ADJUSTMENT TOOLS FOR PFR TYPE INJECTION PUMPS (3KX ~ 4KX AND 2MD ~ 4MD) FOR KUBOTA

PUMP KUBOTA S.I. 44 / 9 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.. 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. 0578-4320). 2. APPLICABLE PUMP PART NUMBERS [] 3KX ~ 4KX types RBAJ part no. Kubota part no. Pump type Plate (for preventing rotation) Applicable engine 0435-304 6496-502 3KX Not equipped D503-T-RP 0439-300 G750-50 3KX Equipped D803-M DI 0439-3020 G730-50 3KX Equipped D503-MDI-T 0439-3030 G720-50 3KX Equipped D503-MDI 0439-3050 6098-9077A 3KX Equipped 03-DI 0439-4070 G9-50 4KX Equipped V2203-DI 0439-4080 G790-50 4KX Equipped V2403-M DI 0439-4090 G9-502 4KX Equipped V2203-DI 0439-40 A093-50 4KX Equipped V2403-M DI 0439-420 A07-50 4KX Equipped V2003-MDI-T 0439-440 G922-50 4KX Equipped V2003-MDI-T The plate is used to prevent delivery valve holder rotation. Bosch Automotive Systems Corporation Service Dept. Printed in Japan

S.I. 44 2 / 9 [2] 2MD ~ 4MD types RBAJ part no. Kubota part no. Pump type Applicable engine 04205-205 600-50 2MD New super mini Z482-E 04205-206 7548-502 2MD New super mini Z482-B-ONAN- 04205-207 9007-502 2MD New super mini Z482-B-F.King- 04205-307 6006-50 3MD New super mini D662-E 04205-308 7549-502 3MD New super mini D722-B-ONAN- 04205-309 7529-502 3MD New super mini D722-B-F.King- 04206-300 6030-502 3MD Super 5 D05-EBB-STD- 04206-30 6032-502 3MD Super 5 D05-EF 04206-3020 6029-50 3MD Super 5 D005-EBBS-SDX-2 04206-3030 6027-50 3MD Super 5 D005-E 04206-304 9420-502 3MD Super 5 D05-B-F.King- 04206-400 6060-502 4MD Super 5 V505-EBB-STD- 04206-40 6062-502 4MD Super 5 V505-E 04206-4020 6054-50 4MD Super 5 V305-EBBS-SDX-2 04206-4030 6055-50 4MD Super 5 V405-E 04206-404 6695-503 4MD Super 5 V205-B-F.King- 04206-4050 728-50 4MD Super 5 V505-T-KA-TCM-R3

3. ADJUSTMENT TOOL PART NUMBERS [] 3KX ~ 4KX types S.I. 44 3 / 9 Key no. Part no. Part name 3KX Qty 4KX Remarks 0578-4320 Driving stand Pump driving stand (existing part) 2 5787-5420 For pump installation (newly available) 3 5787-332 For pump installation (modified part) 4 5787-5220 For rack's standard 0 position (newly available) 5 5787-32 For rack's standard 0 position (modified part) 6 5787-2820 With function for preventing rack joint connection play (existing part) 7 05782-6270 Measuring device For confirming rack position (existing part) 7/ 57827-6220 Adapter 7/2 57827-6820 7/3 57954-350 Dial gauge. 0578-4320 Driving stand 2. 5787-5420 3. 5787-332 4-M8X.25 6 06 0 6-M8X.25 6 06 0 90 0 25 24 24 4. 5787-5220 5. 5787-32 6. 5787-2820 2-M8X.25 2-M8X.25 0 86 24 5 80 5 80 2 23

S.I. 44 4 / 9 7. 05782-6270 Measuring device 7/ 57827-6220 Adapter 7/2 57827-6820 7/3 57954-350 Dial gauge 52 M8X.5 SW22 M6X.5 M4X0.7 M2.5X0.45 ZW9 SW9 66.5 M4X0.7 28.5 M8X.5 8 M6X M6X 20.5 59 M6X.5 30 3 [2] 2MD ~ 4MD types Key no. Part no. Part name Qty A B C D Remarks 0578-4320 Driving stand Pump driving stand (existing part) 2 5787-4020 For pump installation (newly available) 3 5787-420 For pump installation (newly available) 4 5787-4220 For pump installation (newly available) 5 5787-4320 For pump installation (newly available) 6 5787-4420 For rack's standard 0 position (newly available) 7 5787-4620 For rack's standard 0 position (newly available) 8 5787-4820 With function for preventing rack joint connection play (existing part) 9 05782-6270 Measuring device For confirming rack position (existing part) 9/ 57827-6220 Adapter (See above for individual part drawings.) 9/2 57827-6820 9/3 57954-350 Dial gauge 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

