Toro 30410 User Manual
PART NO. 02097SL (Rev. F)
Service Manual
(Model 30410)
Groundsmaster
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Groundsmaster 4000--D.
REFER TO THE TRACTION UNIT AND CUTTING
UNIT OPERATOR’S MANUALS FOR OPERATING,
MAINTENANCE, AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to
insert the Operator’s Manuals and Parts Catalogs for
your machine. Replacement Operator’s Manuals and
Parts Catalogs are available on the internet at www.Toro.com.
TheToroCompanyreserves therighttochangeproduct
specifications or this publication without notice.
R
4000--D
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: ANOTE will give generalinformation about the
correct operation, maintenance, service, testing, or repair of the machine.
IMPORTANT: The IMPORTANT notice will give importantinstructionswhichmustbefollowed toprevent damage to systems or components on the
machine.
E The Toro Company -- 2002, 2003, 2004, 2006, 2007, 2012
This page is intentionally blank.
Groundsmaster 4000−D
Table Of Contents
Chapter 1 − Safety
General Safety Instructions 1 − 2. . . . . . . . . . . . . . . . . .
Jacking Instructions 1 − 4. . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 1 − 5. . . . . . . . . . . . . . . .
Chapter 2 − Product Records and Maintenance
Product Records 2 − 1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 2 − 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 2 − 2. . . . . . . . . . . . . . . .
Torque Specifications 2 − 3. . . . . . . . . . . . . . . . . . . . . . .
Chapter 3 − Kubota Diesel Engine
General Information 3 − 2. . . . . . . . . . . . . . . . . . . . . . . .
Specifications 3 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 3 − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 3 − 6. . . . . . . . . . . . . . . . . . . . . . . .
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
V2003−T SERIES
Chapter 4 − Hydraulic System
Specifications 4 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information 4 − 3. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Schematic 4 − 6. . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Flow Diagrams 4 − 8. . . . . . . . . . . . . . . . . . . .
Special Tools 4 − 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 4 − 20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing 4 − 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 4 − 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 4 − 49. . . . . . . . . . . . . . . . . . . . . . .
Chapter 5 − Electrical System
Electrical Schematic, Circuit Diagrams, and
Wire Harness Drawings 5 − 2. . . . . . . . . . . . . . . . . . . .
Special Tools 5 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 5 − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System Quick Checks 5 − 7. . . . . . . . . . . . . .
Component Testing 5 − 8. . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 5 − 28. . . . . . . . . . . . . . . . . . . . . . .
Chapter 6 − Axles, Planetaries, and Brakes
Specifications 6 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 6 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 6 − 4. . . . . . . . . . . . . . . . . . . . . . . .
Chapter 7 − Chassis
Service and Repairs 7 − 2. . . . . . . . . . . . . . . . . . . . . . . .
Chapter 8 − Cutting Units
Specifications 8 − 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 8 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustments 8 − 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs 8 − 6. . . . . . . . . . . . . . . . . . . . . . . .
Chapter 9 − Electrical Diagrams
Electrical Schematic 9 − 3. . . . . . . . . . . . . . . . . . . . . . . .
Circuit Diagrams 9 − 5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Wire Harness Drawings 9 − 9. . . . . . . . . . . . . . . . . . . . .
SafetyProduct Records
and Maintenance
Kubota
Diesel Engine
System
Hydraulic
System
Electrical
Groundsmaster 4000−D
Rev. E
and Brakes
Axles, Planetaries,
Cutting Units Chassis
Electrical
Diagrams
This page is intentionally blank.
Groundsmaster 4000−D
Table of Contents
Chapter 1
Safety
Safety
GENERAL SAFETY INSTRUCTIONS 2. . . . . . . . . . . .
Before Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service 3. . . . . . . . . . . . . . . . . . . .
JACKING INSTRUCTIONS 4. . . . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS 5. . . . . . . . . .
Groundsmaster 4000−D
Page 1 − 1
Safety
General Safety Instructions
The GROUNDSMASTER 4000-D was tested and certified by T ORO for compliance with the B71.4-1999 specifications of the American National Standards Institute.
