KUBOTA JUNE 2003 S.I. 441 1 / 19
PUMP
ADJUSTMENT TOOLS FOR FO R PFR TYPE INJECTION PUMPS (3KX ~ 4KX AND 2MD ~ 4MD) FOR KUBOTA New and modified adjustment tools are now available available for PFR type injection i njection pumps for Kubota.
1. OUTLINE The holders (for pump installation) and the gauges (for the rack's standard 0 position) are newly available. available. The connectors (with a function to t o prevent rack rack connection play) are used together with the existing parts and the existing drive stand (part (par t no. 105781-4320). 105781-4320).
2. APPLICABLE APPLICABLE PUMP PART NUMB NUMBERS ERS [1] 3KX ~ 4KX types types Plate
RBAJ BAJ par part no.
Kub Kubota ota par part no.
Pum Pump type
104135-3041
16496-51012
3KX
Not equipped
D1503-T-RP
104139-3010
1G 1G750-51011
3KX
Equipped
D1803-M·DI
104139-3020
1G 1G730-51011
3KX
Equipped
D1503-MDI-T
104139-3030
1G 1G720-51011
3KX
Equipped
D1503-MDI
104139-3050
16098-9077A
3KX
Equipped
03-DI
104139-4070
1G911-51011
4KX
Equipped
V2203-DI
104139-4080
1G 1G790-51011
4KX
Equipped
V2403-M·DI
104139-4090
1G 1G911-51012
4KX
Equipped
V2203-DI
104139-4110
1A 1 A093-51011
4KX
Equipped
V2403-M·DI
104139-4120
1A071-51011
4KX
Equipped
V2003-MDI-T
104139-4140
1G 1G922-51011
4KX
Equipped
V2003-MDI-T
(for preventing rotation)
Applicable engine
Note: The plate is used to prevent delivery delivery valve holder rotation.
Bosch Automotive Systems Corporation
Service Dept. Printed in Japan
JUNE 2003 S.I. 441 2 / 19
[2] 2MD ~ 4MD types RBAJ part no.
Kubota part no.
Pump type
Applicable engine
104205-2051
16001-51011
2MD
New super mini Z482-E
104205-2061
17548-51012
2MD
New super mini Z482-B-ONAN-1
104205-2071
19007-51012
2MD
New super mini Z482-B-F.King-1
104205-3071
16006-51011
3MD
New super mini D662-E
104205-3081
17549-51012
3MD
New super mini D722-B-ONAN-1
104205-3091
17529-51012
3MD
New super mini D722-B-F.King-1
104206-3001
16030-51012
3MD
Super 5 D1105-EBB-STD-1
104206-3011
16032-51012
3MD
Super 5 D1105-EF
104206-3020
16029-51011
3MD
Super 5 D1005-EBBS-SDX-2
104206-3030
16027-51011
3MD
Super 5 D1005-E
104206-3041
19420-51012
3MD
Super 5 D1105-B-F.King-1
104206-4001
16060-51012
4MD
Super 5 V1505-EBB-STD-1
104206-4011
16062-51012
4MD
Super 5 V1505-E
104206-4020
16054-51011
4MD
Super 5 V1305-EBBS-SDX-2
104206-4030
16055-51011
4MD
Super 5 V1405-E
104206-4041
16695-51013
4MD
Super 5 V1205-B-F.King-1
104206-4050
17218-51011
4MD
Super 5 V1505-T-KA-TCM-R3
JUNE 2003 S.I. 441 3 / 19
3. ADJUSTMENT TOOL PART NUMBERS [1] 3KX ~ 4KX types Key
Part no.
no.
Part name
Qty 3KX
4KX 1
1
105781-4320 Driving stand
1
2
157817-5420 Holder
1
3
157817-3321 Holder
4
157817-5220 Gauge
5
157817-3121 Gauge
6
157817-2820 Connector
Remarks Pump driving stand (existing part) For pump installation (newly available)
1
For pump installation (modified part)
1
For rack's standard 0 position (newly available)
1
1
For rack's standard 0 position (modified part)
1
With function for preventing rack joint connection play (existing part)
7
105782-6270 Measuring device
7/1
157827-6220 Adapter
7/2
157827-6820 Connector
7/3
157954-3501 Dial gauge
1. 105781-4320 Driving stand
1
1
For confirming rack position (existing part)
2. 157817-5420 Holder
4-M8X1.25
3. 157817-3321 Holder
6
106
6-M8X1.25
106
6
10
10
90 214
214 110 125
4. 157817-5220 Gauge
5. 157817-3121 Gauge
6. 157817-2820 Connector
2-M8X1.25
2-M8X1.25 101
86
24
80 5
80 5
12
23
JUNE 2003 S.I. 441 4 / 19 7. 105782-6270 Measuring device
7/1 157827-6220 Adapter
7/2 157827-6820 Connector
7/3 157954-3501 Dial gauge
M18X1.5
66.5 M2.5X0.45
SW22 M16X1.5
152
SW19
M4X0.7
ZW19
28.5
M4X0.7 M6X1
8
M18X1.5
20.5
M6X1
59
131
M16X1.5 30
[2] 2MD ~ 4MD types Key no.