. 0578-4320 Driving stand 2. 5787-4020 3. 5787-420 S.I. 44 5 / 9 4-M6X 6 06 5-M6X 6 06 0 0 90 0 25 24 24 4. 5787-4220 5. 5787-4320 6. 5787-4420 4-M6X 6 06 0 5-M6X 6 06 0 2-M6X 56 24 24 4 66 7. 5787-4620 8. 5787-4820 9. 05782-6270 Measuring device 2-M6X 2 52 27 77 4 66 7 M4X0.7 M6X M6X.5

S.I. 44 6 / 9 4. SEPARATE ADJUSTING TOOL PART NUMBER The following plate is necessary between the holder and the pump only when installing the PFR- 3KX type pump with a part no. 0435-304 (Kubota part no.: 6496-502) to the previously mentioned driving stand. If the pump is operated without the plate, the driving stand or the pump may be damaged. Key no. Part no. Part name Qty Remarks 5787-5500 Plate For pump part no:. 0435-304. 5787-5500 Plate 4-8.5 82 2-6.3 0.5 Distinguishing mark 5. ADJUSTING TOOL USE [] 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 5786-720 6KD 2MD ~ 4MD type 5786-7220 6MD Refer to service information bulletin S.I. 333 for the camshaft replacement procedure. Driving stand 0578-4320 Installation stand

Adapters (2) S.I. 44 7 / 9 [2] Driving stand installation () If the pump test bench center height is 25 mm, attach the adapters to the bed. It is not necessary to install the adapters if the center height is 0 mm. Adapter 57992-4200 For 7NP, 5NP, 20NP Driving stand (2) Attach the driving stand to the pump test bench bed. Driving stand 0578-4320 Installation stand Spacer Cover [3] replacement () Remove the holder, the spacer and the cover. (2) Remove the existing connector and replace it with the connector for the applicable PFR pump type. (Tighten temporarily.) PFR type part no. Marking 3KX ~ 4KX type 5787-2820 2MD ~ 4MD type 5787-4820

Spacers (2) Dowel pins (2) Pin M8x.25; =25 (4) [4] installation S.I. 44 8 / 9 3KX ~ 4KX types () 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. Dowel pin 05060-3680 For fixing holder Spacer 5787-800 (4) Position the pins up and assemble the holder together with the spacers to the driving stand. 5787-5420 For 3KX 5787-332 For 4KX Refer to service information bulletin S.I. 333 for the socket head bolts for holder installation. Collars (2) Washer M6x.0; = 55 (2) (5) Insert the collars between the holder and the driving stand. If there is any clearance between the holder and the driving stand and the collars, use washers to adjust the clearance. Part name Part no. Remarks Collar 5787-200 L = 43 mm Washer 029300-600 t = 0.8 mm Washer 029300-6020 t = 0.35 mm Washer 029300-6030 t = 0.5 mm Dowel pins (2) Washer 029300-6040 t =.0 mm 2MD ~ 4MD types () Remove the existing holder and spacers. (See previous page.) Spacer installation is not necessary for the PFR-MD type. (2) Assemble the dowel pins to the driving stand.

Pin M8x.25; =2 (4) S.I. 44 9 / 9 (3) Position the pins up and assemble the holder to the driving stand. 5787-4020 For 2MD for new super mini 5787-420 For 3MD for new super mini 5787-4220 For 3MD for super 5 5787-4320 For 4MD for super 5 Collars (2) Washer M6x.0; =45 (2) 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. If there is any clearance between the holder and the driving stand and the collars, use washers to adjust the clearance. Part name Part no. Remarks Collar 5787-0800 L = 3 mm Washer 029300-600 t = 0.8 mm Washer 029300-6020 t = 0.35 mm Washer 029300-6030 t = 0.5 mm Lubricating oil Washer 029300-6040 t =.0 mm [5] Supplying lubricating oil Add lubricating oil to the driving stand cam box. Lubricating oil quantity: 400 cm 3 Dial gauge [6] Measuring device installation () Attach the joint to the end of the dial gauge. Measuring device 05782-6270 Dial gauge 57954-350 Joint Joint 57827-6920 With magnet The dial gauge and joint are included with the measuring device.

Adapter Gasket S.I. 44 0 / 9 (2) Assemble the adapter together with the gasket to the driving stand. Adapter 57827-6220 The adapter is included with the measuring device. Dial gauge (3) Loosely assemble the dial gauge to the connector and attach it to the adapter. 57827-6820 The connector is included with the measuring device. Rack pin [7] Setting the rack's standard 0 position using the gauge The gauge (in particular, the rack pin) has been manufactured to great precision. Do not knock or drop it. 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. Pin hole () Align the gauge hole with the holder's positioning pin. 5787-5220 For 3KX 5787-32 For 4KX 5787-4420 5787-4620 For 2MD and 3MD for new super mini For 3MD and 4MD for super 5

Pin S.I. 44 / 9 (2) Insert the gauge pin into the connector groove. Keep the chamfered side of the control rack vertical and the connector horizontal. Screws (3) Turn the gauge clockwise and counterclockwise and confirm that there is a little play. Set the gauge so that the clockwise and counterclockwise play is equal. 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. Screw (5) Fix the connector to the control rack. Dial gauge (6) Set the dial gauge so that it can move to about 0 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.

