plate as shown at left. 2, Remove the capnut and gasket. 3. Remove the locknut. 4, Remove the set screw and adjusting screw.[6] KBL2.1-S TYPE 5. Remove the second spring. econd pushrod. 6. Remove the se isting shim. 7. Remove the pre-lift adju 8 Remove the spacer.First spring First pushrod Shim KBL2.1-S TYPE 9. Remove the first opening pressure adjusting shim, first spring and first pushrod. 10.Position the nozzle holder with the nozzle facing up, then remove the retaining nut, nozzle and pins. 11.Soak the disassembled parts in clean solvent and remove any carbon using the cleaning kit (105789-0010). 12.Visually inspect the cleaned parts for wear, rust, erosion, etc. Note: Refer to the Nozzle and Nozzle Holder Service Manual (EE17E-11011) for cleaning kit use and inspection standards. 25KBL2.1-S TYPE 28 KBL2.1-S TYPE REASSEMBLY AND ADJUSTMENT The nozzle holder is adjusted as the components are reassembled in the sequence below. As adjustment of the two-spring nozzle holder is made in hundredths of a millimeter, clean the parts thoroughly in light oil to completely remove any dirt or foreign matter. REASSEMBLY AND ADJUSTMENT PROCEDURE 1 First nozzle opening pressure Adjust the first nozzle opening pressure adjustment using the shim. Page 27 CAUTION Do not install the pre-lift adjusting shim during procedures 1 to 3. 2 Preclft adjusting shim selection t Page 29 3[ Second nozzle opening pressure adjustment t Page 32 ov Pre-lift shim assembly t Page 33 5 Final inspection Page 34 Select the pre-lit adjusting shim. Adjust the second nozzle opening pressure using the adjusting screw. Install the pre-lift adjusting shim selected in procedure 2. Confirm the condition of the fuel spray with the nozzle and nozzle holder assembled.Nozzle holder [6] KBL2.1-S TYPE First nozzle opening pressure adjustment 1. Position the nozzle holder on the plate with the capnut facing down. 2. Assemble the pins in the nozzle holder. 3. Assemble the nozzle on the pins. 4, Hand-tighten the retaining nut to the nozzle holder. 5. Tighten the retaining nut to the specified torque using the wrench (157914-2800). Specified torque: 59~78 N-m {6.0~8.0 kgf - m} 6. Position the nozzle holder on the plate with the capnut facing up. 7. Install the first pushrod, first spring, shim and spacer in the nozzle holder.[6] KBL2.1-S TYPE ‘Nozze holder Part No. Thickness (mm) 50523-5000 0.50 150523-5100 0.52 150523-5200 0.54 150523-5300 0.56 150523-5400 0.58 150523-5500 0.60 150523-6000 0.70 10523-6500 0.80 150523-7000 0.90 150523-7500 1.00 10532-6700 0.10 150532-6800 0.20 150532-6900 0.30 150532-7000 0.40 28 8. Install the set screw on the nozzle holder and tighten to the specified torque. Specified torque: 49~59 Nm {5.0~6.0 kgf - m} 9, Attach the nozzle holder to the nozzle tester and confirm the first nozzle opening pressure. If the first nozzle opening pressure is not — as specified, vary the thickness of the shim until it is as specified. Adjusting shims are listed below. CAUTION @ Two shims may be necessary. @ Use a micrometer to measure shim thickness. © Opening pressure adjusting shims and pre-lift adjusting shims are identical. © First nozzle opening pressure and pre- lift adjusting shims 4 Shape f 4.5 Thickness $11.5:|or| KBL2.1-S TYPE * Reading the beginning-of-Injection pressure ie nozzle tester handle is operated, the nozzle tester’s pressure gauge needle moves as shown below. The point Po shown below is the beginning-of-injection pressure. Measure this value. nozzle tester is operated, the nozzle multaneously, the gauge needle iddenly begins to deflect. ‘The boginning of this Geflecton le te begining-othiecton.prowsure. For example, at P,=19.6 MPa {200 kglom?}, the neodie's maximum deflection differs from’ the bbeginning-ot-injection pressure. Opening pressure ihe Gaver) [ 10.6 MPa {200 katlom2) 1 (8808) —= Pre-lift adjusting shim selection 1. Attach the pin to the dial gauge. Tool Name | Part No. Remarks Pin 157892-1100 | L= 60.5 mm Dial gauge _| 157954-3800 2. Insert the dial a8 je into the adjusting device (157892-02: 3. Attach the dial gauge to the adjusting device.KBL2.1-S TYPE ‘Second pushrod Adjusting ‘device Vise 4. Secure the base (157892-1800) in the vise. 5. Assemble the second pushrod in the base. 8. Assemble the adjusting device in the 7. Bush the adjusting device down and zero the dial gauge. CAUTION © Confirm the zero position several _ times. Handle the adjusting device carefully after setting the zero position so that the zero position Is maintained.lor] KBL2.1-S TYPE 8. Position the nozzle holder on the plate. 9. Assemble the second pushrod in the nozzle holder. CAUTION Do not assemble the second spring or the pre-lift adjusting shim at this time. 10.Attach the adjusting device to the nozzle holder set screw and tighten the middle adjusting device screw. CAUTION Hold the dial gauge holder, move the dial gauge up and down, and confirm that the dial gauge needle moves smoothly. 11.Push the adjust ting device down (in the direction of the arrow) and measure the dial gauge lift ‘h.’ CAUTION Measure the lift to within 0.01mm.KBL2.1-S TYPE Adjusting ‘device — Sat sorew 12,Select the pre-lift adjusting shim. teeth t: shim thickness (measured value) €: pre-lift (specified value) h: Value measured in 11 above T: thickness of actual selected shim T=t+0.015 mm Note: Refer to the first nozzle opening pressure and pre-lift adjusting shims on page 28. Example: h=0.98 mm, 1 + 0.98 08 + 0.015 = 1.065~ 1.095 , the selected shims (2) are part £=0.1 mm 08 That numbers 150523-5000 and 150523-5400, which give a total shim thickness of 1.08. | ~ CAUTION © Two shims may be necessary. @ Use a micrometer to measure shim thickness. © Do not assemble the selected shim(s) at this time. 18.Remove the adjusting device. Second nozzle opening pressure adjustment 1. Assemble the second spring, adjusting ‘screw and nut in the nozzle holder. Note: - In this condition the first and second pushrods contact. CAUTION 32 Do not assemble the pre-lift adjusting ‘shim(s) at this time.