Part no.
Part name
Qty A
B
C
D
1
1
1
1
105781-4320 Driving stand
1
2
157817-4020 Holder
1
3
157817-4120 Holder
4
157817-4220 Holder
5
157817-4320 Holder
6
157817-4420 Gauge
Pump driving stand (existing part) For pump installation (newly available)
1
For pump installation (newly available) 1
For pump installation (newly available) 1
1
Remarks
1
For pump installation (newly available) For rack's standard 0 posi tion (newly available)
7
157817-4620 Gauge
1
1
For rack's standard 0 posi tion (newly available)
8
157817-4820 Connector
1
1
1
1
With functio n for preventing rack jo int connection play (existing part)
9
105782-6270 Measuring device
9/1
157827-6220 Adapter
9/2
157827-6820 Connector
9/3
157954-3501 Dial gauge
1
1
1
Note: The symbols in the 'Qty' column refer to the following. A: For 2MD for new super mini B: For 3MD for new super mini C: For 3MD for super 5 D: For 4MD for super 5
1
For confirming rack position (existing part) (See above for individual part drawings.)
JUNE 2003 S.I. 441 5 / 19 1. 105781-4320 Driving stand
2. 157817-4020 Holder
4-M6X1
6
3. 157817-4120 Holder
5-M6X1
106
106
6
10
10
90 214
214
5. 157817-4320 Holder
6. 157817-4420 Gauge
110 125
4. 157817-4220 Holder
4-M6X1
6
5-M6X1
106
2-M6X1
6
56
106
10
10
66 214
214
7. 157817-4620 Gauge
8. 157817-4820 Connector
2-M6X1
4
9. 105782-6270 Measuring device
152
12 27
17
77
M4X0.7
66 M6X1 4 M16X1.5
JUNE 2003 S.I. 441 6 / 19
4. SEPARATE ADJUSTING TOOL PART NUMBER The following plate is necessary between the holder and the pump only when installing the PFR3KX type pump with a part no. 104135-3041 (Kubota part no.: 16496-51012) to the previously mentioned driving stand. Note: If the pump is operated without the plate, the driving stand or the pump may be damaged. Key no. 1
Part no.
Part name
157817-5500 Plate
Qty 1
Remarks For pump part no:. 104135-3041
1. 157817-5500 Plate 4- 8.5 111
82
2- 6.3 0.5
Distinguishing mark
5. ADJUSTING TOOL USE [1] Driving stand preparation Replace the driving stand camshaft with the camshaft for the applicable pump type. PFR type
Camshaft part no.
Marking
3KX ~ 4KX type
157816-7120
6KD
2MD ~ 4MD type
157816-7220
6MD
Advice Refer to service information bulletin S.I. 333 for the camshaft replacement procedure. Tool name Driving stand
Part no. 105781-4320
Remarks Installation stand
JUNE 2003 S.I. 441 7 / 19
[2] Driving stand installation
Adapters (2)
(1) If the pump test bench center height is 125 mm, attach the adapters to the bed. Advice It is not necessary to install the adapters if the center height is 110 mm. Tool name Adapter
Driving stand
Part no. 157992-4200
Driving stand
Holder
Cover
For 7NP, 15NP, 20NP
(2) Attach the driving stand to the pump test bench bed. Tool name
Spacer
Remarks
Part no. 105781-4320
Remarks Installation stand
[3] Connector replacement (1) Remove the holder, the spacer and the cover.
Connector
(2) Remove the existing connector and replace it with the connector for the applicable PFR pump type. (Tighten temporarily.) PFR type
Connector part no.
3KX ~ 4KX type
157817-2820
2MD ~ 4MD type
157817-4820
Marking
JUNE 2003 S.I. 441 8 / 19 Spacers (2)
Dowel pins (2)
[4] Holder installation 3KX ~ 4KX types (1) Remove the existing holder and spacers. (See previous page.) (2) Assemble the dowel pins to the driving stand. (3) Assemble the spacers to the dowel pins, aligning the spacers' holes with the driving stand's threaded holes. Tool name
Holder
M8x1.25;
Pi n
=25 (4)
Part no.