Although hazard control and accident prevention partially are dependent upon the design and configuration
of the machine, these factors are also dependent upon
the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine. Improper use or
maintenance of the machine can result in injury or
Before Operating
1. Read and understand the contents of the Operator’s
Manual before starting and operating the machine. Become familiar with the controls and know how to stop the
machine and engine quickly . A replacement Operator’s
Manual is available on the Internet at www.Toro.com or
by sending the complete model and serial number to:
The Toro Company
Attn. Technical Publications
8111 Lyndale Avenue South
Bloomington, Minnesota 55420−1196
2. Keep all shields, safety devices, and decals in place.
If a shield, safety device, or decal is defective, illegible
or damaged, repair or replace it before operating the
machine. Also tighten any loose nuts, bolts or screws to
ensure machine is in safe operating condition.
death. To reduce the potential for injury or death, comply
with the following safety instructions.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
3. Assure interlock switches are adjusted correctly so
engine cannot be started unless traction pedal is in
NEUTRAL and cutting units are DISENGAGED.
4. Since diesel fuel is highly flammable, handle it carefully:
A. Use an approved fuel container.
B. Do not remove fuel tank cap while engine is hot or
running.
C. Do not smoke while handling fuel.
D. Fill fuel tank outdoors and only to within an inch of
the top of the tank, not the filler neck. Do not overfill.
E. Wipe up any spilled fuel.
While Operating
1. Sit on the seat when starting and operating the machine.
2. Before starting the engine:
A. Engage the parking brake.
B. Make sure traction pedal is in neutral and the
PTO switch is OFF (disengaged).
C. After engine is started, release parking brake and
keep foot off traction pedal. Machine must not move.
If movement is evident, the traction pedal linkage is
adjusted incorrectly; therefore, shut engine off and
adjust until machine does not move when traction
pedal is released.
3. Do not run engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
4. Do not touch engine, muffler or exhaust pipe while
engine is running or soon after it is stopped. These areas
could be hot enough to cause burns.
Safety
Page 1 − 2
5. Before getting off the seat:
A. Ensure that traction pedal is in neutral.
B. Set parking brake.
C. Disengage cutting units and wait for blades to
stop.
D. Stop engine and remove key from switch.
E. Toro recommends that anytime the machine is
parked (short or long term), the cutting units should
be lowered to the ground. This relieves pressure
from the lift circuit and eliminates the risk of cutting
units accidentally lowering to the ground.
F. Do not park on slopes unless wheels are chocked
or blocked.
Groundsmaster 4000−D
Maintenance and Service
1. Before servicing or making adjustments, lower
decks, stop engine, set parking brake, and remove key
from the switch.
2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
3. Never store the machine or fuel container inside
where there is an open flame, such as near a water heater or furnace.
4. Make sure all hydraulic line connectors are tight, and
all hydraulic hoses and lines are in good condition before applying pressure to the system.
5. Keep body and hands away from pin hole leaks in hydraulic lines t h a t e j e c t h i gh p r essure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
6. Before disconnecting or performing any work on the
hydraulic system, all pressure in system must be relieved by stopping engine and lowering cutting units to
the ground.
10.Do not overspeed the engine by changing governor
setting. To assure safety and accuracy, check maximum
engine speed.
11.Shut engine off before checking or adding oil to the
crankcase.
12.Disconnect battery before servicing the machine.
Disconnect negative cable first and positive cable last.
If battery voltage is required for troubleshooting or test
procedures, temporarily connect the battery. Reconnect
positive cable first and negative cable last.
13.Battery acid is poisonous and can cause burns.
Avoid cont a c t with skin, eyes, and clothing. Protect your
face, eyes, and clothing when working with a battery.
14.Battery gases can explode. Keep cigarettes, sparks,
and flames away from the battery.
15.At the time of manufacture, the machine conformed
to the safety standards for riding mowers. To assure optimum performance and continued safety certification of
the machine, use genuine Toro replacement parts and
accessories. Replacement parts and accessories made
by other manufacturers may result in non-conformance
with the safety standards, and the warranty may be
voided.
Safety
7. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.
8. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt. Clean
protective screen on machine frequently.
9. If engine must be running to perform maintenance or
an adjustment, keep hands, feet, clothing and other
parts of the body away from cutting units and other moving parts. Keep bystanders away.
16.When changing attachments, tires, or performing
other service, use correct blocks, hoists, and jacks.
Make sure machine is parked on a solid level surface
such as a concrete floor. Prior to raising the machine, remove any attachments that may interfere with the safe
and proper raising of the machine. Always chock or
block wheels. Use jack stands or solid wood blocks to
support the raised machine. If the machine is not properly supported by blocks or jack stands, the machine may
move or fall, which may result in personal injury (see
Jacking Instructions).