[o>] KBL2.1-S TYPE 2. Attach the nozzle holder to the nozzle Adjusting crow Nozale tester tester and adjust the second nozzle opening pressure using the adjusting screw. Then, secure the adjusting screw using the nut. 3. Remove the nozzle holder from the nozzle tester. 4. Position the nozzle holder on the plate and tighten the nut. Specified torque: 20~25 N-m {2.0~2.5 kgf-m} 5. Confirm the second nozzle opening pressure. If not as specified, readjust the opening pressure. CAUTION Reconfirmation Is necessary as the second nozzle opening, pressure may change when the nut is tightened. Pre-lift shim assembly Set screw assembly Adjusting serow 1. Remove the set screw assembly (je, the set screw, adjusting screw and nut as an assembly). CAUTION Do not loosen the nut at this time. 2. Remove the second spring and second pushrod. 33,KBL2.1-S TYPE 3. Assemble the pre-lift adjusting shim (selected in 12 on page 32) on the second pushrod, and then assemble the second spring and second pushrod in the nozzle holder. 4. Install the set screw assembly and tighten the set screw to the specified torque. Specified torque: 49~59 N-m {5.0~6.0 kgf-m} Note: In this condition, pre-lift clearance can be maintained between the first pushrod and the second pushrod. CAUTION Do not tighten the nut at this time. Final Inspection 1, Insta the gasket and capnut. 2. Tighten the capnut to the specified torque. Specified torque: 39~49 N-m {4.0~5.0 kgf-m} 3. Attach the nozzle holder to the nozzle tester and check first nozzle opening pressure, spray pattern, seat oil-tightness and each part for oil leaks. Note: Refer to the Nozzle and Nozzle Holder Service Manual (EE17E-11011) for spray patterns and inspection standards.7] KBL2.1-P TYPE Disassembly, reassembly and adjustment procedures are identical to those for the KBL2.1-S type two spring nozzle holder. Refer to pages 22~34. KBL2.1-P TYPE NOZZLE HOLDER: EXPLODED VIEW Key no Part name ‘Nozzle holder body Pins 1 2 3 | Spacer 4 [Retaining nut 5 | First pushrod 6 | First spring 7 | Shim (for frst pening pressure adjustment) © The plate (157992-2521) is necessary for the disassembly, reassembly and adjustment of the KBL2.1-P type two- spring nozzle holder. Examples of its use are shown at left and on the following page. 35KBL2.1-P TYPE © Plate use © First nozzle opening pressure and pre-lft Part No. Thickness (mm) Adjusting shim 150591-1000 0.10 150591-2000 0.20 ‘Shape 150591-3000 0.30 150591-4000 0.40 | 150591-5000 0.50 ry 150591-5100 0.51 Thickness 150591-5200 0.52 72 150591-5300 0.53 150591-5400 0.54 150591-5500 0.55 CAUTION 150591-5600 0.56 Two shims may be necessary. 150591-5700 0.57 Use a micrometer to measure shim 180591-5800 0.58 . Sponiee’s ressure adjusting shims and 10591-5900 0.59 pre-lit sdjusting shims are identical.2-spring nozzle holder Wire brush (15790-1100) Nozzle holes KBL2.2-P TYPE KBL2.2-P TYPE DISASSEMBLY Before disassembly, remove any carbon from the nozzle holder using a wire brush and wash the outside. CAUTION © Do not touch the nozzle holes with the wire brush. © Place all disassembled parts In order of disassembly on the bench. KBL2.2-P TYPE NOZZLE HOLDER: EXPLODED VIEW Key no Part name 1 [Nozzie holder 2 | Shim (or first ‘opening pressure nt) 3 | First spring 4 | Spring soat 8 | Spacer 8 [Pins 7 | Retaining nut 8 | Shim (or pros ‘adustment) 9 | Pustrod 30 | Second spring 11 | Shim (for second ng pressure adjustment) 12 | Spring seat 13 | Gapnut 14 | Gasket 15 | Nut 16 | O-ring 17 | inlet comector 1 A | Nozzie 371. Position the nozzle holder on the plate (157992-2820). 2. Remove the retaining nut. 3. Remove the nozzle, pins, spacer, spring ‘seat, first spring and shim. 4, Position the nozzle holder with the nozzle facing down and remove the capnut.KBL2.2-P TYPE 5. Remove the spring seat, shim, second spring, pushrod, shim and O-ring. 6. Soak the disassembled parts in clean solvent and remove any carbon using the cleaning kit (105789-0010). 7. Visually inspect the cleaned parts for wear, rust, erosion, etc. Note: Refer to the Nozzle and Nozzle Holder Service Manual (EE17E-11011) for cleaning kit use and inspection standards.8] KBL2.2-P TYPE KBL2.2-P TYPE REASSEMBLY AND ADJUSTMENT The nozzle holder is adjusted as the holder is made in hundredths of a millimeter, components are reassembled in the clean the parts thoroughly in light oil to sequence below. completely remove any dirt or foreign matter. As adjustment of the two-spring nozzle REASSEMBLY AND ADJUSTMENT PROCEDURE 1 5 Zero the dial gauge in preparation for Zeroing the dial gauge selecting the presift adjusting shim, Page 41 CAUTION Do not install the pre-lift adjusting shim during procedures 1~4, 2 First nozzle opening pressure Adjust the first nozzle opening pressure adjustment using the shim. t Page 42 i Adjust the second nozzle opening pressure 3 [Second nozzle opening pressure | iat he see t Page 43 4) Presi adjusting shim selection Select the pre-lift adjusting shim. t Page 44 5 ; Install the pre-lit adjusting shim selected in Preslit shim assembly mocerea t Page 45 6 ; 5 Confirm the condition of the fuel spray with Linallinepeciion the nozzle and nozzle holder assembled. Page 46Dial gauge Nozze holder KBL2.2-P TYPE Zeroing the dial gauge 1. Position the nozzle holder on the plate. 