Dowel pin
015060-3680
Spacer
157817-1800
Remarks For fixing holder
(4) Position the pins up and assemble the holder together with the spacers to the driving stand. Tool name
Part no.
Remarks
Holder
157817-5420
For 3KX
Holder
157817-3321 For 4KX
Advice Refer to service information bulletin S.I. 333 for the socket head bolts for holder installation. Collars (2)
Washer
M6x1.0;
= 55 (2)
(5) Insert the collars between the holder and the driving stand. Advice If there is any clearance between the holder and the driving stand and the collars, use washers to adjust the clearance. Part name
Dowel pins (2)
Part no.
Remarks
Collar
157817-1200
L = 43 mm
Washer
029300-6010
t = 0.8 mm
Washer
029300-6020
t = 0.35 mm
Washer
029300-6030
t = 0.5 mm
Washer
029300-6040
t = 1.0 mm
2MD ~ 4MD types (1) Remove the existing holder and spacers. (See previous page.) Advice Spacer installation is not necessary for the PFR-MD type. (2) Assemble the dowel pins to the driving stand.
JUNE 2003 S.I. 441 9 / 19 Holder
Pin
M8x1.25;
=12 (4)
(3) Position the pins up and assemble the holder to the driving stand. Tool name
Collars (2)
Washer
M6x1.0;
=45 (2)
Part no.
Holder
157817-4020 For 2MD for new super mini
Holder
157817-4120 For 3MD for new super mini
Holder
157817-4220
For 3MD for super 5
Holder
157817-4320
For 4MD for super 5
Advice Refer to service information bulletin S.I. 333 for the socket head bolts for holder installation. (4) Insert the collars between the holder and the driving stand. Advice If there is any clearance between the holder and the driving stand and the collars, use washers to adjust the clearance. Part name
Lubricating oil
Remarks
Part no.
Remarks
Collar
157817-0800
L = 31 mm
Washer
029300-6010
t = 0.8 mm
Washer
029300-6020
t = 0.35 mm
Washer
029300-6030
t = 0.5 mm
Washer
029300-6040
t = 1.0 mm
[5] Supplying lubricating oil Add lubricating oil to the driving stand cam box. Advice Lubricating oil quantity: 400 cm3
Dial gauge
[6] Measuring device installation (1) Attach the joint to the end of the dial gauge. Tool name
Joint
Part no.
Measuring device
105782-6270
Dial gauge
157954-3501
Joint
157827-6920
Remarks
With magnet
Note: The dial gauge and joint are included with the measuring device.
JUNE 2003 S.I. 441 10 / 19 Adapter
(2) Assemble the adapter together with the gasket to the driving stand.
Gasket
Tool name Adapter
Part no.
Remarks
157827-6220
Note: The adapter is included with the measuring device.
(3) Loosely assemble the dial gauge to the connector and attach it to the adapter.
Dial gauge
Tool name Connector
Part no.
Remarks
157827-6820
Note: The connector is included with the measuring device.
[7] Setting the rack's standard 0 position using the gauge Advice The gauge (in particular, the rack pin) has been manufactured to great precision. Do not knock or drop it. Note: If the gauge is knocked or dropped, there may be a difference in the relationship between the injection pump's adjusted injection quantity and the rack position.
Rack pin
Pin
Gauge hole
(1) Align the gauge hole with the holder's positioning pin. Tool name
Part no.
Remarks
Gauge
157817-5220
For 3KX
Gauge
157817-3121 For 4KX
Gauge
157817-4420
For 2MD and 3MD for new super mini
Gauge
157817-4620
For 3MD and 4MD for super 5
JUNE 2003 S.I. 441 11 / 19 Connector
Gauge
Screws
Screw
Connector
Dial gauge
Pin
Gauge
(2) Insert the gauge pin into the connector groove. Advice Keep the chamfered side of the control rack vertical and the connector horizontal.
(3) Tu r n t h e g a u g e c l o c k w i s e a n d counterclockwise and confirm that there is a little play. Set the gauge so that the clockwise and counterclockwise play is equal. Note: There is play because there is a little clearance at the gauge hole to which the holder's positioni ng pin is assembled. This step increases the accuracy of adjustment. (4) Fix the gauge to the holder using the screws. (5) Fix the connector to the control rack.
(6) Set the dial gauge so that it can move to about 10 mm on the scale, then zero the dial gauge. (7) Tighten the control rack fixing screw (see above) to fix the control rack. (8) Reconfirm that the dial gauge is at the zero position, then remove the gauge.