Groundsmaster 4000−D
Page 1 − 3
Safety
Jacking Instructions
CAUTION
When changing attachments, tires, or performing other service, use correct blocks, hoists,
and jacks. Make sure machine is parked on a
solid level surface such as a concrete floor.
Prior to raising machine, remove any attachments that may interfere with the safe and proper raising of the machine. Always chock or block
wheels. Use jack stands or solid wood blocks to
support the raised machine. If the machine is
not properly supported by blocks or jack
stands, the machine may move or fall, which
may result in personal injury.
Jacking the Front End (Fig. 1)
1. Set parking brake and chock both rear tires to prevent the machine from moving.
2. Position jack securely under the frame, just to the inside of the front tire.
1
2
Figure 1
1. Frame jacking point 2. Front tire
2
3. Position jack stands or hardwood blocks under the
frame as close to the wheels as possible to support the
machine.
Jacking the Rear End (Fig. 2)
1. Place jack securely under the center of rear axle.
2. Chock both front tires. Jack rear of machine off the
ground.
3. Use jack stands or blocks under the axle to support
the machine.
2
1. Rear axle jacking point 2. Rear tire
1
Figure 2
2
Safety
Page 1 − 4
Groundsmaster 4000−D
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to the Groundsmaster 4000−D. If any decal becomes illegible or
damaged, install a new decal. Part numbers are listed in your Parts Catalog.
Safety
Groundsmaster 4000−D
Page 1 − 5
Safety
This page is intentionally blank.
Safety
Page 1 − 6
Groundsmaster 4000−D
Product Records and Maintenance
Table of Contents
Chapter 2
PRODUCT RECORDS 1. . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS 2. . . . . . . . . . .
Decimal and Millimeter Equivalents 2. . . . . . . . . . . .
U.S. to Metric Conversions 2. . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . .
Fastener Identification 3. . . . . . . . . . . . . . . . . . . . . . .
Product Records
Insert Operator’s Manual and Parts Catalog for your
Groundsmaster 4000−D at the end of this chapter . Additionally, if any optional equipment or accessories have
been installed to your machine, insert the Installation Instructions, Operator’s Manuals and Parts Catalogs for
those options at the end of this chapter.
Maintenance
Maintenance procedures and recommended service intervals for the Groundsmaster 4000−D are covered in
the Operator’s Manual. Refer to that publication when
performing regular equipment maintenance.
Standard Torque for Dry, Zinc Plated, and
Steel Fasteners (Inch Series) 4. . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and
Steel Fasteners (Metric Fasteners) 5. . . . . . . . . .
Other Torque Specifications 6. . . . . . . . . . . . . . . . . .
Conversion Factors 6. . . . . . . . . . . . . . . . . . . . . . . . .
Product Records
and Maintenance
Groundsmaster 4000−D Page 2 − 1 Product Records and Maintenance
Rev. E
Equivalents and Conversions
0.09375
Rev. E
Groundsmaster 4000−DPage 2 − 2Product Records and Maintenance
Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and specified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Service Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature,
hardness of the surface underneath the fastener’s head,
or similar condition which affects the installation.
Fastener Identification
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread engagement, etc.