2. Assemble the pushrod and spring seat in the nozzle holder. CAUTION Do not assemble the pre-lift or second opening pressure adjusting shims. 3. Attach the pin to the dial gauge. Tool Name Part No. Remarks Pin 157892-3500 | L=45 mm Dial gauge 157954-3800 4. Insert the dial gauge into the connector assembly (157892-3620). 5. Attach the connector assembly to the nozzle holder and tighten it using a torque wrench, Specified torque: 20~25 N-m {2.0~2.5 kgf-m} 6. Zero the dial gauge and tighten the nut. CAUTION © Secure the dial gauge so that a 2 mm ‘stroke can be measured. © Do not over tighten the nut as the dial gauge. shaft may jam. (Confirm from the dial gauge that the shaft moves smoothly’) —_——___. 7. Loosen then remove the connector assembly (with the dial gauge). CAUTION Engure the dlal gauge reading remains at ‘0’. ——————______ 4KBL2.2-P TYPE Retaining nut Nozzle Wrench Retaining nut 8. Remove the spring seat and pushrod. First nozzle opening pressure adjustment 1. Position the nozzle holder on the plate with the nozzle facing up. a 2. Assemble the first nozzle opening pressure adjusting shim, first spring, Spring seat, spacer and pins in the nozzle older. 3. Assemble the nozzle on the pins and hand-tighten the retaining nut to the nozzle holder. B . Tighten the retaining nut to the specified torque. Specified torque: 29~39 N-m {3.0~4.0 kgf-m}Nozzle holder Nozzle tstor Part No. Thickness (mm) 150591-1000 0.10 150591-2000 0.20 150591-3000 0.30 150591-4000 0.40 150591-5000 0.50 150591-5100 0.51 150591-5200 0.52 10591-5300 0.53 150591-5400 0.54 150591-5500 0.55 150591-5600 0.56 150591-5700 0.57 150591-5800 0.58 150591-5900 0.59 Nozlehoider Plate 8] KBL2.2-P TYPE 5. Attach the nozzle holder to the nozzle tester and adjust the first nozzle opening pressure. If the first nozzle opening pressure is not as specified, vary the thickness of the shim until it is as specified. CAUTION @ Two shims may be necessary. Us micrometer to measure shim thicknes: e ppenng djusting ata adjusting shims and ift adjusting shims tical. © First opening pressure and pre-lift adjusting shims ‘Shape Thickness Second nozzle opening pressure adjustment . Position the nozzle holder on the plate.[8] KBL2.2-P TYPE Pre-it adjusting shim ‘Spring seat ‘Adjusting shim Second spring Pushrod 2. Assemble the pushrod, second spring, second nozzle opening pressure adjusting shim and spring seat on the nozzle jolder. CAUTION Do not assemble the O-ring or pre-lift adjusting shim at this time. ———— 3. Install the capnut on the nozzle holder and tighten it to the specified torque. Specified torque: 20~25 N-m {2.0~2.5 kgf-m} 4. Attach the nozzle holder to the nozzle tester and adjust the second nozzle ‘opening pressure. 5. If the second nozzle opening pressure is not as specified, vary the shim thickness N until it is as specified. lote: Refer to the first and second opening pressure and pre-lift adjusting shims listed on the previous page. Pre-lift adjusting shim selection 1. Position the nozzle holder with the nozzle facing down and then remove the capnut from the nozzle holder. 2. Attach the connector assembly (with dial gauge, set to ‘0’) to the nozzle holder and tighten to the specified torque. Specified torque: 20~25 Nem {2.0~2.5 kgf-m}‘Second spring Pushrod Proctt adjusting shim KBL2.2-P TYPE 3. Measure and record the dial gauge indication ‘h.’ 4, Calculate the thickness (T) of the pre-lift adjusting shim using the formula: T=(h+€)£0.005 T: thickness of assembled shim hi dial gauge indication from 3 above €: pre-lift (as specified) Note: Refer to the first and second opening pressure and pre-lift adjusting shims listed on page 43. Pre-lift shim assembly 1. Remove the connector assembly (with the dial gauge). 2. Remove the spring seat, shim, second spring and pushrod. 3. Assemble the pre-lift adjusting shim (selected above), pushrod, second spring, shim and spring seat.8] KBL2.2-P TYPE Final inspection opt . Install the O-ring on the nozzle holder and tighten the capnut to the specified torque. Specified torque: 20~25 N-m voor UF ona {2.0~2.5 kgf-m} Nome hoe Nowe wer 2. Attach the nozzle holder to the nozzle tester and check first nozzle opening pressure, spray pattern, seat oil-tightness and each part for oil leaks. “ Note: Refer to the Nozzle and Nozzle Holder Service Manual (EE17E-11011) for spray patterns and inspection standards.KBL2.3-S TYPE 2-spring nozzle holder Wire brush (157890-1100) KBL2.3-S TYPE DISASSEMBLY Before disassembly, remove any carbon from the nozzle holder using a wire brush and wash the outside. CAUTION © Do not clean the nozzle holes. © Place all disassembled parts in order of disassembly on the bench. Part name Nozzle holder body Pushrod Fest spring ‘Adjusting screw ‘Gasket Cepnut ‘Shim (or second a7KBL2.3-S TYPE Pins (2) 1. Secure the pins to the plate using the nuts. Nozzle holder Without flanges Tool Name Part No. Remarks Pin 157944-1900 | L=115 mm Plate 157944-9500 Nut 013010-8020 | M8x1.25 Note: The above parts comprise the plate (157944- 9520) 2. Position the nozzle holder on the plate. Retaining nut wrench Nozzle CAUTION Secure nozzle holders without flanges ctly In the vise between two metal 8. 3. Remove the retaining nut using the wrench (157914-2800).. 4, Remove the nozzle and pins.Pins ‘ a Spacer First spring Pushrod ' ro TLE 9] KBL2.3-S TYPE 5. Remove the spacer, pins and lift piece. 6. Remove the spring seat, second spring and shim. 7. Position the nozzle holder with the nozzle facing down and remove the capnut and gasket. 8. Remove the adjusting screw, first spring and pushrod. 