JUNE 2003 S.I. 441 12 / 19 PFR-KX type
Rack stroke 16 mm 8 mm
8 mm
-8
0
+8
Gauge's rack pin position PFR-MD type
Rack stroke 10 mm 5 mm -5
5 mm 0
+5
Gauge's rack pin position
Plate
104135-3041 only
Note: • The PFR-KX type injection pump has a rack stroke of 16 mm and the middle (ie, the 8 mm position) is the 0 point. Because of this, an 8 mm stroke is necessary on the + side and the – side. • The PFR-MD type injection pump has a rack stroke of 10 mm and the middle (ie, the 5 mm position) is the 0 point. Because of this, a 5 mm stroke is necessary on the + side and the – side.
[8] Injection pump installation Advice The following plate is necessary between the holder and the pump only when installing the PFR-3KX type pump with a part no. 104135-3041 (Kubota part no.: 16496-51012) to the driving stand. Tool name Plate
Control rack pin
Pin
Connector
Control rack pin
Connector
Part no.
Remarks
157817-5500
Th/ness 0.5 mm
Note: If the pump is operated without the plate, the driving stand or the pump may be damaged. (1) Align the injection pump's control rack pin with the connector. (2) Assemble the injection pump to the driving stand.
(3) Align the injection pump's hole with the holder pin and insert the control rack pin into the connector groove. At this time, the connector must be horizontal.
JUNE 2003 S.I. 441 13 / 19
2
3
4
1
Advice Tighten the pump installation socket head bolts gradually and uniformly in the order shown at left.
5 2
3
4
1 6
(4) Fix the injection pump in the holder using the socket head bolts. Advice Refer to service information bulletin S.I. 333 for the socket head bolts for holder installation. (5) Turn the camshaft 1 ~ 2 times and confirm that the injection pump operates smoothly.
Socket head bolts
Cover
(6) Attach the cover to the driving stand.
JUNE 2003 S.I. 441 14 / 19 Installation bolts (2 locations)
Coupling
Drive coupling
(7) Connect the driving stand coupling to the pump test bench coupling and fix it. (8) Fix the driving stand's installation bolts to the pump test bench bed. Advice Operate the pump test bench's flywheel using the lever and confirm that the injection pump rotates smoothly.
CAUTION
Lever
Remove the lever after operating the flywheel. Operating the test bench without removing the lever can cause serious injury and damage the test bench.
Plate
PFR-4KX type
PFR-3KX type
[9] Injection timing adjustment (1) Remove the plate for preventing rotation using the wrench (only if equipped; see page 1). Tool name Wrench
Part no. 157915-8100
Remarks For torx bolts
Note: The shapes of the plates for PFR-3KX types and PFR-4KX types differ.
Fuel hose
Fix at standard rack position
(2) Connect the pump test bench fuel hose to the injection pump. (3) Fix the control rack in the standard rack position (refer to the calibration data sheet).
JUNE 2003 S.I. 441 15 / 19 (4) Remove the delivery valve holder. Advice This step is performed to measure pre-stroke and adjust it to the specified value. After adjusting the No. 1 cylinder to the specified value, adjust all cylinders in sequence in the same way.
Delivery valve holder
Delivery valve
Measuring device
(5) Remove the delivery valve spring and the delivery valve.
Delivery valve spring
Flywheel
(6) Attach the measuring device to the injection pump. Tool name Measuring device
Lever
Test oil
Part no.
Remarks
105782-4320
(7) Operate the pump test bench flywheel to position the cylinder where the measuring device is installed in the bottom dead center position. (Confirm the bottom dead center position using the dial gauge.) (8) Zero the dial gauge. Advice Remove the lever after operating the flywheel. (9) Set the pump test bench oil delivery pressure at 20 kPa {0.2 kgf/cm2} and supply test oil to the injection pump. Advice Test oil will flow from the measuring device's pipe. Place a container under the pipe.
JUNE 2003 S.I. 441 16 / 19 (10) Slowly turn the flywheel in the specified direction of rotation (refer to the calibration data sheet) using the lever and read the dial gauge reading (ie, the pre-stroke) when test oil stops flowing from the pipe (ie, when fuel flow is 2 ~ 3 drops per second). (11) If the pre-stroke is not as specified (refer to the calibration data sheet), adjust it by replacing the plate. Advice Refer to the service manuals below for plate part numbers.
Test oil
Injection pipes
PFR pump type
Manual title
Publication no.