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Product Records
and Maintenance
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 1
Class 8.8 Class 10.9
Metric Bolts and Screws
Figure 2
Groundsmaster 4000−D Page 2 − 3 Product Records and Maintenance
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
10 + 2
13 + 2
147 + 23
13 + 2
25 + 5
282 + 30
18 + 2
30 + 5
339 + 56
Grade 1, 5, &
Thread Size
# 6 − 32 UNC
# 6 − 40 UNF
# 8 − 32 UNC
# 8 − 36 UNF
# 10 − 24 UNC
# 10 − 32 UNF
1/4 − 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170
1/4 − 28 UNF 53 + 7 65 + 10 734 + 113 115 + 10 1300 + 100 160 + 15 1800 + 170
5/16 − 18 UNC 115 + 15 105 + 17 1186 + 169 200 + 25 2250 + 280 300 + 30 3390 + 340
5/16 − 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2540 + 280 325 + 30 3670 + 340
3/8 − 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 4 58 + 5
8 with Thin
Height Nuts
in−lb in−lb N−cm in−lb N−cm in−lb N−cm
ft−lb ft−lb N−m ft−lb N−m ft−lb N−m
SAE Grade 1 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
15 + 2 170 + 20 23 + 2 260 + 20
17 + 2 190 + 20 25 + 2 280 + 20
29 + 3 330 + 30 41 + 4 460 + 45
31 + 3 350 + 30 43 + 4 485 + 45
42 + 4 475 + 45 60 + 6 675 + 70
48 + 4 540 + 45 68 + 6 765 + 70
SAE Grade 8 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
3/8 − 24 UNF 17 + 2 18 + 2 24 + 3 35 + 3 47 + 4 50 + 4 68 + 5
7/16 − 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 − 20 UNF 29 + 3 29 + 3 39 + 4 55 + 5 75 + 7 77 + 7 104 + 9
1/2 − 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 10 142 + 14
1/2 − 20 UNF 32 + 3 53 + 7 72 + 9 85 + 8 115 + 11 120 + 10 163 + 14
5/8 − 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 20 285 + 27
5/8 − 18 UNF 75 + 10 95 + 15 129 + 20 170 + 15 230 + 20 240 + 20 325 + 27
3/4 − 10 UNC 93 + 12 140 + 20 190 + 27 265 + 25 359 + 34 375 + 35 508 + 47
3/4 − 16 UNF 115 + 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47
7/8 − 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 − 14 UNF 155 + 25 260 + 30 353 + 41 475 + 45 644 + 61 660 + 60 895 + 81
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the miniNote: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
mum proof load specified in SAE J429. The tolerance is
approximately +
10% of the nominal torque value. Thin
height nuts include jam nuts.
Groundsmaster 4000−DPage 2 − 4Product Records and Maintenance
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Thread Size
Regular Height Nuts
Regular Height Nuts
Class 8.8 Bolts, Screws, and Studs with
(Class 8 or Stronger Nuts)
M5 X 0.8 57 + 5 in−lb 640 + 60 N−cm 78 + 7 in−lb 885 + 80 N−cm
M6 X 1.0 96 + 9 in−lb 1018 + 100 N−cm 133 + 13 in−lb 1500 + 150 N−cm
M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 27 + 2 ft−lb 36 + 3 N−m
M10 X 1.5 38 + 4 ft−lb 52 + 5 N−m 53 + 5 ft−lb 72 + 7 N−m
M12 X 1.75 66 + 7 ft−lb 90 + 10 N−m 92 + 9 ft−lb 125 + 12 N−m
M16 X 2.0 166 + 15 ft−lb 225 + 20 N−m 229 + 22 ft−lb 310 + 30 N−m
M20 X 2.5 325 + 33 ft−lb 440 + 45 N−m 450 + 37 ft−lb 610 + 50 N−m
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite, or thread sealant such as Loctite.
Note: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Note: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately +
nominal torque value.
Class 10.9 Bolts, Screws, and Studs with
(Class 10 or Stronger Nuts)
10% of the
Product Records
and Maintenance
Groundsmaster 4000−D Page 2 − 5 Product Records and Maintenance
Other Torque Specifications
Thread Size
Size
Baseline Torque*
SAE Grade 8 Steel Set Screws
Recommended Torque
Square Head Hex Socket
1/4 − 20 UNC 140 + 20 in−lb 73 + 12 in−lb
5/16 − 18 UNC 215 + 35 in−lb 145 + 20 in−lb
3/8 − 16 UNC 35 + 10 ft−lb 18 + 3 ft−lb
1/2 − 13 UNC 75 + 15 ft−lb 50 + 10 ft−lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size Baseline Torque*
No. 6 − 32 UNC 20 + 5 in−lb
Wheel Bolts and Lug Nuts
Thread Size
7/16 − 20 UNF
Grade 5
1/2 − 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non−lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
No. 6 18 20 20 + 5 in−lb
Threads per Inch
Type A Type B
Recommended Torque**
65 + 10 ft−lb 88 + 14 N−m
80 + 10 ft−lb 108 + 14 N−m
80 + 10 ft−lb 108 + 14 N−m
80 + 10 ft−lb 108 + 14 N−m
No. 8 − 32 UNC 30 + 5 in−lb
No. 10 − 24 UNC 38 + 7 in−lb
1/4 − 20 UNC 85 + 15 in−lb
5/16 − 18 UNC 110 + 20 in−lb
3/8 − 16 UNC 200 + 100 in−lb
Conversion Factors
in−lb X 11.2985 = N−cm N−cm X 0.08851 = in−lb
ft−lb X 1.3558 = N−m N−m X 0.7376 = ft−lb
No. 8 15 18 30 + 5 in−lb
No. 10 12 16 38 + 7 in−lb
No. 12 11 14 85 + 15 in−lb
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non−lubricated
fasteners.