PFR-KX type PFR-MD type Rack stroke 6 mm 8 mm 8 mm -8 0 +8 's rack pin position Rack stroke 0 mm 5 mm 5 mm -5 0 +5 's rack pin position S.I. 44 2 / 9 The PFR-KX type injection pump has a rack stroke of 6 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 0 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. Plate 0435-304 only [8] Injection pump installation The following plate is necessary between the holder and the pump only when installing the PFR-3KX type pump with a part no. 0435-304 (Kubota part no.: 6496-502) to the driving stand. Plate 5787-5500 Th/ness 0.5 mm Control rack pin If the pump is operated without the plate, the driving stand or the pump may be damaged. () Align the injection pump's control rack pin with the connector. (2) Assemble the injection pump to the driving stand. Pin Control rack pin (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.

2 3 S.I. 44 3 / 9 Tighten the pump installation socket head bolts gradually and uniformly in the order shown at left. 4 2 3 5 4 6 Socket head bolts (4) Fix the injection pump in the holder using the socket head bolts. Refer to service information bulletin S.I. 333 for the socket head bolts for holder installation. (5) Turn the camshaft ~ 2 times and confirm that the injection pump operates smoothly. Cover (6) Attach the cover to the driving stand.

S.I. 44 4 / 9 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. Operate the pump test bench's flywheel using the lever and confirm that the injection pump rotates smoothly. Lever CAUTION 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 () Remove the plate for preventing rotation using the wrench (only if equipped; see page ). Wrench 5795-800 For torx bolts 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).

Delivery valve holder S.I. 44 5 / 9 (4) Remove the delivery valve holder. This step is performed to measure pre-stroke and adjust it to the specified value. After adjusting the No. cylinder to the specified value, adjust all cylinders in sequence in the same way. Delivery valve Delivery valve spring (5) Remove the delivery valve spring and the delivery valve. Measuring device Test oil Flywheel Lever (6) Attach the measuring device to the injection pump. Measuring device 05782-4320 (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. Remove the lever after operating the flywheel. (9) Set the pump test bench oil delivery pressure at 20 kpa {0.2 kgf/cm 2 } and supply test oil to the injection pump. Test oil will flow from the measuring device's pipe. Place a container under the pipe.

Test oil Injection pipes Fix at standard rack position S.I. 44 6 / 9 (0) 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). () If the pre-stroke is not as specified (refer to the calibration data sheet), adjust it by replacing the plate. Refer to the service manuals below for plate part numbers. PFR pump type Manual title Publication no. 3KX ~ 4KX type PFR-KX EE2E-042 2MD ~ 4MD type PFR-KD & MD EE2E-022 (2) 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. (3) 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} [0] Injection quantity adjustment () 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: 5 ~ 25 N m {.5 ~ 2.5 kgf m} (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.

Pentagonal bolt PFR-KX type Torx bolt PFR-MD type S.I. 44 7 / 9 Injection quantity adjustment procedure 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. Injection pipes () Slowly loosen the injection pipe of the cylinder being adjusted. Wrench Fixing bolts (2 locations) (2) Loosen the sleeve flange fixing bolts. Wrench 5794-300 PFR-KX: pentagonal bolt Wrench 5795-800 PFR-MD: torx bolt Sleeve flange (3) Tap the sleeve flange lightly to adjust the injection quantity. 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

Fixing bolts S.I. 44 8 / 9 (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 8 ~ 23 N m PFR-MD type {.8 ~ 2.3 kgf m} 0 ~ 5 N m {.0 ~.5 kgf m} (5) After completing adjustment, remove the test oil hose and the injection pipes. Knurling Plate B Plate C Knurling [] Plate installation (for preventing rotation; only if equipped, see page ). PFR-3KX type Plates A, B, and C are installed to the knurling in the positions shown at left. Plate A Knurling Plate B Plate C Plate A Torx bolts (2) () 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 ~ 3 N m {.0 ~.3 kgf m} Wrench 5795-800 For torx bolts Plate B Knurling Knurling Plate A Plate D Knurling Knurling Plate C PFR-4KX type 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.

Plate B Plate D Plate A Plate C Markings (4 locations) Torx bolts (2) S.I. 44 9 / 9 () 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 ~ 3 N m {.0 ~.3 kgf m} Confirm that the plate markings (4 locations) are positioned facing the outside. Wrench 5795-800 For torx bolts 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 EE2E-042 2MD ~ 4MD type PFR-KD & MD EE2E-022