KUBOTA

JUNE 2003
S.I. 441 1 / 19

PUMP

ADJUSTMENT TOOLS FOR PFR TYPE INJECTION PUMPS

(3KX ~ 4KX AND 2MD ~ 4MD) FOR KUBOTA
New and modified adjustment tools are now available for PFR type injection pumps for Kubota.

1. OUTLINE
The holders (for pump installation) and the gauges (for the rack's standard 0 position) are newly
available. The connectors (with a function to prevent rack connection play) are used together with
the existing parts and the existing drive stand (part no. 105781-4320).

2. APPLICABLE PUMP PART NUMBERS

[1] 3KX ~ 4KX types
RBAJ part no.

Kubota part no.

Pump type

Plate
(for preventing rotation)

104135-3041

16496-51012

3KX

Not equipped

D1503-T-RP

104139-3010

1G750-51011

3KX

Equipped

D1803-MDI

104139-3020

1G730-51011

3KX

Equipped

D1503-MDI-T

104139-3030

1G720-51011

3KX

Equipped

D1503-MDI

104139-3050

16098-9077A

3KX

Equipped

03-DI

104139-4070

1G911-51011

4KX

Equipped

V2203-DI

104139-4080

1G790-51011

4KX

Equipped

V2403-MDI

104139-4090

1G911-51012

4KX

Equipped

V2203-DI

104139-4110

1A093-51011

4KX

Equipped

V2403-MDI

104139-4120

1A071-51011

4KX

Equipped

V2003-MDI-T

104139-4140

1G922-51011

4KX

Equipped

V2003-MDI-T

Applicable engine

Note:
The plate is used to prevent 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
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3. ADJUSTMENT TOOL PART NUMBERS

[1] 3KX ~ 4KX types
Key
Part no.

Part name

no.

Qty
3KX

4KX
1

105781-4320 Driving stand

157817-5420 Holder

157817-3321 Holder

157817-5220 Gauge

157817-3121 Gauge

157817-2820 Connector

Remarks
Pump driving stand (existing part)
For pump installation (newly available)

For pump installation (modified part)

For rack's standard 0 position (newly available)

For rack's standard 0 position (modified part)

With function for preventing rack joint connection

play (existing part)

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

For confirming rack position (existing part)

2. 157817-5420
Holder

4-M8X1.25

3. 157817-3321
Holder

106

6-M8X1.25

106

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

M18X1.5

20.5

M6X1

59

131

M16X1.5
30

[2] 2MD ~ 4MD types

Key
Part no.

Part name

no.

Qty
A

105781-4320 Driving stand

157817-4020 Holder

157817-4120 Holder

157817-4220 Holder

157817-4320 Holder

157817-4420 Gauge

Pump driving stand (existing part)

For pump installation (newly available)
For pump installation (newly available)

For pump installation (newly available)

1
1
1

Remarks

For pump installation (newly available)

F o r ra c k ' s s ta nd a rd 0 p o s i ti o n (ne wly

available)
7

157817-4620 Gauge

F o r ra c k ' s s ta nd a rd 0 p o s i ti o n (ne wly

available)

157817-4820 Connector

W i th func ti o n fo r p re ve nti ng ra c k jo i nt
connection play (existing part)

105782-6270 Measuring device

9/1

157827-6220 Adapter

9/2

157827-6820 Connector

9/3

157954-3501 Dial gauge

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

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

3. 157817-4120
Holder

5-M6X1

106

106

10

10

90
214

214

5. 157817-4320
Holder

6. 157817-4420
Gauge

110
125

4. 157817-4220
Holder

4-M6X1

5-M6X1

106

2-M6X1

56

106

10

10

66
214

214

7. 157817-4620
Gauge

8. 157817-4820
Connector

2-M6X1

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
Part no.

Part name

Qty

Remarks

no.
1

157817-5500 Plate

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;

Pin

=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.

Holder

Pin

M8x1.25;

=12 (4)

JUNE 2003
S.I. 441 9 / 19
(3) Position the pins up and assemble the holder
to the driving stand.
Tool name

Collars (2)

Washer

M6x1.0;

=45 (2)

Part no.

Remarks

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

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

Joint

[6] Measuring device installation

(1) Attach the joint to the end of the dial gauge.
Tool name

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.

Adapter

JUNE 2003
S.I. 441 10 / 19
(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

Connector

Gauge

Screws

Screw

Connector

Dial gauge

Pin

Gauge

JUNE 2003
S.I. 441 11 / 19
(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
positioning 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

+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

Advice
Tighten the pump installation socket head
bolts gradually and uniformly in the order
shown at left.

5
2

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.

Remarks

157915-8100 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 deliver y
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. Adjust 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 Nm
{4.0 ~ 4.5 kgfm}

[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 Nm
{1.5 ~ 2.5 kgfm}
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
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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 Nm
{1.8 ~ 2.3 kgfm}
PFR-MD type
10 ~ 15 Nm
{1.0 ~ 1.5 kgfm}
(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 Nm
{1.0 ~ 1.3 kgfm}
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.

Plate B

Plate D

Markings (4 locations)

Plate A

Plate C

JUNE 2003
S.I. 441 19 / 19
(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 Nm
{1.0 ~ 1.3 kgfm}
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