9. Soak the disassembled parts in clean solvent and remove any carbon using the cleaning kit (05789-0010). 10.Visually inspect the cleaned parts for wear, rust, erosion, etc. Note: Refer to the Nozzle and Nozzle Holder Service Manual (EE17E-11011) for cleaning kit use and inspection standards.50 KBL2.3-S TYPE KBL2.3-S TYPE REASSEMBLY AND ADJUSTMENT The nozzle holder is adjusted as the components are reassembled in the sequence below. As adjustment of the two-spring nozzle REASSEMBLY AND ADJUSTMENT PROCEDURE 1 First nozzle opening pressure adjustment Page 51 t Full needle valve lift confirmation Page 54 t Pre-lift confirmation holder is made in hundredths of a millimeter, clean the parts thoroughly in light oil 0 completely remove any dirt or foreign matter. Adjust the first nozzle opening pressure using the adjusting screw. Confirm the full needle valve lift in accordance with the closed method. Confirm pre-lift in accordance with the closed method. Page 56 Second nozzle opening pressure confirmation Page 57 Second nozzle opening pressure adjustment Page 58 t Final inspection Page 59 CAUTION If not as specified, replace the nozzle assembly, lift plece, pins and spacer using the nozzle service kit. Confirm the second nozzle opening pressure in accordance with the closed method. Adjust the second nozzle opening pressure using the shim. Confirm the condition of the fuel spray with the nozzle and nozzle holder assembled.fo) KBL2.3-S TYPE First nozzle opening pressure adjustment 1. Position the nozzle holder on the plate. CAUTION Secure nozzle holders without flanges directly in the vise between two metal plates. 2. Assemble the shim, second spring and spring seat in the nozzle holder. CAUTION e second spring and first spring are ntical 3. Assemble the pins, lift piece and spacer in the nozzle holder. Note: The indented face of the lift piece faces the pushrod. 4. Assemble the pins in the spacer and then assemble the nozzle on the pins. 51KBL2.3-S TYPE fo] 5. Hand-tighten the adjustment retaining nut together with the gasket to the nozzle holder. Tool Name | PartNo. | Remarks Adjustment Gasket 157892-1500 rearing nt Retaining nut | 17892-4000 — 6. Tighten the adjustment retaining nut to Toraye wrench the specified torque using the wrench Adjsimant '157914-0500). retaining nut pecified torque: 59~78 N-m [—___ {6.0~8.0 kgf-m} Wrench 7. Position the nozzle holder on the plate Capnut ise with the nozzle holder capnut facing up. Nozze holder 8 Assemble the pushrod, first, spring and adjusting screw in the nozzle holder. 9. Install the gasket and capnut on the adjusting screw.Nozzle tester KBL2.3-S TYPE 10.Attach the nozzle holder to the nozzle tester. 11.Operate the nozzle tester and adjust the adjusting screw until the first nozzle no cPening Pressure is as specified. lote: Temporarily loosen the capnut and then adjust the adjusting screw. 12.Secure the nozzle holder using a wrench and tighten the capnut to the specified torque. Specified torque: 29~39 N-m {3.0~4.0 kgt-m}9] KBL2.3-S TYPE Full needle vaive lift confirmation 1. Install the gasket and plug on the adjustment retaining nut. Tool Name Part No. Remarks Gasket 026508-1140 Plug 157892-1600 | SW 12 mm 2. Position the nozzle holder on the plate with the nozzle holder capnut facing up. g. Attach the holder tothe capnut, lote: There are three types of holder. Choose the ‘one that fits the capnut and thread. Tool Name Part No. Remarks Holder 157892-4100 |M10x1.0 Holder 157892-5400 |M101.25 Holder 157892-4400 | M8 x 1.0 4. Attach the nut (157892-1000; SW17 mm) to the holder. 5. Attach the pin to the dial gauge. Note: There are three types of pin. Select a pin . that contacts the tip of the nozzle holder i! gauss : pushrod in the following procedure. oe Tool Name | PartNo. | Remarks Dial gauge _| 157954-3800 Pin 157892-4200 [L=160 mm Pin 157892-4300 |L=110 mm Pin 157892-4700 [L=85 mmNozzle holder Dial gauge Pushod Noodle valve it (mm). ° First opening pressure Instine pressure 34.9~44.1 MPA. {350~450 kglem?) fo) KBL2.3-S TYPE 6. Secure the dial gauge to the nozzle holder using the nut so that the pin contacts the tip of the pushrod. CAUTION © Secure the dial gauge so that a stroke of 2 mm can be measured. © Do not over-tighten the nut as the dial jauge shaft may jam. (Confirm from e dial gauge that the shaft moves smoothly§ 7. Attach the nozzle holder to the nozzle tester and zero the dial gauge. 8. Operate the nozzle tester to bleed any air from inside the adjustment retaining nut and to confirm that no fuel leaks. 9. Operate the nozzle tester and increase the in-line pressure to 34.3~44.1 MPa {350~ 450 kgt/cm2} so that the nozzle’s needle valve moves through its full lift. Record full lift ‘L.’ Note: The above operation is used to determine whether the nozzle seat is worn and whether the nozzle assembly is in good condition. 553] KBL2.3-S TYPE ‘ —_— é ood vave wt (rm) a Inti pressure L Need vane in) e ° Pressure Frat opening Fist opening preseure ++epprox 1 MPa Iivine pressure ‘Spring seat ‘Spacer Pushrod Second spring oh @\& Noodle valve Lit piece: Pre-lift confirmation 1. With the needle valve in the full lift condition, release the nozzle tester handle. in-line pressure will decrease and needle valve lit (as indicated on the dial gauge) will also decrease a little. 2. Read the needle valve lift ‘’ from the dial gauge indication (once the needle valve has descended when the second spring has stopped operating). Refer to the pre- lift measuring point for ‘¢”. Pre-lift measuring point Read the dial gauge at first nozzle opening pressure + approx 1 MPa {10 kgf/cm2}. ~m lote: This point can be found when the pressure is decreasing. 