3KX ~ 4KX type
PFR-KX
EE12E-11042
2MD ~ 4MD type
PFR-KD & MD
EE12E-11022
(12) Attach the measuring device to the other cylinders and measure the plunger prestroke in the same way. Adjus t as described above if not as specified. (13) After completing adjustment, remove the measuring device and reinstall the delivery valve, the delivery valve spring and the delivery valve holder in their original positions. Specified torque: 39 ~ 44 N·m {4.0 ~ 4.5 kgf·m}
[10] Injection quantity adjustment (1) Attach the test nozzle holders (refer to the calibration data sheet) to the pump test bench. (2) Connect the injection pipes (refer to the calibration data sheet) to all cylinders' test nozzle holders and delivery valve holders. Specified torque: 15 ~ 25 N·m {1.5 ~ 2.5 kgf·m} Fix at standard rack position
(3) Fix the control rack in the standard rack position and operate the injection pump in the specified direction of rotation and at the specified speed (refer to the calibration data sheet). (4) Measure the injection quantity under the conditions described on the data sheet. (5) If the fuel injection quantities are not as specified, adjust as described on the following pages.
JUNE 2003 S.I. 441 17 / 19 Injection quantity adjustment procedure Pentagonal bolt
Torx bolt
PFR-KX type
PFR-MD type
Injection pipes
Wrench
Fixing bolts (2 locations)
Note: Although the PFR-KX type and PFR-MD type adjustment procedures are the same, the shapes of the sleeve flange fixing bolts are different. PFR-KX type: pentagonal bolts PFR-MD type: torx bolts The following adjustment procedure is based on the PFR-KX type pump.
(1) Slowly loosen the injection pipe of the cylinder being adjusted.
(2) Loosen the sleeve flange fixing bolts. Tool name
Sleeve flange
Part no.
Remarks PFR-KX: pentagonal bolt
Wrench
157914-3100
Wrench
157915-8100 PFR-MD: torx bolt
(3) Tap the sleeve flange lightly to adjust the injection quantity. Note: When the sleeve flange is turned clockwise when viewed from above as shown at left, the injection quantity changes as described below. Right lead plunger: injection quantity increases Left lead plunger: injection quantity decreases
JUNE 2003 S.I. 441 18 / 19 (4) Tighten the left and right sleeve flange fixing bolts uniformly to the specified torque, measure injection quantity again and adjust until it is as specified. Specified torque: PFR-KX type 18 ~ 23 N·m {1.8 ~ 2.3 kgf·m} PFR-MD type 10 ~ 15 N·m {1.0 ~ 1.5 kgf·m} (5) After completing adjustment, remove the test oil hose and the injection pipes.
Fixing bolts
Plate B
Plate C
Knurling
Knurling
[11] Plate installation (for preventing rotation; only if equipped, see page 1). PFR-3KX type Note: Plates A, B, and C are installed to the knurling in the positions shown at left.
Knurling
Plate A
Plate B
Plate C
Plate A
Torx bolts (2)
(1) Assemble and align plates B and C so that they contact the delivery valve holders. (The plates can be assembled on either side.) (2) Position plate A against the delivery valve holders from the opposite side and fix it using the torx bolts. Specified torque: 9.8 ~ 13 N·m {1.0 ~ 1.3 kgf·m} Tool name Wrench
Plate B
Plate D Knurling
Knurling
Knurling Plate C
Remarks
157915-8100 For torx bolts
PFR-4KX type Note: • Plates A, B, C, and D are installed to the knurling in the positions shown at left. • Plate pair A and B is identical to pair C and D. Only their orientations are different. • The plate markings show the positions of the front and back as well as the outside of the injection pump.
Knurling Plate A
Part no.
JUNE 2003 S.I. 441 19 / 19 Plate B
Plate D
Markings (4 locations)
Plate A
Plate C
(1) Hold plate B against the delivery valve holders. (2) Hold plate A against the opposite side of the delivery valve holders and fix both plates using the torx bolt. (3) Attach plates C and D to the delivery valve holders in the same way. Specified torque: 9.8 ~ 13 N·m {1.0 ~ 1.3 kgf·m} Advice Confirm that the plate markings (4 locations) are positioned facing the outside.
Torx bolts (2)
Tool name Wrench
Part no.
Remarks
157915-8100 For torx bolts
Advice Refer to the following service manuals for each screw's tightening torque, injection pump handling, troubleshooting and an explanation of the part numbers. PFR pump type
Manual title
Publication no.
3KX ~ 4KX type
PFR-KX
EE12E-11042
2MD ~ 4MD type
PFR-KD & MD
EE12E-11022