Groundsmaster 4000−DPage 2 − 6Product Records and Maintenance
Table of Contents
GENERAL INFORMATION 2. . . . . . . . . . . . . . . . . . . . .
Stopping the Engine 2. . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run Solenoid 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS 6. . . . . . . . . . . . . . . . . . . . . .
Air Filter System 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Fuel Lines and Connections 11. . . . . . . . . .
Drain and Clean Fuel Tank 11. . . . . . . . . . . . . . . . . .
Fuel Tank Removal 11. . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Installation 11. . . . . . . . . . . . . . . . . . . . . . .
Chapter 3
Kubota Diesel Engine
Radiator 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Removal 15. . . . . . . . . . . . . . . . . . . . . . . . . .
Coupling Disassembly 17. . . . . . . . . . . . . . . . . . . . .
Coupling Assembly 17. . . . . . . . . . . . . . . . . . . . . . .
Engine Installation 17. . . . . . . . . . . . . . . . . . . . . . . .
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
V2003−T SERIES
Kubota
Diesel Engine
Groundsmaster 4000−D Page 3 − 1 Kubota Diesel Engine (Rev. B)
General Information
This Chapter gives information about specifications and
repair of the diesel engine used in the Groundsmaster
4000−D.
General maintenance procedures are described in your
Operator’s Manual. Information on engine troubleshooting, testing, disassembly and reassembly is identified in
the Kubota Workshop Manual, Diesel Engine, V2003−T
that is included at the end of this section.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
Stopping the Engine
IMPORTANT: Before stopping the engine after
mowing or full load operation, cool the turbo-charger by allowing the engine to idle at low speed for 5
minutes. Failure to do so may lead to turbo-charger
trouble.
tools are described in the Kubota Workshop Manual,
Diesel Engine, V2003−T. The use of some specialized
test equipment is explained. However, the cost of the
test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility.
Service and repair parts for Kubota engines are supplied through your Authorized Toro Distributor. If no
parts list is available, be prepared to provide your distributor with the Toro model and serial number.
Groundsmaster 4000−DPage 3 − 2Kubota Diesel Engine (Rev. B)
Specifications
Item Description
Make / Designation Kubota, 4−Cycle, 4 Cylinder,
Water Cooled, Turbocharged, Diesel Engine
Horse Power 58 HP (43.3 kW) @ 2600 RPM
Bore mm (in.) 83.0 (3.27)
Stroke mm (in.) 92.4 (3.64)
Total Displacement cc (cu. in.) 1999 (122.12)
Firing Order 1−3−4−2
Combustion Chamber Spherical Type
Fuel No. 2 Diesel Fuel (ASTM D975)
Fuel Capacity liters (U.S. gallons) 72 (19.0)
Fuel Injection Pump Bosch Type Mini Pump (PFR)
Governor Centrifugal Mechanical
Low Idle (no load) 1450 + 50 RPM
High Idle (no load) 2730 + 30 RPM
Kubota
Diesel Engine
Direction of Rotation Counterclockwise (Viewed from Flywheel)
Compression Ratio 22.0:1
Injection Nozzle Bosch Throttle Type
Engine Oil SAE 10W30 or 10W40 Detergent (API CD, or higher)
Oil Pump Trochoid Type
Crankcase Oil Capacity liters (U.S. quarts) 7.6 (8.0) with Filter
Starter 12 VDC, 1.4 kW
Alternator/Regulator 12 VDC, 40 AMP
Coolant Capacity liters (U.S. quarts) 10.4 (11) with 0.9 (1.0) Reservoir
Engine Dry Weight kilograms (U.S. pounds) 184 (406)
Groundsmaster 4000−D Page 3 − 3 Kubota Diesel Engine (Rev. B)
Adjustments
Run Solenoid
1. When ignition switch is in the RUN position, the run
solenoid should energize and position the fuel stop lever
to within 1/16” (1.6 mm) of stop on the injection pump.