3. Confirm that pre-lift ‘¢’ is as specified.Lit piece Pin Pin ‘Spacer pressure pressure Instn pressure First opening Second opening _94.9~44.1 MPa {950~450 kglem?)| Needle valve it at €+0.05 mm Full needie valve it fo] KBL2.3-S TYPE 4. If pre-lift is not as specified, replace the pins, lift piece, spacer ‘and nozzle assembly with the nozzle service kit. Second nozzle opening pressure confirmation 1. After pre-lift confirmation, operate the nozzle tester to increase in-line Pes to 34.3~44.1 MPa {350~450 kaf/cm2} so that the nozzle’s needle valve moves through its full lift. 2. Release the nozzle tester handle so that in-line pressure decreases. 3. Read the pressure gauge indication the instant that the dial gauge indicates the specified needle valve lift (usually pre-lift N £+0.05 mm; see top figure, next page). ote: The pressure gauge indicates second nozzle opening pressure. 72] KBL2.3-S TYPE Roading ‘the pressure gauge Pressure gauge Second nozzle opening pressure adjustment. 1. When the second nozzle opening pressure is a little outside the specified Tange, readjust the first nozzle opening pressure (within the first nozzle opening pressure’s specified range). ¢ When the second nozzle opening pressure is less than the specified value: Readjust the first nozzle opening pressure to the maximum specification and measure the second nozzle opening pressure. @ When the second nozzle opening pressure is more than the specified value: Readjust the first nozzle opening pressure to the minimum specification and measure the second nozzle opening ressure. 2. If the second nozzle opening pressure is still not as specified, despite readjusting the first nozzle opening pressure, disassemble the nozzle and remove the adjusting shim. 3. When the second nozzle opening pressure exceeds the specified pressure, install a thinner adjusting shim. When less than specified, install a thicker shim. 4. After adjusting ‘shim replacement, remeasure and adjust the second nozzle opening pressure until it is as specified. Part No. Thickness (mm) CAUTION 150538-4900 0.40 Use a micrometer to measure shims. 150538-5000 0.60 150538-5100 0.52 9 pressure adjusting sl 150538-5200 0.54 ‘Shape 150538-5300 0.56 150538-5400 0.58 {EE 150538-5500 0.60 , Thi 15058-5600 0.70 vexnessNozze holder Adjustment retaining nut Nozzle lo KBL2.3-S TYPE Final Inspection 1. Remove the dial gauge, nut and holder. 2 Remove the adjustment retaining nut and jasket. onfirm that the pin is fully inserted into ‘the nozzle and then install the specified retaining nut. First hand-tighten the nut, and then tighten it to the specified torque. Specified torque: 59~78 Nm {6.0~8.0 kgf-m} 4. Attach the nozzle holder to the nozzle tester and check first nozzle opening pressure, spray pattern, seat oil tightness and each part for oil leaks. Note: Refer to the Nozzle and Nozzle Holder Service Manual (EE17E-11011) for spray Patterns and inspection standards. 5. When replacing the nozzle, replace the nozzle, lit piece, pins and spacer as a set with the nozzle service kit. CAUTION Pre-lift will not be as specified If only the nozzle Is replaced. 59KBL2.4-P TYPE 2-spring nozzle holder Nozze holes Wire brush (187890-1100) KBL2.4-P TYPE DISASSEMBLY Before disassembly, remove any carbon from the nozzle holder using a wire brush and wash the outside. CAUTION © Do not touch the nozzle holes with the wire brush. © Place all disassembled parts In order ly on the bench. KBL2.4-P TYPE NOZZLE HOLDER: EXPLODED VIEW Key no Part name 1. [Nozzle holder body 2 | Shim (or 1st opening pressure adjustment) 3 | First spring 4 | Spring seat 8 | Colar 7 | Second spring 3 | Pustrod 9 | Shim (tor 2nd pening pressure a adjustment) 10 | Spring seat 11 | Pins ; 12 | Lit piece 13 15 | Retaining nut 8 20 | Eye bolt 10 31 | Gasket 50 | Oxing 12 A | Nozze10] KBL2.4-P TYPE 1. Position the nozzle holder on the plate (157992-2820). Note: For nozzle holders with flanges, use a different plate (15794-9520). 2. Remove the retaining nut. 3. Remove the nozzle. 4. Remove the spacer, pins and lift piece. e10] KBL2.4-P TYPE Pustrod ‘Spring seat First spring ‘Shim 2 5. Remove the spring seat, shim, second ‘spring, pushrod and collar. 6. pene ‘the spring seat, first spring and shim. 7. Soak the disassembled parts in clean solvent and remove any carbon using the cleaning kit (105789-0010). 8. Visually inspect the cleaned parts for wear, rust, erosion, etc. Note: Refer to the Nozzle and Nozzle Holder Service Manual (EE17E-11011) for cleaning kit use and inspection standards.KBL2.4-P TYPE 1 lo KBL2.4-P TYPE REASSEMBLY AND ADJUSTMENT The nozzle holder is adjusted as the holder is made in hundredths of a millimeter, components are reassembled in the clean the parts thoroughly in light ll to sequence below. completely remove any dirt or foreign matter. As adjustment of the two-spring nozzle REASSEMBLY AND ADJUSTMENT PROCEDURE 1 First nozzle opening pressure Adjust the first nozzle opening pressure adjustment using the shim. t Page 64 2 Confirm the full needle valve lift in Full needle vaive lift confirmation Y Page 66 accordance with the closed method. Confirm pre-lift in accordance with the closed S Preslift confirmation method.” Page 68 CAUTION if not as specified, replace the nozzle assembly, lift plece, pins and spacer using the nozzle service kit. 4] Second nozzle opening pressure] Confirm the second nozzle opening pressure confirmation in accordance with the closed method. t Page 69 5 | Second nozzle opening pressure] Adjust the second nozzle opening pressure adjustment using the shim. | Page 71 Final inspection Confirm the condition of the fuel spray with the nozzle and nozzle holder assembled. Page 7110] KBL2.4-P TYPE Nozzle holder sen = 8 “S Pins (2) 8 Lt piece Pushrod First nozzle opening pressure adjustment 1. Position the nozzle holder on the plate. 2. Assemble the shim, first spring and spring seat in the nozzle holder. 3. Assemble the collar, second spring, shim, spring seat and pushrod. 4. Assemble the pins, lift piece and spacer in the nozzle holder. Note: Position the lift piece with the rounded indentation facing the pushrod.Gasket ‘Adjustment retaining nut ‘Adjustment retaining rut 10] KBL2.4-P TYPE 5. Assemble the nozzle on the pins. 6. Hand-tighten the adjustment retaining nut on the nozzle holder together with the gasket. Tool Name Part No. Remarks Gasket 157892-3200 Retaining nut | 157892-5100 7. Tighten the adjustment retaining nut to the specified torque. Specified torque: 29~39 N-m {3.0~4.0 kgt-m} 8. Attach the nozzle holder to the nozzle tester. 9. Operate the nozzle tester and measure the first nozzle opening pressure.10) KBL2.4-P TYPE 10.If the first nozzle opening pressure is not as specified, disassemble the nozzle holder and replace the shim until the pressure is as specified. Record opening pressures and adjusting shim thicknesses to facilitate adjustment. CAUTION Part No. Thickness (mm) 150538-9800 0.40 150538-9900 0.50 150539-0000 0.52 150539-0100 0.54 150539-0200 0.56 150539-0300 0.58 150539-0400 0.60 150539-0500 0.70 Use a micrometer to measure shim thickness. © First opening pressure adjusting shims Thickness Full needle valve lift confirmation 1. Install the gasket and plug on the adjustment retaining nut. Tool Name Part No. Remarks Gasket 026508-1140 Plug 157892-1600 swi2 2. Position the nozzle holder on the plate with the nozzle facing down. 3. Install the holder (157892-5000) on the nozzle holder."Nozzle holder Spring seat 10) KBL2.4-P TYPE 4. Install the nut (157892-1000) on the holder. 5. Attach the pin to the dial gauge. Tool Name Part No. Remarks L=100 mm Pin 157892-5200 | (excluding thread) Dial gauge 157954-3800 6. Install the dial gauge to the nozzle holder ‘so that the pin contacts the top face of the spring seat and then tighten the nut. CAUTION © Secure the dial gauge so that a stroke of 2 mm can be measured. © Do not over-tighten the nut as the dial jauge shaft may jam. (Confirm from the dial gauge that the shaft moves smoothly.) 6710) KBL2.4-P TYPE INeodte vaive it (om) ° First opening pressure Insine pressure 343~44.1 MPa {350~450 kglom?) Pressure gauge Neodio valve ft (mm) First opening pressure Insine pressure 7. Attach the nozzle holder to the nozzle tester and zero the dial gauge. 8. Operate the nozzle tester to bieed any air from inside the adjustment retaining nut and to confirm that no fuel leaks. 2 . Operate the nozzle tester and increase the in-line pressure to 34.3~44.1 MPa {350~ 450 kgf/cm2} so that the nozzle’s Needle valve moves through its full lift. —\ Record full lift ‘L.” Note: The above operation is used to determine whether the nozzle seat is worn and whether the nozzle assembly is in good condition. Pre-lift confirmation 1. With the needle valve at full lift, release the nozzle tester handle. Note: The in-line pressure will decrease and needle valve lift (as indicated on the dial gauge) will also decrease a little. -_Fromm =— En = veota te ' ~ 0 First opening First opening pressure ante eng ——— Spring seat it e i ‘Spacer Litt piece | ven capes ms i see es — a 10] KBL2.4-P TYPE 2. Read the needle valve lift ‘e” from the dial gauge indication (once the needle valve as descended when the second spring has stopped operating). Refer to the pre- lift measuring point for ‘e’. Pre-lift measuring point Read the dial gauge at first nozzle opening pressure + approx 1 MPa {10 kgf/cm?}. Note: This point can be found when the pressure is decreasing. 3. Confirm that pre-lift ‘€’ is as specified. 4. If pre-lift is not as specified, replace the pins, lift piece, spacer and nozzle assembly with the nozzle service kit. Second nozzle opening pressure confirmation. 1. After pre-lift confirmation, operate the nozzle tester to increase in-line pressure to 34.3~44.1 MPa {350~450 kgficm2} ‘so that the nozzle’s needle valve moves through its full lift.10) KBL2.4-P TYPE L ‘Noodle valve it (mm) +005] e First opening Second opening 34:3~44.1 MPa rossure pressure {(350~450 kgllom?) Inne pressure Needle valve it ‘at €+0.05 mm Full noodte vate it Dial gauge Pressure gauge 70 2. Release the nozzle tester handle. Note: The ‘in-line pressure will decrease and needle valve lift (as indicated on the dial gauge) will also decrease a little. 3. Then, read the pressure gauge indication the instant that the dial gauge indicates the specified needle valve lift (usually pre- litt €+0.05mm).= »—__ § | : E 40) KBL2.4-P TYPE Second nozzle opening pressure adjustment If the second nozzle opening pressure is not as specified, disassemble the nozzle from the nozzle holder and replace the shim until the pressure is as specified. Adjusting shims are listed below. Part No. Thickness (mm) 160591-1000 0.10 150591-2000 0.20 160591-3000 0.30 150591-4000 0.40 150591-5000 0.50 150591-5100 0.51 150591-5200 0.52 150591-5300 0.53 150591-5400 0.54 150591-5500 0.55 150591-5600 0.56 150591-5700 0.57 150591-5800 0.58 150591-5900 0.59 CAUTION @ Because the second opening pressure changes when the first Opening pressure changes, the second opening pressure must be adjusted when the first opening ressure changes. @ Use a micrometer to measure shim thickness. ® Second nozzle opening pressure adjusting shims Shape Thickness Final inspection 1. Remove the dial gauge, nut and holder. nTorque wrench 2. Remove the adjustment retaining nut and jasket. 