2. If adjustment is needed, loosen lock nut and rotate
the threaded end of the swivel until the lever is properly
positioned.
3. Tighten lock nut. Recheck adjustment.
1
1. Run solenoid
2. Solenoid lever (run)
Figure 1
1
4
3. Swivel
4. Lock nut
2
3
1. Run solenoid
2. Solenoid lever (off)
3
2
Figure 2
3. Injection pump stop
Groundsmaster 4000−DPage 3 − 4Kubota Diesel Engine (Rev. B)
This page is intentionally blank.
Kubota
Diesel Engine
Groundsmaster 4000−D Page 3 − 5 Kubota Diesel Engine (Rev. B)
Service and Repairs
Air Filter System
RIGHT
FRONT
11
10
1. Air cleaner hose
2. Hose clamp
3. Air cleaner assembly
4. Indicator
Figure 3
5. Air cleaner strap
6. Lock nut
7. Hose clamp
8. Air cleaner hose
9
7
11
8
1
6
5
4
3
2
EVACUATOR
DIRECTION
9. Hose clamp
10. Cap screw
11. Flat washer
Groundsmaster 4000−DPage 3 − 6Kubota Diesel Engine (Rev. B)
Removal
1. Remove air cleaner components as needed using
Figure 3 as a guide.
Installation
4
1
IMPORTANT: Any leaks in the air filter system will
cause serious engine damage. Make sure daily that
all air cleaner components are in good condition
and are properly secured during reassembly.
1. Reassemble air cleaner system using Figure 3 as a
guide.
2. When installing air cleaner hose (8) between air
cleaner and turbo−charger (Fig. 4):
A. Make sure that hose does not contact engine
valve cover . To modify clearance, move and/or rotate
air cleaner body in air cleaner strap. Verify that tabs
in strap mesh fully with slots in air cleaner body.
B. Position hose to allow maximum clearance between air cleaner hose and muffler bracket.
3
2
1. Air cleaner hose
2. Engine valve cover
3. Air cleaner strap
Figure 4
4. Air cleaner body
5. Muffler bracket
5
Kubota
Diesel Engine
Groundsmaster 4000−D Page 3 − 7 Kubota Diesel Engine (Rev. B)
Exhaust System
16 to 22 ft−lb
(21 to 29 N−m)
RIGHT
FRONT
3
8
7
6
16 to 22 ft−lb
(21 to 29 N−m)
1
14
11
4
2
16 to 22 ft−lb
(21 to 29 N−m)
5
12
11
7
8
9
6
10
13
1. Muffler
2. Muffler bracket
3. Exhaust pipe
4. Flange head screw
5. Exhaust gasket
6. Lock nut
Figure 5
7. Cap screw
8. Flat washer
9. Spacer
10. Rubber hanger
11. Flange nut
12. Flange head screw
13. Engine mount
14. Muffler clamp
Groundsmaster 4000−DPage 3 − 8Kubota Diesel Engine (Rev. B)
Removal
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and exhaust system to cool before working on the muffler.
1. Park machine on alevel surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Remove muffler and/or muffler bracket from the engine as necessary using Figure 5 as a guide.
3
2
4
1
Installation
IMPORTANT: If exhaust studs were removed from
engine cylinder head, thoroughly clean threads in
head and apply Loctite #277 (or equivalent) to stud
threads before installing studs into head.
Note: Makesure muffler flange and exhaust manifold
sealing surfaces are free of debris or damage that may
prevent a tight seal.
1. Install new gasket if original gasket is damaged or
torn.
IMPORTANT: Failure to follow the suggested mufflerfastener sequence mayresultin premature muffler failure.
2. Install muffler and/or muffler bracket to the engine
usingFigure5 as a guide. Hand tighten andthentorque
thefollowingfastenersfrom 16to22ft--lb(21to 29N--m)
in the sequence listed (Fig. 6):
A. Locknuts used on rubber hanger cap screws.
B. Flange nuts that secure muffler to muffler brack-
et.
Figure 6
Kubota
Diesel Engine
C. Flange head screws that securemufflerflangeto
engine.
D. Flange nuts that secure muffler bracket to engine.
3. Tailpipeshouldhaveequalclearancebetweenframe
and engine after installation.