3. Confirm that the pin is fully inserted into the nozzle and then install the specified retaining nut. First hand-tighten the nut and then tighten it to the specified torque. Specified torque: 29~39 Nm {3.0~4.0 kgf-m} 4. Attach the nozzle holder to the nozzle tester and check first nozzle opening pressure, spray pattern, seat oil tightness and each part for oil leaks. Note: Refer to the Nozzle and Nozzle Holder Service Manual (EE17E-11011) for spray patterns and inspection standards. 5. When replacing the nozzle, replace the nozzle, lift piece, pins and spacer as a set with the nozzle service kit. CAUTION Pre-lift will not be as specified if only the nozzle Is replact2-epring nozzle holdor Wire brush (157890-1100) ii] KBL2.4-S TYPE KBL2.4-S TYPE DISASSEMBLY Before disassembly, remove any carbon from the nozzle holder using a wire brush and wash the outside. CAUTION ® Do not touch the nozzle holes with the wire brush. © Place all disassembled parts in order of disassembly on the bench. KBL2.4-S TYPE NOZZLE HOLDER: EXPLODED VIEW Key no Part name 1 | Nozzle holder body 2 | Shim (lor 1st opening pressure adjustment) 3 | First spring 4 | Spring seat 6 lar 7 | Second spring 8 8 | Shim (tor and pening prssire 10 | Spring seat 11 Pins 12 | Lit piece 13 | Spacer 14 [Pins 15. | Retaining nut 30 ‘ot 31 | Gasket ‘A__| NozzleTi] KBL2.4-S TYPE ‘Without tanges 1. Position the nozzle holder on the plate (157944-9520). fa lote: Assemble the plate as shown at left. CAUTION 4 Secure nozzle holders without flanges elreotly in the vise between two metal lates. 2. Remove the retaining nut. 3. Remove the nozzle and pins. 4. Remove the spacer, lift piece and pins.11) KBL2.4-S TYPE 5. Remove the spring seat, shim, second spring, pushrod and collar. 6. pemere the spring seat, first spring and shim. 7. Soak the disassembled parts in clean solvent and remove any carbon using the cleaning kit (105789-0010). 8. Visually inspect the cleaned parts for wear, rust, erosion, etc. Note: Refer to the Nozzle and Nozzle Holder Service Manual (EE17E-11011) for cleaning kit use and inspection standards. 711] KBL2.4-S TYPE KBL2.4-S TYPE REASSEMBLY AND ADJUSTMENT The nozzle holder is adjusted as the components are reassembled in the sequence below. As adjustment of the two-spring nozzle holder is made in hundredths of a millimeter, clean the parts thoroughly in light oil to completely remove any dirt or foreign matter. REASSEMBLY AND ADJUSTMENT PROCEDURE 1 First nozzle opening pressure adjustment v Page 77 2 Full needle valve lift confirmation t Page 79 Pre-lift confirmation Page 81 4[ Second nozzle opening pressure confirmation v Page 62 5 Second nozzle opening pressure adjustment t Page 84 Final inspection Page 84 Adjust the first nozzle opening pressure using the shim. Confirm the full needle valve accordance with the closed method. lift in Confirm pre-lift in accordance with the closed method. CAUTION If not as Specified, replace the nozzle assembly, plece, pins and spacer using the nozzle service kit. Confirm the second nozzle opening pressure in accordance with the closed method. Adjust the second nozzle opening pressure using the shim. Confirm the condition of the fuel spray with the nozzle and nozzle holder assembled.11) KBL2.4-S TYPE First nozzle opening pressure adjustment 1. Position the nozzle holder on the plate. CAUTION Secure nozzle holders without flanges directly In the vise between two metal plates. 2. Assemble the shim, first spring and spring ‘seat in the nozzle holder. 3. Assemble the collar, second spring, shim, spring seat and pushrod in the nozzle holder. 4. Assemble the pins, lift piece and spacer in the nozzle holder. Note: Assemble the lift piece with the rounded indentation facing the pushrod.77] KBL2.4-S TYPE Adjustment retaining nut 78 5. Assemble the pins in the spacer. 6. Assemble the nozzle on the pins. 7. Hand-tighten the adjustment retaining nut together with the gasket to the nozzle holder. Tool Name Part No. Remarks Retaining nut | 157892-4000 Gasket 157892-1500 8. Tighten the adjustment retaining nut to the speciied torque using the torque wrench and wrench (157914-0500; SW22 mm). Specified torque: 29~39 N-m {3.0~4.0 kgt-m} 9. Attach the nozzle holder to the nozzle tester. 10.Operate the nozzle tester and measure the first nozzle opening pressure. 11.1f the first nozzle opening pressure is not as specified, disassemble the nozzle holder and replace the shim until the pressure is as specified. CAUTION Use a micrometer to measure shim thickness.Part No. Thickness (mm) 150539-0700 0.40 150539-0800 0.50 150539-0900 0.52 150539-1000 0.54 150539-1100 0.56 150539-1200 0.58 150539-1300 0.60 15059-1400 0.70 Adjusimont retaining nut Gasket 41) KBL2.4-S TYPE © First opening pressure adjusting shims ‘Shape t ea Thickness $8.9 Full needle valve lift confirmation 1. Install the gasket (026508-1140) and plug (157892-1600; SW12) on the adjustment retaining nut. 2. Position the nozzle holder with the nozzle facing down and install the holder on the nozzle holder. Note: There are three types of holder. Use a holder that fits the nozzle holder thread. Tool Name Part No. Remarks Holder 157892-4400 | M8 x 1.0 Holder 17892-4100 |M10X1.0 Holder 157892-5400 |M10X 1.25 3. Install the nut (157892-1000) on the holder.11] KBL2.4-S TYPE Dial gauge. alder First spring ‘seat Holder 4, Attach the pin to the dial gauge. Note: -1. There are five types of pin. Select a pin that contacts the tip of the first spring seat. Refer to the figure below. -2. The lengths of the pins do not include the threaded portions. Tool Name | Part No. Remarks Pin 157892-4700 |L=85 mm Pin 157892-5200 [L=100 mm Pin 157892-5300 [L=60 mm Pin 157892-5500 | =55 mm Pin 157892-5700 [L=120 mm Dial gauge | 157954-3800 5. Secure the dial gauge to the nozzle holder using the nut so that the pin contacts the tip of the first spring seat. CAUTION © Secure the dial gauge so that a stroke 2 mm can be measured. © Do not over-tighten the nut as the dial gauge shaft may jam. (Confirm from e dial gauge that the shaft moves smoothly.)11] KBL2.4-S TYPE Dial gauge "Nozzle holder Nozzle tester Noodle valve it (om) First opening 34.3~44.1 MPa pressure {(950~450 kglom?) Invine pressure Pressure gauge Neodte valve Ait (mm e {tne pressure 6. Attach the nozzle holder to the nozzle tester and zero the dial gauge. 7. Operate the nozzle tester to bleed any air from inside the retaining nut and to confirm that no fuel leaks. 8 Operate the nozzle tester and increase the inline pressure to 34.3~44.1 MPa {350~450 kgf/cm2} so that the nozzle’s Needle valve moves through its full lift. Record full lift ‘L.” Note: The above operation is used to determine whether the nozzle seat is worn and whether the nozzle assembly is in good condition. Pre-lift confirmation 1. With the needle valve at full lit, release the nozzle tester handle. Note: The ‘in-line pressure will decrease and needle valve lift (as indicated on the dial gauge) will also decrease a little. at11) KBL2.4-S TYPE ‘Noodle valve fi (mm) © First opening First opening pressure pressure Mi 2. Read the needle vaive lift ‘€’ from the dial gauge indication (once the needle valve as descended when the second spring has stopped operating). Refer to the pre- lift measuring point for *€.’ Prevlift measuring point: Read the dial gauge at first nozzle opening pressure + approx 1 MPa {10 kgf/cm?}. Note: This point can be found while the pressure is decreasing. 3. Confirm that pre-lift 4. If pre-lift is not as specified, replace the pins, lift piece, spacer and nozzle assembly as a set with the service kit. Second nozzle opening pressure confirmation 1, After pre-lift confirmation, operate the nozzle tester to increase in-line pressure to 34.3~44.1 MPa {350~450 kgf/cm2} ‘so that the nozzle’s needle valve moves through its full lift.L Neodte vate: it (em £40.05} t First opening Second opening 94.9~44.1 MPa Pressure ressure—_{950~450 kaom a vem GP /] CEI eS — ji] KBL2.4-S TYPE 2. Release the nozzle tester handle so that fe pressure decreases. Note: The ‘in-line pressure will decrease and needle valve lift (as indicated on the dial gauge) will also decrease a little. 3. Then, read the pressure gauge indication (second nozzle opening pressure) the instant that the dial gauge indicates the specified needle valve lift (usually pre-lift £+0.05mm).11) KBL2.4-S TYPE Second nozzle opening pressure adjustment If the second nozzle opening pressure is not as specified, disassemble the nozzle from the nozzle holder and replace the shim until the pressure is as specified. CAUTION @ Because the second opening pressure changes when the first opening pressure changes, the second opening pressure must be adjusted when the first opening ressure changes. e Use a micrometer to measure shim thickness. 7 © Second nozzle opening pressure “ Part No. Thickness (mm) adjusting shime 150590-0600 0.40 150590-0700 0.50 ‘Shape 150590-0800 0.52 150590-0900 0.54 | Ee 150590-1000 0.56 f 4.8 150590-1100 0.58 Thickness 150590-1200 0.60 9.9 150590-1300 0.70 Final Inspection Dial gauge 1, Remove the dial gauge, nut and holder. “vO ~ Holder‘Adjustment retaining nut Gasket ‘Nozzle holder 31] KBL2.4-S TYPE 2. Remove the adjustment retaining nut and jasket. stall the spectied retaining nut, confirm that the pins are inserted fully into the nozzle, and then hand-tighten the retaining nut. Then, tighten the retaining nut to the specified torque using the torque wrench and wrench (157914-2800; SW19 mm). Specified torqu 59~79 Nm {6.0~8.0 kgf-m} 4, Attach the nozzle holder to the nozzle tester and check first nozzle opening pressure, spray pattern, seat oil tightness and each part for oil leaks. Note: Refer to the Nozzle and Nozzle Holder Service Manual (EE17E-11011) for spray patterns and inspection standards. 5. When replacing the nozzle, replace the nozzle, lift piece, pins and spacer as a set with the nozzle service kit. CAUTION Pre-lift will not be as specified If only the nozzle Is replaced.TIGHTENING TORQUES KBL2.1-S TYPE AND -P TYPE KBL2.1-S KBL2.1-P SW12: 9.8~15 Nm {1.0~1.5 kgm} ‘SW22: 39~49 Nm {4.0~5.0 kgf-m} SW14: 49~59 Nm {5.0~6.0 kgf} SW17: 49~59 Nm {5.0~6.0 kgfm} Swi9: 59~78 N-m {6.0~8.0 kgf-m} SW17: 29~34 Nm {3.0~3.5 kgfm} SW12: 20~25 Nm SW17: 20~25 N-m {2.0~2.5 kgf-m} 2.0~2.5 kgf t atm} SW12: 34~39 Nm {3.5~4.0 kgfm} SW14: 49~59 Nm {5.0~6.0 kgf-m} SW14: 29~39 N-m {3.0~4.0 kgfm} SW12: 9.8~15 N-m {1.0~1.5 kgf-m}12) TIGHTENING TORQUES KBL2.2-P TYPE AND 2.3-S TYPE KBL2.2-P KBL2.3-S SW14: 15~20 Nem {1.5~2.0 kgm} SW12: 9.8~15N-m swig: 29~39 N-m {1.0~1.5 kgf-m} {3.0~4.0 kgf-m} SW14: 20~25 Nm {2.0~2.5 kgt-m} SW14: 49~59 Nem {5.0~6.0 kgf-m} SW14: 29~39 N-m {3.0~4.0 kgfm} SW14: 69~78 Nm {7.0~8.0 kgf-m} SW19: 59~78 N'm {6.0~8.0 kgf-m} a772) TIGHTENING TORQUES KBL2.4-P TYPE AND -S TYPE KBL2.4-P KBL2.4-S SW12; 9.8~14.7 Nm SW12: 10~15 Nm {1.0~1.5 kot} {1.0~1.5 kgm} 1 ISW14: 29.4~89.2 N-m {3.0~4.0 kgf-m} SW19: 59~78 Nem {8.0~8.0 kgf-m}Pub. No.: EE17E-11040 TWO-SPRING NOZZLE HOLDER Service Manual Construction & Operation Repair & Maintenance Printing: December, 1996 Published by: ZEXEL CORPORATION Service Department Printed in Japan © Copyright 1996, ZEXEL CORPORATION 194-200-02 JPWS-02 Printed on recycled paper