Groundsmaster 4000--D Page 3 -- 9 Kubota Diesel Engine (Rev. B)
Rev. F
Fuel System
RIGHT
FRONT
14
20
21
38
39
37
36
24
25
26
27
28
29
30
35
34
2
22
31
41
23
33
1
3
32
4
5
40
6
7
1. Fuel tank
2. Fuel tank bracket
3. Air breather
4. Female hose barb
5. Tank support assembly
6. Fuel hose
7. Locking flange nut
8. Cap screw
9. Flat washer
10. Cap screw
11. Carriage screw
12. Washer
13. Battery strap
14. Battery
18
17
16
15
19
7
12
11
13
60 to 80 in−lb
(6.8 to 9 N−m)
15. Retaining ring
16. Battery cover
17. Flat washer
18. Knob
19. Battery plate
20. Negative cable
21. Positive cable
22. Carriage screw
23. Gasket
24. Bushing
25. Stand pipe
26. Fuel sender
27. Lock washer
28. Phillips head screw
8
9
10
135 to 165 ft−lb
(183 to 223 N−m)
Figure 7
29. Fuel hose
30. Hose clamp
31. Elbow fitting
32. Fuel cap
33. Locking flange nut
34. Speed nut
35. Tank cover
36. Phillips head screw
37. Vent tube
38. Insulated clip
39. Washer head screw
40. Hose clamp
41. ROPS assembly
Groundsmaster 4000−DPage 3 − 10Kubota Diesel Engine (Rev. B)
Fuel Tank Installation
DANGER
Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke
while filling the fuel tank. Do not fill fuel tank
while engine is running, hot, or when machine is
in an enclosed area. Always fill fuel tank outside
and wipe up any spilled diesel fuel before starting the engine. Store fuel in a clean, safety−approved container and keep cap in place. Use diesel fuel for the engine only; not for any other
purpose.
Check Fuel Lines and Connections
Check fuel lines and connections periodically as recommended in the O p erator’s Manual. Check lines for deterioration, damage, leaking, or loose connections.
Replace hoses, clamps, and connections as necessary.
Drain and Clean Fuel Tank
Drain and clean the fuel tank periodically as recommended in the Operator’s Manual. Also, drain and clean
the fuel tank if the fuel system becomes contaminated
or if the machine is to be stored for an extended period.
1. Install fuel tank using Figure 7 as a guide.
A. Torque two locking flange nuts that secure the
fuel tank to the frame from 60 to 80 in−lb (7 to 9 N−m).
2. Install two (2) tank covers to ROPS assembly.
3. Connect fuel hose to the standpipe and venting
hoses to the elbow fittings.
4. Connect electrical wiring to the sending unit.
A. Connect white wire to the center terminal and
black wire to any of the screws that secure the fuel
sender to the fuel tank.
B. Apply skin−over grease to the wire terminal connections.
CAUTION
Connecting battery cables to the wrong battery
post could result in personal injury and/or damage to the electrical system.
Kubota
Diesel Engine
To clean fuel tank, flush tank out with clean diesel fuel.
Make sure tank is free of contaminates and debris.
Fuel Tank Removal (Fig. 7)
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Raise seat and hood.
3. Remove battery cover and strap. Disconnect negative battery cable first and then positive battery cable.
Remove battery from machine.
4. Use a fuel transfer pump to remove fuel from the fuel
tank and into a suitable container.
5. Disconnect electrical wiring from the sending unit.
6. Disconnect fuel hose from the standpipe and venting
hoses from elbow fittings in top of tank.
7. Remove phillips head screws that secure two (2)
tank covers to ROPS assembly. Remove tank covers.
5. Position battery in machine. Connect positive battery
cable first and then negative battery cable. Install battery strap and cover.
6. Lower seat and hood.
7. Fill fuel tank (see Operator’s Manual).
8. Remove fuel tank using Figure 7 as a guide.
Groundsmaster 4000−D Page 3 − 11 Kubota Diesel Engine (Rev. B)
Rev. E
Radiator
18
20
21
23
46
22
RIGHT
FRONT
47
17
16
19
45
1
27
24
25
13
14
15
35
11
38
10
37
41
34
12
32
31
2
26
3
33
28
30
8
29
10
11
9
7
6
12
5
4
8
6
39
40
36
1. Radiator cap
2. Foam strip
3. Foam strip
4. Lower radiator hose
5. Upper radiator hose
6. Hose clamp
7. Radiator shroud
8. Lock nut
9. Radiator
10. Hose clamp
11. Reservoir hose
12. Flange head screw
13. Grommet
14. Flange nut
15. Retaining ring
16. Knob
12
42
12
44
17. Bulb seal
18. Radiator support assembly
19. Retaining ring
20. Oil cooler bracket
21. Oil cooler
22. Carriage screw
23. Hydraulic fitting
24. Flange head screw
25. Clamp
26. Flange nut
27. Oil cooler bracket (RH shown)
28. Flat washer
29. Foam plug
30. Lock nut
31. Foam strip
32. Lower radiator support
43
Figure 8
33. Flange head screw
34. Bulb seal
35. Grommet
36. Frame cover
37. Flange head screw
38. Plate
39. Flat washer
40. Knob
41. Shoulder bolt
42. Flat washer
43. Coolant reservoir
44. Coolant reservoir bracket
45. O−ring
46. O−ring
47. Air cleaner hose
Groundsmaster 4000−DPage 3 − 12Kubota Diesel Engine (Rev. B)
Removal
Installation
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch.
2. Open engine hood on the machine.
CAUTION
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
Ethylene−glycol antifreeze is poisonous. Dispose of coolant properly , or store it in a properly
labeled container away from children and pets.
3. Drain radiator into a suitable container using the radiator drain. The radiator drain hose is located near the
engine oil filter.
4. Disconnect hoses (upper and lower) from the radiator.
5. Remove air cleaner hose.
1. Remove any plugs used during the removal proce-
dure.
2. Position radiator to the support frame. Secure radia-
tor to the support frame with lock nuts, flat washers, and
screws.
3. Attach radiator shroud to the radiator with flange
screws and flat washers. Make sure that clearance between shroud and fan is at least .180” (4.6 mm) at all
points.
4. Connect reservoir hose to the vent tube.
5. Connect hoses (upper and lower) to the radiator.
6. Reinstall air cleaner hose.
7. Make sure radiator drain is closed. Fill radiator with
coolant (see Operator’s Manual).
8. Close and secure engine hood on the machine.
Kubota
Diesel Engine
6. Disconnect reservoir hose from the vent tube.
7. Detach radiator shroud from the radiator by removing four flange head screws and flat washers. Position
shroud away from radiator.
8. Remove screws, flat washers and lock nuts securing
the radiator to the support frame. Pull radiator from the
machine.
9. Plug any radiator or hose openings to prevent contamination.
Groundsmaster 4000−D Page 3 − 13 Kubota Diesel Engine (Rev. B)
Engine
12
10
5
17 to 21 ft−lb
(23 to 28.5 N−m)
47
45
46
42
40
43
44
RIGHT
FRONT
49
40
41
39
42
31
38
48
37
(47.5 to 58.3 N−m)
6
29
35
36
35 to 43 ft−lb
26
10
30
32
33
34
10 to 12 ft−lb
(13.6 to 16.3 N−m)
29
27
28
6
7
8
9
10
13
11
25
16
14
17
18
12
10
15
19
20
21
22
3
2
4
1
23
24
23
1. Engine
2. Engine mount bracket (RH shown)
3. Lock washer
4. Cap screw
5. Barb fitting
6. Hose clamp
7. Hose
8. Fuel line
9. Fuel filter
10. Fuel line
11. Coolant drain hose
12. Hose clamp
13. Cap screw
14. Barb fitting (female)
15. Coolant drain cock fitting
16. Engine mount bracket (RH shown)
17. Lock washer
18. Cap screw
Figure 9
19. Lock washer
20. Cap screw
21. Cap screw
22. Rubber engine mount
23. Flange head locking nut
24. Rebound washer
25. Hose clamp
26. Fuel line
27. Coupler spacer
28. Dowel
29. Lock washer
30. Shoulder bolt
31. Cap screw
32. Spring center coupling
33. Plate pin
34. Cap screw
35. Pump adapter plate
36. Lock washer
37. Cap screw
38. Traction cylinder assembly
39. Cap screw
40. O−ring
41. Cylinder piston
42. Back−up ring
43. Retaining ring
44. Seal
45. Hydraulic fitting
46. O−ring
47. O−ring
48. Shim plate
49. Hydraulic hose
Groundsmaster 4000−DPage 3 − 14Kubota Diesel Engine (Rev. B)
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